Ultrasonic Testing Device Automatic Defect Detection
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Solution Overview
Problem
The challenge is to reduce the time required for ultrasonic testing and enable quantitative evaluation, as the current method relies heavily on qualified testers for qualitative assessment, which can lead to long wait times and inefficiencies.
Innovation Solution
An ultrasonic testing device that includes a signal acquisition unit, a defect detection unit, and a display unit. The defect detection unit uses the maximum signal strength of the reflected echo signal beyond a threshold value to automatically detect defects within the test object, allowing for quantitative evaluation and reducing the need for qualified testers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If qualified testers manually confirm ultrasonic waveforms and determine acceptance or rejection, then measurement precision is improved, but productivity deteriorates due to long testing time and difficulty in securing qualified testers
Solution Approach 1:
The ultrasonic testing device performs automatic defect detection and evaluation without requiring manual intervention from qualified testers. The system autonomously processes ultrasonic waveforms, detects defects, and determines acceptance or rejection, enabling the device to serve itself and eliminating dependency on human operators for routine testing tasks
Solution Approach 2:
The patent replaces the manual mechanical process of waveform analysis by qualified testers with an automated electronic signal processing system. The defect detection unit automatically analyzes ultrasonic waveforms using electronic circuits and algorithms, substituting human cognitive and manual operations with automated electronic detection and evaluation mechanisms
2Measurement precision
If qualified testers manually evaluate ultrasonic waveforms, then measurement precision is improved, but loss of time deteriorates due to extensive effort and time required for each test
Solution Approach 1:
The ultrasonic testing device continuously processes ultrasonic waveforms without interruption, automatically detecting defects and evaluating results in real-time. The system maintains continuous operation through automated signal processing, eliminating the intermittent nature of manual testing where testers must repeatedly examine waveforms, thereby reducing total testing time while maintaining detection accuracy
3Measurement precision
If manual defect detection by qualified testers is used, then measurement precision is improved, but device complexity deteriorates due to requirement for highly trained personnel
Solution Approach 1:
The system performs self-diagnosis and automatic defect detection without requiring external expert intervention. The ultrasonic testing device autonomously analyzes waveforms, identifies defects, and generates evaluation results, making the system self-sufficient and eliminating the need for complex human qualification structures
Solution Approach 2:
The patent substitutes the complex human expertise system with automated electronic detection circuits and analysis algorithms. The defect detection unit employs electronic signal processing and automated evaluation logic to replace the need for highly trained testers, thereby simplifying the operational requirements while maintaining detection precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables faster ultrasonic testing and allows for quantitative defect detection, reducing the reliance on qualified testers and improving efficiency in manufacturing and maintenance sites.
Implementation Method 1
an ultrasonic probe, which irradiates an inside of a test object with an ultrasonic wave and receives the reflected echo from the test object
Implementation Method 2
receives the reflected echo from the test object
Data Source
AI summary
An ultrasonic testing device includes: a signal acquiring unit which receives a reflected echo signal relating to a reflected echo of ultrasonic waves from an object being inspected, a defect detecting unit which detects a defect of the object being inspected on the basis of the reflected echo signal, and a display unit which displays the detection result of the defect detecting unit. The defect detecting unit uses the maximum signal strength of the reflected echo signal exceeding a first threshold value to detect the defect. The first threshold value is a value with which the signal strength is less than the maximum signal strength of the reflected echo signal from the surface of the object, using as an evaluation range an interval between a position which is positioned a first distance from the surface of the object and a bottom surface of the object.