Ultrasonic Testing Device Surface Tension Water Coupling
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Solution Overview
Problem
Existing ultrasound inspection methods face challenges in inspecting multi-layer structures with array probes, as they require high water pressure to maintain a stable water column, leading to foam generation and attenuation of high-frequency waves, and struggle with focusing on specific depths within the workpiece, especially when wetting is minimized to avoid corrosion and contamination.
Innovation Solution
An ultrasound inspection apparatus with a subject holding mechanism, an array probe immersed in a liquid tank, and a probe holding mechanism that adjusts the array probe's position relative to the workpiece, utilizing surface tension to maintain a stable liquid interface for horizontal scanning and focusing on specific layers, while minimizing wetting to the inspection surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high water pressure is applied to maintain a stable water column for array probe inspection, then the water column stability is improved, but foam generation increases and high-frequency wave quality deteriorates
Solution Approach 1:
The patent extracts the water supply function from a high-pressure system and implements it through a low-pressure reservoir fed by natural convection and capillary action. The water reservoir is positioned to allow gravity-driven flow, eliminating the need for high-pressure pumps and preventing foam generation while maintaining stable water column for ultrasonic inspection.
Solution Approach 2:
The patent changes the water pressure parameter from high pressure to atmospheric/low pressure by redesigning the water supply mechanism. Instead of using pressurized systems, the invention relies on gravitational potential energy and surface tension to maintain water flow, thereby preventing cavitation and foam formation while ensuring adequate water coupling for the array probe.
2Reliability
If water is used for ultrasonic inspection coupling, then ultrasonic wave transmission is improved, but wetting causes corrosion and contamination
Solution Approach 1:
The patent applies local quality by providing water coupling only in the specific region where ultrasonic inspection is performed, rather than immersing the entire workpiece. The water reservoir is positioned to create a localized water layer between the array probe and the inspection surface, ensuring good acoustic coupling while minimizing water contact with the workpiece to prevent corrosion and contamination.
Solution Approach 2:
The patent implements a rapid inspection process where the array probe quickly scans the inspection surface and moves through the water coupling layer without prolonged contact. The localized water application and fast scanning methodology minimize the time water is in contact with the workpiece, reducing the risk of corrosion and contamination while maintaining effective ultrasonic inspection.
3Object-affected harmful factors
If sampling inspection is performed to avoid wetting, then corrosion and contamination are reduced, but defect detection coverage is insufficient
Solution Approach 1:
The patent implements a self-regulating water supply system where the water reservoir automatically maintains the water level and flow rate needed for inspection without requiring external intervention. The system uses gravitational convection and capillary action to self-adjust water delivery, ensuring consistent coupling for 100% inspection coverage while minimizing water usage and contact time to prevent corrosion and contamination.
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
This solution enables effective inspection of multi-layer structures with reduced wetting, preventing foam generation and maintaining high-frequency wave quality, allowing for precise defect detection without significant water exposure, thus addressing the need for 100% inspection in sensitive components.
Implementation Method 1
horizontal scanning means that horizontally scans the subject and/or the array probe, with a liquid surface coming into contact with the inspection surface of the subject due to surface tension of a liquid stored in the tank
Data Source
AI summary
The invention is applied to an ultrasound inspection apparatus including an array probe such that wetting is substantially limited to an inspection surface of the work. The ultrasound inspection apparatus includes: a work holder that holds a work with an inspection surface thereof facing downward; an array probe that probes the work with an ultrasonic wave; a water tank in which the array probe is immersed in water; an arm that holds the array probe such that the array probe faces an underside of the inspection surface of the work; X-axial direction scanning means that horizontally scans the work, with a liquid surface coming into contact with the inspection surface of the work due to surface tension of a liquid stored in the water tank; and Y-axial direction scanning means that horizontally scans the array probe.