Ultrasonic Transducer Light Beam Alignment
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Solution Overview
Problem
Current ultrasonic material inspection methods face challenges in accurately positioning the transducer to achieve optimal ultrasonic energy focus and alignment with the material surface, especially when submerged in a coupling medium, leading to potential errors in detecting flaws and measuring material thickness.
Innovation Solution
The integration of light sources, such as line lasers, positioned around the ultrasonic transducer to project beam patterns that intersect the ultrasonic energy axis, allowing for visual confirmation of the correct water path distance and alignment with the material surface, ensuring optimal ultrasonic energy application and data collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the transducer is submerged in water for ultrasonic inspection, then the ultrasonic energy can be transmitted through the coupling medium to the material surface, but the alignment and positioning accuracy of the transducer becomes difficult to maintain due to refraction and visual distortion
Solution Approach 1:
The patent introduces light beams as an intermediary visual reference system that projects through the water coupling medium to indicate the correct transducer positioning. The light beams serve as a mediator between the operator and the submerged transducer, providing accurate visual feedback despite the refraction and distortion caused by the water medium.
Solution Approach 2:
The patent utilizes light sources that emit visible beams with distinct patterns (such as intersecting lines or converging points) that change the visual appearance of the water medium. These optical patterns provide clear visual indicators of correct positioning, allowing operators to accurately align the transducer even when submerged.
2Manufacturing precision
If the transducer is positioned at a predetermined water path distance from the material surface, then the ultrasonic energy focus can be optimized, but the visual confirmation of correct positioning becomes difficult due to refraction in the coupling medium
Solution Approach 1:
The light beams act as an intermediary reference system that projects through the water to provide visual confirmation of the correct water path distance. The beams create visible indicators (such as intersecting lines or focal points) that allow operators to verify positioning accuracy despite the refraction effects of the coupling medium.
Solution Approach 2:
The light sources are pre-positioned and configured to project beams that automatically indicate the correct transducer position before the actual ultrasonic inspection begins. This preliminary visual guidance system is set up in advance to guide the operator to the optimal positioning.
3Measurement precision
If multiple light sources are added to the transducer assembly for visual alignment, then the positioning accuracy can be improved, but the device complexity increases
Solution Approach 1:
The light sources are integrated into the transducer assembly in a way that serves multiple functions: they provide visual alignment guidance, indicate water path distance, and mark the ultrasonic energy axis. This multi-functionality reduces the need for separate alignment tools and minimizes the overall increase in device complexity.
Solution Approach 2:
The patent combines the light sources with the transducer housing or mounting structure, merging the optical alignment system with the ultrasonic inspection device. This integration allows both functions to work together from a single unified apparatus rather than requiring separate systems.
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 approach enhances the accuracy of ultrasonic testing by providing a visual indication of the correct transducer position, reducing errors due to refraction and ensuring the maximum ultrasonic energy is applied at the desired point on the material surface, thereby improving flaw detection and thickness measurement precision.
Implementation Method 1
Each light source of a plurality of light sources is configured to emit a light beam that defines a beam pattern
Implementation Method 2
an ultrasonic transducer configured to emit ultrasonic energy in a direction from a transmitting surface
Implementation Method 3
That distance is filled by a coupling material, e.g., water, capable of transmitting the ultrasonic energy therethrough at an acceptable attenuation level
Data Source
AI summary
An ultrasonic transducer system has an ultrasonic transducer configured to emit ultrasonic energy in a direction and a plurality of light sources, each light source configured to emit a light beam that defines a beam pattern that intersects an axis of the emitted ultrasonic energy.