Ultrasonic Weld Inspection Using Circularity-Based Joint Evaluation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current non-destructive inspection methods for welds lack accuracy in determining the appropriateness of weld joints due to reliance on human interpretation and limited precision in assessing the circularity and ellipticity of weld regions, leading to potential misclassification of weld quality.
Innovation Solution
A processing system that includes a detector with multiple detection elements arranged in orthogonal directions, transmitting ultrasonic waves and analyzing reflected waves to determine joint points and calculate circularness, roundness, and ellipticity of weld regions, thereby assessing the appropriateness of weld quality through automated processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If human inspectors manually interpret ultrasonic wave data to assess weld quality, then flexibility and adaptability are maintained, but measurement precision and reliability deteriorate due to subjectivity and human error
Solution Approach 1:
The patent replaces the mechanical human inspection process with an automated computer-based system that processes ultrasonic wave data. The computer automatically determines joint points, calculates circularness and ellipticity, and assesses weld quality without human intervention, thereby eliminating subjectivity and human error while maintaining measurement precision.
Solution Approach 2:
The inspection system performs self-assessment by automatically analyzing ultrasonic wave data to determine weld quality. The computer system independently calculates geometric parameters (circularness, ellipticity) and makes quality determinations without requiring external human interpretation, enabling the system to serve itself in the inspection process.
2Reliability
If automated processing is implemented to eliminate human error, then measurement precision and reliability improve, but device complexity increases due to additional processing requirements
Solution Approach 1:
The patent segments the weld inspection process into distinct automated steps: ultrasonic wave transmission, reflected wave detection, joint point determination, circularness calculation, ellipticity calculation, and quality assessment. Each segment is handled by the computer system independently, ensuring consistent and reliable results while managing complexity through structured processing.
Solution Approach 2:
The system transforms raw ultrasonic wave data into meaningful quality parameters by calculating geometric characteristics (circularness, ellipticity) and comparing them against predetermined thresholds. This parameter transformation approach ensures reliable and consistent weld quality assessment through objective mathematical criteria rather than subjective human judgment.
3Measurement precision
If multiple geometric parameters (circularness, ellipticity) are calculated to comprehensively assess weld quality, then measurement precision improves, but loss of time increases due to additional calculations
Solution Approach 1:
The patent performs preliminary determination of joint points along the ultrasonic wave transmission direction before calculating circularness and ellipticity. This preliminary action organizes the data structure in advance, enabling efficient subsequent calculations of geometric parameters without requiring redundant data processing, thereby reducing overall inspection time while maintaining comprehensive weld characterization.
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
Enhances the accuracy of weld inspection by objectively determining the appropriateness of weld joints, reducing human error and providing more reliable data on weld quality, even in cases where the detector's tilt may affect inspection results.
Implementation Method 1
An ultrasonic wave is transmitted from the detector toward the weld portion, and data related to the welding object is derived based on the reflected waves
Data Source
AI summary
A processing system according to an embodiment includes a processing device. The processing device receives a detection result of a reflected wave from a detector that includes multiple detection elements arranged in a first direction and a second direction crossing each other, and performs a probe that includes transmitting an ultrasonic wave toward a welding object and detecting the reflected wave. The processing device performs a first determination of determining a joint and a non-joint at multiple points along the first and second directions of the welding object based on the detection result. The processing device performs a second determination of determining an appropriateness of a result of the first determination by using a circularness of a first region based on the points determined to be joints.