Ultrasonic Weld Inspection Using Circularness Validation
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Solution Overview
Problem
Existing welding inspection technologies face challenges in accurately determining the joint quality and defects in welds, often resulting in incorrect assessments due to factors like detector tilt and material properties.
Innovation Solution
A processing system that includes a detector for transmitting ultrasonic waves and detecting reflected waves, a processing device for analyzing the data, and a display device for presenting the results. The system performs two determinations: first, it assesses whether points are joined based on the reflected wave data, and second, it evaluates the appropriateness of the first determination by calculating the circularness of the weld region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional ultrasonic inspection methods are used with a single determination criterion, then the inspection process is simple, but the accuracy of weld quality assessment is reduced due to detector tilt and material variations
Solution Approach 1:
The inspection determination is segmented into two independent stages: first determination based on reflected wave intensity ratios, and second determination based on circularness calculation. This segmentation allows each stage to focus on specific aspects of weld quality, improving overall accuracy while maintaining manageable complexity through modular processing
Solution Approach 2:
The system implements feedback by using the first determination result as input for the second determination. The circularness calculation in the second determination provides feedback on the geometric validity of the detected weld region, which can confirm or correct the initial assessment, thereby improving measurement precision through iterative validation
2Reliability
If only reflected wave intensity is used for determination, then the inspection is quick, but errors occur due to detector tilt and material property variations
Solution Approach 1:
The system performs preliminary action by calculating the circularness of the weld region before making the final quality determination. This preliminary geometric validation prepares the data structure needed for robust determination, allowing the system to quickly assess whether the detected region is valid without being affected by detector tilt or material variations
Solution Approach 2:
The system changes parameters by introducing circularness as an additional determination criterion alongside reflected wave intensity. This parameter change transforms the determination from a single-intensity-based assessment to a multi-parameter assessment that includes geometric properties, making it more robust against detector tilt and material variations
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 system significantly improves the accuracy of weld inspection by reducing errors associated with detector tilt and material variations, enabling more reliable determination of joint quality and defect detection.
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
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AI summary
[Problem] To provide a processing system (100), a processing method, a program, and a storage medium in which the accuracy of data related to a welding object can be improved. [Means for Solving Problem] A processing system (100) according to an embodiment includes a processing device (110). The processing device (110) receives a detection result of a reflected wave (RW) from a detector (130) that includes multiple detection elements (132) arranged in a first direction and a second direction crossing each other, and performs a probe that includes transmitting an ultrasonic wave (US) toward a welding object and detecting the reflected wave (RW). The processing device (110) 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 (110) performs a second determination of determining an appropriateness of a result of the first determination by using a circularness of a first region (R1) based on the points determined to be joints.