Ultrasonic Weld Inspection Contact Detection Using Reflected Waves
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Solution Overview
Problem
In ultrasonic welding inspection, determining whether a detector appropriately contacts the weld portion is challenging due to issues like foreign matter, surface irregularities, and inadequate acoustic coupling, leading to unreliable detection results.
Innovation Solution
A processing system with a detector that includes multiple detection elements arranged in a specific configuration, transmitting ultrasonic waves, and determining contact based on the intensity and distribution of reflected waves, using a hard or soft propagating member to facilitate accurate contact assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a detector is used to inspect weld portions through ultrasonic waves, then the inspection capability is provided, but reliable determination of detector contact with the weld portion becomes difficult due to foreign matter, surface irregularities, and inadequate acoustic coupling
Solution Approach 1:
A shoe (acoustic coupling member) is introduced as an intermediary between the detector and the weld portion. The shoe includes a curved surface that contacts the weld portion and transmits ultrasonic waves, ensuring stable acoustic coupling even when the weld portion surface has irregularities or foreign matter. This mediator resolves the contact determination reliability issue by providing a consistent coupling interface.
Solution Approach 2:
The system utilizes changes in ultrasonic wave reflection characteristics (analogous to color changes in optical detection) to determine contact state. By analyzing the intensity and pattern of reflected ultrasonic waves from the shoe's curved surface, the system can detect whether proper acoustic coupling is achieved, thereby determining detector contact reliability.
2Reliability
If the detector directly contacts the weld portion for inspection, then inspection can be performed, but contact stability is reduced due to surface irregularities and foreign matter
Solution Approach 1:
The shoe serves as a protective intermediary layer between the detector and the weld portion surface. It prevents direct contact between the detector and harmful surface conditions (irregularities, foreign matter), while still allowing effective ultrasonic wave transmission. This mediator shields the detection system from surface-related harmful factors.
Solution Approach 2:
The shoe's curved surface geometry is specifically designed to match or complement the weld portion surface characteristics. By changing the physical parameters of the coupling interface (curvature, material properties), the system achieves stable acoustic coupling that is less sensitive to surface irregularities and foreign matter on the weld portion.
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 ensures accurate determination of detector contact with the weld portion, preventing mistaken results and enhancing the reliability of weld inspection by analyzing the intensity and distribution of reflected waves.
Implementation Method 1
The detector transmits an ultrasonic wave toward the welding object and detects a reflected wave
Implementation Method 2
issues like foreign matter, surface irregularities, and inadequate acoustic coupling
Data Source
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AI summary
According to one embodiment, a processing system includes a processing device. The processing device performs at least a first determination of determining whether or not a detector contacts a welding object. The detector includes a plurality of detection elements arranged in a first direction. The detector transmits an ultrasonic wave toward the welding object and detects a reflected wave. The first determination is based on a detection result when the reflected wave is detected by the detector.