Ultrasonic Weld Detector Contact Verification for Accurate Tilt Inspection
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Solution Overview
Problem
In welding inspection, determining whether a detector appropriately contacts the weld portion is challenging, leading to potential misinterpretation of detection results due to factors like foreign matter or surface irregularities, which can result in incorrect tilt calculations and inspection outcomes.
Innovation Solution
A processing system that includes a detector with multiple detection elements arranged in a specific configuration, transmitting ultrasonic waves and detecting reflected waves to determine contact through intensity analysis and threshold settings, ensuring accurate contact determination and subsequent inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a human inspector manually operates the detector to contact the weld portion, then the inspection can be performed, but the contact accuracy is difficult to ensure due to foreign matter or surface irregularities
Solution Approach 1:
The patent replaces manual mechanical contact operation with an automated detection system that uses ultrasonic waves to determine detector-weld portion contact status. The system automatically analyzes reflected wave intensity to judge contact appropriateness, eliminating the need for manual inspection and ensuring consistent contact accuracy regardless of surface conditions.
Solution Approach 2:
The system enables self-determination of contact status by automatically analyzing the reflected ultrasonic wave intensity. The detector itself provides feedback about its contact state with the weld portion through the intensity analysis, allowing the system to self-regulate and ensure proper contact without external intervention.
2Productivity
If the detector contacts the weld portion without proper contact determination, then inspection speed increases, but incorrect tilt calculations and inspection outcomes occur
Solution Approach 1:
The system performs preliminary determination of contact appropriateness before conducting the actual inspection. By analyzing the reflected wave intensity in advance to confirm proper detector-weld portion contact, the system ensures that subsequent tilt calculations and inspection results are accurate, preventing wasted inspection cycles on improper contact scenarios.
3Measurement precision
If multiple detection elements are arranged in a specific configuration, then contact determination accuracy improves, but device complexity increases
Solution Approach 1:
The multiple detection elements serve multiple functions: they detect ultrasonic waves from different angles, determine contact status through intensity analysis, and enable tilt calculations. This multi-functionality justifies the increased device complexity by providing comprehensive inspection capabilities from a single detector configuration.
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 effectively determines detector contact with the weld portion, enhancing the accuracy of tilt calculations and inspection results by differentiating between appropriate and inappropriate contact scenarios, thereby improving the reliability of weld assessments.
Implementation Method 1
An ultrasonic wave is transmitted from the detector toward the weld portion, and the existence or absence of the joint is inspected based on the reflected wave
Data Source
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.