Phased Array Ultrasonic Weld Positioning via Morphological Image Cross-Correlation
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Solution Overview
Problem
Current phased array ultrasonic sensing systems for non-destructive evaluation of welds face challenges in accurately positioning the probe, especially when the weld cap is removed, as they rely on surface features and lack precise alignment without additional sensors, leading to poor positional accuracy and limited applicability in complex geometries.
Innovation Solution
A system utilizing a phased array ultrasonic probe with a processor and controller that generates morphological images, compares them to a weld mask using cross-correlation, and provides direction indications to guide the user in moving the probe to an ideal position, reducing displacement and improving accuracy through image processing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual positioning of the phased array ultrasonic probe is used, then the system is simple to operate, but the positional accuracy relative to the weld is poor
Solution Approach 1:
The system captures ultrasonic signals, processes them to generate morphological images, compares these images to a weld mask using cross-correlation, and uses the correlation results to calculate displacement and provide directional guidance. This closed-loop feedback mechanism continuously adjusts probe positioning based on real-time ultrasonic feedback, achieving high positional accuracy without requiring complex external positioning hardware.
Solution Approach 2:
The patent replaces complex mechanical positioning systems (such as laser alignment systems or mechanical guides) with an ultrasonic-based feedback system. Instead of using mechanical or optical external references, the system uses ultrasonic wave propagation and echo analysis to determine probe-weld relative position, substituting mechanical complexity with acoustic field-based measurement and control.
2Adaptability or versatility
If laser-based positioning is used to identify weld position, then positioning is automated, but it only works with simple welds and requires visible weld cap
Solution Approach 1:
The ultrasonic-based morphological image comparison system serves multiple functions: it works with various weld geometries (simple and complex), functions with or without visible weld caps, and provides both positioning guidance and weld characterization. The system processes ultrasonic echoes to generate morphological images that can be compared against weld masks, making it universally applicable across different weld types and geometries without requiring visible surface features.
Solution Approach 2:
The patent introduces morphological images as an intermediary representation between the raw ultrasonic signals and the weld mask comparison. These morphological images extract structural features from the ultrasonic echo data, serving as a mediator that enables reliable comparison with ideal weld geometry masks. This intermediary processing step allows the system to reliably identify weld positions and geometries regardless of surface appearance or complexity.
3Measurement precision
If additional sensors are added to improve positioning accuracy, then measurement precision improves, but device complexity and cost increase
Solution Approach 1:
The phased array ultrasonic probe performs multiple functions simultaneously: it transmits ultrasonic waves for weld inspection, receives echo signals for positioning feedback, generates morphological images for weld geometry identification, and provides real-time displacement calculation. This multi-functional use of a single sensor system achieves high positioning accuracy without requiring additional dedicated positioning sensors, reducing overall system complexity.
Solution Approach 2:
The ultrasonic probe system is self-sufficient for positioning tasks. It uses its own transmitted ultrasonic signals and received echoes to generate morphological images and calculate its relative position to the weld. The system does not require external positioning sensors, mechanical guides, or separate reference systems - it services its own positioning needs through intelligent processing of its primary inspection signals.
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 achieves a mean positional error of 0.8 mm in predicting the weld position, enhancing the accuracy and flexibility of non-destructive evaluation, particularly in complex geometries, and reduces the need for additional sensors, thus minimizing costs and training requirements.
Implementation Method 1
a phased array ultrasonic probe for sending and receiving phased array ultrasonic signals
Data Source
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AI summary
The present disclosure relates to phased array ultrasonic sensing system. The system comprises: a phased array ultrasonic probe for sending and receiving phased array ultrasonic signals; a processor configured to generate phased array ultrasonic images using the received phased array ultrasonic signals; a display for displaying direction indications to guide a user in moving the phased array ultrasonic probe during a non-destructive evaluation of a weld of a component; and a controller configured to control the display to display the direction indications to guide the user in moving the phased array ultrasonic probe based on a position of the weld in the generated phased array ultrasonic images.