Ultrasonic Weld Inspection Probe Angle Adjustment
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Solution Overview
Problem
Existing welding inspection systems face challenges in accurately determining the angle of ultrasonic probes, leading to incomplete weld detection due to inappropriate probe angles, especially when multiple ultrasonic sensors are used.
Innovation Solution
An inspection system with a probe and controller that adjusts the angle of the probe based on the detection of joints and non-joints along the weld portion by analyzing reflected ultrasonic waves, allowing for precise alignment and improved inspection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single ultrasonic sensor is used for weld inspection, then the device complexity is low, but the measurement precision and reliability of weld detection are insufficient
Solution Approach 1:
The probe is divided into multiple ultrasonic sensors arranged in specific patterns (linear arrays, circular arrays, or matrix arrays). Each sensor independently transmits and receives ultrasonic waves, allowing the system to collect data from multiple angles and positions simultaneously, thereby improving weld detection accuracy without requiring complex mechanical adjustment mechanisms.
Solution Approach 2:
Each ultrasonic sensor in the array serves multiple functions: transmitting ultrasonic waves, receiving reflected waves, and providing spatial information for angle calculation. This multi-functionality allows the system to achieve both high measurement precision and reliable weld detection while maintaining relatively simple device structure.
2Reliability
If the probe angle is fixed, then the device complexity is low, but the reliability of weld detection decreases due to inappropriate angles
Solution Approach 1:
The system dynamically calculates the optimal probe angle based on real-time detection data from multiple ultrasonic sensors. The controller processes reflected wave signals to determine the actual weld geometry and automatically adjusts the probe angle accordingly, ensuring reliable weld detection without requiring complex manual adjustment mechanisms.
Solution Approach 2:
The system uses feedback from the reflected ultrasonic waves to continuously monitor and adjust the probe angle. By analyzing the timing and intensity of reflected signals from multiple sensors, the controller determines the optimal angle for detecting weld defects and adjusts the probe orientation to maintain maximum detection reliability.
3Measurement precision
If multiple ultrasonic sensors are arranged in complex patterns, then the measurement precision improves, but the ease of operation and alignment becomes difficult
Solution Approach 1:
The system performs self-alignment by automatically calculating the probe angle and orientation based on the spatial arrangement of multiple ultrasonic sensors and the characteristics of reflected waves. The controller processes data from all sensors to determine the optimal detection angle, eliminating the need for manual alignment and making the probe easy to operate while maintaining high measurement precision.
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 adjusts the probe angle to ensure accurate detection of welds, reducing false negatives and improving the reliability of weld inspections by optimizing the probe's orientation relative to the weld portion.
Implementation Method 1
Each of the plurality of ultrasonic sensors transmits an ultrasonic wave toward the weld portion and receives a reflected wave
Implementation Method 2
the existence or absence of the joint is verified based on the reflected wave
Data Source
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AI summary
According to one embodiment, an inspection system includes a probe and a controller. The probe includes a plurality of ultrasonic sensors arranged in a first direction. The probe contacts a weld portion by moving in a second direction crossing the first direction. Each of the plurality of ultrasonic sensors transmits an ultrasonic wave toward the weld portion and receives a reflected wave. The controller detects a joint and a non-joint at a plurality of points along the first direction of the weld portion based on the plurality of reflected waves. The controller adjusts an angle of the probe around a third direction based on a number of the joints or the non-joints detected for the plurality of points. The third direction is perpendicular to the first direction and crossing the second direction.