Pulse-Echo Ultrasound Probe Calibration Using Interface Echo Alignment
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Solution Overview
Problem
Existing ultrasound probes for measuring internal and backwall features of objects, such as turbine blades, require complex setups like water immersion or local couplant application, which are time-consuming and inefficient, especially at higher frequencies, and lack effective calibration methods that do not rely on internal or backwall structure information.
Innovation Solution
A method for calibrating a pulse-echo ultrasound probe by measuring interface echo signals at various orientations to determine an axis of optimum signal, using a deformable coupling element and automated processing to record calibration parameters, allowing orientation optimization without relying on internal or backwall structure knowledge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water immersion or local couplant application is used for ultrasound inspection, then acoustic coupling is improved, but inspection time and operational complexity increase significantly
Solution Approach 1:
The deformable coupling element automatically adapts to the object surface geometry through its own deformation, eliminating the need for external coupling agents or complex positioning systems. The element self-adjusts to maintain optimal acoustic contact during automated scanning movements.
Solution Approach 2:
The coupling element's physical state is changed from rigid to deformable, allowing it to conform to varying surface geometries. This parameter change enables reliable acoustic coupling without requiring manual intervention for couplant application or complex water immersion setups.
2Measurement precision
If traditional calibration methods using internal or backwall structures are employed, then calibration accuracy is improved, but applicability to objects with unknown or complex internal structures deteriorates
Solution Approach 1:
The calibration method extracts the calibration function from dependence on internal object structures. By using only the front surface reflection signal, the calibration process is decoupled from requirements about backwall or internal feature geometry, making it universally applicable.
Solution Approach 2:
Instead of using backwall reflections to calibrate (traditional approach), the invention inverts the approach by using the front surface reflection signal. This inversion allows calibration without needing to know anything about internal structures, reversing the traditional dependency.
3Reliability
If manual couplant application and gimbal mounting are used, then acoustic coupling is achieved, but operational complexity and time consumption increase
Solution Approach 1:
The deformable coupling element automatically conforms to the object surface without requiring manual couplant application. The element's inherent deformability provides self-adjusting acoustic contact, eliminating manual operations while maintaining reliable coupling.
Solution Approach 2:
The coupling element is designed as a flexible, deformable structure that can conform to various surface geometries. This flexibility replaces the need for rigid gimbal mounts and manual positioning, simplifying operation while maintaining acoustic contact.
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
Facilitates fast and accurate calibration of ultrasound probes, enabling efficient measurement of internal structures by ensuring optimal signal alignment, independent of the object's internal or backwall configuration, and improving measurement efficiency and accuracy.
Implementation Method 1
measuring an interface echo signal that was created by a reflection of sound from the interface between the ultrasound probe and an object
Data Source
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AI summary
A method of calibrating a pulse-echo ultrasound probe having a coupling element for contacting an object, in which the pulse-echo ultrasound probe and an object are provided on a positioning apparatus having at least one axis about which the relative orientation of the pulse-echo ultrasound probe and the object can be changed, the method comprising: i) at each of a plurality of different relative orientations between the pulse-echo ultrasound probe and the object about the at least one axis: • the pulse-echo ultrasound probe generates an ultrasound pulse, and • a measure is taken of an interface echo signal of the ultrasound pulse as received by the pulse-echo ultrasound probe, said interface echo signal being created by a reflection of the ultrasound pulse at the interface between the coupling element and the object; and ii) using said measures of the interface echo signal to determine at least one calibration parameter, and recording the at least one calibration parameter for subsequent use.