Ultrasound Probe Segmentation for Non-Parallel Surface Inspection
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Solution Overview
Problem
Existing non-destructive ultrasound inspection methods face challenges in achieving high spatial resolution when inspecting parts with non-flat or non-parallel surfaces, as directional probes are sensitive to relative positioning deviations, making automated inspections difficult, especially when the probe is distant from the part and positioning errors occur.
Innovation Solution
The method involves emitting an ultrasound wave with a wide beam oriented along a specific axis and measuring reflected waves on smaller sections that remain within the path of the waves regardless of the part's position, allowing for less precise alignment and enabling simultaneous measurement on multiple sections to improve inspection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If directional sensors are used to achieve high spatial resolution, then measurement precision is improved, but the system becomes sensitive to relative positioning deviations between the probe and part
Solution Approach 1:
The probe surface is divided into a central emission-reception area and a peripheral emission area. The central area contains sensors for receiving reflected waves, while the peripheral area contains transducers for emitting ultrasound waves. This segmentation allows the emission and reception functions to be separated spatially, enabling the reception area to remain in the path of reflected waves even when the probe is not precisely positioned normal to the part surface.
Solution Approach 2:
The peripheral emission area acts as an intermediary that generates ultrasound waves at an angle to ensure that reflected waves from non-parallel surfaces still reach the central reception area. This intermediary emission zone compensates for positioning deviations by creating a broader angular coverage for wave emission and reception.
2Ease of operation
If the probe is positioned at a distance from the part for automated inspection, then ease of operation is improved, but measurement precision deteriorates due to positioning deviations
Solution Approach 1:
By separating the probe into central reception and peripheral emission areas, the system can maintain effective measurement at distances. The peripheral emission area projects waves at angles that ensure reflected waves from the part surface return to the central reception area, compensating for the increased distance and reducing the impact of positioning deviations.
3Adaptability or versatility
If probes are used for parts with non-parallel faces, then adaptability is improved, but device complexity increases due to requiring multiple measurements
Solution Approach 1:
The segmented probe design with peripheral emission and central reception areas allows single-pass inspection of parts with non-parallel faces. The peripheral emitters project waves at multiple angles simultaneously, ensuring that reflected waves from non-parallel surfaces are captured by the central reception area without requiring multiple measurements or repositioning.
Solution Approach 2:
The probe design provides universal functionality for inspecting various part geometries including flat surfaces, non-parallel faces, and complex shapes. The peripheral emission area's angular coverage enables the same probe to effectively inspect different surface orientations without requiring configuration changes or multiple specialized probes.
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
This approach reduces the impact of positioning deviations and allows for faster, high-quality measurements of parts with complex geometries, including those made of composite materials, without requiring precise probe positioning, thus simplifying automated inspection processes.
Implementation Method 1
The general principle of non-destructive ultrasound inspection of structural parts is these days well known and widely implemented... emitting ultrasound waves towards points of the part to be inspected and collecting the reflected waves in the form of echoes from the part
Implementation Method 2
The waves are reflected by the different interfaces of the part each time a discontinuity provokes a reflection of a portion of the energy of the emitted acoustic wave
Implementation Method 3
These probes more often than not use transducers based on piezoelectric technologies which are perfectly suited to the frequencies of the ultrasounds used
Data Source
AI summary
A method for inspecting a part by a non-destructive ultrasound inspection, the part is immersed in an acoustic wave conducting medium and an incident ultrasound wave having a wide beam of section Σ is emitted into the ultrasound-conducting medium towards the part. The characteristics of the waves reflected by faces of the part to be inspected are measured on at least a small section σ, the characteristic dimensions of which are substantially less than those of the section Σ. The location of the section or sections σ is determined such that, despite the possible variations of the position of the part and the relative slopes of its faces, the section σ is always located in the volumes passed through by the reflected waves, for example substantially in an area close to the axis of the incident beam when the incident beam is controlled to be oriented substantially in a direction perpendicular to a face of the part.