Ultrasound Transducer Array for Complex Geometry Inspection
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Solution Overview
Problem
Existing ultrasound-based non-destructive testing methods face challenges with multiple echoes and crosstalk in complex geometries, leading to faulty echo indications, which reduces the reliability of material inspection.
Innovation Solution
The method employs ultrasonic holography techniques using an array of individually drivable transducers to generate a tailored ultrasonic field geometry that adapts to the test object, allowing for optimal insonification and suppression of multiple echoes and crosstalk, enabling efficient scanning of large sectors with fewer pulses and improved processing speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ultrasound methods are used for non-destructive testing, then the testing process is simple, but multiple echoes and crosstalk occur in complex geometries leading to faulty echo indications
Solution Approach 1:
The patent divides the test object volume into multiple smaller sub-volumes and scans them sequentially using multiple ultrasonic pulses with different insonification angles. This segmentation approach allows the system to handle complex geometries by processing smaller, more manageable regions, thereby reducing echo interference and improving inspection reliability without requiring an overly complex system architecture.
Solution Approach 2:
The patent introduces the dimension of varying insonification angles by transmitting ultrasonic pulses from multiple directions (e.g., 0°, 45°, 90°) to scan the same volume region. This multi-dimensional approach enables the system to distinguish between true echoes and multiple echoes by comparing signals from different angular perspectives, thereby improving reliability while maintaining reasonable system complexity.
2Productivity
If multiple ultrasonic pulses are used to scan the test object volume, then scanning coverage is improved, but testing time increases
Solution Approach 1:
The patent performs preliminary calculations to determine the optimal insonification angles and pulse sequences before actual scanning begins. By pre-planning the scanning strategy and calculating the necessary beam directions in advance, the system can execute the scanning process more efficiently, reducing the total number of pulses needed and thereby decreasing testing time while maintaining comprehensive coverage.
Solution Approach 2:
The patent dynamically adjusts the insonification angles and pulse parameters based on the specific geometry and requirements of the test object. This dynamic adaptation allows the system to optimize the scanning process in real-time, selecting the most efficient pulse sequences for each region, thereby improving productivity without excessive time loss.
3Measurement precision
If a tailored ultrasonic field geometry is generated using ultrasonic holography, then echo interference is reduced, but the system complexity increases
Solution Approach 1:
The patent changes the parameters of the ultrasonic field by varying the insonification angles and pulse characteristics based on the test object's geometry. By adjusting these parameters dynamically and using pre-calculated beam directions, the system generates tailored ultrasonic fields that reduce echo interference and improve measurement precision without requiring excessively complex transducer array control mechanisms.
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 enhances testing reliability and speed by generating ultrasonic fields that are optimally suited to the test object geometry, reducing echo interference and allowing for faster, more accurate non-destructive testing of complex geometries.
Implementation Method 1
an array of individually drivable ultrasonic transmitting transducers for generating and transmitting ultrasonic waves into the test object
Implementation Method 2
an array of individually drivable ultrasonic receiving transducers for receiving ultrasonic echo signals from the test object
Implementation Method 3
it is now possible to synthetically focus the ultrasonic echo in such a manner that all echo signals that are associated, for example, with a certain depth region in the test object or a certain volume element (voxel) in the test object volume are specifically added up
Implementation Method 4
phased array technique, which is based on the use of a plurality of independently drivable ultrasonic transducers and which permits a specific control of the insonification angle and the focus position of the generated ultrasonic field in the test object by variation of the transmission aperture and the relative phase position of the transmitting transducer elements
Data Source
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AI summary
A method for the nondestructive testing of a test object by ultrasound, the method including generating a pulsed ultrasonic field in the test object by means of an array of individually drivable ultrasonic transmitting transducers acoustically coupled to the test object, by the ultrasonic transmitting transducers each being driven with a specific analog transient excitation signal, wherein each analog transient excitation signal is generated based on an ultrasonic transmitting transducer-specific stored digital transient excitation function, receiving resulting echo signals from the test object by means of an array of individually drivable ultrasonic receiving transducers, with each ultrasonic receiving transducer providing an analog time-resolved echo signal, temporarily storing the time-resolved, transducer-specific, digitized echo signals in the form of an echo signal set, and applying a plurality of different reception processing rules to the echo signal set.