Ultrasound Probe Fusion Joint Inspection System
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Solution Overview
Problem
Existing methods for inspecting fusion joints in pipes, such as electrofusion, butt-fusion, and saddle-fusion, face challenges in efficiently detecting defects like voids and contamination, which can lead to joint failures, especially in buried pipes where access is difficult and re-excavation is costly.
Innovation Solution
An ultrasound (US) probe system with a processor that generates initial scanning positions, measures US pulse-echo spectrums, compares them to known spectrums, and classifies anomalies, allowing for the identification of defects and voids in fusion joints, including electrofusion, butt-fusion, and saddle-fusion joints, using a database of classification rules and sub-tests to evaluate joint integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ultrasonic inspection methods are used to detect defects in fusion joints, then defect detection capability is provided, but inspection efficiency is low and extensive scanning is required
Solution Approach 1:
The system performs preliminary actions by generating an initial set of scanning positions based on fusion joint geometry and US probe characteristics before actual inspection. This pre-planning of scan locations optimizes the inspection path and reduces the number of required scanning positions, thereby improving inspection efficiency while maintaining defect detection capability
Solution Approach 2:
The system applies partial action by selectively scanning only specific positions rather than performing exhaustive scanning of the entire joint area. The processor determines a subset of scanning positions that are sufficient to detect defects, reducing inspection time and resource consumption while maintaining adequate detection reliability
2Measurement precision
If comprehensive scanning is performed to minimize false negatives, then detection accuracy improves, but inspection time and complexity increase
Solution Approach 1:
The system performs preliminary classification of scanning positions into mandatory and optional categories based on defect risk assessment. Mandatory positions are scanned to ensure minimum detection accuracy, while optional positions are scanned based on available time and resources, balancing detection precision with inspection time constraints
Solution Approach 2:
The inspection process is segmented into different scanning phases with varying levels of comprehensiveness. The system divides scanning positions into priority levels, allowing inspectors to complete high-priority scans quickly while having the option to perform additional lower-priority scans if time permits, thus managing the trade-off between accuracy and time
3Reliability
If multiple scanning positions are used to evaluate joint integrity, then detection reliability improves, but device complexity and operation difficulty increase
Solution Approach 1:
The processor pre-calculates and stores the optimal set of scanning positions based on fusion joint geometry and US probe characteristics before inspection begins. This preliminary determination of scan locations simplifies the inspection process by providing a clear, pre-planned sequence of positions to scan, reducing operational complexity while maintaining detection reliability
Solution Approach 2:
The system automatically determines and manages the scanning positions without requiring complex manual planning or operator intervention. The processor self-manages the inspection workflow by selecting positions, controlling the US probe movements, and evaluating results, thereby reducing operational difficulty while ensuring reliable multi-position scanning
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 detects defects and voids in fusion joints, reducing the need for extensive scanning and minimizing false negatives, thereby ensuring joint integrity and reducing costly re-excavation by providing accurate, efficient inspection results.
Implementation Method 1
supply power to an ultrasonic transducer of one of the ultrasonic optical probes to input an ultrasonic wave from the ultrasonic transducer to the pipe
Implementation Method 2
a signal processing unit that receives, detects an echo, and generates a three-dimensional image
Implementation Method 3
a light detection module configured to detect laser light transmitted through the optical fiber sensor of the other ultrasonic optical probe
Data Source
AI summary
A method and apparatus for inspecting a fusion joint is provided. The apparatus includes a processor, an ultrasound (“US”) probe in communication with the processor, and a database comprising classification rules. The processor is configured to generate an initial set of US scanning positions about the fusion joint based on information of at least one of the US probe and the fusion joint; measure, via the US probe, a US pulse-echo spectrum from at least two of the initial US scanning positions; compare each measured US pulse-echo spectrum with one or more known US pulse-echo spectrums; classify each measured US pulse-echo spectrum according to the classification rules; and evaluate an aggregate of measured US pulse-echo spectrums to determine if the fusion joint is defective.