Phased-Array Weld Inspection Beam Selection for Lower Scan Load
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Solution Overview
Problem
Existing ultrasonic probe systems inefficiently operate all transducer elements during weld inspection, leading to unnecessary energy and time consumption, as many beams do not provide useful data for weld root and cap analysis.
Innovation Solution
Selectively operate and process data from only the necessary transducer elements that will effectively cover the weld area by calculating and segregating beams based on their entry points and coverage, using algorithms to determine which elements to idle or omit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all transducer elements are operated during weld inspection, then comprehensive coverage of the weld area is achieved, but energy consumption and processing time increase unnecessarily
Solution Approach 1:
The transducer array is segmented into multiple groups, where each group corresponds to a specific angular range. Only the transducer elements within the angular range needed to cover the weld area are activated, while other groups remain inactive. This segmentation allows the system to maintain comprehensive weld coverage while reducing the number of active elements, thereby lowering energy consumption.
Solution Approach 2:
Different transducer elements are assigned different functions based on their angular positions. Elements are selectively activated only when their corresponding angular ranges intersect with the weld area. This local quality approach ensures that each element operates only when needed for specific inspection tasks, optimizing energy usage while maintaining inspection reliability.
2Reliability
If all transducer elements are operated during weld inspection, then complete data acquisition is achieved, but processing time increases unnecessarily
Solution Approach 1:
The data acquisition process is segmented by angular ranges corresponding to different transducer element groups. Only groups whose angular ranges intersect with the weld area activate their elements and acquire data. This segmentation eliminates the need to process data from all elements, significantly reducing processing time while maintaining complete weld inspection coverage.
Solution Approach 2:
Instead of activating all transducer elements (excessive action), the system activates only the partial set of elements needed to cover the weld area. This partial action approach acquires sufficient data for complete weld inspection without the overhead of processing data from unnecessary elements, thereby reducing processing time.
3Loss of energy
If transducer elements are selectively operated based on angular range intersection, then energy efficiency is improved, but system complexity increases
Solution Approach 1:
The angular ranges of transducer element groups are pre-calculated and stored before inspection begins. During operation, the system simply compares the weld area angular range with the pre-stored group ranges to determine which elements to activate. This preliminary action eliminates the need for complex real-time calculations, reducing system complexity while maintaining energy efficiency.
Solution Approach 2:
An intermediary computational layer is introduced that manages the complexity of selective element activation. This intermediary handles the angular range intersection logic and element selection, shielding the rest of the system from complexity while enabling energy-efficient selective operation. The intermediary acts as a mediator between the weld area definition and the transducer element activation.
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
Reduces operational costs and time by minimizing the number of active transducer elements and processed data, ensuring comprehensive weld inspection with improved efficiency.
Implementation Method 1
Each transducer element is capable of emitting a signal that proceeds though the one of the connected portions and into the weld itself
Data Source
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AI summary
A method of computing optimal beam numbers of a phased-array ultrasonic weld inspection arrangement. The arrangement is for inspecting a weld that is within an area of interest that has a known dimension and with the inspection arrangement being at a known offset distance from the weld. The selection is such that operation of the at least one element provides sufficient information data for weld analysis. The elements extend along an ultrasonic transmission wedge of the arrangement that supports the extent of the elements at a wedge angle relative to the welded material. The method includes utilizing the dimension of the weld area of interest and dimension of offset of the inspection arrangement from the weld within calculation that yields the selection of the at least one element.