Welding Inspection Probe Guide Member Wear Reduction
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Solution Overview
Problem
Welding portion inspection devices using ultrasonic waves face issues with wear and unevenness of the sound propagation medium, leading to reduced inspection accuracy and frequent replacement due to direct contact with the welding surface.
Innovation Solution
Incorporating a guide member with protruding parts made of a harder material than the metal plate, positioned beyond the tip surface of the sound propagation medium, which abuts against the welding surface instead, maintaining the sound propagation medium's orthogonal posture and preventing direct contact, thus reducing wear and enhancing inspection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sound propagation medium (shoe) directly contacts the metal plate surface during inspection, then ultrasonic wave transmission is effective, but the tip surface of the shoe wears and becomes uneven, reducing inspection accuracy
Solution Approach 1:
The guide member acts as an intermediary between the sound propagation medium and the metal plate surface. The guide member's protruding parts contact the metal plate surface first, preventing direct contact between the shoe tip and the surface, thereby eliminating wear while maintaining effective ultrasonic wave transmission through the shoe
Solution Approach 2:
The contact function is segmented from the sound propagation medium to the guide member. The guide member is divided into protruding parts that specifically contact the metal plate surface, while the sound propagation medium maintains its function of transmitting ultrasonic waves without experiencing wear
2Reliability
If the shoe is made of soft material for good ultrasonic transmission, then ultrasonic wave propagation is excellent, but the material is harder than the shoe causing wear to the shoe tip
Solution Approach 1:
The guide member serves as a protective intermediary that absorbs the mechanical contact stress. The guide member is made of hard material suitable for contacting the metal plate surface, while the shoe maintains its soft, ultrasonic-transmissive material properties without experiencing wear
Solution Approach 2:
Different parts of the inspection device have different material properties optimized for their specific functions: the guide member uses hard material for wear-resistant contact with the metal plate surface, while the sound propagation medium uses soft material for optimal ultrasonic wave transmission
3Adaptability or versatility
If the detector is inclined relative to the welding surface, then the floating mechanism can adjust the direction, but uneven wear occurs due to partial contact between the shoe tip and surface
Solution Approach 1:
The guide member's protruding parts act as intermediaries that distribute the contact load across multiple points on the metal plate surface. This prevents concentrated partial contact on the shoe tip, ensuring uniform contact even when the detector is inclined, while the floating mechanism maintains directional adaptability
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 solution significantly reduces wear and extends the lifespan of the sound propagation medium, maintaining high inspection accuracy and minimizing the need for replacement, while also ensuring proper ultrasonic wave emission by filling the gap between the medium and the surface with gel.
Implementation Method 1
a probe (41) configured to oscillate an ultrasonic wave and detect a reflected wave of the ultrasonic wave
Implementation Method 2
an elastic support mechanism (7) configured to allow the probe (41) and the sound propagation medium (42) to be elastically supported to the device body (2)
Data Source
AI summary
A welding portion inspection device includes a device body, a probe, a sound propagation medium, an elastic support mechanism configured to allow the probe and the sound propagation medium to be elastically supported to the device body, and a guide member formed of a material higher in hardness than a metal plate. The guide member is disposed such that a first part is positioned on a side of the sound propagation medium and second parts protrude beyond a tip surface of the sound propagation medium. The probe is configured to oscillate a ultrasonic wave such that the ultrasonic wave is emitted to a welding portion of the metal plate through the sound propagation medium and perform inspection of the welding portion based on a detected reflected wave of the ultrasonic wave in a state where the tip surface of the sound propagation medium faces the welding portion.