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Ultrasonic Thickness Measurement Method and System Implementation Based on Sampling Reconstruction and Phase Feature

Wenqiang Gong1, Xuanze Wang1, Zhenyu Yang1

  • 1Hubei Key Laboratory of Modern Manufacturing Quantity Engineering, College of Mechanical Engineering, Hubei University of Technology, Wuhan 430068, China.

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Summary

This study introduces a novel ultrasonic thickness measurement method using conventional sampling frequencies. It achieves high accuracy by reconstructing signals and combining FFT with sine fitting, reducing system complexity and cost.

Keywords:
moving sine fittingmultipliersampling reconstructionultrasonic signal

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Area of Science:

  • Materials Science and Engineering
  • Non-Destructive Testing
  • Signal Processing

Background:

  • Conventional ultrasonic thickness measurement systems necessitate high sampling frequencies, complicating circuit design and increasing costs.
  • Accurate extraction of ultrasonic echo signal characteristics for precise thickness determination remains a significant challenge.

Purpose of the Study:

  • To propose a novel method for acquiring high-frequency ultrasonic echo signals using conventional sampling frequencies, circumventing Nyquist-Shannon limitations.
  • To enhance the accuracy and reduce the complexity and cost of ultrasonic thickness measurement systems.

Main Methods:

  • Implemented an improved sampling reconstruction technique to increase equivalent sampling frequency by rearranging multi-cycle signals.
  • Employed a hybrid approach combining Fast Fourier Transform (FFT) for coarse estimation and moving sine fitting for precise phase extraction.
  • Addressed limitations of traditional methods like peak detection, envelope detection, and Hilbert autocorrelation.

Main Results:

  • Achieved high-accuracy thickness measurements on steel blocks, with errors of ±0.01 mm for thicknesses between 3 mm and 20 mm.
  • Demonstrated a measurement error of ±0.05 mm for thicknesses ranging from 1 mm to 50 mm.
  • Successfully overcame the limitations of high-frequency data acquisition and low measurement accuracy inherent in existing systems.

Conclusions:

  • The proposed method effectively acquires high-frequency ultrasonic echo signals using conventional sampling frequencies, enabling accurate thickness measurements.
  • The combination of signal reconstruction and advanced estimation algorithms significantly improves measurement precision while simplifying system design.
  • This approach offers a cost-effective and accurate solution for ultrasonic thickness measurement across a wide range of material thicknesses.