Real-Time 3D TFM Phased Array Ultrasound HZSN-PAUD-3DUltra

Quick answer

The HZSN-PAUD-3DUltra is a portable phased-array ultrasound system that performs real-time 3D total focusing method (TFM) imaging at 100 frames per second with up to 1,000,000 focus points. Built for wind turbine non-destructive testing, it covers bolts from M20 to M56 up to 1 m long, tower welds, main shafts and pitch bearings, and weighs 3.65 kg in a split design with at least four hours of battery operation.

Technical Specifications

Parameter	Value
Channels	32:128
Sampling	100 MHz, 16-bit
TFM focus points	up to 1,000,000
Frame rate	100 fps
Display depth	up to 1.0 m
Bolt coverage	M20 to M56, length <= 1 m
Dimensions	291 x 221 x 99 mm
Weight	3.65 kg
Battery endurance	>= 4 h
Operating temperature	-10 to 45 C

Overview

Wind turbine bolts fail in fatigue, and the failure almost always starts as a small crack that conventional ultrasonic testing struggles to characterise. A single-angle A-scan can tell you something is there; it rarely tells you how long it is, how deep, or which direction it is growing. That uncertainty drives conservative replacement decisions, unnecessary downtime and, occasionally, missed cracks.

The PAUD-3DUltra addresses this with real-time 3D total focusing. With 32:128 channels, 100 MHz 16-bit sampling and display depth to 1.0 m, the system reconstructs up to 1,000,000 focus points per frame at 100 fps, producing a volumetric image of the defect rather than a single trace. Dedicated wind-bolt modules handle hex-head and socket-head geometries, tower welds can be scanned as continuous 4D imaging, and raw full-matrix capture data is stored so scans can be re-analysed offline.

How it works

Acquire: the 32:128 phased-array probe captures full matrix capture (FMC) raw data from the component.
Focus: the total focusing method reconstructs up to 1,000,000 focus points per frame.
Render: A, B, C, D, 3D and 4D display modes show the defect in context, updated at 100 fps.
Compensate: ultrasound-field measurement with calibration compensation corrects for coupling and geometry.
Archive: raw FMC data is stored so any scan can be re-analysed later without re-visiting the turbine.

Key features

Dedicated wind-bolt inspection modules for hex-head and socket-head bolts
Continuous 4D imaging scans of tower welds
Simultaneous multi-group, multi-mode real-time 2D TFM imaging
Ultrasound-field measurement with calibration compensation
Raw full-matrix capture (FMC) data acquisition and storage
A / B / C / D / 3D / 4D display modes
Wired or wireless connection to a high-performance tablet

Applications

Tower and foundation bolt inspection

Detect fatigue cracks in M20 to M56 foundation, tower-flange and yaw-bearing bolts without removal.

Blade root bolt inspection

Assess blade-root studs and T-bolt inserts where load concentration makes fatigue cracking most likely.

Tower weld inspection

Continuous 4D imaging scans of circumferential and longitudinal tower welds.

Main shaft and pitch bearing inspection

Volumetric imaging of main shafts and pitch-bearing raceways for subsurface defects.

Frequently asked questions

What is total focusing method (TFM) imaging?

Total focusing method is an advanced phased-array ultrasound technique that post-processes full matrix capture data to focus the ultrasound beam at every point in the region of interest, rather than at a single focal depth. The result is a uniformly focused image with much better resolution and signal-to-noise ratio than a conventional phased-array scan.

Which wind turbine components can the PAUD-3DUltra inspect?

It covers bolts from M20 to M56 up to 1 m in length, tower welds, main shafts and pitch bearings, using dedicated wind-bolt modules for both hex-head and socket-head geometries.

What is the difference between phased array and TFM?

A conventional phased-array scan focuses at one depth at a time, so resolution degrades away from the focal point. TFM focuses at every pixel, using up to 1,000,000 focus points per frame on the PAUD-3DUltra, giving uniform resolution throughout the image and making small fatigue cracks far easier to size.

Is the system practical for rope-access or tower work?

Yes. The split design weighs 3.65 kg including the 291 x 221 x 99 mm main unit, runs on battery for at least four hours, and connects to a rugged tablet by cable or wirelessly, so no mains power is needed up-tower.

Can scans be re-analysed after leaving the site?

Yes. The system stores raw full-matrix capture data, so an archived scan can be re-processed and re-interpreted later without returning to the turbine.