Chapter 1

Introduction

Technology is, simply put, ever-changing. It is the application of scientific knowledge for

the betterment of human life. This nonstop evolution is evident in the field of engineering, where

innovation is always a factor during its practice.

In the electrical side of engineering, engineers often work with high voltages that is a

serious safety hazard when handled incorrectly. These electrical equipment require constant

testing and calibrating to ensure that it is functioning properly. Before, testing these equipment

were done meticulously, removing parts out of their cases and proceeding to perform multiple

tests to determine their condition. If found malfunctioning, the equipment will be put on hold

until it is fixed and brought back to its proper condition. That was in simpler times. As stated in

the beginning, technology is ever-changing, and this side of technology is a testament to that

statement.

Electrical apparatus are now, in comparison to earlier times, crucial to the efficiency of

work surrounding electrical systems. A small delay because of maintenance can cause a big effect

on the productivity of a machine. One of the most time-consuming activity in machine

maintenance is troubleshooting. Pinpointing a problem in a complex electrical system has been

proven to take a long time. Non-destructive testing is an effective method that allows tests to be

done from outside of the enclosed systems. It uses ultrasounds, sound waves with frequencies

higher than what the human ear can normally hear, to find a problem in an electrical system.

Ultrasonic sensors are now available commercially, devices that can sense high frequency sounds

produced by operating equipment, leaks and electrical discharges. Common problems

encountered by equipment that require careful testing and repair.

Background of the Study

Air leak detection has come a long way in the last few years, from the days of going

around plants with a soapy rag, to today, where ultrasonic testing is quickly becoming the new

norm in terms of inspection. One of the most notable developments in the history of detection and

testing was made by Penrose E. Chapman, inventor of a testing device now commonly referred to

as a growler. Growlers have been around for a long time, serving as the first electrical insulation

testing device that uses sensors similar to the piezoelectric and ultrasonic transducers. It consists

of a coil of wire wrapped around an iron core and is connected to an AC source. The growler will

produce a growling noise once it detects that a coil is shorted, hence the name. Several years after

growlers, airborne ultrasound was utilized to create a new testing method that is capable of non-

contact and long range inspection. A company called “UE Systems” has been developing several

ultrasonic detection equipment, the Ultraprobe® Series, for predictive maintenance and energy

conservation for over thirty years. These devices are able to detect leaks and electrical discharges

by analyzing the high frequency sounds produced by electrical systems, allowing faster and more

reliable maintenance to be performed.

Statement of the Problem

In an industry filled with innovations in technology, great things start with a simple base.

In terms of predictive maintenance, the growler served as the start. Growlers were made for a

specific purpose and was limited to what it can and cannot do. Improving on this concept, a high-

end device was developed, capable of testing systems at a long range and without making contact.

This kind of development, however, required expensive components to help achieve its goals.

Due to these components, the affordability of the service is low. A low cost alternative is

desirable to widen the influence of ultrasonic airborne testing, an emerging and effective testing

method.
Objectives

The main objective of this research is to develop a handheld device capable of measuring

high frequency sounds produced by electrical equipment, to detect the presence of electrical

discharges from within an enclosed system through ultrasonic airborne testing. Specifically, the

study should satisfy the following intentions:

 To determine the working temperature of a motor before, during, and after experiencing

technical problems

 To distinguish the different sounds produced by electrical equipment such as motors and

circuit breakers.

 To determine the presence of degradation in a system’s insulation by monitoring changes

in voltage drops due to a decreasing resistance.

Scope and Limitations

The study is primarily focused on the concept of ultrasonic with the help of a

microcontroller. With its many applications, the study aims to use it to find faults inside an

enclosed system. The researchers aim to develop a low cost ultrasonic device using affordable

materials and components.

To test the effectiveness of the project, the researchers opted to use accessible and safe

enclosed systems in place of high voltage equipment such as circuit breakers, motors, generators,

etc. For cost-cutting solutions, several features possessed by commercially available devices,

deemed unimportant by the researchers, were removed and replaced with simple but practical

modifications.
Significance of the Study

This research is a step towards a better way of testing open and enclosed systems to find

the presence of leaks and electrical discharges. It aims to create a safer and more accessible

alternative to a high-end product that is currently not available in the country. It also lessens the

time. This study could also introduce the concept of ultrasonic airborne testing to fellow

researchers for their future endeavors.

 UNIVERSITY OF THE EAST – MANILA
COLLEGE OF ENGINEERING
ELECTRICAL ENGINEERING DEPARTMENT

DESIGNING AND DEVELOPING A LOW-COST ULTRASONIC

SENSOR FOR NON-DESTRUCTIVE TESTING

LEADER:
PASCUAL, MARK JILMER R.

MEMBERS:
GRABELLO, LISETTE GRACE C.
MARTINEZ, JEFREY M.
MERQUITA, SHERWIN VINCENT S.
PALLORINA, EDLEY GLENN C.

ENGR. DARWIN ALPIS

ADVISER