An ultrasonic intelligent detection method and system for forgings

Abstract

The present invention relates to the field of ultrasonic testing technology, and in particular to an ultrasonic intelligent testing method and system for forgings. The method comprises: determining an ultrasonic scanning mode of a scanner based on a structural evaluation value; performing ultrasonic testing on the forging to obtain a reflection waveform diagram and a C-scan view of the forging; obtaining a scanning fluctuation rate and a dark band similarity based on the C-scan view; and, when it is determined that the ultrasonic testing of the forging does not meet the standard based on the peak interval dispersion, performing a secondary determination based on the scanning fluctuation rate whether the ultrasonic testing of the forging meets the standard, or determining the reason why the ultrasonic testing of the forging does not meet the standard based on the dark band similarity. The system comprises: an ultrasonic testing module; a structural parameter acquisition module; a data acquisition module; a mode selection module; and a control module for determining whether the ultrasonic testing of the forging meets the standard based on the peak interval dispersion. The present invention improves the accuracy of ultrasonic testing.

Description

Technical Field

[0001] The present invention relates to the field of ultrasonic detection technology, and in particular to an ultrasonic intelligent detection method and system for forgings. Background Art

[0002] In industrial manufacturing, ring forgings, as critical load-bearing components, are widely used in high-end equipment such as aircraft engines, gas turbines, and pressure vessels. Accurate detection of internal defects (such as cracks, inclusions, and looseness) is directly related to the operational safety and lifespan of these equipment. Ultrasonic testing technology, due to its non-destructive, highly penetrating, and highly sensitive properties, has become a core method for forging quality inspection.

[0003] Ultrasonic testing refers to the use of ultrasonic waves interacting with workpieces to analyze reflected, transmitted, and scattered echoes, thereby detecting and characterizing the workpiece's macroscopic defects, geometric characteristics, organizational structure, and mechanical properties, and further evaluating its specific applicability. C-scan (Constant Depth Scan) is a two-dimensional imaging technology based on the amplitude of ultrasonic reflection signals. The probe scans the workpiece surface along a preset path, mapping the reflection signal intensity at a specific depth (usually the focal area of ​​the sound beam) into a grayscale or color image, intuitively presenting the distribution and intensity of defects.

[0004] In the existing technology, most companies use qualified inspectors to use portable ultrasonic testing equipment for inspection. They apply coupling agent to the surface of roughly processed large forgings and then manually scan them. The inspectors observe the display screen of the portable testing equipment throughout the process and determine the internal quality of the forgings based on the waveform displayed by the equipment. This relies on experienced inspectors to manually scan, and single-piece inspection is time-consuming and prone to missed inspections due to fatigue. In addition, the scanning rate, gain and other parameters of existing equipment (such as portable flaw detectors) need to be manually set, and cannot be dynamically optimized according to the geometric characteristics of the forgings, resulting in a low detection rate of near-surface defects.

[0005] Chinese patent application publication number: CN104076089A, discloses an automatic ultrasonic C-scan inspection system for ring forgings. The inspection system includes a mechanical scanning control unit, an automatically controlled mechanical scanning device, a rotary worktable, a water supply and drainage device, a water spray coupling device, an ultrasonic detection probe, an ultrasonic flaw detector and its communication unit, a data acquisition device, and a C-scan non-destructive measurement unit. The mechanical scanning control unit provides a synchronization signal to the C-scan non-destructive measurement unit and controls the movement of the mechanical scanning device and the rotary worktable, thereby driving the detection probe installed in the water spray coupling device to scan. The rotary worktable is equipped with a water supply and drainage device at the edge to facilitate real-time water supply and discharge. The ultrasonic flaw detector sends and receives pulses through the detection probe and transmits the detected echo information to the C-scan non-destructive measurement unit through the data acquisition device for imaging analysis.

[0006] It can be seen that the above technical solution does not dynamically select the scanning mode according to the structural parameters of the forging, and cannot adapt to forgings of different shapes, resulting in redundant ultrasonic scanning; it only relies on C-scan imaging for defect identification, and does not extract parameters such as peak interval discreteness and scanning fluctuation rate, and cannot quantitatively evaluate the detection results, resulting in a high detection misjudgment rate, which leads to low detection accuracy. Summary of the Invention

[0007] To this end, the present invention provides an ultrasonic intelligent detection method and system for forgings, which is used to overcome the problems in the prior art that the scanning mode is not dynamically selected according to the structural parameters of the forgings, and the system cannot adapt to forgings of different shapes, resulting in redundant ultrasonic scanning; the system only relies on C-scan imaging for defect identification, does not extract parameters such as the peak interval discreteness and the scanning fluctuation rate, and cannot quantitatively evaluate the detection results, resulting in a high detection misjudgment rate and thus low detection accuracy.

[0008] To achieve the above objectives, the present invention provides, on the one hand, an ultrasonic intelligent detection method for forgings, comprising:

[0009] Obtaining the height, outer diameter, and inner diameter of the annular forging to be inspected, and obtaining a structural evaluation value of the forging;

[0010] installing a scanner on the forging, and determining an ultrasonic scanning mode of the scanner according to the structural evaluation value;

[0011] The scanner performs ultrasonic testing on the forging according to a preset scanning rate and a preset water couplant flow rate to obtain a reflection waveform diagram and a C-scan view of the forging;

[0012] According to the reflection waveform diagram, the peak interval dispersion is obtained; according to the C-scan view, the scanning wave rate and the dark band similarity are obtained;

[0013] When it is determined that the ultrasonic testing of the forging does not meet the standard based on the peak interval dispersion, a secondary determination is made as to whether the ultrasonic testing of the forging meets the standard based on the scanning wave motion rate, or a reason why the ultrasonic testing of the forging does not meet the standard is determined based on the dark band similarity, where the reasons include insufficient water couplant flow and defects in the forging.

[0014] Furthermore, the ultrasonic scanning mode of the scanner is determined according to the structural evaluation value of the forging, wherein:

[0015] If the structural evaluation value is less than a first preset structural threshold, the scanner adopts a type of ultrasonic scanning mode;

[0016] If the structural evaluation value is greater than or equal to the first preset structural threshold and less than the second preset structural threshold, the scanner adopts the second type ultrasonic scanning mode;

[0017] If the structural evaluation value is greater than or equal to the second preset structural threshold and less than the third preset structural threshold, the scanner adopts the third type of ultrasonic scanning mode;

[0018] If the structural evaluation value is greater than or equal to the third preset structural threshold, the fourth type of ultrasonic scanning mode is adopted;

[0019] The structural evaluation value is determined by the aspect ratio of the forging and the inner diameter of the forging.

[0020] Furthermore, the first type of ultrasonic scanning mode is that the scanner performs radial scanning of the end face of the forging, and after the probe of the scanner moves radially along the end face of the forging by a first preset length, the probe rotates circumferentially around the end face by a first preset angle, and the radial movement and circumferential rotation are performed sequentially;

[0021] The second type of ultrasonic scanning mode is that the scanner performs a circumferential scanning of the end surface of the forging, and after the probe of the scanner rotates circumferentially around the end surface of the forging to form a closed loop path, the probe moves radially along the end surface of the forging by a second preset length, and the circumferential rotation and radial movement are performed sequentially;

[0022] The third type of ultrasonic scanning mode is that the scanner performs an axial scanning of the annular surface of the forging, and after the probe of the scanner moves axially along the annular surface of the forging for a third preset length, the probe rotates circumferentially around the annular surface of the forging for a second preset angle, and the axial movement and circumferential rotation are performed sequentially;

[0023] The four types of ultrasonic scanning modes are that the scanner performs circumferential scanning of the annular surface of the forging. After the probe of the scanner rotates circumferentially around the annular surface of the forging to form a closed loop path, the probe moves axially along the annular surface of the forging by a fourth preset length, and the circumferential rotation and axial movement are performed sequentially.

[0024] Furthermore, whether the ultrasonic testing of the forging meets the standard is determined based on the peak interval dispersion, wherein:

[0025] If the peak interval dispersion is less than the first preset interval dispersion, it is determined that the ultrasonic testing of the forging meets the standard;

[0026] If the peak interval dispersion is greater than or equal to the first preset interval dispersion and less than the second preset interval dispersion, it is determined that the ultrasonic testing of the forging does not meet the standard, and a second determination is made based on the scanning fluctuation rate of the C-scan view whether the ultrasonic testing of the forging meets the standard;

[0027] If the peak interval dispersion is greater than or equal to a second preset interval dispersion, it is determined that the ultrasonic testing of the forging does not meet the standard, and the reason why the ultrasonic testing of the forging does not meet the preset standard is determined based on the dark band similarity in the C-scan view.

[0028] Furthermore, the process of obtaining the peak interval dispersion includes:

[0029] Obtaining a reflection waveform diagram of the forging;

[0030] Obtaining the time interval between adjacent preset peak values;

[0031] The variance of several time intervals is obtained and recorded as the peak interval dispersion.

[0032] Furthermore, a second determination is made based on the scanning fluctuation rate whether the ultrasonic testing of the forging meets the standard, wherein:

[0033] If the scanning fluctuation rate is less than a preset scanning fluctuation rate, it is determined that the ultrasonic testing of the forging meets the standard;

[0034] If the scanning fluctuation rate is greater than or equal to the preset scanning fluctuation rate, it is determined that the ultrasonic inspection of the forging does not meet the standard, and the scanning rate of the scanner is reduced according to the difference between the scanning fluctuation rate and the preset scanning fluctuation rate.

[0035] Furthermore, the process of obtaining the scanning volatility includes:

[0036] Performing ultrasonic scanning on the forging several times in the same scanning mode, and recording a signal amplitude matrix of a C-scan view of each scan;

[0037] Obtain the average value of the amplitude of several scan signals of each pixel;

[0038] Obtaining an average value of the signal amplitude of the forging;

[0039] Obtaining a standard deviation of the signal amplitude of the forging;

[0040] The ratio of the standard deviation of the signal amplitude of the forging to the average value of the signal amplitude of the forging is recorded as the scanning fluctuation rate.

[0041] Further, the reason why the accuracy of ultrasonic testing of the forging does not meet the preset standard is determined based on the similarity of the dark bands in the C-scan view, wherein:

[0042] If the dark band similarity is less than a preset dark band similarity, it is determined that the reason why the accuracy of the ultrasonic testing of the forging does not meet the preset standard is that the preset water couplant flow rate is insufficient, and the preset water couplant flow rate is increased according to the difference between the preset dark band similarity and the dark band similarity;

[0043] If the dark band similarity is greater than or equal to a preset dark band similarity, it is determined that the reason why the accuracy of the ultrasonic inspection of the forging does not meet the preset standard is that the forging has a defect and an alarm is issued;

[0044] The dark band similarity is the similarity between the outline of a region in which the grayscale value of a pixel point in the C-scan view is less than a preset grayscale value and the outline of a preset region.

[0045] Furthermore, the increase range of the preset water coupling agent flow rate is positively correlated with the dark band similarity difference, wherein the dark band similarity difference is the difference between the preset dark band similarity and the dark band similarity.

[0046] On the other hand, the present invention also provides an ultrasonic intelligent detection system for an ultrasonic intelligent detection method for forgings, comprising:

[0047] An ultrasonic detection module, which is a scanner, includes an inverted L-shaped frame consisting of a horizontal frame and a vertical frame, a first fixture disposed on the horizontal frame, and a second fixture disposed on the vertical frame, wherein the first fixture and the second fixture are both provided with an ultrasonic transmitting and receiving probe and a water couplant tube disposed on one side of the ultrasonic transmitting and receiving probe;

[0048] A pressure wheel is provided at one end of the horizontal frame, and a pulley group is provided at an end of the horizontal frame away from the pressure wheel, wherein the pulley group is composed of a pair of driving wheels and symmetrically arranged driven wheels;

[0049] A structural parameter acquisition module, which is used to acquire the height, inner diameter and outer diameter of the ring forging to be tested;

[0050] A data acquisition module includes a peak acquisition unit for acquiring a preset peak value and a corresponding time interval in a reflection waveform graph, an amplitude acquisition unit for acquiring a pixel signal amplitude of a C-scan view, and an image acquisition unit for acquiring a pixel image of the C-scan view;

[0051] a mode selection module connected to the structural parameter acquisition module, for determining an ultrasonic scanning mode of the scanner according to the structural evaluation value of the forging;

[0052] a control module, which is connected to the data acquisition module and the mode selection module respectively, and is used to determine whether the ultrasonic testing of the forging meets the standard based on the scanning fluctuation rate under the condition that the ultrasonic testing of the forging does not meet the standard based on the peak interval dispersion, or to determine the reason why the ultrasonic testing of the forging does not meet the standard based on the dark band similarity.

[0053] Compared with the prior art, the present invention has the following beneficial effects: it obtains the structural evaluation value by real-time acquisition of the three-dimensional geometric parameters (height, outer diameter, inner diameter) of the forging, dynamically matches the optimal scanning mode, breaks through the limitations of traditional detection, and reduces the problem of missed detection caused by structural differences in forgings; evaluates the internal quality of the forging and the stability of the detection system through the discreteness of the peak interval; and, when the ultrasonic detection is judged to be at risk of failing to meet the standards based on the discreteness of the peak interval, introduces the scanning fluctuation rate of the C-scan view for secondary judgment to improve the reliability of the evaluation; adjusts the scanning rate based on the scanning fluctuation rate to balance the detection accuracy and efficiency; when the ultrasonic detection of the forging is obviously failing to meet the standards, distinguishes the forging defects or insufficient water coupling agent flow through the similarity of dark bands, achieves accurate classification, reduces misjudgment, and thus improves the accuracy of ultrasonic detection.

[0054] Furthermore, the present invention quantifies the geometric characteristics of the forging through the structural evaluation value and dynamically selects the scanning mode according to the structural evaluation value, avoiding the detection blind area generated by the traditional single path, thereby ensuring the integrity of the sound beam coverage.

[0055] Furthermore, the present invention introduces the quantitative indicator of peak interval dispersion to quantify the degree of dispersion of the actual arrival time of adjacent preset peaks, which is used to evaluate the internal quality of forgings and the stability of the detection system. A large peak interval dispersion indicates that it is caused by forging defects such as cracks, inclusions or looseness, or by signal distortion caused by excessive movement of the probe, resulting in a large peak interval dispersion. The scanning fluctuation rate is then introduced for secondary judgment to eliminate evaluation errors, thereby improving the reliability of the evaluation.

[0056] Furthermore, the present invention constructs a signal amplitude matrix through repeated scanning, which can eliminate the influence of accidental interference on a single detection result, obtain the standard deviation and the average value, calculate the scanning fluctuation rate, and quantify the discrete degree of the signal amplitude. If the scanning fluctuation rate is less than the preset value, it indicates that the signal amplitude is highly consistent in the time and space dimensions and the detection system is stable; if the scanning fluctuation rate is greater than or equal to the preset value, it indicates that the detection system is unstable; the scanning fluctuation rate effectively distinguishes between real defects and false defects of forgings (problems with the ultrasonic detection operating parameters), thereby improving the efficiency of ultrasonic detection.

[0057] Furthermore, the present invention effectively distinguishes between real material defects and artifacts caused by water coupling anomalies based on the geometric matching degree of the dark band contour; when the dark band similarity is insufficient, the system automatically determines that the coupling agent flow is insufficient; when the dark band similarity meets the standard, it is directly associated with the internal defects of the material, thereby improving the detection accuracy.

[0058] Furthermore, the present invention achieves precise control of the increase range of the water couplant flow rate by setting the increase range of the preset water couplant flow rate to be positively correlated with the dark band similarity difference. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Figure 1 This is a flow chart of an ultrasonic intelligent detection method for forgings according to an embodiment of the present invention;

[0060] Figure 2 This is a flow chart of determining whether ultrasonic testing of forgings meets standards based on the dispersion of peak intervals according to an embodiment of the present invention;

[0061] Figure 3 This is a schematic diagram of module connections of an ultrasonic intelligent detection system for forgings according to an embodiment of the present invention;

[0062] Figure 4 Schematic diagram of the structure of a scanner for an ultrasonic intelligent detection system for forgings according to an embodiment of the present invention;

[0063] In the figure, 1, scanner; 111, horizontal frame; 112, vertical frame; 12, first clamp; 13, second clamp; 14, pressure wheel; 15, pulley assembly. DETAILED DESCRIPTION

[0064] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention.

[0065] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0066] It should be pointed out that the data in this embodiment are all obtained by comprehensive analysis and evaluation of the historical test data of the present invention in the three months before this test and the corresponding historical test results. Those skilled in the art can understand that the method of determining the above-mentioned single parameter of the method of the present invention can be to select the value with the highest proportion as the preset standard parameter according to the data distribution, use weighted summation to use the obtained value as the preset standard parameter, substitute each historical data into a specific formula and use the value obtained by the formula as the preset standard parameter or other selection methods, as long as the method of the present invention can clearly define the different specific situations in the single determination process through the obtained value.

[0067] See also Figure 1 、 Figure 2 、 Figure 3 as well as Figure 4As shown, they are respectively a flow chart of the ultrasonic intelligent detection method for forgings according to an embodiment of the present invention; a flow chart of determining whether the ultrasonic detection of forgings meets the standard according to the peak interval dispersion according to an embodiment of the present invention; a module connection diagram of the ultrasonic intelligent detection system for forgings according to an embodiment of the present invention; and a structural diagram of the scanner of the ultrasonic intelligent detection system for forgings according to an embodiment of the present invention.

[0068] In one aspect, an embodiment of the present invention provides an ultrasonic intelligent detection method for forgings, comprising:

[0069] Step S1, obtaining the height, outer diameter and inner diameter of the annular forging to be inspected, and obtaining a structural evaluation value of the forging;

[0070] Step S2, installing the scanner 1 on the forging, and determining the ultrasonic scanning mode of the scanner 1 according to the structural evaluation value;

[0071] Step S3, the scanner 1 performs ultrasonic testing on the forging at a preset scanning rate of 15 mm / s and a preset water couplant flow rate of 2.25 mL / s to obtain a reflection waveform diagram and a C-scan view of the forging;

[0072] Step S4, obtaining the peak interval dispersion according to the reflection waveform diagram; obtaining the scanning wave rate and dark band similarity according to the C-scan view;

[0073] Step S5: When it is determined that the ultrasonic testing of the forging does not meet the standard based on the peak interval dispersion, a second determination is made based on the scanning wave fluctuation rate whether the ultrasonic testing of the forging meets the standard, or the reason why the ultrasonic testing of the forging does not meet the standard is determined based on the dark band similarity, where the reasons include insufficient water couplant flow and defects in the forging.

[0074] Specifically, the ultrasonic scanning mode of the scanner 1 is determined according to the structural evaluation value of the forging, wherein:

[0075] If the structural evaluation value is less than the first preset structural threshold value of 0.6, the scanner 1 adopts a type I ultrasonic scanning mode;

[0076] If the structural evaluation value is greater than or equal to the first preset structural threshold and less than the second preset structural threshold of 1.3, the scanner 1 adopts the second type of ultrasonic scanning mode;

[0077] If the structural evaluation value is greater than or equal to the second preset structural threshold and less than the third preset structural threshold of 2.1, the scanner 1 adopts the third type of ultrasonic scanning mode;

[0078] If the structural evaluation value is greater than or equal to the third preset structural threshold, the fourth type of ultrasonic scanning mode is adopted.

[0079] In this embodiment, the value range of the first preset structure threshold is (0.3, 0.7), the value range of the second preset structure threshold is (1.0, 1.5), and the value range of the third preset structure threshold is (1.8, 2.2). Preferably, the first preset structure threshold is 0.6, the second preset structure threshold is 1.3, and the third preset structure threshold is 2.1.

[0080] The structural evaluation value is calculated by the following formula:

[0081]

[0082] Where S represents the structural evaluation value; α represents the first weight, which is set to 0.45; L represents the height of the forging; D represents the outer diameter of the forging; d represents the inner diameter of the forging; d0 represents the preset inner diameter of the forging, which is set to 500 mm; β represents the second weight, which is set to 0.55.

[0083] In this embodiment, the preset inner diameter of the forging is selected as 500 mm. The preset inner diameter is obtained by taking the average value of the inner diameter of the forging when the pulley motion trajectory deviation is controlled within ±0.5 mm during the process of the scanner 1 scanning the annular forging. However, the above value is not limited to this, and those skilled in the art can also adjust the value according to actual needs.

[0084] Specifically, the first type of ultrasonic scanning mode is that the scanner 1 performs radial scanning of the end face of the forging, wherein the probe of the scanner 1 moves radially along the end face of the forging by a first preset length, and then rotates circumferentially around the end face by a first preset angle of 30°, with radial movement and circumferential rotation being performed sequentially.

[0085] The second type of ultrasonic scanning mode is that the scanner 1 performs a circumferential scan of the end face of the forging. After the probe of the scanner 1 rotates circumferentially around the end face of the forging to form a closed loop path, the probe moves radially along the end face of the forging by a second preset length, and the circumferential rotation and radial movement are performed sequentially.

[0086] The third type of ultrasonic scanning mode is that the scanner 1 performs an axial scanning of the annular surface of the forging, and after the probe of the scanner 1 moves axially along the annular surface of the forging for a third preset length, the probe rotates circumferentially around the annular surface of the forging for a second preset angle of 20°, and the axial movement and circumferential rotation are performed sequentially;

[0087] The four types of ultrasonic scanning modes are that the scanner 1 performs circumferential scanning of the annular surface of the forging. After the probe of the scanner 1 rotates circumferentially around the annular surface of the forging to form a closed loop path, the probe moves axially along the annular surface of the forging by a fourth preset length, and the circumferential rotation and axial movement are performed sequentially.

[0088] Specifically, the first preset length is set to the wall thickness of the forging, the first preset angle is selected as 30°, the second preset length is set to 30% of the wall thickness of the forging, the third preset length is set to the height of the forging, the second preset angle is selected as 20°, and the fourth preset length is selected as 15% of the height of the forging.

[0089] Specifically, whether the ultrasonic testing of the forging meets the standard is determined based on the peak interval dispersion, wherein:

[0090] If the peak interval dispersion is less than the first preset interval dispersion of 0.03 μs 2 , it is determined that the ultrasonic testing of the forging meets the standard;

[0091] If the peak interval dispersion is greater than or equal to the first preset interval dispersion and less than the second preset interval dispersion of 0.18 μs 2 , it is determined that the ultrasonic testing of the forging does not meet the standard, and a second determination is made based on the scanning fluctuation rate of the C-scan view whether the ultrasonic testing of the forging meets the standard;

[0092] If the peak interval dispersion is greater than or equal to a second preset interval dispersion, it is determined that the ultrasonic testing of the forging does not meet the standard, and the reason why the ultrasonic testing of the forging does not meet the preset standard is determined based on the dark band similarity in the C-scan view.

[0093] In this embodiment, the value range of the first preset interval discreteness is (0.015μs 2 , 0.045μs 2 ), the value range of the second preset interval discreteness is (0.15μs 2 , 0.20μs 2 ), preferably, the first preset interval discreteness is selected as 0.03μs 2 The second preset interval discreteness is selected as 0.18μs 2 .

[0094] Specifically, the peak interval dispersion reflects the changes in the ultrasonic propagation path due to cracks, inclusions, etc. inside the forging or the abnormal disturbance of the ultrasonic propagation path due to improper setting of ultrasonic testing operating parameters by calculating the variance of the time intervals between adjacent peaks.

[0095] Specifically, the process of obtaining the peak interval dispersion includes:

[0096] Obtaining a reflection waveform diagram of the forging;

[0097] Obtaining the time interval between adjacent preset peak values;

[0098] The variance of several time intervals is obtained and recorded as the peak interval dispersion.

[0099] Specifically, several historical forgings with exactly the same preparation process and geometric structure as the ring forging to be tested are obtained in the historical experimental data, and the average value of the peak value of the bottom surface echo of the defect-free area of ​​the several historical forgings is obtained. This average value is recorded as the preset peak value. In this embodiment, the preset peak value is selected as 80dB, but the above value is not limited to this. Those skilled in the art can also adjust the value according to actual needs.

[0100] Specifically, the ultrasonic testing of the forging is secondarily determined to be in compliance with the standard based on the scanning fluctuation rate, wherein:

[0101] If the scanning fluctuation rate is less than a preset scanning fluctuation rate of 0.08, it is determined that the ultrasonic testing of the forging meets the standard;

[0102] If the scanning fluctuation rate is greater than or equal to the preset scanning fluctuation rate, it is determined that the ultrasonic inspection of the forging does not meet the standard, and the scanning rate of the scanner 1 is reduced according to the difference between the scanning fluctuation rate and the preset scanning fluctuation rate.

[0103] In this embodiment, the preset scanning fluctuation rate is selected as 0.08, but the above value is not limited thereto, and those skilled in the art can also adjust the value according to actual needs.

[0104] Specifically, the process of obtaining the scanning volatility includes:

[0105] Performing ultrasonic scanning on the forging several times in the same scanning mode, and recording a signal amplitude matrix of a C-scan view of each scan;

[0106] Obtain the average value of the amplitude of several scan signals of each pixel;

[0107] Obtaining an average value of the signal amplitude of the forging;

[0108] Obtaining a standard deviation of the signal amplitude of the forging;

[0109] The ratio of the standard deviation of the signal amplitude of the forging to the average value of the signal amplitude of the forging is recorded as the scanning fluctuation rate.

[0110] Specifically, the reason why the accuracy of ultrasonic testing of the forging does not meet the preset standard is determined based on the similarity of the dark bands of the C-scan view, wherein:

[0111] If the dark band similarity is less than a preset dark band similarity of 0.85, it is determined that the reason why the accuracy of the ultrasonic testing of the forging does not meet the preset standard is that the preset water couplant flow rate is insufficient, and the preset water couplant flow rate is increased according to the difference between the preset dark band similarity and the dark band similarity;

[0112] If the dark band similarity is greater than or equal to a preset dark band similarity, it is determined that the reason why the accuracy of the ultrasonic inspection of the forging does not meet the preset standard is that the forging has a defect and an alarm is issued;

[0113] The dark band similarity is the similarity between the outline of the region in which the grayscale value of the pixel point in the C-scan view is less than the preset grayscale value 65 and the preset region outline.

[0114] Through the C-scan image of the defect-free forging completely covered by water coupling agent, the dark band area contour is extracted using OpenCV as the preset area contour.

[0115] In this embodiment, the preset dark band similarity is selected as 0.85, but the above value is not limited thereto, and those skilled in the art may also adjust the value according to actual needs.

[0116] Specifically, the increase in the preset water couplant flow rate is positively correlated with the dark band similarity difference. The positive correlation may be a linear positive correlation or a nonlinear positive correlation. The linear slope of the linear positive correlation is not specifically limited. It is understood that the greater the dark band similarity difference, the greater the increase in the preset water couplant flow rate. The dark band similarity difference is the difference between the preset dark band similarity and the dark band similarity.

[0117] On the other hand, an embodiment of the present invention further provides an ultrasonic intelligent detection system for an ultrasonic intelligent detection method for forgings, comprising:

[0118] The ultrasonic detection module is a scanner 1 comprising an inverted L-shaped frame consisting of a horizontal frame 111 and a vertical frame 112, a first fixture 12 disposed on the horizontal frame 111, and a second fixture 13 disposed on the vertical frame 112. The first fixture 12 and the second fixture 13 are both provided with ultrasonic transmitting and receiving probes and a water couplant tube disposed on one side of the ultrasonic transmitting and receiving probes.

[0119] A pressure wheel 14 is provided at one end of the horizontal frame 111, and a pulley group 15 is provided at the end of the horizontal frame 111 away from the pressure wheel 14, wherein the pulley group 15 is composed of a pair of driving wheels and symmetrically arranged driven wheels;

[0120] A structural parameter acquisition module, which is used to acquire the height, inner diameter and outer diameter of the ring forging to be tested;

[0121] A data acquisition module includes a peak acquisition unit for acquiring a preset peak value and a corresponding time interval in a reflection waveform graph, an amplitude acquisition unit for acquiring a pixel signal amplitude of a C-scan view, and an image acquisition unit for acquiring a pixel image of the C-scan view;

[0122] a mode selection module connected to the structural parameter acquisition module, for determining the ultrasonic scanning mode of the scanner 1 according to the structural evaluation value of the forging;

[0123] a control module, which is connected to the data acquisition module and the mode selection module respectively, and is used to determine whether the ultrasonic testing of the forging meets the standard based on the scanning fluctuation rate under the condition that the ultrasonic testing of the forging does not meet the standard based on the peak interval dispersion, or to determine the reason why the ultrasonic testing of the forging does not meet the standard based on the dark band similarity.

[0124] Specifically, there is no limitation on the specific structures of the mode selection module and the control module. The mode selection module and the control module themselves and the units therein can be composed of logic components, and the logic components include field programmable components, computers or microprocessors in computers.

[0125] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

[0126] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that the present invention is susceptible to various modifications and variations. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. An ultrasonic intelligent detection method for forgings, characterized in that: include: Obtaining the height, outer diameter, and inner diameter of the annular forging to be inspected, and obtaining a structural evaluation value of the forging; installing a scanner on the forging, and determining an ultrasonic scanning mode of the scanner according to the structural evaluation value; The scanner performs ultrasonic testing on the forging according to a preset scanning rate and a preset water couplant flow rate to obtain a reflection waveform diagram and a C-scan view of the forging; According to the reflection waveform diagram, the peak interval dispersion is obtained; according to the C-scan view, the scanning wave rate and the dark band similarity are obtained; When it is determined that the ultrasonic testing of the forging does not meet the standard based on the peak interval dispersion, a second determination is made based on the scanning wave fluctuation rate whether the ultrasonic testing of the forging meets the standard, or a reason why the ultrasonic testing of the forging does not meet the standard is determined based on the dark band similarity, where the reasons include insufficient water couplant flow and defects in the forging; The ultrasonic scanning mode of the scanner is determined according to the structural evaluation value of the forging, wherein: If the structural evaluation value is less than a first preset structural threshold, the scanner adopts a type of ultrasonic scanning mode; If the structural evaluation value is greater than or equal to the first preset structural threshold and less than the second preset structural threshold, the scanner adopts the second type ultrasonic scanning mode; If the structural evaluation value is greater than or equal to the second preset structural threshold and less than the third preset structural threshold, the scanner adopts the third type of ultrasonic scanning mode; If the structural evaluation value is greater than or equal to the third preset structural threshold, the fourth type of ultrasonic scanning mode is adopted; The structural evaluation value is determined by the aspect ratio of the forging and the inner diameter of the forging; The first ultrasonic scanning mode is that the scanner performs radial scanning of the end face of the forging, wherein the probe of the scanner moves radially along the end face of the forging by a first preset length, and then rotates circumferentially around the end face by a first preset angle, with the radial movement and circumferential rotation being performed sequentially. The second type of ultrasonic scanning mode is that the scanner performs a circumferential scanning of the end surface of the forging, and after the probe of the scanner rotates circumferentially around the end surface of the forging to form a closed loop path, the probe moves radially along the end surface of the forging by a second preset length, and the circumferential rotation and radial movement are performed sequentially; The third type of ultrasonic scanning mode is that the scanner performs an axial scanning of the annular surface of the forging, and after the probe of the scanner moves axially along the annular surface of the forging for a third preset length, the probe rotates circumferentially around the annular surface of the forging for a second preset angle, and the axial movement and circumferential rotation are performed sequentially; The fourth type of ultrasonic scanning mode is that the scanner performs a circumferential scanning of the annular surface of the forging, and after the probe of the scanner rotates circumferentially around the annular surface of the forging to form a closed loop path, the probe moves axially along the annular surface of the forging by a fourth preset length, and the circumferential rotation and axial movement are performed sequentially; The ultrasonic testing of the forging is determined to be in compliance with the standard according to the dispersion of the peak intervals, wherein: If the peak interval dispersion is less than the first preset interval dispersion, it is determined that the ultrasonic testing of the forging meets the standard; If the peak interval dispersion is greater than or equal to the first preset interval dispersion and less than the second preset interval dispersion, it is determined that the ultrasonic testing of the forging does not meet the standard, and a second determination is made based on the scanning fluctuation rate of the C-scan view whether the ultrasonic testing of the forging meets the standard; If the peak interval dispersion is greater than or equal to a second preset interval dispersion, it is determined that the ultrasonic testing of the forging does not meet the standard, and the reason why the ultrasonic testing of the forging does not meet the preset standard is determined based on the dark band similarity in the C-scan view; The process of obtaining the scanning volatility includes: Performing ultrasonic scanning on the forging several times in the same scanning mode, and recording a signal amplitude matrix of a C-scan view of each scan; Obtain the average value of the amplitude of several scan signals of each pixel; Obtaining an average value of the signal amplitude of the forging; Obtaining a standard deviation of the signal amplitude of the forging; The ratio of the standard deviation of the signal amplitude of the forging to the average value of the signal amplitude of the forging is recorded as the scanning fluctuation rate; The dark band similarity is the similarity between the outline of the region where the grayscale value of the pixel point in the C-scan view is less than the preset grayscale value and the outline of the preset region; The structural evaluation value is calculated by the following formula: ， Where S represents the structural evaluation value; α represents the first weight, which is set to 0.45; L represents the height of the forging; D represents the outer diameter of the forging; d represents the inner diameter of the forging; d0 represents the preset inner diameter of the forging, which is set to 500 mm; β represents the second weight, which is set to 0.

55.

2. The ultrasonic intelligent detection method for forgings according to claim 1, characterized in that: The process of obtaining the peak interval dispersion includes: Obtaining a reflection waveform diagram of the forging; Obtaining the time interval between adjacent preset peak values; The variance of several time intervals is obtained and recorded as the peak interval dispersion.

3. The ultrasonic intelligent detection method for forgings according to claim 2, characterized in that: The ultrasonic testing of the forging is secondarily determined to determine whether it meets the standards based on the scanning fluctuation rate, wherein: If the scanning fluctuation rate is less than a preset scanning fluctuation rate, it is determined that the ultrasonic testing of the forging meets the standard; If the scanning fluctuation rate is greater than or equal to the preset scanning fluctuation rate, it is determined that the ultrasonic inspection of the forging does not meet the standard, and the scanning rate of the scanner is reduced according to the difference between the scanning fluctuation rate and the preset scanning fluctuation rate.

4. The ultrasonic intelligent detection method for forgings according to claim 3, characterized in that: The reason why the accuracy of ultrasonic testing of the forging does not meet the preset standard is determined based on the similarity of the dark bands in the C-scan view, wherein: If the dark band similarity is less than a preset dark band similarity, it is determined that the reason why the accuracy of the ultrasonic testing of the forging does not meet the preset standard is that the preset water couplant flow rate is insufficient, and the preset water couplant flow rate is increased according to the difference between the preset dark band similarity and the dark band similarity; If the dark band similarity is greater than or equal to a preset dark band similarity, it is determined that the reason why the accuracy of the ultrasonic inspection of the forging does not meet the preset standard is that the forging has a defect, and an alarm is issued.

5. The ultrasonic intelligent detection method for forgings according to claim 4, characterized in that: The increase range of the preset water coupling agent flow rate is positively correlated with the dark band similarity difference, wherein the dark band similarity difference is the difference between the preset dark band similarity and the dark band similarity.

6. An ultrasonic intelligent detection system for forgings applied to the method according to any one of claims 1 to 5, characterized in that: include: An ultrasonic detection module, which is a scanner, includes an inverted L-shaped frame consisting of a horizontal frame and a vertical frame, a first fixture disposed on the horizontal frame, and a second fixture disposed on the vertical frame, wherein the first fixture and the second fixture are both provided with an ultrasonic transmitting and receiving probe and a water couplant tube disposed on one side of the ultrasonic transmitting and receiving probe; A pressure wheel is provided at one end of the horizontal frame, and a pulley group is provided at an end of the horizontal frame away from the pressure wheel, wherein the pulley group is composed of a pair of driving wheels and symmetrically arranged driven wheels; A structural parameter acquisition module, which is used to acquire the height, inner diameter and outer diameter of the ring forging to be tested; A data acquisition module includes a peak acquisition unit for acquiring a preset peak value and a corresponding time interval in a reflection waveform graph, an amplitude acquisition unit for acquiring a pixel signal amplitude of a C-scan view, and an image acquisition unit for acquiring a pixel image of the C-scan view; a mode selection module connected to the structural parameter acquisition module, for determining an ultrasonic scanning mode of the scanner according to the structural evaluation value of the forging; a control module, which is connected to the data acquisition module and the mode selection module respectively, and is used to determine whether the ultrasonic testing of the forging meets the standard based on the scanning fluctuation rate under the condition that the ultrasonic testing of the forging does not meet the standard based on the peak interval dispersion, or to determine the reason why the ultrasonic testing of the forging does not meet the standard based on the dark band similarity.

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