Composite material ultrasonic nondestructive testing array device and testing method

Abstract

The invention discloses a composite material ultrasonic nondestructive testing array device and a testing method.The composite material ultrasonic nondestructive testing array device comprises a scanning matrix structure, a mechanical arm and a control unit, and the scanning matrix structure comprises a flaw detection frame, a plurality of transverse driving mechanisms, a plurality of longitudinal driving mechanisms, a laser scanner and a plurality of ultrasonic probes; the laser scanner and the plurality of ultrasonic probes are mounted on the flaw detection frame, and the laser scanner is used for acquiring a three-dimensional model of the to-be-detected composite material component. The mechanical arm is used for flexibly positioning the carried scanning matrix structure, so that the scanning matrix structure can quickly reach different detection areas of the large composite material component; a laser scanner and a plurality of ultrasonic probes are integrated in the scanning matrix structure, firstly, the laser scanner obtains the local three-dimensional shape of a component, the control unit plans a scanning path in real time according to the model and divides detection sub-areas, and then the multiple ultrasonic probes are driven to independently move in the frame at the same time; and performing synchronous parallel scanning on the respective distribution areas.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite material nondestructive testing, and particularly relates to a composite material ultrasonic nondestructive testing array device and a detection method. BACKGROUND

[0002] Large composite components are widely used in the field of aviation due to their high specific strength, good fatigue resistance and strong designability, such as wind power blades of tens of meters or even hundreds of meters long and aviation composite wallboards of several meters long. However, various defects are prone to occur in the production and use of composite components, and therefore, nondestructive testing is required during production. Traditional detection methods mostly rely on single ultrasonic probe or a small number of ultrasonic probes for point-by-point scanning. Due to the large size and wide detection area of the components, a single detection often takes several hours or even several days, which not only seriously restricts the production rhythm, but also is difficult to meet the rapid detection requirements in equipment maintenance. At the same time, the long detection process is easily disturbed by the environment, which may lead to a decrease in data stability and further affect the detection reliability. This contradiction between efficiency and accuracy has become an important obstacle to the large-scale application of large composite components, and innovative detection technology is urgently needed to break through this dilemma. SUMMARY

[0003] The present application relates to the technical field of composite material nondestructive testing, and particularly relates to a composite material ultrasonic nondestructive testing array device and a detection method.

[0004] To solve the above technical problems, the technical scheme adopted by the present application is as follows: The application provides a composite material ultrasonic nondestructive testing array device, which comprises a scanning matrix structure, a mechanical arm and a control unit, the scanning matrix structure comprises a flaw detection frame, a plurality of transverse driving mechanisms and a plurality of longitudinal driving mechanisms, a laser scanner and a plurality of ultrasonic probes, the laser scanner and the plurality of ultrasonic probes are installed on the flaw detection frame, and the laser scanner is used for acquiring a three-dimensional model of a composite material component to be detected; the plurality of transverse driving mechanisms are respectively in transmission connection with the plurality of ultrasonic probes, the transverse driving mechanisms are used for driving the ultrasonic probes to move along the transverse direction relative to the flaw detection frame, the plurality of longitudinal driving mechanisms are respectively in transmission connection with the plurality of ultrasonic probes, and the longitudinal driving mechanisms are used for driving the ultrasonic probes to move along the longitudinal direction relative to the flaw detection frame; the mechanical arm is in transmission connection with the flaw detection frame; and the control unit is in signal connection with the laser scanner, the transverse driving mechanisms, the longitudinal driving mechanisms and the mechanical arm respectively, wherein the control unit is configured to generate a scanning path of each ultrasonic probe based on the three-dimensional model acquired by the laser scanner, control the mechanical arm to drive the flaw detection frame to move in a three-dimensional space, and control the transverse driving mechanisms and the longitudinal driving mechanisms to drive the ultrasonic probes to move on the flaw detection frame, so that the ultrasonic probes move and scan along the scanning path.

[0005] The composite material ultrasonic nondestructive testing array device has the following beneficial effects: The scanning matrix structure carried by the mechanical arm can quickly reach different detection areas of a large composite material component; the laser scanner and the plurality of ultrasonic probes are integrated in the scanning matrix structure, the three-dimensional model of a local component is acquired by the laser scanner first, the control unit plans a scanning path and divides a detection sub-area according to the model in real time, then the plurality of ultrasonic probes are driven to move independently in the frame, and the assigned areas are scanned synchronously and in parallel. The cooperation of the mechanical arm and the multi-ultrasonic probe scanning matrix realizes global coverage and flexible positioning of a large-size complex structure, improves the detection efficiency of a local area through parallel operation of the plurality of ultrasonic probes, and solves the problem that the efficiency and the precision cannot be considered simultaneously in the detection of a large composite material component.

[0006] As a further improvement of the above technical scheme, the plurality of ultrasonic probes are arranged in a row on the flaw detection frame, and the laser scanner is located at the center of the flaw detection frame.

[0007] As a further improvement of the above technical solution, the transverse driving mechanism comprises a transverse guide rail, a transverse driving motor and a transverse sliding block, the transverse guide rail is fixed to the flaw detection frame, the transverse sliding block is driven by the transverse driving motor and moves along the transverse guide rail, the longitudinal driving mechanism comprises a longitudinal guide rail, a longitudinal driving motor and a longitudinal sliding block, the longitudinal guide rail is installed on the transverse sliding block, the longitudinal sliding block is driven by the longitudinal driving motor and moves along the longitudinal guide rail, and the ultrasonic probe is installed on the longitudinal sliding block.

[0008] As a further improvement of the above technical solution, the ultrasonic probe is provided with a probe orientation adjusting mechanism, the probe orientation adjusting mechanism is used to drive the ultrasonic probe to rotate to adjust the detection direction of the ultrasonic probe, and the probe orientation adjusting mechanism is connected with the control unit. The control unit is further configured to calculate the surface normal vector of the composite component in real time based on the three-dimensional model obtained by the laser scanner, and control the detection direction of the ultrasonic probe to be the same as the surface normal vector of each position of the composite component.

[0009] As a further improvement of the above technical solution, the longitudinal sliding block is further provided with a flaw detection curved arm, and the ultrasonic probe is arranged at the free end of the flaw detection curved arm.

[0010] The present application provides a composite material ultrasonic nondestructive testing method, comprising: controlling a laser scanner to scan a composite component, obtaining three-dimensional point cloud data and constructing a three-dimensional model, and extracting a surface two-dimensional development drawing of the composite component based on the three-dimensional model; controlling the surface two-dimensional development drawing to be divided into a plurality of sub-regions according to a preset rule; controlling a plurality of ultrasonic probes to scan a plurality of sub-regions one by one to obtain ultrasonic detection data of each sub-region; controlling the ultrasonic detection data to be fused and spliced to generate a complete internal defect image of the composite component.

[0011] As a further improvement of the above technical solution, the surface two-dimensional development drawing is divided into a plurality of sub-regions according to a preset rule, which further comprises: controlling the edge overlapping part between adjacent sub-regions to have a preset width; controlling the time required for each ultrasonic probe to scan the sub-region allocated to it to be consistent.

[0012] As a further improvement of the above technical solution, the time required for each ultrasonic probe to scan the sub-region allocated to it is controlled to be consistent, which comprises: calculating a total scanning path amount of the probe based on the three-dimensional digital model data and the two-dimensional surface development model data of the composite material component; determining a scanning time of each ultrasonic probe according to the number of ultrasonic probes and the scanning efficiency of the probe; dividing the two-dimensional surface development model into sub-regions and assigning scanning paths to the sub-regions, so that the scanning times of the probes approach the scanning time.

[0013] As a further improvement of the above technical solution, the control of the ultrasonic detection data fusion and splicing to generate the complete internal defect image of the composite material component comprises: obtaining coordinate position information of each sub-region on the composite material component; using the detection data in the overlapping part of adjacent sub-regions to perform data registration through a feature point matching algorithm; According to the data registration result, the sub-region detection data collected by different ultrasonic probes is calibrated and aligned in a unified coordinate system through coordinate transformation, and finally fused to form a complete internal defect image.

[0014] As a further improvement of the above technical solution, the control of the ultrasonic detection data fusion and splicing to generate the complete internal defect image of the composite material component comprises: analyzing the collected ultrasonic data to identify defects in the composite material component; Marking the identified defects in the three-dimensional model of the composite material component, and generating a detection report based on the marking result. BRIEF DESCRIPTION OF DRAWINGS

[0015] The application will be further described below in conjunction with the drawings and examples; Figure 1 It is a schematic diagram of the overall structure of a composite material ultrasonic non-destructive testing array device; Figure 2 It is a schematic diagram of the overall structure of a scanning matrix part of a composite material ultrasonic non-destructive testing array device; Figure 3 It is a schematic diagram of the division of the region to be tested of the composite material component in a composite material ultrasonic non-destructive testing array device; Figure 4 It is a schematic diagram of the scanning path of an ultrasonic scanning ultrasonic probe in a composite material ultrasonic non-destructive testing array device; Figure 5 It is a schematic diagram of the detection method flow of a composite material ultrasonic non-destructive testing array device.

[0016] Reference signs: The mechanical arm 100, the base 110, the steering ball seat 120, the vertical arm 130, the connecting ball seat 140, the horizontal arm 150, the terminal ball seat 160, the connecting arm 170, the scanning matrix structure 200, the flaw detection frame 210, the laser scanner 220, the ultrasonic probe 230, the horizontal guide rail 240, the longitudinal guide rail 250, the flaw detection curved arm 260, and the composite material component 300. DETAILED DESCRIPTION

[0017] This part will describe the specific embodiments of the present application in detail, and the preferred embodiments of the present application are shown in the drawings, and the drawings are used to supplement the description of the text part of the specification, so that people can intuitively and visually understand each technical feature and the overall technical scheme of the present application, but it cannot be understood as a limitation on the protection scope of the present application.

[0018] In the description of the present application, it should be understood that the orientation description, such as the orientation or position relationship indicated by the above, below, front, back, left, right, etc. is based on the orientation or position relationship shown in the drawings, and is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0019] In the description of the present application, if the word "several" or the like is described, the meaning is one or more, the meaning of more is two or more, greater than, less than, more than, etc. are not included in the number, above, below, within, etc. are understood to include the number.

[0020] In the description of the present application, unless otherwise explicitly limited, the words such as setting, installing, connecting, etc. should be understood in a broad sense, and the person skilled in the art can reasonably determine the specific meaning of the above words in the present application in combination with the specific content of the technical scheme.

[0021] Reference Figures 1 to 5 The present application provides a composite material ultrasonic nondestructive testing array device and a detection method, and the following embodiments are made: The composite material ultrasonic nondestructive testing array device comprises a mechanical arm 100, a scanning matrix structure 200 and a control unit, the mechanical arm 100 is a multi-degree-of-freedom mechanical arm 100, the mechanical arm 100 is drivingly connected with the detection frame 210, and wide-range movement and positioning capability are provided; the scanning matrix structure 200 comprises a detection frame 210, a plurality of transverse driving mechanisms and a plurality of longitudinal driving mechanisms, a laser scanner 220 and a plurality of ultrasonic probes 230, the laser scanner 220 is installed on the detection frame 210 and is used for acquiring a three-dimensional model of the composite material component 300, the purpose of laser scanning is to obtain the shape contour and size parameters (such as length, width, height, curvature and the like) of the composite material component, after denoising, smoothing and feature extraction and the like, a three-dimensional numerical model of the composite material component is constructed, and a 3D laser scanner 220, an industrial camera and other single or combined image acquisition devices can be used.

[0022] The plurality of transverse driving mechanisms and the plurality of longitudinal driving mechanisms are arranged on the detection frame 210, the plurality of transverse driving mechanisms are drivingly connected with the plurality of ultrasonic probes 230 respectively, the transverse driving mechanisms are used for driving the ultrasonic probes 230 to move along the transverse direction relative to the detection frame 210, the plurality of longitudinal driving mechanisms are drivingly connected with the plurality of ultrasonic probes 230 respectively, and the longitudinal driving mechanisms are used for driving the ultrasonic probes 230 to move along the longitudinal direction relative to the detection frame 210. The control unit is signal-connected with the laser scanner 220, the transverse driving mechanisms, the longitudinal driving mechanisms and the mechanical arm 100 respectively, wherein the control unit is configured to generate a scanning path of each ultrasonic probe 230 based on the three-dimensional model acquired by the laser scanner 220, and control the mechanical arm 100 to drive the detection frame 210 to move in a three-dimensional space and control the transverse driving mechanisms and the longitudinal driving mechanisms to drive the ultrasonic probes 230 to move on the detection frame 210, so as to control the ultrasonic probes 230 to move and scan along the scanning path.

[0023] The application flexibly positions the scanning matrix structure 200 carried by the mechanical arm 100, so that it can quickly reach different detection areas of a large composite component; the scanning matrix structure 200 is integrated with a laser scanner 220 and multiple ultrasonic probes 230 inside, first, the laser scanner 220 obtains the local three-dimensional topography of the component, and the control unit plans the scanning path and divides the detection sub-area in real time according to the model, then simultaneously drives multiple ultrasonic probes 230 to move independently in the frame, and synchronously and parallelly scans each allocated area. The cooperation of the mechanical arm 100 and the multi-ultrasonic probe 230 scanning matrix not only realizes the global coverage and flexible positioning of large-size complex structural parts, but also significantly improves the detection efficiency of local areas through the parallel operation of multiple ultrasonic probes 230, and overall solves the problem that efficiency and precision are difficult to balance in the detection of large composite components.

[0024] Specifically, the embodiment of the application adopts a six-degree-of-freedom mechanical arm 100, including a base 110, a steering ball seat 120, a vertical arm 130, a connecting ball seat 140, a horizontal arm 150, a terminal ball seat 160, and a connecting arm 170. The base 110 provides a foundation and fixed counterweight for the overall device, and a counterweight mechanism can be added to balance the weight of the ultrasonic probes 230 and the laser scanner 220. Through dynamic counterweighting, the device can maintain balance under different ultrasonic probe 230 configurations, reducing shaking and vibration, and can adapt to ultrasonic probes 230 and accessories of different weights, expanding the application range of the device. In addition, a stable mechanical structure helps to reduce errors during the detection process, thus also being conducive to improving the accuracy of data acquisition. For example, when using 10 light ultrasonic probes 230 (each 1 kg) and a laser scanner 220 (5 kg), 45 kg of counterweight can be added to the base. If 5 heavy ultrasonic probes 230 (each 3 kg) are replaced, the counterweight can be adjusted to 40 kg, always keeping the center of gravity of the overall device stable, ensuring accurate positioning and stable movement during the detection process.

[0025] The base 110 is provided with a steering ball seat 120 on the upper side, the steering ball seat 120 is connected with the base 110 and the force arm, and provides the force arm with a spherical degree of freedom relative to the base 110; the force arm is provided with a connecting ball seat 140 on the upper side, the force arm is connected with the steering ball seat 120 and the connecting ball seat 140, and provides support and necessary distance between the two spherical degree of freedom steering mechanisms to widen the effective activity area of the composite material ultrasonic nondestructive testing array device; the connecting ball seat 140 is provided with a cross arm 150 on the other side, the cross arm 150 is connected with the connecting ball seat 140 and a terminal ball seat 160, and the cross arm 150 provides necessary support and necessary distance for the connecting ball seat 140 and the terminal ball seat 160 to widen the effective activity area of the composite material ultrasonic nondestructive testing array device; the terminal ball seat 160 is connected with the cross arm 150 and a connecting arm 170, and the terminal ball seat 160 provides the connecting body with a spherical degree of freedom relative to the cross arm 150, so that the scanning matrix part of the composite material ultrasonic nondestructive testing array device can keep a proper distance and angle with the scanning area.

[0026] The upper side of the flaw detection frame 210 is connected with the connecting arm 170, the flaw detection frame 210 keeps relative fixation with the connecting arm 170, and the flaw detection frame 210 provides frame support and fixation for the scanning matrix part; a plurality of ultrasonic scanning ultrasonic probes 230 are arranged on the flaw detection frame 210, the ultrasonic scanning ultrasonic probes 230 are connected with longitudinal sliders on the flaw detection frame 210 through flaw detection curved arms 260, the flaw detection curved arms 260 are in the shape of "Z", and the purpose is to remove the influence of the frame width on the scanning range; a laser scanner 220 is arranged in the flaw detection frame 210, and the main function of the laser scanner 220 is to quickly obtain three-dimensional point cloud data of a large composite material part and real-time position of the composite material ultrasonic nondestructive testing array device relative to the composite material component; The transverse driving mechanism includes a transverse guide rail 240, a transverse driving motor and a transverse slider, the transverse guide rail 240 is fixed on the flaw detection frame 210, the transverse slider is driven by the transverse driving motor and can move along the transverse guide rail 240, the longitudinal driving mechanism is installed on the transverse slider, the longitudinal driving mechanism includes a longitudinal guide rail 250, a longitudinal driving motor and a longitudinal slider, the longitudinal slider is driven by the longitudinal driving motor and can move along the longitudinal guide rail 250, and the ultrasonic probe 230 is installed on the longitudinal slider. Through cooperation of the longitudinal guide rail 250 and the transverse guide rail 240, the ultrasonic scanning ultrasonic probe 230 can be moved to any position on the flaw detection frame 210.

[0027] Further, the flaw detection frame 210 is provided with a grid-shaped clamping groove or guide rail, the transverse driving mechanism is provided with a buckle or a slider matched with the clamping groove or the guide rail, the detachable movement and fixation of the driving mechanism on the frame are realized, and the number of ultrasonic scanning ultrasonic probes 230 arranged in the transverse moving shaft and the longitudinal moving shaft can be adjusted according to the to-be-detected area of the composite material component and the scanning requirements.

[0028] Further, the plurality of ultrasonic probes 230 are arranged in a row on the inspection frame 210, and can be quickly controlled to enter the corresponding allocated sub-region and start scanning according to the allocated sub-region. When installed, the optimal installation position of the laser scanner 220 is at the center of the inspection frame 210, so as to facilitate determination of the relative position of the inspection frame 210 relative to the composite component.

[0029] The control unit is further connected in signal with the laser scanner 220, the transverse driving mechanism and the longitudinal driving mechanism, and is configured to generate a scanning path plan for the ultrasonic probes 230 based on the three-dimensional model obtained by the laser scanner 220, and control the transverse driving mechanism and the longitudinal driving mechanism to drive each ultrasonic probe 230 to independently move along the planned path in the plane of the inspection frame 210, so as to cover and position to each detection position of the inspection frame 210. In some other embodiments, the control unit is configured to dynamically optimize and allocate the scanning path of each ultrasonic probe 230 based on the three-dimensional model data obtained by the laser scanner 220 in real time, so as to minimize the total scanning time. The scanning matrix structure 200 further comprises at least one other type of non-destructive testing sensor, and the control unit is configured to synchronously acquire ultrasonic data and other sensor data and perform fusion analysis.

[0030] Further, adaptive ultrasonic detection for large composite components with complex curved surfaces can be further added. The ultrasonic probe 230 is provided with a probe orientation adjusting mechanism for driving the ultrasonic probe 230 to rotate to adjust the detection direction of the ultrasonic probe 230, and the probe orientation adjusting mechanism is connected with the control unit; the control unit is further configured to calculate the surface normal vector of the composite component 300 in real time based on the three-dimensional model obtained by the laser scanner, and control the detection direction of the ultrasonic probe 230 to be the same as the surface normal vector of each position of the composite component 300.

[0031] In the specific operation of the composite ultrasonic non-destructive testing array device, the entire scanning matrix structure is first moved to a position covering a large composite component (such as an aircraft wing skin) by a mechanical arm.

[0032] The laser scanner 220 scans the component to quickly obtain a high-precision three-dimensional point cloud model and reconstruct a three-dimensional digital surface. The control unit receives the three-dimensional model data, and not only plans an optimal scanning path for each ultrasonic probe based on the three-dimensional model data, divides the detection region into a plurality of sub-regions, but also calculates the normal direction of the component surface corresponding to each point on the scanning path in real time.

[0033] Each ultrasonic probe 230 is mounted on a probe orientation adjusting mechanism, which is usually composed of two micro servo motors, and can realize two degrees of freedom deflection. The control unit generates control instructions according to the current planned path point and the calculated surface normal vector, and drives the probe orientation adjusting mechanism to act, so as to adjust the spatial pose of the ultrasonic probe in real time, and ensure that the emission surface of the ultrasonic wave is perpendicular to the curved surface of the component at each detection moment.

[0034] On this basis, the control unit controls the plurality of transverse driving mechanisms and longitudinal driving mechanisms to drive each probe to move synchronously and in parallel in the respective sub-regions according to the planned path. At this time, the ultrasonic probe 230 not only moves and positions in a two-dimensional plane, but also has the ability to "look up and down", and can actively adapt to the change of the curved surface.

[0035] Finally, the ultrasonic echo data collected by all ultrasonic probes 230 is transmitted back to the control unit. Since it is ensured that the ultrasonic wave always enters at the best angle, the signal quality obtained is significantly higher than that of fixed angle scanning. The system then uses a data splicing algorithm to fuse the high-quality data of each sub-region, and generates a complete and high-reliability detection image and report that can accurately reflect the internal defects (such as delamination, porosity, and inclusions) of the complex curved surface component.

[0036] The present application provides an embodiment of a detection method of a composite material ultrasonic nondestructive testing array device, comprising: Step S100: control the laser scanner 220 to scan the composite material component 300, obtain its three-dimensional point cloud data and construct a three-dimensional model, and extract a surface two-dimensional development drawing of the composite material component based on the three-dimensional model; Step S200: according to a preset rule, control the surface two-dimensional development drawing to be divided into a plurality of sub-regions; Step S300: control a plurality of ultrasonic probes 230 to correspondingly scan a plurality of the sub-regions to obtain ultrasonic detection data of each of the sub-regions; Step S400: control the ultrasonic detection data to be fused and spliced to generate a complete internal defect image of the composite material component.

[0037] Taking the detection of a wind power blade with a length of 20 meters as an example, the specific implementation process is as follows: In step S100, the scanning surface of the composite component 300 is cleaned to remove oil stains / dust and other attached impurities, and then the composite component 300 is fixed. Subsequently, a composite ultrasonic nondestructive testing array device is started to perform laser scanning on the laser scanner 220 of the composite component 300, and three-dimensional point cloud data of the composite component 300 is quickly obtained. The obtained three-dimensional point cloud data is preprocessed by denoising, smoothing, feature extraction, etc., to accurately capture the shape profile and size parameters (such as length, width, height, curvature, etc.) of the composite component, establish a three-dimensional numerical model of the composite component, and extract a two-dimensional unfolded model of the surface of the composite component.

[0038] In step S200, the controller divides the entire blade into 10 sub-regions according to the three-dimensional numerical model and the two-dimensional unfolded model of the blade, and the scanning time of each sub-region is approximately equal. According to the number and distribution of the divided regions, a corresponding matrix of ultrasonic probes 230 is prepared on a composite ultrasonic nondestructive testing array device to form a detection square matrix. If the blade is divided into 10 regions, 10 ultrasonic probes 230 are installed.

[0039] Further, step S200 further includes controlling an edge overlap part with a preset width between adjacent sub-regions; when the 10 sub-regions are divided, an edge overlap part with a preset width between any adjacent sub-regions is ensured, and the position and width of the overlap region can be adjusted. Generally, the overlap width is 5mm-10mm. After the division is completed, the system generates coordinate position information and boundary parameters of each sub-region, which provides a basis for subsequent positioning of the scanning device. After the division is completed, the system generates coordinate position information and boundary parameters of each sub-region, which provides a basis for subsequent positioning of the ultrasonic probes 230.

[0040] Further, step S200 further includes controlling the scanning time of each ultrasonic probe 230 in the sub-region allocated to it to be consistent. The specific steps are as follows: based on the three-dimensional numerical model data and the two-dimensional unfolded model data of the composite component, the total scanning path amount of the probe is calculated; According to the number of ultrasonic probes, combined with the scanning efficiency of the probe, the scanning time of each ultrasonic probe is determined; In order to make the scanning time of each probe close to the scanning time, the two-dimensional unfolded model is divided into sub-regions and the scanning path is allocated.

[0041] That is, the three-dimensional numerical model of the composite component and the two-dimensional surface unfolding model data of the composite component are combined to calculate the total amount of scanning for non-destructive testing of the composite material, the scanning efficiency of the existing non-destructive scanning equipment and mode is calculated, the three-dimensional numerical model of the composite component and the two-dimensional surface unfolding model data of the composite component are divided into regions according to the preset rules, and the scanning time of each scanning ultrasonic probe 230 in the composite material ultrasonic non-destructive testing array device for each partition is consistent, wherein the calculation of the scanning time required by the ultrasonic probe 230 is based on the following factors: three-dimensional digital model data of the composite component 300; two-dimensional surface unfolding model data of the composite component; total amount of non-destructive testing scanning calculated based on the three-dimensional digital model and the two-dimensional unfolding model data; and scanning efficiency of the selected non-destructive scanning equipment and scanning mode.

[0042] In step S300: start scanning the composite component by the composite material ultrasonic non-destructive testing array device according to the preset path, each ultrasonic probe 230 in the matrix synchronously scans the corresponding region, and simultaneously transmits the scanning data to the data center for analysis and processing. Each ultrasonic probe 230 has sufficient degrees of freedom to ensure a suitable distance and angle with the surface to be measured. After the scanning of the current region is completed, the large composite material ultrasonic non-destructive testing array is moved to the next scanning region by the mechanical arm 100 for scanning, until all regions are scanned.

[0043] In step S400: the data center of the controller processes and splices the sub-region detection data transmitted by each ultrasonic probe 230 according to the preset splicing algorithm. First, the coordinate position information of each sub-region on the composite component is obtained. According to the coordinate position information of each sub-region and the detection data of the overlapping part, the data collected by different ultrasonic probes 230 is calibrated and aligned through feature point matching and coordinate transformation, so as to eliminate the data deviation caused by the installation error or movement error of the ultrasonic probe 230. The calibrated sub-region data is fused and spliced to form a complete detection data image of the entire large composite component. At the same time, the ultrasonic analysis part of the composite material ultrasonic non-destructive testing array device can use a trained convolutional neural network model to identify common defects such as delamination, porosity and cracks in the composite component, and mark them in the three-dimensional model.

[0044] The following is an actual detection example: First, the scanning surface of the sample to be measured is cleaned to remove oil stains, dust and other attached impurities, so as to avoid damage caused by foreign matter connection or adhesion on the surface of the component. Then, the sample to be measured is placed on the detection platform and fixed by the clamp to prevent the component from moving during scanning and affecting the establishment of the three-dimensional numerical model and damage detection.

[0045] The composite material ultrasonic nondestructive testing array device is started, which is composed of a mechanical arm 100 part and a scanning matrix part. The position of the scanning matrix part is adjusted by controlling the mechanical arm 100 part to align the laser scanner 220 on the flaw detection frame 210 with one side of the sample to be tested. The laser scanner 220 is started to perform laser scanning on the complete sample to be tested, and the three-dimensional point cloud data of the sample to be tested is quickly obtained. The obtained data is preprocessed such as denoising, smoothing and feature extraction, and the shape contour and size parameters (such as length, width, height, curvature, etc.) of the component are accurately captured. A three-dimensional numerical model is established, and a two-dimensional development model of the surface is extracted.

[0046] The data processing unit of the controller integrates the three-dimensional numerical model and the two-dimensional development model data, calculates the total nondestructive testing scanning amount, combines the existing equipment scanning efficiency, and divides the area according to the preset rules, taking the scanning time of each scanning ultrasonic probe 230 for the corresponding subarea as the standard. When dividing, ensure that there is a 5mm overlapping part between adjacent subareas, and the position and width are adjustable. After the division is completed, the coordinate position information and boundary parameters of each subarea are generated, as shown in Figure 3

[0047] According to the number and distribution of the divided areas, a horizontal guide rail 240 and two longitudinal guide rails 250 are installed on the flaw detection frame 210, which are configured to correspond to the ultrasonic probe 230 matrix to form a detection square matrix. The ultrasonic scanning ultrasonic probe 230 is connected to the longitudinal guide rail 250 through the "Z" shaped ultrasonic probe 230 curved arm, so as to remove the influence of the width of the flaw detection frame 210 and the horizontal guide rail 240 and the two longitudinal guide rails 250 on the scanning range.

[0048] The position of each ultrasonic scanning ultrasonic probe 230 is adjusted so that it is in the scanning position, ensuring that each ultrasonic scanning ultrasonic probe 230 has sufficient freedom to maintain an appropriate distance and angle with the surface of the sample to be tested, and there is no interference between each ultrasonic scanning ultrasonic probe 230 and other components. The device starts to scan the sample to be tested according to the preset path, as shown in Figure 4

[0049] After the scanning of this area is completed, the scanning matrix structure 200 moves to the next scanning area through the mechanical arm 100 for scanning. If the sample to be tested exceeds the active area of the device, the partition scanning can be continued until all areas are scanned.

[0050] ​​The data center processes and splices the sub-region detection data transmitted by each ultrasonic scanning ultrasonic probe 230 according to a preset splicing algorithm, aligns the data through feature point matching and coordinate transformation calibration according to the coordinate position information of each sub-region and the detection data of the overlapping part, fuses and splices the complete detection data image after eliminating the offset. The trained convolutional neural network model is used for defect recognition on the complete detection image, common defects such as layering, porosity and cracks are recognized and marked in the three-dimensional model, and a detection report containing defect parameters, evaluation results and image annotation is generated. The detection personnel review the report through the visual interface to finally determine whether the quality of the sample to be tested is qualified.

[0051] After the detection is completed, the mechanical arm 100 is adjusted to restore the ultrasonic scanning ultrasonic probe 230 and the laser scanner 220 to the initial position, the mechanical arm 100 is controlled to move the scanning matrix part to a safe position, the fixing of the sample to be tested is released, the component is taken out, and the whole detection process is completed.

[0052] The preferred embodiments of the application are specifically described above, but the application is not limited to the embodiments, and those skilled in the art can make various equivalent modifications or replacements without departing from the spirit of the application. These equivalent modifications or replacements are all included in the scope defined by the claims of the present application.

Claims

1. An ultrasonic non-destructive testing array device for composite materials, characterized in that, Comprise: A scanning matrix structure composite component, comprising a flaw detection frame composite component, a plurality of transverse driving mechanisms and a plurality of longitudinal driving mechanisms, a laser scanner composite component, and a plurality of ultrasonic probe composite components, the laser scanner composite component and the plurality of ultrasonic probe composite components are installed on the flaw detection frame composite component, the laser scanner composite component is used to obtain a three-dimensional model of a composite component to be detected; a plurality of transverse driving mechanisms are respectively in transmission connection with a plurality of ultrasonic probe composite components, the transverse driving mechanism is used to drive the ultrasonic probe composite component to move along the transverse direction relative to the flaw detection frame composite component, a plurality of longitudinal driving mechanisms are respectively in transmission connection with a plurality of ultrasonic probe composite components, the longitudinal driving mechanism is used to drive the ultrasonic probe composite component to move along the longitudinal direction relative to the flaw detection frame composite component; A mechanical arm composite component in transmission connection with the flaw detection frame composite component; A control unit in signal connection with the laser scanner composite component, the transverse driving mechanism, the longitudinal driving mechanism and the mechanical arm composite component respectively, wherein the control unit is configured to generate a scanning path of each ultrasonic probe composite component based on the three-dimensional model obtained by the laser scanner composite component, and control the mechanical arm composite component to drive the flaw detection frame composite component to move in a three-dimensional space, and control the transverse driving mechanism and the longitudinal driving mechanism to drive the ultrasonic probe composite component to move on the flaw detection frame composite component, so as to control the ultrasonic probe composite component to move and scan along the scanning path.

2. The composite ultrasonic nondestructive testing array device according to claim 1, wherein: A plurality of ultrasonic probe composite components are arranged in an array on the flaw detection frame composite component, and the laser scanner composite component is located at a central position of the flaw detection frame composite component.

3. The composite ultrasonic nondestructive testing array device according to claim 2, wherein: The transverse driving mechanism comprises a transverse guide rail composite component, a transverse driving motor and a transverse sliding block, the transverse guide rail composite component is fixed on the flaw detection frame composite component, the transverse sliding block is driven by the transverse driving motor and moves along the transverse guide rail composite component, the longitudinal driving mechanism comprises a longitudinal guide rail composite component, a longitudinal driving motor and a longitudinal sliding block, the longitudinal guide rail composite component is installed on the transverse sliding block, the longitudinal sliding block is driven by the longitudinal driving motor and moves along the longitudinal guide rail composite component, and the ultrasonic probe composite component is installed on the longitudinal sliding block.

4. The composite ultrasonic nondestructive testing array device according to claim 1, wherein: The ultrasonic probe composite component is provided with a probe orientation adjusting mechanism for driving the ultrasonic probe composite component to rotate to adjust the detection direction of the ultrasonic probe composite component, and the probe orientation adjusting mechanism is connected with the control unit. The control unit is further configured to calculate the surface normal vector of the composite component in real time based on the three-dimensional model obtained by the laser scanner, and control the detection direction of the ultrasonic probe composite component to be the same as the surface normal vector of each position of the composite component.

5. The composite ultrasonic nondestructive testing array device according to claim 3, characterized in that: The longitudinal slider is further provided with a flaw detection curved arm composite component, and the ultrasonic probe composite component is arranged at the free end of the flaw detection curved arm composite component.

6. A method of ultrasonic non-destructive testing of a composite material, characterized in that, Comprising: controlling the laser scanner composite component to scan the composite component, obtaining three-dimensional point cloud data and constructing a three-dimensional model, and extracting a surface two-dimensional development drawing of the composite component based on the three-dimensional model; controlling the surface two-dimensional development drawing to be divided into a plurality of sub-regions according to a preset rule; controlling a plurality of ultrasonic probe composite components to scan a plurality of sub-regions one by one to obtain ultrasonic detection data of each sub-region; controlling the ultrasonic detection data to be fused and spliced to generate a complete internal defect image of the composite component.

7. The detection method according to claim 6, characterized in that, Comprising: The control of the surface two-dimensional development drawing into a plurality of sub-regions according to a preset rule further comprises: controlling the edge overlapping part between adjacent sub-regions to have a preset width; controlling the time required for each ultrasonic probe composite component to scan the sub-region allocated to it to be consistent.

8. The detection method according to claim 7, characterized in that, Comprising: The control of the time required for each ultrasonic probe composite component to scan the sub-region allocated to it to be consistent comprises: calculating the total scanning path length of the probe based on the three-dimensional digital model data and the surface two-dimensional development model data of the composite component; determining the scanning time of each ultrasonic probe according to the number of ultrasonic probes and the scanning efficiency of the probe; taking the scanning time of each probe approaching the scanning time as the optimization target, and performing sub-region division and scanning path allocation on the two-dimensional development model.

9. The method of claim 6, wherein, Comprising: The control of the ultrasonic detection data to be fused and spliced to generate a complete internal defect image of the composite component comprises: obtaining coordinate position information of each sub-region on the composite component; using the detection data in the overlapping part of adjacent sub-regions to perform data registration through a feature point matching algorithm; according to the data registration result, calibrating and aligning the sub-region detection data collected by different ultrasonic probe composite components in a unified coordinate system through coordinate transformation, and finally fusing to form a complete internal defect image.

10. The method of claim 6, wherein, Comprising: The control of the ultrasonic detection data to be fused and spliced to generate a complete internal defect image of the composite component comprises: analyzing the collected ultrasonic data to identify defects in the composite component; labeling the identified defects in the three-dimensional model of the composite component, and generating a detection report based on the labeling result.

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