Ultrasonic probe device and method for blade in-situ detection

Abstract

The invention discloses an ultrasonic probe device and method for blade in-situ detection, and belongs to the technical field of nondestructive detection. The device comprises a surface wave probe, an extension bar, a handle, a reed, a camera, a graduated scale, a flaw detector and a display screen. And the calibrated scale is fixed on the side surface of the probe. The detection method comprises the following steps: processing a reference block with artificial defects; assembling a probe device and connecting equipment; adjusting the detection sensitivity on the test block, and observing the distance between the graduated scale and the edge of the test block; the probe extends into the engine to detect the blade, the distance between the graduated scale and the blade edge is observed through the display screen, the calibration time interval is kept, and the defect is judged according to the waveform; when defects are found, the probe is transversely moved and the coupling state is kept, and the defect length is measured through graduated scale reading variation. According to the invention, the real-time observation of the probe position and the accurate measurement of the defect length are realized, and the detection accuracy and efficiency are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of non-destructive testing, in particular to an ultrasonic probe device and method for in-situ detection of a blade, which is suitable for in-situ ultrasonic detection of an aero-engine blade. BACKGROUND

[0002] As a conventional non-destructive testing method, ultrasonic detection is widely used in the manufacturing and in-service detection of aero-engine blades. Due to the complex internal structure of the engine, the hidden position of the blade and the narrow space, it is difficult to directly observe the relative position of the probe and the blade during in-situ detection, which limits the accuracy of the detection results.

[0003] In the prior art, patent application No. CN117368324A discloses a probe device and method for in-situ ultrasonic detection of a blade. The device includes a surface wave ultrasonic probe, an extension rod and a syringe. The extension rod is provided with a handle at one end, and the surface wave ultrasonic probe is installed at the other end of the extension rod and coupled with the blade through a coupling agent adsorption structure (such as a water-absorbing cotton or a water-absorbing cloth). The coupling agent is water, which is replenished in real time through the syringe and the hose to maintain the coupling effect. Although this method solves the problems of difficult removal of the coupling agent and poor coupling, it still has the following defects: (1) The position of the probe relative to the edge of the blade cannot be observed in real time, and the positioning relies on the experience of the operator, which may lead to missed detection or misjudgment due to position deviation; (2) There is no defect size measurement function, and the length of the defect cannot be quickly evaluated after the defect is found, which affects the maintenance decision; (3) In the dark or obstructed engine cavity, the operator has difficulty in accurately controlling the movement path and detection range of the probe.

[0004] Therefore, there is an urgent need in the art for an ultrasonic probe device and method for in-situ detection of a blade, which can observe the position of the probe in real time, accurately position the defect and measure the length of the defect. SUMMARY

[0005] The main purpose of the present application is to provide an ultrasonic probe device and method for in-situ detection of a blade, which realizes real-time observation of the position of the probe and accurate measurement of the length of the defect by integrating a camera and a scale.

[0006] To achieve the above purpose, in a first aspect, the present application provides a blade ultrasonic probe device, comprising: a surface wave probe for emitting ultrasonic waves to the surface of the blade and receiving reflected signals; an extension rod, the front end of which is connected to the surface wave probe through a spring leaf, and the rear end of which is fixedly connected with a handle, and the spring leaf is made of an elastic material, so that the surface wave probe can be self-adapted to the curved surface of the blade; A camera is installed at one end of the extension rod close to the surface wave probe, with lighting and camera functions, for real-time shooting of the relative position of the probe and the blade. A scale is fixed on one side of the surface wave probe, with the scale along the moving direction of the probe; A probe cable is electrically connected to the surface wave probe; A camera cable is electrically connected to the camera; A belt is used to fix the probe cable and the camera cable on the extension rod; A flaw detector is connected to the surface wave probe through the probe cable, for displaying and analyzing ultrasonic signals; A display screen is connected to the camera through the camera cable, for real-time display of the image shot by the camera.

[0007] Further, the camera is integrated with an LED lighting module to ensure clear shooting of the scale and the edge of the blade in a dark environment.

[0008] Further, the scale is made of metal or plastic, with the scale in millimeters or centimeters for direct reading.

[0009] Further, the spring leaf is made of spring steel or elastic polymer, which can provide stable elastic force to keep the probe and the blade surface well coupled during detection.

[0010] Further, the extension rod is designed with adjustable length to adapt to detection requirements of different depths.

[0011] In a second aspect, the present application provides a method for in-situ detection of a blade, using the above-mentioned probe device, comprising the following steps: Step S1, processing a comparison test block: processing artificial defects on the comparison test block for calibration of detection sensitivity; Step S2, assembling the probe device: connecting the surface wave probe to the extension rod through the spring leaf, installing the camera and the scale, and fixing the cable; Step S3, connecting the equipment: connecting the surface wave probe to the flaw detector through the probe cable, and connecting the camera to the display screen through the camera cable; Step S4, adjusting the detection sensitivity: coupling the surface wave probe on the comparison test block, adjusting the parameters of the flaw detector so that the defect wave height of the artificial defect is 80% of the full screen and located before the 8th horizontal scale, and the bottom wave is located after the 8th horizontal scale, while observing the distance of the scale relative to the edge of the comparison test block through the display screen and recording; Step S5, detecting the blade: the surface wave probe is inserted into the engine cavity, coupled on the blade to be detected, the distance between the scale and the edge of the blade is observed through the display screen, the time interval is kept, the wave form of the detector is observed, if the defect wave exceeding 80% of the full screen appears before the 8th horizontal scale, it is judged as unqualified; Further, in step S5, ensure good coupling effect, and the bottom wave appears after the 8th horizontal scale.

[0012] Further, it further comprises step S6, measuring the defect length: when the defect wave appears, the surface wave probe is moved horizontally, and the change amount of the distance between the scale and the edge of the blade is observed to measure the defect length. Specifically, under the premise of keeping the probe coupled with the blade to be detected, the defect length is calculated by the change amount of the scale reading.

[0013] Further, during the detection process, if the coupling effect is not good and the bottom wave disappears, the coupling can be restored by slightly adjusting the probe position or cleaning the blade surface.

[0014] Further, the camera transmits images to the display screen in real time, and the operator can adjust the probe posture according to the images to ensure that the detection path is parallel to the edge of the blade.

[0015] Further, during the measurement of the defect length, the surface wave probe must be kept in good coupling state with the blade to be detected during the horizontal movement, so as to ensure the continuity and stability of the ultrasonic wave signal during the measurement, so as to obtain accurate defect length measurement result.

[0016] Due to the adoption of the above technical scheme, the present application has the following advantages: (1) The present application sets a camera with lighting function near the probe end of the lengthening rod, and the display screen displays the relative position of the scale and the edge of the blade in real time. The operator can accurately control the distance between the probe and the edge of the blade, avoiding positioning deviation caused by experience judgment. For example, in the engine cavity blade detection, the distance between the scale and the edge of the blade can be clearly observed through the display screen, ensuring that the probe always scans along the preset path, greatly reducing the risk of defect misjudgment or omission, and improving the detection accuracy.

[0017] (2) The present application fixes the scale on the surface wave probe, without disassembling the blade or replacing the tool after finding the defect, only needs to move the probe horizontally and observe the change amount of the scale distance, so as to quickly obtain the defect length. This design solves the problem that the existing device cannot measure the defect size, avoids the low efficiency caused by additional operation, meets the core demand of defect evaluation in blade maintenance, and significantly improves the detection efficiency.

[0018] (3) In the sensitivity adjustment stage, the distance between the scale and the edge of the contrast test block is observed through the display screen, and the distance is kept unchanged during detection, so as to ensure that the sensitivity parameter is completely matched with the probe positioning. The mechanism avoids the problem that the sensitivity adjustment is disconnected with the positioning in the prior art, reduces the improper sensitivity adaptation caused by the positioning deviation, ensures the accuracy of defect signal acquisition, and improves the reliability of the detection result.

[0019] (4) On the basis of the existing extended rod probe device, only the camera, the display screen and the scale are added, the structure is slightly changed, the cost is controllable, and all components are connected in a simple manner (such as a cable fixed by a belt and a camera directly installed), so that an operator can master the use method without complex training. Meanwhile, the device can be adapted to a conventional surface wave probe and a flaw detector, has strong compatibility, and is easy to popularize and apply in the field of aero-engine blade detection.

[0020] (5) The present application can use the efficient mode of "water as a coupling agent" in the prior art CN117368324A, and the coupling agent does not need to be removed after flaw detection, so that the operation steps are reduced. Meanwhile, the surface wave probe can be self-adapted to the surface morphology of the blade through the setting of the reed, so as to ensure that the probe is tightly coupled with the blade, avoid signal attenuation caused by poor coupling, and balance the operation convenience and detection stability. BRIEF DESCRIPTION OF DRAWINGS

[0021] In order to more clearly illustrate the technical solutions of the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiment or prior art description. Obviously, the drawings in the following description only show some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor on the basis of the drawings shown.

[0022] Figure 1 It is a side view of the overall structure of the ultrasonic probe device provided by the present application. Figure 2 It is a top view when the surface wave probe is coupled with the contrast test block in the present application. Figure 3 It is Figure 2 a local enlarged view, showing the distance Y between the surface wave probe and the edge of the contrast test block. Figure 4 It is a typical waveform graph when there is no defect. Figure 5 It is a typical waveform graph when there is a defect.

[0023] Brief Description of Drawings: 1, surface wave probe; 2, contrast test block; 3, scale; 4, interface; 5, probe cable; 6, flaw detector; 7, display screen; 8, handle; 9, camera cable; 10, extension rod; 11, camera; 12, reed; 13, scale; 14, artificial defect; 15, bottom wave; 16, defect wave. DETAILED DESCRIPTION

[0024] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0025] It should be noted that all directionality indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present application are only used to explain the relative positional relationship, movement condition, etc. between components in a certain specific posture (as shown in the drawings), and if the specific posture changes, the directionality indications will also change accordingly.

[0026] As shown in the drawings, the present embodiment provides an ultrasonic probe device and method for in-situ detection of a blade. Figures 1 to 3

[0027] In a first aspect, the ultrasonic probe device comprises a surface wave probe 1, a reed 12, an extension rod 10, a handle 8, a camera 11, a scale 3, a probe cable 5, a camera cable 9, a flaw detector 6, and a display screen 7.

[0028] The surface wave probe 1 is a conventional surface wave ultrasonic probe, and the frequency and size thereof are selected according to the blade material and detection requirements. The probe is connected to the extension rod 10 through the reed 12, which is made of spring steel and has a certain elasticity and toughness, so that the surface wave probe 1 can adapt to the change of the curved surface when contacting the blade and maintain stable coupling.

[0029] The extension rod 10 is a stainless steel hollow pipe, which has a sleeve structure formed by an inner pipe body and an outer pipe body, and the length thereof can be manually adjusted according to the depth requirement of the engine cavity. One end of the extension rod 10 is inserted into the handle 8, and the other end is fixed with the surface wave probe 1 through the reed 12. The surface of the handle 8 is provided with anti-slip patterns, which facilitates holding and operation.

[0030] The camera 11 is installed at one end of the extension rod 10 close to the probe, and is a miniature high-definition camera integrated with LED lamp beads, which can provide illumination in dark environments. The camera 11 is connected to the display screen 7 through the camera cable 9, and transmits images in real time.

[0031] ​The scale 3 is a thin stainless steel sheet, fixed to the side of the surface wave probe 1 with the interface 4 by screws. Its scale is in millimeters, and the zero point is aligned with the center of the probe. The length of the scale 3 is slightly larger than the width of the probe for easy reading in the image.

[0032] The probe cable 5 and camera cable 9 are secured to the extension rod 10 with plastic straps to prevent tangling or pulling during the inspection process. One end of the probe cable 5 is inserted into the interface 4 of the surface wave probe 1, and the other end is connected to the flaw detector 6.

[0033] The flaw detector 6 is a digital ultrasonic flaw detector with waveform display, parameter setting, and data storage functions. The display screen 7 is a portable LCD screen that can display the images captured by the camera in real time.

[0034] Secondly, a method for in-situ detection of blades, employing the aforementioned ultrasonic probe device, includes the following steps: Step S1: Process the comparison test block 2, and process the artificial defect 14 on the comparison test block 2; Step S2: Assemble the probe device, connect the surface wave probe 1 to the handle 8 via the spring 12 and the extension rod 10, and install the camera 11 and the scale 3; Step S3: Connect the equipment. Connect the surface wave probe 1 to the flaw detector 6 via the probe cable 5, and connect the camera 11 to the display screen 7 via the camera cable 9. Step S4: Adjust the detection sensitivity, couple the surface wave probe 1 to the comparison test block 2, adjust the parameters of the flaw detector 6 so that the wave height of the defect wave 16 of the artificial defect 14 is 80% of the full screen and is located before the 8th division of the horizontal scale, and the bottom wave 15 is located after the 8th division of the horizontal scale. At the same time, observe the distance of the scale ruler 3 relative to the edge of the comparison test block 2 through the display screen 7. Step S5: Inspect the blade. Insert the surface wave probe 1 into the engine and couple it to the blade to be inspected. Observe the distance between the scale 3 and the edge of the blade through the display screen 7. Keep the same distance as when adjusting the sensitivity. Observe the waveform of the flaw detector 6. If more than 80% of the defect wave 16 appears before the 8th division of the horizontal scale, it is judged as unqualified. Otherwise, it is judged as qualified.

[0035] In step S5, ensure good coupling effect, and the bottom wave 15 appears after the 8th division of the horizontal scale.

[0036] The procedure also includes step S6: measuring the defect length. When defect wave 16 appears, the surface wave probe 1 is moved laterally, and the change in distance of the scale 3 relative to the blade edge is observed to measure the defect length. The surface wave probe 1 maintains coupling with the blade under test during lateral movement.

[0037] In step S1, when processing the comparison test block 2, a comparison test block 2 of the same material is processed according to the material of the blade to be tested, and an artificial defect 14 is processed on the comparison test block 2. The type of artificial defect 14 needs to simulate the actual defects that may occur in the blade to ensure that the subsequent sensitivity adjustment can match the actual detection requirements.

[0038] In step S3, after the equipment is connected, it is necessary to confirm again that: ① the surface wave probe 1 and the flaw detector 6 are connected normally through the probe cable 5; ② the camera 11 and the display screen 7 are connected normally through the camera cable 9, and the image is displayed clearly; ③ the scale 3 is fixed firmly, and the scale 13 is visible; ④ the probe cable 5 and the camera cable 9 are fixed to the extension rod 10 with a strap, and there is no looseness.

[0039] In step S4, the specific process is as follows: I. Equipment Preheating Turn on the power to the flaw detector 6 and the display screen 7 to preheat them, ensuring that the electronic components of the equipment work stably and avoiding the impact of temperature drift on the waveform acquisition accuracy.

[0040] II. Probe Coupling and Waveform Adjustment Couple the surface of the surface wave probe 1 with the surface of the comparison test block 2 using water as a coupling agent. Slowly move the surface wave probe 1 until the defect wave 16 corresponding to the artificial defect 14 appears on the display screen of the flaw detector 6. Adjust the parameters of the flaw detector 6, such as gain and attenuation, so that the wave height of the defect wave 16 reaches 80% of the full screen. At the same time, adjust the horizontal scale parameters of the flaw detector 6 so that the defect wave 16 is before the 8th division of the horizontal scale, and the bottom wave 15 of the comparison test block 2 is after the 8th division of the horizontal scale.

[0041] III. Confirmation of Positioning Benchmark After adjusting the sensitivity parameters, observe the image captured by the camera 11 through the display screen 7, determine the distance of the scale 3 relative to the edge "Y" of the comparison test block 2, and record this distance as the positioning reference for subsequent testing to ensure that the distance between the probe and the edge of the blade is consistent with this reference during subsequent testing.

[0042] In step S5, the specific operation process is as follows: I. Probe Insertion and Positioning Open the engine access port and slowly insert the assembled surface wave probe 1 into the engine cavity along with the extension rod 10, avoiding collisions between the probe and internal engine components such as rotors and guide tubes; observe the images captured by the camera 11 in real time through the display screen 7, and adjust the probe position so that the distance of the scale 3 relative to the edge "Y" of the blade to be tested is consistent with the positioning reference recorded in step S4.

[0043] II. Coupling and Waveform Observation Combination Figure 4 andFigure 5 As shown, ensure that the coupling surface of the surface wave probe 1 is tightly coupled to the surface of the blade to be inspected. If the coupling is poor, add water coupling agent. Observe the waveform of the flaw detector 6: if the bottom wave 15 appears stably after the 8th division of the horizontal scale, and there is no defect wave 16 with a wave height exceeding 80% of the full screen before the 8th division of the horizontal scale, then the blade to be inspected is deemed qualified; if a defect wave 16 with a wave height exceeding 80% of the full screen appears before the 8th division of the horizontal scale, then the blade to be inspected is deemed unqualified.

[0044] If the blade is determined to be defective in step S5 and the defect length needs to be measured, maintain the coupling state between the surface wave probe 1 and the blade, and move the surface wave probe 1 laterally along the blade surface; observe the image captured by the camera 11 through the display screen 7, record the distance of the ruler 3 relative to the blade edge "Y" when the defect wave 16 first appears, and the distance of the ruler 3 relative to the blade edge "Y" when the defect wave 16 completely disappears; calculate the change in distance between the two times, and this change is the length of the defect.

[0045] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. An ultrasonic probe device for in-situ inspection of blades, characterized in that, include: Surface wave probe (1) is used to transmit and receive ultrasonic signals; The extension rod (10) is connected to the surface wave probe (1) at the front end via a spring (12) and a handle (8) is fixedly attached to the rear end. A camera (11) is located at the front end of the extension pole (10) and has lighting and video recording functions; A scale (3) is fixed on one side of the surface wave probe (1) and has a scale (13). The probe cable (5) is electrically connected to the surface wave probe (1); The camera cable (9) is electrically connected to the camera (11); The flaw detector (6) is connected to the surface wave probe (1) via the probe cable (5); The display screen (7) is connected to the camera (11) via the camera cable (9).

2. The ultrasonic probe device according to claim 1, characterized in that, The camera (11) integrates an illumination module for providing a light source in dark environments.

3. The ultrasonic probe device according to claim 1, characterized in that, The scale (13) of the ruler (3) is set along the probe moving direction and is used to measure the probe moving distance.

4. The ultrasonic probe device according to claim 1, characterized in that, The reed (12) is made of an elastic material, which enables the surface wave probe (1) to adaptively conform to the blade surface.

5. The ultrasonic probe device according to claim 1, characterized in that, It also includes straps for securing the probe cable (5) and camera cable (9) to the extension rod (10).

6. The ultrasonic probe device according to claim 1, characterized in that, The extension rod (10) has an adjustable length.

7. A method for in-situ inspection of leaf blades, employing the ultrasonic probe device according to any one of claims 1 to 6, characterized in that, Includes the following steps: Step S1: Process the comparison test block (2) and process artificial defects (14) on the comparison test block (2); Step S2: Assemble the probe device, connect the surface wave probe (1) to the handle (8) through the spring (12) and the extension rod (10), and install the camera (11) and the scale (3). Step S3: Connect the equipment. Connect the surface wave probe (1) to the flaw detector (6) through the probe cable (5), and connect the camera (11) to the display screen (7) through the camera cable (9). Step S4: Adjust the detection sensitivity, couple the surface wave probe (1) to the comparison test block (2), adjust the parameters of the flaw detector (6) so that the wave height of the defect wave (16) of the artificial defect (14) is 80% of the full screen and is located before the 8th division of the horizontal scale, and the bottom wave (15) is located after the 8th division of the horizontal scale. At the same time, observe the distance of the scale ruler (3) relative to the edge of the comparison test block (2) through the display screen (7). Step S5: Inspect the blade. Insert the surface wave probe (1) into the engine and couple it to the blade to be inspected. Observe the distance of the scale (3) relative to the edge of the blade through the display screen (7). Keep the same distance as when adjusting the sensitivity. Observe the waveform of the flaw detector (6). If more than 80% of the defect wave (16) appears before the 8th division of the horizontal scale, it is judged as unqualified. Otherwise, it is judged as qualified.

8. The method as described in claim 7, characterized in that, In step S5, ensure good coupling effect, and the bottom wave (15) appears after the 8th division of the horizontal scale.

9. The method as described in claim 7, characterized in that, It also includes step S6: measuring the defect length. When a defect wave (16) appears, the surface wave probe (1) is moved laterally and the change in distance of the scale (3) relative to the blade edge is observed to measure the defect length.

10. The method as described in claim 9, characterized in that, When the surface wave probe (1) moves laterally, it maintains coupling with the blade to be tested.

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