Ultrasonic flaw detection system and ultrasonic flaw detection method

Abstract

The system can acquire both the ultrasonic testing results and the location where the results were obtained, as well as identify and acquire the location of the object being tested for defects. [Solution] The system includes a probe 1 that transmits and receives an ultrasonic signal 11 to and from the object to be inspected, an ultrasonic flaw detection device 20 that processes the ultrasonic signal from the probe and outputs the result of ultrasonic flaw detection, a position measuring device 2 that outputs the inspection position of the probe on the object to be inspected as position information 12, an angle measuring device 3 that outputs the orientation and attitude of the probe during inspection as orientation information 13, and a calculation processing device 4 that receives the ultrasonic signal 11, position information 12 and orientation information 13, outputs the position information as the position where the detection result was obtained, and is equipped with a means for identifying the position of the object to be detected 8. The means for identifying the position of the object to be detected is configured to calculate the ultrasonic incidence direction 6 of the ultrasonic signal 11 to the object to be inspected based on the position information and orientation information, and to identify the position of the object to be detected 7 based on this ultrasonic incidence direction and ultrasonic signal.

Description

Technical Field

[0001] Embodiments of the present invention relate to an ultrasonic flaw detection system and an ultrasonic flaw detection method.

Background Art

[0002] Ultrasonic testing (UT) is a technique that can non-destructively confirm the integrity of the surface and interior of structural materials and has become an essential inspection technique in various fields. To evaluate the integrity of an inspection target such as a structural material non-destructively by UT or the like, recording of the position of a detection target (defect, crack, etc.) is required based on the inspection result and the position where the inspection result was obtained.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Summary of the Invention

Problems to be Solved by the Invention

[0004] Until now, automatic controllers such as scanners have been used to acquire probe position information as digital data to obtain inspection results (Patent Document 1). However, in UTs, for example, the probe position has not been recorded as digital data due to the complexity of the installation work of automatic controllers, and because scanning methods, including manual methods that do not have means for measuring self-position, are common. In recent years, digital position measurement devices that can be used with UTs using scanning methods that do not have means for measuring self-position have also been proposed (Patent Documents 2, 3, and 4). However, all of these patent documents measure the position of the probe, and do not specify the position of the object to be detected.

[0005] The embodiments of the present invention have been made in consideration of the above circumstances, and aim to provide an ultrasonic flaw detection system and ultrasonic flaw detection method that can acquire both the ultrasonic flaw detection results and the location where the inspection results were obtained, as well as the location of the detected object being inspected. [Means for solving the problem]

[0006] The ultrasonic flaw detection system in an embodiment of the present invention comprises: a probe that transmits and receives ultrasonic signals to and from an object to be inspected while installed on the object to be inspected; an ultrasonic flaw detection device connected to the probe that processes the ultrasonic signals from the probe and outputs an ultrasonic flaw detection inspection result; a position measuring device that identifies the inspection position of the probe on the object to be inspected and outputs it as position information; an angle measuring device that identifies the orientation and posture of the probe during inspection and outputs it as orientation information; and a calculation processing device connected to the probe, the ultrasonic flaw detection device, the position measuring device, and the angle measuring device that receives the ultrasonic signal, the position information, and the orientation information as input, outputs the position information as the position from which the detection result was obtained, and is equipped with means for identifying the position of the object to be detected. The means for identifying the position of the object to be detected is configured to calculate the direction of incidence of the ultrasonic signal to the object to be inspected based on the position information and the orientation information, and to identify the position of the object to be detected based on this incidence direction and the ultrasonic signal.

[0007] The ultrasonic flaw detection method in an embodiment of the present invention includes: a probe that transmits and receives ultrasonic signals to and from an object to be inspected while installed on the object to be inspected; an ultrasonic flaw detection device connected to the probe that processes the ultrasonic signals from the probe and outputs the results of ultrasonic flaw detection; a position measuring device that identifies the inspection position of the probe on the object to be inspected and outputs it as position information; an angle measuring device that identifies the orientation and posture of the probe during inspection and outputs it as orientation information; and a device connected to the probe, the ultrasonic flaw detection device, the position measuring device, and the angle measuring device that receives the ultrasonic signals, the position information, and the orientation information, and the position information is used to process the position information. The ultrasonic flaw detection device is characterized by sequentially performing the following steps: preparing a arithmetic processing unit that outputs the detection result as the acquired position and is equipped with means for identifying the position of the detection target; the ultrasonic flaw detection device processing the ultrasonic signal from the probe and outputting the ultrasonic flaw detection inspection result; the arithmetic processing unit outputting the position information from the position measuring device as the position from which the ultrasonic flaw detection result was acquired; the means for identifying the position of the detection target calculating the incidence direction of the ultrasonic signal to the inspection target based on the position information and orientation information; and identifying the position of the detection target based on the incidence direction and the ultrasonic signal. [Effects of the Invention]

[0008] According to embodiments of the present invention, both the ultrasonic testing results and the location where the test results were obtained can be acquired, and the location of the object being tested can be identified and acquired. [Brief explanation of the drawing]

[0009] [Figure 1] A block diagram showing the configuration of an ultrasonic flaw detection system according to one embodiment. [Figure 2] Figure 1 shows a first specific example of the position measuring device, with (A) showing the position before the probe moves and (B) showing the position after the probe moves. [Figure 3] This is an explanatory diagram showing a second specific example of the position measuring device shown in Figure 1. [Figure 4]Explanatory drawing showing a third specific example of the position measuring device in FIG. 1. [Figure 5] Explanatory drawing showing a fourth specific example of the position measuring device in FIG. 1. [Figure 6] Explanatory drawing showing a first specific example of the angle measuring device in FIG. 1, where (A) shows before rotation of the probe and (B) shows after rotation of the probe. [Figure 7] Explanatory drawing showing a second specific example of the angle measuring device in FIG. 1. [Figure 8] Explanatory drawing showing a third specific example of the angle measuring device in FIG. 1. [Figure 9] Explanatory drawing showing a fourth specific example of the angle measuring device in FIG. 1, where (A) is the overall side surface part, (B) is the top surface explanatory drawing before rotation of the probe, and (C) is the top surface explanatory drawing after rotation of the probe. [Figure 10] Block diagram showing an ultrasonic flaw detection system equipped with a position - angle measuring device in which the position measuring device and the angle measuring device in FIG. 1 are integrated. [Figure 11] Top surface explanatory drawing regarding the probe orientation indicator in FIG. 1. [Figure 12] First explanatory drawing regarding the position converter included in the ultrasonic flaw detection system in FIG. 1. [Figure 13] Second explanatory drawing regarding the position converter included in the ultrasonic flaw detection system in FIG. 1. [Figure 14] Explanatory drawing showing the contact determination device included in the ultrasonic flaw detection system in FIG. 1, where (A) shows the state where the wedge with the probe installed contacts the inspection target and (B) shows the non - contact state. [Figure 15] First explanatory drawing regarding the detection target dimension calculation means included in the ultrasonic flaw detection system in FIG. 1. [Figure 16] Second explanatory drawing regarding the detection target dimension calculation means included in the ultrasonic flaw detection system in FIG. 1. [Figure 17] Explanatory drawing regarding the sound ray indicator included in the ultrasonic flaw detection system in FIG. 1.

Embodiments for Carrying Out the Invention

[0010] Hereinafter, embodiments for carrying out the present invention will be described based on the drawings. FIG. 1 is a block diagram showing the configuration of an ultrasonic flaw detection system according to an embodiment. The ultrasonic flaw detection system 10 shown in FIG. 1 mainly includes a probe 1, an ultrasonic flaw detector 20, a position measuring device 2, an angle measuring device 3, and an arithmetic processing device 4. The probe 1 transmits and receives an ultrasonic signal 11 to / from an inspection target 5. The ultrasonic flaw detector 20 processes the ultrasonic signal 11 from the probe 1 and outputs an inspection result of ultrasonic flaw detection. The position measuring device 2 measures the position (position information 12) of the probe 1. The angle measuring device 3 measures the orientation (orientation information 13) of the probe 1. The arithmetic processing device 4 obtains the inspection position of the probe 1 (the position where the above inspection result is obtained) based on the position information 12 from the position measuring device 2 and includes a detection target position specifying means 8. This detection target position specifying means 8 calculates the incident direction of the ultrasonic signal 11 to the inspection target 5 (ultrasonic incident direction 6) based on the position information 12 and the orientation information 13, and specifies and outputs the position of a detection target 7 such as a defect existing in the inspection target 5. This will be described in detail below.

[0011] The probe 1 is composed of a piezoelectric element made of ceramics, composite materials, or other materials capable of generating ultrasonic waves due to the piezoelectric effect, a piezoelectric element made of a polymer film other than the above materials, or a mechanism capable of generating ultrasonic waves other than these, a damping material for damping ultrasonic waves, a front panel attached to the oscillation surface of the ultrasonic waves, and is configured as any one of these configurations or a combination thereof, and is generally referred to as an ultrasonic probe. In this embodiment, a flaw detection method of transmitting and receiving the ultrasonic signal 11 mainly with one probe 1 will be described, but the transmission and reception of the ultrasonic signal 11 may be separated using two or more probes 1. Also, a probe 1 called an ultrasonic array probe in which a plurality of piezoelectric elements are arranged one-dimensionally or two-dimensionally may be used.

[0012] In a state where the probe 1 is installed on the inspection target 5, the ultrasonic signal 11 is propagated in an oblique ultrasonic incident direction 6 with respect to the surface of the inspection target 5, which is generally called angle beam flaw detection. The ultrasonic signal 11 is transmitted to the detection target 7 existing in the inspection target 5, and the ultrasonic signal 11 with the detection target 7 as a reflection source is received.

[0013] As a method for propagating the ultrasonic signal 11 diagonally to the object to be inspected 5, methods utilizing Snell's law, generally referred to as ultrasonic testing (UT), may be used, such as a method in which a wedge 9 is combined with the probe 1 to create a flaw detection refraction angle α, a method in which the space between the probe 1 and the object to be inspected 5 is filled with an acoustic coupling medium to create a flaw detection refraction angle α, or a method in which a probe 1 in which the transducer and wedge 9 are integrated.

[0014] Furthermore, as an alternative method for propagating the ultrasonic signal 11 diagonally to the object 5 under inspection, the UT, generally known as phased array ultrasonic testing (PAUT), may be based on ultrasonic imaging methods such as the linear scan method, which electronically scans the ultrasonic element while forming an ultrasonic beam in a constant direction; the sector scan method, which changes the angle at which the ultrasonic beam is formed in a fan shape while fixing or electronically scanning the ultrasonic element; the Total Focusing Method (TFM), which focuses the beam by comprehensively setting a focus in an arbitrary coordinate region; or the so-called aperture synthesis method.

[0015] When setting up probe 1, especially in the case of a short probe, a wedge 9 is used to direct the ultrasonic signal 11 onto the object to be inspected 5 at a desired angle. The wedge 9 can be made of isotropic material such as acrylic, polyimide, gel, or other polymers, on which the ultrasonic signal 11 can propagate and whose acoustic impedance is known. The wedge 9 can be made of a material with an acoustic impedance close to or the same as that of the front plate, or a material with an acoustic impedance close to or the same as that of the object to be inspected 5. The wedge 9 may also be made of a composite material that changes its acoustic impedance in steps or gradually. The wedge 9 can, of course, be made of materials other than those mentioned above. Furthermore, the wedge 9 may have a multiple reflection reduction mechanism, such as placing damping material inside or outside the wedge 9, or providing a mountain-shaped wave-canceling shape, so that multiple reflected waves within the wedge 9 do not affect the flaw detection results.

[0016] The ultrasonic testing method can be any method commonly used for unintended testing, such as single-probe testing, dual-probe testing, PAUT, TOFD (Time of Flight Diffraction), or TFM. The ultrasonic signal 11 obtained here may be ultrasonic waveform data, voxel intensity data forming a PAUT or TFM image, or image data after image conversion.

[0017] In UT, in order to introduce the ultrasonic signal 11 into the interior of the object to be inspected 5, it is necessary to apply an acoustic coupling medium between the probe 1 and the object to be inspected 5, the probe 1 and the wedge 9, or the object to be inspected 5 and the wedge 9. Here, the acoustic coupling medium is a medium that can propagate ultrasonic waves, such as water, glycerin, machine oil, castor oil, acrylic, polystyrene, gel, etc., and other examples besides those mentioned above may also be applied.

[0018] The ultrasonic flaw detection device 20 is connected to the probe 1 and processes the ultrasonic flaw detection electrical signal (ultrasonic signal 11) from the probe 1 to output the ultrasonic flaw detection inspection result. The ultrasonic flaw detection device 20 has the function of transmitting an electrical signal to the probe 1, receiving the ultrasonic signal 11 obtained by the probe 1 and converting it into an electrical signal, and displaying the electrical signal as a waveform, i.e., displaying the ultrasonic flaw detection inspection result. This ultrasonic flaw detection device 20 is composed of a voltage application unit 21, an A / D conversion unit 22, a signal processing unit 23, a user interface unit 24, and a display unit 25.

[0019] The voltage application unit 21 has the function of applying a voltage of any waveform. The applied voltage waveform can be a sine wave, sawtooth wave, square wave, spike pulse, etc., and may be a so-called bipolar waveform with positive and negative values, a unipolar waveform with only positive or negative amplitude, or an offset may be added to either the positive or negative side. Furthermore, the applied voltage waveform can be a single pulse, burst, or continuous wave, and the application time, repetition rate, and center frequency can be increased or decreased. When probe 1 is used as an array probe, it is also possible to use a switching mechanism to switch whether or not to apply voltage to each channel, or to switch the timing according to the delay time.

[0020] The A / D conversion unit 22 receives the analog ultrasonic signal 11 from the probe 1 via a receiving circuit (not shown), and has the function of discretizing this ultrasonic signal 11 and converting it into digital ultrasonic data. In other words, the A / D conversion unit 22 converts the magnitude of the time-continuous ultrasonic signal 11 into digital ultrasonic data.

[0021] The signal processing unit 23 has the function of analyzing and imaging ultrasonic data from the A / D conversion unit 22. For example, analysis processing may include frequency analysis such as Fourier transform and wavelet transform, correlation processing, averaging processing, or general filtering processing. Imaging processing may include voxel intensity data conversion to form PAUT or TFM images. Furthermore, the signal processing unit 23 may process the ultrasonic flaw detection inspection results processed as described above in association with position information 12 acquired from the position measuring device 2 and orientation information 13 input from the angle measuring device 3. This signal processing unit 23 may be composed of a PC or a collection of multiple devices including a control panel.

[0022] The user interface unit 24 has the function of setting at least one condition from among the voltage application unit 21, the A / D conversion unit 22, and the signal processing unit 23, such as the applied voltage value, the A / D conversion setting value, or the signal processing setting value. The user interface unit 24 can be anything that allows input, deletion, and modification of conditions, and examples include a PC keyboard and mouse, numeric keypad input, button input, touch panel, etc.

[0023] The display unit 25 displays data including ultrasonic waveforms processed by the signal processing unit 23, i.e., the inspection results of ultrasonic flaw detection. The display unit 25 can be any device capable of displaying digital data, such as a PC monitor, television, projector, smart device, head-mounted display, or 3D image display. It may also be a device that converts the signal to analog before displaying it, like a cathode ray tube, or a combination with the screen of a measuring instrument such as an oscilloscope. The display unit 25 may also generate alarms with sound or light according to set conditions, and may have the functions of a user interface unit 24 as a touch panel.

[0024] The position measuring device 2 identifies the inspection position of the probe 1 on the inspection target 5 and outputs it as position information 12. This position measuring device 2 is a device that measures the position and amount of movement of the probe 1, and outputs position information 12 in at least one direction when the probe 1 moves. The position measuring device 2 can create an origin and use any method that can output the position of the moving probe 1, and the output position information 12 may be either an absolute value or a relative value. Here, the origin is the central position for recording the position information 12 of the probe 1, and as a method of setting it, for example, the position of the probe 1 or the position measuring device 2 at the start of recording, or a newly defined position to become the origin may be defined. Furthermore, the coordinate system referenced by the position measuring device 2 is preferably three-dimensional, but it is sufficient if it consists of axes that define at least one-dimensional position information.

[0025] Here, the coordinate system refers to the origin and direction recorded as coordinates for recording position information 12. Generally, in addition to the orthogonal coordinate system represented by the three directions x, y, and z, other examples include oblique coordinate systems where the directions do not intersect at right angles, polar coordinate systems represented by diameter and angle, coordinate systems with only one direction, coordinate systems with two directions, and other coordinate systems for outputting position information 12 of one dimension or more. Note that the position information 12 may be output not only as an integer but also as a decimal, fraction, exponential, real number, imaginary number, etc.

[0026] Examples of position measurement devices 2 include self-position estimation by constructing an environmental map 32 by capturing the surrounding environment 31 using a method called SLAM (Simultaneous Localization and Mapping) (Figure 2), estimation by detecting markers 34 in images 33 acquired by a camera (Figure 3), identification by a machine learning unit 35 trained on acquired images 33 (Figure 4), position identification method by measuring the distance 36 between the position measurement device 2 and the probe 1 using a laser or infrared light (Figure 5), position estimation by capturing a 2D pattern, position estimation by capturing and synthesizing surface shapes, and acceleration sensors.

[0027] In other words, in Figure 2, the position measuring device 2 is a camera, and the position of probe 1 is estimated by recognizing the amount of movement 12L of probe 1 and the position measuring device 2 from the position of the surrounding environment 31 in the image (environment map 32) of the position measuring device 2. Note that the reference numeral 14 in Figure 2 is a fixing jig that fixes probe 1 and position measuring device 2. Also, in Figure 3, the position measuring device 2 is a camera, and a marker 34 is provided on the side of probe 1. By detecting the position of the marker 34 in the image 33 acquired by the position measuring device 2, the position of probe 1 on which the marker 34 is provided (position information 12) is estimated.

[0028] In Figure 4, the position measuring device 2 is a camera, and the machine learning unit 35, which has learned the relationship between the position of probe 1 in the image 33 acquired by the position measuring device 2 and the actual position of probe 1, identifies the actual position of probe 1 from the position of probe 1 in the image 33 acquired by the position measuring device. In Figure 5, the position measuring device 2 is a distance measuring device, and since the position of the position measuring device 2 is known, the position of probe 1 is identified from the measured distance 36 between the position measuring device 2 and probe 1 and the position of the position measuring device 2.

[0029] The angle measuring device 3 measures and identifies the orientation and attitude of the probe 1 and outputs it as orientation information 13. When the orientation of the probe 1 changes, it outputs orientation information 13 for at least one rotation. The angle measuring device 3 can use any method that allows it to output orientation information 13 in response to changes in the orientation of the probe 1. The output format of the orientation information 13 can be an integer, decimal, fraction, exponential, real, imaginary, etc., and the unit of the orientation information 13 is not restricted. It is desirable to output the orientation information 13 of the probe 1 at the origin and coordinate system set by the position measuring device 2.

[0030] Examples of output formats for the orientation information 13 include Euler angles or radians for each position direction expressed in roll, pitch, and yaw; definitions of rotation directions on arbitrary rotation axes expressed in quaternions or quaternions; and rotation matrices representing rotations centered on the origin in Euclidean space. Furthermore, the numerical values, rotation directions, and output format definitions output as orientation information 13 can be freely set by the angle measuring device 3. For example, the angle measuring device 3 may measure the relative direction from the orientation information 13 of the angle measuring device 3 at the start of measurement, or it may measure the amount of change in the rotation direction based on the rotation axes of roll, pitch, and yaw that are set in advance (for example, the mutually orthogonal x, y, and z axes shown in Figure 7).

[0031] Examples of angle measuring devices 3 include estimating the orientation of probe 1 by constructing an environmental map 32 using SLAM (Figure 6), determining the direction of probe 1 using an acceleration sensor 37 and a gyro sensor 38 (Figure 7), estimating the orientation of probe 1 by detecting markers 34 in acquired images 33 using multiple cameras (Figure 8), and estimating the rotation direction perpendicular to the surface of the inspection target 5 by photographing a two-dimensional pattern or surface shape provided on the surface of the inspection target 5 (Figure 9).

[0032] In Figure 6, the angle measuring device 3 consists of, for example, two cameras. The orientation (orientation information 13) of the probe 1 and the angle measuring device 3 is estimated based on the rotation angle θ, derived from the differences in the positions of the surrounding environment 31 in the images (environmental map 32) from each of these cameras. The fixing jig 14 in Figure 6 fixes the probe 1 and the angle measuring device 3 in place. In Figure 7, the orientation (orientation information 13) of the probe 1 is determined by the measurement values ​​of the acceleration sensor 37 or gyro sensor 38 in the angle measuring device 3 installed on the probe 1.

[0033] In Figure 8, the angle measuring device 3 is, for example, two cameras (angle measuring devices 3A and 3B), with image 33A being acquired by angle measuring device 3A and image 33B being acquired by angle measuring device 3B. In addition, markers 34 of different shapes are provided on each side of probe 1. The orientation of probe 1 (orientation information 13) is estimated based on the presence or absence of markers 34 acquired by angle measuring devices 3A and 3B, as well as the image position.

[0034] In Figure 9, the angle measuring device 3 is, for example, a single camera. When multiple two-dimensional patterns 39 on the surface of the object to be inspected 5 are photographed by the angle measuring device 3, the rotation angle θ around the Z-axis perpendicular to the surface of the object to be inspected 5 is determined for the angle measuring device 3 and the probe 1 from the orientation of the multiple two-dimensional patterns 39 in the acquired image 33. From this rotation angle θ, the orientation of the probe 1 (orientation information 13) is estimated. Note that reference numeral 15 in Figure 9 indicates a fixing jig that secures the wedge 9 and the angle measuring device 3.

[0035] The position measuring device 2 and the angle measuring device 3 can be replaced by an integrated position and angle measuring device 16 (Figure 10). Figure 10 shows an ultrasonic flaw detection system 10-1 configured with the position and angle measuring device 16. The position and angle measuring device 16 is a device that measures the position information 12 and orientation information 13 of the probe 1. The position information 12 and orientation information 13 output by the position and angle measuring device 16 can be defined by the position and angle measuring device 16, regardless of their format, similar to the position measuring device 2 and angle measuring device 3 described above.

[0036] For example, the relative movement and relative rotation amounts may be measured based on the initial position and initial direction when measured by the position and angle measuring device 16, or the absolute movement and absolute rotation amounts may be measured based on a pre-set direction of movement and rotation. In addition, the position information 12 and orientation information 13 may be output simultaneously or at different timings. Examples of the position and angle measuring device 16 include self-position and orientation estimation using SLAM, and orientation and position determination by photographing the probe 1 using multiple cameras. Hereafter, the term ultrasonic flaw detection system 10 will include ultrasonic flaw detection system 10-1.

[0037] As shown in Figures 1 and 10, the arithmetic processing unit 4 is connected to the probe 1, ultrasonic flaw detection device 20, position measuring device 2, and angle measuring device 3, or connected to the probe 1, ultrasonic flaw detection device 20, and position and angle measuring device 16. It outputs the inspection position of the probe 1 (i.e., the position where the ultrasonic flaw detection inspection result was obtained) using the position information 12 from the input ultrasonic signal 11, position information 12, and orientation information 13, and also has a means for identifying the detection target position 8. The ultrasonic signal 11 is input to the arithmetic processing unit 4 from the probe 1 or ultrasonic flaw detection device 20. This arithmetic processing unit 4 has hardware resources such as a CPU, ROM, RAM, and HDD, and is composed of a computer in which software-based information processing is realized using hardware resources by the CPU executing various programs.

[0038] The connection method for the probe 1, position measuring device 2, and angle measuring device 3 to the arithmetic processing unit 4 may be wired or wireless, and furthermore, it may be an indirect connection via other equipment such as an ultrasonic flaw detection device 20. In Figure 1, the arithmetic processing unit 4 is shown as independent, but it may be built into other devices, for example, by being built into the position measuring device 2, angle measuring device 3, or ultrasonic flaw detection device 20.

[0039] The detection target position identification means 8 identifies the direction of incidence of the ultrasonic signal 11 to the inspection target 5 (ultrasonic incidence direction 6) from the ultrasonic signal 11, position information 12, and orientation information 13 input to the arithmetic processing unit 4, and calculates the position of the detection target 7 based on this ultrasonic incidence direction 6 and the ultrasonic signal 11. The detection target position identification means 8 in the ultrasonic flaw detection system 10 of this embodiment is realized by having a computer execute various programs.

[0040] The location of the detection target 7 is determined as follows: The direction in which the ultrasonic signal 11 propagates from the probe 1 into the interior of the inspection target 5 is set in advance. Based on the orientation information 13 at the location information 12 of the probe 1 and the pre-set propagation direction of the ultrasonic signal 11, the flaw detection refraction angle α of the ultrasonic signal 11 when the probe 1 is positioned at the location information 12 is determined, and the ultrasonic incidence direction 6 in which the ultrasonic signal 11 is incident on the inspection target 5 is determined by this flaw detection refraction angle α.

[0041] If the speed of sound within the inspection target 5 and wedge 9 is known, the relative distance from probe 1 to detection target 7 can be calculated when a reflected echo with the detection target 7 as the reflection source is obtained by the propagation of the ultrasonic signal 11 to wedge 9 and inspection target 5. Therefore, by combining the identified ultrasonic incidence direction 6 and the relative distance from probe 1 to detection target 7, the relative position from probe 1 to detection target 7 can be determined. Furthermore, since the position measurement device 2 acquires the position information 12 of probe 1, the position of detection target 7 can be calculated by combining the relative position from probe 1 to detection target 7 with the position information 12 of probe 1.

[0042] The ultrasonic flaw detection system 10 can be fitted with a probe orientation indicator 41 that displays the recorded position information 12 and orientation information 13 in the same coordinate system. Specifically, this probe orientation indicator 41 is a process performed by the arithmetic processing unit 4, which records one or more position information 12 from the position measuring device 2 and displays them in the position coordinate system, and displays the orientation information 13 from the angle measuring device 3 corresponding to each position information 12. Figure 11 shows how the orientation information 13 is displayed by the probe orientation indicator 41.

[0043] In Figure 11, probe 1A is positioned at position A and probe 1B is positioned at position B relative to the detection target 7, and the detection target 7 is detected. Since probes 1A and 1B have different position information 12A and 12B, they are recorded at different positions in the position coordinate system. Along with the position information 12A and 12B of each point of probes 1A and 1B, orientation information 13A and 13B are stored and displayed. In Figure 11, probe 1A is installed on wedge 9A and probe 1B is installed on wedge 9B, and a position angle measuring device 16A is installed on wedge 9A and a position angle measuring device 16B is installed on wedge 9B. Also, the symbols 6A and 6B in Figure 11 indicate the direction of ultrasonic incidence.

[0044] The display format of the orientation information 13 is not limited; for example, a location may be provided where the orientation information 13 is always displayed, or the orientation information 13 may be displayed as one of the parameters acquired at a specified position by specifying the position coordinates. The data format of the orientation information 13 to be displayed is not limited; examples include Euler angles, radians, quaternions, rotation matrices, etc. In addition to the position information 12 and orientation information 13, the probe orientation indicator 41 may also display the ultrasonic signal 11, the processing results from the signal processing unit 23, and the conditions set in the user interface unit 24.

[0045] In the ultrasonic flaw detection system 10, especially when the position measuring device 2 scans in accordance with the scanning of the probe 1, a position converter 42 can be applied, as shown in Figures 12 and 13, to convert the position information 12 acquired by the position measuring device 2 into position information acquired at the position on the probe 1 side (for example, the center position of the probe 1), based on the relative distance between the center position of the probe 1 and the measurement center position of the position measuring device 2. Figure 12 shows an example in which ultrasonic signal 11 is transmitted and received using a single probe, and Figure 13 shows an example in which the transmission and reception of ultrasonic signal 11 are separated using multiple probes 1.

[0046] As shown in Figure 12, the probe 1 is set to a probe center position 43. The position measuring device 2 is set to a measurement reference position 44 as the measurement center position from which position information 12 is acquired and output. By fixing the positional relationship between the probe 1 and the position measuring device 2, it becomes possible to uniquely determine the relative distance R between the probe center position 43 and the measurement reference position 44. Using this relative distance R, the position converter 42 converts the position information 12 measured and acquired at the measurement reference position 44 into position information acquired at the probe center position 43.

[0047] Figure 13 defines the relative distance R between the measurement reference position 44 and the probe center position 43 of the receiving probe 1. Although Figure 13 uses two independent probes 1 as an example of transmission and reception, a probe 1 with two or more oscillators, such as an array probe, may also be used, with the center of each oscillator defined as the probe center position 43.

[0048] Furthermore, the location to be set as the coordinate after position transformation (the position on the probe 1 side) may include positions other than the probe center position 43, which is uniquely set by defining it as such. For example, the position on the probe 1 side may include the centroid position of the probe 1, the center position of the wedge 9, and the incident point position of the ultrasonic signal 11 at the interface between the wedge 9 and the object to be inspected 5. In addition, the position converter 42 may be connected externally to the ultrasonic flaw detection system 10, or it may be built into each of the devices that make up the ultrasonic flaw detection system 10. For example, the position converter 42 may be built into the position measuring device 2, the angle measuring device 3, the calculation processing device 4, or the ultrasonic flaw detection device 20.

[0049] The ultrasonic flaw detection system 10 can be fitted with a contact detector 45 (Figure 14) that determines the contact status between the probe 1 and wedge 9 and the object to be inspected 5. This contact detector 45 determines, based on the ultrasonic signal 11 from the probe 1, whether the probe 1 and wedge 9 are in contact with the object to be inspected 5 and whether the ultrasonic signal 11 is propagating into the interior of the object to be inspected 5. As shown in Figure 14, regardless of contact between the wedge 9 and the object to be inspected 5 in angle-bevel flaw detection, the ultrasonic signal 11 originating from the interface between the wedge 9 and the object to be inspected 5 is acquired from the probe 1.

[0050] As shown in Figure 14(A), when the wedge 9 is in contact with the object to be inspected 5, this ultrasonic signal 11 is a reflected signal (ultrasonic signal 11B) reflected at the interface between the wedge 9 and the object to be inspected 5, and as shown in Figure 14(B), when the wedge 9 is not in contact with the object to be inspected 5, it is a reflected signal (ultrasonic signal 11C) reflected at the bottom surface of the wedge 9. Here, the reflected signal (ultrasonic signal 11A) is the reflected signal reflected at the interface between the probe 1 and the wedge 9.

[0051] The ultrasonic signal 11 is detected with a higher intensity when the wedge 9 is not in contact with the object 5 compared to the ultrasonic signal 11B when the wedge 9 is in contact with the object 5. This is because when the wedge 9 is in contact with the object 5, some of the energy of the ultrasonic signal 11 is lost as the ultrasonic signal 11 propagates into the object 5. Therefore, the contact detector 45 sets a threshold 40 for the signal intensity of the ultrasonic signal 11C, and if the ultrasonic signal 11C is less than or equal to the threshold 40, it is possible to determine that the wedge 9 and the object 5 are in contact. The contact detector 45 may be external to the ultrasonic flaw detection system 10 or it may be built into it. An example of the contact detector 45 being built into the ultrasonic flaw detection system 10 is that it may be built into the processing unit 4 or the ultrasonic flaw detection device 20.

[0052] The ultrasonic flaw detection system 10 can be fitted with a detection target dimension calculation means 47 (Figures 15 and 16) that calculates the detection target geometric shape 46 of the detection target 7 based on the position of the detection target 7 calculated by the detection target position identification means 8 (Figures 1 and 10) and the change in the ultrasonic signal 11 from the detection target 7. Here, the detection target geometric shape 46 represents the dimensions of the detection target 7, and examples include the depth, length, and opening width of the detection target 7.

[0053] As shown in Figure 15, when the probe 1 is scanned from position B to position A, the detection target position identification means 8 identifies and records the position of the detection target 7 at position B from the position information 12 and orientation information 13 of the probe 1, and identifies and records the position of the detection target 7 at position A from the position information 12 and orientation information 13 of the probe 1. The detection target dimension calculation means 47 calculates the length that has been continuously recorded as the detection target 7 when the probe 1 is scanned from position B to position A as the length dimension of the detection target 7 as the detection target geometric shape 46.

[0054] Furthermore, as shown in Figure 16, the detection target position identification means 8 calculates the ultrasonic incidence direction 6 of the ultrasonic signal 11 from the probe 1 to the inspection target 5 from the position information 12 and orientation information 13 of the probe 1. The detection target dimension calculation means 47 determines the dimension N from the surface of the inspection target 5 to the detection target 7 based on the ultrasonic incidence direction 6 calculated by the detection target position identification means 8 and the distance between the point of incidence of the ultrasonic signal 11 to the inspection target 5 and the detection target 7, and calculates the depth dimension of the detection target 7 as the detection target geometric shape 46 from this dimension N and the thickness M of the inspection target 5.

[0055] The detection target dimension calculation means 47 may be included in any configuration of the ultrasonic flaw detection system 10, for example, it may be built into the position measuring device 2, angle measuring device 3, calculation processing device 4, detection target position identification means 8, ultrasonic flaw detection device 20, or probe orientation indicator 41.

[0056] The ultrasonic flaw detection system 10 can be fitted with a sound ray indicator 48 (Figure 17) that displays the propagation direction of the ultrasonic signal 11 within the inspection target 5. As shown in Figure 17, in the ultrasonic flaw detection system 10, the ultrasonic incidence direction 6 is determined using the detection target position identification means 8. By setting information on the shape and material of the inspection target 5, it becomes possible to uniquely calculate the propagation path (beam path) of the ultrasonic signal 11 transmitted by the probe 1 within the inspection target 5 based on the ultrasonic incidence direction 6. The sound ray indicator 48 represents this beam path as a sound ray 49. In other words, the sound ray indicator 48 represents the propagation path of the ultrasonic signal 11 as a sound ray 49, along the ultrasonic incidence direction 6 of the ultrasonic signal 11 calculated by the detection target position identification means 8 based on the position information 12 of the probe 1 and the orientation information 13 of the probe 1.

[0057] The display method of the sound line indicator 48 is not limited; for example, it could be a format in which the sound lines 49 are represented in two dimensions on a cross-sectional view of the shape of the object to be inspected 5, or a format in which the sound lines 49 are represented in three dimensions on three-dimensional shape data. Furthermore, the display method of the sound lines 49 is not limited in terms of thickness, length, shape, color, etc., as long as it indicates the propagation path of the ultrasonic signal 11 into the object to be inspected 5. In addition, although Figure 17 describes the sound line indicator 48 as being connected externally to the processing unit 4, it may also be built into other equipment of the ultrasonic flaw detection system 10, such as the processing unit 4 or the ultrasonic flaw detection device 20.

[0058] In the ultrasonic flaw detection systems 10 and 10-1 configured as described above (Figures 1 and 10), ultrasonic testing is performed on the target object as follows.

[0059] First, the ultrasonic flaw detection device 20 processes the ultrasonic signal 11 from the probe 1 and outputs the ultrasonic flaw detection inspection result. Next, the arithmetic processing device 4 outputs the position information 12 of the probe 1 from the position measuring device 2 as the position where the ultrasonic flaw detection result was obtained. Then, the detection target position identification means 8 of the arithmetic processing device 4 calculates the direction of incidence of the ultrasonic signal 11 to the inspection target 5 (ultrasonic incidence direction 6) based on the position information 12 of the probe 1 and the orientation information 13 of the probe 1 from the angle measuring device 3. Subsequently, the detection target position identification means 8 identifies the position of the detection target 7 based on the ultrasonic incidence direction 6 and the ultrasonic signal 11 from the probe 1.

[0060] As configured as described above, this embodiment provides the following effects (1) to (8). (1) The ultrasonic flaw detection device 20 processes the ultrasonic signal 11 from the probe 1 and outputs the ultrasonic flaw detection inspection result. The arithmetic processing device 4 outputs the inspection position of the probe 1, which is the position information 12 of the probe 1 from the position measuring device 2, as the position from which the ultrasonic flaw detection result was obtained. Furthermore, the detection target position identification means 8 of the arithmetic processing device 4 calculates the direction in which the probe 1 incidents the ultrasonic signal 11 onto the inspection target 5 (ultrasonic incidence direction 6) based on the position information 12 of the probe 1 from the position measuring device 2 and the orientation information 13 of the probe 1 from the angle measuring device 3, and identifies the position of the detection target 7 based on the ultrasonic signal 11 in this ultrasonic incidence direction 6. As a result, the ultrasonic flaw detection system 10 can obtain the ultrasonic flaw detection inspection result and the position from which the inspection result was obtained, as well as identify and obtain the position of the detected target 7 that was inspected.

[0061] (2) In the ultrasonic flaw detection system 10, in UT where the ultrasonic incidence direction 6 changes due to the scanning method, such as manual scanning, the position of the object to be detected 7 is recorded as digital data, for example in 3D coordinates, based on the position measuring device 2 and the angle measuring device 3, and visualized and output. In this way, the position of the object to be detected 7 in field work can be identified by the ultrasonic flaw detection system 10, so the work of calculating the position of the object to be detected 7 when it is found during on-site inspection work can be reduced. In addition, since the position of the object to be detected 7 is recorded, it is possible to reduce overestimation of the object to be detected 7 or inspection omissions due to detecting the same object to be detected 7 at different locations. As a result, the man-hours required for detailed on-site inspection and evaluation of ultrasonic signals can be reduced, and the efficiency of inspection can be improved.

[0062] (3) According to the ultrasonic flaw detection system 10, the location of the detection target 7, which is necessary when reporting the UT inspection results, is identified by the detection target location identification means 8 of the arithmetic processing unit 4, and this location information is also recorded as digital data. This reduces the manual work required for recording and reporting related to the detection target 7, such as matching the ultrasonic flaw detection inspection results with the location information from which the inspection results were obtained and the location of the detection target 7, as well as sketching. As a result, not only is the burden on inspectors due to manual work reduced, but the man-hours are also reduced, and the overall efficiency of the inspection can be improved.

[0063] (4) The probe orientation indicator 41 displays orientation information 13 from the angle measuring device 3 that corresponds to each position information 12 of the probe 1 from the position measuring device 2. Therefore, by applying this probe orientation indicator 41, detailed information of the inspected area and the scope of the inspected area can be visualized in on-site inspection work and evaluation work in subsequent processes. This makes it possible to reduce inspection omissions due to deviations in the ultrasonic incidence direction 6, especially in angle-angle flaw detection where the ultrasonic incidence direction 6 changes due to the scanning method. As a result, it is possible to reduce the rework process caused by inspection omissions discovered after on-site inspection work, thereby realizing efficient inspection work.

[0064] (5) The position converter 42 shown in Figures 12 and 13 converts the position information acquired by the position measuring device 2 into position information acquired at the position of the probe 1 (for example, the probe center position 43). Therefore, by applying the position converter 42, when the position measuring device 2 moves in conjunction with the movement of the probe 1, the position of the position measuring device 2 is corrected (converted) to the position of the probe 1 based on the difference (distance) between the position measuring device 2 and the probe 1, so that the position of the object to be detected 7 can be displayed with high accuracy. As a result, even a position measuring device 2 that is not necessarily highly accurate can be used for precise UTs that require an error of 1 to 2 mm or less, such as defect detection in structures. As a result, a position measuring device 2 suitable for various conditions can be applied, expanding the application of the position measuring device 2 and improving the efficiency of inspections using the ultrasonic flaw detection system 10.

[0065] (6) By applying the contact detector 45 shown in Figure 14, it becomes possible to determine whether an ultrasonic signal 11 with the object to be detected 7 as the reflector source is not obtained for the ultrasonic signal 11 obtained by angle-angle flaw detection, or whether the probe 1 and the object to be inspected 5 are not in contact and the ultrasonic signal 11 is not being transmitted or received properly. In other words, it is possible to easily determine whether the probe 1 is in contact with or not with the object to be inspected 5 that occurs in angle-angle flaw detection. This reduces inspection omissions due to non-contact with the object to be inspected 5, and reduces human error or failures in which data recorded in a later process is found to be non-contact. As a result, it is possible to achieve efficient inspection work with reduced rework after the discovery of inspection omissions.

[0066] (7) By applying the detection target dimension calculation means 47 shown in Figures 15 and 16, the crack dimension required when detecting a crack, which is a planar detection target 7, can be measured by the detection target dimension calculation means 47 of the ultrasonic flaw detection system 10. This makes it possible to replace the measurement of defect dimensions, which was previously done by measuring the position of the probe 1 that was detecting the detection target 7 with a ruler or scribed line, with the ultrasonic flaw detection system 10, thereby reducing the man-hours required for measuring defect dimensions.

[0067] (8) By applying the sound line indicator 48 shown in Figure 17, the propagation direction of the ultrasonic signal 11 inside the inspection target 5, starting from the position information 12 of the probe 1, can be visualized during on-site inspection work or evaluation work in subsequent processes. This makes it possible to estimate the position of the detection target 7 when an ultrasonic signal 11 with the detection target 7 as the reflection source is acquired during on-site inspection work. As a result, the burden on inspectors regarding the evaluation of the position of the detection target 7 during on-site inspection work can be reduced. Furthermore, detailed inspection of the detection target 7, which is performed immediately after detection, can be carried out without losing sight of the target detection target 7, and the man-hours required for detailed inspection can be reduced. As a result, efficient inspection of the detection target 7 can be achieved.

[0068] Although embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented in various other forms, and various omissions, substitutions, modifications, and combinations can be made without departing from the spirit of the invention. Such substitutions, modifications, and combinations are included in the scope and spirit of the invention, as well as in the claims and their equivalents. [Explanation of Symbols]

[0069] 1...Probe, 2...Position measuring device, 3...Angle measuring device, 4...Calculation processing device, 5...Inspection target, 6...Ultrasonic incidence direction, 7...Detection target, 8...Detection target position identification means, 10...Ultrasonic flaw detection system, 11...Ultrasonic signal, 12...Position information, 13...Orientation information, 16...Position and angle measuring device, 20...Ultrasonic flaw detection device, 22...A / D conversion unit, 23...Signal processing unit, 24...User interface unit, 25...Display unit, 41...Probe orientation indicator, 42...Position converter, 45...Contact determination device, 47...Detection target dimension calculation means, 48...Sound wire indicator, 49...Sound wire.

Claims

1. A probe that is installed on the object to be inspected and transmits and receives ultrasonic signals to the object to be inspected, An ultrasonic flaw detection device connected to the probe, which processes the ultrasonic signal from the probe and outputs the results of ultrasonic flaw detection inspection, A position measuring device that identifies the inspection position of the probe on the object to be inspected and outputs it as position information, An angle measuring device that identifies the orientation and posture of the probe during inspection and outputs it as orientation information, The system comprises a arithmetic processing unit connected to the probe, the ultrasonic flaw detection apparatus, the position measuring device, and the angle measuring device, which receives the ultrasonic signal, the position information, and the orientation information as input, outputs the position information as the position where the detection result was obtained, and is equipped with means for identifying the position of the detection target, The ultrasonic flaw detection system is characterized in that the means for determining the location of the detection target is configured to calculate the direction of incidence of the ultrasonic signal to the inspection target based on the position information and the orientation information, and to determine the location of the detection target based on this incidence direction and the ultrasonic signal.

2. The ultrasonic flaw detection apparatus includes an A / D conversion unit that discretizes the ultrasonic signal from the probe and converts it into digital ultrasonic data, A signal processing unit that performs analysis and imaging processing of the ultrasonic data from the A / D conversion unit, A user interface unit for setting at least one condition of the A / D conversion unit and the signal processing unit, The ultrasonic flaw detection system according to claim 1, further comprising: a display unit that displays data including an ultrasonic waveform processed by the signal processing unit as an ultrasonic flaw detection inspection result.

3. The ultrasonic flaw detection system according to claim 1, characterized in that the processing unit has a probe orientation indicator capable of displaying positional information of one or more points from a position measuring device in a coordinate system and orientation information from an angle measuring device corresponding to each positional information.

4. The ultrasonic flaw detection system according to claim 1, characterized in that it has a position converter that converts position information acquired by the position measuring device into position information acquired at the probe side, based on the distance between the center position of the probe and the measurement center position of the position measuring device.

5. The ultrasonic flaw detection system according to claim 1, further comprising a contact detector that determines the contact status of the probe with respect to the object to be inspected based on the ultrasonic signal from the probe.

6. The ultrasonic flaw detection system according to claim 1, further comprising a detection target dimension calculation means for measuring the dimensions of the detection target within the inspection target based on the position of the detection target identified by the detection target position identification means.

7. The ultrasonic flaw detection system according to claim 1, characterized in that the processing unit displays a position coordinate system in which the position information of one or more probes is recorded, and has a sound line display that displays as a sound line the propagation path of the ultrasonic signal as it propagates within the inspection target along the incident direction of the ultrasonic signal calculated by the detection target position identification means based on the position information and the orientation information of the probe.

8. A probe that is installed on the object to be inspected and transmits and receives ultrasonic signals to the object to be inspected, An ultrasonic flaw detection device connected to the probe, which processes the ultrasonic signal from the probe and outputs the results of ultrasonic flaw detection inspection, A position measuring device that identifies the inspection position of the probe on the object to be inspected and outputs it as position information, An angle measuring device that identifies the orientation and posture of the probe during inspection and outputs it as orientation information, A calculation processing unit is prepared, which is connected to the probe, the ultrasonic flaw detection apparatus, the position measuring device, and the angle measuring device, and receives the ultrasonic signal, the position information, and the orientation information as input, outputs the position information as the position where the detection result was obtained, and is equipped with means for identifying the position of the target of detection. The ultrasonic flaw detection apparatus processes the ultrasonic signal from the probe and outputs the ultrasonic flaw detection inspection result, The arithmetic processing unit outputs the position information from the position measuring device as the position from which the ultrasonic flaw detection result was obtained. The means for identifying the location of the object to be detected includes the step of calculating the direction of incidence of the ultrasonic signal to the object to be inspected based on the location information and the orientation information, An ultrasonic flaw detection method characterized by sequentially performing the steps of: identifying the position of the object to be detected based on the incident direction and the ultrasonic signal.

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