A conformal eddy current detection method and detection device for special-shaped metal parts

Abstract

The present invention discloses a conformal eddy current detection method for a special-shaped metal part and a detection device thereof, which is used for electromagnetic eddy current detection of special-shaped metal parts with curved surfaces of different shapes or a special-shaped metal part composed of curved surfaces of different shapes. The detection device is characterized in that it comprises a plurality of detection surfaces (11) and external array eddy current detection sensors (12) on the detection surfaces, wherein at least a first detection surface (111) and a second detection surface (112) of the detection surface (11) are curved surfaces of different curvatures; and the detection is realized by selecting approximate coil curved surface segments for detection according to different detection parts of the workpiece.

Description

Technical Field

[0001] The present invention relates to the field of nondestructive testing technology, in particular to eddy current testing technology for metal parts of different shapes, and in particular to a conformal eddy current testing method for special-shaped metal parts and a testing device thereof. Background Art

[0002] In modern industry, various metal parts emerge in an endless stream, especially for some key parts, the indicators such as surface hardness and carburized layer depth are particularly important. For example, a certain automobile parts production uses 100% low-frequency eddy current to evaluate the surface and near-surface state of its products to ensure product quality. Since its appearance has multiple concave and convex parts to be inspected, according to conventional thinking, different profiling eddy current sensors must be configured. Although modern industrial robots are gradually becoming popular, frequent replacement of sensors or the use of multiple robots to meet production needs have become a practical problem that manufacturers have to make a dilemma between investment cost and efficiency. Most of the existing domestic and foreign products are designed in this way, which not only increases a lot of equipment costs, but also requires a corresponding increase in manual operation.

[0003] In view of the above shortcomings, the present invention adopts the following technical solutions. Summary of the invention

[0004] The purpose of the present invention is to provide a conformal eddy current detection method and detection device for special-shaped metal parts. The disclosed technical solution is as follows:

[0005] A conformal eddy current detection method for special-shaped metal parts is used for electromagnetic eddy current detection of special-shaped metal parts with different shapes of curved surfaces or a special-shaped metal part composed of different curved surfaces. It is characterized by using detection surfaces with different curvatures for alternate detection. The specific method steps are as follows:

[0006] a. Customize the detection device with different curvature detection surfaces: Customize the detection device with a surface conforming to the curved surface according to the curved surface to be detected of different special-shaped metal parts to be detected;

[0007] b. Setting the inspection surface sequence: according to the requirements of the inspection of the special-shaped metal parts to be inspected in turn, set the inspection sequence of each surface of the inspection device;

[0008] c. Implement electromagnetic eddy current sequential testing: According to the testing sequence of each curved surface of the testing device set in step b, perform electromagnetic eddy current testing on the special-shaped metal parts to be tested in turn, and transmit the test data to the data analysis and processing instrument.

[0009] Furthermore, the detection sequence in step b is the order in which the surfaces of a detection device including multiple curved surfaces are detected in turn, and also includes the repeated detection of the detection surfaces of the multiple curved surfaces of the detection device. That is, it is applied to various on-site automated detections such as production lines or in-service, especially large-scale production equipment with automatic processing by artificial intelligence and robot intelligent detection equipment, and also includes the repeated detection of multiple curved surface detection surfaces in sequence.

[0010] Furthermore, the data analysis of the sequential detection in step c, the analysis of the single round detection data of a sequential rotation, and the comparative analysis between the sequential detection data of each round after repeated multiple detections. That is, the data comparative analysis between multiple special-shaped metal parts repeatedly detected in turn can calculate and analyze the difference between two identical special-shaped parts, and in automated production or in-service monitoring, timely monitor the changes of special-shaped metal parts, so as to timely discover abnormal conditions of special-shaped metal parts.

[0011] Furthermore, during the conformal electromagnetic eddy current testing process, each curved surface detection surface device also includes detecting changes in the curvature of each surface of the special-shaped metal parts. By having a double-layer electromagnetic eddy current detection sensor set in the different curved surface detection surface devices, the changes in the lift-off values ​​of the inner and outer electromagnetic eddy current detection are compared to analyze the changes in the surface curvature of the special-shaped metal parts, or analyze various defects such as surface cracks, pits and bumps formed on the surface of the inspected special-shaped metal parts.

[0012] Furthermore, in the sequence of the curved surface detection surfaces, two curved surfaces with different curvatures may be used in whole or in part as a combined detection surface.

[0013] The present invention also discloses a conformal eddy current detection device for special-shaped metal parts, which is used for electromagnetic eddy current detection of special-shaped metal parts with different shapes of curved surfaces or a special-shaped metal part composed of curved surfaces with different curvatures, and is characterized by comprising a plurality of detection surfaces (11) and external eddy current detection sensors (12) on the detection surfaces, wherein at least a first detection surface (111) and a second detection surface (112) of the detection surface (11) are curved surfaces with different curvatures. In one embodiment, the external eddy current detection sensor (12) is configured as a single coil extending along the detection surface in a runway shape; or in another embodiment, the external eddy current detection sensor (12) is configured as a single coil wound around the detection surface; or in another embodiment, the external eddy current detection sensor (12) is configured as an array of eddy current detection sensors arranged on the detection surface.

[0014] In one embodiment, the first detection surface (111) and the second detection surface (112) are respectively adapted to different curved surfaces of the special-shaped component (1) to be detected.

[0015] In one embodiment, the entire surface or partial surface of the first detection surface (111) and the second detection surface (112) are combined into a curved surface adapted to the special-shaped component (1) to be detected.

[0016] The present invention also discloses a conformal eddy current detection probe for special-shaped metal parts, which is used for electromagnetic eddy current detection of special-shaped metal parts with different radian surfaces or a special-shaped metal part composed of different radian surfaces. The invention is characterized in that the probe comprises an external conformal detection device (10) and an internal conformal detection device (20), wherein the external conformal detection device (10) comprises a plurality of detection surfaces (11) and an external eddy current detection sensor (12) on the detection surface, wherein the detection surface (11) comprises at least a first detection surface (111) and a second detection surface (122). The two detection surfaces (112) are curved surfaces with different radians; the internal conformal detection device (20) comprises a plurality of internal conformal detection surfaces (21) and internal eddy current detection sensors (22) on the internal conformal detection surfaces, wherein at least one internal first detection surface (211) and an internal second detection surface (212) of the internal conformal detection surface (21) are curved surfaces with different radians; a spacer layer (13) is arranged between the external conformal detection device (10) and the internal conformal detection device (20), and the spacer layer (13) is made of a deformable soft material. Generally, the spacer layer is made of a deformable soft foam, rubber, silicone and other materials, and when external pressure is applied, the curved surface to which the pressure is applied will deform. Usually, the internal shape detection device (20) is made of a hard material that does not deform. When the curvature of the external curved surface to be detected changes, or bumps, pits, etc. are formed on the detected surface, the shape of the intermediate spacer changes, causing the lift-off value of the detection sensor detection signal of the external conformal detection device (10) and the internal conformal detection device (20) to change, thereby detecting the deformation or defects of the special-shaped metal parts. In one embodiment, the external eddy current detection sensor (12) and the internal eddy current detection sensor (22) are arranged as a single coil extending along the detection surface in a runway shape; or in another embodiment, the external eddy current detection sensor (12) and the internal eddy current detection sensor (22) are single coils respectively wound on the surface of the external conformal detection device (10) and the internal conformal detection device (20); or in another embodiment, the external eddy current detection sensor (12) and the internal eddy current detection sensor (22) are arranged as array eddy current detection sensors arranged on the detection surface.

[0017] Furthermore, the present invention discloses a curved surface monitoring method for conformal eddy current detection of special-shaped metal parts, which is used for electromagnetic eddy current detection of special-shaped metal parts with different shapes of curved surfaces or a special-shaped metal part composed of different curved surfaces, characterized in that the detection device is provided with an external conformal detection surface and an internal conformal detection surface having a deformable flexible intermediate layer, and corresponding eddy current detection sensors are respectively provided on the external conformal detection surface and the internal conformal detection surface, and the specific method steps are as follows:

[0018] a. Calibration of lift-off value: By testing standard special-shaped parts, the lift-off value between the eddy current detection sensor corresponding to the external conformal detection surface and the internal conformal detection surface is extracted as the calibration lift-off value;

[0019] b. Detect lift-off value: Perform corresponding electromagnetic eddy current detection on the special-shaped parts to be tested, and record the corresponding lift-off value detection data;

[0020] c. Comparative analysis: Compare the corresponding lift-off value test data extracted in step b with the calibration value, compare and analyze the change of lift-off value, and determine the abnormality of the surface of the special-shaped parts.

[0021] When the detection surface of the monitored special-shaped metal parts is a curved surface with multiple different curvatures, and the eddy current detection sensors corresponding to the external conformal detection surface and the internal conformal detection surface are set as array eddy current detection sensors, the sensors are set as corresponding eddy current detection sensors by numbering, or the signal values ​​between the detection sensor signals are compared to determine the corresponding eddy current detection sensors, or the corresponding eddy current detection sensors are determined by distance value detection between the eddy current detection sensors.

[0022] According to the above technical scheme, the present invention has the following beneficial effects:

[0023] 1. The present invention uses electromagnetic eddy current detection as the principle of material sorting, designs a peach-shaped or other special-shaped coil, and can be made into a multi-station universal sensor that conforms to the curved surface of metal parts. According to different workpiece detection parts, select the approximate coil arc surface segment for detection. For low-frequency eddy current, its fit with the workpiece surface does not need to be as

[0024] The same precision as flaw detection is to allow a certain lifting gap, and the detection of the surface treatment state of similar automotive parts does not require detection at a single point, but a small local area. Therefore, by utilizing this characteristic of low-frequency eddy current and the detection requirements of such metal workpieces, the eddy current signal analysis of the present invention can meet the quality control requirements of such products, and at the same time can greatly reduce the number of sensors. By adaptively adjusting the parameters (such as frequency amplification, phase alarm area, etc.) of the eddy current detector (usually an eddy current spectrum analyzer), the problem encountered in the automated detection of special-shaped metal parts in modern industry as described in the background technology is better solved.

[0025] Second, in the present invention, the detection device has different curved detection surfaces, either individually or in free combination, which are suitable for various curved surfaces of various special-shaped metal parts, and are flexible and diverse to choose from. While increasing the application of automation engineering, the cost of producing the detection sensor is greatly reduced;

[0026] 3. In the present invention, by using the corresponding detection surfaces of different detection devices on the inner and outer layers of the deformable material spaced in the middle, lift-off value detection and analysis are performed to monitor the curvature deformation, protrusions, pits, etc. of the curved surface of special-shaped metal parts, thereby realizing more functions of automated detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 A schematic diagram of a detection method flow chart of a preferred embodiment of the present invention;

[0028] Figure 2 A schematic diagram of the use status of the detection device of the best embodiment of the present invention;

[0029] Figure 3 A schematic diagram of another detection device in use according to the best embodiment of the present invention;

[0030] Figure 4 A schematic diagram of another detection device in use according to the best embodiment of the present invention;

[0031] Figure 5 A schematic diagram of another detection device in use according to the best embodiment of the present invention;

[0032] Figure 6 A schematic diagram of another detection device in use according to the best embodiment of the present invention;

[0033] Figure 7 A schematic diagram of another detection device in use according to the best embodiment of the present invention;

[0034] Figure 8 A schematic diagram of the structure of a detection device or a detection probe according to a preferred embodiment of the present invention;

[0035] Fig. 9A schematic diagram of another detection device or detection probe structure according to the best embodiment of the present invention;

[0036] Fig.10 A schematic diagram of another detection device or detection probe structure according to the best embodiment of the present invention;

[0037] Fig.11 A schematic diagram of a detection probe for another embodiment of the best embodiment of the present invention;

[0038] Fig.12 A schematic diagram of the use status of the detection probe in another implementation mode of the best embodiment of the present invention;

[0039] Fig.13 A schematic diagram of the use status of a detection device or a detection probe in another embodiment of the best embodiment of the present invention;

[0040] Fig.14 The figure is a flow chart of the curved surface monitoring method according to the best embodiment of the present invention. DETAILED DESCRIPTION

[0041] The present invention will be further described below in conjunction with the accompanying drawings and specific implementation methods.

[0042] like Figure 1 As shown in the flowchart, a conformal eddy current testing method for special-shaped metal parts is Figures 2 to 6 As shown in the figure, it is used for special-shaped metal parts with different shapes and curved surfaces or Figure 7 A detection method of electromagnetic eddy current detection of special-shaped metal parts composed of curved surfaces with different curvatures is shown in the figure. The method uses detection curved surfaces with different curvatures to perform alternate detection. The specific method steps are as follows:

[0043] a. Customize the detection device with different curvature detection surfaces: Customize the detection device with a surface conforming to the curved surface according to the curved surface to be detected of different special-shaped metal parts to be detected;

[0044] b. Setting the inspection surface sequence: according to the requirements of the inspection of the special-shaped metal parts to be inspected in turn, set the inspection sequence of each surface of the inspection device;

[0045] c. Implement electromagnetic eddy current sequential testing: According to the testing sequence of each curved surface of the testing device set in step b, perform electromagnetic eddy current testing on the special-shaped metal parts to be tested in turn, and transmit the test data to the data analysis and processing instrument.

[0046] like Figures 2 to 7In the detection method of various detection surfaces, the detection order in step b is the order in which the detection devices including multiple curved surfaces are detected in turn, and also includes the repeated detection of the detection surfaces of the multiple curved surfaces of the detection device. That is, it is applied to various on-site automated detection such as production lines or in-service, especially large-scale production equipment automatically processed by artificial intelligence and robot intelligent detection equipment, and also includes the repeated detection of multiple curved surface detection surfaces in sequence.

[0047] And, the data analysis of the sequential detection in step c, the analysis of the single round detection data of a sequential rotation, and the comparative analysis between the sequential detection data of each round after repeated multiple detections. That is, the data comparative analysis between multiple special-shaped metal parts that are repeatedly detected in turn can calculate and analyze the differences between two identical special-shaped parts. In automated production or in-service monitoring, the changes of special-shaped metal parts can be monitored in a timely manner to detect abnormal conditions of special-shaped metal parts in a timely manner.

[0048] like Figure 7 The multiple surface inspection of a metal component is also repeated inspection of various surfaces from N1 to N4 in turn.

[0049] During the conformal electromagnetic eddy current testing process of each curved surface detection surface device, it also includes detecting the changes in the curvature of each surface of the special-shaped metal parts. By using a double-layer electromagnetic eddy current detection sensor set in the different curved surface detection surface devices, the changes in the lift-off values ​​of the inner and outer electromagnetic eddy current detection are compared to analyze the changes in the surface curvature of the special-shaped metal parts, or analyze various defects such as surface cracks, pits and bumps formed on the surface of the inspected special-shaped metal parts.

[0050] like Figure 3 and Figure 5 As shown in , in the order of the curved surface detection surfaces, two curved surfaces with different curvatures can be used in whole or in part as a combined detection surface.

[0051] like Figures 8 to 10 As shown, the present invention also discloses a conformal eddy current detection device for special-shaped metal parts, which is used for electromagnetic eddy current detection of special-shaped metal parts with different curvature surfaces or a special-shaped metal part composed of different curvature surfaces, including a plurality of detection surfaces 11 and external eddy current detection sensors 12 on the detection surfaces, wherein at least a first detection surface 111 and a second detection surface 112 of the detection surface 11 are surfaces with different curvatures. Figure 8 As shown in , in one way, the external eddy current detection sensor 12 is configured as a single coil extending in a racetrack shape along the detection surface; Fig. 9 As shown in, or in another way, the external eddy current detection sensor 12 is configured as a single coil wound around the detection surface; Fig.10 As shown in , or in another embodiment, the external eddy current detection sensor 12 is configured as an array type eddy current detection sensor arranged on the detection surface.

[0052] In one embodiment, the first detection surface 111 and the second detection surface 112 are respectively adapted to different curved surfaces of the special-shaped component 1 to be detected.

[0053] In one embodiment, the entire surface or a partial surface of the first detection surface 111 and the second detection surface 112 are combined into a curved surface adapted to the special-shaped component 1 to be detected.

[0054] like Figures 8 to 13 As shown, the present invention also discloses a conformal eddy current detection probe for special-shaped metal parts, which is used for electromagnetic eddy current detection of special-shaped metal parts with different shapes of curvature surfaces or a special-shaped metal part composed of different curvature surfaces. The detection probe 100 includes an external conformal detection device 10 and an internal conformal detection device 20, wherein the external conformal detection device 10 is composed of a plurality of detection surfaces 11, and an external eddy current detection sensor 12 on the detection surface, wherein at least a first detection surface 111 and a second detection surface 112 of the detection surface 11 are surfaces with different curvatures; the internal conformal detection device 20 includes a plurality of internal conformal detection surfaces 21 and an internal eddy current detection sensor 22 on the internal conformal detection surface, wherein at least an internal first detection surface 211 and an internal second detection surface 212 of the internal conformal detection surface 21 are surfaces with different curvatures; a spacer layer 13 is arranged between the external conformal detection device 10 and the internal conformal detection device 20, and the spacer layer 13 is made of a deformable soft material. Generally, it is made of deformable soft foam, rubber, silicone and other materials. When external pressure is applied, it will deform according to the curved surface to which the pressure is applied. Usually, the internal shape detection device 20 is made of non-deformable hard material, such as Fig.12As shown in , when the curvature of the detected external curved surface changes, or convex points, pits, etc. are formed on the detected surface, the stress of the intermediate spacer 13 changes, so that the spacing value D1 between the external eddy current detection sensor 12 and the internal eddy current detection sensor 22 changes. Generally, the changed spacing value D2 is less than the D1 value, and the curvature of the metal component surface is deformed, or there are convex points. If the changed spacing value D2 is greater than the D1 value, it is judged as a crack or depression. Under normal circumstances, the D1 value is within the range of the electromagnetic eddy current detection lift-off value, generally 1 to 2 mm. When the lift-off value of the detection sensor detection signal of the external conformal detection device 10 and the internal conformal detection device 20 changes, the deformation or defect of the special-shaped metal component is detected. In one embodiment, the external eddy current detection sensor 12 and the internal eddy current detection sensor 22 are configured as a single coil extending along the detection surface in a runway shape; or in another embodiment, the external eddy current detection sensor 12 and the internal eddy current detection sensor 22 are single coils wound around the surfaces of the external conformal detection device 10 and the internal conformal detection device 20, respectively; or in another embodiment, the external eddy current detection sensor 12 and the internal eddy current detection sensor 22 are configured as array-type eddy current detection sensors arranged on the detection surface.

[0055] like Fig.14 As shown in the method flow chart in the figure, the present invention also discloses a curved surface monitoring method for conformal eddy current detection of special-shaped metal parts, which is used for electromagnetic eddy current detection of special-shaped metal parts with different shapes of curved surfaces or a special-shaped metal part with different curved surfaces. The detection device is provided with an external conformal detection surface and an internal conformal detection surface having a deformable flexible intermediate layer, and the corresponding eddy current detection sensors are respectively arranged on the external conformal detection surface and the internal conformal detection surface. The specific method steps are as follows:

[0056] a. Calibration of lift-off value: By testing standard special-shaped parts, the lift-off value between the eddy current detection sensor corresponding to the external conformal detection surface and the internal conformal detection surface is extracted as the calibration lift-off value;

[0057] b. Detect lift-off value: Perform corresponding electromagnetic eddy current detection on the special-shaped parts to be tested, and record the corresponding lift-off value detection data;

[0058] c. Comparative analysis: Compare the corresponding lift-off value test data extracted in step b with the calibration value, compare and analyze the change of lift-off value, and determine the abnormality of the surface of the special-shaped parts.

[0059] When the detection surface of the monitored special-shaped metal parts is a curved surface with multiple different curvatures, and the eddy current detection sensors corresponding to the external conformal detection surface and the internal conformal detection surface are set as array eddy current detection sensors, the sensors are set as corresponding eddy current detection sensors by numbering, or the signal values ​​between the detection sensor signals are compared to determine the corresponding eddy current detection sensors, or the corresponding eddy current detection sensors are determined by distance value detection between the eddy current detection sensors.

[0060] The above is one embodiment of the present invention. In addition, it should be noted that any equivalent or simple changes made based on the structure, features and principles described in this patent concept are included in the protection scope of this patent.

Claims

1. A conformal eddy current testing method for special-shaped metal parts, characterized in that The method of using detection surfaces with different curvatures to perform rotation detection, the specific method steps are as follows: a. Customize the detection device with different curvature detection surfaces: Customize the detection device with a surface conforming to the curved surface according to the curved surface to be detected of different special-shaped metal parts to be detected; b. Setting the inspection surface sequence: According to the requirements of the inspection of the special-shaped metal parts to be inspected in turn, set the inspection sequence of each surface of the inspection device. The inspection sequence of each surface is that two surfaces with different curvatures are regarded as a combined inspection surface in whole or in part; c. Implement electromagnetic eddy current sequential testing: According to the testing sequence of each curved surface of the testing device set in step b, electromagnetic eddy current testing is performed on the irregular metal parts to be tested in turn, and the test data is transmitted to the data analysis and processing instrument; the curved surface testing device also includes testing the change of the curvature of each surface of the irregular metal parts during the conformal electromagnetic eddy current testing process, and by comparing the lift-off value changes of the inner and outer layers of the electromagnetic eddy current testing by using the double-layer electromagnetic eddy current testing sensors set in the different curved surface testing devices, the change of the curvature of the surface of the irregular metal parts is analyzed, or various defects formed on the surface of the irregular metal parts by surface cracks, pits and convex points are analyzed.

2. The conformal eddy current testing method for special-shaped metal parts according to claim 1, characterized in that The detection sequence in step b is the order in which each curved surface of a detection device including multiple curved surfaces is detected in turn, and also includes the repeated detection of multiple curved surface detection surfaces in sequence.

3. The conformal eddy current testing method for special-shaped metal parts according to claim 2, characterized in that The data analysis of the sequential detection in step c, the analysis of the single round detection data of a sequential rotation, and the comparative analysis between the sequential detection data of each round after repeated detection.

4. A conformal eddy current detection device for special-shaped metal parts, using any one of the detection methods in claims 1 to 3, characterized in that The invention comprises a plurality of detection surfaces (11) and external array eddy current detection sensors (12) on the detection surfaces, wherein at least a first detection surface (111) and a second detection surface (112) of the detection surface (11) are curved surfaces with different radians.

5. The conformal eddy current testing device for special-shaped metal parts according to claim 4, characterized in that The first detection surface (111) and the second detection surface (112) are respectively adapted to different curved surfaces of the special-shaped component (1) to be detected.

6. The conformal eddy current testing device for special-shaped metal parts according to claim 4, characterized in that The entire surface or partial surface of the first detection surface (111) and the second detection surface (112) are combined into a curved surface adapted to the special-shaped component (1) to be detected.

7. A conformal eddy current detection probe for special-shaped metal parts, characterized in that The invention comprises an external conformal detection device (10) and an internal conformal detection device (20), wherein the external conformal detection device (10) comprises a plurality of detection surfaces (11) and an external array eddy current detection sensor (12) on the detection surface, wherein at least a first detection surface (111) and a second detection surface (112) of the detection surface (11) are curved surfaces with different radians; the internal conformal detection device (20) comprises a plurality of internal conformal detection surfaces (21) and an array eddy current detection sensor (22) on the internal conformal detection surface, wherein at least a first internal detection surface (211) and a second internal detection surface (212) of the internal conformal detection surface (21) are curved surfaces with different radians; A spacing layer (13) is provided between the external conformal detection device (10) and the internal conformal detection device (20), and the spacing layer (13) is made of a deformable soft material.

8. A curved surface monitoring method for conformal eddy current testing of special-shaped metal parts, characterized in that The detection device is configured to have an external conformal detection surface and an internal stress detection surface with a deformable flexible intermediate layer, and corresponding eddy current detection sensors are respectively arranged on the external conformal detection surface and the internal stress detection surface. The specific method steps are as follows: a. Calibration of lift-off value: By testing standard special-shaped parts, the lift-off value between the eddy current detection sensor corresponding to the external conformal detection surface and the internal conformal detection surface is extracted as the calibration lift-off value; b. Detect lift-off value: Perform corresponding electromagnetic eddy current detection on the special-shaped parts to be tested, and record the corresponding lift-off value detection data; c. Comparative analysis: Compare the corresponding lift-off value test data extracted in step b with the calibration value, compare and analyze the change of lift-off value, and determine the abnormality of the surface of the special-shaped parts.

Images