Test block device for phased array ultrasonic testing and ultrasonic sensitivity calibration method

Abstract

The present invention provides a test block device for phased array ultrasonic detection and an ultrasonic sensitivity calibration method. The device comprises a stepped test block which is sequentially composed of test blocks of corresponding sizes. A grooved reflective surface with different depths is arranged at a preset position on each step of the stepped test block, so as to perform ultrasonic sensitivity calibration on workpieces of different thicknesses through the grooved reflective surface at the step positions of different thicknesses. The test blocks are rectangular blocks of different thicknesses, and the grooved reflective surface is arranged at a preset position on the step surface of each step of the stepped test block. Alternatively, the test blocks are semi-cylinders of different diameters, and the grooved reflective surface is arranged at a preset position on the circular cross section of each step of the stepped test block.

Description

Technical Field

[0001] The invention relates to the field of ultrasonic testing, in particular to a test block device for phased array ultrasonic testing and an ultrasonic sensitivity calibration method. Background Art

[0002] Ultrasonic testing (UT) is one of the methods of nondestructive testing. When ultrasonic waves enter an object and encounter defects, part of the sound waves will be reflected. The receiver can receive the reflected waves and display them, so that the defects can be detected and the location and size of the internal defects can be displayed. For defects of fixed size, the larger the sound path, the lower the amplitude of the reflected echo. For defects at the same depth, the larger the incident angle of the sound beam, the longer the sound path, and the lower the amplitude of the reflected echo. In phased array ultrasonic shear wave testing, in order to obtain the same detection sensitivity at different depths for sound beams with different incident angles, it is necessary to use a standard reflector on the test block for sensitivity calibration.

[0003] In the existing ultrasonic testing standards, the reflectors used on the sensitivity calibration test blocks are mostly transverse holes, which perform sensitivity compensation for sound beams at different angles and different depths (sound paths). According to the ultrasonic reflection characteristics, when the sound beam is incident vertically on the reflecting surface, the reflected echo amplitude is the highest. For the transverse hole, by moving the probe back and forth, the sound beam can be incident vertically and the highest echo can be obtained. Therefore, the transverse hole has good versatility as a standard reflector and is widely used in ultrasonic testing. However, when detecting area defects such as cracks, the echo form of the defect is mainly end angle reflection, which is different from the reflection mechanism of the transverse hole. At this time, if the transverse hole is used to calibrate the sensitivity, the measured crack echo equivalent is inaccurate, which may lead to misjudgment or even missed detection.

[0004] During the sensitivity calibration of existing phased array ultrasonic testing, the curvature change of the detection surface where the probe is placed is synchronized with the curvature change of the bottom surface of the detected area. At this time, the sensitivity calibration of sound beams at different angles and depths can be completed using a cross-hole test block. For some complex structures, the curvature change of the detection surface where the probe is placed may be out of sync with the curvature change of the bottom surface of the detected area. There is an angle change in the relative position between the detection surface where the probe is placed and the bottom surface of the detected area. Due to the change in this angle, even if the depth and sound beam angle are calibrated, it is still impossible to ensure consistent echo amplitudes for defects of the same size during the detection process, and it affects the subsequent measurement of the defect size, resulting in missed detection and misjudgment of defects. Summary of the invention

[0005] The present invention aims to provide a test block device for phased array ultrasonic testing and an ultrasonic sensitivity calibration method, so as to calibrate the sensitivity of the detection of area defects such as cracks.

[0006] To achieve the above-mentioned purpose, the present invention provides a test block device for phased array ultrasonic testing, which comprises a stepped test block composed of a plurality of test blocks of different sizes arranged in sequence according to corresponding sizes; wherein grooved reflective surfaces of different depths are arranged at preset positions on each step of the stepped test block, so as to perform ultrasonic sensitivity calibration on workpieces of different thicknesses through the grooved reflective surfaces at step positions of different thicknesses.

[0007] In the above-mentioned test block device for phased array ultrasonic testing, preferably, the test block is a rectangular block with different thicknesses, and the grooved reflective surface is arranged at a preset position on the step surface of each step of the stepped test block.

[0008] In the above-mentioned test block device for phased array ultrasonic testing, preferably, the test block is a semi-cylinder with different diameters, and the grooved reflective surface is arranged at a preset position on the circular cross section of each step of the stepped test block.

[0009] The present invention also provides an ultrasonic sensitivity calibration method including a test block device for phased array ultrasonic testing, the method comprising: initializing the phased array detection system; placing an ultrasonic probe on a surface to be tested according to a predetermined plurality of grooved reflective surfaces of different depths, and setting a gate parameter value so that the gate can cover the reflected signal of the grooved reflective surface at each angle; obtaining a signal envelope formed by reflection of the ultrasonic wave on the grooved reflective surface by adjusting the position of the ultrasonic probe; obtaining calibration points of an end angle TCG or DAC curve according to the stability of the envelope amplitude of the signal envelope; constructing an end angle TCG or DAC curve according to the calibration points; and performing sensitivity compensation according to the end angle TCG or DAC curve.

[0010] The present invention also provides an ultrasonic sensitivity calibration method including a test block device for phased array ultrasonic testing, the method comprising: obtaining a torsion angle range according to structural information of a workpiece to be tested, and obtaining a torsion angle value according to the torsion angle range; initializing the phased array detection system, placing an ultrasonic probe on a surface to be tested according to a predetermined plurality of grooved reflective surfaces of different depths, and setting a gate parameter value so that the gate can cover the reflected signal of the grooved reflective surface at each angle; adjusting the position of the ultrasonic probe and the ultrasonic emission angle according to the torsion angle value to obtain a signal envelope formed by the ultrasonic wave reflected from the grooved reflective surface; obtaining calibration points of an end angle TCG or DAC curve according to the stability of the envelope amplitude of the signal envelope, and constructing an end angle TCG or DAC curve corresponding to the torsion angle value according to the calibration points; and performing sensitivity compensation according to the end angle TCG or DAC curve.

[0011] In the above ultrasonic sensitivity calibration method, preferably, initialization settings for the phased array detection system include focal law settings, scanning settings, sound velocity calibration settings and wedge calibration settings.

[0012] In the above-mentioned ultrasonic sensitivity calibration method, preferably, obtaining the signal envelope formed by the ultrasonic wave reflected on the grooved reflecting surface includes: moving the ultrasonic probe back and forth so that ultrasonic beams of different angles form end-angle reflections on the grooved reflecting surface; and forming a signal envelope based on the maximum end-angle reflection wave of the ultrasonic beams of all angles.

[0013] In the above-mentioned ultrasonic sensitivity calibration method, preferably, obtaining the calibration point of the end angle TCG or DAC curve according to the stability of the envelope line amplitude of the signal envelope includes: adjusting the gain value so that the envelope line amplitude of the signal envelope reaches a preset fixed value, and determining the calibration point of the end angle TCG or DAC curve.

[0014] The present invention also provides an electronic device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor implements the above method when executing the computer program.

[0015] The present invention also provides a computer-readable storage medium, wherein the computer-readable storage medium stores a computer program for executing the above method.

[0016] The phased array ultrasonic testing test block device and ultrasonic sensitivity calibration method provided by the present invention can effectively improve the correction sensitivity, and the measured crack echo equivalent is also more accurate, thus avoiding missed detection and misjudgment of defects. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings described herein are used to provide a further understanding of the present invention, constitute a part of the present application, and do not constitute a limitation of the present invention. In the drawings:

[0018] Figure 1 and Figure 2 A schematic diagram of the structure of a test block device for phased array ultrasonic testing provided by an embodiment of the present invention;

[0019] Figure 3 A schematic diagram of a flow chart of an ultrasonic sensitivity calibration method provided by an embodiment of the present invention;

[0020] Figure 4 and Figure 5 A schematic diagram of the structure of a test block device for phased array ultrasonic testing provided by an embodiment of the present invention;

[0021] Figure 6 A schematic diagram of a flow chart of an ultrasonic sensitivity calibration method provided by an embodiment of the present invention;

[0022] Fig. 7A and Figure 7B A schematic diagram of a torsion angle provided by an embodiment of the present invention;

[0023] Figure 8 A schematic diagram of the structure of an electronic device provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0024] The following will describe the implementation methods of the present invention in detail with reference to the accompanying drawings and embodiments, so that the implementation process of how the present invention applies technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly. It should be noted that as long as there is no conflict, the various embodiments of the present invention and the various features in the embodiments can be combined with each other, and the technical solutions formed are all within the protection scope of the present invention.

[0025] In addition, the steps shown in the flowcharts of the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions, and although a logical order is shown in the flowcharts, in some cases, the steps shown or described can be performed in an order different from that shown here.

[0026] The present invention provides a test block device for phased array ultrasonic testing, the device comprising a stepped test block composed of a plurality of test blocks of different sizes in sequence of corresponding sizes; wherein grooved reflective surfaces of different depths are provided at preset positions on each step of the stepped test block, for ultrasonic sensitivity calibration of workpieces of different thicknesses through the grooved reflective surfaces at step positions of different thicknesses. In actual work, in view of the different ultrasonic reflection mechanisms of transverse holes and cracks, the stepped test block with grooves is designed for sensitivity calibration at different depths and different sound beam angles, and is suitable for sensitivity calibration of area-type defect detection such as cracks. For details, please refer to Figure 1 and Figure 2 As shown, the test block is a rectangular block of different thicknesses, and the grooved reflective surface is set at a preset position on the step surface of each step of the step-type test block. In this embodiment, a groove is machined on the step test block. On the one hand, the groove is used instead of the horizontal hole to simulate the end angle reflection of the crack, and on the other hand, the different thicknesses of the step test block can be used for the sensitivity calibration when testing workpieces of different thicknesses.

[0027] Please refer to Figure 3 The present invention also provides an ultrasonic sensitivity calibration method including a test block device for phased array ultrasonic testing, the method comprising:

[0028] S301 performs initialization settings on the phased array detection system;

[0029] S302: placing an ultrasonic probe on a surface to be detected according to the grooved reflective surfaces of a plurality of predetermined different depths, and setting a gate parameter value so that the gate can cover the reflected signal of the grooved reflective surface at each angle;

[0030] S303 obtains a signal envelope formed by the ultrasonic wave reflected from the grooved reflective surface by adjusting the position of the ultrasonic probe;

[0031] S304: obtaining a calibration point of the end angle TCG or DAC curve according to the stability of the envelope amplitude of the signal envelope;

[0032] S305 constructs an end angle TCG or DAC curve according to the calibration points, and performs sensitivity compensation according to the end angle TCG or DAC curve.

[0033] For the detection of cracks and other area defects, if the curvature change of the detection surface where the probe is placed is not synchronized with the curvature change of the bottom surface of the detected area, please refer to Figure 4 and Figure 5 As shown, in one embodiment of the present invention, a test block device for phased array ultrasonic testing is further provided, wherein the test blocks are semi-cylinders of different diameters, and the grooved reflective surface is arranged at a preset position on the circular cross section of each step of the stepped test block. Using the semi-cylindrical stepped test block with grooves, the different echo amplitudes caused by the angle change between the incident surface of the sound beam and the area defect when the probe is placed at different circumferential positions are recorded to determine the sensitivity compensation value.

[0034] Please refer to Figure 6 As shown, the present invention also provides an ultrasonic sensitivity calibration method including a test block device for phased array ultrasonic testing, the method comprising:

[0035] S601 obtains a torsion angle range according to structural information of the inspected workpiece, and obtains a torsion angle value according to the torsion angle range;

[0036] S602 initializes the phased array detection system, places the ultrasonic probe on the surface to be detected according to the predetermined grooved reflective surfaces of multiple different depths, and sets the gate parameter value so that the gate can cover the reflection signal of the grooved reflective surface at each angle;

[0037] S603 adjusts the position of the ultrasonic probe and the ultrasonic emission angle according to the torsion angle value to obtain a signal envelope formed by the ultrasonic wave reflected from the grooved reflection surface;

[0038] S604: obtaining a calibration point of an end angle TCG or DAC curve according to the stability of the envelope amplitude of the signal envelope, and constructing an end angle TCG or DAC curve corresponding to the torsion angle value according to the calibration point;

[0039] S605 performs sensitivity compensation according to the end angle TCG or DAC curve.

[0040] In actual work, the initialization settings for the phased array detection system described in the above embodiment include focusing law settings, scanning settings, sound velocity calibration settings, and wedge calibration settings. Further obtaining the signal envelope formed by the reflection of the ultrasonic wave on the grooved reflection surface may include: moving the ultrasonic probe back and forth so that ultrasonic sound beams of different angles form end angle reflections on the grooved reflection surface; forming a signal envelope based on the maximum end angle reflection waves of ultrasonic sound beams at all angles. In another embodiment, obtaining the calibration point of the end angle TCG or DAC curve based on the stability of the envelope amplitude of the signal envelope includes: adjusting the gain value so that the envelope amplitude of the signal envelope reaches a preset fixed value, and determining the calibration point of the end angle TCG or DAC curve.

[0041] In order to facilitate a clearer understanding of the above embodiments provided by the present invention, the specific application of the above process is exemplified by two embodiments below. Relevant technical personnel in the field should know that this example is only for facilitating understanding of the applicable manner of the present invention and does not impose any limitation thereto.

[0042] Please refer to Figure 1 and Figure 2 As shown, the specific steps for the sensitivity calibration of the test block are as follows:

[0043] 1. After completing the basic settings of the connected phased array detection system, such as focal law, scanning settings, sound velocity calibration, and wedge calibration, select slots of different depths to make TCG (or DAC) curves (usually at least 3 depths of slots are selected).

[0044] 2. Place the probe on the detection surface coated with coupling agent, set the starting point, width and threshold of the gate so that the gate can cover the reflection signal of the groove to be made at every angle.

[0045] 3. Move the probe back and forth. Sound beams at different angles form end-angle reflections in the bottom groove. The maximum end-angle reflection waves of all angle sound beams form a smooth signal envelope. Adjust the gain value so that the envelope amplitude is at a fixed value (usually 80% of the full screen height), which determines a calibration point of the end-angle TCG curve.

[0046] 4. Repeat steps 2 and 3 for different depths, determine the calibration points at different depths (at least 3), and you can make a TCG curve.

[0047] At this point, the production of TCG curves for the end angles of workpieces with different thicknesses has been completed.

[0048] Please refer to Figure 4 , Figure 5 , Fig. 7A and Figure 7B As shown, the specific steps of the sensitivity calibration of the semi-cylindrical test block are similar to the above, and the overall steps are as follows:

[0049] 1. After completing the basic settings of the connected phased array detection system, such as focal law, scanning settings, sound velocity calibration, and wedge calibration, select slots of different depths to make TCG (or DAC) curves (usually at least 3 depths of slots are selected).

[0050] 2. Place the probe on the detection surface coated with coupling agent, set the starting point, width and threshold of the gate so that the gate can cover the reflection signal of the groove to be made at every angle.

[0051] 3. Move the probe back and forth. Sound beams at different angles form end-angle reflections in the bottom groove. The maximum end-angle reflection waves of all angle sound beams form a smooth signal envelope. Adjust the gain value so that the envelope amplitude is at a fixed value (usually 80% of the full screen height), which determines a calibration point of the end-angle TCG curve.

[0052] 4. Determine the range of the torsion angle according to the actual workpiece geometry, and make an end angle TCG curve at a certain torsion angle according to steps 1-3. Each TCG curve contains at least three calibration points at different depths.

[0053] 5. As Fig. 7A and Figure 7B As shown, by repeating steps 1 to 4 for different torsion angles α, an end angle TCG curve including the variable of the torsion angle can be produced.

[0054] So far, the sensitivity calibration of different depths and different sound beam angles has been completed for area defects such as cracks, including the variable of the angle between the ultrasonic incident surface and the through slot. When using this end angle TCG curve for phased array ultrasonic testing, the structural information of the workpiece to be inspected and the probe movement trajectory need to be entered into the instrument. The instrument automatically calculates the torsion angle when the probe moves to different positions and calls the corresponding end angle TCG curve for sensitivity compensation.

[0055] The phased array ultrasonic testing test block device and ultrasonic sensitivity calibration method provided by the present invention can effectively improve the correction sensitivity, and the measured crack echo equivalent is also more accurate, thus avoiding missed detection and misjudgment of defects.

[0056] The present invention also provides an electronic device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor implements the above method when executing the computer program.

[0057] The present invention also provides a computer-readable storage medium, wherein the computer-readable storage medium stores a computer program for executing the above method.

[0058] like Figure 8As shown, the electronic device 600 may further include: a communication module 110, an input unit 120, an audio processing unit 130, a display 160, and a power supply 170. It is worth noting that the electronic device 600 does not necessarily have to include Figure 8 In addition, the electronic device 600 may also include Figure 8 For components not shown, reference may be made to the prior art.

[0059] like Figure 8 As shown, the central processor 100 is sometimes also referred to as a controller or an operation control, and may include a microprocessor or other processor devices and / or logic devices. The central processor 100 receives inputs and controls the operations of various components of the electronic device 600.

[0060] The memory 140 may be, for example, one or more of a cache, a flash memory, a hard drive, a removable medium, a volatile memory, a non-volatile memory or other suitable devices. The above-mentioned information related to the failure may be stored, and a program for executing the relevant information may also be stored. The CPU 100 may execute the program stored in the memory 140 to implement information storage or processing.

[0061] The input unit 120 provides input to the CPU 100. The input unit 120 is, for example, a key or a touch input device. The power supply 170 is used to provide power to the electronic device 600. The display 160 is used to display display objects such as images and text. The display may be, for example, an LCD display, but is not limited thereto.

[0062] The memory 140 may be a solid-state memory, such as a read-only memory (ROM), a random access memory (RAM), a SIM card, etc. It may also be a memory that saves information even when the power is off, can be selectively erased, and is provided with more data, examples of which are sometimes referred to as EPROMs, etc. The memory 140 may also be some other type of device. The memory 140 includes a buffer memory 141 (sometimes referred to as a buffer). The memory 140 may include an application / function storage unit 142, which is used to store application programs and function programs or processes for executing the operation of the electronic device 600 through the central processor 100.

[0063] The memory 140 may also include a data storage unit 143 for storing data, such as contacts, digital data, pictures, sounds, and / or any other data used by the electronic device. The driver storage unit 144 of the memory 140 may include various drivers for communication functions of the electronic device and / or for executing other functions of the electronic device (such as messaging applications, address book applications, etc.).

[0064] The communication module 110 is a transmitter / receiver 110 that transmits and receives signals via an antenna 111. The communication module (transmitter / receiver) 110 is coupled to the central processor 100 to provide input signals and receive output signals, which may be the same as the case of a conventional mobile communication terminal.

[0065] Based on different communication technologies, multiple communication modules 110 may be provided in the same electronic device, such as a cellular network module, a Bluetooth module and / or a wireless LAN module. The communication module (transmitter / receiver) 110 is also coupled to a speaker 131 and a microphone 132 via an audio processor 130 to provide an audio output via the speaker 131 and receive an audio input from the microphone 132, thereby realizing a common telecommunication function. The audio processor 130 may include any suitable buffer, decoder, amplifier, etc. In addition, the audio processor 130 is also coupled to the central processor 100, so that the sound can be recorded on the local machine through the microphone 132, and the sound stored on the local machine can be played through the speaker 131.

[0066] Those skilled in the art will appreciate that embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0067] The present invention is described with reference to flowcharts and / or block diagrams of methods, devices (systems), and computer program products according to embodiments of the present invention. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0068] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0069] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0070] The specific embodiments described above further illustrate the objectives, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A test block device for phased array ultrasonic testing, characterized in that: The device comprises a plurality of test blocks of different sizes, which are sequentially constructed into a stepped test block according to corresponding sizes; Wherein, a grooved reflective surface of different depths is respectively arranged at a preset position on each step of the step-type test block, so as to perform ultrasonic sensitivity calibration on workpieces of different thicknesses through the grooved reflective surface at the step positions of different thicknesses; The test blocks are semi-cylinders with different diameters, and the grooved reflective surface is arranged on a plane perpendicular to the circular cross-section of each step of the step-type test block.

2. An ultrasonic sensitivity calibration method comprising the test block device for phased array ultrasonic testing according to claim 1, characterized in that: The method comprises: Obtaining a torsion angle range according to structural information of the inspected workpiece, and obtaining a torsion angle value according to the torsion angle range; Initializing the phased array detection system, placing the ultrasonic probe on the surface to be detected according to the predetermined grooved reflective surfaces of multiple different depths, and setting the gate parameter value so that the gate can cover the reflection signal of the grooved reflective surface at each angle; According to the torsion angle value, the position of the ultrasonic probe and the ultrasonic emission angle are adjusted to obtain the signal envelope formed by the ultrasonic wave reflected on the grooved reflection surface; obtaining the signal envelope formed by the ultrasonic wave reflected on the grooved reflection surface comprises: moving the ultrasonic probe forward and backward to make ultrasonic beams of different angles form end angle reflections on the grooved reflection surface; forming a signal envelope according to the maximum end angle reflection wave of the ultrasonic beams of all angles; Obtaining calibration points of the end angle TCG or DAC curve according to the stability of the envelope amplitude of the signal envelope, and constructing the end angle TCG or DAC curve corresponding to the torsion angle value according to the calibration points; Sensitivity compensation is performed according to the end angle TCG or DAC curve.

3. The ultrasonic sensitivity calibration method according to claim 2, characterized in that: The initialization settings for the phased array detection system include focal law settings, scanning settings, sound velocity calibration settings, and wedge calibration settings.

4. The ultrasonic sensitivity calibration method according to claim 2, characterized in that: Obtaining the calibration points of the end angle TCG or DAC curve according to the stability of the envelope amplitude of the signal envelope includes: The gain value is adjusted so that the envelope amplitude of the signal envelope reaches a preset fixed value, and the calibration point of the end angle TCG or DAC curve is determined.

5. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that: When the processor executes the computer program, the method of claim 2 is implemented.

6. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a computer program for causing a computer to execute the method of claim 2.

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