A Visual Positioning Method for Determining the Position of Phased Array Ultrasonic Weld Detection

Abstract

The present invention discloses a visual positioning method for determining the phased array ultrasonic weld detection position. The method comprises the following steps: Step 1, acquiring the weld surface contour information; Step 2, calculating the weld feature parameters according to the contour information; Step 3, determining the phased array ultrasonic weld detection position according to the feature parameters. The visual positioning method of the present invention realizes the rapid determination of weld features, achieves the accurate coverage of the phased array ultrasonic scanning area, and can realize the precise positioning of phased array ultrasonic weld detection.

Description

Technical Field

[0001] The present invention relates to the technical field of ultrasonic testing for welds, and particularly to a visual positioning method for determining the detection position of phased array ultrasonic welds. Background Art

[0002] Phased array ultrasonic testing technology is an advanced non-destructive testing technology that can be used to analyze the size and position information of weld defects. Its core is to use a computer to control multiple independent piezoelectric wafers in an array on the probe, which are excited and received at a certain delay time, so as to achieve the effects of changing the focusing characteristics and beam displacement. Since more piezoelectric wafers are equipped, there is no need to move the probe multiple times during the detection process, and the detection efficiency is high, which is more suitable for on-line detection of weld quality in thin plate production lines.

[0003] In the prior art, generally, it is required that the tester designs the phased array ultrasonic detection position according to the weld groove shape and determines the interpretation area according to the groove shape after detection. This method of determining the detection area manually according to the groove requires trial and error of the probe position and is affected by human factors. Moreover, laser welding of thin plates with small grooves and laser-arc hybrid welding are widely used in the fields of automobile and ship manufacturing, and it is difficult to directly determine the detection parameters and detection area according to the groove shape. This method of determining the detection position by trial and error of the position is inaccurate and has a long determination period. Currently, the vision-based weld measurement technology has developed rapidly, and using vision technology to determine weld features can quickly and accurately determine the probe position of phased array ultrasonic weld detection.

[0004] Therefore, those skilled in the art are committed to providing a visual positioning method for determining the detection position of phased array ultrasonic welds, which can effectively solve the problem that it is difficult to quickly determine the weld detection position on the welding site. Summary of the Invention

[0005] In view of the deficiencies in the prior art, the technical problem to be solved by the present invention is how to provide a visual positioning method for determining the detection position of phased array ultrasonic welds that can solve the problem that it is difficult to quickly determine the weld detection position on the welding site.

[0006] To achieve the above object, the present invention provides a visual positioning method for determining the detection position of phased array ultrasonic welds, and the method includes the following steps:

[0007] Step 1, collect the surface contour information of the weld;

[0008] Step 2, calculate the weld feature parameters according to the contour information;

[0009] Step 3, determine the phased array ultrasonic weld detection position according to the feature parameters.

[0010] Preferably, in step 1, the profile information is collected by a vision positioning device.

[0011] Further, the vision positioning device includes a vision scanner, a scanning frame, and a motion module. The vision scanner is rotatably connected to the scanning frame, the scanning frame is movably connected to the motion module, the scanning frame is configured to move in a first direction and a second direction, and the scanning frame moves relative to the motion module in a third direction.

[0012] Preferably, the weld surface includes the front and back of the weld.

[0013] Preferably, the characteristic parameters include the weld toe position, the weld reinforcement, and the weld width.

[0014] Further, step 2 specifically includes:

[0015] Step 2.1: Take the first-order difference of the profile information to determine the weld toe positions on the left and right sides, and obtain the weld width.

[0016] Step 2.2: Take the maximum height of the profile between the weld toes to determine the weld reinforcement.

[0017] Further, step 2 further includes taking the average of the weld width and the weld reinforcement to obtain the weld width and weld reinforcement during welding.

[0018] Further, step 3 specifically includes:

[0019] Step 3.1: Determine the number of wave reflections of the phased array ultrasound between the plate layers according to the plate thickness of the welded part, and determine the weld area in the detected wave according to the characteristic parameters.

[0020] Step 3.2: Determine the sound path where the sound beam of the phased array ultrasound scanning device can completely cover the weld area, and obtain the relationship between the scanning angle and the stepping axis displacement in the sound path according to the geometric relationship.

[0021] Step 3.3: Determine the scanning angle in combination with the wedge parameters of the phased array ultrasound scanning device, and then determine the stepping axis displacement.

[0022] Preferably, when using the second wave for drawing, the scanning angles include an upper limit angle and a lower limit angle, satisfying:

[0023]

[0024]

[0025] where U is the stepping axis displacement, D is the plate thickness of the welded part, α is the lower limit angle, and β is the upper limit angle.

[0026] Preferably, it further includes calibrating the phased array ultrasonic inspection device according to the step axis displacement and the scanning angle.

[0027] The present invention has at least the following beneficial technical effects:

[0028] The visual positioning method for determining the phased array ultrasonic weld inspection position provided by the present invention first performs visual scanning on the weld, then extracts weld features for a large number of weld contours, and then designs the scanning position for the on-site phased array ultrasonic device. The method for extracting the weld area of the present invention is fast and accurate, can quantitatively extract a large number of contours, and provides a basis for the design of the phased array ultrasonic scanning position and the determination of the inspection area. The method for determining the phased array ultrasonic weld inspection position of the present invention realizes the rapid determination of weld features, achieves accurate coverage of the phased array ultrasonic scanning area, and can realize the precise positioning of phased array ultrasonic weld inspection.

[0029] The following will further illustrate the concept, specific structure and technical effects generated by the present invention with reference to the drawings, so as to fully understand the purpose, features and effects of the present invention. Brief Description of the Drawings

[0030] Figure 1 is a schematic structural diagram of a visual positioning device for determining the phased array ultrasonic weld inspection position provided by an embodiment of the present invention;

[0031] Figure 2 is a flowchart of a visual positioning method for determining the phased array ultrasonic weld inspection position provided by an embodiment of the present invention;

[0032] Figure 3 is the angular range and step axis displacement of the sound beam completely covering the weld area in an embodiment of the present invention;

[0033] Figure 4 is a schematic diagram of the welding structure of a narrow groove weld in an embodiment of the present invention;

[0034] Figure 5 is a schematic diagram of the upper surface contour of the weld in an embodiment of the present invention;

[0035] Figure 6 is a schematic diagram of the differential result of the upper surface contour of the weld in an embodiment of the present invention;

[0036] Figure 7 is a schematic diagram of the weld area in the secondary wave in an embodiment of the present invention.

[0037] In the figure,

[0038] 1 - Visual scanner, 2 - Scanning frame, 3 - Motion module. Detailed Description of the Preferred Embodiment

[0039] The following describes several preferred embodiments of the present invention with reference to the accompanying drawings of the specification to make its technical content clearer and easier to understand. The present invention can be embodied in many different forms of embodiments, and the protection scope of the present invention is not limited to the embodiments mentioned in the text.

[0040] In the drawings, components with the same structure are denoted by the same numeral labels, and components with similar structures or functions everywhere are denoted by similar numeral labels. The size and thickness of each component shown in the drawings are arbitrarily shown, and the present invention does not limit the size and thickness of each component. To make the illustration clearer, the thickness of some parts in the drawings is appropriately exaggerated.

[0041] The present invention provides a visual positioning method for determining the position of phased array ultrasonic weld inspection. By visually scanning the weld, weld features are extracted for a large number of weld profiles, and then the scanning position is designed according to the parameters of the phased array ultrasonic scanning equipment on site.

[0042] In this embodiment, the Figure 1 as shown in the figure, the visual positioning device is used to collect the surface contour information of the weld. The visual positioning device includes a visual scanner 1, a scanning frame 2, and a motion module 3. The visual scanner 1 is used to scan the surface contour of the weld, and the visual scanner 1 is a commonly used image acquisition device. The visual scanner 1 is rotatably connected to the scanning frame 2, and the scanning frame 2 is movably connected to the motion module 3. The scanning frame 2 can adjust the position of the visual scanner 1 in the first direction and the second direction, and the scanning frame 2 moves relative to the motion module 3 in the third direction. The first direction, the second direction, and the third direction form a spatial rectangular coordinate system, thereby realizing the position adjustment of the visual scanner 1 in three free directions.

[0043] As Figure 2 shown, the visual positioning method for determining the position of phased array ultrasonic weld inspection in this embodiment includes the following steps:

[0044] Step 1: Collect the surface contour information of the weld.

[0045] The weld has a certain length. Therefore, in this step, the contour information of the entire weld surface under this welding process is collected. For double-sided welds such as V-groove welds, the surface of the weld includes the front and the back. Therefore, the contour information can be collected from the front and the back respectively to obtain the contour information of the two surfaces of the double-sided weld. For fillet welds, etc., only the contour information of one surface needs to be collected.

[0046] Step 2: Calculate the weld feature parameters according to the contour information.

[0047] In this step, the weld feature parameters include the weld toe position, the weld reinforcement, and the weld width. This step specifically includes the following specific steps:

[0048] Step 2.1: Take the first-order difference of the contour information to determine the weld toe positions on the left and right sides, and obtain the weld width.

[0049] Step 2.2: Take the maximum height of the contour between the weld toes to determine the weld reinforcement.

[0050] Step 2.3: Take the average of the weld width and weld reinforcement of the entire weld to obtain the weld width and weld reinforcement under this welding process.

[0051] Step 3: Determine the phased array ultrasonic weld inspection position according to the characteristic parameters.

[0052] After collecting the weld surface contour information and calculating the weld characteristic parameters, combined with the wedge parameters of the phased array ultrasonic scanning device, the phased array ultrasonic weld inspection position can be determined. This step specifically includes the following steps:

[0053] Step 3.1: Determine the number of wave reflections of the phased array ultrasonic waves between the plate layers according to the plate thickness of the welded part, and determine the weld area in the inspection wave according to the characteristic parameters.

[0054] Step 3.2: Determine the sound path where the sound beam of the phased array ultrasonic scanning device can completely cover the weld area, and obtain the relationship between the scanning angle and the stepping axis displacement in the sound path according to the geometric relationship.

[0055] Step 3.3: Determine the scanning angle in combination with the wedge parameters of the phased array ultrasonic scanning device, and then determine the stepping axis displacement.

[0056] Step 3.4: Calibrate the phased array ultrasonic scanning device according to the stepping axis displacement and the scanning angle.

[0057] As Figures 3 to 7 shown, the present invention also discloses the following specific embodiments of the visual positioning method for determining the phased array ultrasonic weld inspection position.

[0058] Embodiment 1

[0059] Step S1: Place the motion module on the left side of the weld to be inspected, and collect the upper surface contour of the butt weld under this welding process; the welded part and the welding type are as Figure 4 shown, and the collected weld contour information is as Figure 5 shown.

[0060] Step S21: Take the first-order difference of the upper surface weld contour as Figure 5 shown, and the result is as Figure 6 shown; according to Figure 5 the left and right weld toe positions can be determined, and the scatter points as Figure 5 are obtained, corresponding to Figure 6 the weld width of 3.00 mm in

[0061] Step S22: Take the maximum height of the weld profile between the left and right weld toes to determine the weld reinforcement. As shown in Figure 5 it is 1.5 mm.

[0062] Step S23: Take the average value of the weld width and weld reinforcement of the entire weld to obtain the weld width and weld reinforcement under this welding process.

[0063] As Figure 5 shown, the weld toe positions are the starting points a and b of the arc profile on the left and right sides. The weld width is the distance between points a and b on the horizontal axis, and the weld reinforcement is the distance from the highest point c of the arc profile to the ab connection line on the vertical axis.

[0064] Correspondingly, collect the weld bottom surface profile of the butt joint specimen under this welding process according to the above steps, and extract the weld width and weld reinforcement from all the bottom surface weld profiles according to steps S21 to S23 to obtain the weld width and weld reinforcement of the bottom surface.

[0065] Step S31: Determine the number of wave reflections of the phased array ultrasonic wave between the plate layers according to the plate thickness of the welded part, and determine the weld area in the detected wave according to the characteristic parameters. As shown in Figure 3 and Figure 7 this embodiment uses the second wave to draw the weld profile. In Figure 7 the solid line is the welded part in space and the weld area drawn according to the weld characteristic parameters, and the dotted line is the weld area in the simulated second wave.

[0066] Step S32: Determine the sound path where the sound beam of the phased array ultrasonic inspection equipment can completely cover the weld area, and obtain the relationship between the scanning angle and the stepping axis displacement in the sound path according to the geometric relationship. The upper and lower limit sound paths drawn by the second wave are as shown in Figure 3 Let the plate thickness be D, the stepping axis displacement be U, the lower limit angle be α, and the upper limit angle be β. The geometric relationship is as follows:

[0067]

[0068]

[0069] Step S33: Determine the scanning angle in combination with the wedge block parameters of the phased array ultrasonic inspection equipment, and then determine the stepping axis displacement.

[0070] As Figure 3 shown, the stepping axis displacement is the distance between the phased array ultrasonic inspection equipment and the weld, that is, the weld inspection position to be determined. The lower limit angle and the upper limit angle are determined according to the parameters of the phased array ultrasonic inspection equipment. According to different lower limit angles and upper limit angles, the corresponding stepping axis displacement can be determined.

[0071] Step S34: Calibrate the phased array ultrasonic inspection device according to the displacement of the stepping axis and the scanning angle.

[0072] After determining the displacement of the stepping axis, the position of phased array ultrasonic weld inspection is determined, and then phased array ultrasonic weld inspection of the weld can be carried out.

[0073] The preferred specific embodiments of the present invention have been described in detail above. It should be understood that those of ordinary skill in the art can make many modifications and variations based on the concept of the present invention without creative work. Therefore, all technical solutions that can be obtained by those skilled in the art in the technical field of the present invention through logical analysis, reasoning or limited experiments based on the concept of the present invention on the basis of the prior art should be within the protection scope determined by the claims.

Claims

1. A visual positioning method for determining the position of phased array ultrasonic weld inspection, characterized in that, The method includes the following steps: Step 1, collect the weld surface profile information; Step 2, calculate the weld feature parameters according to the profile information; Step 3, determine the phased array ultrasonic weld detection position according to the feature parameters, The feature parameters include the weld toe position, weld reinforcement, and weld width, The specific content of Step 2 includes: Step 2.1, take the first-order difference of the profile information to determine the weld toe positions on the left and right sides, and obtain the weld width; Step 2.2, take the maximum height of the profile between the weld toes to determine the weld reinforcement, Step 2 also includes taking the average of the weld width and the weld reinforcement to obtain the weld width and weld reinforcement, The specific content of Step 3 includes: Step 3.1, determine the wave times of phased array ultrasonic reflection between the plate layers according to the plate thickness of the welded part, and determine the weld area in the detection wave times according to the feature parameters; Step 3.2, determine the sound path where the sound beam of the phased array ultrasonic scanning device can completely cover the weld area, and obtain the relationship between the scanning angle and the stepping axis displacement in the sound path according to the geometric relationship; Step 3.3, determine the scanning angle in combination with the wedge block parameters of the phased array ultrasonic scanning device, and then determine the stepping axis displacement.

2. The visual positioning method for determining the phased array ultrasonic weld detection position according to claim 1, wherein In Step 1, the profile information is collected by a vision positioning device.

3. The visual positioning method for determining the phased array ultrasonic weld inspection position according to claim 2, characterized in that, The vision positioning device includes a vision scanner, a scanning frame, and a motion module. The vision scanner is rotatably connected to the scanning frame, the scanning frame is movably connected to the motion module, the scanning frame is configured to move in a first direction and a second direction, and the scanning frame moves relative to the motion module in a third direction.

4. The visual positioning method for determining the phased array ultrasonic weld inspection position according to claim 1, characterized in that, The weld surface includes the front and back of the weld.

5. The visual positioning method for determining the phased array ultrasonic weld detection position according to claim 1, wherein When using the second wave for drawing, the scanning angles include an upper limit angle and a lower limit angle, satisfying: In the formula, U is the stepping axis displacement, D is the plate thickness of the welded part, α is the lower limit angle, and β is the upper limit angle.

6. The visual positioning method for determining the phased array ultrasonic weld detection position according to claim 1, characterized in that It also includes calibrating the phased array ultrasonic scanning device according to the stepping axis displacement and the scanning angle.

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