Inspection system, control device, control method and storage medium

Abstract

An inspection system according to a related embodiment includes a probe and a control unit. The probe includes multiple ultrasonic sensors arranged along a first direction and moves along a second direction intersecting the first direction to contact the weld. The multiple ultrasonic sensors each transmit ultrasonic waves to the weld and receive reflected waves. Based on the received reflected waves, the control unit detects the joints and non-joints at multiple points along the first direction on a first surface of the weld, detects the positions of each of the detected joints in the second direction, and calculates a first inclination of the first surface about a third direction, perpendicular to the first direction and intersecting the second direction, based on the detection results of the multiple positions. The angle of the probe about the third direction is adjusted to correct the first inclination.

Description

[0001] This application is a divisional application of the Chinese patent application with application number 201880017850.9 and invention name “Inspection system, control method and storage medium”. Technical Field

[0002] Embodiments of the present invention relate to an inspection system, a control device, a control method, and a storage medium. Background Art

[0003] In welding, parts of two or more components are melted together to form a single part. Welded parts are inspected to ensure proper bonding (hereinafter referred to as the weld). For example, in nondestructive testing, a probe containing an ultrasonic sensor is brought into contact with the weld. Ultrasonic waves are then transmitted into the weld, and the reflected waves are used to determine if a bond has formed.

[0004] During inspection, the angle of the probe relative to the component affects the inspection results. For example, if the inspection is conducted at an inappropriate angle, parts may be judged as not joined even though they are actually properly joined. Therefore, it is desirable to set the probe angle to an appropriate value. In particular, for inspection equipment that utilizes multiple ultrasonic sensors, the development of technology that can adjust the probe angle to a more appropriate value is desirable.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent No. 5618529 Summary of the Invention

[0008] Problems to be solved by the invention

[0009] An object of the present invention is to provide an inspection system, a control method, and a storage medium capable of adjusting the angle of a probe to a more appropriate value.

[0010] Means for solving problems

[0011] An inspection system according to a related embodiment includes a probe and a control unit. The probe includes multiple ultrasonic sensors arranged along a first direction and moves along a second direction intersecting the first direction to contact the weld. The multiple ultrasonic sensors each transmit ultrasonic waves to the weld and receive reflected waves. Based on the received reflected waves, the control unit detects the joints and non-joints at multiple points along the first direction on a first surface of the weld, detects the positions of each of the detected joints in the second direction, and calculates a first inclination of the first surface about a third direction, perpendicular to the first direction and intersecting the second direction, based on the detection results of the multiple positions. The angle of the probe about the third direction is adjusted to correct the first inclination. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic diagram showing an inspection system according to an embodiment.

[0013] Figure 2 It is a perspective view showing a part of the inspection system according to the embodiment.

[0014] Figure 3 Schematic diagram showing the internal structure of the probe tip of the inspection system according to the embodiment.

[0015] Figure 4 This is a flowchart showing an overview of the operation of the inspection system according to the embodiment.

[0016] Figure 5 It is a schematic diagram for explaining the inspection method of the inspection system related to the embodiment.

[0017] Figure 6 This is a flowchart showing a method for adjusting the probe angle of the inspection system according to the embodiment.

[0018] Figure 7 It is a diagram for explaining an inspection system according to an embodiment.

[0019] Figure 8 It is a diagram for explaining the effects of the inspection system according to the embodiment.

[0020] Figure 9 This is a flowchart showing another method of adjusting the probe angle of the inspection system according to the embodiment.

[0021] Figure 10 Graphs illustrating data detected by the inspection system according to the embodiment.

[0022] Figure 11 This is a flowchart showing another method of adjusting the probe angle of the inspection system according to the embodiment. DETAILED DESCRIPTION

[0023] Hereinafter, various embodiments of the present invention will be described with reference to the accompanying drawings.

[0024] In addition, the drawings are schematic or conceptual, and the relationship between the thickness and width of each part, the ratio of the dimensions between the parts, etc. are not necessarily the same as the actual situation. Even when showing the same part, the relative dimensions and ratios may be shown differently depending on the drawing.

[0025] In the present specification and the drawings, the same elements as those already described are denoted by the same reference numerals, and detailed description thereof will be appropriately omitted.

[0026] Figure 1 It is a schematic diagram showing an inspection system according to an embodiment.

[0027] Figure 2 It is a perspective view showing a part of the inspection system according to the embodiment.

[0028] The inspection system 100 according to the embodiment is used for performing nondestructive inspection on a weld portion integrating two or more components.

[0029] like Figure 1 As shown, the inspection system 100 of the embodiment includes an inspection device 1 and a control unit 2. Figure 2 As shown, the inspection device 1 includes a probe 10 , an imaging unit 20 , a coating unit 30 , and a robot arm (hereinafter referred to as an arm) 40 .

[0030] The probe 10 includes multiple ultrasonic sensors for inspecting welds. The imaging unit 20 captures images of welded components. The imaging unit 20 extracts weld marks from the images and detects the location of the weld. The coating unit 30 applies a coupling agent to the upper surface of the weld. The coupling agent is used to achieve acoustic matching of ultrasonic waves between the probe 10 and the inspection object. The coupling agent can be either liquid or gel.

[0031] The probe 10, the imaging unit 20 and the application unit 30 are configured as follows. Figure 2 As shown, it is provided at the front end of arm 40. Arm 40 is, for example, a multi-jointed robot arm. By driving arm 40, the positions of probe 10, imaging unit 20, and coating unit 30 can be changed. Control unit 2 controls the operation of these components included in inspection apparatus 1.

[0032] The inspection device 1 is connected to a device including the control unit 2 by wired communication or wireless communication, for example. Alternatively, the control unit 2 may be provided in the inspection device 1 to realize the inspection system 100 of the embodiment.

[0033] Figure 3 Schematic diagram showing the internal structure of the probe tip of the inspection system according to the embodiment.

[0034] The interior of the front end of the probe 10 is provided with Figure 3 The matrix sensor 11 shown in FIG. The matrix sensor 11 includes a plurality of ultrasonic sensors 12. The ultrasonic sensors 12 are, for example, transducers. The plurality of ultrasonic sensors 12 are arranged along a first direction D1 and a third direction D3 that are orthogonal to each other. The probe 10 moves along a second direction D2 that intersects a plane including the first direction D1 and the third direction D3, and contacts the inspection object. Figure 3 In the example, the second direction D2 is perpendicular to a plane including the first direction D1 and the third direction D3.

[0035] Figure 3 The diagram shows the state of component 5 during inspection. Component 5 is manufactured by spot-welding a metal plate 51 and a metal plate 52 at a weld 53. At weld 53, portions of metal plate 51 and metal plate 52 melt, mix, and solidify, forming a solidified portion 54. Each ultrasonic sensor 12 transmits ultrasonic waves US toward component 5, to which coupling agent 55 is applied, and receives reflected waves RW from component 5.

[0036] As a more specific example, Figure 3 As shown, a single ultrasonic sensor 12 transmits ultrasonic waves US toward the weld 53. A portion of the ultrasonic waves US is reflected by the surface or bottom of the component 5. Multiple ultrasonic sensors 12 receive and detect the reflected waves RW. Each ultrasonic sensor 12 sequentially transmits ultrasonic waves US, and the multiple ultrasonic sensors 12 receive the reflected waves RW, thereby performing a two-dimensional inspection of the vicinity of the weld 53 of the component 5.

[0037] Figure 4 This is a flowchart showing an overview of the operation of the inspection system according to the embodiment.

[0038] First, the imaging unit 20 captures an image of the component 5 and detects the position of the weld 53 based on the captured image (step S1). The arm 40 moves the applicator 30 to a position facing the weld 53 in the second direction D2. The applicator 30 applies coupling agent to the weld (step S2). The arm 40 moves the probe 10 in the second direction D2 until it contacts the weld 53 (step S3).

[0039] With the probe 10 in contact with the weld 53, the multiple ultrasonic sensors 12 transmit ultrasonic waves US toward the component 5 including the weld 53 and receive reflected waves RW. The control unit 2 adjusts the angle of the probe 10 based on the multiple reflected waves RW (step S4). Once the angle of the probe 10 has been adjusted, the weld 53 is inspected using the multiple ultrasonic sensors 12 (step S5). The control unit 2 determines whether any welds 53 remain uninspected (step S6).

[0040] If there are no uninspected welds 53, the inspection is completed. If there are still uninspected welds 53, the control unit 2 drives the arm 40 to move the probe 10, imaging unit 20, and coating unit 30 to another weld 53 (step S7). Then, steps S1 to S6 are executed again.

[0041] Figure 5 It is a schematic diagram for explaining the inspection method of the inspection system related to the embodiment.

[0042] like Figure 5 As shown in (a), part of the ultrasonic wave US is reflected by the upper surface 5a of the metal plate 51 or the upper surface 5b of the weld 53. The other part of the ultrasonic wave US enters the component 5 and is reflected by the bottom surface 5c of the metal plate 51 or the bottom surface 5d of the weld 53.

[0043] The upper surface 5a, upper surface 5b, bottom surface 5c, and bottom surface 5d are located at different positions in the second direction D2. In other words, the distances between these surfaces and the ultrasonic sensor 12 in the second direction D2 are different. When the ultrasonic sensor 12 receives reflected waves from these surfaces, it detects the peak intensity of the reflected waves. By calculating the time from the transmission of the ultrasonic wave US to the detection of each peak, it is possible to determine which surface the ultrasonic wave US was reflected from.

[0044] Figure 5 (b) and Figure 5 (c) is a graph illustrating the relationship between the time after the ultrasonic wave US is transmitted and the intensity of the reflected wave RW. Figure 5 The graph in (b) illustrates the reception result of the reflected wave RW from the upper surface 5 a and the bottom surface 5 c of the metal plate 51 . Figure 5 The graph in (c) illustrates the result of receiving the reflected wave RW from the upper surface 5 b and the bottom surface 5 d of the weld portion 53 .

[0045] exist Figure 5In the graph (b), the first peak Pe1 is based on the reflected wave RW from the upper surface 5a. The second peak Pe2 is based on the reflected wave RW from the bottom surface 5c. The times at which peaks Pe1 and Pe2 are detected correspond to the positions of the upper surface 5a and bottom surface 5c of the metal plate 51, respectively, in the second direction D2. The time difference TD1 between the times at which peaks Pe1 and Pe2 are detected corresponds to the distance Di1 between the upper surface 5a and bottom surface 5c in the second direction D2.

[0046] Likewise, in Figure 5 In the graph (c), the first peak Pe3 is based on the reflected wave RW from the upper surface 5b. The second peak Pe4 is based on the reflected wave RW from the bottom surface 5d. The times at which peaks Pe3 and Pe4 are detected correspond to the positions of the upper surface 5b and bottom surface 5d of the weld portion 53, respectively, in the second direction D2. The time difference TD2 between the times at which peaks Pe3 and Pe4 are detected corresponds to the distance Di2 between the upper surface 5b and bottom surface 5d in the second direction D2.

[0047] Therefore, by detecting the time from the transmission of the ultrasonic wave US to the detection of the first peak (first peak) and the second peak (second peak) of the reflected wave RW, the position of the surface reflecting the ultrasonic wave US in the second direction D2 can be detected. The distance in the second direction D2 between the surfaces reflecting the ultrasonic wave US can be detected based on the difference between the time of detection of the first peak and the time of detection of the second peak.

[0048] The method of adjusting the angle performed in step S4 will be described in detail.

[0049] Figure 6 This is a flowchart showing a method for adjusting the probe angle of the inspection system according to the embodiment.

[0050] Figure 7 It is a diagram for explaining an inspection system according to an embodiment.

[0051] Ultrasonic waves US are transmitted from the plurality of ultrasonic sensors 12, and reflected waves RW are received (step S401). Figure 3 As described, each ultrasonic sensor 12 sequentially transmits ultrasonic waves US, and each reflected wave RW is received by the plurality of ultrasonic sensors 12 .

[0052] Figure 7 (a) and Figure 7 (d) is a top view showing the vicinity of the welded portion 53 of the component 5. In step S401, for example, Figure 7(a) shows the structure of the detection area DA. Specifically, the connection or non-connection of each point in the detection area DA is detected. The control unit 2 adjusts the angle of the probe 10 about the third direction D3 based on the detection results along the line segment L1 along the first direction D1. For example, the line segment L1 is located near the center of the detection area DA in the third direction D3.

[0053] Figure 7 (b) is an example of the detection results of each point on the line segment L1. Figure 7 In (b), the vertical axis represents the position in the second direction D2, and the horizontal axis represents the position in the first direction D1. Figure 7 In (b), ○ (white circles) indicate the position of the first reflecting surface (first reflecting surface) of component 5 in the second direction D2. Specifically, ○ indicates the position of upper surface 5a or upper surface 5b. ● (black circles) indicate the position of the second reflecting surface (second reflecting surface) of component 5 in the second direction D2. Specifically, ○ indicates the position of bottom surface 5c or bottom surface 5d. As described above, these positions are calculated based on the time from the transmission of ultrasonic wave US to the detection of the peak of reflected wave RW. ◆ indicates the results of bonded and unbonded detection, which will be described later.

[0054] exist Figure 7 In the results (b), the distance between the first and second reflecting surfaces is short in the detection results near the end of line segment L1 in the first direction D1. This indicates that the ultrasonic wave US is reflected by the upper surface 5a and the bottom surface 5c. In the detection results near the center of the first direction D1, the distance between the first and second reflecting surfaces is long. This indicates that the ultrasonic wave US is reflected by the upper surface 5b and the bottom surface 5d.

[0055] The control unit 2 calculates the distance between the first reflecting surface and the second reflecting surface. For example, if the distance is greater than a preset threshold, the control unit 2 determines that the point is joined. If the distance is less than the threshold, the control unit 2 determines that the point is not joined. Figure 7 In the graph shown in (b), points determined to be joined are represented by a value of 1, and points determined to be unjoined are represented by a value of 0.

[0056] According to the above method, the control unit 2 detects joints and non-joints at multiple points along the first direction D1 of the component 5. The control unit 2 extracts the number of detected joints (hereinafter referred to as the detection count) (step S402). The control unit 2 determines whether the detection count is greater than a predetermined threshold (step S403). The threshold is set based on the dimensions of the weld 53 in the first direction D1, the density of the ultrasonic sensors 12 in the first direction D1, and other factors.

[0057] When the number of detections is greater than the threshold, the control unit 2 maintains the angle of the probe 10 around the third direction D3 and ends the angle adjustment. Figure 4 Step S5 is shown. Since a sufficient number of detections have been detected, it can be considered that the welded portion 53 is properly joined. If the number of detections is less than the threshold, the control unit 2 compares the number m1 of times steps S401 and S402 have been executed so far with a preset value n1 (step S404).

[0058] If the number m1 is less than the value n1, the control unit 2 changes the angle of the probe 10 about the third direction D3 (step S405). Step S401 is then executed again. Thus, while the angle about the third direction D3 is changed, steps S401 and S402 are repeatedly executed. If the number m1 is greater than the value n1, the control unit 2 derives an appropriate first angle of the probe 10 about the third direction D3 based on the detection results to that point (step S406).

[0059] Figure 7 (c) shows an example of the detection result obtained by repeatedly executing steps S401 to S405. Figure 7 In (c), the horizontal axis represents the angle around the third direction D3, and the vertical axis represents the number of detections for each angle. For example, the control unit 2 sets the angle θ1 with the largest number of detections as the first angle. Alternatively, the control unit 2 may generate a quadratic function QF representing the relationship between angle and number of detections, and set the angle θ2, which is the inflection point of the quadratic function QF, as the first angle. The control unit 2 sets the angle of the probe 10 around the third direction D3 as the first angle (step S407).

[0060] Then, ultrasonic waves US are transmitted from the plurality of ultrasonic sensors 12 and reflected waves RW are received (step S408 ). For example, similar to step S401 , each ultrasonic sensor 12 sequentially transmits ultrasonic waves US and receives reflected waves RW.

[0061] The structure in the detection area DA is detected in step S408. Figure 7 (d) shows the detection result of the line segment L2 along the third direction D3, and adjusts the angle of the probe 10 around the third direction D3. The line segment L2 is located near the center of the detection area DA in the first direction D1, for example.

[0062] The control unit 2 extracts the number of detections at multiple points along the third direction D3 of the component 5 in the same manner as in step S402 (step S409). The control unit 2 determines whether the number of detections is greater than a preset threshold (step S410). The threshold is set based on the dimensions of the weld 53 in the third direction D3, the density of the ultrasonic sensors 12 in the third direction D3, and other factors.

[0063] If the number of detections is greater than the threshold, the control unit 2 maintains the angle of the probe 10 about the first direction D1 and ends the angle adjustment. If the number of detections is less than the threshold, the control unit 2 compares the number m2 of times steps S408 and S409 have been executed to date with a preset value n2 (step S411).

[0064] If the number m2 is smaller than the value n2, the control unit 2 changes the angle of the probe 10 around the first direction D1 (step S412), and then executes steps S408 to S410 again.

[0065] If the number m2 is equal to or greater than the value n2, the control unit 2 derives an appropriate second angle of the probe 10 about the first direction D1 based on the detection results up to that point (step S413). The derivation of the second angle is performed in the same manner as in step S406. The control unit 2 sets the angle of the probe 10 about the first direction D1 as the second angle (step S414).

[0066] By the above method, the angle of the probe 10 is adjusted appropriately, and then the probe 10 is used to inspect the weld portion 53 .

[0067] In step S411, if the number m2 reaches n2 or more, it means that there are many unjoined points in the weld 53. This is because although the angle of the probe 10 has been changed in the steps up to this point, the number of detections has not been sufficient. Therefore, in step S411, if the number m2 reaches n2 or more, it can be determined that the weld 53 is not joined. In this case, the angle adjustment is completed and the process is omitted. Figure 4 Step S5 is shown.

[0068] In the above method, the angle of the probe 10 is adjusted using the detection results on the line segment L1 along the first direction D1 and the detection results on the line segment L3 along the third direction D3 among the detection results performed by all ultrasonic sensors 12 included in the matrix sensor 11.

[0069] The angle adjustment control method of the inspection system 100 of the embodiment is not limited to this. For example, the detection of engagement and disengagement of component 5 at multiple points along the first direction D1 can be performed using only a portion of the multiple ultrasonic sensors 12 along the first direction D1. Similarly, the detection of engagement and disengagement of component 5 at multiple points along the third direction D3 can be performed using only a portion of the multiple ultrasonic sensors 12 along the third direction D3. If the detection results of engagement and disengagement at multiple points along a specific direction can be obtained, the specific detection method of the inspection system 100 of the embodiment can be appropriately modified. This also applies to the angle adjustment control method described below.

[0070] Figure 8 It is a diagram for explaining the effects of the inspection system according to the embodiment.

[0071] exist Figure 8 In the figure, the two horizontal axes represent the angles θ around the first direction D1. D1 and the angle θ around the third direction D3 D3 The vertical axis represents the number of detections. Figure 8 Points P1 to P5 in the figure illustrate how the angle θ D1 and angle θ D3 The trajectory of the change in the number of detections when the value changes.

[0072] The above angle adjustment method is to adjust the angle θ around the first direction D1. D1 and the angle θ around the third direction D3 D3 Changes, while achieving an increase in the number of detections. Figure 8 Points P1 to P5 in FIG. 5 are equivalent to climbing a higher position of the mountain of detection numbers. The larger the detection number, the more appropriate the angle at which the component 5 can be inspected.

[0073] In the above example, the angle around the first direction D1 or around the third direction D3 is adjusted based on the number of engagements detected at multiple points along the first direction D1 or the third direction D3 of the component 5. The inspection system 100 and the control method of the relevant embodiment are not limited to this example. Alternatively, the angle around the first direction D1 or around the third direction D3 may be adjusted based on the number of non-engagements detected at multiple points along the first direction D1 or the third direction D3 of the component 5. In this case, the angle around the first direction D1 or around the third direction D3 is adjusted in such a way that the number of detected non-engagements is reduced. Similarly, in other methods described below, the angle of the probe 10 may be adjusted using the number of detected non-engagements instead of the number of detected engagements.

[0074] The effects of the embodiment will be described.

[0075] As described above, in the inspection system 100 of the embodiment, joints and non-joints are detected at multiple points along the first direction D1 of the weld 53. Furthermore, the angle of the probe 10 along the third direction D3 is adjusted based on the number of joints or non-joints detected at these multiple points. By employing this method, the inventors have discovered that the angle of the probe 10 along the third direction D3 can be adjusted to a more appropriate value. Specifically, according to this embodiment, the angle of the probe 10 can be adjusted to a more appropriate value for a probe having multiple ultrasonic sensors arranged therein.

[0076] For example, the control unit 2 varies the angle of the probe 10 about the third direction D3 while extracting the number of detections at each angle. Furthermore, the control unit 2 sets the first angle whose detection count exceeds a preset threshold as the angle of the probe 10 about the third direction D3. This method narrows the range of angles for which detection counts are examined, allowing more appropriate angles about the third direction D3 to be detected in a shorter time.

[0077] Alternatively, the control unit 2 may also be as follows Figure 7 As shown in (c), while varying the angle of the probe 10 about the third direction D3 within a first range, the first angle with the highest number of detections is set as the angle of the probe 10 about the third direction D3. Alternatively, the control unit 2 may vary the angle of the probe 10 about the third direction D3 within the first range while generating a quadratic function representing the relationship between the angle and the number of detections. The control unit 2 sets the first angle, which is the inflection point of the quadratic function, as the angle of the probe 10 about the third direction D3.

[0078] The first range is set based on the accuracy required for inspecting the welded portion 53. Typically, the wider the first range, the easier it is to set a more appropriate angle. According to these methods, a more appropriate angle around the third direction D3 can be detected.

[0079] Furthermore, even when the number of detections within the first range is small, by generating an approximate curve of a quadratic function, it is possible to efficiently determine the first angle having a large value of the number of detections estimated based on the quadratic function.

[0080] After setting the angle of the probe 10 about the third direction D3 using any of these methods, it is preferable to set the angle of the probe 10 about the first direction D1. For example, similar to the angle about the third direction D3, the control unit 2 varies the angle of the probe 10 about the first direction D1 while extracting the number of detections for each angle. The control unit 2 sets the angle for which the number of detections exceeds a preset threshold as the angle of the probe 10 about the third direction D3.

[0081] Alternatively, the control unit 2 may set the angle with the largest number of detections as the angle around the third direction D3 of the probe 10. Alternatively, the control unit 2 may generate a quadratic function representing the relationship between the angle and the number of detections, and set the angle serving as the inflection point of the quadratic function as the angle around the third direction D3 of the probe 10.

[0082] Thus, the angle of the probe 10 around the first direction D1 and the angle around the third direction D3 are adjusted to more appropriate values. By inspecting the weld 53 with the angle of the probe 10 adjusted, the weld 53 can be inspected more accurately.

[0083] In the inspection system of the embodiment, angle adjustment may also be performed by the following method.

[0084] Figure 9 This is a flowchart showing another method of adjusting the probe angle of the inspection system according to the embodiment.

[0085] Figure 10 Graphs illustrating data detected by the inspection system according to the embodiment.

[0086] right Figure 9 (a) is used for explanation.

[0087] First, similarly to step S401 , ultrasonic waves US are sequentially transmitted from the respective ultrasonic sensors 12 , and respective reflected waves RW are received by the plurality of ultrasonic sensors 12 (step S421 ).

[0088] Figure 10 The data detected by the plurality of ultrasonic sensors 12 arranged along the first direction D1 in step S421 are exemplified. Figure 10 , the vertical axis represents the position in the second direction D2, and the horizontal axis represents the position of each ultrasonic sensor 12 in the first direction D1.

[0089] The control unit 2 calculates the first inclination of the upper surface 5b or the bottom surface 5d around the third direction D3 based on the detection result (step S422). For example, the control unit 2 only uses the results determined to be joined, and calculates the first inclination of the upper surface 5b or the bottom surface 5d around the third direction D3 based on the detection result (step S422). Figure 10 The linear function LF is generated as shown. The linear function LF represents the relationship between the position in the first direction D1 and the position in the second direction D2. The linear function LF is generated based on the reflected wave RW of the upper surface 5b or the bottom surface 5d. More preferably, the linear function LF is as follows Figure 10 The figure shows the generation of the reflected wave RW from the bottom surface 5d.

[0090] The slope of the linear function LF is used as the first inclination. The larger the first inclination, the greater the inclination of the matrix sensor 11 relative to the upper surface 5b or the bottom surface 5d about the third direction D3. The control unit 2 detects the direction and magnitude of the first inclination and changes the angle of the probe 10 about the third direction D3 to correct the first inclination (step S423). For example, the larger the first inclination, the larger the angle changed by the control unit 2. The so-called inclination correction means reducing the inclination to 0, so that the linear function LF is substantially parallel to the horizontal axis. In this way, the inclination of the matrix sensor 11 relative to the upper surface 5b and the bottom surface 5d can be reduced.

[0091] Then, similarly to step S408, ultrasonic waves US are sequentially transmitted from the plurality of ultrasonic sensors 12 arranged along the third direction D3, and reflected waves RW are received by the plurality of ultrasonic sensors 12 (step S424). Similar to step S422, the control unit 2 calculates the second inclination of the upper surface 5b or the bottom surface 5d about the first direction D1 (step S425). The greater the second inclination, the greater the inclination of the matrix sensor 11 about the first direction D1 relative to the upper surface 5b or the bottom surface 5d. Similar to step S423, the control unit 2 changes the second angle of the probe 10 about the first direction D1 to correct the second inclination (step S426).

[0092] Alternatively, you can Figure 9 As shown in (b), based on the detection result obtained in step S421, steps S425 and S426 are executed in parallel with steps S422 and S423. According to this method, step S424 can be omitted, thereby shortening the time required for adjusting the angle of the probe 10.

[0093] According to this adjustment method, based on a single test result, at least one of the angles of the probe 10 about the first direction D1 and about the third direction D3 can be adjusted to a more appropriate value. Therefore, the number of tests performed for adjusting the angle of the probe 10 can be reduced, shortening the time required for angle adjustment.

[0094] Alternatively, you can combine Figure 6 The method shown in the flowchart and Figure 9 The method is shown in the flowchart.

[0095] Figure 11 This is a flowchart showing another method of adjusting the probe angle of the inspection system according to the embodiment.

[0096] First, similar to step S401, ultrasonic waves US are sequentially transmitted from the plurality of ultrasonic sensors 12, and reflected waves RW are received by the plurality of ultrasonic sensors 12 (step S441). The control unit 2 extracts the number of detections at a plurality of points along the first direction D1 of the component 5 (step S442). The control unit 2 determines whether the number of detections is greater than a predetermined first threshold (step S443).

[0097] For example, a value sufficient to determine that the entire weld portion 53 is fully joined is set as the first threshold. If the number of detections is greater than the first threshold, the angle of the probe 10 is determined to be appropriate, and the angle adjustment of the probe 10 is completed. If the number of detections is less than the first threshold, the control unit 2 determines whether the number of detections is greater than a pre-set second threshold (step S444).

[0098] The second threshold is smaller than the first threshold. As the second threshold, a value sufficient to calculate the number of detections of the first inclination is set. When the number of detections is greater than the second threshold, Figure 9 The process shown Figure 1 The first inclination is calculated similarly (step S445), and the angle of the probe 10 around the third direction D3 is adjusted to correct the first inclination (step S446).

[0099] If the number of detections is less than the second threshold, the number m1 of times steps S441 to S444 have been executed is compared with a preset value n1 (step S447). If the number m1 is less than the value n1, the control unit 2 changes the angle of the probe 10 around the third direction D3 (step S448). Then, step S441 is executed again. If the number m1 is greater than the value n1, the control unit 2 derives an appropriate first angle of the probe 10 around the third direction D3 based on the detection results up to this point (step S449). The control unit 2 sets the angle of the probe 10 around the third direction D3 to the first angle (step S450).

[0100] Then, ultrasonic waves US are sequentially transmitted from the plurality of ultrasonic sensors 12, and reflected waves RW are received by the plurality of ultrasonic sensors 12 (step S451). The control unit 2 extracts the number of detections at a plurality of points along the third direction D3 of the component 5 (step S452). The control unit 2 determines whether the number of detections is greater than or equal to a predetermined third threshold value (step S453).

[0101] As with the first threshold, the third threshold is set to a value sufficient to determine that the entire weld portion 53 is fully joined. If the number of detections is greater than the third threshold, the angle of the probe 10 is determined to be appropriate, and the angle adjustment of the probe 10 is completed. If the number of detections is less than the third threshold, the control unit 2 determines whether the number of detections is greater than a predetermined fourth threshold (step S454).

[0102] The fourth threshold is smaller than the third threshold. As the fourth threshold, a value sufficient to calculate the number of detections of the second inclination is set. When the number of detections is greater than the fourth threshold, Figure 9 The process shown Figure 1 The second inclination is calculated similarly (step S455), and the angle of the probe 10 around the first direction D1 is adjusted to correct the second inclination (step S456).

[0103] When the number of detections is less than the fourth threshold, the number m2 of times steps S451 to S454 have been executed is compared with a pre-set value n2 (step S457). When the number m2 is less than the value n2, the control unit 2 changes the angle of the probe 10 around the first direction D1 (step S458). And, step S451 is executed again. When the number m2 is greater than the value n2, the control unit 2 derives an appropriate second angle of the probe 10 around the first direction D1 based on the detection results up to this point (step S459). The control unit 2 sets the angle of the probe 10 around the third direction D3 to the second angle (step S460).

[0104] According to this method, the angle of the probe 10 can be set to Figure 6 and Figure 9 The method shown also gives the appropriate value.

[0105] exist Figure 11 In the flowchart shown, step S451 may be omitted. In this case, step S452 is executed based on the detection result obtained in step S441. According to this method, the time required for adjusting the angle of the probe 10 can be shortened.

[0106] The embodiment of the present invention includes the following procedures.

[0107] A program for adjusting the angle of a probe, the probe including a plurality of ultrasonic sensors arranged along a first direction, the probe moving along a second direction intersecting the first direction and contacting a weld portion, the program causing a control unit to perform the following processing:

[0108] detecting bonding and non-bonding at a plurality of points along the first direction of the weld part based on a plurality of reflected waves received by the plurality of ultrasonic sensors when ultrasonic waves are respectively transmitted to the weld part;

[0109] An angle of the probe around a third direction is adjusted according to the number of engagements or disengagements detected at the plurality of points. The third direction is perpendicular to the first direction and intersects the second direction.

[0110] A program for adjusting the angle of a probe, the probe including a plurality of ultrasonic sensors arranged along a first direction, the probe moving along a second direction intersecting the first direction and contacting a weld portion, the program causing a control unit to perform the following processing:

[0111] For a plurality of points on the first surface of the weld portion along the first direction, positions of the plurality of points along the second direction are detected based on the plurality of reflected waves.

[0112] calculating a first inclination of the first surface around a third direction based on detection results of at least a portion of the plurality of positions, wherein the third direction is perpendicular to the first direction and intersects the second direction;

[0113] The angle of the probe around the third direction is adjusted to correct the first tilt.

[0114] According to the inspection system 100 or the control method of the embodiment described above, the angle of the probe 10 can be adjusted to a more appropriate value. Similarly, by using a program that causes the control unit 2 to execute the above-mentioned control method or a storage medium storing the program, the angle of the probe 10 can be adjusted to a more appropriate value.

[0115] The above examples illustrate several embodiments of the present invention, but these embodiments are provided as examples and are not intended to limit the scope of the invention. These new embodiments can be implemented in various other forms and can be omitted, replaced, or modified in various ways without departing from the scope of the invention. These embodiments and their variations are included in the scope or spirit of the invention and are included in the invention described in the claims and their equivalents. The aforementioned embodiments can be implemented in combination with each other.

Claims

1. An inspection system comprising: a probe including a plurality of ultrasonic sensors arranged along a first direction, and moving along a second direction intersecting the first direction to contact a weld, wherein the plurality of ultrasonic sensors respectively transmit ultrasonic waves to the weld and receive reflected waves; and a control unit for detecting, based on the received plurality of reflected waves, joints and non-joints at a plurality of points along the first direction on a first surface of the weld, detecting the positions of the plurality of points in the second direction, and, when the number of points detected as being joined is greater than a predetermined threshold, calculating a first position of the first surface around a third direction using the detection results of the positions of the detected joined points among the plurality of points. inclination, the third direction is perpendicular to the first direction and intersects with the second direction, the angle of the probe around the third direction is adjusted to correct the first inclination, when the number of points detected to be joined is less than a preset threshold value and the number of times the detection of the joining and non-joining of the multiple points is performed is less than a preset value, the angle of the probe around the third direction is changed while the number of points detected to be joined is detected at each angle, when the number of points detected to be joined is less than the preset threshold value and the number of times the detection of the joining and non-joining of the multiple points is performed is greater than or equal to the preset value, the angle of the probe around the third direction is set.

2. The inspection system according to claim 1, wherein a plurality of ultrasonic sensors are arranged in the third direction, and the control unit detects the positions of a plurality of points of the first surface along the third direction in the second direction based on the plurality of reflected waves, and the control unit calculates the second inclination of the first surface around the first direction based on the detection results of at least a part of the plurality of positions along the third direction, and the control unit adjusts the angle of the probe around the first direction to correct the second inclination. 3 . The inspection system according to claim 2 , wherein the control unit calculates the second inclination using the position at which the joint is detected among the plurality of positions along the third direction. 4 . The inspection system according to claim 1 , wherein after adjusting the angle of the probe, the control unit transmits ultrasonic waves from the plurality of ultrasonic sensors to the welded portion to inspect the welded portion. 5 . The inspection system according to claim 1 , further comprising an application portion for applying a coupling agent to the weld portion, wherein the probe contacts the weld portion to which the coupling agent is applied.

6. A control device for adjusting an angle of a probe, the probe comprising a plurality of ultrasonic sensors arranged along a first direction, the probe moving in a second direction intersecting the first direction to contact a welding portion, the control device performing the following processing: referring to reception results of reflected waves of each of the plurality of ultrasonic sensors after transmitting ultrasonic waves to the welding portion; detecting, based on the plurality of received reflected waves, whether a plurality of points along the first direction of a first surface of the welding portion are joined or not joined; detecting the position of each of the plurality of points in the second direction; and, when the number of points detected to be joined is greater than a predetermined threshold value, calculating a first inclination of the first surface about a third direction using the detection results of the positions of the detected joined points among the plurality of points, the third direction being perpendicular to the first direction and intersecting the second direction; adjusting the angle of the probe around the third direction to correct the first tilt; And when the number of points detected to be joined is less than a preset threshold value and the number of times the detection of joining and non-joining of the multiple points is performed is less than a preset value, the angle of the probe around the third direction is changed while the number of points detected to be joined is detected at each angle; when the number of points detected to be joined is less than the preset threshold value and the number of times the detection of joining and non-joining of the multiple points is performed is greater than or equal to the preset value, the angle of the probe around the third direction is set.

7. According to the control device according to claim 6, a plurality of ultrasonic sensors are arranged in the third direction, and the control device performs the following processing: detecting the positions of a plurality of points along the third direction of the first surface in the second direction based on the plurality of reflected waves, calculating the second inclination of the first surface around the first direction based on the detection results of at least a part of the plurality of positions along the third direction, and adjusting the angle of the probe around the first direction to correct the second inclination. 8 . The control device according to claim 7 , wherein the control device calculates the second inclination using the position at which engagement is detected among the plurality of positions along the third direction.

9. A control method comprising the following steps: A method of making a probe including a plurality of ultrasonic sensors arranged along a first direction contact the weld portion in a second direction intersecting the first direction; transmitting ultrasonic waves from the plurality of ultrasonic sensors to the weld portion and receiving reflected waves; detecting, based on the received plurality of reflected waves, whether a plurality of points on a first surface of the weld portion are joined or not joined along the first direction; detecting the position of each of the plurality of points in the second direction; and, when the number of points detected as joined is greater than a predetermined threshold, calculating a first inclination of the first surface about a third direction perpendicular to the first direction and intersecting the second direction using the detection results of the positions of the detected joined points among the plurality of points; adjusting the angle of the probe around the third direction to correct the first tilt; And when the number of points detected to be joined is less than a preset threshold value and the number of times the detection of joining and non-joining of the multiple points is performed is less than a preset value, the angle of the probe around the third direction is changed while the number of points detected to be joined is detected at each angle; when the number of points detected to be joined is less than the preset threshold value and the number of times the detection of joining and non-joining of the multiple points is performed is greater than or equal to the preset value, the angle of the probe around the third direction is set.

10. The control method according to claim 9, wherein a plurality of ultrasonic sensors are arranged in the third direction, and the control method further comprises the following steps: detecting positions of a plurality of points on the first surface along the third direction in the second direction according to the plurality of reflected waves; calculating a second inclination of the first surface around the first direction based on detection results of at least a portion of the plurality of positions along the third direction; and adjusting the angle of the probe around the first direction to correct the second tilt.

11. The control method according to claim 10, further comprising the following steps: The second inclination is calculated using the position where engagement is detected among the plurality of positions along the third direction.

12. A storage medium storing a program, the program being configured to adjust an angle of a probe, the probe comprising a plurality of ultrasonic sensors arranged along a first direction, the probe moving in a second direction intersecting the first direction to contact a weld portion, the program causing a control unit to perform the following processing: detecting, based on a plurality of received reflected waves, whether a plurality of points on a first surface of the weld portion are joined or not joined along the first direction; detecting the position of each of the plurality of points in the second direction; and, when the number of points detected as joined is greater than a predetermined threshold, calculating, using the detection results of the positions of the detected joined points among the plurality of points, a first inclination of the first surface about a third direction perpendicular to the first direction and intersecting the second direction; adjusting the angle of the probe around the third direction to correct the first tilt; And when the number of points detected to be joined is less than a preset threshold value and the number of times the detection of joining and non-joining of the multiple points is performed is less than a preset value, the angle of the probe around the third direction is changed while the number of points detected to be joined is detected at each angle; when the number of points detected to be joined is less than the preset threshold value and the number of times the detection of joining and non-joining of the multiple points is performed is greater than or equal to the preset value, the angle of the probe around the third direction is set.

13. The storage medium according to claim 12, wherein a plurality of ultrasonic sensors are arranged in the third direction, and the program further causes the control unit to perform the following processing: detecting the positions of a plurality of points along the third direction of the first surface in the second direction based on the plurality of reflected waves; calculating the second inclination of the first surface around the first direction based on the detection results of at least a part of the plurality of positions along the third direction; and adjusting the angle of the probe around the first direction to correct the second inclination. 14 . The storage medium according to claim 13 , wherein the program further causes the control unit to perform processing for calculating the second inclination using the position at which engagement is detected among the plurality of positions along the third direction.

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