Apparatus and system for weld quality detection

Abstract

The embodiment of the present application provides a device and system for weld quality detection, and belongs to the technical field of welding. The device for weld quality detection comprises: a phased array ultrasonic transducer, which comprises a plurality of annularly arranged array elements for transmitting ultrasonic signals and receiving echo signals, any array element in the plurality of array elements is responsive to receiving an excitation signal and transmits the excitation signal to the array element adjacent to the any array element until the plurality of array elements all receive the excitation signal, and the plurality of array elements are responsive to receiving the excitation signal to sequentially transmit ultrasonic signals to the weld and receive echo signals corresponding to the ultrasonic signals; and a processor, which is electrically connected with the phased array ultrasonic transducer, and is configured to: acquire the echo signals received by the phased array ultrasonic transducer; and process the echo signals to complete the quality detection of the weld. The present application can reduce the control difficulty of the phased array ultrasonic transducer.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and more specifically to a device and system for inspecting weld quality. Background Technology

[0002] Non-destructive testing (NDT) technology is the foundation and crucial guarantee of modern industry. In particular, NDT of weld seams (e.g., boom weld seams) is key to ensuring the quality and safety of construction machinery. Due to various factors, defects of various types may occur during the actual processing of construction machinery components (e.g., booms), leading to performance degradation or even failure. Furthermore, construction machinery often operates under conditions of wear and corrosion, making its components (e.g., booms) prone to cracks and other damage, and in severe cases, even breakage, posing a risk to operator safety.

[0003] Traditional ultrasonic testing relies on analyzing and processing the echo signals collected by an ultrasonic flaw detector to obtain defect signals within the weld. Traditional ultrasonic non-destructive testing has low utilization of echo signals from inside and outside the working arm, typically requiring manual operation to determine defect location and failing to effectively identify defects within the weld. Therefore, the emergence of ultrasonic phased array technology has greatly improved this situation. Applying ultrasonic phased array technology to non-destructive testing can effectively detect the type and location of weld defects. However, ultrasonic phased array technology usually requires individual control of each array element for signal excitation, which presents significant control challenges when there are many array elements. Summary of the Invention

[0004] The purpose of this invention is to provide a device and system for weld quality inspection, so as to solve the problem that the existing technology has great difficulty in control when there are many array elements.

[0005] To achieve the above objectives, a first aspect of the present invention provides an apparatus for weld quality inspection, the apparatus comprising:

[0006] A phased array ultrasonic transducer includes: multiple array elements arranged in a ring for transmitting ultrasonic signals and receiving echo signals. Any array element in the multiple array elements responds to receiving an excitation signal and transmits the excitation signal to an array element adjacent to the receiving array element until all array elements receive the excitation signal. The multiple array elements respond to receiving the excitation signal and sequentially transmit ultrasonic signals to the weld and receive echo signals corresponding to the ultrasonic signals.

[0007] The processor, electrically connected to the phased array ultrasonic transducer, is configured to:

[0008] Acquire the echo signal received by the phased array ultrasonic transducer;

[0009] The echo signal is processed to complete the quality inspection of the weld.

[0010] In this embodiment of the invention, the interval between the multiple array elements emitting ultrasonic signals is the interval between the multiple array elements receiving excitation signals.

[0011] In this embodiment of the invention, the processor is configured to acquire the echo signal received by the phased array ultrasonic transducer, including: the processor is configured to acquire the echo signal of each array element in the phased array ultrasonic transducer after a preset time length following the transmission of the ultrasonic signal.

[0012] In this embodiment of the invention, the preset time length is the interval between multiple array elements receiving excitation signals.

[0013] In this embodiment of the invention, the processor is configured to process the echo signal, including: converting the echo signal into point cloud coordinates; sequentially establishing corresponding spatial dynamic planes for the point cloud coordinates to determine effective point cloud coordinates; and fitting the effective point cloud coordinates to obtain the contour curve of the weld.

[0014] In this embodiment of the invention, before the processor establishes the corresponding spatial dynamic plane for the point cloud coordinates in sequence, the processor is further configured to sort the point cloud coordinates in descending or ascending order according to the three dimensions based on the point cloud dimensionality reduction sorting algorithm or the point cloud dimensionality increase sorting algorithm, so as to obtain the sorted point cloud coordinates.

[0015] In this embodiment of the invention, the processor is configured to sequentially establish corresponding spatial dynamic planes for point cloud coordinates to determine valid point cloud coordinates, including: the processor is configured to: sequentially determine the two nearest adjacent point cloud coordinates that are not collinear with the point cloud coordinates; establish corresponding spatial dynamic planes based on the point cloud coordinates and the two adjacent point cloud coordinates; and determine point cloud coordinates that are not on the spatial dynamic plane and whose distance from the spatial dynamic plane is less than or equal to a preset distance threshold as valid point cloud coordinates.

[0016] In this embodiment of the invention, the device further includes: a signal controller, electrically connected to the phased array ultrasonic transducer, for sending an excitation signal to any array element.

[0017] In this embodiment of the invention, the processor is further configured to send an excitation signal to any array element.

[0018] In this embodiment of the invention, the device further includes a display device electrically connected to the processor for displaying the contour curve of the weld.

[0019] A second aspect of the present invention provides a system for weld quality inspection, comprising: the apparatus for weld quality inspection as described above.

[0020] The above technical solution achieves signal excitation of the entire ring array element by individually controlling any one element in the ring array element of the phased array ultrasonic transducer. This, in turn, controls the transmission and reception of excitation signals of each element in the entire phased array ultrasonic transducer, thus completing the scanning and sampling of the weld. By adopting a point-to-full signal excitation method, it solves the problem of high control difficulty caused by the large number of array elements in existing phased array ultrasonic testing technology, reduces the control difficulty of the phased array ultrasonic transducer, improves the automation level of weld inspection, and reduces equipment costs.

[0021] Other features and advantages of the embodiments of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0022] The accompanying drawings are provided to further illustrate embodiments of the present invention and form part of the specification. They are used together with the following detailed description to explain the embodiments of the present invention, but do not constitute a limitation thereof. In the drawings:

[0023] Figure 1 This schematic diagram illustrates the structure of a device for weld quality inspection according to an embodiment of the present invention.

[0024] Figure 2 The diagram illustrates the excitation transmission method of the internal ring array element of a phased array ultrasonic transducer in one embodiment of the present invention.

[0025] Figure 3 The diagram illustrates a method for dividing the sampling interval in one embodiment of the present invention.

[0026] Figure 4 The schematic diagram illustrates a process for obtaining the weld contour curve in one embodiment of the present invention.

[0027] Figure 5 The schematic diagram illustrates the structure of an excavator boom weld inspection device according to an embodiment of the present invention.

[0028] Explanation of reference numerals in the attached figures

[0029] 102 Phased Array Ultrasonic Transducer 104 Processor

[0030] 501 Cross carriage; 502 Gantry carriage

[0031] 503 Industrial Robot; 504 Phased Array Ultrasonic Transducer

[0032] 505 Excavator under inspection 506 Positioner arm Detailed Implementation

[0033] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the scope of the present invention.

[0034] In existing technologies, ultrasonic phased arrays are combinations of ultrasonic probe crystals, consisting of multiple piezoelectric crystals arranged in a specific pattern. Each crystal is then excited sequentially with a predetermined delay time, and the ultrasonic waves emitted by all the crystals form a unified wavefront. This allows for effective control of the shape and direction of the emitted ultrasonic beam (wavefront), enabling beam scanning, deflection, and focusing of ultrasonic waves. It provides greater capability than single or multiple probe systems in determining the shape, size, and direction of discontinuities.

[0035] Ultrasonic phased array detection technology uses multi-element transducers of different shapes (e.g., ring or linear) to generate and receive ultrasonic beams. By controlling the different delay times of the pulses emitted (or received) by each element in the transducer array, the phase relationship when the sound wave arrives at (or originates from) a point within the object is changed, thereby changing the focal point and the direction of the sound beam, thus achieving beam scanning, deflection, and focusing of the ultrasonic waves. Then, a combination of mechanical and electronic scanning methods is used to achieve image imaging. The ultrasonic phased array transducer consists of an array of multiple independent piezoelectric crystals. An electronic system controls the excitation of each crystal unit according to certain rules and timing to adjust and control the position and direction of the focal point.

[0036] Therefore, existing ultrasonic phased array technology requires individual control of each array element for signal excitation. The control unit setup and internal devices are complex and the units are susceptible to interference. In addition, existing echo signal data processing algorithms are complex, and the processing of echo signals requires the coordination of highly complex digital image processing algorithms, resulting in low research on the location and visualization of weld defects.

[0037] Figure 1 The diagram illustrates the structure of a device for weld quality inspection according to an embodiment of the present invention. Figure 1 As shown in the embodiment of the present invention, an apparatus for weld quality inspection is provided, which may include:

[0038] The phased array ultrasonic transducer 102 includes: multiple array elements arranged in a ring for transmitting ultrasonic signals and receiving echo signals. Any array element in the multiple array elements responds to receiving an excitation signal and transmits the excitation signal to an array element adjacent to the receiving array element until all array elements receive the excitation signal. The multiple array elements respond to receiving the excitation signal and sequentially transmit ultrasonic signals to the weld and receive echo signals corresponding to the ultrasonic signals.

[0039] It is understood that the phased array ultrasonic transducer 102 in this embodiment of the invention includes multiple array elements arranged in a ring. These array elements are used to transmit ultrasonic signals and receive echo signals, where the echo signal is the signal reflected back after the ultrasonic signal encounters an object. The weld is formed by melting and connecting the welding rod and the metal at the joint using the high temperature of a welding heat source. After the weld metal cools, the two welded parts are joined into a whole.

[0040] Specifically, in this embodiment of the invention, after receiving an excitation signal, any one of the multiple array elements (e.g., N array elements) of the phased array ultrasonic transducer 102 (e.g., array element 1) transmits the excitation signal to the array elements adjacent to it (e.g., array element 2 and array element 3). Understandably, since the array elements are arranged in a ring, the number of array elements adjacent to the received element can be more than one, typically two. After receiving the excitation signal, the adjacent array elements (e.g., array element 2 and array element 3) transmit the excitation signal to the remaining array elements in the same signal transmission manner as the received element (e.g., array element 1), until all array elements (array element 1 to array element N) have received the excitation signal. After all array elements have received the excitation signal, the multiple array elements sequentially transmit ultrasonic signals to the weld seam in response to receiving the excitation signal, and receive the echo signals corresponding to the ultrasonic signals.

[0041] The processor 104 is electrically connected to the phased array ultrasonic transducer 102 and is configured to: acquire the echo signal received by the phased array ultrasonic transducer 102; and process the echo signal to complete the quality inspection of the weld.

[0042] Specifically, the processor 104 is electrically connected to the phased array ultrasonic transducer 102 to acquire the echo signal received by the phased array ultrasonic transducer 102, and processes the echo signal to complete the quality inspection of the weld. Understandably, the echo signal processing method may include, but is not limited to, using a combination of mechanical scanning and electronic scanning to achieve image imaging, thereby realizing the quality inspection of the weld.

[0043] The aforementioned device for weld quality inspection achieves signal excitation of the entire ring array element by individually controlling any one element in the ring array element of the phased array ultrasonic transducer 102. This, in turn, controls the transmission and reception of excitation signals of each element in the entire phased array ultrasonic transducer 102, thereby completing the scanning and sampling of the weld. By adopting a point-to-full signal excitation method, it solves the problem of high control difficulty caused by the large number of array elements in existing phased array ultrasonic testing technology, reduces the control difficulty of the phased array ultrasonic transducer, improves the automation level of weld inspection, and reduces equipment costs.

[0044] In one embodiment, the interval between the multiple array elements emitting ultrasonic signals is the interval between the multiple array elements receiving excitation signals.

[0045] It is understandable that the point-to-total signal excitation method means that multiple array elements do not receive the excitation signal simultaneously. Each array element emits ultrasonic signals sequentially according to the time it receives the excitation signal. That is, each array element emits ultrasonic signals to the weld seam sequentially according to the interval between receiving the excitation signal. For example, after receiving the excitation signal, array element 1 emits the excitation signal to array elements 2 and 3 adjacent to array element 1. Array elements 2 and 3 receive the excitation signal within 1 second after array element 1 emits it. Then, in the subsequent emission of ultrasonic signals, array elements 2 and 3 emit ultrasonic signals 1 second after array element 1 emits its ultrasonic signal. In other words, the time interval between each array element emitting ultrasonic signals is the same as the time interval between each array element receiving the excitation signal. Furthermore, in some embodiments, the time interval between multiple array elements emitting ultrasonic signals can also be the same as the time interval between multiple array elements emitting excitation signals, where the time interval between array elements emitting excitation signals is equal to the time interval between array elements receiving excitation signals. In existing phased array ultrasonic transducers, each array element emits ultrasonic signals at different times according to a certain delay rule, and then focuses them on the object under test to enhance the intensity of the echo signal. However, each array element has a corresponding controller to control the transmission and reception of ultrasonic signals. In this embodiment of the invention, all array elements are controlled by controlling array element 1 to achieve the same effect. It is not necessary to set up a separate controller for each array element, nor is it necessary to control the transmission of ultrasonic signals according to a certain delay rule. Each array element can emit ultrasonic signals according to the interval of the received excitation signal, which can reduce the number of controllers, reduce costs, and improve the degree of automation.

[0046] In one embodiment, the processor is configured to acquire echo signals received by the phased array ultrasonic transducer, including: the processor is configured to acquire echo signals of each element in the phased array ultrasonic transducer for a preset time length after emitting ultrasonic signals.

[0047] It is understandable that the preset time length is the pre-set time length for each array element to receive the echo signal corresponding to each array element.

[0048] Specifically, after each element emits an ultrasonic signal, the phased array ultrasonic transducer will receive a large number of echo signals over a relatively long period of time. The processor can obtain the echo signals received by the phased array ultrasonic transducer within a preset time length (e.g., 20s) after each element emits an ultrasonic signal as the corresponding echo signal for each element. In other words, after the ring element emits an ultrasonic signal and receives the echo signal, each element will receive different echo signals at different time periods. Each element receives the echo signal within a certain time period (e.g., 20s) at different time periods to equivalently replace all elements receiving all echo signals for all time periods (e.g., 10 minutes), because the latter echo signals for all time periods may have a lot of clutter or useless signals.

[0049] In one embodiment, the preset time length is the interval between the multiple array elements receiving the excitation signal.

[0050] It can be understood that the preset time length after each array element emits an ultrasonic signal can be the length of the interval between the previous array elements receiving the excitation signal. In other words, the sampling interval of the echo signal can be divided according to the interval between receiving (or emitting) the excitation signal. The interval between each array element receiving the excitation signal can be equal to the interval between each array element emitting the excitation signal. That is, the echo signal is filtered according to the interval time. The processor only needs to obtain the echo signal received within the interval time after each array element emits an ultrasonic signal. For example, if array element 1 emits an ultrasonic signal for 2 minutes, array elements 2 and 3 (which can be regarded as a group) emit ultrasonic signals simultaneously. However, array element 1 can actually receive 10 minutes of echo signal. Therefore, only the echo signal within 2 minutes after array element 1 emits an ultrasonic signal is taken as the echo signal corresponding to array element 1. And so on. The sum of the time periods for all array elements to receive echo signals is the product of the number of array element groups and the interval time, which can improve detection efficiency and shorten the echo signal collection time. In this group, elements 2 and 3 form one group, elements 4 and 5 form another group, and so on. That is, the two elements within the same group are symmetrically distributed about the horizontal line where element 1 is located. Specifically, it can be seen as follows: Figure 2 As shown, if the interval angle between each array element is α, the entire ring array element scanning interval (i.e., the echo signal sampling interval) can be divided into sector regions according to equal arithmetic angles α, and each sector region symmetrical along the horizontal line can be divided into the same interval, such as... Figure 3As shown in ①, ②, ③..., where ① can represent the echo signals corresponding to array elements 2 and 3. Compared with the existing technology where the sampling interval is divided according to angle or intermittent selection, the echo signal sampling interval is symmetrically divided according to the transmission time of the array element excitation signal (i.e., the interval time of receiving the excitation signal). This can improve the stability of the data in the sampling interval within each time period, filter out clutter signals or useless signals, and make the sampled data more realistic and effective.

[0051] In one embodiment, the processor is configured to process the echo signal, including: converting the echo signal into point cloud coordinates; sequentially establishing corresponding spatial dynamic planes for the point cloud coordinates to determine effective point cloud coordinates; and fitting the effective point cloud coordinates to obtain the contour curve of the weld.

[0052] It can be understood that the spatial dynamic plane is a spatial plane that includes point cloud coordinates. Effective point cloud coordinates are point cloud coordinates that can reflect the quality of the weld. Point cloud coordinates include coordinates in three dimensions.

[0053] Specifically, the processor can convert the acquired echo signal into point cloud coordinates. The specific conversion method will not be described in detail here. Then, it can establish a corresponding spatial dynamic plane for the point cloud coordinates, thereby determining the effective point cloud coordinates based on the spatial dynamic plane, and fitting the effective point cloud coordinates to obtain the weld contour curve. Based on the weld contour curve, the quality inspection result of the weld can be obtained.

[0054] In one embodiment, before the processor establishes the corresponding spatial dynamic plane for the point cloud coordinates sequentially, the processor is further configured to: arrange the point cloud coordinates in descending or ascending order according to the three dimensions based on a point cloud dimensionality reduction sorting algorithm or a point cloud dimensionality increase sorting algorithm to obtain sorted point cloud coordinates.

[0055] It can be understood that the point cloud dimensionality reduction sorting algorithm is an algorithm that sorts the point cloud coordinates in descending order from largest to smallest. Similarly, the point cloud dimensionality increase sorting algorithm is an algorithm that sorts the point cloud coordinates in ascending order from smallest to largest.

[0056] Specifically, the processor can sort the coordinates of the point cloud in descending or ascending order according to the three dimensions, based on a point cloud dimensionality reduction or ascending sorting algorithm, to obtain sorted point cloud coordinates. Since the sorting is performed according to the three dimensions, the number of sorted point cloud coordinates is three times the number of unsorted point cloud coordinates. Sort the point cloud coordinates in descending or ascending order, which reduces computation, speeds up the processing of echo signals, and improves processing efficiency.

[0057] In one embodiment, the processor is configured to sequentially establish corresponding spatial dynamic planes for point cloud coordinates to determine valid point cloud coordinates, including: the processor is configured to: sequentially determine the two nearest adjacent point cloud coordinates that are not collinear with the point cloud coordinates; establish corresponding spatial dynamic planes based on the point cloud coordinates and the two adjacent point cloud coordinates; and determine point cloud coordinates that are not on the spatial dynamic plane and whose distance from the spatial dynamic plane is less than or equal to a preset distance threshold as valid point cloud coordinates.

[0058] It is understandable that the preset distance threshold is the maximum distance between the pre-set valid point cloud coordinates and the spatial moving plane.

[0059] Specifically, the processor can sequentially determine the two nearest adjacent point cloud coordinates that are not collinear with each point cloud coordinate, and establish a spatial dynamic plane corresponding to the point cloud coordinate based on the point cloud coordinate and the two adjacent point cloud coordinates corresponding to the point cloud coordinate. This allows the processor to determine the distance between the remaining point cloud coordinates that are not on the spatial dynamic plane and the spatial dynamic plane. If the distance is less than or equal to a preset distance threshold, the point cloud coordinate that is not on the spatial dynamic plane can be determined as a valid point cloud coordinate. In other words, by determining the spatial dynamic plane corresponding to each point cloud coordinate, a set of valid point cloud coordinates corresponding to each point cloud coordinate is obtained. After summarizing, all valid point cloud coordinates can be obtained.

[0060] In one embodiment, fitting effective point cloud coordinates to obtain a weld contour curve includes: the processor being configured to: fit effective point cloud coordinates based on least squares to obtain a weld contour curve.

[0061] Specifically, the processor can use the least squares method to fit all valid point cloud coordinates to obtain the weld contour curve, thereby obtaining defect information inside and outside the weld and completing the quality inspection of the weld.

[0062] In one embodiment, the apparatus for weld quality inspection further includes a signal controller electrically connected to the phased array ultrasonic transducer for sending an excitation signal to any element of the array.

[0063] It is understandable that the device used for weld quality inspection can be equipped with a separate signal controller. The signal controller is electrically connected to the phased array ultrasonic transducer. The signal controller can be used to send excitation signals to any one of the multiple array elements of the phased array ultrasonic transducer.

[0064] In one embodiment, the processor is further configured to send an excitation signal to any element.

[0065] It is understandable that the device used for weld quality inspection can directly send excitation signals to any one of the multiple array elements of the phased array ultrasonic transducer through the processor.

[0066] In one embodiment, the apparatus for weld quality inspection further includes a display device electrically connected to the processor for displaying the contour curve of the weld.

[0067] This invention also provides a system for weld quality inspection, comprising: an apparatus for weld quality inspection according to the above embodiments.

[0068] To address the problems of individual control of each element and complex data processing algorithms in existing ultrasonic phased array technologies, a specific embodiment of this invention provides a device for weld quality inspection. This device combines a ring-shaped array element excitation method with a point cloud dimensionality reduction and sorting algorithm for identifying and locating defects within the weld seam of an excavator boom, thereby accelerating the quality inspection of the excavator boom weld seam.

[0069] The device for weld quality inspection provided in this invention mainly consists of a phased array ultrasonic signal excitation system, a phased array ultrasonic signal processing system, and an image shaping system. The phased array ultrasonic excitation system uses a ring array element excitation method to scan and sample the weld of the excavator boom. The phased array ultrasonic processing system divides the entire scanning interval into several fan-shaped regions with equal angles α according to the delay interval of the echo signal received by the ring array elements, and divides each fan-shaped region symmetrically distributed along the horizontal line into the same interval. The image shaping system uses a point cloud dimensionality reduction and sorting algorithm to process the point cloud information inside and outside the weld, and uses the least squares method to fit the effective cloud points in the three sub-information planes to obtain the effective contour curves inside and outside the weld, thereby obtaining the defect information inside and outside the weld, and thus completing the quality inspection of the weld on the excavator boom.

[0070] A schematic diagram of the excitation transmission method of the internal array elements of a phased array ultrasonic transducer is shown below. Figure 2As shown, the phased array ultrasonic excitation system consists of a ring phased array transducer and a signal controller. The ring phased array transducer is composed of N array elements arranged in a ring. The signal controller first transmits a pre-set excitation signal to array element 1. When array element 1 receives the transmitted excitation signal, it emits pulsed ultrasonic signals in all directions along the ring array lines. When the nearest adjacent array elements 2 and 3 receive the signal, they immediately transmit the pulsed ultrasonic signals to the remaining array elements in the same signal transmission mode as array element 1, until array element N receives the signal. This ensures that each array element in the ring phased array transducer completes the transmission of pulsed ultrasonic signals. By controlling array element 1, the signal excitation of the entire ring array element is achieved, thereby controlling the transmission of the excitation signal of the entire ring phased array transducer. At the same time, each array element also emits ultrasonic signals to the weld seam of the working arm (e.g., boom) according to the speed at which it receives the excitation signal, and receives the echo signal with the same delay time, completing the signal transmission and reception of the entire ring phased array transducer. The signal controller is used to control the phase of the signal transmitted to array element 1, so that the entire ring array element is excited by a delayed signal in the same phase, and ultrasonic signals are emitted to the boom weld according to a certain delay time. The echo signal is received according to the same delay time, thereby controlling the transmission and reception of the signal of the entire ring phased array transducer and completing the scanning and sampling of the excavator boom weld.

[0071] The phased array ultrasonic excitation system uses a ring array element excitation method to scan and sample the weld seam of the excavator boom. The phased array ultrasonic processing system establishes a three-dimensional coordinate system based on the location of the boom weld seam. After the pulsed ultrasonic signal emitted by the phased array ultrasonic transducer (4) scans and samples the boom weld seam, the collected echo signal is processed and converted into the three-dimensional coordinates (X, X, Y) of the point cloud inside and outside the boom weld seam. i Y i Z i The anti-pulse interference averaging filter method is used to screen out spatial cloud points with large positional deviations. Its advantage is that it can eliminate sampling value deviations caused by occasional pulse interference, while also overcoming fluctuation interference caused by random factors. After the phased array ultrasonic signal excitation system scans and samples the weld seam of the excavator boom using the ring array element excitation method, the phased array ultrasonic processing system divides the entire ring array element scanning interval into sector regions according to equal arithmetic angles α, and divides each sector region symmetrical along the horizontal line into the same interval, such as... Figure 3 As shown in ①, ②, ③..., compared to the general sampling interval being divided according to angle or intermittent selection, dividing the sampling interval symmetrically according to the transmission time of the array element pulse signal can improve the stability of the data within each time period of the sampling interval, and the obtained sampling data is more realistic and effective.

[0072] The image shaping system uses a point cloud dimensionality reduction and sorting algorithm to achieve the image imaging process, as follows: Figure 4 As shown, the echo signal obtained from the boom weld is processed according to the above-defined sampling intervals, and the echo signal is converted into point cloud information inside and outside the weld, that is, the point cloud coordinates (X, Y, Z) within all sampling intervals. i Y i Z i The entire point cloud information is divided into three sub-information planes: XY, YZ, and XZ. Within each of these sub-information planes, x... max y max , z max The coordinate points are sorted in descending order of the point cloud, and the two closest non-collinear adjacent points are selected to establish a spatial moving plane P. i Substitute the three-dimensional coordinates of the scanned spatial point cloud within the sampling interval into the spatial moving plane P. i In the process, determine the relationship between each point cloud and its corresponding spatial plane P. i relative distance d i Then set a distance threshold d0, when the point cloud and the spatial plane P i distance d i When the value is greater than the threshold d0, the cloud point is considered to be part of the spatial plane P. i Invalid cloud points within the space, when the cloud point is perpendicular to the spatial plane P i distance d i When the value is less than the threshold d0, the cloud point is identified as the spatial plane P. i Valid cloud points within the area are identified and stored in the valid point data set. Then, the least squares method is used to fit the spatial moving plane P. i The algorithm identifies valid points in the image and obtains effective contour curves within three sub-planes. These curves represent the 3D reconstruction of the image based on reverse engineering, leading to defect information inside and outside the weld and enabling quality inspection of the weld on the excavator boom. Compared to other complex data processing algorithms, this point cloud dimensionality reduction and sorting algorithm first divides the 3D image reconstruction into three 2D planes for selecting valid points, then performs 3D spatial fitting on the valid points to obtain the final image information inside the weld. This algorithm not only reduces the dimensionality of the spatial point cloud information but also simplifies the computational difficulty, thereby improving the efficiency of boom weld quality inspection.

[0073] The device for weld quality inspection provided in this invention combines a ring array element excitation method with a point cloud dimensionality reduction and sorting algorithm for the identification and localization of defects within the boom weld, thereby accelerating the quality inspection of excavator boom welds. The excavator boom weld inspection device can be as follows: Figure 5As shown, the excavator boom weld inspection device mainly consists of a cross slide (501), a gantry slide (502), an industrial robot (503), a phased array ultrasonic transducer (504), the excavator boom to be inspected (505), and a positioner (506). A cross slide (501) is installed at the upper end of the gantry slide (502), and an inverted industrial robot (503) is installed at the lower end of the cross slide (501). By controlling the linkage between the gantry slide (502) and the cross slide (501), the position of the industrial robot (503) in the XYZ axis direction can be adjusted at will, so that the phased array ultrasonic transducer (504) can adapt to any working condition. The excavator arm (505) to be tested is fixed on two positioners (506) and placed together below the industrial robot (503). At the same time, a phased array ultrasonic transducer (504) is installed on the sixth axis end of the industrial robot (503) to control the transmission and reception of pulse excitation signals.

[0074] In summary, the apparatus for weld quality inspection provided in the embodiments of the present invention has the following advantages:

[0075] (1) By using the ring array element excitation method to individually control any one array element in the phased array ultrasonic transducer, the signal excitation of the entire ring array element can be realized, thereby controlling the transmission and reception of the excitation signal of the entire phased array transducer, and completing the scanning and sampling of the weld seam of the excavator boom (e.g., boom). This point-to-whole signal excitation method solves the problem of increased control difficulty caused by the large number of array elements in phased array ultrasonic testing technology.

[0076] (2) Compared with the general sampling intervals divided by angle or intermittent selection, the sampling intervals are symmetrically divided according to the excitation signal delay transmission order, which can improve the stability of the data in each time period sampling interval and the obtained sampling data is more realistic and effective.

[0077] (3) The sampling point cloud data is processed by a simple point cloud dimensionality reduction and sorting algorithm, which not only reduces the dimensionality of spatial point cloud information, but also simplifies the computational difficulty, thereby improving the efficiency of image forming.

[0078] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied 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.

[0079] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0080] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0081] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0082] In a typical configuration, a computing device includes one or more processors (CPU), input / output interfaces, network interfaces, and memory.

[0083] Memory may include non-persistent memory in computer-readable media, such as random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash RAM. Memory is an example of computer-readable media.

[0084] Computer-readable media includes both permanent and non-permanent, removable and non-removable media that can store information using any method or technology. Information can be computer-readable instructions, data structures, modules of programs, or other data. Examples of computer storage media include, but are not limited to, phase-change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, CD-ROM, digital versatile optical disc (DVD) or other optical storage, magnetic tape, magnetic magnetic disk storage or other magnetic storage devices, or any other non-transferable medium that can be used to store information accessible by a computing device. As defined herein, computer-readable media does not include transient computer-readable media, such as modulated data signals and carrier waves.

[0085] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0086] The above are merely embodiments of this application and are not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A device for inspecting weld quality, characterized in that, The device includes: A phased array ultrasonic transducer includes: a plurality of array elements arranged in a ring for transmitting ultrasonic signals and receiving echo signals; any one of the array elements responds to receiving an excitation signal and transmits the excitation signal to an array element adjacent to it, until all the array elements receive the excitation signal; the plurality of array elements respond to receiving the excitation signal and sequentially transmit ultrasonic signals to the weld and receive echo signals corresponding to the ultrasonic signals; the interval between the plurality of array elements transmitting ultrasonic signals is the interval between the plurality of array elements receiving the excitation signal. A processor, electrically connected to the phased array ultrasonic transducer, is configured to: Acquire the echo signal received by the phased array ultrasonic transducer; The echo signal is processed to complete the quality inspection of the weld. The processor is configured to acquire the echo signal received by the phased array ultrasonic transducer, which includes: the processor is configured to acquire the echo signal of each array element in the phased array ultrasonic transducer after transmitting an ultrasonic signal for a preset time length, and use the echo signal of the preset time length as the echo signal corresponding to each array element, wherein the preset time length is the interval between the multiple array elements receiving the excitation signal.

2. The apparatus according to claim 1, characterized in that, The processor is configured to process the echo signal, including: the processor is configured to: The echo signal is converted into point cloud coordinates; Establish corresponding spatial dynamic planes for the point cloud coordinates in sequence to determine the effective point cloud coordinates; The effective point cloud coordinates are fitted to obtain the contour curve of the weld.

3. The apparatus according to claim 2, characterized in that, Before the processor sequentially establishes the corresponding spatial moving plane for the point cloud coordinates, the processor is further configured to: The point cloud coordinates are sorted in descending or ascending order according to three dimensions based on point cloud dimensionality reduction or ascending sorting algorithms to obtain sorted point cloud coordinates.

4. The apparatus according to claim 2, characterized in that, The processor is configured to sequentially establish corresponding spatial dynamic planes for the point cloud coordinates to determine valid point cloud coordinates, including: the processor is configured to: Sequentially determine the two nearest adjacent point cloud coordinates that are not collinear with the point cloud coordinates; Establish a corresponding spatial moving plane based on the point cloud coordinates and the coordinates of two adjacent point clouds; Point cloud coordinates that are not on the spatial moving plane and whose distance from the spatial moving plane is less than or equal to a preset distance threshold are determined as valid point cloud coordinates.

5. The apparatus according to claim 1, characterized in that, The device further includes: A signal controller, electrically connected to the phased array ultrasonic transducer, is used to send the excitation signal to any one of the array elements.

6. The apparatus according to claim 1, characterized in that, The processor is also configured to send the excitation signal to any one of the array elements.

7. The apparatus according to claim 5, characterized in that, The device further includes: A display device, electrically connected to the processor, is used to display the contour curve of the weld.

8. A system for inspecting weld quality, characterized in that, include: The apparatus for weld quality inspection according to any one of claims 1 to 7.

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