A phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces

Abstract

The present invention relates to a phased array ultrasonic flexible probe suitable for use in confined spaces and non-planar workpieces. The probe comprises a probe housing, a coaxial cable, and multiple flexible probe bodies. A controller is housed within the probe housing. One end of each flexible probe body is connected to the probe housing via a rotating shaft. Leads from each flexible probe body are connected to the controller, which is connected to the coaxial cable. Compared to existing technologies, the flexible probe body of the present invention has a rectangular, narrow strip structure and is made of a flexible material, making it suitable for use in confined spaces.

Description

Technical Field

[0001] The invention relates to a phased array ultrasonic probe, in particular to a phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces. Background Art

[0002] Phased array ultrasonic testing technology, due to its recordable, visualizable, highly sensitive, and accurate features, has matured in industrial applications and, in many cases, can replace conventional ultrasonic testing for nondestructive testing. The inspection of various metal parts and materials, particularly in-service testing, often encounters complex conditions such as confined spaces, small planes, and curved surfaces. For example, turbine blades and high-temperature bolts undergoing in-service maintenance at power generation companies are often inspected using specialized, small conventional ultrasonic probes. However, even these probes still face challenges such as low sensitivity, insufficient detection rates, and low reliability.

[0003] Existing engineering practices and related flexible probes disclosed in relevant literature have great shortcomings and have not fully utilized the advantages of flexible probes. They are either too large, or have complex structures, or the probes can only be simply bent, resulting in poor coupling effect on curved workpieces, especially for workpieces with curved surfaces in narrow spaces. It is difficult to achieve good coupling and obtain good sound pressure emission. Summary of the Invention

[0004] The purpose of the present invention is to provide a phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces. The flexible probe body is a rectangular narrow strip structure, and the probe body is made of flexible material, which is suitable for narrow spaces.

[0005] The purpose of the present invention can be achieved by the following technical solutions:

[0006] A phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces includes a probe housing, a coaxial cable, and multiple flexible probe bodies. A controller is provided in the probe housing. One end of all the flexible probe bodies is connected to the probe housing via a rotating shaft, and the leads of all the flexible probe bodies are connected to the controller, which is connected to the coaxial cable.

[0007] The flexible probe body comprises a matching layer, a flexible piezoelectric ceramic composite material wafer and a damping back material which are stacked in sequence.

[0008] The matching layer, the flexible piezoelectric ceramic composite material wafer and the damping back material are bonded in sequence.

[0009] The probe further comprises a liquid silicone sleeve which is sleeved on the flexible probe body.

[0010] The liquid silicone sleeve is made of a silicone film.

[0011] The thickness of the silica gel film is 1 to 2 mm.

[0012] There are three flexible probe bodies in total, and the wafer type of the flexible probe bodies is a one-dimensional linear array.

[0013] The first flexible probe body has 8 array elements, a chip length of 6 mm, an excitation aperture of 8 mm, and a center frequency of 7.5 MHz.

[0014] The second flexible probe body has 12 array elements, an 8mm chip length, a 12mm excitation aperture, and a center frequency of 5MHz.

[0015] The third flexible probe body has 16 array elements, a chip length of 10 mm, an excitation aperture of 20 mm, and a center frequency of 2.5 MHz.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] 1. Wide range of applications: Since it is composed of multiple probes with different parameters and specifications, it can be selected according to different testing requirements.

[0018] 2. Suitable for narrow spaces: It has a rectangular narrow strip structure, and the probe body is made of flexible material, so it can penetrate deep into narrow spaces.

[0019] 3. Suitable for non-planar workpieces: Based on the flexible probe body, it is designed with a matching liquid silicone sleeve for good coupling effect.

[0020] 4. High detection reliability: The probe with appropriate parameters is selected, and the overall design of the probe makes the coupling performance good, which can fully obtain the sound pressure reflection signal inside the workpiece.

[0021] 5. Simple structure and strong practicality: The design of rotating probes for selecting different parameters has a simple structure and occupies a small space. The design of using liquid silicone sleeve can achieve the effect of using complex water spray immersion coupling equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a front view of a phased array ultrasonic flexible probe according to an embodiment of the present invention;

[0023] Figure 2 This is a schematic diagram of the side view and the internal structure of the phased array ultrasonic flexible probe according to an embodiment of the present invention;

[0024] Figure 3 This is a top view of a phased array ultrasonic flexible probe according to an embodiment of the present invention;

[0025] Figure 4This is a side view schematic diagram of a phased array ultrasonic flexible probe in a flexible state coupled with a workpiece according to an embodiment of the present invention;

[0026] Figure 5 This is a graph showing the test data of a fir-tree blade root of a steam turbine in a narrow space using a phased array ultrasonic flexible probe according to an embodiment of the present invention;

[0027] Figure 6 This is a graph showing the test data of a forked blade root of a steam turbine in a narrow space using a phased array ultrasonic flexible probe according to an embodiment of the present invention;

[0028] Including: 1. Flexible probe body, 2. Probe shell, 3. Rotating axis, 4. Wire protection sleeve, 5. Coaxial cable, 6. Damping backing material, 7. Flexible piezoelectric ceramic composite chip, 8. Matching layer, 9. Liquid silicone sleeve. DETAILED DESCRIPTION

[0029] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0030] A phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces. The probe consists of three flexible probe bodies containing flexible piezoelectric ceramic composite chips. The three probes have different specifications, such as the number of chip array elements and excitation aperture. The three probe bodies are connected in series by a common rotation axis and can rotate by an angle of not less than 90 degrees. The probe body contains a flexible piezoelectric ceramic composite chip, a damping backing material, a matching layer, and a flexible circuit board. The probe is connected to the instrument by a coaxial cable and a probe interface. The probe is equipped with a flexible liquid silicone sleeve. Figures 1 to 4 As shown, it includes a probe shell 2, a coaxial cable 5 and multiple flexible probe bodies 1. A controller is provided in the probe shell 2. One end of all flexible probe bodies 1 is connected to the probe shell 2 through a rotating shaft 3, and the leads of all flexible probe bodies 1 are connected to the controller, and the controller is connected to the coaxial cable 5.

[0031] The flexible probe body 1 includes a matching layer 8, a flexible piezoelectric ceramic composite wafer 7, and a damping backing material 6 stacked in sequence. The matching layer 8, flexible piezoelectric ceramic composite wafer 7, and damping backing material 6 are bonded together in sequence. The flexible piezoelectric ceramic composite wafer 7 is a piezoelectric ceramic with a high dielectric constant. The three flexible probe bodies 1 have different specifications to accommodate different spatial locations, surface conditions, and detection requirements. The first flexible probe body 1 has 8 array elements, a wafer length of 6mm or 8mm, an excitation aperture of 6-12mm, and a center frequency of 7.5MHz. The second flexible probe body 1 has 12 array elements, a wafer length of 8mm or 10mm, an excitation aperture of 8-20mm, and a center frequency of 5MHz. The third flexible probe body 1 has 16 array elements, a wafer length of 10mm, an excitation aperture of 16-40mm, and a center frequency of 2.5MHz.

[0032] The width of probe body 1 in the above probe assembly is smaller than that of probe bodies 2 and 3, improving its applicability for small step and non-planar detection. The rotation angle of each flexible probe body is not less than 90 degrees. The above rotating shaft 3 has a locking buckle.

[0033] The probe also includes a liquid silicone sleeve 9, which is fitted over the flexible probe body 1. The sleeve is made of a silicone membrane with a thickness of 1 to 2 mm. This silicone membrane has a high acoustic impedance, meeting basic acoustic property requirements, while also exhibiting high ductility and elasticity, meeting coupling performance requirements.

[0034] The flexible probe body 1 of the present application can select the appropriate flexible probe body from the probe body group based on different detection objects, detection requirements, workpiece surfaces, and spatial locations. The three probe bodies have different parameters and widths, and the chip array adopts a one-dimensional linear array. A locking buckle is provided at the rotation axis position of the probe group, and different probe bodies can be selected by rotation. The probe body is an overall flexible design, and the internal structure includes a matching layer, a flexible piezoelectric ceramic composite chip, and a damping backing material, which are bonded together in sequence to form an acoustic stack. It is connected to the flexible piezoelectric ceramic composite chip through a flexible circuit board, and finally a multi-core coaxial cable is led out from the flexible circuit board. In order to increase its overall flexibility and the coupling effect of small space non-planar surfaces, a special liquid silicone sleeve is designed for use with the flexible probe group. The silicone sleeve can be designed as a sleeve structure according to the shape of the probe body and can be put into use. It can also be a rectangular silicone membrane that wraps the probe and fits each other with self-adhesive backs. When testing, select the corresponding probe body, apply an appropriate amount of coupling agent between the probe body and the silicone membrane, and exclude air. During testing, apply a certain amount of coupling agent to the surface of the workpiece at the same time. For different surface conditions, appropriate pressure can be applied to the probe body to promote perfect coupling and obtain atlas data that meets the testing requirements.

[0035] This application is mainly designed for detecting surfaces in relatively small spaces, non-planar surfaces, and relatively small workpieces. The parameters and sizes of the three probe bodies are different, and a superimposed rotatable structure design is adopted. Because the flexible probe body containing the flexible circuit board is not flexible enough as a whole, and the coupling between the matching layer of the probe itself and the non-planar surface is relatively limited, a similar concept to the wedge block used in conventional phased array probes is adopted, in the form of a liquid silicone membrane. Without the need for a complex water spray immersion coupling device, the coupling effect is maximized. The structure is simple and convenient, highly practical, and effective.

Claims

1. A phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces, characterized by: The invention comprises a probe housing (2), a coaxial cable (5) and a plurality of flexible probe bodies (1), wherein a controller is provided in the probe housing (2), the flexible probe bodies (1) are of a narrow strip structure, one end of all the flexible probe bodies (1) are connected to the probe housing (2) via a rotating shaft (3), and the leads of all the flexible probe bodies (1) are connected to the controller, the controller is connected to the coaxial cable (5), the wafer type of the flexible probe bodies (1) is a one-dimensional linear array, and the rotation angle of each flexible probe body is not less than 90 degrees.

2. The phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces according to claim 1, characterized in that: The flexible probe body (1) comprises a matching layer (8), a flexible piezoelectric ceramic composite material chip (7), and a damping backing material (6) which are stacked in sequence.

3. The phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces according to claim 2, characterized in that: The matching layer (8), the flexible piezoelectric ceramic composite material chip (7) and the damping backing material (6) are bonded in sequence.

4. The phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces according to claim 1, characterized in that: The probe further comprises a liquid silicone sleeve (9), which is sleeved on the flexible probe body (1).

5. The phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces according to claim 4, characterized in that: The liquid silicone sleeve (9) is made of a silicone film.

6. The phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces according to claim 5, characterized in that: The thickness of the silica gel film is 1 to 2 mm.

7. The phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces according to claim 1, characterized in that: There are three flexible probe bodies (1) in total.

8. The phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces according to claim 7, characterized in that: The first flexible probe body (1) has 8 array elements, a chip length of 6 mm, an excitation aperture of 8 mm, and a center frequency of 7.5 MHz.

9. The phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces according to claim 7, characterized in that: The second flexible probe body (1) has 12 array elements, a chip length of 8 mm, an excitation aperture of 12 mm, and a center frequency of 5 MHz.

10. The phased array ultrasonic flexible probe suitable for non-planar workpieces in narrow spaces according to claim 7, characterized in that: The third flexible probe body (1) has 16 array elements, a chip length of 10 mm, an excitation aperture of 20 mm, and a center frequency of 2.5 MHz.

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