A billet water film method ultrasonic flaw detection coupling device and a using method thereof

Abstract

The application discloses a billet water film method ultrasonic flaw detection coupling device and a use method thereof, which comprises a roller brush mechanism, a water wetting system, a wear-resistant block, a wear-resistant block self-defense compression mechanism, an adjusting mechanism, a probe and a flaw detection coupling water system; by combining the seven parts, the water film method ultrasonic flaw detection of the billet is realized, meanwhile, the surface of the probe can be prevented from being scratched during the flaw detection process, and the service life of the probe is prolonged. Specifically, the roller brush mechanism and the wear-resistant block are used for brushing and removing the oxide scale or protrusions on the surface of the billet; the wear-resistant block self-defense compression mechanism is used for realizing the stable adhesion between the probe and the surface of the billet to be detected; the adjusting mechanism is used for independently adjusting the coupling water depth of each probe; the flaw detection signals of each probe are acquired by a flaw detection host, and the surface wear of the probe, the adhesion of the probe and the surface of the billet to be detected, the coupling layer depth and the coupling water state are judged; once a problem occurs, an alarm is given in time, so that corresponding treatment can be carried out subsequently.

Description

Technical Field

[0001] This invention relates to the field of automated ultrasonic water film flaw detection technology for billets, specifically to a coupling device and method for using ultrasonic water film flaw detection for billets. Background Technology

[0002] A square billet is a type of steel billet with equal width and height in its cross-section. It is mainly used as raw material for rolling structural steel, train axles, and wire rod. With technological advancements and increasingly stringent requirements for structural steel, train axles, and wire rod, the internal quality inspection of square billets has become increasingly important. Therefore, utilizing ultrasonic automatic flaw detection to detect internal defects in square billets has become particularly crucial.

[0003] When performing ultrasonic testing of billets using the water film method, there are several problems: the billet structure is different from that of round steel and steel pipes; each of the four sides of the rolled billet is not flat; and the billet surface has protrusions caused by oxide scale and roll marks. Therefore, when performing ultrasonic testing on billets, there are problems such as poor contact between the probe and the surface of the billet being tested, difficulty in adjusting the coupling water layer, inability to maintain the coupling water, and short probe life. Summary of the Invention

[0004] The purpose of this invention is to provide a coupling device and method for ultrasonic flaw detection using water film method on billets, which can improve the coupling effect of ultrasonic flaw detection using water film method and extend the service life of water film probe, so as to solve the problems of oxide scale and roll scratches on the surface of water film probe and billet, stable adhesion between probe and the plane of the billet being inspected, adjustment and fixation of water film coupling layer depth, and ensuring pre-wetting and stable bubble-free coupling water.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a billet water film ultrasonic flaw detection coupling device, comprising a roller brush mechanism, a water wetting system, a wear-resistant block, a wear-resistant block self-defense clamping mechanism, an adjustment mechanism, a probe, and a flaw detection coupling water system; the roller brush mechanism is provided in multiple sets and fixed on a frame; the water wetting system is arranged on the frame, and a housing is provided on one side of the frame, in which the wear-resistant block, the wear-resistant block self-defense clamping mechanism, the adjustment mechanism, the probe, and the flaw detection coupling water system are correspondingly installed; the adjustment mechanism is used to independently adjust the coupling water layer depth for each probe, and a high-hardness wear-resistant layer is applied to the surface of the probe.

[0006] Furthermore, the roller brush mechanism consists of four independently driven roller brushes, a roller brush frame for adjusting the contact angle between the roller brush and the billet, a pressing mechanism with an adjusting handwheel, and a pressing locking handle. The roller brushes, the pressing mechanism, and the pressing locking handle are all mounted on the roller brush frame. The pressing mechanism adjusts the contact depth between the roller brush and the billet surface through the pressing handwheel, thereby controlling the brushing force of the roller brush on the oxide scale of the billet surface.

[0007] Furthermore, the wear-resistant block is provided with a scraper groove in front of the probe in the forward direction. The scraper groove is used to remove the oxide scale or protrusions that the roller brush has not removed. The front end face of the wear-resistant block is also provided with a guide arc to prevent the probe from getting stuck.

[0008] Furthermore, the wear-resistant block self-defense clamping mechanism is used to ensure that the flaw detection distance between the probe and the surface of the billet remains unchanged. It consists of a lifting cylinder, a clamping spring, a clamping frame, a follower frame, and a probe seat. The lifting cylinder is connected to the clamping frame via the clamping spring, and the clamping frame is located below the lifting cylinder. The follower frame is connected to the clamping frame by a pin, and the probe seat is fixed on the follower frame.

[0009] Furthermore, the adjustment mechanism includes a clamping screw, a lifting screw, and a locking nut; the clamping screw, lifting screw, and locking nut are used to fasten the probe holder, and the optimal depth of probe coupling water on the probe holder is adjusted by turning the clamping screw, lifting screw, and locking nut.

[0010] Furthermore, the probe includes a probe acoustic wedge layer, and a high-hardness wear-resistant layer is added in front of the probe acoustic wedge layer.

[0011] Furthermore, the probe holder is provided with a corresponding water channel structure. After the coupling water passes through the water channel on the probe holder, it can evenly and without bubbles spread the coupling water to the surface of each probe, so as to form a stable water film layer on the probe surface and the surface of the billet to be inspected.

[0012] This invention provides another technical solution: a method for using a coupling device for ultrasonic flaw detection of billets using the water film method, comprising the following steps:

[0013] S1: Use a roller brush mechanism and wear-resistant blocks to brush and scrape off the oxide scale or protrusions on the surface of the billet;

[0014] S2: Divide the probes used on each surface into multiple groups, place each group of probes on the same base, and place a wear-resistant block at the front end of each group of probes. Then, install a self-protection and clamping mechanism for the wear-resistant block at the back. By pressing down with a constant pressure through a clamping spring, a stable fit between the probe and the surface of the billet under inspection is achieved.

[0015] S3: The coupling water depth of each probe can be independently adjusted using the adjustment mechanism through two threaded holes at the rear of the probe and two clamping screws and lifting screws on the holes;

[0016] S4: Obtain the flaw detection signal of each probe through the flaw detection host, and use the written processing software to analyze the flaw detection start wave, detection section and bottom wave signal of each probe to determine the wear condition of the probe surface, the adhesion between the probe and the surface to be inspected of the billet, the depth of the coupling layer and the state of the coupling water.

[0017] Compared with the prior art, the beneficial effects of the present invention are:

[0018] 1. The present invention provides a billet water film ultrasonic flaw detection coupling device and its usage method. The device uses a roller brush mechanism and specially designed wear-resistant blocks to brush and remove oxide scale or protrusions on the surface of the billet, thereby avoiding scratching the probe. At the same time, the wear-resistant layer is added to the front end of the probe to improve its scratch resistance.

[0019] 2. The present invention provides a coupling device and method for ultrasonic flaw detection of billet using water film method. In order to achieve stable bonding, multiple probes on each surface are grouped to reduce the bonding area between the wear-resistant block at the front end of the probe and the billet. At the same time, a cross-shaped self-defense mechanism is added to the probe seat of each group. In addition, a spring-pressed cylinder lifting method is used to solve the problem of stable bonding between the probe and the plane of the billet being inspected.

[0020] 3. The present invention provides a billet water film ultrasonic flaw detection coupling device and its usage method. To solve the problem of adjusting and fixing the coupling layer depth in the water film method, a set of mechanisms is used to realize the distance adjustment between the entire probe group and the surface being tested. The present invention directly realizes the independent adjustment and fixing of the coupling depth of each probe by directly machining threaded holes and light holes on both sides of the probe at diagonal angles.

[0021] 4. The present invention provides a billet water film ultrasonic flaw detection coupling device and its usage method. The flaw detection signal of each probe is obtained through the flaw detection host, and the flaw detection start wave, detection section and bottom wave signal of each probe are analyzed by the written processing software to determine the wear condition of the probe surface, the adhesion between the probe and the surface to be inspected of the billet, the depth of the coupling layer and the state of the coupling water. Once a problem occurs, an alarm is triggered in time so that the corresponding processing can be carried out. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0023] Figure 2 This is a schematic diagram of the roller brush mechanism of the present invention;

[0024] Figure 3 This is a schematic diagram of the wear-resistant block structure of the present invention;

[0025] Figure 4 This is a schematic diagram of the self-defense clamping mechanism for the wear-resistant block of the present invention;

[0026] Figure 5 This is a schematic diagram of the coupling water depth adjustment mechanism of the present invention;

[0027] Figure 6 This is a schematic diagram of the probe structure with an added high-hardness wear-resistant layer according to the present invention;

[0028] Figure 7 This is a top view of the probe seat waterway structure of the present invention;

[0029] Figure 8 For the present invention Figure 7 UU cross-sectional view;

[0030] Figure 9 For the present invention Figure 7 SS cross-section;

[0031] Figure 10 This is a flowchart of the method for analyzing flaw detection status and abnormal conditions according to the present invention.

[0032] In the diagram: 1. Roller brush mechanism; 11. Roller brush; 12. Roller brush frame; 13. Pressing mechanism; 14. Pressing locking handle; 2. Water wetting system; 3. Wear-resistant block; 31. Scraper groove; 32. Guide arc; 4. Wear-resistant block self-defense pressing mechanism; 41. Lifting cylinder; 42. Pressing spring; 43. Pressing frame; 44. Follow-up frame; 45. Probe seat; 5. Adjustment mechanism; 51. Pressing screw; 52. Lifting screw; 53. Locking nut; 6. Probe; 61. Probe acoustic wedge layer; 62. High-hardness wear-resistant layer; 7. Flaw detection coupling water system. Detailed Implementation

[0033] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] Please see Figure 1 This invention provides a water film ultrasonic flaw detection coupling device for billets, comprising a roller brush mechanism 1, a water wetting system 2, a wear-resistant block 3, a wear-resistant block self-defense clamping mechanism 4, an adjustment mechanism 5, a probe 6, and a flaw detection coupling water system 7. The roller brush mechanism 1 has multiple sets fixed to a frame. The water wetting system 2 is arranged on the frame, and a housing is provided on one side of the frame. The wear-resistant block 3, the wear-resistant block self-defense clamping mechanism 4, the adjustment mechanism 5, the probe 6, and the flaw detection coupling water system 7 are correspondingly installed inside the housing. By combining these seven parts, water film ultrasonic flaw detection of billets can be achieved, while also preventing the surface of the probe 6 from being scratched during the flaw detection process, thus extending the service life of the probe 6.

[0035] Please see Figure 2In this embodiment, the roller brush mechanism 1 consists of four independently driven roller brushes 11, a roller brush frame 12 for adjusting the contact angle between the roller brushes 11 and the billet, a pressing mechanism 13 with an adjusting handwheel, and a pressing locking handle 14. The roller brushes 11, the pressing mechanism 13, and the pressing locking handle 14 are all mounted on the roller brush frame 12. In use, the contact depth between the roller brushes 11 and the surface of the billet is adjusted by pressing the handwheel, thereby controlling the brushing force of the roller brushes 11 on the oxide scale of the billet surface. This effectively removes the oxide scale and protrusions on the surface of the billet before flaw detection, and avoids scratching the surface of the probe 6.

[0036] Please see Figure 3 In this embodiment, the wear-resistant block 3 is provided with a scraper groove 31 in front of the probe 6 in the forward direction. The scraper groove 31 is used to remove the oxide scale or protrusions that the roller brush 11 has not removed, so as to avoid being scratched by the probe 6. At the same time, the wear-resistant block 3 is also a special wear-resistant and high-hardness material. A guide arc 32 is provided in the forward direction of the probe 6 to ensure that the wear-resistant block 3 will not get stuck when it comes into contact with the surface of the billet, thus ensuring the normal progress of the flaw detection.

[0037] Please see Figure 4 In this embodiment, the wear-resistant block self-defense clamping mechanism 4 consists of a lifting cylinder 41, a clamping spring 42, a clamping frame 43, a follower frame 44, and a probe seat 45. The lifting cylinder 41 is connected to the clamping frame 43 via the clamping spring 42, and the clamping frame 43 is located below the lifting cylinder 41. The follower frame 44 is pin-connected to the clamping frame 43, and the probe seat 45 is fixed on the follower frame 44. The wear-resistant block self-defense clamping mechanism 4 is used to ensure that the wear-resistant block 3 is always flexibly and smoothly flat against the billet surface at a suitable pressure throughout the entire flaw detection process, ensuring that the flaw detection distance between the probe 6 and the billet surface remains unchanged.

[0038] Please see Figure 5 In this embodiment, the adjustment mechanism 5 includes a clamping screw 51, a lifting screw 52, ​​and a locking nut 53. The clamping screw 51, lifting screw 52, ​​and locking nut 53 are used to fasten the probe holder 45. The optimal depth of the coupling water for the probe 6 on the probe holder 45 is adjusted by tightening the clamping screw 51, lifting screw 52, ​​and locking nut 53. When adjusting the coupling water depth, first loosen the two clamping screws 51 that are fastened to the probe holder 45, then adjust the two lifting screws 52 so that the coupling water layer meets the detection requirements, then tighten the two clamping screws 51, and finally, after inserting an Allen wrench behind the lifting screw 52 and fixing the direction of the wrench, tighten the locking nut 53 on the lifting screw 52. Through this adjustment method, the optimal depth of the coupling water for each probe 6 can be adjusted independently.

[0039] Please see Figure 6In this embodiment, the probe 6 includes a probe acoustic wedge layer 61. A high-hardness wear-resistant layer 62 is added in front of the probe acoustic wedge layer 61. During the flaw detection process, if there are protrusions on the surface of the billet that are higher than the coupling water depth, they will first come into contact with the high-hardness wear-resistant layer 62, thus avoiding wear of the probe acoustic wedge layer 61 and extending the service life of the probe 6.

[0040] Please see Figure 7-9 In this embodiment, the probe holder 45 is provided with a corresponding water channel structure. After the coupling water passes through the water channel on the probe holder 45, it can evenly and without air bubbles spread the coupling water to the surface of each probe 6, thereby forming a stable water film layer on the surface of the probe 6 and the surface of the billet to be inspected, achieving a good flaw detection coupling effect and ensuring the normal progress of flaw detection.

[0041] Please see Figure 10 To further explain the embodiments of the present invention, a method for using the ultrasonic flaw detection coupling device for billet water film method is also provided, including the following steps:

[0042] Step 1: Use the roller brush mechanism 1 and wear-resistant block 3 to brush and remove the oxide scale or protrusions on the surface of the blank; this avoids scratching the probe 6, and at the same time, by adding a wear-resistant layer 62 to the front end of the probe 6, its scratch resistance is improved.

[0043] Step 2: Divide the probes 6 used on each surface into multiple groups, place each group of probes 6 on the same base, and place a wear-resistant block 3 at the front end of each group of probes 6, and install a wear-resistant block self-protection clamping mechanism 4 at the back. By pressing down with a constant pressure through a clamping spring 42, a stable fit between the probe 6 and the surface of the billet being inspected is achieved.

[0044] Step 3: Using the adjustment mechanism 5, the coupling water depth of each probe 6 is independently adjusted through the two threaded holes at the rear of the probe 6 and the two clamping screws 51 and lifting screws 52 on the holes, in order to solve the problem of adjusting and fixing the coupling layer depth of each probe 6.

[0045] Step 4: Obtain the flaw detection signal of each probe 6 through the flaw detection host, and use the written processing software to analyze the flaw detection start wave, detection section and bottom wave signal of each probe 6 to determine the wear condition of the probe 6 surface, the adhesion between the probe 6 and the surface to be inspected of the billet, the depth of the coupling layer and the state of the coupling water. If any problem occurs, an alarm will be set in time so that it can be dealt with accordingly.

[0046] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A coupling device for ultrasonic flaw detection using a water film method on billets, characterized in that, The system includes a roller brush mechanism (1), a water wetting system (2), a wear-resistant block (3), a wear-resistant block self-defense clamping mechanism (4), an adjustment mechanism (5), a probe (6), and a flaw detection coupling water system (7). The roller brush mechanism (1) is provided with multiple sets fixed on the frame. The water wetting system (2) is arranged on the frame, and a housing is set on one side of the frame. The wear-resistant block (3), the wear-resistant block self-defense clamping mechanism (4), the adjustment mechanism (5), the probe (6), and the flaw detection coupling water system (7) are installed in the housing. The adjustment mechanism (5) is used to independently adjust the coupling water layer depth of each probe (6). A high-hardness wear-resistant layer (62) is added to the surface of the probe (6). The roller brush mechanism (1) consists of four independently driven roller brushes (11), a roller brush frame (12) for adjusting the contact angle between the roller brushes (11) and the billet, a pressing mechanism (13) with an adjusting handwheel, and a pressing locking handle (14). The roller brushes (11), the pressing mechanism (13), and the pressing locking handle (14) are all mounted on the roller brush frame (12). The pressing mechanism (13) adjusts the contact depth between the roller brushes (11) and the surface of the billet by pressing the handwheel, thereby controlling the brushing force of the roller brushes (11) on the surface oxide scale of the billet. The wear-resistant block (3) has a scraper groove (31) in front of the probe (6) in the forward direction. The scraper groove (31) is used to remove the oxide scale or protrusions that the roller brush (11) has not removed. The front end face of the wear-resistant block (3) is also provided with a guide arc (32) to prevent the probe (6) from getting stuck. The wear-resistant block self-defense clamping mechanism (4) is used to ensure that the flaw detection distance between the probe (6) and the billet surface remains unchanged. It consists of a lifting cylinder (41), a clamping spring (42), a clamping frame (43), a follower frame (44), and a probe seat (45). The lifting cylinder (41) is connected to the clamping frame (43) through the clamping spring (42). The clamping frame (43) is located below the lifting cylinder (41). The follower frame (44) is connected to the clamping frame (43) by a pin shaft. The probe seat (45) is fixed on the follower frame (44). The adjustment mechanism (5) includes a clamping screw (51), a lifting screw (52), and a locking nut (53); the clamping screw (51), the lifting screw (52), and the locking nut (53) are used to fasten the probe seat (45) respectively, and the optimal depth of the probe (6) coupled to the water on the probe seat (45) is adjusted by tightening the clamping screw (51), the lifting screw (52), and the locking nut (53).

2. The ultrasonic flaw detection coupling device for billet water film method as described in claim 1, characterized in that: The probe (6) includes a probe acoustic wedge layer (61), and a high-hardness wear-resistant layer (62) is added in front of the probe acoustic wedge layer (61).

3. The ultrasonic flaw detection coupling device for billet water film method as described in claim 1, characterized in that: The probe holder (45) is provided with a corresponding water channel structure. After the coupling water passes through the water channel on the probe holder (45), it can evenly and without bubbles spread the coupling water to the surface of each probe (6) to form a stable water film layer on the surface of the probe (6) and the surface of the billet to be inspected.

4. A method of using the ultrasonic flaw detection coupling device for billet water film method as described in claim 1, characterized in that, Includes the following steps: S1: Use the roller brush mechanism (1) and wear-resistant block (3) to brush and remove the oxide scale or protrusions on the surface of the billet; S2: Divide the probes (6) used on each face into multiple groups, place each group of probes (6) on the same base, and place a wear-resistant block (3) at the front end of each group of probes (6), and install a wear-resistant block self-defense clamping mechanism (4) at the back. By pressing down with constant pressure through the clamping spring (42), the probe (6) and the inspected billet plane can be stably attached. S3: The coupling water depth of each probe (6) is independently adjusted by using the adjustment mechanism (5) through the two threaded holes at the rear of the probe (6) and the two clamping screws (51) and lifting screws (52) on the holes; S4: Obtain the flaw detection signal of each probe (6) through the flaw detection host, and use the written processing software to analyze the flaw detection start wave, detection section and bottom wave signal of each probe (6) to determine the wear condition of the probe (6) surface, the fit between the probe (6) and the billet surface to be inspected, the coupling layer depth and the coupling water state.

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