Non-destructive testing sensor and non-destructive testing system

Abstract

The application discloses a kind of nondestructive testing sensor and nondestructive testing system.Magnetic yoke in nondestructive testing sensor includes base, first magnetic bridge and second magnetic bridge, base is connected with first magnetic bridge and second magnetic bridge respectively;First end of base, first permanent magnet, first pole shoe are sequentially contacted, second end of base, second permanent magnet, second pole shoe are sequentially contacted;First magnetic bridge and second magnetic bridge are located between first end and second end of base;At least one first magnetic sensitive element is arranged between first magnetic bridge and second magnetic bridge, at least one second magnetic sensitive element is arranged below first magnetic bridge, and at least one third magnetic sensitive element is arranged below second magnetic bridge.By setting first magnetic sensitive element, second magnetic sensitive element and third magnetic sensitive element, the cross mutual inspection of crack defect can be realized, and the detection accuracy and detection efficiency are improved.

Description

Technical Field

[0001] This invention relates to the field of industrial nondestructive testing technology, and more particularly to nondestructive testing sensors and nondestructive testing systems. Background Technology

[0002] Non-destructive testing (NDT) is a technique that detects surface or internal defects or performance issues in an object without damaging or affecting its continued use. It plays a crucial role in providing early warnings of structural safety and protecting life and property.

[0003] Defect detection in commonly tested components typically employs magnetic flux leakage (MF) and magnetic perturbation techniques. MF leakage works by exploiting a sudden change in magnetic permeability at the defect, causing a magnetic field to leak into the air and form a leakage magnetic field. Magnetic perturbation, on the other hand, uses a permanent magnet to vertically excite the component under test. As the permanent magnet and component move relative to each other, the magnetic flux density between the lower surface of the permanent magnet at the defect and the surface of the component is disturbed. MF leakage is sensitive to surface or shallow surface defects, and the amplitude of the MF leakage signal has a good linear relationship with the defect depth. However, it is insensitive to cracks within a certain angular range. Conversely, magnetic perturbation cannot detect defects below the surface, and the amplitude of the magnetic perturbation signal has limited depth characterization capabilities. However, magnetic perturbation exhibits good detection sensitivity for cracks in different directions.

[0004] Existing technologies for detecting magnetic flux leakage and magnetic disturbances use independent sensors. To achieve the aforementioned detection objectives, both sensors and the detection instrument must be used together. When inspecting the component under test, magnetic flux leakage detection technology is first used to scan the surface of the component, leveraging its sensitivity to internal defects and accurate characterization of defect depth. Then, magnetic disturbance detection technology is used to scan the surface again, utilizing its strong ability to characterize opening morphology and its good detection sensitivity for cracks in all directions, to determine internal and external defects, achieving precise defect imaging and cross-verification to ensure no defects were missed. Therefore, the existing technology, which uses multiple independent sensors to detect the object, increases the complexity and cost of the detection system and has low detection efficiency. Summary of the Invention

[0005] This invention provides a non-destructive testing sensor and a non-destructive testing system to solve the problems of low accuracy of single-technology testing and high cost and low efficiency of separate testing technology in the non-destructive testing of the tested components.

[0006] According to one aspect of the present invention, a non-destructive testing sensor is provided, comprising: a magnetic yoke, a first permanent magnet, a second permanent magnet, a first pole shoe, a second pole shoe, at least one first magnetic sensitive element, at least one second magnetic sensitive element, and at least one third magnetic sensitive element;

[0007] The magnetic yoke includes a base, a first magnetic bridge, and a second magnetic bridge, wherein the base is connected to the first magnetic bridge and the second magnetic bridge, respectively.

[0008] The top surface of the first permanent magnet is in contact with the first end of the substrate, the bottom surface of the first permanent magnet is in contact with the top surface of the first pole shoe, the top surface of the second permanent magnet is in contact with the second end of the substrate, the bottom surface of the second permanent magnet is in contact with the top surface of the second pole shoe, and the distances from the bottom surfaces of the first and second pole shoes to the preset surface of the component under test are both within a preset range.

[0009] The magnetic poles on the top surface of the first permanent magnet are opposite to those on the top surface of the second permanent magnet, and the magnetic poles on the bottom surface of the first permanent magnet are opposite to those on the bottom surface of the second permanent magnet.

[0010] The first magnetic bridge and the second magnetic bridge are located between the first end and the second end of the substrate;

[0011] At least one of the first magnetic sensitive elements is located below the substrate and disposed between the first magnetic bridge and the second magnetic bridge, at least one of the second magnetic sensitive elements is disposed below the first magnetic bridge, and at least one of the third magnetic sensitive elements is disposed below the second magnetic bridge;

[0012] The distances between at least one first magnetic sensing element, at least one second magnetic sensing element, at least one third magnetic sensing element and the preset surface of the component being measured are all within the preset distance range.

[0013] Optionally, the non-destructive testing sensor includes a plurality of first magnetic sensing elements, a plurality of second magnetic sensing elements, and a plurality of third magnetic sensing elements, wherein the first magnetic bridge and the second magnetic bridge are arranged along a first direction;

[0014] Multiple first magnetic sensitive elements are soldered onto a first flexible circuit board, the length of the first flexible circuit board along the second direction is less than or equal to the length of the substrate along the second direction; the second direction is perpendicular to the first direction.

[0015] Multiple second magnetic sensitive elements are soldered onto a second flexible circuit board, and the vertical projection of the second flexible circuit board onto the substrate overlaps with the vertical projection of the first magnetic bridge onto the substrate;

[0016] Multiple third magnetic sensitive elements are soldered onto a third flexible circuit board, and the vertical projection of the third flexible circuit board onto the substrate overlaps with the vertical projection of the second magnetic bridge onto the substrate.

[0017] Optionally, the plurality of first magnetic sensing elements, the plurality of second magnetic sensing elements, and the plurality of third magnetic sensing elements are all arranged in a staggered manner.

[0018] Optionally, the first flexible circuit board, and / or the second flexible circuit board, and / or the third flexible circuit board are parallel to a preset surface of the component under test.

[0019] Optionally, the bottom surfaces of both the first and second pole shoes are parallel to a preset surface of the component being tested.

[0020] Optionally, the first magnetic sensitive element is a tunnel magnetoresistive element, a Hall element, or a giant magnetoresistive element;

[0021] The second magnetic sensitive element is a tunnel magnetoresistive element, a Hall element, or a giant magnetoresistive element;

[0022] The third magnetic sensitive element is a tunnel magnetoresistive element, a Hall element, or a giant magnetoresistive element.

[0023] Optionally, the preset distance range is 0mm-10mm.

[0024] Optionally, the magnetic yoke, the first permanent magnet, the second permanent magnet, the first pole shoe, the second pole shoe, at least one first magnetic sensitive element, at least one second magnetic sensitive element, and at least one third magnetic sensitive element are all encapsulated in a housing.

[0025] According to another aspect of the present invention, a non-destructive testing system is provided, including a motion control module, a host computer, and a non-destructive testing sensor as described in any one of the above. The motion control module is electrically connected to the host computer and connected to the non-destructive testing sensor. The motion control module is used to control the relative movement of the non-destructive testing sensor and the component under test according to the control signal output by the host computer.

[0026] The host computer is electrically connected to the first magnetic sensing element, the second magnetic sensing element, and the third magnetic sensing element in the non-destructive testing sensor, and is used to determine whether the tested component has crack defects based on the signals output by the first magnetic sensing element, the second magnetic sensing element, and the third magnetic sensing element.

[0027] Optionally, the non-destructive testing system further includes a signal processing module, which is electrically connected to the first magnetic sensing element, the second magnetic sensing element, and the third magnetic sensing element, respectively. The signal processing module is used to filter, amplify, and perform analog-to-digital conversion on the signals output by the first magnetic sensing element, the second magnetic sensing element, and the third magnetic sensing element, and then output them to the host computer.

[0028] The non-destructive testing sensor provided in this embodiment of the invention includes a magnetic yoke, a first permanent magnet, a second permanent magnet, a first pole shoe, a second pole shoe, at least one first magnetic sensing element, at least one second magnetic sensing element, and at least one third magnetic sensing element. The first permanent magnet is connected to the first end of the magnetic yoke and the first pole shoe, respectively. The second permanent magnet is connected to the second end of the magnetic yoke and the second pole shoe, respectively. At least one first magnetic sensing element is disposed directly below the magnetic yoke, at least one second magnetic sensing element is disposed below the first magnetic bridge, and at least one third magnetic sensing element is disposed below the second magnetic bridge. The first magnetic sensing element, in combination with the second (or third) magnetic sensing element, can detect crack defects of different depths and angles. Because the first magnetic sensing element is disposed directly below the substrate, the magnetic field lines in the first magnetic sensing element and the test component at the corresponding position of the first magnetic sensing element are all in the first direction. Therefore, the amount of magnetic flux acquired by the first magnetic sensing element is related to the depth of the test component, and the first magnetic sensing element is more sensitive to the detection of crack defects of different depths. The magnetic field lines in the second magnetic sensing element and the component under test at the corresponding position of the second magnetic sensing element are all in the second direction Y. Therefore, the amount of magnetic flux acquired by the second magnetic sensing element 7 is related to the length of the component under test along the first direction X. Since the length of each crack defect along the first direction X varies depending on the crack defect angle, the second magnetic sensing element is more sensitive to the detection of small-angle crack defects. Combining the first, second, and third magnetic sensing elements allows for the detection of crack defects of different depths and angles, avoiding missed detections and improving detection accuracy. Furthermore, magnetic leakage and magnetic disturbance occur simultaneously in a single detection, improving detection efficiency. The non-destructive testing sensor provided in this embodiment has a simple structure, small size, light weight, is easy to operate, and has low energy consumption, reducing detection costs.

[0029] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the structure of a non-destructive testing sensor provided in an embodiment of the present invention;

[0032] Figure 2 This is a schematic diagram of a magnetic circuit in a non-destructive sensor provided in an embodiment of the present invention;

[0033] Figure 3 This is a schematic diagram of another magnetic circuit in the non-destructive sensor provided in the embodiment of the present invention;

[0034] Figure 4 It is a schematic diagram showing the distribution of multiple crack defects with the same length, width, and depth but different angles in the component under test;

[0035] Figure 5 This is a waveform diagram of the signal output by the first magnetic sensing element when detecting crack defects at different angles, as provided in an embodiment of the present invention.

[0036] Figure 6 This is a waveform diagram of the signal output by the second magnetic sensing element when detecting crack defects at different angles, as provided in an embodiment of the present invention.

[0037] Figure 7 It is a top view of the distribution of multiple crack defects in the tested component, all with the same angle, length, and width but different depths.

[0038] Figure 8 It is a sectional view of the component being measured;

[0039] Figure 9 This is a waveform diagram of the signal output by the first magnetic sensing element when detecting crack defects of different depths, as provided in an embodiment of the present invention.

[0040] Figure 10 This is a waveform diagram of the signal output by the second magnetic sensing element when detecting crack defects of different depths, as provided in an embodiment of the present invention.

[0041] Figure 11 This is a schematic diagram of the arrangement of the first magnetic sensing element in a non-destructive sensor provided in an embodiment of the present invention;

[0042] Figure 12 This is a schematic diagram of a non-destructive testing system provided in an embodiment of the present invention. Detailed Implementation

[0043] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. 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 should fall within the scope of protection of the present invention.

[0044] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0045] Figure 1 This is a schematic diagram of the structure of a non-destructive testing sensor provided in an embodiment of the present invention. Figure 2 This is a schematic diagram of a magnetic circuit in a non-destructive sensor provided in an embodiment of the present invention. Figure 3 This is a schematic diagram of another magnetic circuit in the non-destructive sensor provided in an embodiment of the present invention, with reference to... Figures 1-3 The non-destructive sensor includes: a magnetic yoke, a first permanent magnet 2, a second permanent magnet 3, a first pole shoe 4, a second pole shoe 5, at least one first magnetic sensitive element 6, at least one second magnetic sensitive element 7, and at least one third magnetic sensitive element 8;

[0046] The magnetic yoke includes a base 11, a first magnetic bridge 12, and a second magnetic bridge 13, with the base 11 connected to the first magnetic bridge 12 and the second magnetic bridge 13 respectively.

[0047] The top surface of the first permanent magnet 2 is in contact with the first end of the base 11, the bottom surface of the first permanent magnet 2 is in contact with the top surface of the first pole shoe 4, the top surface of the second permanent magnet 3 is in contact with the second end 112 of the base 11, the bottom surface of the second permanent magnet 3 is in contact with the top surface of the second pole shoe 5, and the distances from the bottom surface of the first pole shoe 4 and the bottom surface of the second pole shoe 5 to the preset surface of the measured component 01 are both within a preset range.

[0048] The magnetic poles on the top surface of the first permanent magnet 2 are opposite to the magnetic poles on the top surface of the second permanent magnet 3, and the magnetic poles on the bottom surface of the second permanent magnet 2 are opposite to the magnetic poles on the bottom surface of the second permanent magnet 3.

[0049] The first magnetic bridge 12 and the second magnetic bridge 13 are located between the first end 111 and the second end 112 of the base 11;

[0050] At least one first magnetic sensitive element 6 is located below the base of the magnetic yoke and disposed between the first magnetic bridge 12 and the second magnetic bridge 13, at least one second magnetic sensitive element 7 is disposed below the first magnetic bridge 12, and at least one third magnetic sensitive element 8 is disposed below the second magnetic bridge 13.

[0051] The distances between at least one first magnetic sensing element 6, at least one second magnetic sensing element 7, at least one third magnetic sensing element 8 and the preset surface of the measured component 01 are all within a preset distance range.

[0052] The magnetic yoke is a soft magnetic material that does not generate a magnetic field itself, but only transmits magnetic field lines in the magnetic circuit. The base 11 of the yoke, the first magnetic bridge 12, and the second magnetic bridge 13 are integrated into one unit. The first magnetic bridge 12 and the second magnetic bridge 13 are arranged along the first direction X, and both the first magnetic bridge 12 and the second magnetic bridge 13 extend along the second direction Y. The lengths of the first magnetic bridge 12 and the second magnetic bridge 13 along the second direction Y are the same, and the first direction X and the second direction Y are perpendicular. Magnetic field leakage may also occur in the first permanent magnet 2 and the second permanent magnet 3. The first magnetic bridge 12 and the second magnetic bridge 13 can provide magnetic shielding to reduce the magnetic compression effect of the background magnetic field. The first permanent magnet 2 and the first end 111 of the base 11 are magnetically attracted together, and the first permanent magnet 2 and the first pole piece 4 are magnetically attracted together. The second permanent magnet 3 and the second end 112 of the base 11 are magnetically attracted together, and the second permanent magnet 3 and the second pole piece 5 are magnetically attracted together. The length of the first pole piece 4 along the second direction Y is the same as the length of the second pole piece 5 along the second direction Y. The component under test 01 can be the equipment to be inspected, such as the weld of a wind turbine tower. The preset surface of the component under test 01 is the side of the component under test closest to the non-destructive testing sensor. Optionally, the preset range is 0mm-10mm. The non-destructive testing sensor can be directly located on the preset surface of the component under test 01, or at a certain distance from the preset surface of the component under test 01. The distance between the magnetic sensing element and the preset surface of the component under test 01 should not be too far to avoid a small leakage magnetic field and a weak signal output by the magnetic sensing element, which could lead to missed detection of crack defects. Optionally, the first magnetic sensing element 6 is disposed directly below the substrate 11, and the distance between the first magnetic sensing element 6 and the side of the substrate 11 closest to the preset surface of the component under test 01 is set. For example, when the preset surface of the component under test 01 is a plane, the first magnetic sensing element 6, the second magnetic sensing element 7, and the third magnetic sensing element 8 are at the same vertical distance from the preset surface. The magnetic poles on the top surface of the first permanent magnet 2 are opposite to those on the top surface of the second permanent magnet 3, and the magnetic poles on the bottom surface of the first permanent magnet 2 are opposite to those on the bottom surface of the second permanent magnet 3. For example, the top surface of the first permanent magnet 2 is an S pole and the bottom surface is an N pole, while the top surface of the second permanent magnet 3 is an N pole and the bottom surface is an S pole; or, the top surface of the first permanent magnet 2 is an N pole and the bottom surface is an S pole, while the top surface of the second permanent magnet 3 is an S pole and the bottom surface is an N pole. This creates closed magnetic field lines between the first permanent magnet 2, the first pole shoe 4, the component under test 01, the second pole shoe 5, the second permanent magnet 3, and the yoke, facilitating subsequent crack defect detection of the component under test. In this embodiment, the top surface of the first permanent magnet 2 is an S pole and the bottom surface is an N pole, and the top surface of the second permanent magnet 3 is an N pole and the bottom surface is an S pole, as exemplarily shown.

[0053] The magnetic yoke, first permanent magnet 2, first pole shoe 4, second permanent magnet 3, and second pole shoe 5 form a symmetrical pattern. The first magnetic bridge 12 and second magnetic bridge 13 are symmetrical, as are the first pole shoe 4 and second pole shoe 5, and the first permanent magnet 2 and second permanent magnet 3. The first magnetic sensitive element 6 can be a tunneling magnetoresistive element, a Hall element, or a giant magnetoresistive element; the second magnetic sensitive element 7 can be a tunneling magnetoresistive element, a Hall element, or a giant magnetoresistive element; and the third magnetic sensitive element 8 can be a tunneling magnetoresistive element, a Hall element, or a giant magnetoresistive element. This embodiment does not specifically limit the specific type of element. Optionally, the magnetic yoke, first permanent magnet 2, second permanent magnet 3, first pole shoe 4, second pole shoe 5, at least one first magnetic sensitive element 6, at least one second magnetic sensitive element 7, and at least one third magnetic sensitive element 7 are all encapsulated within a housing. When the non-destructive testing sensor includes a first magnetic sensitive element 6, the first magnetic sensitive element is positioned perpendicularly below the intersection of the midpoint of the substrate 11 along the first direction X and the midpoint of the substrate 11 along the second direction. When the non-destructive testing sensor includes multiple first magnetic sensing elements 6, the multiple first magnetic sensing elements 6 are disposed vertically below the middle position of the substrate 11 along the first direction X, and the multiple first magnetic sensing elements 6 are arranged along the second direction Y. When the non-destructive testing sensor includes a second magnetic sensing element 7, the second magnetic sensing element 7 can be disposed vertically below the intersection of the middle position of the first magnetic bridge 12 along the first direction X and the middle position along the second direction Y. When the non-destructive testing sensor includes multiple second magnetic sensing elements 7, the multiple second magnetic sensing elements 7 are disposed vertically below the middle position of the first magnetic bridge 12 along the first direction X, and the multiple second magnetic sensing elements 7 are arranged along the second direction Y. The arrangement of the third magnetic sensing element 8 is similar to that of the second magnetic sensing element 7, and will not be described again here.

[0054] During non-destructive testing of the component under test, a closed magnetic circuit is formed between the first permanent magnet 2, the first pole shoe 4, the component under test 01, the second pole shoe 5, the second permanent magnet 3, and the substrate 11, and magnetic lines of force are transmitted within this closed magnetic circuit. The first magnetic sensing element 6 is located above a preset surface of the component under test 01. When a crack defect occurs in the component under test 01, the magnetic flux at the defect location leaks into the air. This leakage flux is acquired by the first magnetic sensing element 6, thereby determining the defect information of the component under test 01. Simultaneously, a closed magnetic circuit is formed between the first permanent magnet 2, the first pole shoe 4, the component under test 01, the first magnetic bridge 12, and the first end of the substrate 11, and magnetic lines of force are transmitted within this magnetic circuit. A closed magnetic circuit is also formed between the symmetrically structured second magnetic bridge 13, the component under test 01, the second pole shoe 5, the second permanent magnet 3, and the first end of the substrate 11, transmitting magnetic lines of force; these details will not be elaborated further here. The second magnetic sensing element 7 is located between the first magnetic bridge 12 and the preset surface of the component under test. When a crack defect occurs in the component under test 01, the magnetic flux at the defect location leaks into the air. The leaked magnetic flux is acquired by the second magnetic sensing element 7, thereby determining the defect information of the component under test 01. The third magnetic sensing element 8 works on the same principle as the second magnetic sensing element 7, and will not be described in detail here.

[0055] Figure 4 This is a schematic diagram showing the distribution of multiple crack defects with the same length, width, and depth but different angles in the component under test. Figure 5 The waveform diagram of the signal output by the first magnetic sensing element when detecting crack defects at different angles, as provided in an embodiment of the present invention. Figure 6 The waveform diagram of the signal output by the second magnetic sensing element when detecting crack defects at different angles, as provided in an embodiment of the present invention. Figure 5 and Figure 6 The signal waveforms in the diagrams are all for Figure 4 The waveform diagram shown is output when multiple defects are detected. Figure 4 The five cracks in the test component 01 are all 5mm long, 1mm wide, and 1mm deep, and are arranged along the first direction X. Along the first direction X, from left to right, the angles between the five cracks and the horizontal axis L of the test component 01 are 0°, 15°, 30°, 45°, and 60°, respectively. The horizontal axis L extends along the first direction X and bisects the test component 01 in the second direction Y. When using a non-destructive testing sensor to inspect the test component 01, the sensor is controlled to slowly move to the right along the first direction X, starting from the leftmost end of the test component 01 in the figure, to perform the scan. Figure 5 and Figure 6The horizontal axis represents the distance from the measured component 01 to the starting end along the first direction X, in mm. The vertical axis represents the amplitude of the signal output by the corresponding magnetic sensing element, in mV. It is worth noting that the signal output by the magnetic sensing element is a voltage value, and the voltage value is proportional to the magnetic flux. Therefore, by observing the magnitude of the voltage value output by the magnetic sensing element, it is possible to determine whether magnetic leakage has occurred, and further determine whether there are cracks or defects at the corresponding location of the measured component that cause magnetic leakage.

[0056] refer to Figures 1-6 At the locations of the third to fifth crack defects (corresponding to the 30°, 45°, and 60° crack defects), the amplitude of the signal output by the first magnetic sensing element 6 is relatively significant. However, at the first and second crack defects (corresponding to the 0° and 15° crack defects), the signal resolution of the first magnetic sensing element 6 is not high, indicating that the first magnetic sensing element 6 has low resolution for small-angle crack defects between 0° and 15°. In contrast, the amplitude of the signal output by the second magnetic sensing element 7 is more significant at the first and second crack defects, meaning that the second magnetic sensing element 7 has higher resolution for small-angle crack defects. The reason why the second magnetic sensing element 7 has a high resolution for small-angle crack defects is that, at the second magnetic sensing element 7 and in the measured component 01 corresponding to the vertically below the second magnetic sensing element 7, the direction of the magnetic field lines is the second direction Y. Therefore, the amount of magnetic flux that leaks into the air and can be obtained by the second magnetic sensing element 7 is mainly related to the length of the crack defect along the first direction X. Since the length of the small-angle crack defect along the first direction X is relatively large, the second magnetic sensing element 7 also has a high resolution for small-angle crack defects.

[0057] Figure 7 This is a top view showing the distribution of multiple crack defects in the tested component, all with the same angle, length, and width but different depths. Figure 8 for Figure 7 Middle AA , Sectional view of the direction, Figure 9 The waveform diagram of the signal output by the first magnetic sensing element when detecting crack defects of different depths is provided in an embodiment of the present invention. Figure 10 The waveform diagram of the signal output by the second magnetic sensing element when detecting crack defects of different depths, as provided in the embodiments of the present invention. Figure 9 and Figure 10 The waveforms in the diagrams are all for Figure 7 and Figure 8 The waveforms shown are output when the five crack defects are detected. Figure 7 and Figure 8The five crack defects are all 5 mm long, 0.5 mm wide, and 90° at an angle to the horizontal axis. The five crack defects are arranged along the first direction X, and from left to right along the first direction X, the depths of the five crack defects are 0.5 mm, 1.0 mm, 1.5 mm, 2.0 mm, and 3.0 mm, respectively. Figure 9 and Figure 10 The horizontal axis represents the distance from the measured component 01 to the starting end along the first direction X, in mm. The vertical axis represents the amplitude of the signal output by the corresponding magnetic sensitive element, in mV.

[0058] refer to Figures 1-3 , Figures 7-10 At the third to fifth crack defects, i.e., cracks with depths of 1.5 mm, 2.0 mm, and 3.0 mm, the amplitude of the signal output by the second magnetic element 7 is relatively significant. However, at the first and second crack defects, i.e., cracks with depths of 0.5 mm and 1.0 mm, the signal resolution of the second magnetic element 7 is not high, indicating that the second magnetic element 7 has low resolution for cracks with shallower depths. In contrast, the amplitude of the signal output by the first magnetic element 6 is more significant at the first and second crack defects, meaning that the first magnetic element 6 has higher resolution for cracks with shallower depths. The reason why the first magnetic sensing element 6 has a high resolution for crack defects with shallow depth is that the direction of the magnetic field lines is the first direction Y in the measured component 01 corresponding to the first magnetic sensing element 6 and the component 01 directly below the first magnetic sensing element 6. Therefore, the amount of magnetic flux that can be obtained by the first magnetic sensing element 6 when it leaks into the air is mainly related to the depth of the crack defect. Thus, the first magnetic sensing element 6 has a high resolution for crack defects of different depths.

[0059] The first magnetic sensing element 6, combined with the second magnetic sensing element 7 (or the third magnetic sensing element 8), can detect crack defects of different depths and angles. Since the first magnetic sensing element 6 is positioned directly below the substrate 11, the magnetic lines of force in the first magnetic sensing element 6 and the corresponding component 01 under test are all in the first direction X. Therefore, the amount of magnetic flux acquired by the first magnetic sensing element 6 is mainly related to the depth of the component 01 under test, making it highly sensitive to crack defects of different depths. Similarly, the magnetic lines of force in the second magnetic sensing element 7 and the corresponding component 01 under test are all in the second direction Y. Therefore, the amount of magnetic flux acquired by the second magnetic sensing element 7 is mainly related to the length of the component 01 under test along the first direction X. Since the length of each crack defect along the first direction X varies depending on its angle, the second magnetic sensing element 7 is highly sensitive to crack defects with small angles. By combining the first magnetic sensing element 6, the second magnetic sensing element 7, and the third magnetic sensing element 8, crack defects of different depths and angles can be detected, avoiding missed detections and improving detection accuracy. Furthermore, magnetic leakage and magnetic disturbance occur simultaneously in a single detection, increasing detection efficiency. The non-destructive testing sensor provided in this embodiment has a simple structure, small size, light weight, is easy to operate, and consumes little energy, thus reducing detection costs.

[0060] refer to Figure 1 The non-destructive testing sensor includes multiple first magnetic sensing elements 6, multiple second magnetic sensing elements 7 and multiple third magnetic sensing elements 8, with the first magnetic bridge 12 and the second magnetic bridge 13 arranged along the first direction X;

[0061] Multiple first magnetic sensitive elements 6 are welded to a first flexible circuit board. The length of the first flexible circuit board along the second direction Y is less than or equal to the length of the base 11 of the magnetic yoke along the second direction. The second direction Y is perpendicular to the first direction X.

[0062] Multiple second magnetic sensitive elements 7 are soldered onto a second flexible circuit board, and the vertical projection of the second flexible circuit board onto the base 11 of the magnetic yoke overlaps with the vertical projection of the first magnetic bridge 12 onto the base 11 of the magnetic yoke.

[0063] Multiple third magnetic sensitive elements 8 are soldered onto a third flexible circuit board, and the vertical projection of the third flexible circuit board onto the base 11 of the magnetic yoke overlaps with the vertical projection of the second magnetic bridge 13 onto the base 11 of the magnetic yoke.

[0064] For example, the first magnetic sensing element 6 can be arranged in an array on the first flexible circuit board, the second magnetic sensing element 7 can be arranged in an array on the second flexible circuit board, and the third magnetic sensing element 8 can be arranged in an array on the third flexible circuit board. The length of the first flexible circuit board along the second direction can be equal to the length of the base 11 of the magnetic yoke along the second direction Y to improve detection efficiency. Specifically, when performing non-destructive testing on the component under test, if the length of the component under test 01 along the second direction Y is 12cm and the length of the base 11 along the second direction Y is 3cm, in the first test, the non-destructive sensor is controlled to move from the starting end along the first direction X to perform defect detection on the component under test 01. Since the length of the first flexible circuit board along the second direction Y is 3cm, the component under test 01 can be detected in a 3cm wide area in the second direction each time it is tested. Only four tests along the second direction Y by the non-destructive sensor are needed to complete the detection of the component under test 01. The reasons for setting the second magnetic sensing element 7 and the third magnetic sensing element 8 are the same as those for setting the first magnetic sensing element 6, and will not be repeated here.

[0065] Figure 11 This is a schematic diagram of the arrangement of the first magnetic sensing element in a non-destructive sensor provided by an embodiment of the present invention. The arrangement of the second magnetic sensing element 7 and the third magnetic sensing element 8 is similar to that of the present invention. Figure 11 Same. Reference Figure 1 and Figure 11 Multiple first magnetic sensing elements 6, multiple second magnetic sensing elements 7, and multiple third magnetic sensing elements 8 are arranged in a staggered manner. The first magnetic sensing elements 6 are disposed on the first flexible circuit board 9, and the staggered arrangement of the first magnetic sensing elements 6 improves spatial resolution.

[0066] Optionally, the first flexible circuit board, and / or the second flexible circuit board, and / or the third flexible circuit board are parallel to a preset surface of the component under test. The bottom surfaces of both the first and second pole shoes are parallel to the preset surface of the component under test. The flexible circuit board can be bent to a certain extent to adapt to different geometric shapes of the component under test. The first, second, and third magnetic elements are parallel to the preset surface of the component under test to facilitate the acquisition of leakage flux. The parallelism of the bottom surfaces of the first and second pole shoes to the preset surface of the component under test facilitates the uniform distribution of magnetic field lines on the component under test.

[0067] This invention also provides a non-destructive testing system. Figure 12 This is a schematic diagram of a nondestructive testing system provided in an embodiment of the present invention, with reference to... Figure 12The non-destructive testing system includes a motion control module 02, a host computer 03, and the aforementioned non-destructive testing sensor 04. The motion control module 02 is electrically connected to the host computer 03 and is also connected to the non-destructive testing sensor 04. The motion control module 02 is used to control the relative movement of the non-destructive testing sensor 04 and the component under test 01 according to the control signal output by the host computer 03.

[0068] The host computer 03 is electrically connected to the first magnetic sensitive element 6, the second magnetic sensitive element 7, and the third magnetic sensitive element 8 in the non-destructive testing sensor 04, and is used to determine whether there are cracks or defects in the component under test based on the signals output by the first magnetic sensitive element 6, the second magnetic sensitive element 7, and the third magnetic sensitive element 8.

[0069] The motion control module 02 controls the non-destructive testing sensor 04 to move relative to the component under test 01. For example, the component under test 01 is stationary, and the non-destructive testing sensor 04 is controlled to move along a preset trajectory to complete the non-destructive testing of the component under test 01.

[0070] Optionally, the non-destructive testing sensor also includes a signal processing module 05 and a data acquisition module 06. The signal processing module 05 is electrically connected to the first magnetic sensing element 6, the second magnetic sensing element 7, and the third magnetic sensing element 8, respectively. The signal processing module 05 is used to filter, amplify, and perform analog-to-digital conversion on the signals output by the first magnetic sensing element 6, the second magnetic sensing element 7, and the third magnetic sensing element 8. The signal processing module 05 is electrically connected to the data acquisition module 06, and the data acquisition module 06 is connected to the host computer 03. The host computer 03 is indirectly connected to the first magnetic sensing element 6, the second magnetic sensing element 7, and the third magnetic sensing element 8 through the data acquisition module 06 and the signal processing module 05.

[0071] The signal processing module 05 may include a power supply circuit, a filtering circuit, an A / D conversion circuit, and a memory. The power supply circuit is connected to each of the first magnetic sensing elements 6, the second magnetic sensing elements 7, and the third magnetic sensing elements 8, respectively, to provide power voltage to each of these elements. The filtering circuit is connected to each of the first magnetic sensing elements 6, the second magnetic sensing elements 7, and the third magnetic sensing elements 8, respectively, to filter the signals output by each magnetic sensing element. The A / D conversion circuit is connected to the filtering circuit to perform analog-to-digital conversion on the filtered signals. The memory is connected to the A / D conversion circuit to store the analog-to-digital conversion information for subsequent retrieval by the host computer 03.

[0072] The beneficial effects of the non-destructive testing system in this embodiment are the same as those of the non-destructive testing sensor, and will not be repeated here.

[0073] It should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and no limitation is imposed herein.

[0074] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A non-destructive testing sensor, characterized in that, The application relates to a magnetic field sensor, comprising: a magnetic yoke, a first permanent magnet, a second permanent magnet, a first pole shoe, a second pole shoe, a plurality of first magnetic sensitive elements, a plurality of second magnetic sensitive elements and a plurality of third magnetic sensitive elements; the magnetic yoke comprises a base, a first magnetic bridge and a second magnetic bridge, the base is connected with the first magnetic bridge and the second magnetic bridge respectively, the first magnetic bridge and the second magnetic bridge are arranged along a first direction, the first magnetic bridge and the second magnetic bridge have the same length along a second direction, the first direction is perpendicular to the second direction, and the first magnetic bridge and the second magnetic bridge are used for magnetically shielding leakage magnetic of the first permanent magnet and the second permanent magnet; a top surface of the first permanent magnet is in contact with a first end portion of the base, a bottom surface of the first permanent magnet is in contact with a top surface of the first pole shoe, a top surface of the second permanent magnet is in contact with a second end portion of the base, and a bottom surface of the second permanent magnet is in contact with a top surface of the second pole shoe, distances between bottom surfaces of the first pole shoe and the second pole shoe and a preset surface of a measured component are within a preset range; magnetic poles of the top surface of the first permanent magnet are opposite to magnetic poles of the top surface of the second permanent magnet, and magnetic poles of the bottom surface of the first permanent magnet are opposite to magnetic poles of the bottom surface of the second permanent magnet; the first magnetic bridge and the second magnetic bridge are located between the first end portion and the second end portion of the base; the plurality of first magnetic sensitive elements are located below the base and are arranged between the first magnetic bridge and the second magnetic bridge, the plurality of second magnetic sensitive elements are arranged below the first magnetic bridge, the plurality of third magnetic sensitive elements are arranged below the second magnetic bridge, and the plurality of first magnetic sensitive elements, the plurality of second magnetic sensitive elements and the plurality of third magnetic sensitive elements are arranged in a staggered manner; distances between the plurality of first magnetic sensitive elements, the plurality of second magnetic sensitive elements, the plurality of third magnetic sensitive elements and the preset surface of the measured component are within a preset distance range, and the plurality of first magnetic sensitive elements and the plurality of second magnetic sensitive elements, or the plurality of first magnetic sensitive elements and the plurality of third magnetic sensitive elements are used for detecting crack defects of different depths and different angles.

2. The non-destructive testing sensor of claim 1, wherein, the plurality of first magnetic sensitive elements are welded on a first flexible circuit board, a length of the first flexible circuit board along the second direction is less than or equal to a length of the base along the second direction, and the second direction is perpendicular to the first direction; the plurality of second magnetic sensitive elements are welded on a second flexible circuit board, a vertical projection of the second flexible circuit board on the base overlaps a vertical projection of the first magnetic bridge on the base; the plurality of third magnetic sensitive elements are welded on a third flexible circuit board, a vertical projection of the third flexible circuit board on the base overlaps a vertical projection of the second magnetic bridge on the base.

3. The non-destructive testing sensor of claim 2, wherein, the first flexible circuit board, the second flexible circuit board and / or the third flexible circuit board are parallel to the preset surface of the measured component.

4. The non-destructive testing sensor of claim 2, wherein, the bottom surface of the first pole shoe and the bottom surface of the second pole shoe are parallel to the preset surface of the measured component.

5. The non-destructive testing sensor of claim 1, wherein, the first magnetic sensitive element is a tunneling magnetoresistance element, a Hall element or a giant magnetoresistance element. The second magnetic sensitive element is a tunnel magnetoresistance element, a Hall element or a giant magnetoresistance element; and the third magnetic sensitive element is a tunnel magnetoresistance element, a Hall element or a giant magnetoresistance element.

6. The non-destructive testing sensor of claim 1, wherein, The preset distance range is 0-10 mm.

7. The non-destructive testing sensor of claim 1, wherein, The magnetic yoke, the first permanent magnet, the second permanent magnet, the first pole shoe, the second pole shoe, the plurality of first magnetic sensitive elements, the plurality of second magnetic sensitive elements and the plurality of third magnetic sensitive elements are all encapsulated in a shell.

8. A non-destructive testing system characterized by, The nondestructive testing sensor, the motion control module and the upper computer are connected electrically, and the motion control module is used for controlling the relative motion between the nondestructive testing sensor and the measured component according to the control signal output by the upper computer. The upper computer is electrically connected with the first magnetic sensitive element, the second magnetic sensitive element and the third magnetic sensitive element in the nondestructive testing sensor, and is used for determining whether the measured component has a crack defect according to the signals output by the first magnetic sensitive element, the second magnetic sensitive element and the third magnetic sensitive element.

9. The non-destructive testing system of claim 8, wherein, The signal processing module is electrically connected with the first magnetic sensitive element, the second magnetic sensitive element and the third magnetic sensitive element respectively, and is used for filtering, amplifying and analog-digital converting the signals output by the first magnetic sensitive element, the second magnetic sensitive element and the third magnetic sensitive element and then outputting the signals to the upper computer.

Images