A quantitative detection method and system for ultrasonic phased array defects in wind turbine bearing rings.

Abstract

This invention discloses a method for quantitative detection of defects in wind turbine bearing ring components using ultrasonic phased array. Based on the material properties and cross-sectional geometry of the wind turbine bearing ring component under test, end-face and ring-face comparison test blocks are fabricated. Corresponding ultrasonic phased array probes are used to acquire quantitative evaluation DAC curves for end-face and ring-face defects. Then, based on the cross-sectional geometry of the wind turbine bearing ring component under test, the detection area is divided, and each detection area is associated with a corresponding comparison test block to plan a scanning path. The detection system enables linear focusing ultrasonic phased array scanning and quantitative detection of defect sizes in large ring components with complex geometries. The method and system of this invention can reduce the number of comparison test block defects processed, while automatically identifying and recording defect locations. It has advantages such as high detection speed, high detection accuracy, and applicability to raceway curved surface structures, and has high application value.

Description

Technical Field

[0001] This invention belongs to the field of ultrasonic nondestructive testing technology, specifically relating to a method and system for quantitative detection of defects in wind turbine bearing ring components using ultrasonic phased array, applicable to quantitative detection of defects in irregularly shaped cross-section ring components. Background Technology

[0002] With the rapid development of the new energy industry, onshore and offshore wind power have become important clean energy sources. Bearing rings used in wind turbines are crucial load-bearing components, and their internal defects can severely affect the safe operation and service life of wind power equipment. Wind turbine bearing rings are complex rotating structures with varied cross-sectional shapes; the internal and external gear rings typically have raceway surfaces with different curvatures. Conventional ultrasonic testing techniques use a fixed sound beam, resulting in severe scattering at curved surfaces, making it impossible to detect the raceway surface structure. Ultrasonic phased array testing technology, however, features beam deflection and focusing, adapting to the incident curved surface structure, and can effectively detect the raceway surface structure of the bearing rings.

[0003] In conventional ultrasonic testing, the distance-amplitude (DAC) curve is typically used to describe the relationship between defect distance, amplitude, and equivalent size for quantitative defect detection. However, when linear ultrasonic phased array probes inspect curved components, the different radiation paths and emission angles of the sound beams from different apertures within the curved structure cause uneven echo amplitudes of defects in the raceway surface, making quantitative defect evaluation difficult. Currently, no researchers have proposed a quantitative defect method for phased array linear focusing scanning imaging of raceway curved structures. Furthermore, wind turbine bearing rings are large, thick-walled parts requiring a wide depth range for inspection, making it impossible to directly apply ordinary standard test blocks for quantitative defect detection in bearing rings. To address these issues, this invention proposes an ultrasonic phased array defect quantitative detection method and system for wind turbine bearing rings, applicable to the quantitative detection of defects in irregularly shaped cross-section rings. Summary of the Invention

[0004] The technical problem to be solved by this invention is that there is no quantitative detection method for defects in the curved surface structure of wind turbine bearing rings using phased array linear focusing scanning imaging in the existing technology. This invention provides a quantitative detection method and system for defects in wind turbine bearing rings using ultrasonic phased array imaging, which can realize defect detection of wind turbine bearing rings with raceway and stepped cross-sectional geometric features, and has a larger detection range and higher defect detection accuracy.

[0005] The technical solution adopted by this invention to solve its technical problem is:

[0006] A method for quantitative detection of defects in the ring components of wind turbine bearings using ultrasonic phased array technology is provided, comprising the following steps:

[0007] S1. Based on the material properties and cross-sectional geometric characteristics of the wind turbine bearing ring to be tested, prepare end face inspection comparison blocks and ring face inspection comparison blocks;

[0008] S2. Select an end-face ultrasonic phased array probe to test the end-face comparison test block and generate a quantitative evaluation DAC curve for end-face defects; select a toroidal ultrasonic phased array probe to test the toroidal comparison test block and generate a quantitative evaluation DAC curve for toroidal defects.

[0009] S3. Divide the test area according to the cross-sectional geometric characteristics of the wind turbine bearing ring to be tested, and associate each test area with the corresponding comparison test block;

[0010] S4. Plan the scanning path. Based on the detection area divided in step S3, areas with similar geometric features are assigned to the same scanning path to form end face scanning path and toroidal scanning path.

[0011] S5. Fix the wind turbine bearing ring to be tested onto the testing system, and immerse the wind turbine bearing ring under test in liquid ultrasonic coupling agent. According to the planned end face scanning path and ring face scanning path, use the corresponding ultrasonic phased array probes to sequentially complete the detection of the end face and ring face of the wind turbine bearing ring under test, and compare the detection results with the corresponding defect quantitative evaluation DAC curve to determine whether the defect under test exceeds the calibrated defect size. If it exceeds the size, an automatic alarm will be triggered and the defect location will be recorded.

[0012] Following the above technical solution, the method for fabricating the end-face inspection comparison test block in step S1 is as follows: based on the maximum depth range L of the end-face inspection of the wind turbine bearing ring to be tested. max Make a container with a length, width, and thickness of L. max ×L max A 25mm end face comparison test block was machined with n transverse through holes of defects at equal intervals d in both length and width directions, where n = L. max / d.

[0013] Following the above technical solution, the method for fabricating the toroidal surface inspection comparison test block in step S1 is as follows: Based on the radius of curvature R of the toroidal raceway arc of the wind turbine bearing ring and the detection depth H of the toroidal raceway arc region, a toroidal surface comparison test block with a thickness of 25mm is fabricated, combined with the detection angle range of the ultrasonic phased array probe in the toroidal region. Inside, N defective transverse through holes are machined at equal intervals r along the radial direction of the annular raceway arc, where N = H / r. These N defective transverse through holes are distributed at equal angles θ along the circumferential direction of the annular raceway arc. Different toroidal test blocks were made using toroidal raceway arcs with different radii of curvature R.

[0014] Following the above technical solution, the method for obtaining the DAC curve for quantitative evaluation of end-face defects in step S2 is as follows: The upper end face of the end-face detection comparison block is detected using an end-face phased array probe, with a step L... s A radial scan is performed to sequentially obtain the phased array detection amplitude P of n defects at different depths. Ls-n The data is recorded and stored. Based on the amplitude of the ultrasonic phased array detection of the defect in the test block compared with the end face detection, a polynomial fitting is performed to obtain the quantitative evaluation curve DAC of the upper end face defect. au The same method was used to obtain the DAC (Defect Quantitative Evaluation Curve) for side end face defects. as .

[0015] Following the above technical solution, the method for obtaining the DAC curve for quantitative evaluation of toroidal defects in step S2 is as follows: A toroidal phased array probe is used to detect the toroidal detection comparison block. Starting from the effective boundary of the toroidal raceway arc, the toroidal phased array probe rotates and scans around the center of the toroidal raceway arc with a step angle α, sequentially obtaining the phased array detection amplitude P of N defects at different depths. α-N Based on the amplitude values ​​of ultrasonic phased array detection of defects in the toroidal test block, polynomial fitting was performed to obtain N quantitative evaluation curves (DACs) for toroidal defects at different axial angles. bi , where i = 1, 2, ..., N.

[0016] Following the above technical solution, the association between each detection area and the corresponding comparison test block in step S3 means that each detection area and the corresponding comparison test block of the wind turbine bearing ring under test use the same ultrasonic phased array probe, detection configuration file, and defect quantitative evaluation curve.

[0017] Following the above technical solution, the detection configuration file includes water layer height, emission aperture, and focusing depth.

[0018] This invention also provides a quantitative detection system for ultrasonic phased array defects in wind turbine bearing rings, used to implement the quantitative detection method for ultrasonic phased array defects in wind turbine bearing rings as described in claim 1. The system includes an open-top box containing liquid ultrasonic coupling agent, a rotating worktable at the bottom center of the box, a three-jaw chuck for clamping wind turbine bearing rings on the rotating worktable, an end-face scanning frame, and a toroidal scanning frame. An end-face ultrasonic phased array probe is mounted on the end-face scanning frame, and a toroidal ultrasonic phased array probe is mounted on the toroidal scanning frame. The end-face and toroidal ultrasonic phased array probes are connected to a computer via an end-face ultrasonic phased array detector and a toroidal ultrasonic phased array detector, respectively. Ultrasonic phased array software is installed on the computer.

[0019] Following the above technical solution, the rotary worktable is an electric worktable capable of full-circumference rotation, and the three-jaw chuck is a centering three-jaw chuck.

[0020] According to the above technical solution, the end face scanning frame and the annular scanning frame have at least the axial and radial translational degrees of freedom of the worktable and the rotational degrees of freedom of the end along the worktable axis.

[0021] The beneficial effects of this invention are as follows: The proposed method for quantitative detection of defects in wind turbine bearing ring components using ultrasonic phased array technology can achieve ultrasonic phased array linear focusing scanning imaging and quantitative detection of defect dimensions in large ring components with complex geometric features. Based on the detection dimensions of the ring component's end face and the radius of curvature of the raceway surface, end face comparison blocks and ring face comparison blocks with artificial defects were designed respectively. The proposed comparison block design method can save on the number of artificial defects processed. The proposed ultrasonic phased array linear focusing scanning imaging defect DAC curve determination method can automatically determine and record defect locations, and has advantages such as fast detection speed, high sensitivity, and applicability to raceway curved surface structures, making it highly valuable for application. Attached Figure Description

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the accompanying drawings:

[0023] Figure 1 This is a flowchart of the method for quantitative detection of defects in the ultrasonic phased array of wind turbine bearing rings according to the present invention;

[0024] Figure 2 This is a schematic diagram of the cross-sectional geometric features of the wind turbine bearing ring of the present invention;

[0025] Figure 3 This is a schematic diagram of the design of the wind turbine bearing ring end face inspection comparison test block of the present invention;

[0026] Figure 4 This is a schematic diagram of the design of the wind turbine bearing ring surface inspection comparison test block of the present invention;

[0027] Figure 5 This is a schematic diagram of the rotational testing of the comparative test block for the testing of the ring surface of the wind turbine bearing of the present invention;

[0028] Figure 6 This is a schematic diagram of the wind turbine bearing ring surface detection system of the present invention;

[0029] Figure 7 This is a cross-sectional dimension diagram of the wind turbine bearing ring according to a specific embodiment of the present invention;

[0030] Figure 8 This is a defect feature distribution diagram of the end face comparison test block according to a specific embodiment of the present invention;

[0031] Figure 9 This is a distribution diagram of defect features of a ring-shaped comparison test block according to a specific embodiment of the present invention;

[0032] Figure 10This is a flowchart of the ultrasonic phased array detection process according to a specific embodiment of the present invention;

[0033] Figure 11 This is a quantitative defect determination diagram of the DAC curve in a specific embodiment of the present invention.

[0034] In the figure: 1-computer, 2-end face ultrasonic phased array detector, 3-toroidal ultrasonic phased array detector, 4-end face scanning frame, 5-end face ultrasonic phased array probe, 6-wind turbine bearing ring, 7-three-jaw chuck, 8-toroidal scanning frame, 9-upper open box, 10-toroidal ultrasonic phased array probe, 11-rotary worktable. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0036] like Figure 1 As shown, a method for quantitative detection of defects in the ring components of wind turbine bearings using ultrasonic phased array technology is provided, comprising the following steps:

[0037] S1, such as Figure 2 As shown, end face inspection comparison blocks and ring face inspection comparison blocks are made according to the material properties and cross-sectional geometric characteristics of the wind turbine bearing ring to be tested. The ultrasonic characteristics of the comparison blocks with characteristic defects can effectively solve the problem of difficulty in quantitative evaluation of defects in ultrasonic phased array testing of large and complex ring components.

[0038] S2. Select an end-face ultrasonic phased array probe to test the end-face comparison test block and form a quantitative evaluation DAC curve for end-face defects; select a toroidal ultrasonic phased array probe to test the toroidal comparison test block and form a quantitative evaluation DAC curve for toroidal defects; use the quantitative evaluation curve of defects formed by the comparison test block with characteristic defects as the defect judgment standard for actual detection, thereby improving the accuracy of defect detection.

[0039] S3. Divide the test area according to the cross-sectional geometric characteristics of the wind turbine bearing ring to be tested, and associate each test area with the corresponding comparison test block; different cross-sectional geometric characteristics correspond to different comparison test blocks, corresponding to the optimal test configuration parameters and a near-realistic quantitative evaluation curve of defects.

[0040] S4. Plan the scanning path. Based on the detection area divided in step S3, regions with similar geometric features are assigned to the same scanning path, forming end-face scanning paths and toroidal scanning paths. Similar geometric features correspond to the same comparison test blocks and have the same detection configuration files, which can improve scanning detection efficiency. Figure 2As shown, for toroidal surfaces, regions with similar toroidal cross-sectional features (cylindrical, concave, and convex toroidal surfaces) correspond to the same comparison test block, use the same detection configuration file, and are merged into the same scanning path. For example, the concave toroidal surface region can be scanned first, and then the cylindrical surface region can be scanned.

[0041] S5. Fix the wind turbine bearing ring to be tested onto the testing system, and immerse the wind turbine bearing ring under test in liquid ultrasonic coupling agent. According to the planned end face scanning path and ring face scanning path, use the corresponding ultrasonic phased array probes to sequentially complete the detection of the end face and ring face of the wind turbine bearing ring under test, and compare the detection results with the corresponding quantitative evaluation curve of defects to determine whether the defect under test exceeds the calibrated defect size. If it exceeds the size, an automatic alarm will be triggered and the defect location will be recorded.

[0042] The specific scanning method involves simultaneously measuring the end face and the ring face using different ultrasonic phased array probes. The end face ultrasonic phased array probe and the ring face ultrasonic phased array probe start from their respective starting positions according to the configuration parameters S1 to S4. After each step, a 360° scan measurement is performed along the entire circumference of the wind turbine bearing ring, ultimately completing the full-size scan inspection of the entire wind turbine bearing ring.

[0043] This invention utilizes the material properties and cross-sectional geometric features of the wind turbine bearing ring to create comparative test blocks and generate DAC defect quantitative evaluation curves. It can achieve full coverage of defect equivalent size determination in areas such as the end face and ring surface of the wind turbine bearing ring, effectively solving the problem of difficulty in quantitative evaluation of defects in large and complex ring components detected by ultrasonic phased array. It has significant application value for automated industrial testing of wind turbine bearing ring components using ultrasonic phased array.

[0044] Furthermore, such as Figure 3 As shown, the method for preparing the end-face inspection comparison test block in step S1 is as follows: based on the maximum depth range L of the end-face inspection of the wind turbine bearing ring to be tested. max Make a container with a length, width, and thickness of L. max ×L max A 25mm end face comparison test block was machined with n transverse through holes of defects at equal intervals d in both length and width directions, where n = L. max / d. The sampling interval d mainly affects the number of sampling points. The smaller the sampling interval, the more sampling points, and the higher the accuracy of the subsequent fitted DAC curve. Referring to the American ASME ultrasonic phased array testing standard, a point is generally taken at 1 / 8 of the detection depth range as the interval d to create a feature defect. In practice, to reduce the number of defects processed and save manufacturing costs, a 2d interval can be used to create a feature defect.

[0045] Furthermore, such as Figure 4As shown, the method for fabricating the toroidal surface inspection comparison block in step S1 is as follows: Based on the radius of curvature R of the toroidal raceway of the wind turbine bearing ring and the detection depth H of the toroidal raceway arc region, a toroidal surface comparison block with a thickness of 25mm is fabricated, combined with the detection angle range of the ultrasonic phased array in the toroidal region. N defective transverse through holes are machined at equal radial intervals r along the annular raceway arc, where N = H / r. These N defective transverse through holes are distributed at equal angles θ along the circumferential direction of the annular raceway arc. Different toroidal test blocks with varying radii of curvature R are used to create toroidal raceway arcs for comparative testing. The radial spacing r here is the same as the defect spacing d of the end-face comparison blocks mentioned above, primarily affecting the number of sampling points. A smaller sampling spacing results in more sampling points, leading to higher accuracy of the subsequently fitted DAC curve. Referring to the ASME ultrasonic phased array testing standard, a point is typically taken at 1 / 8 of the testing depth range to create a characteristic defect.

[0046] Furthermore, the method for obtaining the DAC curve for quantitative evaluation of end-face defects in step S2 is as follows: The upper end face of the end-face inspection comparison block is detected using an end-face phased array probe, with a step L... s A radial scan is performed to sequentially obtain the phased array detection amplitude P of n defects at different depths. Ls-n The data is recorded and stored. Based on the amplitude of the ultrasonic phased array detection of the defect in the test block compared with the end face detection, a polynomial fitting is performed to obtain the quantitative evaluation curve DAC of the upper end face defect. au The same method was used to obtain the DAC (Defect Quantitative Evaluation Curve) for side end face defects. as In practice, the depth detection range of different end faces is considered, such as... Figure 2 As shown, polynomial fitting was performed on the ultrasonic phased array detection amplitude of the end face comparison test block defects to obtain the DAC curves for quantitative evaluation of end face defects at different detection depths.

[0047] Furthermore, such as Figure 5 As shown, the method for obtaining the DAC curve for quantitative evaluation of toroidal defects in step S2 is as follows: A toroidal phased array probe is used to detect the toroidal detection comparison block. Starting from the effective boundary of the toroidal raceway arc circumferentially, the toroidal phased array probe rotates and scans around the center of the toroidal raceway arc with a step angle α, sequentially obtaining the phased array detection amplitude P of N defects at different depths. α-N Based on the amplitude values ​​of ultrasonic phased array detection of defects in the toroidal test block, polynomial fitting was performed to obtain N quantitative evaluation curves (DACs) for toroidal defects at different axial angles. bi Where i = 1, 2, ..., N. A quantitative evaluation curve for toroidal defects is fitted for each scanning angle to obtain data on the variation of defect amplitude with depth at each excitation aperture scanning line of the phased array probe.

[0048] For the step L during end face scanning sThe step angle α during toroidal scanning can be determined based on the dimensions of the end-face phased array probe and the toroidal phased array probe, respectively. As a preferred embodiment, the step angle L during end-face scanning... s The radial dimension of the optional phased array probe on the end face is between 1 / 3 and 1 / 5, so that the adjacent detection coverage areas overlap by 1 / 3 to 1 / 5. The step angle α during toroidal scanning should ensure that the detection coverage areas of the toroidal phased array probe overlap by 1 / 3 to 1 / 5 when two adjacent angles are measured, so that the detection range can cover the entire wind turbine bearing ring under test.

[0049] Furthermore, in step S3, associating each detection area with the corresponding comparison test block means that each detection area and the corresponding comparison test block of the wind turbine bearing ring under test use the same ultrasonic phased array probe, detection configuration file, and defect quantitative evaluation curve.

[0050] Furthermore, the test configuration file includes water layer height, emission aperture, and focusing depth, and the parameters of the test process configuration file are consistent with the test parameters of the comparison test block.

[0051] like Figure 6 As shown, the present invention also provides a quantitative detection system for ultrasonic phased array defects in wind turbine bearing rings, used to realize a quantitative detection method for ultrasonic phased array defects in wind turbine bearing rings. The system includes an open-top box 9 containing liquid ultrasonic coupling agent, a rotating worktable 11 at the bottom center of the open-top box 9, a three-jaw chuck 7 for clamping wind turbine bearing rings on the rotating worktable 11, an end-face scanning frame 4, and a ring-face scanning frame 8. An end-face ultrasonic phased array probe 5 is mounted on the end-face scanning frame 4, and a ring-face ultrasonic phased array probe 10 is mounted on the ring-face scanning frame 8. The end-face ultrasonic phased array probe 5 and the ring-face ultrasonic phased array probe 10 are connected to a computer 1 via an end-face ultrasonic phased array detector 2 and a ring-face ultrasonic phased array detector 3, respectively. Ultrasonic phased array software is installed on the computer 1.

[0052] Furthermore, the rotary table 11 is an electric worktable capable of making full circular rotations, and the three-jaw chuck 7 is a centering three-jaw chuck.

[0053] Furthermore, the end face scanning frame 4 and the toroidal scanning frame 8 have at least the axial and radial translational degrees of freedom of the worktable and the rotational degrees of freedom of the end face along the worktable axis.

[0054] As a specific embodiment, the method and system of the present invention are illustrated using the specific testing process of a certain type of wind turbine bearing ring component. The target of this embodiment is the slewing bearing ring component of the internal gear ring of a wind turbine bearing, made of 42CrMo4V material. Figure 7As shown, the ring has a maximum outer diameter of 2958 mm, an inner diameter of 2613 mm, a maximum detection depth of 301 mm, a step surface detection depth of 140 mm, a circumferential raceway, a concave radius of R = 27.5 mm, and water as the coupling agent.

[0055] Based on the material properties and cross-sectional geometry of the target wind turbine bearing ring, comparative test blocks for end-face inspection and ring-face inspection were fabricated. For example... Figure 8 As shown, for the end face inspection comparison test block, machining defects are located at 20mm intervals. According to the ultrasonic testing standard for forgings, the equivalent size of the machining defects is... The number of defects is n = 8. For example... Figure 9 As shown, the annular surface here is the concave surface of the circumferential raceway. For the comparison test block with the concave surface of the circumferential raceway, defects are machined at positions 5mm apart radially and 10° apart circumferentially. The equivalent size of the machined defects is... The number of defects is N=4.

[0056] The end-face inspection comparison block was placed in the upper-opening box 9, and the end-face comparison block was immersed in coupling agent. The end-face phased array probe 5 was used to inspect the comparison block from the upper and side ends respectively, and the depth, location, and maximum amplitude of the defects were recorded. The results are summarized in Table 1.

[0057] Table 1: Defect amplitude data at various locations within the end-face comparison test block

[0058] 20mm <![CDATA[P1]]> 40mm <![CDATA[P2]]> 60mm <![CDATA[P3]]> 80mm <![CDATA[P4]]> … … 300mm <![CDATA[P 15 ]]>

[0059] A concave surface comparison test block of the circumferential raceway was placed in the upper open box 9, and couplant was injected to immerse the test block to a suitable height. A toroidal phased array probe 10 was used to inspect the concave surface comparison test block of the circumferential raceway. The maximum amplitude of defects on each of the 17 scan lines was obtained by rotating the probe, with a step size of 2°, rotating from -17° at the leftmost end to 17° at the rightmost end. The defect amplitude and location data for each scan line were recorded and summarized in Table 2.

[0060] Table 2: Defect amplitude data at various locations in the raceway curved surface area

[0061]

[0062] like Figure 11 As shown, the quadratic polynomial fitting method was used to fit the data in Tables 1 and 2 to obtain the DAC curve for quantitative evaluation of end face defects and the DAC curve for quantitative evaluation of defects of each scan line in the concave area of ​​the circumferential raceway.

[0063] The target wind turbine bearing ring 6 is divided into inspection areas, and a scanning path is planned. Based on different end-face inspection depths, it is divided into two upper end-face inspection areas and two side end-face inspection areas, using the same inspection area configuration file. DAC curves are used to quantitatively evaluate end-face defects at different inspection depths. The entire end-face area is assigned to a single scanning path and scanned by the end-face phased array probe 5. The entire ring surface consists of two concave raceways with the same radius of curvature, which can be assigned to a single ring-shaped scanning path and scanned by the ring-shaped phased array probe 10.

[0064] The target wind turbine bearing ring 6 is immersed in the upper open housing 9, and couplant is injected to a suitable height to submerge the target wind turbine bearing ring 6. The end face phased array probe 5, using the same configuration file as the end face comparison test block, scans and detects the end face of the target wind turbine bearing ring 6 along the end face scanning path, and compares it with the corresponding defect quantitative evaluation DAC curve. If the defect echo amplitude exceeds the height of the DAC curve, it is determined that the defect size exceeds the calibrated size, and the defect location and size are recorded. The toroidal phased array probe 10, using the same configuration file as the circumferential raceway concave comparison test block, scans and detects the toroidal surface of the target wind turbine bearing ring 6 along the toroidal scanning path, and compares it with the corresponding defect quantitative evaluation DAC curve. If the defect echo amplitude exceeds the height of the DAC curve, it is determined that the defect size exceeds the calibrated size, and the defect location and size are recorded. The end face scanning and toroidal scanning are performed simultaneously.

[0065] The specific testing procedure for the target component of the wind turbine bearing internal gear ring slewing bearing ring in the embodiment is as follows: Figure 10 As shown.

[0066] In summary, the ultrasonic phased array defect quantitative detection method and system for wind turbine bearing rings of this invention utilizes the material properties and cross-sectional geometric features of the bearing rings to create end-face and ring-face test comparison blocks and obtain corresponding quantitative defect evaluation DAC curves. This enables full-coverage defect equivalent size determination across the end-face and ring-face areas of wind turbine bearing rings, effectively solving the problem of difficult quantitative evaluation of defects in large and complex ring components using ultrasonic phased array detection. The method offers high detection accuracy and is easily implemented for industrial automation detection and evaluation, making it of significant application value for automated industrial detection of wind turbine bearing rings using ultrasonic phased arrays.

[0067] It should be noted that, depending on the implementation needs, the various steps / components described in this application can be broken down into more steps / components, or two or more steps / components or parts of the operation of steps / components can be combined into new steps / components to achieve the purpose of this invention.

[0068] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for quantitative detection of defects in the ring components of wind turbine bearings using ultrasonic phased array, characterized in that, Includes the following steps: S1. Based on the material properties and cross-sectional geometric characteristics of the wind turbine bearing ring to be tested, prepare end face inspection comparison blocks and ring face inspection comparison blocks; S2. Select an end-face ultrasonic phased array probe to inspect the end-face comparison test block and form a quantitative evaluation of end-face defects. Curve; Select a toroidal ultrasonic phased array probe to test the toroidal comparison block, and form a quantitative evaluation of toroidal defects. curve; S3. Divide the test area according to the cross-sectional geometric characteristics of the wind turbine bearing ring to be tested, and associate each test area with the corresponding comparison test block; S4. Plan the scanning path. Based on the detection area divided in step S3, areas with similar geometric features are assigned to the same scanning path to form end face scanning path and toroidal scanning path. S5. Fix the wind turbine bearing ring to be tested onto the testing system, and immerse the wind turbine bearing ring under test in liquid ultrasonic coupling agent. According to the planned end face scanning path and ring face scanning path, the end face and ring face of the wind turbine bearing ring under test are sequentially tested through the corresponding ultrasonic phased array probes. The test results are compared with the corresponding defect quantitative evaluation DAC curve to determine whether the defect under test exceeds the calibrated defect size. If it exceeds the calibrated defect size, an automatic alarm is triggered and the defect location is recorded to achieve ultrasonic phased array linear focusing scanning imaging and quantitative detection of defect size for large rings with complex geometric features. In step S2, a quantitative evaluation of end-face defects is obtained. The method for obtaining the curve is as follows: An end-face phased array probe is used to detect the upper end face of the comparison test block, using a step-by-step approach. A radial scan is performed to sequentially obtain the phased array detection amplitudes of n defects at different depths. The data is recorded and stored. Based on the ultrasonic phased array detection amplitude of the test block defects compared with the end face detection, a polynomial fitting is performed to obtain the quantitative evaluation curve of the upper end face defects. ; The same method was used to obtain the quantitative evaluation curve of the side end face defects. ; In step S2, obtain a quantitative evaluation of the toroidal defect. The method for detecting curves is as follows: A toroidal phased array probe is used to detect the toroidal detection comparison block. Starting from the effective boundary of the toroidal raceway arc, the probe moves around the center of the toroidal raceway arc in steps of [missing information]. Rotational scanning is used to sequentially obtain the phased array detection amplitudes of N defects at different depths. Based on the amplitude values ​​of ultrasonic phased array detection of defects in the toroidal test block, polynomial fitting was performed to obtain N quantitative evaluation curves for toroidal defects at different axial angles. ,in .

2. The method for quantitative detection of defects in wind turbine bearing rings using ultrasonic phased array as described in claim 1, characterized in that, The method for preparing the end-face inspection comparison test block in step S1 is as follows: based on the maximum depth range of the end-face inspection of the wind turbine bearing ring to be tested. The length, width, and thickness are... The end faces of the comparison blocks are spaced at equal intervals in the length and width directions. d Processing n There are 1 defective transverse through-hole, where n = / d.

3. The method for quantitative detection of ultrasonic phased array defects in wind turbine bearing rings according to claim 1, characterized in that, The method for preparing the toroidal test comparison block in step S1 is as follows: based on the radius of curvature of the toroidal raceway of the wind turbine bearing ring. The detection depth H of the toroidal raceway arc region was determined by fabricating a 25mm thick toroidal comparison test block, combined with the detection angle range of the ultrasonic phased array probe in the toroidal region. Inside, N transverse through holes with defects are machined at equal intervals r along the radial arc of the annular raceway, among which... The N defective transverse through holes are at equal angles along the circumferential arc of the annular raceway. Distribution, among which radius of curvature Different toroidal raceway arcs were used to create different toroidal test comparison blocks.

4. The method for quantitative detection of defects in wind turbine bearing rings using ultrasonic phased array as described in claim 1, characterized in that, The association between each test area and the corresponding comparison test block in step S3 means that each test area and the corresponding comparison test block of the wind turbine bearing ring under test use the same ultrasonic phased array probe, test configuration file and defect quantitative evaluation curve.

5. The method for quantitative detection of ultrasonic phased array defects in wind turbine bearing rings according to claim 4, characterized in that, The detection configuration file includes water layer height, emission aperture, and focusing depth.

6. A quantitative detection system for ultrasonic phased array defects in wind turbine bearing rings, characterized in that, The method for quantitative detection of defects in wind turbine bearing ring components using ultrasonic phased array as described in claim 1 includes an open-top box containing liquid ultrasonic coupling agent, a rotating worktable at the bottom center of the box, a three-jaw chuck for clamping wind turbine bearing ring components on the rotating worktable, an end-face scanning frame and a toroidal scanning frame, an end-face ultrasonic phased array probe mounted on the end-face scanning frame, and a toroidal ultrasonic phased array probe mounted on the toroidal scanning frame. The end-face ultrasonic phased array probe and the toroidal ultrasonic phased array probe are respectively connected to a computer via an end-face ultrasonic phased array detector and a toroidal ultrasonic phased array detector, and ultrasonic phased array software is installed on the computer.

7. The system according to claim 6, characterized in that, The rotary table is an electric worktable capable of full-circumference rotation, and the three-jaw chuck is a centering three-jaw chuck.

8. The system according to claim 6, characterized in that, The end face scanning frame and the toroidal scanning frame have at least one degree of freedom for axial and radial translation of the worktable and one degree of freedom for rotation of the end along the worktable axis.

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