An ultrasonic testing method, a nondestructive testing device and a track block

Abstract

The application provides an ultrasonic detection method, a nondestructive flaw detection device and a track test block. The ultrasonic detection method comprises the following steps: scanning a track test block along a preset route, identifying structural features, and obtaining first data; obtaining track features according to the first data; scanning a workpiece to be detected along the preset route, identifying defect features, and obtaining second data; and calibrating the second data by using the track features. The ultrasonic detection method first scans the track test block, collects data of the structural features during the scanning, analyzes the actual motion track during the scanning along the preset route, and calibrates the second data by using the track features during the scanning of the workpiece to be detected, so that whether the scanned feature signal is a defect can be determined more accurately. The ultrasonic detection method is not affected by acceleration and fitting accuracy, is more suitable for precise workpieces to be detected, can more fully meet the demand of high-speed scanning, and is helpful to reduce the risk of misjudgment.

Description

Technical Field

[0001] This application relates to the field of ultrasonic testing, and in particular to an ultrasonic testing method, a non-destructive testing device, and a trajectory test block. Background Technology

[0002] Ultrasonic testing is often used for internal flaw detection in workpieces, such as inspecting the welding quality of welds. During the inspection process, the ultrasonic probe scans along the welding path and determines whether there is a defect at the current location based on the reflected signal.

[0003] If the ultrasonic probe's tracking is inaccurate, it becomes difficult to determine whether the detected characteristic signal originates from a defect in the weld or from structural features surrounding the weld, leading to misjudgments during the inspection process. Furthermore, as the inspection speed increases, the acceleration of the ultrasonic probe's motion continuously increases, further amplifying tracking deviations and increasing the risk of misjudgments.

[0004] While tracking accuracy can be improved by adjusting the motion using negative feedback, the required response speed increases accordingly during high-speed detection, making implementation more difficult. Furthermore, since ultrasonic probes are typically mounted on the spindle of a flexible robot, and the spindle's actual motion trajectory is fitted based on the weld seam trajectory, a deviation inevitably exists between the two, making it difficult to completely eliminate misjudgments. Summary of the Invention

[0005] This application aims to address at least one of the technical problems existing in the prior art. To this end, this application proposes an ultrasonic testing method, a non-destructive testing device, and a trajectory test block. The ultrasonic testing method helps to reduce the risk of misjudgment.

[0006] The ultrasonic testing method provided in this application includes scanning along a preset route on a trajectory test block to identify structural features and obtain first data; obtaining trajectory features based on the first data; scanning along the preset route on the workpiece to be inspected to identify defect features and obtain second data; and calibrating the second data using the trajectory features.

[0007] The ultrasonic testing method provided in this application has at least the following technical advantages: Before performing actual ultrasonic testing on the workpiece to be inspected, the ultrasonic testing method first scans the track block. By collecting data on structural features during the scan, the actual motion trajectory during scanning along a preset route can be analyzed, i.e., trajectory features are obtained. Thus, when scanning the workpiece to be inspected, the trajectory features can be used to calibrate the second data, thereby more accurately determining whether the scanned feature signal is a defect. The ultrasonic testing method does not require negative feedback adjustment of the ultrasonic testing motion, thus it is not affected by acceleration and fitting accuracy, making it more suitable for precision workpieces to be tested, and it can also more fully meet the needs of high-speed scanning. Therefore, the ultrasonic testing method helps to reduce the risk of misjudgment.

[0008] According to some embodiments of this application, an ultrasonic probe is used to identify the structural features, which are identified by shape.

[0009] According to some embodiments of this application, the structural feature includes a feature line extending along the preset route.

[0010] According to some embodiments of this application, the shape and size of the feature line vary along the preset route to characterize the current scanning position.

[0011] According to some embodiments of this application, the feature line is a feature groove, and the depth of the feature groove varies along the preset route according to a preset rule.

[0012] According to some embodiments of this application, the structural features include feature points spaced at intervals along the preset route, the feature points dividing the feature line into multiple segments to define different scanning intervals.

[0013] According to some embodiments of this application, the feature line includes a straight line segment and a curved segment, and the feature point is disposed at the connection between the straight line segment and the curved segment.

[0014] According to some embodiments of this application, the ultrasonic testing method further includes: constructing the structural features on the trajectory test block.

[0015] The trajectory test block provided in this application is used to implement the ultrasonic testing method provided in this application.

[0016] The non-destructive testing device provided in this application is used to implement the ultrasonic testing method provided in this application.

[0017] The trajectory test block and the non-destructive testing device provided in this application are used to implement the ultrasonic testing method provided in this application. Therefore, the trajectory test block and the non-destructive testing device have the beneficial effects provided by the ultrasonic testing method, which will not be elaborated here. Attached Figure Description

[0018] The accompanying drawings are used to provide a further understanding of the technical solutions disclosed in this application and constitute a part of the specification. They are used together with the embodiments disclosed in this application to explain the technical solutions of this application and do not constitute a limitation on the technical solutions disclosed in the application.

[0019] Figure 1 This is a schematic flowchart of an ultrasonic testing method according to some embodiments of this application;

[0020] Figure 2 This is a schematic flowchart of an ultrasonic testing method according to other embodiments of this application;

[0021] Figure 3 This is a schematic diagram of the structure of the trajectory test block used in some embodiments of this application;

[0022] Figure 4 Yes Figure 3 A schematic diagram showing the results of ultrasonic scanning of the trajectory test block in the embodiment;

[0023] Figure 5 These are schematic diagrams showing the results of ultrasonic scanning of the workpieces under test in some comparative examples of this application;

[0024] Figure 6 This is a schematic diagram showing the results of ultrasonic scanning of the workpiece under test in some embodiments of this application.

[0025] Figure label:

[0026] Trajectory block 100, feature line 110, feature point 120. Detailed Implementation

[0027] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0028] In the description of this application, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0029] In the description of this application, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0030] In the description of this application, unless otherwise expressly defined, terms such as "setup," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this application in conjunction with the specific content of the technical solution.

[0031] Ultrasonic testing is commonly used for flaw detection and quality inspection of workpieces. During the scanning process along a preset route, the ultrasonic probe detects characteristic signals caused by structural changes in the workpiece. These signals may originate from defects to be detected, or from normal structural features such as holes, grooves, steps, and cavities designed into the workpiece. If the actual route of the ultrasonic probe deviates from the preset route, normal structural features near the route may be misidentified as abnormal defects along the route, leading to misjudgments during the inspection process.

[0032] On the one hand, as the detection speed increases, the acceleration of the ultrasonic probe continuously increases, further amplifying the positional deviation of the ultrasonic probe during tracking; on the other hand, as the complexity of the workpiece increases, the distance between defects and structural features gradually decreases. Therefore, the risk of misjudgment further increases.

[0033] While tracking accuracy can be improved by adjusting the motion using negative feedback, the required response speed increases accordingly during high-speed detection, making implementation more difficult. Furthermore, since ultrasonic probes are typically mounted on the spindle of a flexible robot, and the spindle's actual motion trajectory is fitted based on the weld seam trajectory, a deviation inevitably exists between the two, making it difficult to completely eliminate misjudgments.

[0034] To this end, this application provides an ultrasonic testing method to reduce the risk of misjudgment. In addition, this application also provides a trajectory test block 100 for implementing the ultrasonic testing method and a non-destructive testing device.

[0035] Reference Figure 1 The ultrasonic testing method provided according to some embodiments of this application includes the following steps:

[0036] Step S210: Scan along the preset route on the trajectory test block to identify structural features and obtain the first data.

[0037] Understandably, the preset route is the theoretical path that the ultrasonic probe will take when scanning the workpiece, while structural features refer to the features set on the trajectory block that can be detected during scanning. Depending on the tools used for scanning, structural features can be designed into different types.

[0038] For example, in some embodiments, the structural features can be features such as shape and size (length, width, height) that can be detected by an ultrasonic probe. In this case, an ultrasonic probe can be used to scan the trajectory test block 100. Alternatively, in some embodiments, the structural features can also be features such as patterns and colors that can be detected by a camera. In this case, a camera can be used as a probe for scanning, and then the ultrasonic probe can be used to scan the workpiece to be inspected.

[0039] However, cameras can only acquire surface features of the trajectory test block. When the workpiece to be inspected and the preset route are complex, leading to corresponding complexity in the trajectory test block and structural features, the information obtained by the camera cannot meet the requirements of the ultrasonic testing method. Ultrasonic probes, on the other hand, can obtain more comprehensive initial data by combining various scanning modes such as A-scan and B-scan. Therefore, optionally, the same ultrasonic probe used for scanning the workpiece to be inspected can be used to scan the trajectory test block in the same configuration. In other words, in some embodiments, ultrasonic probes are used to identify structural features, which are then identified through shape recognition.

[0040] Figure 3 An exemplary embodiment of a trajectory test block 100 for implementing an ultrasonic testing method is shown, wherein simplified structural features are illustrated, with reference to... Figure 3 The structural features may include feature lines 110 extending along a preset route.

[0041] The shape of the feature line 110 differs from other surrounding structures, thus generating corresponding feature signals during ultrasound probe scanning. By summarizing the various feature signals generated during the scanning process, the first data can be obtained.

[0042] Understandably, feature line 110 can be constructed in different ways. Figure 3 In the illustrated embodiment, feature line 110 is a feature groove extending along a preset route. In other embodiments, feature line 110 may also be a feature ridge extending along a preset route.

[0043] For example, Figure 4 It shows the Figure 3 The ultrasound images obtained when the trajectory test block 100 in the embodiment is scanned are in Figure 3In the diagram, feature line 110 is divided into straight segments A, C, and E, and curved segments B and D. A, B, C, D, and E lie in the same plane and are connected sequentially. Using an ultrasound probe with a 20° incident angle, the obtained feature information is presented as follows: Figure 4 The image shows the characteristic signals generated by segments A, B, C, D, and E on the coordinate axes.

[0044] It should be pointed out that, Figure 3 This diagram is intended only to illustrate the trajectory block 100 used in the ultrasonic testing method. Therefore, the feature lines 110 have been simplified to some extent. For example, A, B, C, D, and E are all located on the same side of the surface of the trajectory block 100 and are all regular line segments. In reality, the segments of the feature lines 110 may be complex curves with intersecting lines, and may also be located on different surfaces of the trajectory block 100. This application does not impose any restrictions on this.

[0045] exist Figure 3 In this embodiment, the width and depth of the feature groove remain constant. Therefore, the probe can only calculate the distance between the current scanning position and the origin (in this case, the starting point of the feature groove), which will produce a certain error. The accumulation of errors will also increase the risk of misjudgment.

[0046] Therefore, optionally, in some embodiments, the shape and size of the feature line 110 vary along a preset route to characterize the current scanning position. In this case, the accurate coordinates of the scanning position can be calculated from the feature signal obtained by the probe scanning, further reducing the risk of misjudgment.

[0047] For example, when the feature line 110 is a feature groove, the depth of the feature groove can be designed to vary along a preset route according to a preset rule.

[0048] In addition, the accumulated error can be reduced by dividing the longer or more complex feature line 110 into multiple segments.

[0049] Therefore, optionally, in some embodiments, the structural features include feature points 120 spaced along a preset route, the feature points 120 dividing the feature line 110 into multiple segments to divide different scanning intervals.

[0050] For example, in Figure 3 In the illustrated embodiment, feature point 120 can be located at the junction of a straight line segment and a curved segment. Furthermore, feature point 120 can be a feature hole.

[0051] Structural features can also be adopted in other ways besides feature lines 110. Optionally, in some other possible embodiments, structural features can be designed as scale lines or feature points arranged at intervals along a preset route, as long as they can accurately represent the theoretical location of the preset route on the trajectory test block 100. This application does not limit this.

[0052] Step S220: Obtain trajectory features based on the first data.

[0053] In step S210, the probe (e.g., an ultrasonic probe) runs on the trajectory test block 100 along a preset route. Based on the structural features detected during the scanning process, the deviation between the theoretical route (i.e., the preset route) and the actual route of the ultrasonic probe can be analyzed, thereby obtaining the trajectory features.

[0054] It should be noted that trajectory features can be presented in different ways, as long as they contain the deviation information required by the ultrasonic testing method.

[0055] For example, in some embodiments, the trajectory features may be presented as a data table containing multiple sampling points, each of which records deviation information.

[0056] The deviation information may include coordinate deviation (the deviation between the actual detected position and the theoretical detected position), angle deviation (the deviation between the actual probe angle and the theoretical probe angle), distance deviation (the actual probe distance and the theoretical probe distance), etc. This application does not limit these deviations.

[0057] Specifically, in some embodiments, the starting point of the preset route can be used as the origin, and a sampling point can be set at certain step intervals. The feature signals generated when the actual scanning structure features are collected and recorded at each sampling point. Then, based on the shape and size of the trajectory test block, the feature signals that will theoretically be generated when scanning along the preset route can be calculated. By comparing and calculating the actual feature signals and the theoretical feature signals, the trajectory features of each sampling point can be obtained in the form of a data table.

[0058] Of course, the above example is only one possible way to construct a data table. Other rules can also be used to achieve the correspondence between sampling points in the theoretical route and the actual route, which will not be elaborated here.

[0059] In other embodiments, trajectory features can also be extracted from the first data through machine learning, in which case the trajectory features can be presented as a feature matrix in a convolutional neural network.

[0060] Step S230: Scan the workpiece to be inspected along a preset route to identify defect features and obtain second data.

[0061] Step S240: Calibrate the second data using trajectory features.

[0062] Before performing actual ultrasonic testing on the workpiece, the ultrasonic testing method first scans the trajectory block 100. By collecting data on structural features during the scan, the actual motion trajectory during scanning along a preset route can be analyzed, i.e., trajectory features are obtained. When scanning the workpiece, the trajectory features can be used to calibrate the second data, thereby more accurately determining whether the scanned feature signals are defects. The ultrasonic testing method does not require negative feedback adjustment of the ultrasonic testing motion, thus it is not affected by acceleration and fitting accuracy, making it more suitable for precision workpieces and better meeting the needs of high-speed scanning. Therefore, the ultrasonic testing method helps reduce the risk of misjudgment.

[0063] The trajectory test block 100 and non-destructive testing device provided in this application are used to implement the ultrasonic testing method, and therefore have the beneficial effects provided by the ultrasonic testing method, which will not be elaborated here.

[0064] It is understandable that a non-destructive testing device includes at least a spindle and an ultrasonic probe. The ultrasonic probe is mounted on the spindle, and the spindle drives the ultrasonic probe to move along a preset path, thereby completing the non-destructive testing of the workpiece.

[0065] Furthermore, the non-destructive testing device also includes a memory and a processor. The memory stores a computer program, and the processor executes the computer program to implement the ultrasonic testing method of this application. The processor is communicatively connected to the spindle and the ultrasonic probe, and is capable of receiving and processing information fed back from the ultrasonic probe.

[0066] In practical applications, production workshops often need to handle complex workpieces of various models. Therefore, the memory and processor can be configured as a cloud server to simultaneously process information from multiple spindles and ultrasonic probes. In this case, the trajectory test blocks 100 corresponding to different workpieces can be pre-scanned and arranged, and the corresponding trajectory features can be stored in the server. When inspecting the workpiece, the trajectory features can be retrieved from the server or changed according to the workpiece's model and specifications.

[0067] Optionally, refer to Figure 2 An ultrasonic testing method according to other embodiments of this application includes the following steps:

[0068] Step S310: Construct structural features on the trajectory test block 100.

[0069] Step S320: Scan along the preset route on the trajectory test block to identify structural features and obtain the first data.

[0070] Step S330: Obtain trajectory features based on the first data.

[0071] Step S340: Scan the workpiece to be inspected along a preset route to identify defect features and obtain second data.

[0072] Step S350: Calibrate the second data using trajectory features.

[0073] Figure 5 The comparison example shows the test results output when the workpiece to be inspected is ultrasonically scanned (20-degree incident angle) in this application. The comparison example does not use ultrasonic testing; instead, the workpiece to be inspected is directly scanned along a preset path. Figure 6 The diagram shows the test results output when using the ultrasonic testing method of this application, after calibrating the second data with the first data generated by the trajectory test block and then performing an ultrasonic scan (20-degree incident angle).

[0074] Reference Figure 5 and Figure 6 When scanning directly, it can be noticed that the detected trajectory has significant jitter, which can easily cause defects to be confused with nearby features. However, by using ultrasonic testing, the detected trajectory can be made more stable, reducing jitter and deviation, thereby reducing the risk of misjudgment.

[0075] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0076] In some alternative embodiments, the functions / operations mentioned in the block diagrams may not occur in the order shown in the operation diagrams. For example, depending on the functions / operations involved, two consecutively shown blocks may actually be executed substantially simultaneously, or the blocks may sometimes be executed in reverse order. Furthermore, the embodiments presented and described in the flowcharts of this application are provided by way of example to provide a more comprehensive understanding of the technology. The disclosed methods are not limited to the operations and logic flows presented herein. Alternative embodiments are contemplated in which the order of various operations is changed and sub-operations described as part of a larger operation are executed independently.

[0077] Although embodiments of this application have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the claims and their equivalents.

Claims

1. An ultrasonic testing method, characterized in that, include: Scan along a preset route on the trajectory block to identify structural features and obtain the first data; The structural features are identified using an ultrasound probe, and the structural features are identified by shape; the structural features include feature lines extending along the preset route; the structural features include feature points spaced at intervals along the preset route, and the feature points divide the feature lines into multiple segments to define different scanning intervals; The trajectory features are obtained based on the first data; Scan the workpiece to be inspected along the preset route to identify defect features and obtain second data. The second data is calibrated using the trajectory features.

2. The ultrasonic testing method according to claim 1, characterized in that, The shape and size of the feature line change along the preset route to represent the current scanning position.

3. The ultrasonic testing method according to claim 2, characterized in that, The feature line is a feature groove, and the depth of the feature groove varies along the preset route according to a preset rule.

4. The ultrasonic testing method according to claim 1, characterized in that, The feature line includes a straight line segment and a curved segment, and the feature point is located at the connection between the straight line segment and the curved segment.

5. The ultrasonic testing method according to claim 1, characterized in that, The ultrasonic testing method further includes: constructing the structural features on the trajectory test block.

6. A non-destructive testing device, characterized in that, The non-destructive testing device is used to implement the ultrasonic testing method according to any one of claims 1 to 5. The non-destructive testing device includes a spindle, an ultrasonic probe, a memory, and a processor. The ultrasonic probe is mounted on the spindle, and the spindle drives the ultrasonic probe to move along the preset path. The memory stores a computer program, and the processor executes the computer program to implement the ultrasonic testing method. The processor is communicatively connected to the spindle and the ultrasonic probe to receive and process information fed back by the ultrasonic probe.

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