Composite insulator ultrasonic detection device and method

Abstract

According to the composite insulator ultrasonic detection device, a roller mechanism is installed in a water tank, the distance between a movable roller set and a fixed roller set is adjusted, composite insulator workpieces of different sizes and models can be adapted, meanwhile, a driving motor is used for driving a transmission shaft to rotate, and the ultrasonic detection efficiency is improved. A composite insulator workpiece can be driven to rotate by a set angle; the probe clamping mechanism can be driven to move relative to the roller mechanism and the composite insulator workpiece through the movement of the scanning mechanism in the X-axis direction, the Y-axis direction and the Z-axis direction which are perpendicular to one another, so that a probe can enter an umbrella skirt gap; the three probes are mounted on the probe mounting seat, and the distances among the three probes can be adjusted, so that the composite insulator detection device can be adapted to composite insulator workpieces with different umbrella skirt distances. The invention also provides a composite insulator ultrasonic detection method. The composite insulator ultrasonic detection device and the composite insulator ultrasonic detection method can realize ultrasonic nondestructive detection on the composite insulator workpiece, and have the advantage of high detection precision.

Description

Technical Field

[0001] The invention belongs to the technical field of nondestructive testing, and specifically relates to an ultrasonic testing device and method for composite insulators. Background Art

[0002] Composite insulators, also known as silicone rubber insulators, are widely used in high-voltage power transmission lines. They are characterized by light weight, small size, not easy to break, high tensile strength, and strong anti-pollution performance. However, due to defects such as bubbles and cracks inside, it is easy to cause defects such as cavities and cracks inside the insulator, which reduces the insulation performance, accelerates the aging and damage of the insulator, and increases the risk of failure of power transmission lines. Unlike porcelain and glass insulators, organic composite insulators are a new type of insulator with a composite structure, mainly composed of core rods, shed skirts, sheaths (or no sheaths), metal accessories, etc. Figure 1 As shown in the figure, the core rod structure consists of multiple layers, made of three materials: rubber, glass, and steel. Many disc-shaped sheds are evenly distributed within the length of the core rod.

[0003] Phased array ultrasonic nondestructive testing is a nondestructive testing technology that does not cause damage to the insulator workpiece. Through the propagation and reflection of ultrasonic waves inside the composite insulator, defects can be located and identified more accurately. It has been widely used in material testing, structural health monitoring, defect detection, etc., providing important support and guarantee for industrial production. However, due to the special skirt structure of composite insulators, it is necessary to manually set the movement points during the ultrasonic nondestructive testing process, resulting in high labor costs, limited accuracy, and low production efficiency. In actual production, it cannot meet the modern production requirements of high automation and high efficiency. Summary of the invention

[0004] In view of this, an object of the present invention is to provide a composite insulator ultrasonic detection device and method, which can realize ultrasonic non-destructive detection of composite insulator workpieces and has the advantage of high detection accuracy.

[0005] In order to achieve the above object, the present invention provides the following technical solutions:

[0006] The present invention firstly proposes an ultrasonic detection device for composite insulators, comprising a device base, a water tank and a scanning mechanism are installed on the device base, a roller mechanism for driving the composite insulator workpiece to rotate is installed in the water tank, and a probe clamping mechanism located above the water tank is installed on the scanning mechanism;

[0007] The scanning mechanism comprises a Y-axis moving track and a Y-axis slide slidably matched with the Y-axis moving track, an X-axis moving track and an X-axis slide slidably matched with the X-axis moving track are installed on the Y-axis slide, and a Z-axis moving track and a Z-axis slide slidably matched with the Z-axis moving track are installed on the X slide; the Y-axis moving track is fixedly installed on the equipment base, and the X-axis, Y-axis and Z-axis are perpendicular to each other;

[0008] The roller mechanism comprises a fixed roller group, a movable roller group, a fixed slide and a driving mechanism; the fixed slide is fixedly installed in the water tank; the fixed roller group comprises a fixed roller frame, two first rollers arranged opposite to each other are installed on the fixed roller frame, and the fixed roller frame is fixedly installed on one end of the fixed slide; a fixed slide is provided on the fixed slide, the movable roller group comprises a movable roller frame, two second rollers arranged opposite to each other are installed on the movable roller frame, and the movable roller frame slidably cooperates with the fixed slide rail; a transmission shaft is provided between the movable roller frame and the fixed roller frame, and the transmission shaft is used to drive the two first rollers and the two second rollers to rotate synchronously in the same direction; the driving mechanism comprises a driving motor, and the driving motor is connected to the transmission shaft in transmission manner;

[0009] The probe clamping mechanism includes a fixed beam, a probe mounting seat is installed on the fixed beam, three probes are installed on the probe mounting seat, namely a first probe, a second probe and a third probe, and the second probe is located between the first probe and the third probe; the probe mounting seat is provided with a first spacing adjustment mechanism for adjusting the spacing of the first probe relative to the second probe and a first locking knob for locking the position of the first probe; the probe mounting seat is provided with a third spacing adjustment mechanism for adjusting the spacing of the third probe relative to the second probe and a third locking knob for locking the position of the third probe; the fixed beam is installed on the Z-axis slide.

[0010] Furthermore, the water tank includes a main water tank and two auxiliary water tanks located at both ends of the main water tank. The main water tank is installed on the equipment base, and the two auxiliary water tanks are respectively installed at both ends of the main water tank.

[0011] The present invention also proposes a composite insulator ultrasonic detection method, using the composite insulator ultrasonic detection device as described above, the method comprises the following steps:

[0012] Step 1: Determine the basic parameters of the workpiece

[0013] Determine the total length L and shaft diameter D of the composite insulator workpiece axis 、Number of shed skirts shed , shed spacing P and maximum shed diameter D max ;

[0014] Step 2: Calibrate the workpiece reference point

[0015] Install the composite insulator workpiece on the roller mechanism, locate the probe to the first gap between the sheds, and record the coordinates of each axis of the reference point;

[0016] Step 3: Calculate the scan point table

[0017] There are three probes installed on the probe mounting base. The three probes are used to scan the three shed gap positions simultaneously. The number of scans is:

[0018]

[0019] Among them, N scan N is the total number of scans for a single composite insulator workpiece; shed is the number of sheds of the composite insulator workpiece; is the ceiling rounding function;

[0020] Based on the obtained reference point coordinates (X1, Z1), the X-axis coordinate of the Nth scan point is N for:

[0021] X N =X1+(N-1)×3×P

[0022] Where: P is the distance between shed skirts;

[0023] The Z-axis coordinate Z of the Nth scanning point N is equal to Z1;

[0024] Step 4: Perform the scan

[0025] Connect the ultrasound software to the positive motion control card, and realize the control of the imaging and automated detection process based on the position information by calling the positive motion control card interface; including the following steps:

[0026] 41) The ultrasonic software sends the basic parameters and reference point coordinates of the composite insulator workpiece to the positive motion control card and starts the scanning process;

[0027] 42) The X-axis slide and the Z-axis slide move to the waiting position;

[0028] 43) Generate a scanning point table according to the basic parameters of the composite insulator workpiece and the reference point coordinates;

[0029] 44) According to the scanning point coordinates, after the X-axis slide is moved to the specified X-coordinate position, the probe is pressed down to the specified Z-coordinate position by moving the Z-axis slide, and a fixed water layer distance is maintained from the workpiece surface;

[0030] 45) Use the roller mechanism to drive the composite insulator workpiece to rotate one circle to complete the scanning action of one point;

[0031] 46) Using ultrasound software to record and store the ultrasound data collected by the three probes in real time;

[0032] 47) After scanning a point, the Z-axis slide moves upward, driving the probe away from the workpiece surface and avoiding the shed structure, and the Z-axis slide is lifted upward to a height higher than the maximum radius of the shed.

[0033] 48) Loop through steps 44)-47) until all points have been scanned and all the scanning processes of a single composite insulator workpiece have been completed, and the X-axis slide, Y-axis slide and Z-axis slide return to zero position.

[0034] Step 5: Stitching images

[0035] During the scanning process, each time a scanning process of a scanning point is started, the positive motion control card will send a signal to the ultrasonic software. After receiving the signal, the ultrasonic software will draw a dividing line at the current scanning axis position and splice it with the scanning images of other shed gaps.

[0036] Further, in step 45), a length encoder is installed in the roller mechanism, and the resolution of the length encoder is E. axis The converted rotation length of the roller is:

[0037]

[0038] Wherein: LR is the rotation length of the roller.

[0039] Furthermore, in step 5, the shed gap corresponding to the scanned image is marked below the dividing line. Then, assuming that in the Mth scan, the marked data below the scanned image obtained by the nth probe scan is:

[0040] S nM =n+3×M

[0041] Where: S nM It is the annotation data below the scan image obtained by the nth probe in the Mth scan.

[0042] The beneficial effects of the present invention are:

[0043] The composite insulator ultrasonic detection device of the present invention is provided with a water tank and a scanning mechanism installed on the equipment base. During the scanning process, water can be filled in the water tank to detect the composite insulator workpiece by using a water immersion phased array pulse echo method; by installing a roller mechanism in the water tank, by adjusting the spacing between a movable roller group and a fixed roller group, the composite insulator workpiece of different sizes and models can be adapted; at the same time, by driving a transmission shaft to rotate using a driving motor, two first rollers and two second rollers can be driven to rotate synchronously in the same direction, so that the composite insulator workpiece can be driven to rotate a set angle; by moving the scanning mechanism in mutually perpendicular X-axis, Y-axis and Z-axis directions, the probe clamping mechanism can be driven to move relative to the roller mechanism and the composite insulator workpiece, so that the probe can enter the shed gap to detect the core rod; by installing three probes on the probe mounting seat and making the spacing between the three probes adjustable, the composite insulator workpiece with different shed spacings can be adapted; in summary, the composite insulator ultrasonic detection device of the present invention can realize ultrasonic non-destructive detection of the composite insulator workpiece, and has the advantage of high detection accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] In order to make the purpose, technical solution and beneficial effects of the present invention clearer, the present invention provides the following drawings for illustration:

[0045] Figure 1 It is a structural schematic diagram of a composite insulator workpiece;

[0046] Figure 2 It is a structural schematic diagram of an embodiment of a composite insulator ultrasonic detection device of the present invention;

[0047] Figure 3 It is a structural diagram of the water tank;

[0048] Figure 4 It is a schematic diagram of the structure of the scanning mechanism;

[0049] Figure 5 It is a structural schematic diagram of the roller mechanism;

[0050] Figure 6 It is a structural schematic diagram of the probe clamping mechanism;

[0051] Figure 7 It is a flow chart of an embodiment of the composite insulator ultrasonic detection method of the present invention;

[0052] Figure 8 It is the basic parameters of the workpiece counted in the ultrasonic software;

[0053] Fig. 9 This is a mosaic of scanned images.

[0054] Description of reference numerals:

[0055] 10- Equipment base;

[0056] 20-sink; 21-main sink; 22-auxiliary sink;

[0057] 30- scanning mechanism; 31- Y-axis moving track; 32- Y-axis slide 32; 33- X-axis moving track; 34- Z-axis moving track 34; 35- Z-axis slide 35;

[0058] 40-roller mechanism; 41-fixed slide; 42-fixed roller frame; 43-first roller; 44-fixed slide rail; 45-movable roller frame; 46-second roller; 47-transmission shaft; 48-drive motor; 49-belt transmission mechanism;

[0059] 50-probe clamping mechanism; 51-fixed beam; 52-probe mounting seat; 53-first probe; 54-second probe; 55-third probe; 56-first spacing adjustment mechanism; 57-first locking knob; 58-third spacing adjustment mechanism; 59-third locking knob. DETAILED DESCRIPTION

[0060] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments so that those skilled in the art can better understand the present invention and implement it, but the embodiments are not intended to limit the present invention.

[0061] like Figure 2 As shown, the composite insulator ultrasonic detection device of this embodiment includes an equipment base 10, on which a water tank 20 and a scanning mechanism 30 are installed. A roller mechanism 40 for driving the composite insulator workpiece to rotate is installed in the water tank 20, and a probe clamping mechanism 50 located above the water tank 20 is installed on the scanning mechanism 30.

[0062] like Figure 3 As shown, the water tank 20 of this embodiment includes a main water tank 21 and two auxiliary water tanks 22 located at both ends of the main water tank 21. The main water tank 21 is installed on the equipment base 10, and the two auxiliary water tanks 22 are installed at both ends of the main water tank 21. In this way, by installing the auxiliary water tanks 22 on both sides of the main water tank 21, the length of the water tank 20 can be increased to meet the inspection requirements of composite insulator workpieces of different lengths. At the same time, since composite insulator workpieces of different lengths need to be adapted, the length of the water tank 20 needs to be set long enough. In this way, the water tank 20 is divided into a main water tank 21 and two auxiliary water tanks 22, which can shorten the length of the main water tank 21 and the auxiliary water tank 22 for easy carrying, and can meet the use requirements of outdoor inspection operations.

[0063] like Figure 4As shown, in this embodiment, the scanning mechanism 30 includes a Y-axis moving track 31 and a Y-axis slide 32 that slides with the Y-axis moving track, an X-axis moving track 33 and an X-axis slide that slides with the X-axis moving track 33 are installed on the Y-axis slide 32, and a Z-axis moving track 34 and a Z-axis slide 35 that slides with the Z-axis moving track 34 are installed on the X-axis slide; the Y-axis moving track 31 is fixedly installed on the equipment base 10, and the X-axis, Y-axis and Z-axis are perpendicular to each other. In this way, the position of the Z-axis slide 35 relative to the water tank 20 can be adjusted by moving in the mutually perpendicular X-axis, Y-axis and Z-axis directions.

[0064] like Figure 5 As shown, in this embodiment, the roller mechanism 40 includes a fixed roller group, a mobile roller group, a fixed slide 41 and a driving mechanism. Specifically, the fixed slide 41 is fixedly installed in the water tank 20. The fixed roller group includes a fixed roller frame 42, on which two first rollers 43 arranged opposite to each other are installed, and the fixed roller frame 42 is fixedly installed at one end of the fixed slide 41. The fixed slide 41 is provided with a fixed slide rail 44, and the mobile roller group includes a mobile roller frame 45, on which two second rollers 46 arranged opposite to each other are installed, and the mobile roller frame 45 and the fixed slide rail 44 are slidably matched. In this embodiment, a transmission shaft 47 is provided between the movable roller frame 45 and the fixed roller frame 42, and the transmission shaft 47 is used to drive the two first rollers 43 and the two second rollers 46 to rotate synchronously in the same direction. In this way, the composite insulator workpiece is installed between the two first rollers 43 and the two second rollers 46, and the two first rollers 43 and the two second rollers 46 can be used to drive the composite insulator workpiece to rotate in a set direction by a set angle. The driving mechanism of this embodiment includes a driving motor 48, and the driving motor 48 is connected to the transmission shaft 47. In this embodiment, the driving motor 48 and the transmission shaft 47 are connected to each other by a belt transmission mechanism 49.

[0065] like Figure 6As shown, the probe clamping mechanism 50 of this embodiment includes a fixed beam 51, on which a probe mounting seat 52 is mounted, and on which three probes are mounted, namely, a first probe 53, a second probe 54 and a third probe 55, wherein the second probe 54 is located between the first probe 53 and the third probe 55. The probe mounting seat 52 of this embodiment is provided with a first spacing adjustment mechanism 56 for adjusting the spacing between the first probe 53 and the second probe 54, and a first locking knob 57 for locking the position of the first probe 53. Similarly, the probe mounting seat 52 of this embodiment is provided with a third spacing adjustment mechanism 58 for adjusting the spacing between the third probe 55 and the second probe 54, and a third locking knob 59 for locking the position of the third probe 55. The fixed beam 51 of this embodiment is mounted on the Z-axis slide 35, that is, the probe clamping mechanism 50 and the Z-axis slide 35 move synchronously relative to the water tank 20 and the composite insulator workpiece mounted on the roller mechanism 40.

[0066] The composite insulator ultrasonic detection device of the present embodiment installs a water tank 20 and a scanning mechanism 30 on the equipment base 10. During the scanning process, water can be filled in the water tank 20 to detect the composite insulator workpiece using a water immersion phased array pulse echo method; by installing a roller mechanism 40 in the water tank 20 and adjusting the spacing between the movable roller group and the fixed roller group, composite insulator workpieces of different sizes and models can be adapted. At the same time, the drive motor 48 is used to drive the transmission shaft 47 to rotate, so that the two first rollers 43 and the two second rollers 46 can be driven to rotate synchronously in the same direction, so that the composite insulator workpiece can be driven to rotate a set angle. By moving the scanning mechanism 30 in mutually perpendicular X-axis, Y-axis and Z-axis directions, the probe clamping mechanism 50 can be driven to move relative to the roller mechanism 40 and the composite insulator workpiece, so that the probe can enter the shed gap to detect the core rod; by installing three probes on the probe mounting seat 52 and making the spacing between the three probes adjustable, composite insulator workpieces with different shed spacings can be adapted; in summary, the composite insulator ultrasonic detection device of this embodiment can realize ultrasonic non-destructive detection of the composite insulator workpiece, and has the advantage of high detection accuracy.

[0067] The specific implementation of the composite insulator ultrasonic detection method of the present invention is described in detail below in conjunction with the above composite insulator ultrasonic detection device.

[0068] like Figure 1As shown in the figure, the composite insulator workpiece is mainly composed of a core rod and a shed. The core rod is a uniform circular tubular structure without obstacles such as protrusions or depressions, and the coupling effect of the probe is good. The shed is a disc-shaped structure of varying sizes, evenly distributed along the length of the core rod. In order to meet the coverage scan of the core rod of the insulator, and considering the special structure of the shed, during the scanning process, the probe needs to be lifted up to skip the shed structure, penetrate through the gap between the sheds, and perform a coverage scan on the core rod.

[0069] Specifically, in this embodiment, in order to meet the defect detection in the rubber layer and the glass layer in the composite insulator workpiece, and considering the shed structure of the composite insulator workpiece, the detection area is finally defined as the gap between the sheds (hereinafter referred to as "shed gap"). The system of this embodiment adopts the water immersion phased array pulse echo method for detection. The probe is placed in the shed gap, and the core rod position directly below the probe is covered and scanned through the deflection and focusing of the phased array probe. At the same time, the core rod is placed flat on the roller mechanism 40, and the rotation of the roller mechanism 40 drives the entire composite insulator workpiece to rotate in the circumferential direction. One rotation completes a full scan of one point of the core rod. In the same way, the probe is placed in each shed gap in turn to cover and scan the entire core rod.

[0070] Specifically, Figure 7 As shown, the composite insulator ultrasonic detection method of this embodiment includes the following steps.

[0071] Step 1: Determine the basic parameters of the workpiece

[0072] Specifically, for composite insulator workpieces of different specifications, the points of the phased array ultrasonic scanning path are different. For the selection of the ultrasonic scanning path, the following factors of the composite insulator workpiece need to be considered, such as Figure 8 shown.

[0073] Total length L: the total length of the composite insulator workpiece. In this embodiment, the total length of the composite insulator workpiece is 1200.00 mm.

[0074] Shaft diameter D axis : The core rod diameter of the composite insulator workpiece is used to calculate the length of movement required for the composite insulator workpiece to rotate one circle, which affects the scanning length in the circumferential direction. In this embodiment, the shaft diameter D axis It is 48.50mm.

[0075] Number of sheds N shed: The number of sheds of the composite insulator workpiece. The area between two adjacent sheds is the detectable area of ​​the phased array probe. The probe is moved and placed in the shed gap between the sheds to detect defects in the rubber layer and the glass layer below the shed gap. The number of sheds affects the number of scans required for the complete coverage scan of the composite insulator workpiece. In this embodiment, the number of sheds N shed There are 26 of them.

[0076] Shed spacing P: The shed spacing of the composite insulator workpiece affects the spacing between adjacent probes in the probe clamping mechanism 50 and the accuracy of calculation of each scanning point in path planning. In this embodiment, the shed spacing P is 27.00 mm.

[0077] Maximum shed diameter D max : That is, the maximum diameter of the shed of the composite insulator workpiece. When the probe moves between the sheds, it is necessary to lift the probe to a safe position to avoid collision with the shed in the Z-axis direction when the probe moves in the X-axis direction, thereby damaging the probe. Determining the maximum shed diameter can help better select a safe path and improve the safety and stability of the equipment.

[0078] Step 2: Calibrate the workpiece reference point

[0079] Since the composite insulator workpiece needs to be manually loaded, the placement of the composite insulator workpiece may be deviated, which may easily cause the overall offset of the subsequent movement points, thereby causing the probe to collide with the umbrella skirt during the movement. In order to ensure the accuracy of the calculation of the path movement points, it is necessary to calibrate the initial point, that is, the reference point of the workpiece. Specifically, after the composite insulator workpiece is installed on the roller mechanism 40, the probe is positioned at the first gap position between the umbrella skirts, and the axis coordinates of the reference point are recorded. In this way, the reference point coordinates can be substituted into the path planning calculation formula of step three to update the motion path table.

[0080] In this embodiment, the X-axis is moved to the gap between the first shed skirts, and the probe is moved downward to the appropriate water layer position according to the ultrasonic effect, and the water layer distance is kept at about 15 mm during the measurement process. The ultrasonic software obtains the coordinate information of the current X-axis and Z-axis and displays that the X-axis coordinate is 0.000 and the Z-axis coordinate is 127.875. After confirmation, the ultrasonic software records the current probe position coordinates as the reference point coordinates to recalculate and update the scan point table.

[0081] Step 3: Calculate the scan point table

[0082] After determining the workpiece parameters and workpiece reference points, it is particularly important to use these parameters to calculate the motion path. The composite insulator ultrasonic detection device of this embodiment carries three probes at a time. In the probe clamping mechanism 50, the spacing between the probes is adjusted to match the average gap between the umbrella leaves, so that it can just penetrate into the gaps of three adjacent umbrella leaves at the same time, and complete the scanning work of three positions to be inspected at the same time, which greatly reduces the number of required scans, shortens the overall scanning time of the workpiece, and greatly improves the scanning efficiency. Three probes are installed on the probe mounting seat 52. The three probes are used to scan the three umbrella skirt gap positions at the same time. The number of scans is:

[0083]

[0084] Among them, N scan N is the total number of scans for a single composite insulator workpiece; shed is the number of sheds of the composite insulator workpiece; is a round-up function. Since the number of umbrella pages is 26, the calculation requires a total of 9 scans.

[0085] Based on the obtained reference point coordinates (X1, Z1), the X-axis coordinate of the Nth scan point is N for:

[0086] X N =X1+(N-1)×3×P

[0087] Wherein: P is the shed spacing. In this embodiment, the shed spacing P is 27.00 mm.

[0088] Since the core rod diameter is uniform, the depth of the probe is basically the same. Therefore, the Z-axis coordinate Z of the Nth scanning point is N Equal to Z1.

[0089] In this way, the ultrasonic scanning path of a single composite insulator workpiece is planned and the coordinate table of all scanning points is obtained, as shown in Table 1:

[0090] Table 1 Scanning point coordinates

[0091] Scan points X-axis coordinate Z-axis coordinate 1 0 127.875 2 81 127.875 3 162 127.875 4 243 127.875 5 324 127.875 6 405 127.875 7 486 127.875 8 567 127.875 9 648 127.875

[0092] Step 4: Perform the scan

[0093] The ultrasound software is connected to the positive motion control card, and the imaging based on the position information and the control of the automatic detection process are realized by calling the positive motion control card interface, and the system performs a complete scanning operation. Specifically, in this embodiment, performing a complete scanning operation includes the following steps.

[0094] 41) The ultrasonic software sends the basic parameters and reference point coordinates of the composite insulator workpiece to the positive motion control card and starts the scanning process. Specifically, in this embodiment, the total length of the workpiece L = 1200.00 mm, the workpiece shaft diameter D axis =48.50mm, number of leaves N shed =26, umbrella leaf spacing P = 27.00mm, maximum umbrella skirt diameter D max =200.00mm, X1=0.00, Z1=127.875.

[0095] 42) The X-axis slide and the Z-axis slide move to the waiting position. Specifically, the waiting position is pre-set, and the Z-axis slide 35 can be moved to a reasonable, safe and convenient position. On the one hand, it can avoid the collision between the workpiece and the probe during the manual loading and unloading process; on the other hand, it avoids the loading and unloading process, where the zero point and the scanning starting point may be far apart, and more waiting time is consumed in the middle.

[0096] 43) Generate a scanning point table based on the basic parameters of the composite insulator workpiece and the reference point coordinates.

[0097] 44) According to the scanning point coordinates, after the X-axis slide is moved to the specified X-coordinate position, the probe is pressed down to the specified Z-coordinate position through the movement of the Z-axis slide, and a fixed water layer distance is maintained from the workpiece surface.

[0098] 45) The roller mechanism 40 is used to drive the composite insulator workpiece to rotate one circle to complete a point scanning action. In this embodiment, a length encoder is installed in the roller mechanism 40, and the resolution of the length encoder is E. axis The converted rotation length of the roller is:

[0099]

[0100] Wherein: LR is the rotation length of the roller. In this embodiment, according to the shaft diameter D axis The calculated rotation length of the roller is LR = 104.60 mm

[0101] 46) Use ultrasound software to record and store the ultrasound data collected by the three probes in real time.

[0102] 47) After scanning a point, the Z-axis slide moves upward, driving the probe away from the workpiece surface and avoiding the shed structure, and the Z-axis slide is lifted upward to a height higher than the maximum radius of the shed. In this embodiment, the lifting height in the Z-axis direction is 100.00 mm higher than the maximum radius of the shed.

[0103] 48) Loop through steps 44)-47) until all points have been scanned and all the scanning processes of a single composite insulator workpiece have been completed, and the X-axis slide, Y-axis slide and Z-axis slide return to zero position.

[0104] Step 5: Stitching images

[0105] Since one scan contains ultrasonic images of multiple points, the ultrasonic software needs to clearly and intuitively distinguish the image of each part so that the operator can locate the specific position of the defect on the workpiece.

[0106] During the scanning process, when the scanning process of a scanning point is started each time, the positive motion control card will send a signal to the ultrasonic software. After receiving the signal, the ultrasonic software will draw a dividing line at the current scanning axis position and splice the scanning images of other shed gaps, such as Fig. 9 shown.

[0107] Specifically, the shed gap corresponding to the scanned image is marked below the dividing line. In this embodiment, it is assumed that in the Mth scan, the marked data below the scanned image obtained by the nth probe scan is:

[0108] S nM =n+3×M

[0109] Where: S nM It is the annotation data below the scan image obtained by the nth probe in the Mth scan.

[0110] The dividing lines and subscripts of each shed gap are drawn in sequence and displayed on the ultrasonic scanning image for easy identification by the operator.

[0111] The above-described embodiments are only preferred embodiments for fully illustrating the present invention, and the protection scope of the present invention is not limited thereto. Equivalent substitutions or changes made by those skilled in the art based on the present invention are within the protection scope of the present invention. The protection scope of the present invention shall be subject to the claims.

Claims

1. A composite insulator ultrasonic detection device, characterized in that: It comprises an equipment base, a water tank and a scanning mechanism are installed on the equipment base, a roller mechanism for driving the composite insulator workpiece to rotate is installed in the water tank, and a probe clamping mechanism located above the water tank is installed on the scanning mechanism; The scanning mechanism comprises a Y-axis moving track and a Y-axis slide slidably matched with the Y-axis moving track, an X-axis moving track and an X-axis slide slidably matched with the X-axis moving track are installed on the Y-axis slide, and a Z-axis moving track and a Z-axis slide slidably matched with the Z-axis moving track are installed on the X slide; the Y-axis moving track is fixedly installed on the equipment base, and the X-axis, Y-axis and Z-axis are perpendicular to each other; The roller mechanism comprises a fixed roller group, a movable roller group, a fixed slide and a driving mechanism; the fixed slide is fixedly installed in the water tank; the fixed roller group comprises a fixed roller frame, two first rollers arranged opposite to each other are installed on the fixed roller frame, and the fixed roller frame is fixedly installed on one end of the fixed slide; a fixed slide is provided on the fixed slide, the movable roller group comprises a movable roller frame, two second rollers arranged opposite to each other are installed on the movable roller frame, and the movable roller frame slidably cooperates with the fixed slide rail; a transmission shaft is provided between the movable roller frame and the fixed roller frame, and the transmission shaft is used to drive the two first rollers and the two second rollers to rotate synchronously in the same direction; the driving mechanism comprises a driving motor, and the driving motor is connected to the transmission shaft in transmission manner; The probe clamping mechanism includes a fixed beam, a probe mounting seat is installed on the fixed beam, three probes are installed on the probe mounting seat, namely a first probe, a second probe and a third probe, and the second probe is located between the first probe and the third probe; the probe mounting seat is provided with a first spacing adjustment mechanism for adjusting the spacing of the first probe relative to the second probe and a first locking knob for locking the position of the first probe; the probe mounting seat is provided with a third spacing adjustment mechanism for adjusting the spacing of the third probe relative to the second probe and a third locking knob for locking the position of the third probe; the fixed beam is installed on the Z-axis slide.

2. The composite insulator ultrasonic detection device according to claim 1, characterized in that: The water tank comprises a main water tank and two auxiliary water tanks located at both ends of the main water tank. The main water tank is installed on the equipment base, and the two auxiliary water tanks are respectively installed at both ends of the main water tank.

3. A composite insulator ultrasonic detection method, characterized in that: Using the composite insulator ultrasonic detection device as claimed in claim 1 or 2, the method comprises the following steps: Step 1: Determine the basic parameters of the workpiece Determine the total length L and shaft diameter D of the composite insulator workpiece axis 、Number of shed skirts shed , shed spacing P and maximum shed diameter D max ; Step 2: Calibrate the workpiece reference point Install the composite insulator workpiece on the roller mechanism, locate the probe to the first gap between the sheds, and record the coordinates of each axis of the reference point; Step 3: Calculate the scan point table There are three probes installed on the probe mounting base. The three probes are used to scan the three shed gap positions simultaneously. The number of scans is: N scan =[(N shed ―1)÷3] Among them, N scan N is the total number of scans for a single composite insulator workpiece; shed is the number of sheds of the composite insulator workpiece; is the ceiling rounding function; Based on the obtained reference point coordinates (X1, Z1), the X-axis coordinate of the Nth scan point is N for: X N =X1+(N―1)×3×P Where: P is the distance between shed skirts; The Z-axis coordinate Z of the Nth scanning point N is equal to Z1; Step 4: Perform the scan Connect the ultrasound software to the positive motion control card, and realize the control of the imaging and automated detection process based on the position information by calling the positive motion control card interface; including the following steps: 41) The ultrasonic software sends the basic parameters and reference point coordinates of the composite insulator workpiece to the positive motion control card and starts the scanning process; 42) The X-axis slide and the Z-axis slide move to the waiting position; 43) Generate a scanning point table according to the basic parameters of the composite insulator workpiece and the reference point coordinates; 44) According to the scanning point coordinates, after the X-axis slide is moved to the specified X-coordinate position, the probe is pressed down to the specified Z-coordinate position by moving the Z-axis slide, and a fixed water layer distance is maintained from the workpiece surface; 45) Use the roller mechanism to drive the composite insulator workpiece to rotate one circle to complete the scanning action of one point; 46) Using ultrasound software to record and store the ultrasound data collected by the three probes in real time; 47) After scanning a point, the Z-axis slide moves upward, driving the probe away from the workpiece surface and avoiding the shed structure, and the Z-axis slide is lifted upward to a height higher than the maximum radius of the shed. 48) looping through steps 44)-47) until all points are scanned and all scanning processes of a single composite insulator workpiece are completed, and the X-axis slide, the Y-axis slide, and the Z-axis slide return to zero position; Step 5: Stitching images During the scanning process, each time a scanning process of a scanning point is started, the positive motion control card will send a signal to the ultrasonic software. After receiving the signal, the ultrasonic software will draw a dividing line at the current scanning axis position and splice it with the scanning images of other shed gaps.

4. The composite insulator ultrasonic testing method according to claim 3, characterized in that: In the step 45), a length encoder is installed in the roller mechanism, and the resolution of the length encoder is E. axis The converted rotation length of the roller is: Wherein: LR is the rotation length of the roller.

5. The composite insulator ultrasonic testing method according to claim 3, characterized in that: In step 5, the shed gap corresponding to the scanned image is marked below the dividing line. Then, assuming that in the Mth scan, the marked data below the scanned image obtained by the nth probe scan is: S nM =n+3×M Where: S nM It is the annotation data below the scan image obtained by the nth probe in the Mth scan.

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