Casting component detection method and system applied to high-collapsibility sodium silicate sand casting

Abstract

The invention relates to the technical field of ultrasonic detection of sodium silicate-bonded sand, in particular to a casting component detection method and system applied to high-collapsibility sodium silicate-bonded sand casting. The method comprises the following steps: firstly, acquiring detection data of each detection point of a casting sample; further obtaining a sand hole area according to the difference between the initial wave intensity and the echo intensity in combination with the distribution characteristics of the detected object; further obtaining the inclination expression degree of each sand hole area; further dividing the sand hole area into an uncovered sand hole area and a covered sand hole area; further obtaining a high-similarity sand hole area of each covered sand hole area according to similar characteristics of the inclination representation degree; further obtaining the complete echo intensity of each covered sand hole area according to the relative characteristics of the echo intensity between the covered sand hole area and the high-similarity sand hole area in combination with the inclination expression degree; and finally, the quality defect score of the casting sample is obtained, sand hole area inclination and covered errors are reduced, and the detection accuracy of casting component defects is improved.

Description

Technical Field

[0001] The invention relates to the technical field of ultrasonic detection of water glass sand, and in particular to a casting composition detection method and system applied to high-collapse water glass sand casting. Background Art

[0002] Traditionally, the sand holes in water glass sand castings are often detected by ultrasonic flaw detectors. The flaw detector sends a starting wave signal to each detection point of the casting. Because the medium will suddenly change at the sand hole, resulting in strong signal reflection, the higher the echo signal intensity at the detection point, the stronger the sand hole performance at the detection point is considered.

[0003] In actual scenarios, there may be multiple internal sand hole areas of different heights in the vertical field of view of the same inspection point of the casting, and because the sand hole area has strong absorption and reflection of ultrasonic waves, the echo information of the top sand hole area will cover the echo information of the lower sand hole area under vertical field of view, which will lead to the echo intensity information of the detection interlaced area with multiple sand hole areas in the same vertical field of view being falsely low, thereby reducing the assessment accuracy of casting composition quality inspection. Summary of the invention

[0004] In order to solve the technical problem that some sand hole areas are covered, resulting in unsatisfactory quality inspection accuracy of water glass sand castings, the purpose of the present invention is to provide a casting composition detection method and system for high-collapse water glass sand casting, and the technical scheme adopted is as follows: A casting composition detection method for high-collapsibility water glass sand casting, the method comprising: Obtaining the initial wave intensity, echo intensity and echo duration of each detection point of the high-collapsibility water glass sand casting sample; constructing a three-dimensional spatial model of the detection object based on the detection point distribution and the echo duration; According to the difference characteristics of the initial wave intensity and the echo intensity of each detection point, the possibility of sand holes in the detection object at each detection point is obtained; according to the distribution characteristics of the detection object in the three-dimensional space model, combined with the sand hole possibility, the sand hole area is obtained; according to the inclination characteristics of each sand hole area in the three-dimensional space model, the inclination expression degree of each sand hole area is obtained; according to the distribution characteristics of the sand hole area, it is divided into uncovered sand hole area and covered sand hole area; According to the similarity characteristics between the tilt expression of the uncovered sand hole area and the covered sand hole area, a highly similar sand hole area of ​​each covered sand hole area is obtained; according to the relative characteristics of the echo intensity of the whole of each covered sand hole area and the echo intensity of the whole of the corresponding highly similar sand hole area, combined with the tilt expression, the complete echo intensity of each covered sand hole area is obtained; The quality defect score of the casting sample is obtained according to the complete echo intensity of all the covered sand hole areas and combined with the overall characteristics of the echo intensity in all the uncovered sand hole areas.

[0005] Furthermore, the method for acquiring the three-dimensional space model includes: A plane is constructed with all the detection points, and the plane coordinates of the detection points are used as the horizontal and vertical coordinates of the corresponding detection object respectively. The difference between the longest echo duration and the echo duration of the detection object is used as the vertical coordinate of the corresponding detection object, so as to obtain a three-dimensional spatial model of the detection object and obtain the spatial coordinates of the detection object.

[0006] Furthermore, the method for obtaining the possibility of sand holes includes: After negative correlation mapping is performed on the absolute value of the difference between the initial wave intensity and the echo intensity at each detection point, the mapping value is used as the possibility of trachoma in the detection object at each detection point.

[0007] Furthermore, the method for obtaining the sand hole area includes: Density clustering is performed based on the spatial coordinates of the detected objects and the trachoma possibilities, and the areas corresponding to the clusters whose mean values ​​of the trachoma possibilities of all detected objects are greater than a preset trachoma threshold are marked as trachoma areas.

[0008] Furthermore, the method for obtaining the tilt expression degree includes: Obtain the angle between the fitting plane of each of the sand hole areas and the xoy plane as the first inclination angle; obtain the angle between the fitting plane of each of the sand hole areas and the yoz plane as the second inclination angle; obtain the angle between the fitting plane of each of the sand hole areas and the xoz plane as the third inclination angle; According to the first inclination angle, the second inclination angle and the third inclination angle, the inclination expression of the corresponding sand hole area is obtained; the first inclination angle is positively correlated with the inclination expression; the second inclination angle and the third inclination angle are both negatively correlated with the inclination expression.

[0009] Furthermore, the method of dividing the sand hole area into uncovered sand hole area and covered sand hole area according to the distribution characteristics of the sand hole area includes: When the ordinates of the detection objects at the edge of the trachoma area are not less than the ordinates of the detection objects adjacent to the trachoma area, the corresponding trachoma area is divided into an uncovered trachoma area; and the remaining trachoma areas are divided into covered trachoma areas.

[0010] Furthermore, the method for obtaining the high similarity sand hole area includes: Matching the covered sand hole area with the uncovered sand hole area to form a regional binary; performing negative correlation mapping on the absolute values ​​of the difference in the tilt expression between the sand hole areas in each regional binary, and using the mapping value as the tilt similarity of the regional binary; The uncovered sand hole area corresponding to the maximum tilt similarity corresponding to the covered sand hole area is taken as the high-similarity sand hole area of ​​the covered sand hole area.

[0011] Furthermore, the method for obtaining the complete echo intensity of the covered sand hole area includes: For each of the covered sand hole areas: obtaining the fitted ellipses of the covered sand hole area and the corresponding highly similar sand hole area; mapping the area of ​​the covered sand hole area in the fitted ellipse to the fitted ellipse of the highly similar sand hole area to obtain a mapping area; The ratio of the mean value of the echo intensity in the high similarity sand hole area to the mean value of the echo intensity in the corresponding mapping area is used as the proportional characteristic coefficient; the product of the mean value of the echo intensity in the covered sand hole area and the corresponding proportional characteristic coefficient is used as the initial echo intensity of the covered sand hole area; The product of the tilt expression of the covered sand hole area and the initial echo intensity and the sum of the initial echo intensity are taken as the complete echo intensity of the covered sand hole area.

[0012] Furthermore, the method for obtaining the quality defect score includes: Taking the mean value of the echo intensity of the detected object in the uncovered blisters area as the complete echo intensity of the uncovered blisters area; The average value of the complete echo intensity of all the sand hole areas is normalized by the maximum and minimum values ​​and is used as the quality defect score of the corresponding casting sample.

[0013] The present invention also proposes a casting composition detection system applied to high-disintegrability water glass sand casting, the system comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, and the processor implements any one of the steps of a casting composition detection method applied to high-disintegrability water glass sand casting when executing the computer program.

[0014] The present invention has the following beneficial effects: The present invention first obtains the initial wave intensity, echo intensity and echo duration of each detection point of the high-collapsibility water glass sand casting sample to obtain the basis for analysis data; further builds a three-dimensional spatial model of the detection object to facilitate the analysis of the spatial distribution of the detection object; further locates the sand hole area according to the difference between the initial wave intensity and the echo intensity of each detection point, combined with the distribution characteristics of the detection object in the three-dimensional spatial model, to prepare for the subsequent analysis of the coverage of the sand hole area; further obtains the tilt expression of each sand hole area according to the tilt characteristics of each sand hole area in the three-dimensional spatial model, to prepare for the subsequent accurate evaluation of the complete echo intensity of the covered sand hole area; further According to the similar characteristics between the tilt performance degrees, the uncovered sand hole area with the most accurate echo intensity assessment for the covered sand hole area is determined to ensure the reliability of the subsequent complete echo intensity; further, with the reference benchmark provided by the echo intensity of the high-similar sand hole area, the echo characteristics of the covered sand hole area are accurately assessed, and the echo intensity error caused by the tilt of the sand hole area is corrected to obtain the complete echo intensity of each covered sand hole area, reflecting the complete physical properties of the covered sand hole area, reducing the tilt and covering errors of the sand hole area, and improving the detection accuracy of the casting component defects; finally, the quality defect score of the casting sample is obtained to obtain the test result. The present invention determines the covered sand hole area and determines the most referenced high-similar sand hole area, evaluates the complete echo characteristics of the covered sand hole area with the echo performance of the high-similar sand hole area, and performs tilt compensation at the same time, reduces the tilt and covering errors of the sand hole area, and improves the accuracy of component detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the technical solutions and advantages in the embodiments of the present invention or the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0016] Figure 1 A flow chart of a casting composition detection method for high-collapse water glass sand casting provided by one embodiment of the present invention; Figure 2 A schematic diagram of the distribution of high-similarity sand hole areas provided by an embodiment of the present invention; Figure 3 A schematic diagram of a fitted ellipse provided by an embodiment of the present invention; Figure 4 A schematic diagram of a mapping area provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0017] In order to further explain the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the following is a detailed description of a casting composition detection method and system for high-disintegrability water glass sand casting according to the present invention, its specific implementation method, structure, features and effects, in conjunction with the accompanying drawings and preferred embodiments. In the following description, different "one embodiment" or "another embodiment" does not necessarily refer to the same embodiment. In addition, specific features, structures or characteristics in one or more embodiments may be combined in any suitable form.

[0018] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0019] The following is a detailed description of a method and system for detecting the composition of castings provided by the present invention and applied to high-disintegrability water glass sand casting in conjunction with the accompanying drawings.

[0020] See also Figure 1 , which shows a flow chart of a casting composition detection method applied to high-disintegrability water glass sand casting provided by an embodiment of the present invention, specifically comprising: Step S1: Obtain the initial wave intensity, echo intensity and echo duration of each detection point of the high-collapsibility water glass sand casting sample; and construct a three-dimensional spatial model of the detection object based on the detection point distribution and echo duration.

[0021] In the embodiment of the present invention, firstly, each detection point on the surface of the high-disintegrability water glass sand casting sample is detected by an ultrasonic flaw detector to obtain the initial wave intensity, echo intensity and echo duration of each detection point.

[0022] It should be noted that the analysis method for each high-disintegrability water glass sand casting sample is the same, and only any casting sample in the sampling is described here as an example; in one embodiment of the present invention, the detection points are located on the horizontal surface of the casting sample, distributed in a square grid with a side length of 0.5 mm, and the implementer can also adjust it by himself. The working principle and signal acquisition method of the ultrasonic flaw detector are already existing technologies and will not be repeated here.

[0023] In order to analyze the distribution characteristics of the sand hole area, a three-dimensional spatial model of the detection object is constructed based on the detection point distribution and echo duration.

[0024] Preferably, in one embodiment of the present invention, a plane is constructed with all detection points, and the plane coordinates of the detection points are used as the horizontal and vertical coordinates of the corresponding detection object, respectively. The difference between the longest echo duration and the echo duration of the detection object is used as the vertical coordinate of the corresponding detection object to obtain a three-dimensional spatial model of the detection object and obtain the spatial coordinates of the detection object.

[0025] It should be noted that, in one embodiment of the present invention, among the two mutually perpendicular directions of the plane where the detection points are located, the direction with the most detection points is selected as the horizontal direction, and the other direction is selected as the vertical direction.

[0026] Step S2: According to the difference characteristics of the initial wave intensity and the echo intensity of each detection point, the possibility of sand holes in the detection object at each detection point is obtained; according to the distribution characteristics of the detection object in the three-dimensional space model, combined with the possibility of sand holes, the sand hole area is obtained; according to the inclination characteristics of each sand hole area in the three-dimensional space model, the inclination expression of each sand hole area is obtained; according to the distribution characteristics of the sand hole area, it is divided into uncovered sand hole area and covered sand hole area.

[0027] Taking into account the medium change between the sand hole area and the normal material area, which will cause the initial wave signal emitted by the flaw detector to have a strong reflection phenomenon, the possibility of sand holes in the test object at each test point can be obtained based on the difference characteristics of the initial wave intensity and echo intensity of each test point, and the possibility of the test object at the test point being a sand hole can be characterized, providing a basis for locating the sand hole area.

[0028] Preferably, in one embodiment of the present invention, after negative correlation mapping is performed on the absolute value of the difference between the initial wave intensity and the echo intensity at each detection point, the mapping value is used as the possibility of sand holes in the detection object at each detection point.

[0029] As an example, the formula for calculating the probability of sand holes includes: ; Among them, i is the serial number of the detection point; Indicates the possibility of sand holes in the test object at the i-th test point; represents the linear normalized function; P represents the initial wave intensity of the detection point; Indicates the echo intensity of the i-th detection point; Indicates taking the absolute value.

[0030] In the calculation formula of the possibility of sand holes, the difference characteristics of the initial wave intensity and the echo intensity of the detection point are expressed by the absolute value of the difference, and negative correlation mapping is performed by taking the reciprocal form. Since there is attenuation from signal sending to reception, the signal strength must change, and the denominator will not be 0; The smaller it is, the more obvious the strong reflection characteristics of the detected object are, and the more likely it is a trachoma.

[0031] It should be noted that, in the embodiment of the present invention, the initial wave strength of all detection points is set to be the same, and ultrasonic flaw detection is performed vertically downward, the ultrasonic frequency is set to 5 MHz, and the initial wave strength is set to 0.5 The specific ultrasonic frequency and initial wave intensity can be adjusted according to the process of high-disintegrability water glass sand casting sample, and will not be limited here.

[0032] Considering that the trachoma area involves multiple detection points, it is necessary to further obtain the trachoma area based on the distribution characteristics of the detection objects in the three-dimensional space model and the possibility of trachoma, so as to prepare for the subsequent analysis of the coverage of the trachoma area.

[0033] Preferably, in one embodiment of the present invention, density clustering is performed based on the spatial coordinates of the detected objects and the possibility of trachoma, and the area corresponding to the cluster whose mean value of the trachoma possibility of all detected objects is greater than a preset trachoma threshold is marked as a trachoma area.

[0034] As an example, through DBSCAN density clustering, the trachoma threshold is preset to 0.8, the three-dimensional coordinates of the detected object and the possibility of trachoma are used as the four-dimensional coordinates of the detected object, and the four-dimensional Euclidean distance between the detected objects is used as the clustering distance to obtain multiple clusters.

[0035] Considering that the sand hole area may have a certain degree of inclination, the inclined sand hole area will affect the echo intensity. In order to accurately evaluate the complete echo intensity of the covered sand hole area, it is necessary to analyze the inclination characteristics of the sand hole area, so as to obtain the uncovered sand hole area that is most similar to the covered sand hole area for analysis.

[0036] Preferably, in one embodiment of the present invention, considering that the more inclined the sand hole area is, the greater the inclination angle of the plane corresponding to the detection point is, since the horizontal coordinate and the vertical coordinate are determined according to the detection point, the plane corresponding to the detection point is the xoy plane, and the angle between the fitting plane of each sand hole area and the xoy plane is obtained as the first inclination angle; Considering that the more the sand hole area is tilted, the more likely it is to change the vertical relationship between the sand hole area and the yoz plane, making the angle between the sand hole area and the yoz plane smaller, the angle between the fitting plane of each sand hole area and the yoz plane is obtained as the second inclination angle; similarly, the tilt will change the vertical relationship between the sand hole area and the xoz plane, and the angle between the fitting plane of each sand hole area and the xoz plane is obtained as the third inclination angle; According to the first inclination angle, the second inclination angle and the third inclination angle, the inclination expression degree of the corresponding sand hole area is obtained; As an example, the calculation formula for the tilt performance includes: ; Among them, j is the serial number of the sand hole area; represents the tilt performance of the jth sand hole area; represents the linear normalization function; represents the first inclination angle of the jth sand hole area; represents the second inclination angle of the jth sand hole area; Represents the third inclination angle of the jth sand hole area.

[0037] In the calculation formula of the tilt performance, the tilt angle is in radians, and the tilt angle is the smallest angle between the two planes, that is, the maximum angle is ; The larger it is, the more non-parallel the fitting plane of the sand hole area is to the plane corresponding to the detection point, the more inclined it is during ultrasonic flaw detection, and the greater the degree of inclination. By taking the complementary angle, the second inclination angle and the third inclination angle are negatively correlated. The smaller the second inclination angle is, the more likely the sand hole area is to be inclined, and the greater the degree of inclination. Similarly, the smaller the third inclination angle is, the greater the degree of inclination.

[0038] It should be noted that the method of fitting a plane and the method of obtaining the angle between planes are both existing technologies and will not be described in detail.

[0039] In addition to quantifying the tilt characteristics of the sand hole area, it is also necessary to divide the sand hole area into uncovered sand hole area and covered sand hole area according to its distribution characteristics, determine the covering situation of the sand hole area, and prepare for the subsequent evaluation of the echo signal characteristics of the covered area with the help of the echo signal characteristics of the uncovered area.

[0040] Preferably, in one embodiment of the present invention, considering that the longer the echo duration is, the farther the detection object is from the detection point and the smaller the vertical coordinate is, when the vertical coordinate of the detection object at the edge of the trachoma area is smaller than the vertical coordinate of the detection object adjacent to the trachoma area, it means that there is an adjacent detection object in the upper layer of the trachoma area, and the trachoma area may be covered. Therefore, when the vertical coordinates of the detection objects at the edge of the trachoma area are not smaller than the vertical coordinates of the detection objects adjacent to the trachoma area, the corresponding trachoma area is divided into an uncovered trachoma area; and the remaining trachoma areas are divided into covered trachoma areas.

[0041] Step S3: Based on the similarity characteristics between the tilt expressions of the uncovered sand hole area and the covered sand hole area, obtain the high-similarity sand hole area of ​​each covered sand hole area; based on the relative characteristics of the overall echo intensity of each covered sand hole area and the overall echo intensity of the corresponding high-similarity sand hole area, combined with the tilt expression, obtain the complete echo intensity of each covered sand hole area.

[0042] Taking into account that different inclination states have different effects on the echo intensity during ultrasonic flaw detection, we first obtain the highly similar sand hole area of ​​each covered sand hole area based on the similar characteristics between the inclination performance of the uncovered sand hole area and the covered sand hole area, and determine the uncovered sand hole area with the most accurate echo intensity evaluation for the covered sand hole area, thereby ensuring the reliability of the complete echo intensity characteristics of the covered sand hole area and improving the accuracy of the detection results.

[0043] Preferably, in one embodiment of the present invention, in order to find the uncovered sand hole area that is most similar to the covered sand hole area, the covered sand hole area and the uncovered sand hole area are matched to form a region binary group; Considering that the tilt expression represents the tilt characteristics of the sand hole area, the smaller the absolute value of the difference in tilt expression is, the more obvious the similarity of the tilt expression is. Therefore, the absolute value of the difference in tilt expression between the sand hole areas in each regional binary is negatively correlated and mapped, and the mapping value is used as the tilt similarity of the regional binary. The uncovered sand hole area corresponding to the maximum tilt similarity corresponding to the covered sand hole area is regarded as the high similarity sand hole area of ​​the covered sand hole area.

[0044] As an example, the absolute value of the difference in tilt expression between sand hole areas within a regional binary group is taken as the independent variable, and after negative correlation mapping through the exponential function exp(-x) with the natural constant e as the base, the mapping value is used as the tilt similarity of the regional binary group; wherein x is the independent variable.

[0045] See also Figure 2 , which shows a schematic diagram of a high-similarity sand hole area distribution provided by an embodiment of the present invention; Figure 2 The middle mark includes the sand hole area covered by the upper sand hole, that is, the covered sand hole area, and the mark includes the corresponding high similarity sand hole area.

[0046] The echo intensity of the high-similarity sand hole area provides a reference benchmark. According to the relative characteristics of the overall echo intensity of each covered sand hole area and the corresponding high-similarity sand hole area, by comparing the overall echo intensity characteristics of the covered sand hole area and the high-similarity sand hole area, the echo characteristics of the covered sand hole area can be evaluated more accurately. At the same time, tilt will also cause changes in echo intensity, so the tilt expression is also combined to obtain the complete echo intensity of each covered sand hole area, reflecting the complete physical properties of the covered sand hole area, reducing the tilt and covering errors of the sand hole area, and improving the detection accuracy of casting composition defects.

[0047] Preferably, in one embodiment of the present invention, considering that the sand hole area is usually in the shape of an ellipse, for each covered sand hole area: the fitting ellipse of the covered sand hole area and the corresponding high-similarity sand hole area is obtained, and the complex irregular area is standardized to make the mapping between the two areas consistent; the area of ​​the covered sand hole area in the fitting ellipse is mapped to the fitting ellipse of the high-similarity sand hole area to obtain the mapping area, and the spatial and characteristic connection between the two is established, so as to provide a basis for the comparison and calculation of the subsequent echo intensity; See also Figure 3 , which shows a schematic diagram of a fitted ellipse provided by an embodiment of the present invention, Figure 3 It includes the outlines of the covered sand hole area, the high similarity sand hole area and the fitted ellipse, and also includes the ellipse function fitting process, showing the schematic process of obtaining the fitted ellipse for the covered sand hole area and the corresponding high similarity sand hole area.

[0048] See also Figure 4 , which shows a schematic diagram of a mapping area provided by an embodiment of the present invention, Figure 4 The outlines of the fitting ellipses of the covered sand hole area and the high similarity sand hole area are included, and the mapping part A is marked in the fitting ellipse of the high similarity sand hole area. The mapping part A is the mapping area corresponding to the covered sand hole area.

[0049] Considering that the tilt characteristics of the covered area and the high-similarity sand hole area are relatively consistent, the echo intensity characteristics are relatively similar, and there is a logical relationship of "covered whole / covered part = high-similarity whole / high-similarity part". At the same time, considering that the echo signal intensity in the sand hole area is not uniform, the analysis is carried out through the echo intensity mean; Based on this, the ratio of the mean value of the echo intensity in the high similarity sand hole area to the mean value of the echo intensity in the corresponding mapping area is used as the proportional characteristic coefficient; the product of the mean value of the echo intensity in the covered sand hole area and the corresponding proportional characteristic coefficient is used as the initial echo intensity of the covered sand hole area; Furthermore, the initial echo intensity is tilt compensated. Considering that the higher the tilt degree, the smaller the echo intensity, the product of the tilt performance of the covered sand hole area and the initial echo intensity and the sum of the initial echo intensity are taken as the complete echo intensity of the covered sand hole area.

[0050] The calculation formula for the complete echo strength includes: ; Where k represents the serial number of the covered sand hole area; represents the complete echo intensity of the kth covered sand hole area; represents the tilt performance of the kth covered sand hole area; represents the mean value of the echo intensity in the kth covered sand hole area; It represents the mean value of the echo intensity in the high similarity sand hole area corresponding to the kth covered sand hole area; It represents the mean value of the echo intensity in the mapping area within the high similarity sand hole area corresponding to the kth covered sand hole area; represents the proportional characteristic coefficient corresponding to the kth covered sand hole area; Represents the initial echo intensity corresponding to the kth covered sand hole area.

[0051] In the calculation formula of the complete echo strength, The ratio characteristic of the echo intensity characteristic of the complete area and the echo intensity characteristic of the mapping area in the high similarity sand hole area is expressed. The echo intensity characteristic of the complete area of ​​the covered area, i.e., the initial echo intensity, is evaluated by using the ratio characteristic and the echo intensity characteristic of the local area of ​​the covered area. Then, the initial echo intensity is tilt compensated. The larger it is, the higher the tilt is, the smaller the echo intensity is, the more it is necessary to increase the initial echo intensity, and the greater the complete echo intensity is.

[0052] It should be noted that, considering that the morphological deviation between the sand hole areas is small, the fitted ellipse morphology is consistent, the ellipse fitting method and the area mapping method are already existing technologies and will not be repeated here; the analysis method for each covered sand hole area is consistent, and only one covered sand hole area is taken as an example here and will not be repeated.

[0053] Step S4: Obtain the quality defect score of the casting sample based on the complete echo intensity of all covered sand hole areas and the overall characteristics of the echo intensity in all uncovered sand hole areas.

[0054] The complete echo intensity of the covered sand hole area has been multiple-corrected by tilt expression and echo intensity characteristics of highly similar sand hole areas, which can accurately reflect the internal characteristics of the area and provide a more accurate basis for extracting sand hole defect information of casting samples. Therefore, based on the complete echo intensity of all covered sand hole areas and combined with the overall characteristics of the echo intensity in all uncovered sand hole areas, the overall sand hole defects of the casting samples are evaluated globally to obtain the quality defect score of the casting samples.

[0055] Preferably, in one embodiment of the present invention, considering that the complete echo intensity of the covered sand hole area is the average echo intensity of the entire area, in order to maintain a measurement method in which all sand hole areas have the same echo intensity, thereby analyzing the overall quality characteristics of the casting sample, the average echo intensity of the detection object in the uncovered sand hole area is used as the complete echo intensity of the uncovered sand hole area; The mean value of the complete echo intensity of all sand hole areas is normalized by the maximum and minimum values ​​and used as the quality defect score of the corresponding casting sample.

[0056] Among them, the average value of the complete echo intensity of all sand hole areas in the casting sample represents the overall defect characteristics of the casting sample. With the help of the average value of the complete echo intensity of all sand hole areas of all casting samples, the maximum and minimum values ​​are normalized to unify the data range of the quality defect score, which is more conducive to the evaluation of casting quality. The higher the quality defect score, the more serious the sand hole defect and the worse the quality of the casting sample.

[0057] In one embodiment of the present invention, after obtaining the quality defect score of the casting sample, the method further includes: The casting samples with quality defect scores less than a preset defect threshold, such as 0.68, are judged as excellent products, and the casting samples with quality defect scores greater than or equal to the preset defect threshold, such as 0.68, are judged as defective products; When the defective rate of randomly sampled high-disintegrability water glass castings in a batch is higher than 30%, the component quality inspection of the casting samples in this batch is judged to be unqualified, and feedback of abnormalities in the casting process is promptly issued to relevant personnel.

[0058] One embodiment of the present invention also provides a casting composition detection system applied to high-disintegrability water glass sand casting, the system includes a memory, a processor and a computer program, wherein the memory is used to store the corresponding computer program, the processor is used to run the corresponding computer program, and when the computer program is running in the processor, it can implement a casting composition detection method applied to high-disintegrability water glass sand casting described in steps S1-S4.

[0059] In summary, in order to solve the technical problem that some sand hole areas are covered, resulting in unsatisfactory quality inspection accuracy of water glass sand castings, the present invention proposes a casting composition detection method and system applied to high-collapsibility water glass sand casting. The present invention first obtains the detection data of each detection point of the casting sample, and constructs a three-dimensional spatial model of the detection object; further obtains the possibility of sand holes according to the difference between the initial wave intensity and the echo intensity; further obtains the sand hole area according to the distribution characteristics of the detection object combined with the sand hole possibility; further obtains the tilt expression of each sand hole area; further divides the sand hole area into uncovered sand hole areas and covered sand hole areas; further obtains the high-similar sand hole area of ​​each covered sand hole area according to the similar characteristics of the tilt expression; further obtains the complete echo intensity of each covered sand hole area according to the relative characteristics of the echo intensity between the covered sand hole area and the high-similar sand hole area, combined with the tilt expression; finally obtains the quality defect score of the casting sample, reduces the tilt and covered errors of the sand hole area, and improves the detection accuracy of casting component defects.

[0060] It should be noted that the sequence of the above embodiments of the present invention is only for description and does not represent the advantages and disadvantages of the embodiments. The processes depicted in the accompanying drawings do not necessarily require the specific order or continuous order shown to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0061] The various embodiments in this specification are described in a progressive manner, and the same or similar parts between the various embodiments can be referenced to each other, and each embodiment focuses on the differences from other embodiments.

Claims

1. A casting composition detection method for high-disintegrability water glass sand casting, characterized in that: The method comprises: Obtaining the initial wave intensity, echo intensity and echo duration of each detection point of the high-collapsibility water glass sand casting sample; constructing a three-dimensional spatial model of the detection object based on the detection point distribution and the echo duration; According to the difference characteristics of the initial wave intensity and the echo intensity of each detection point, the possibility of sand holes in the detection object at each detection point is obtained; according to the distribution characteristics of the detection object in the three-dimensional space model, combined with the sand hole possibility, the sand hole area is obtained; according to the inclination characteristics of each sand hole area in the three-dimensional space model, the inclination expression degree of each sand hole area is obtained; according to the distribution characteristics of the sand hole area, it is divided into uncovered sand hole area and covered sand hole area; According to the similarity characteristics between the tilt expression of the uncovered sand hole area and the covered sand hole area, a highly similar sand hole area of ​​each covered sand hole area is obtained; according to the relative characteristics of the echo intensity of the whole of each covered sand hole area and the echo intensity of the whole of the corresponding highly similar sand hole area, combined with the tilt expression, the complete echo intensity of each covered sand hole area is obtained; The quality defect score of the casting sample is obtained according to the complete echo intensity of all the covered sand hole areas and combined with the overall characteristics of the echo intensity in all the uncovered sand hole areas.

2. A casting composition detection method for high-collapsibility water glass sand casting according to claim 1, characterized in that: The method for acquiring the three-dimensional space model includes: A plane is constructed with all the detection points, and the plane coordinates of the detection points are used as the horizontal and vertical coordinates of the corresponding detection object respectively. The difference between the longest echo duration and the echo duration of the detection object is used as the vertical coordinate of the corresponding detection object, so as to obtain a three-dimensional spatial model of the detection object and obtain the spatial coordinates of the detection object.

3. The casting composition detection method for high-collapsibility water glass sand casting according to claim 1 is characterized in that: The method for obtaining the possibility of sand holes comprises: After negative correlation mapping is performed on the absolute value of the difference between the initial wave intensity and the echo intensity at each detection point, the mapping value is used as the possibility of trachoma in the detection object at each detection point.

4. A casting composition detection method for high-disintegrability water glass sand casting according to claim 2, characterized in that: The method for obtaining the sand hole area comprises: Density clustering is performed based on the spatial coordinates of the detected objects and the trachoma possibilities, and the areas corresponding to the clusters whose mean values ​​of the trachoma possibilities of all detected objects are greater than a preset trachoma threshold are marked as trachoma areas.

5. A casting composition detection method for high-collapsibility water glass sand casting according to claim 2, characterized in that: The method for obtaining the tilt expression degree includes: Obtain the angle between the fitting plane of each of the sand hole areas and the xoy plane as the first inclination angle; obtain the angle between the fitting plane of each of the sand hole areas and the yoz plane as the second inclination angle; obtain the angle between the fitting plane of each of the sand hole areas and the xoz plane as the third inclination angle; According to the first inclination angle, the second inclination angle and the third inclination angle, the inclination expression of the corresponding sand hole area is obtained; the first inclination angle is positively correlated with the inclination expression; the second inclination angle and the third inclination angle are both negatively correlated with the inclination expression.

6. A casting composition detection method for high-disintegrability water glass sand casting according to claim 2, characterized in that: The method of dividing the sand hole area into uncovered sand hole area and covered sand hole area according to the distribution characteristics of the sand hole area comprises: When the ordinates of the detection objects at the edge of the trachoma area are not less than the ordinates of the detection objects adjacent to the trachoma area, the corresponding trachoma area is divided into an uncovered trachoma area; and the remaining trachoma areas are divided into covered trachoma areas.

7. The casting composition detection method for high-collapsibility water glass sand casting according to claim 1 is characterized in that: The method for obtaining the high similarity sand hole area comprises: Matching the covered sand hole area with the uncovered sand hole area to form a regional binary; performing negative correlation mapping on the absolute values ​​of the difference in the tilt expression between the sand hole areas in each regional binary, and using the mapping value as the tilt similarity of the regional binary; The uncovered sand hole area corresponding to the maximum tilt similarity corresponding to the covered sand hole area is taken as the high-similarity sand hole area of ​​the covered sand hole area.

8. The casting composition detection method for high-collapsibility water glass sand casting according to claim 1 is characterized in that: The method for obtaining the complete echo intensity of the covered sand hole area comprises: For each of the covered sand hole areas: obtaining the fitted ellipses of the covered sand hole area and the corresponding highly similar sand hole area; mapping the area of ​​the covered sand hole area in the fitted ellipse to the fitted ellipse of the highly similar sand hole area to obtain a mapping area; The ratio of the mean value of the echo intensity in the high similarity sand hole area to the mean value of the echo intensity in the corresponding mapping area is used as the proportional characteristic coefficient; the product of the mean value of the echo intensity in the covered sand hole area and the corresponding proportional characteristic coefficient is used as the initial echo intensity of the covered sand hole area; The product of the tilt expression of the covered sand hole area and the initial echo intensity and the sum of the initial echo intensity are taken as the complete echo intensity of the covered sand hole area.

9. The casting composition detection method for high-collapsibility water glass sand casting according to claim 1 is characterized in that: The method for obtaining the quality defect score includes: Taking the mean value of the echo intensity of the detected object in the uncovered blisters area as the complete echo intensity of the uncovered blisters area; The average value of the complete echo intensity of all the sand hole areas is normalized by the maximum and minimum values ​​and is used as the quality defect score of the corresponding casting sample.

10. A casting composition detection system for high-collapse water glass sand casting, the system comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that: When the processor executes the computer program, the steps of a casting composition detection method applied to high-disintegrability water glass sand casting as described in any one of claims 1 to 9 are implemented.

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