Checking plate of phased array ultrasonic welding spot detector and checking method thereof

Abstract

The invention discloses a checking plate of a phased array ultrasonic welding spot detector and a checking method of the checking plate. The checking plate comprises a substrate, and a detection column perpendicular to the substrate is arranged on the front face of the substrate; a first groove matched with a detector probe is formed in the back surface of the substrate; the axis of the detection column is collinear with the center line of the first groove. And the base plate and the detection column are made of Q235A steel. The checking plate has the advantages that the checking plate is made of Q235A steel similar to automobile steel, the cylindrical detection column is arranged on the front face, the first groove matched with a detector probe is formed in the back face, the axis of the detection column and the center line of the first groove are collinear, a detector can recognize the detection column and conduct accurate measurement, and the detection accuracy is improved. The accuracy of the phased array ultrasonic welding spot detector can be accurately evaluated, the credibility of the measurement result of the phased array ultrasonic welding spot detector is ensured, and the problem that the phased array ultrasonic welding spot detector cannot be measured in China is solved.

Description

Technical Field

[0001] The invention relates to the technical field of phased array ultrasonic solder joint detectors, and in particular to a calibration plate of a phased array ultrasonic solder joint detector and a calibration method thereof. Background Art

[0002] In the process of vehicle manufacturing, the quality of the weld nugget of the body welding is an important evaluation index. The size of the weld nugget directly determines the strength of the body. The phased array ultrasonic weld spot detector can be used to non-destructively measure the size of the weld nugget for the quality evaluation of the weld nugget. If the phased array ultrasonic weld spot detector measures inaccurately, the weld nugget with quality problems will be judged as qualified, and the problem defects cannot be detected. Therefore, it is very necessary to monitor the accuracy of the phased array ultrasonic weld spot detector.

[0003] At present, the phased array ultrasonic solder joint detector cannot measure the standard instrument of the domestic metrology institute, which results in the phased array ultrasonic solder joint detector being unable to monitor its own precision and measurement accuracy through the traceability of the metrology institute. There are two solutions to this problem:

[0004] Solution 1: Cut the common solder joints measured by the phased array ultrasonic solder joint detector, use a metallographic microscope to measure the cut common solder joints, and compare the values ​​measured by the metallographic microscope with those measured by the solder joint tester.

[0005] Solution 2: Multiple solder joint testers measure the same solder joint, and the measurement results between different devices are limited to a certain range.

[0006] However, ordinary solder joints are non-standard cylinders. When monitored through Scheme 1, the values ​​after cutting are highly random, and the diameter of the solder joint cylinder fluctuates widely. In Scheme 2, multiple phased array ultrasonic solder joint detectors may fail at the same time, and the individual deviation values ​​of the equipment cannot be accurately measured. Summary of the invention

[0007] In order to solve at least one of the above technical problems, the present invention provides a calibration plate and a calibration method for a phased array ultrasonic weld detector. A detection column is set on a substrate, and the accuracy of the detector's detection is calibrated by measuring the detection column.

[0008] The present invention solves the technical problem by adopting the following technical solution:

[0009] A calibration plate for a phased array ultrasonic weld detector comprises a substrate, wherein a detection column perpendicular to the substrate is arranged on the front of the substrate; a first groove adapted to a detector probe is arranged on the back of the substrate; an axis of the detection column is colinear with a center line of the first groove; and the substrate and the detection column are made of Q235A steel.

[0010] Furthermore, the diameter of the first groove is larger than the diameter of the detector probe, and the difference between the diameter of the first groove and the diameter of the detector probe is no more than 2 mm, thereby improving the coaxiality of the detector probe and the detection column.

[0011] Furthermore, the diameter d of the detection column is set to 1-10 mm; the height h1 of the detection column is set to 1-3 mm; the thickness h2 of the substrate between the bottom surface of the first groove and the bottom surface of the detection column is set to 1-3 mm; preferably, the diameter d of the detection column includes 3 mm, 4.5 mm and 6 mm.

[0012] Furthermore, a second groove is provided on the front side of the substrate, the detection column is provided on the bottom surface of the second groove, the axis of the detection column is colinear with the center line of the second groove; the height of the detection column is not greater than the depth of the second groove, so as to protect the detection column.

[0013] Furthermore, the distance between the outer wall of the detection column and the side wall of the second groove is not less than 4 mm; preferably, the distance between the outer wall of the detection column and the side wall of the second groove is at least 4.5 mm.

[0014] Furthermore, the substrate and the detection column are integrally arranged to improve the dimensional accuracy of the detection column.

[0015] Furthermore, the detection columns include a plurality; preferably, the detection columns include three.

[0016] Furthermore, the substrate near the detection column is provided with detection column information, which includes the detection column diameter d, the detection column height h1 and the substrate thickness h2 between the bottom surface of the first groove and the bottom surface of the detection column, so as to facilitate input of detection parameters.

[0017] Furthermore, a calibration method for a phased array ultrasonic weld spot detector is applied to the calibration board described above, and the method comprises the following steps:

[0018] Step 1, selecting a detection column to be tested, and setting detection parameters according to the diameter d of the detection column to be tested, the height h1 of the detection column, and the thickness h2 of the substrate between the bottom surface of the first groove and the bottom surface of the detection column;

[0019] Step 2: Apply coupling agent to the detector probe and insert the probe into the first groove corresponding to the test column to be tested on the calibration plate;

[0020] Step 3: Click the test button to perform the test and read the display value of the detector, which includes the measured diameter D and the measured thickness H.

[0021] Step 4: Measure the test column for multiple times and calculate the average value of the measured diameter D and the measured thickness H. and ;

[0022] Step 5: Measure the average diameter and the average value of the measured thickness are respectively compared with the sum h of the diameter d of the detection column to be detected, the height h1 of the detection column, and the thickness h2 of the substrate between the bottom surface of the first groove and the bottom surface of the detection column; if ,and , then the detector is judged to be qualified; if , and / or, When the tester fails, it is judged that the tester fails.

[0023] Furthermore, the method further comprises testing a plurality of different sizes of the test columns to be tested, and when each test column meets the ,and If any of the test columns meets , and / or, When the tester fails, it is judged that the tester fails.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] (1) The calibration plate is made of Q235A steel, which is similar to the steel used in automobiles. Q235A steel has low carbon content and low alloy content, which is suitable for the high-frequency characteristics of the detector. The detector can identify the detection column and measure it accurately, and can accurately evaluate the accuracy of the phased array ultrasonic weld detector, ensuring the credibility of the measurement results of the phased array ultrasonic weld detector, thus solving the problem that the domestic phased array ultrasonic weld detector cannot be measured.

[0026] (2) A cylindrical detection column is arranged on the front of the calibration plate. The detection column has good roundness and high precision, and can more accurately reflect the measurement capability of the detector. A first groove adapted to the detector probe is arranged on the back of the calibration plate. The axis of the detection column is colinear with the center line of the first groove, which can improve the coaxiality of the detector probe and the detection column, make the center of the probe, the center of the first groove and the center of the detection column as coaxial as possible, and improve the measurement accuracy.

[0027] (3) During the test, the test column can be measured directly without destructive cutting, and can be reused. Also, since the same standard device is always used, it is convenient to count the accuracy trend of the detector over the years. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to better understand the above and other purposes, features, advantages and functions of the present invention, reference may be made to the embodiments shown in the accompanying drawings. The same reference numerals in the accompanying drawings refer to the same components. It should be understood by those skilled in the art that the accompanying drawings are intended to schematically illustrate the preferred embodiments of the present invention and have no limiting effect on the scope of the present invention, and the components in the drawings are not drawn to scale.

[0029] Figure 1 It is a front structural schematic diagram of the calibration plate of the phased array ultrasonic weld spot detector of the present invention.

[0030] Figure 2 The figure is a schematic diagram of the back structure of the calibration plate of the phased array ultrasonic weld spot detector of the present invention.

[0031] Figure 3 It is a schematic diagram of the AA cross-sectional structure of the first embodiment of the present invention.

[0032] Figure 4 It is a schematic diagram of the AA cross-sectional structure of the second embodiment of the present invention.

[0033] In the figure: 100 - substrate; 101 - first groove; 102 - second groove; 200 - detection column. DETAILED DESCRIPTION

[0034] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the exemplary embodiments of the present invention are described below in conjunction with the accompanying drawings, including various details of the embodiments of the present invention to facilitate understanding, which should be considered as merely exemplary. Therefore, it should be recognized by those of ordinary skill in the art that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present disclosure. Similarly, for the sake of clarity and conciseness, the description of well-known functions and structures is omitted in the following description.

[0035] In the description of the present invention, it should be noted that the term "including" and its variations represent open inclusion, that is, "including but not limited to". The terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance. The term "and / or" when used to list two or more items means that any one of the listed items can be used, or any combination of two or more of the listed items can be used. In addition, in the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0036] The present invention provides a calibration board for a phased array ultrasonic weld spot detector, referring to Figure 1-Figure 4 As shown, it includes a substrate 100, and a detection column 200 perpendicular to the substrate 100 is arranged on the front side of the substrate 100; a first groove 101 adapted to the detector probe is arranged on the back side of the substrate 100; the axis of the detection column 200 is colinear with the center line of the first groove 101; the material of the substrate 100 and the detection column 200 includes Q235A steel.

[0037] Most of the steel used in automobiles are DX54D, HX180DD, DC05, DC06, etc., and their common characteristics are low carbon content, low alloy content, and good plasticity. According to the ultrasonic frequency of the phased array ultrasonic weld detector (hereinafter referred to as the detector), Q235A steel, which is close to the material of automobile steel, can be used to make the calibration plate. Q235A steel has low carbon content and low alloy content, which is suitable for the high frequency characteristics of the detector. The detector can identify the detection column 200 and measure accurately.

[0038] The detection column 200 is cylindrical, has good roundness, high measurement accuracy, and can more accurately reflect the measurement capability of the detector. When the probe is cylindrical, the first groove 101 is correspondingly set to a cylindrical groove, and the axis of the first groove 101 is collinear with the axis of the detection column 200. When the measurement accuracy of the detector needs to be checked, the detector probe is inserted into the first groove 101, and the diameter d of the detection column 200 and the substrate thickness h2 between the bottom surface of the first groove 101 and the bottom surface of the detection column 200 can be measured. In order to facilitate measurement, the calibration plate can be installed on a fixture during detection, or placed on a desktop with an avoidance groove, so that the back of the substrate 100 faces upward, and the detection column 200 is accommodated in the avoidance groove.

[0039] In order to make the probe be able to be centered with the detection column 200 when inserted into the first groove 101 and improve the accuracy of measurement, the size of the first groove 101 can be designed according to the size of the probe. Preferably, the diameter of the first groove 101 is larger than the diameter of the detector probe, and the difference between the diameter of the first groove 101 and the diameter of the detector probe is not greater than 2 mm. The diameter of the first groove 101 is slightly larger than the size of the probe. For example, the difference between the diameter of the first groove 101 and the diameter of the detector probe can be set to 0.5 mm, 1 mm, 1.5 mm, 2 mm, etc., so that the probe can be easily inserted into the first groove 101, and the coaxiality of the detector probe and the detection column 200 can be improved, so that the center of the probe, the center of the first groove 101 and the center of the detection column 200 are as coaxial as possible, thereby improving the accuracy of measurement.

[0040] The height h1 and diameter d of the detection column 200 can be set according to the height and diameter of the welding point of the vehicle body, and the substrate thickness h2 between the bottom surface of the first groove 101 and the bottom surface of the detection column 200 can be set according to the thickness of the commonly used steel plate of the automobile, so that the height h1 and diameter d of the detection column 200 are close to the height and diameter of the welding point of the vehicle body, and the substrate thickness h2 is close to the thickness of the commonly used steel plate of the automobile. Preferably, the diameter d of the detection column 200 is set to 1-10mm; the height h1 of the detection column 200 is set to 1-3mm; the substrate thickness h2 between the bottom surface of the first groove 101 and the bottom surface of the detection column 200 is set to 1-3mm; more preferably, the diameter d of the detection column 200 includes 3mm, 4.5mm and 6mm. For example, the diameter d of the detection column 200 can be set to 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, 5mm, 5.5mm, 6mm, 6.5mm, 7mm, 7.5mm, 8mm, 8.5mm, 9mm, 9.5mm, 10mm, etc.; the height h1 of the detection column 200 can be set to 1mm, 1.5mm, 2mm, 2.5mm, 3mm, etc.; the substrate thickness h2 between the bottom surface of the first groove 101 and the bottom surface of the detection column 200 can be set to 1mm, 1.5mm, 2mm, 2.5mm, 3mm, etc. In this way, through the detection columns 200 of different diameters and heights and different substrate thicknesses h2 and their combinations, the measurement accuracy of the phased array ultrasonic weld detector under different sizes of weld cores can be reflected, and the accuracy and application range of the detector calibration can be improved.

[0041] In one embodiment, Figure 4 As shown, the front of the substrate 100 is provided with a second groove 102, and the detection column 200 is provided on the bottom surface of the second groove 102, and the axis of the detection column 200 is collinear with the center line of the second groove 102; the height of the detection column 200 is not greater than the depth of the second groove 102. In this way, the detection column 200 is surrounded by steel material, which can protect the detection column 200 from being knocked and worn during use, ensure the standardization and stability of the detection column 200, and improve the accuracy of the calibration. At the same time, during the calibration, the front of the substrate 100 can be placed stably on the desktop for measurement, and the stability of the calibration plate can be maintained during the measurement, thereby improving the accuracy of the measurement.

[0042] like Figure 3 As shown, when the detection column 200 is directly disposed on the plane of the substrate 100, the substrate thickness h2 between the bottom surface of the first groove 101 and the bottom surface of the detection column 200 is the substrate thickness between the bottom surface of the first groove 101 and the front plane of the substrate 100; Figure 4As shown, when the detection column 200 is disposed in the second groove 102 , the substrate thickness h2 between the bottom surface of the first groove 101 and the bottom surface of the detection column 200 is the substrate thickness between the bottom surface of the first groove 101 and the bottom surface of the second groove 102 .

[0043] For ease of measurement, the distance between the outer wall of the detection column 200 and the side wall of the second groove 102 is not less than 4 mm; preferably, the distance between the outer wall of the detection column 200 and the side wall of the second groove 102 is at least 4.5 mm. The second groove 102 can be set as a cylindrical groove with the same diameter as the first groove 101.

[0044] In order to improve the processing accuracy, the substrate 100 and the detection column 200 can be integrated, and the first groove 101, the second groove 102 and the detection column 200 can be finely machined by machining to improve the dimensional accuracy of the detection column 200 and ensure that the detection result is accurate, stable and reliable. Compared with the detection column 200 and the substrate 100 using a split structure, and then assembled by welding or screwing, the coaxiality of the detection column 200 and the first groove 101 can be guaranteed, and the roundness of the detection column 200 can be guaranteed.

[0045] The detection column 200 includes a plurality of detection columns; preferably, the detection column 200 includes three detection columns. Detection columns 200 of different diameters can be arranged on one substrate 100, and the depth of each first groove 101, the depth of each second groove 102 and the height of each detection column 200 can be consistent, which is more convenient when testing detection columns 200 of different sizes.

[0046] In one embodiment, the substrate 100 near the detection column 200 is provided with detection column 200 information, and the detection column 200 information includes the diameter d of the detection column 200, the height h1 of the detection column 200, and the substrate thickness h2 between the bottom surface of the first groove 101 and the bottom surface of the detection column 200. In this way, during the test, the detection parameters can be conveniently input into the detector, and there is no need to measure the diameter d of the detection column 200, the height h1 of the detection column 200, and the substrate thickness h2 between the bottom surface of the first groove 101 and the bottom surface of the detection column 200 on site.

[0047] The present invention also provides a calibration method for a phased array ultrasonic weld spot detector, which is applied to the calibration board described above, and the method comprises the following steps:

[0048] Step 1, selecting the detection column 200 to be tested, and setting the detection parameters according to the diameter d of the detection column 200 to be tested, the height h1 of the detection column 200, and the substrate thickness h2 between the bottom surface of the first groove 101 and the bottom surface of the detection column 200;

[0049] Step 2: Apply coupling agent to the detector probe, and insert the probe into the first groove 101 corresponding to the detection column 200 to be tested on the calibration plate;

[0050] Step 3: Click the test button to perform the test and read the display value of the detector, which includes the measured diameter D and the measured thickness H.

[0051] Step 4: Measure the testing column 200 for multiple times and calculate the average value of the measured diameter D and the measured thickness H. and ;

[0052] Step 5: Measure the average diameter and the average value of the measured thickness The diameter d of the detection column 200 to be detected, the height h1 of the detection column 200, and the thickness h2 of the substrate between the bottom surface of the first groove 101 and the bottom surface of the detection column 200 are respectively compared with each other; if ,and , then the detector is judged to be qualified; if , and / or, When the tester fails, it is judged that the tester fails.

[0053] Different phased array ultrasonic weld detectors have different detection parameters. The detection parameters generally require setting the measurement program, the layer thickness of the weld to be tested (the first layer thickness, the second layer thickness) and the gain value. The settings can be made according to the requirements of the detector and the size of the test column 200 to be tested.

[0054] There are three measurement programs: standard parts program (thin parts thickness less than or equal to 1mm / total thickness less than or equal to 4mm), thin plate program (thin parts thickness less than 1mm and greater than 0.6mm / total thickness less than or equal to 4mm), thick plate program (thin parts thickness greater than or equal to 1mm / total thickness greater than 4mm). The gain value is determined according to the plate thickness. For a total thickness of 2-5mm, the gain value is generally 20-30. For example, if the first layer thickness is set to 1mm, the second layer thickness is set to 3mm, and the total thickness is 4mm, select the standard parts program, and the gain value can be set to 26.

[0055] During measurement, the calibration plate can be placed on a flat and stable table with the back of the substrate 100 facing upwards, and the detector probe is coated with coupling agent and inserted into the first groove 101 corresponding to the detection column 200 to be tested for measurement.

[0056] In order to improve the accuracy of the calibration, the method further includes testing a plurality of different sizes of the test columns 200 to be tested. ,and If any of the test columns 200 meets the , and / or, When the tester fails, it is judged that the tester fails.

[0057] Each detection column 200 can be measured three times and the average value can be taken. As shown in Table 1 and Table 2, they are the results of the 1# detector and the 2# detector measuring different detection columns 200 of the calibration plate.

[0058] Table 1 The results of the measurement of different test columns 200 of the calibration plate by the 1# detector

[0059]

[0060] Table 2 The results of the measurement of different test columns 200 of the calibration plate by the 2# detector

[0061]

[0062] As can be seen from Table 1, when the 1# detector is used to measure the 1-3# detection columns 200, the diameter and thickness of each detection column 200 have small errors compared with the standard values ​​of each detection column 200, and the 1-3# detection columns 200 all meet the ,and , it is judged that the 1# detector is qualified and can measure the body welds normally, and the test results are accurate and reliable. As can be seen from Table 2, when the 2# detector is used to measure the 1-3# detection column 200, the measured diameter and thickness of the 3# detection column 200 have large errors compared with the standard values ​​of the 3# detection column 200. The measurement results of the 2# detector are inaccurate and unqualified, and the 2# detector cannot be used to measure the body welds.

[0063] After the phased array ultrasonic solder joint detector has been used for a certain period of time, the calibration board can be used to calibrate the detector, which can accurately calibrate the accuracy of the phased array ultrasonic solder joint detector. The calibration is convenient and fast with high accuracy.

[0064] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A calibration plate for a phased array ultrasonic weld spot detector, characterized in that: It comprises a substrate, the front side of which is provided with a detection column perpendicular to the substrate; the back side of the substrate is provided with a first groove adapted to the detector probe; the axis of the detection column is colinear with the center line of the first groove; the material of the substrate and the detection column comprises Q235A steel.

2. The calibration plate of the phased array ultrasonic weld detector according to claim 1, characterized in that: The diameter of the first groove is greater than the diameter of the detector probe, and the difference between the diameter of the first groove and the diameter of the detector probe is no greater than 2 mm.

3. The calibration plate of the phased array ultrasonic weld detector according to claim 1, characterized in that: The diameter d of the detection column is set to 1-10mm; the height h1 of the detection column is set to 1-3mm; the thickness h2 of the substrate between the bottom surface of the first groove and the bottom surface of the detection column is set to 1-3mm; preferably, the diameter d of the detection column includes 3mm, 4.5mm and 6mm.

4. The calibration plate of the phased array ultrasonic weld detector according to claim 1, 2 or 3, characterized in that: A second groove is arranged on the front side of the substrate, the detection column is arranged on the bottom surface of the second groove, the axis of the detection column is colinear with the center line of the second groove; the height of the detection column is not greater than the depth of the second groove.

5. The calibration plate of the phased array ultrasonic weld detector according to claim 5, characterized in that: The distance between the outer wall of the detection column and the side wall of the second groove is not less than 4 mm; preferably, the distance between the outer wall of the detection column and the side wall of the second groove is at least 4.5 mm.

6. The calibration plate of the phased array ultrasonic weld detector according to claim 1, characterized in that: The substrate and the detection column are integrally arranged.

7. The calibration plate of the phased array ultrasonic weld detector according to claim 4, characterized in that: The detection columns include a plurality of columns; preferably, the detection columns include three columns.

8. The calibration plate of the phased array ultrasonic weld detector according to claim 4, characterized in that: The substrate near the detection column is provided with detection column information, which includes the detection column diameter d, the detection column height h1 and the substrate thickness h2 between the bottom surface of the first groove and the bottom surface of the detection column.

9. A calibration method for a phased array ultrasonic weld spot detector, applied to the calibration plate according to any one of claims 1 to 8, characterized in that: The method comprises the following steps: Step 1, selecting a detection column to be tested, and setting detection parameters according to the diameter d of the detection column to be tested, the height h1 of the detection column, and the thickness h2 of the substrate between the bottom surface of the first groove and the bottom surface of the detection column; Step 2: Apply coupling agent to the detector probe and insert the probe into the first groove corresponding to the test column to be tested on the calibration plate; Step 3: Click the test button to perform the test and read the display value of the detector, which includes the measured diameter D and the measured thickness H. Step 4: Measure the test column for multiple times and calculate the average value of the measured diameter D and the measured thickness H. and ; Step 5: Measure the average diameter and the average value of the measured thickness are respectively compared with the sum h of the diameter d of the detection column to be detected, the height h1 of the detection column, and the thickness h2 of the substrate between the bottom surface of the first groove and the bottom surface of the detection column; if ,and , then the detector is judged to be qualified; if , and / or, When the tester fails, it is judged that the tester fails.

10. The calibration method according to claim 9, characterized in that: The method further comprises testing a plurality of different sizes of the test columns to be tested, and when each test column meets the ,and If any of the test columns meets , and / or, When the tester fails, it is judged that the tester fails.

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