Flaw detection sensitivity calibration method of hollow axle and storage medium thereof

Abstract

The invention provides a flaw detection sensitivity calibration method for a hollow axle and a storage medium thereof. The flaw detection sensitivity calibration method comprises the following steps: acquiring a space structure parameter and a reference defect parameter of a to-be-detected axle; determining an axle end and an inner hole of the axle to be detected according to the spatial structure parameters, and installing a flaw detection adapter at the axle end of the axle to be detected; controlling the probe arm to probe into the inner hole of the axle to be detected through the probe hole and rotate, and controlling the ultrasonic probe to perform ultrasonic scanning on the axle to be detected based on the scanning sensitivity to obtain scanning defect parameters of the axle to be detected; performing difference comparison on the reference defect parameter and the scanning defect parameter to obtain an error parameter; if the error parameter is in the preset error interval, the scanning sensitivity is determined as the standard sensitivity of the axle to be detected, so that the ultrasonic flaw detection sensitivity of the hollow axle can be quickly and accurately calibrated, all positions of the hollow axle can be effectively subjected to ultrasonic flaw detection, the detection quality is ensured, and the detection efficiency is improved. And the occurrence probability of error detection and missing detection is reduced.

Description

Technical Field

[0001] The present application relates to the field of rail transit vehicles, and particularly to a method for calibrating the flaw detection sensitivity of a hollow axle and its storage medium. Background Art

[0002] The hollow axle is a key and important component of the running gear of rail transit vehicles, and its product quality directly determines the riding comfort, running stability and safety of the vehicles. With the increasing running speed of rail transit vehicles, higher requirements are put forward for the axle quality.

[0003] Ultrasonic flaw detection is an important detection technology for detecting internal and surface defects of hollow axles. At present, the ultrasonic flaw detection of hollow axles has been automated. However, due to the relatively complex structure of the axle, the existing ultrasonic flaw detection sensitivity calibration methods cannot effectively calibrate the arc transition position and the inner hole surface position of the hollow axle, increasing the probability of misdetection and missed detection. Summary of the Invention

[0004] The main purpose of the embodiments of the present application is to propose a method for calibrating the flaw detection sensitivity of a hollow axle and its storage medium, which solves the problem of inability to accurately calibrate the arc transition and the inner hole surface sensitivity of the hollow axle.

[0005] To achieve the above object, a first aspect of the embodiments of the present application proposes a method for calibrating the flaw detection sensitivity of a hollow axle, which is applied to a residual stress detector. The ultrasonic flaw detector includes a flaw detection adapter and a probe arm. The flaw detection adapter is provided with a detection hole and is used to introduce a probe assembly into the inner hole of the axle to be detected. The probe arm includes an ultrasonic probe, and the method includes: Obtaining the spatial structure parameters and reference defect parameters of the axle to be detected; Determining the axle end and the inner hole of the axle to be detected according to the spatial structure parameters, and installing the flaw detection adapter at the axle end of the axle to be detected, wherein the detection hole corresponds to the inner hole; Controlling the probe arm to penetrate into the inner hole of the axle to be detected through the detection hole and rotate, and controlling the ultrasonic probe to perform ultrasonic scanning on the axle to be detected based on the scanning sensitivity, so as to obtain the scanning defect parameters of the axle to be detected, wherein the ultrasonic scanning method is the C-scanning method; Comparing the difference between the reference defect parameters and the scanning defect parameters to obtain an error parameter; If the error parameter is within a preset error range, determining the scanning sensitivity as the standard sensitivity of the axle to be detected; If the error parameter is not within the preset error range, adjust the scanning sensitivity and return to the step of controlling the ultrasonic probe to perform ultrasonic scanning on the axle to be measured based on the scanning sensitivity to obtain the scanning defect parameters of the axle to be measured, until the error parameter between the scanning defect parameters and the reference defect parameters is within the preset error range, and then determine the adjusted scanning sensitivity as the standard sensitivity.

[0006] Further, in some embodiments, the scanning sensitivity is obtained through the following steps: Obtain a calibration test block and determine multiple defect positions of the calibration test block; Control the ultrasonic probe to emit ultrasonic waves to each defect position respectively and continuously receive the ultrasonic echoes corresponding to each defect position; Determine the reference sensitivity of the ultrasonic probe according to each ultrasonic echo; Linearly superimpose the reference sensitivity and a preset compensation gain value to obtain the scanning sensitivity.

[0007] Further, in some embodiments, determining the reference sensitivity of the ultrasonic probe according to each ultrasonic echo includes: Determine the reference sound path between each defect position and the ultrasonic probe according to the time interval between the ultrasonic probe emitting ultrasonic waves and receiving each ultrasonic echo; Adjust the ultrasonic emission frequency corresponding to the ultrasonic probe to respectively increase the amplitude of each ultrasonic echo to the required preset amplitude ratio to obtain each reference echo, and respectively determine the peak value of each reference echo as the reference amplitude value, where the preset amplitude ratio requirement is that the amplitude display of the ultrasonic echo on the screen of the ultrasonic flaw detector reaches 80%; According to each reference sound path and each reference amplitude value, fit the reference relationship curve between the sound path and the amplitude, and use the reference relationship curve as the reference sensitivity, where the linear relationship of the reference relationship curve is a direct proportional relationship or an inverse proportional relationship.

[0008] Further, in some embodiments, when the linear relationship of the reference relationship curve is a direct proportional relationship, fitting the reference relationship curve between the sound path and the amplitude according to each reference sound path and each reference amplitude value includes: According to each reference sound path and each reference amplitude value, respectively determine the relationship data points between the sound path and the amplitude corresponding to each ultrasonic echo; Sort each relationship data point in ascending order of the reference sound path to obtain a set of relationship data points with spatial sequence attributes; Perform linear fitting on the set of relationship data points by the least squares method to obtain the reference relationship curve.

[0009] Further, in some embodiments, the spatial structure parameters include the radius of the axle to be measured and the radius of the inner hole. The number of ultrasonic probes is multiple, and the multiple ultrasonic probes include transverse ultrasonic probes for detecting transverse defects of the axle. Before controlling the probe arm to rotate within the inner hole, the method further includes: Determine a first angle between the transverse ultrasonic probe and the inner wall surface of the axle to be measured; Determine a first detection length of the transverse ultrasonic probe inside the axle to be measured according to the radius of the axle to be measured, the radius of the inner hole, and the first angle; Extend the probe gate of the transverse ultrasonic probe outward at the first angle to the first detection length with respect to the axle to be measured.

[0010] Further, in some embodiments, the multiple ultrasonic probes further include longitudinal ultrasonic probes for detecting longitudinal defects of the axle. Before controlling the probe arm to rotate within the inner hole, the method further includes: Determine a second angle between the probe gate of the longitudinal ultrasonic probe and the inner wall surface of the axle to be measured; Determine a second detection length of the longitudinal ultrasonic probe inside the axle to be measured according to the radius of the axle to be measured, the radius of the inner hole, and the second angle; Extend the probe gate of the longitudinal ultrasonic probe outward at the second angle to the second detection length with respect to the axle to be measured.

[0011] Further, in some embodiments, the multiple ultrasonic probes further include internal ultrasonic probes for detecting internal defects of the axle. Before controlling the probe arm to rotate within the inner hole, the method further includes: Determine a third angle between the probe gate of the internal ultrasonic probe and the inner wall surface of the axle to be measured; Determine a third detection length of the internal ultrasonic probe inside the axle to be measured according to the radius of the axle to be measured and the radius of the inner hole; Extend the probe gate of the internal ultrasonic probe outward at the third angle to the third detection length with respect to the axle to be measured.

[0012] Further, in some embodiments, the absolute value of the first angle is in the interval (0 o , 45 o , and the absolute value of the second angle is in the interval (45 o , 90 o .

[0013] Further, in some embodiments, the third angle is 0 o .

[0014] To achieve the above object, a second aspect of the embodiments of the present application provides a computer-readable storage medium storing a program executable by a processor. When the computer program is executed by the processor, the flaw detection sensitivity calibration method according to the first aspect of the embodiments is implemented.

[0015] In the embodiments of the present application, the following beneficial effects are achieved: by obtaining the spatial structure parameters and reference defect parameters of the axle to be measured; determining the axle end and inner hole of the axle to be measured according to the spatial structure parameters, and installing the flaw detection adapter at the axle end of the axle to be measured; controlling the probe arm to penetrate into the inner hole of the axle to be measured through the detection hole and rotate, and controlling the ultrasonic probe to perform ultrasonic scanning on the axle to be measured based on the scanning sensitivity to obtain the scanning defect parameters of the axle to be measured; comparing the difference between the reference defect parameters and the scanning defect parameters to obtain an error parameter; if the error parameter is within a preset error range, determining the scanning sensitivity as the standard sensitivity of the axle to be measured; if the error parameter is not within the preset error range, adjusting the scanning sensitivity and returning to the step of controlling the ultrasonic probe to perform ultrasonic scanning on the axle to be measured based on the scanning sensitivity to obtain the scanning defect parameters of the axle to be measured, until the error parameter between the scanning defect parameters and the reference defect parameters is within the preset error range, and then determining the adjusted scanning sensitivity as the standard sensitivity. Furthermore, the ultrasonic flaw detection sensitivity of the hollow axle can be calibrated quickly and accurately, ensuring that ultrasonic flaw detection can be effectively performed at all positions of the hollow axle, guaranteeing the detection quality, and reducing the occurrence probability of misdetection and missed detection. Description of the Drawings

[0016] Figure 1 is an optional flowchart of a method for calibrating the flaw detection sensitivity of a hollow axle provided by the embodiments of the present application; Figure 2 is an optional flowchart of obtaining the scanning sensitivity provided by the embodiments of the present application; Figure 3 is provided by the embodiments of the present application Figure 2 in step S203 of which is an optional flowchart; Figure 4 is provided by the embodiments of the present application Figure 3 in step S303 of which is an optional flowchart; Figure 5 is provided by the embodiments of the present application Figure 1 before step S103 of which is an optional flowchart; Figure 6 is provided by the embodiments of the present application Figure 1 before step S103 of which is another optional flowchart; Figure 7 is provided by the embodiments of the present application Figure 1Another alternative flowchart before step S103; Figure 8 It is a schematic diagram of the hardware structure of an electronic device provided by an embodiment of the present application. Detailed implementation manners

[0017] In order to make the objectives, technical solutions and advantages of the present application clearer, the present application will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application, and are not used to limit the present application.

[0018] In the description of the present application, it should be understood that the orientation or positional relationship indicated by terms such as up, down, front, back, left, right, etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present application.

[0019] It should also be noted that in the description of the present application, the meaning of several is more than one, the meaning of multiple is more than two, greater than, less than, exceeding, etc. are understood as not including the recited number, and above, below, within, etc. are understood as including the recited number. If there is a description of first and second, it is only for the purpose of distinguishing technical features, and cannot be understood as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features or implicitly indicating the sequence relationship of the indicated technical features.

[0020] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field to which this application belongs. The terms used herein are only for the purpose of describing the embodiments of this application and are not intended to limit this application.

[0021] In the description of the present application, the descriptions with reference to terms such as "one embodiment", "some embodiments", "schematic embodiments", "examples", "specific examples", or "some examples" mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic descriptions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0022] Ultrasonic flaw detection is an important detection technology for detecting internal and surface defects of hollow axles. At present, the ultrasonic flaw detection of hollow axles has been automated. However, due to the relatively complex structure of the axles, the existing ultrasonic flaw detection sensitivity calibration methods cannot effectively calibrate the arc transition position and the inner hole surface position of the hollow axles, increasing the probability of false detection and missed detection.

[0023] Based on this, the embodiments of the present application provide a method for calibrating the flaw detection sensitivity of a hollow axle and its storage medium, which solves the problem of being unable to accurately calibrate the sensitivity of the arc transition and inner hole surface of the hollow axle.

[0024] The method for calibrating the flaw detection sensitivity of a hollow axle provided by the embodiments of the present application will be specifically described through the following embodiments.

[0025] It should be noted that the method for calibrating the flaw detection sensitivity of a hollow axle provided by the embodiments of the present application is applied to an ultrasonic flaw detector, which includes a flaw detection adapter and a probe arm. The flaw detection adapter is provided with a detection hole and is used to introduce the probe assembly into the inner hole of the axle to be tested. The probe arm includes an ultrasonic probe.

[0026] Refer to Figure 1 as shown, Figure 1 is an optional flowchart of a method for calibrating the flaw detection sensitivity of a hollow axle provided by the embodiments of the present application. This method may include but is not limited to steps S101 to S106.

[0027] Step S101: Obtain the spatial structure parameters and reference defect parameters of the axle to be tested.

[0028] Among them, the spatial structure parameters include the shaft length parameter, diameter parameter, roundness parameter, concentricity parameter, keyway position parameter, form and position tolerance parameter, etc. The reference defect parameters include crack parameters, pore parameters, inclusion parameters, etc. inside and on the surface of the axle to be tested. The present application does not make specific limitations.

[0029] Step S102: Determine the shaft end and inner hole of the axle to be tested according to the spatial structure parameters, and install the flaw detection adapter at the shaft end of the axle to be tested.

[0030] Specifically, before performing the flaw detection of the hollow axle, based on the detailed and accurate spatial structure parameters, first determine the position of the shaft end of the axle to be tested and the specifications and positions of the inner hole. After determining the shaft end and inner hole, install the flaw detection adapter at the shaft end of the axle to be tested to ensure the accuracy, firmness of its installation position and the matching accuracy with the axle, so as to make full preparations for the subsequent flaw detection work.

[0031] Step S103: Control the probe arm to penetrate into the inner hole of the axle to be tested through the detection hole and rotate, and control the ultrasonic probe to perform ultrasonic scanning on the axle to be tested based on the scanning sensitivity to obtain the scanning defect parameters of the axle to be tested.

[0032] Among them, the ultrasonic scanning method is the C-scanning method.

[0033] In one implementation, during the inspection of the hollow axle, through the multi-axis servo control motor in the ultrasonic flaw detector, the intelligent positioning and motion trajectory planning of the probe arm are realized. Then, the operator inputs control parameters through the human-machine interface. Then, the ultrasonic flaw detector aligns the probe arm with the inspection hole of the axle to be tested and controls the probe arm to slowly and steadily penetrate into the inner hole of the axle to be tested through the inspection hole. After the penetration depth reaches the preset threshold, the ultrasonic flaw detector rotates according to the preset program to ensure that the probe can detect the inner hole comprehensively. At the same time, under the control of the ultrasonic flaw detector, the ultrasonic probe conducts a meticulous ultrasonic scan of the axle to be tested according to the preset scan sensitivity. When ultrasonic waves propagate inside the axle to be tested and encounter discontinuities or defect parts in the material, reflected echo signals will be generated. These signals will be acutely captured by the probe and, through complex signal processing and data analysis, the scan defect parameters of the axle to be tested are finally obtained, providing a key basis for the subsequent assessment of the quality of the axle to be tested.

[0034] Step S104: Compare the reference defect parameters with the scan defect parameters by taking the difference to obtain the error parameter.

[0035] During the inspection of the hollow axle, in order to accurately evaluate the quality status of the axle to be tested, it is necessary to conduct a detailed difference comparison between the reference defect parameters and the scan defect parameters. The reference defect parameters are artificially set standard reference values based on experiments, representing the defect characteristics of the axle in an ideal state. The scan defect parameters are the specific values of the internal defects of the axle to be tested actually detected by the ultrasonic probe. By comparing the two, the difference between the actual detection result and the standard can be clearly seen, thus obtaining the error parameter. This process is crucial for judging whether the axle to be tested meets the quality requirements and also provides accurate data support for subsequent defect analysis and processing.

[0036] Step S105: If the error parameter is within the preset error range, determine the scan sensitivity as the standard sensitivity.

[0037] Specifically, when conducting ultrasonic inspection of the hollow axle, when it is found through a series of precise comparisons and analyses that the error parameter is stably within the preset error range, this indicates that the current scan sensitivity matches the standard requirements and can accurately detect the internal defects of the axle. At this time, this scan sensitivity can be determined as the standard sensitivity and used as the reference parameter for subsequent inspection work. This process is crucial for ensuring the accuracy and reliability of the detection results and also provides a solid foundation for subsequent flaw detection work, helping to timely detect potential defects and problems and ensuring the safety of train operation.

[0038] Step S106: If the error parameter is not within the preset error range, adjust the scanning sensitivity and return to Step S103 until the error parameter between the scanned defect parameter and the reference defect parameter is within the preset error range, then determine the adjusted scanning sensitivity as the standard sensitivity.

[0039] Specifically, in the ultrasonic flaw detection process of a hollow axle, if it is found through comparative analysis that the error parameter deviates from the preset error range, it means that the current scanning sensitivity cannot accurately identify the defect situation inside the axle. At this time, the ultrasonic flaw detector will automatically adjust the scanning sensitivity. By finely tuning the parameter settings of the flaw detection equipment, the intensity of ultrasonic wave emission and the sensitivity of reception are changed, and then return to the above-mentioned Step S103, that is, re-enter the ultrasonic scanning stage. The ultrasonic probe will scan the axle to be tested again comprehensively, obtain new scanned defect parameters, and re-compare the difference with the reference defect parameters to calculate a new error parameter. This process will continue to cycle until the error parameter between the scanned defect parameter and the reference defect parameter is stably within the preset error range. After reaching this condition, the ultrasonic flaw detector will accurately determine the adjusted scanning sensitivity at this time as the standard sensitivity, which is a key parameter for subsequent flaw detection work, ensuring the accuracy and reliability of the detection results and providing a solid guarantee for the safe operation of the train.

[0040] Refer to Figure 2 as shown Figure 2 FIG. is an optional flowchart for obtaining the scanning sensitivity provided by an embodiment of the present application. The method may include, but is not limited to, Step S201 to Step S204.

[0041] Step S201: Obtain a calibration test block and determine multiple defect positions of the calibration test block.

[0042] It should be noted that when preparing for ultrasonic flaw detection, first, a calibration test block dedicated to calibrating the sensitivity needs to be obtained. This calibration test block is carefully designed and manufactured. Its material, size, and internal structure are similar to those of the hollow axle to be detected, and it contains multiple known defect positions inside. These defect positions are preset through precise processing techniques, including defects of different depths, sizes, and shapes, such as cracks and holes, to simulate various defect situations that may occur in the actual axle during use. By determining multiple defect positions of the calibration test block, an accurate reference standard can be provided for subsequent flaw detection, ensuring that the sensitivity and accuracy of the detection system meet the requirements, and thus guaranteeing the reliability and effectiveness of the entire detection process.

[0043] Step S202: Control the ultrasonic probe to emit ultrasonic waves to each defect position respectively and continuously receive the ultrasonic echoes corresponding to each defect position.

[0044] During the ultrasonic flaw detection process, the operator inputs control parameters into the ultrasonic flaw detector to control the ultrasonic probe to emit ultrasonic waves to each known defect position of the calibration test block in a preset order and path. When the ultrasonic wave propagates inside the test block, once it encounters a defect, it will be reflected and form an ultrasonic echo. After emitting the ultrasonic wave, the probe will continue to receive the signal, keenly capturing the ultrasonic echo signals corresponding to each defect position. These echo signals carry key information about the defect location, size, shape, etc., and will be transmitted to the signal processing unit of the detection system in real time, providing basic data for subsequent defect analysis and evaluation.

[0045] Step S203: Determine the baseline sensitivity of the ultrasonic probe according to each ultrasonic echo.

[0046] Specifically, during the ultrasonic flaw detection process, when the ultrasonic probe receives the ultrasonic echo reflected from each defect position of the calibration test block, these echo signals will be analyzed and processed in detail by the detection system. The system will determine the baseline sensitivity of the ultrasonic probe based on the echo amplitude, frequency, sound path and other characteristics, combined with the known defect position and characteristics.

[0047] Step S204: linearly superimpose the reference sensitivity and the preset compensation gain value to obtain the scanning sensitivity.

[0048] In one embodiment, the compensation gain value is 10 dB to 15 dB.

[0049] It should be noted that in the actual detection environment, due to the influence of factors such as the material, shape, surface condition of the workpiece and the propagation path of the ultrasonic wave, the ultrasonic signal may attenuate or change, resulting in a decrease in detection sensitivity. In order to compensate for these influences, it is necessary to introduce a preset compensation gain value, which is predetermined based on actual detection conditions and experience, and is used to improve the sensitivity of the detection system to ensure that tiny defects can be accurately detected. The baseline sensitivity and the compensation gain value are linearly superimposed, that is, the two are numerically added to obtain the final scanning sensitivity. This linear superposition method is based on the linear response characteristics of the ultrasonic detection system to the signal amplitude. The gain is adjusted to compensate for the signal loss, thereby ensuring that in the actual detection process, the ultrasonic probe can fully scan the sample axis with sufficient sensitivity to ensure that no potential defects are missed, providing a reliable parameter basis for subsequent flaw detection, and ensuring the accuracy and reliability of the detection results.

[0050] Reference Figure 3 As shown, Figure 3 The embodiment of this application provides Figure 2 An optional flowchart of step S203 in the method may include but is not limited to steps S301 to S303.

[0051] Step S301: Determine the reference sound path between each defect position and the ultrasonic probe according to the time intervals of receiving each ultrasonic echo after the ultrasonic probe emits ultrasonic waves.

[0052] During the ultrasonic flaw detection process, when the ultrasonic probe emits ultrasonic waves towards the defect position of the calibration test block, ultrasonic echoes reflected from the defect position will be received. By accurately measuring the time intervals between emitting the ultrasonic waves and receiving each ultrasonic echo, the distance between each defect position and the ultrasonic probe, that is, the reference sound path, can be calculated using the propagation speed of ultrasonic waves in the medium. The determination of this reference sound path is crucial for subsequent defect location and size measurement. It provides an accurate reference for the detection system and ensures the reliability and accuracy of the detection results. Step S302: Adjust the ultrasonic emission frequency corresponding to the ultrasonic probe to respectively increase the amplitude of each ultrasonic echo to the preset amplitude ratio requirement, obtain each reference echo, and respectively determine the peak value corresponding to each reference echo as the reference amplitude value.

[0053] Among them, the preset amplitude ratio requirement is that the amplitude display ratio of the ultrasonic echo on the screen of the ultrasonic flaw detector reaches 80%.

[0054] Specifically, in the calibration link of ultrasonic flaw detection, in order to ensure the accuracy and reliability of the detection results, the emission frequency of the ultrasonic probe needs to be finely adjusted. The specific operation is as follows: First, by changing the emission frequency of the ultrasonic probe, observe the amplitude changes of each ultrasonic echo received at different frequencies. Then, adjust the amplitude gain of each ultrasonic echo to within the preset amplitude ratio requirement range. This process requires repeated tests and precise adjustments to find the optimal emission frequency. When the amplitude of each ultrasonic echo reaches the preset requirement, these echoes are called reference echoes. Next, measure and record the peak values of each reference echo respectively, and determine these peak values as the reference amplitude values, which are used as the reference standards in subsequent detections. In this way, it can be ensured that the ultrasonic probe can accurately identify and evaluate the defect conditions inside the sample shaft with appropriate sensitivity and accuracy during actual detection.

[0055] Step S303: Fit the reference relationship curve between the sound path and the amplitude according to each reference sound path and each reference amplitude value, and use the reference relationship curve as the reference sensitivity.

[0056] Specifically, according to each reference sound path and each reference amplitude value, fit the reference relationship curve between the sound path and the amplitude, and use the reference relationship curve as the reference sensitivity.

[0057] Among them, the linear relationship of the reference relationship curve is a direct proportional relationship or an inverse proportional relationship.

[0058] Referring to Figure 4 as shown, Figure 4 is an optional flowchart of step S303 provided by an embodiment of the present application. This method may include but is not limited to steps S401 to S403. Figure 3

[0059] Step S401: According to each reference sound path and each reference amplitude value, respectively determine the relationship data points between the sound path and the wave amplitude corresponding to each ultrasonic echo.

[0060] Specifically, regard the reference sound path and the reference amplitude value of each ultrasonic echo as a pair of related relationship data points. Then, take each reference sound path as the abscissa (X-axis) and the corresponding reference amplitude value as the ordinate (Y-axis), and determine the positions of these relationship data points in the two-dimensional coordinate system respectively.

[0061] Step S402: Sort each relationship data point in ascending order of the reference sound path to obtain a set of relationship data points with spatial sequence attributes.

[0062] Specifically, in order to manage the obtained relationship data points in an orderly manner for subsequent analysis and processing, it is necessary to sort these data points according to the proximity of the reference sound path. The specific operation is: compare the reference sound path values corresponding to each relationship data point, and arrange these relationship data points in ascending order from near to far. Finally, a set of relationship data points with spatial sequence attributes is obtained, which can more intuitively reflect the spatial relationship between different defect positions and the probe, and provide ordered data support for subsequent curve fitting and sensitivity calibration.

[0063] Step S403: Perform linear fitting on the set of relationship data points by the least squares method to obtain the reference relationship curve.

[0064] In order to establish an accurate relationship between the sound path and the wave amplitude, linear fitting is performed on the set of relationship data points obtained previously by using the least squares method. Specifically, it is to find a best-fit straight line by minimizing the sum of the squares of the residuals between the observed values and the model predicted values, so that all relationship data points are as close as possible to this straight line. Thus, the obtained reference relationship curve can accurately reflect the linear relationship between the sound path and the wave amplitude, providing a reliable basis for subsequent defect detection and evaluation.

[0065] Furthermore, the spatial structure parameters include the radius of the axle to be measured and the radius of the inner hole.

[0066] ​Optionally, the number of ultrasonic probes is multiple. The multiple ultrasonic probes include a lateral ultrasonic probe for detecting lateral defects of the axle, a longitudinal ultrasonic probe for detecting longitudinal defects of the axle, and an internal ultrasonic probe for detecting internal defects of the axle.

[0067] Referring to Figure 5 shown, Figure 5 is an optional flowchart before step S103 provided by an embodiment of the present application. The method may include but is not limited to steps S501 to S503. Figure 1

[0068]

[0069] Step S501: Determine a first angle between the lateral ultrasonic probe and the inner wall surface of the axle to be measured.

[0070] Among them, the absolute value of the first angle is in the interval (0 o , 45 o .

[0071] In an optional embodiment, the number of lateral ultrasonic probes is multiple. The multiple lateral ultrasonic probes include a lateral ultrasonic probe with a first angle of 45°, a lateral ultrasonic probe with a first angle of -45°, a lateral ultrasonic probe with a first angle of 38°, and a lateral ultrasonic probe with a first angle of -38°.

[0072] Step S502: Determine a first detection length of the lateral ultrasonic probe inside the axle to be measured according to the radius of the axle to be measured, the inner hole radius, and the first angle. It should be noted that the calculation formula for the first detection length is , where is the first detection length, is the radius of the axle to be measured, is the inner hole radius,

[0073] is the first angle.

[0074] Step S503: Extend the probe gate of the lateral ultrasonic probe to the outside of the axle to be measured at the first angle to the first detection length.

[0075] Specifically, in the setting link of ultrasonic flaw detection, the probe gate of the lateral ultrasonic probe is accurately extended from the probe position to the outside of the axle to be measured at a preset first angle until the second detection length is reached.

[0075] It should be noted that the first detection length is determined and the probe gate is extended according to the radius of the axle to be tested, the inner hole radius and the first angle. In order to reduce the impact of the initial ultrasonic wave emitted by the lateral ultrasonic probe on subsequent detection, since there is an unstable sound pressure area for the initial ultrasonic wave, in order to avoid detection in this area as much as possible, the first detection lengths of different sizes are set so that the initial ultrasonic wave delay emitted by the lateral ultrasonic probe at each first angle is different, thereby improving the detection accuracy.

[0076] Reference Figure 6 As shown, Figure 6 The embodiment of this application provides Figure 1 Another optional flowchart before step S103, the method may include but is not limited to steps S601 to S603.

[0077] Step S601: Determine a second angle between a probe gate of the longitudinal ultrasonic probe and the inner wall surface of the axle to be measured.

[0078] The absolute value of the second angle is (45 o ,90 o ].

[0079] In an optional embodiment, there are multiple longitudinal ultrasonic probes, and the multiple longitudinal ultrasonic probes include a transverse ultrasonic probe with a first angle of 50° and a transverse ultrasonic probe with a second angle of -50°.

[0080] Step S602: Determine a second detection length of the longitudinal ultrasonic probe in the axle to be measured according to the radius of the axle to be measured, the inner hole radius and the second angle.

[0081] It should be noted that the second detection length The calculation formula is ,in, is the second detection length, is the radius of the axle to be measured, is the inner hole radius, The second angle.

[0082] Step S603: Extending the probe gate of the longitudinal ultrasonic probe toward the outside of the axle to be tested to a second detection length at a second angle.

[0083] Specifically, in the setting phase of ultrasonic flaw detection, the probe gate of the longitudinal ultrasonic probe is accurately extended from the probe position to the outside of the axle to be tested at a preset second angle until the second detection length is reached.

[0084] It should be noted that the second detection length is determined and the probe gate is extended according to the radius of the axle to be tested, the inner hole radius and the second angle. In order to reduce the impact of the initial ultrasonic wave emitted by the longitudinal ultrasonic probe on subsequent detection, since there is an unstable sound pressure area for the initial ultrasonic wave, in order to avoid detection in this area as much as possible, the second detection lengths of different sizes are set so that the initial ultrasonic wave emitted by the longitudinal ultrasonic probe at each second angle has a different delay, thereby improving the accuracy of detection.

[0085] Reference Figure 7 As shown, Figure 7 The embodiment of this application provides Figure 1 Another optional flowchart before step S103, the method may include but is not limited to steps S701 to S703.

[0086] Step S701: Determine a third angle between the probe gate of the internal ultrasonic probe and the inner wall surface of the axle to be tested.

[0087] Optionally, the third angle is 0 o .

[0088] Step S702: determining a third detection length of the internal ultrasonic probe in the axle to be measured according to the radius of the axle to be measured and the inner hole radius.

[0089] It should be noted that the third detection length The calculation formula is ,in, is the first detection length, is the radius of the axle to be measured, is the inner hole radius.

[0090] Step S703: Extending the probe gate of the internal ultrasonic probe toward the outside of the axle to be tested to a third detection length at a third angle.

[0091] Specifically, in the setting phase of ultrasonic flaw detection, the probe gate of the longitudinal ultrasonic probe is accurately extended from the probe position to the outside of the axle to be tested at a preset second angle until the second detection length is reached. The embodiment of the present application also provides an electronic device, the electronic device includes a memory and a processor, the memory stores a computer program, and the processor implements the above-mentioned flaw detection sensitivity calibration method when executing the computer program. The electronic device can be any smart terminal including a mobile phone, a tablet computer, a car computer, etc.

[0092] See also Figure 8 , Figure 8 1 is a schematic diagram of the hardware structure of an electronic device provided by an embodiment of the present application, and the electronic device includes: The processor 801 can be implemented in the form of a general-purpose CPU (Central Processing Unit), a microprocessor, an application-specific integrated circuit (ASIC), or one or more integrated circuits, etc., and is used to execute relevant programs to implement the flaw detection sensitivity calibration method provided by the embodiments of the present application; The memory 802 can be implemented in the form of a read-only memory (ROM), a static storage device, a dynamic storage device, or a random access memory (RAM), etc. The memory 802 can store an operating system and other application programs. When implementing the technical solutions provided by the embodiments of the present specification through software or firmware, the relevant program codes are stored in the memory 802 and are called by the processor 801 to execute the flaw detection sensitivity calibration method provided by the embodiments of the present application; The input / output interface 803 is used to implement information input and output; The communication interface 804 is used to implement communication interaction between this device and other devices, and can implement communication through a wired method (such as USB, network cable, etc.) or through a wireless method (such as mobile network, WIFI, Bluetooth, etc.); The bus 805 transmits information between the various components of the device (such as the processor 801, the memory 802, the input / output interface 803, and the communication interface 804); Among them, the processor 801, the memory 802, the input / output interface 803, and the communication interface 804 are communicatively connected to each other inside the device through the bus 805.

[0093] The embodiments of the present application also provide a computer-readable storage medium, which stores a computer program. When the computer program is executed by a processor, it is the flaw detection sensitivity calibration method provided by the embodiments of the present application.

[0094] As a non-transitory computer-readable storage medium, the memory can be used to store non-transitory software programs and non-transitory computer-executable programs. In addition, the memory can include high-speed random access memory, and can also include non-transitory memory, such as at least one magnetic disk storage device, a flash memory device, or other non-transitory solid-state storage devices. In some embodiments, the memory may optionally include a memory remotely provided with respect to the processor, and these remote memories can be connected to the processor through a network. Examples of the above networks include, but are not limited to, the Internet, an enterprise intranet, a local area network, a mobile communication network, and combinations thereof.

[0095] The embodiments described in the embodiments of the present application are to more clearly illustrate the technical solutions of the embodiments of the present application, and do not constitute a limitation on the technical solutions provided by the embodiments of the present application. Those skilled in the art can know that with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of the present application are equally applicable to similar technical problems.

[0096] Those skilled in the art can understand that the technical solutions shown in the figures do not constitute a limitation on the embodiments of the present application, and may include more or fewer steps than shown in the figures, or combine certain steps, or different steps.

[0097] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separated, that is, they may be located in one place, or they may be distributed to multiple network units. Some or all of the modules can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0098] Those of ordinary skill in the art can understand that all or some of the steps in the methods disclosed above, and the functional modules / units in the systems and devices, can be implemented as software, firmware, hardware, and their appropriate combinations.

[0099] The terms "first", "second", "third", "fourth", etc. (if any) in the specification of the present application and the above-mentioned drawings are used to distinguish similar objects, and do not have to be used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged under appropriate circumstances, so that the embodiments of the present application described here can be implemented in an order other than those illustrated or described here. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units does not have to be limited to those steps or units clearly listed, but may include other steps or units not clearly listed or inherent to these processes, methods, products, or devices.

[0100] It should be understood that in this application, "at least one (item)" means one or more, and "a plurality" means two or more. "And / or" is used to describe the association relationship of associated objects, indicating that there can be three relationships. For example, "A and / or B" can mean: only A exists, only B exists, and both A and B exist at the same time. Among them, A and B can be singular or plural. The character " / " generally indicates that the associated objects before and after are in an "or" relationship. "At least one (one) of the following" or its similar expressions refer to any combination of these items, including any combination of single items (ones) or plural items (ones). For example, at least one (one) of a, b, or c can mean: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, c can be single or multiple.

[0101] In several embodiments provided in this application, it should be understood that the disclosed systems and methods can be implemented in other ways. For example, the system embodiments described above are merely illustrative. For example, the above division of units is only a logical function division. In actual implementation, there can be other division methods. For example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the displayed or discussed coupling or direct coupling or communication connection between each other can be through some interfaces, and the indirect coupling or communication connection of devices or units can be in electrical, mechanical or other forms.

[0102] The units described above as separate components may or may not be physically separated, and the components displayed as units may or may not be physical units, that is, they can be located in one place, or they can be distributed to multiple network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0103] In addition, each functional unit in various embodiments of this application can be integrated in a processing unit, or each unit can exist physically alone, or two or more units can be integrated in one unit. The above integrated unit can be implemented in the form of hardware or in the form of a software functional unit.

[0104] When an integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-accessible storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of this technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes multiple instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods of various embodiments of this application. The aforementioned storage medium includes: various media that can store programs, such as USB flash drives, mobile hard disks, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical discs.

[0105] The preferred embodiments of the embodiments of this application have been described above with reference to the accompanying drawings, but this does not limit the scope of the rights of the embodiments of this application. Any modifications, equivalent replacements, and improvements made by those skilled in the art without departing from the scope and essence of the embodiments of this application shall fall within the scope of the rights of the embodiments of this application.

Claims

1. A flaw detection sensitivity calibration method for a hollow axle, applied to an ultrasonic flaw detector, characterized in that, The ultrasonic flaw detector includes a flaw detection adapter and a probe arm. The flaw detection adapter is provided with a detection hole. The flaw detection adapter is used to introduce a probe assembly into the inner hole of the axle to be measured. The probe arm includes an ultrasonic probe. The method includes: Obtain the spatial structure parameters and reference defect parameters of the axle to be measured; According to the spatial structure parameters, determine the axle end and inner hole of the axle to be measured, and install the flaw detection adapter at the axle end of the axle to be measured, wherein the detection hole corresponds to the inner hole; Control the probe arm to penetrate into the inner hole of the axle to be measured through the detection hole and rotate, and control the ultrasonic probe to perform ultrasonic scanning on the axle to be measured based on the scanning sensitivity to obtain the scanning defect parameters of the axle to be measured, wherein the ultrasonic scanning method is the C-scanning method; Compare the difference between the reference defect parameters and the scanning defect parameters to obtain an error parameter; If the error parameter is within a preset error range, determine the scanning sensitivity as the standard sensitivity of the axle to be measured; If the error parameter is not within the preset error range, adjust the scanning sensitivity and return to the step of controlling the ultrasonic probe to perform ultrasonic scanning on the axle to be measured based on the scanning sensitivity to obtain the scanning defect parameters of the axle to be measured, until the error parameter between the scanning defect parameters and the reference defect parameters is within the preset error range, and then determine the adjusted scanning sensitivity as the standard sensitivity.

2. The flaw detection sensitivity calibration method according to claim 1, wherein The scanning sensitivity is obtained through the following steps: Obtain a calibration test block and determine multiple defect positions of the calibration test block; Control the ultrasonic probe to emit ultrasonic waves to each of the defect positions respectively, and continuously receive the ultrasonic echoes corresponding to each of the defect positions; Determine the reference sensitivity of the ultrasonic probe according to each of the ultrasonic echoes; Linearly superimpose the reference sensitivity and a preset compensation gain value to obtain the scanning sensitivity.

3. The flaw detection sensitivity calibration method according to claim 2, characterized in that, The determining the reference sensitivity of the ultrasonic probe according to each of the ultrasonic echoes includes: Determine the reference sound path between each of the defect positions and the ultrasonic probe according to the time interval between the ultrasonic probe emitting ultrasonic waves and receiving each of the ultrasonic echoes; Adjust the ultrasonic emission frequency corresponding to the ultrasonic probe to respectively increase the amplitude of each of the ultrasonic echoes to a preset amplitude ratio requirement to obtain each reference echo, and respectively determine the peak value of each reference echo as the reference amplitude value, wherein the preset amplitude ratio requirement is that the amplitude display of the ultrasonic echo on the screen of the ultrasonic flaw detector reaches 80%; According to each of the reference sound paths and each of the reference amplitude values, fit a reference relationship curve between the sound path and the amplitude, and use the reference relationship curve as the reference sensitivity, wherein the linear relationship of the reference relationship curve is a direct proportional relationship or an inverse proportional relationship.

4. The flaw detection sensitivity calibration method according to claim 3, characterized in that, When the linear relationship of the reference relationship curve is a direct proportional relationship, the fitting the reference relationship curve between the sound path and the amplitude according to each of the reference sound paths and each of the reference amplitude values includes: Based on each of the reference sound paths and each of the reference amplitude values, respectively determine the relationship data points between the sound path and the wave amplitude corresponding to each of the ultrasonic echoes; Sort each of the relationship data points in ascending order of the reference sound path to obtain a set of relationship data points with spatial sequence attributes; Perform linear fitting on the set of relationship data points by the least squares method to obtain the reference relationship curve.

5. The flaw detection sensitivity calibration method according to claim 1, characterized in that The spatial structure parameters include the radius of the axle to be measured and the inner hole radius, and the number of the ultrasonic probes is multiple. The multiple ultrasonic probes include transverse ultrasonic probes for detecting transverse defects of the axle. Before controlling the probe arm to rotate within the inner hole, the method further includes: Determine a first angle between the transverse ultrasonic probe and the inner wall surface of the axle to be measured; Determine a first detection length of the transverse ultrasonic probe inside the axle to be measured according to the radius of the axle to be measured, the inner hole radius, and the first angle; Extend the probe gate of the transverse ultrasonic probe to the first detection length outside the axle to be measured at the first angle.

6. The flaw detection sensitivity calibration method according to claim 5, wherein, The multiple ultrasonic probes further include longitudinal ultrasonic probes for detecting longitudinal defects of the axle. Before controlling the probe arm to rotate within the inner hole, the method further includes: Determine a second angle between the probe gate of the longitudinal ultrasonic probe and the inner wall surface of the axle to be measured; Determine a second detection length of the longitudinal ultrasonic probe inside the axle to be measured according to the radius of the axle to be measured, the inner hole radius, and the second angle; Extend the probe gate of the longitudinal ultrasonic probe to the second detection length outside the axle to be measured at the second angle.

7. The flaw detection sensitivity calibration method according to claim 5, characterized in that, The multiple ultrasonic probes further include internal ultrasonic probes for detecting internal defects of the axle. Before controlling the probe arm to rotate within the inner hole, the method further includes: Determine a third angle between the probe gate of the internal ultrasonic probe and the inner wall surface of the axle to be measured; Determine a third detection length of the internal ultrasonic probe inside the axle to be measured according to the radius of the axle to be measured and the inner hole radius; Extend the probe gate of the internal ultrasonic probe to the third detection length outside the axle to be measured at the third angle.

8. The flaw detection sensitivity calibration method according to claim 6, wherein The absolute value of the first angle is in the range of (0 o , 45 o , and the absolute value of the second angle is in the range of (45 o , 90 o .

9. The flaw detection sensitivity calibration method according to claim 7, characterized in that, The third angle is 0 o .

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a program executable by a processor, and when the program executable by the processor is executed by the processor, it implements the flaw detection sensitivity calibration method according to any one of claims 1 to 9.

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