Ultrasonic detection method and device for bearing bush coating layer de-molding defect of hydroelectric generating set

Abstract

The invention relates to the technical field of unit detection, in particular to an ultrasonic detection method and device for the de-molding defect of a hydroelectric generating set bearing bush coating layer, and the method comprises the steps: obtaining ultrasonic data reflected by a base layer and a coating layer of a hydroelectric generating set bearing bush reference block; calculating a first reflectivity between a matrix layer interface and a cladding layer interface and a second reflectivity between the cladding layer interface and an air interface according to the ultrasonic data; according to the first reflectivity and the second reflectivity, the echo height difference is calculated, and the echo height difference is the echo height difference between the matrix layer interface and the cladding layer interface and the echo height difference between the cladding layer interface and the air interface; and according to the echo height and the echo height difference, carrying out ultrasonic detection on the actual hydroelectric generating set bearing bush coating layer to generate a de-molding defect detection result. Therefore, the problems of low detection efficiency, unstable accuracy, influence on safe operation of the unit and the like caused by the fact that the bearing bush coating layer de-molding defect of the hydroelectric generating set is detected depending on manual experience in the related technology are solved.

Description

Technical Field

[0001] The present application relates to the technical field of unit detection, and particularly relates to an ultrasonic detection method and device for the defect of the separation of the clad layer of the bearing bush of a hydropower unit. Background Art

[0002] The bearing bush is an important component in a hydro-generating unit, mainly used to support and guide the operation of a rotating shaft (such as a water turbine shaft or a generator shaft), including a thrust bearing bush and a guide bearing bush, providing support for the rotating shaft of the hydro-generator, ensuring that the rotating shaft can rotate stably, bearing the weights of the rotating shaft and components such as the rotor mounted on the rotating shaft, and transmitting them to the foundation of the unit, as well as providing precise radial positioning for the rotating shaft, restricting the radial swing and deviation of the rotating shaft during operation. The bearing bush is composed of a matrix and a clad layer. The matrix is generally made of ordinary alloy steel, and the clad layer is made of a polymer material. During the long-term operation of the unit, the bearing bush is affected by vibration, oil film corrosion, and high temperature, resulting in wear of the clad layer of the bearing bush, separation of the matrix and the clad layer, causing the running track of the journal to deviate from the designed position, affecting the alignment and stability of the unit, as well as uneven contact between the journal and the bearing bush, deterioration of the lubrication condition, increased friction, accelerating the wear and separation of the bearing bush and the journal, and resulting in increased vibration during the operation of the unit.

[0003] In the related art, currently, the ultrasonic detection of the defect of the separation of the clad layer of the bearing bush of a hydro-power unit relies on manual experience, and the error in determining the defect boundary is relatively large, resulting in low detection efficiency and unstable accuracy, affecting the safe operation of the unit. Summary of the Invention

[0004] The present application provides an ultrasonic detection method, device, electronic device, storage medium, and program for the defect of the separation of the clad layer of the bearing bush of a hydro-power unit to solve the problems in the related art that the detection of the defect of the separation of the clad layer of the bearing bush of a hydro-power unit relying on manual experience results in low detection efficiency and unstable accuracy, affecting the safe operation of the unit, etc.

[0005] The first aspect embodiment of the present application provides an ultrasonic detection method for the defect of the separation of the clad layer of the bearing bush of a hydro-power unit, including the following steps: obtaining the ultrasonic data reflected by the base layer and the clad layer of the comparison test block of the bearing bush of the hydro-power unit; calculating the first reflectivity between the matrix layer interface and the clad layer interface and the second reflectivity between the clad layer interface and the air interface according to the ultrasonic data; calculating the echo height difference according to the first reflectivity and the second reflectivity, where the echo height difference is the difference between the echo heights of the matrix layer interface and the clad layer interface and the echo height of the clad layer interface and the air interface; screening a phased array probe according to the echo height and the echo height difference to perform ultrasonic detection on the clad layer of the actual bearing bush of the hydro-power unit to generate a detection result for the separation defect.

[0006] Optionally, calculating the first reflectivity between the matrix layer interface and the composite layer interface and the second reflectivity between the composite layer interface and the air interface based on the ultrasonic data includes: obtaining the density and sound velocity of the bearing bush matrix and the composite layer material of the hydroelectric unit from the ultrasonic data; calculating the corresponding acoustic impedances of the bearing bush matrix and the composite layer material according to the density and the sound velocity; calculating the first reflectivity between the matrix layer interface and the composite layer interface according to the acoustic impedances of the bearing bush matrix and the composite layer material, and calculating the second reflectivity between the composite layer interface and the air interface according to the acoustic impedance of the composite layer material and the air acoustic impedance.

[0007] Optionally, before screening the phased array probe to perform ultrasonic detection on the composite layer of the actual hydroelectric unit bearing bush according to the echo height and the echo height difference to generate a detection result of the delamination defect, it includes:

[0008] Calibrating the phased array process parameters of the phased array ultrasonic equipment by using the ultrasonic data of the reference block; wherein, the phased array process parameters include probe parameters, instrument setting parameters and scanning parameters, wherein, the probe parameters include probe type, frequency, probe diameter, aperture, number of wafers, size and arrangement mode, the scanning parameters include scanning mode and encoder parameters; the instrument setting parameters are the detection thresholds of the delamination defect, including the complete bonding threshold, the partial delamination threshold and the complete delamination threshold, and corresponding display colors are set according to different detection thresholds of the delamination defect.

[0009] Optionally, obtaining the echo waveform, projection imaging view and the scanning path recorded by the two-dimensional encoder of the composite layer of the actual hydroelectric unit bearing bush; generating the ultrasonic data of the composite layer of the actual hydroelectric unit bearing bush according to the amplitude and time of the echo waveform, the projection imaging view and the scanning path; generating a detection result of the delamination defect according to the ultrasonic data, the echo height and the echo height difference.

[0010] Optionally, generating a detection result of the delamination defect according to the ultrasonic data, the echo height and the echo height difference includes: if the echo height of the matrix layer interface and the composite layer interface of the actual hydroelectric unit bearing bush in the ultrasonic data is less than or equal to the echo height of the matrix layer and the composite layer interface of the reference block, the current matrix and composite layer interface is the complete bonding area; if the echo height of the matrix layer interface and the composite layer interface of the actual hydroelectric unit bearing bush in the ultrasonic data is greater than the echo height of the matrix layer and the composite layer interface of the reference block and less than the sum of the echo height of the matrix layer and the composite layer interface of the reference block and the echo height difference, the current matrix and composite layer interface is the partial delamination area; if the echo height of the matrix layer interface and the composite layer interface of the actual hydroelectric unit bearing bush in the ultrasonic data is greater than or equal to the sum of the echo height of the matrix layer and the composite layer interface of the reference block and the echo height difference, the current matrix and composite layer interface is the delamination area.

[0011] Optionally, after generating the detection result of the delamination defect based on the ultrasonic data, the echo height, and the echo height difference, the method further includes: analyzing the bonding state of the actual global interface of the bearing bush of the hydro-generator unit according to the amplitude of the echo waveform and the projection imaging view; calculating the defect depth according to the time of the echo waveform, and determining the defect position coordinates according to the scanning path; generating the detection result of the delamination defect according to the interface bonding state, the defect depth, and the defect position coordinates.

[0012] An ultrasonic detection device for delamination defects of a bearing bush composite layer of a hydro-generator unit according to a second aspect embodiment of the present application includes: an acquisition module configured to acquire ultrasonic data reflected by a bearing bush base layer and a composite layer of a hydro-generator unit comparison test block; a first calculation module configured to calculate a first reflectivity between a matrix layer interface and a composite layer interface and a second reflectivity between the composite layer interface and an air interface according to the ultrasonic data; a second calculation module configured to calculate an echo height difference according to the first reflectivity and the second reflectivity, where the echo height difference is the echo height difference between the echo heights of the matrix layer interface and the composite layer interface and the echo height of the composite layer interface and the air interface; and a generation module configured to generate a detection result of the delamination defect of the bearing bush composite layer of the hydro-generator unit according to the echo height difference.

[0013] An electronic device according to a third aspect embodiment of the present application includes: a memory, a processor, and a computer program stored on the memory and executable on the processor, where the processor executes the program to perform the ultrasonic detection method for delamination defects of a bearing bush composite layer of a hydro-generator unit as described in the above embodiments.

[0014] A computer-readable storage medium according to a fourth aspect embodiment of the present application stores a computer program, and the program is executed by a processor to perform the ultrasonic detection method for delamination defects of a bearing bush composite layer of a hydro-generator unit as described in the above embodiments.

[0015] A computer program product according to a fifth aspect embodiment of the present application includes a computer program or instruction, and when the computer program or instruction is executed, it implements the ultrasonic detection method for delamination defects of a bearing bush composite layer of a hydro-generator unit as described in the above embodiments.

[0016] Thus, the present application has at least the following beneficial effects:

[0017] In the embodiment of the present application, the first reflectivity between the matrix layer interface and the composite layer interface and the second reflectivity between the composite layer interface and the air interface are calculated by using the ultrasonic data reflected by the base layer and the composite layer of the water turbine bearing comparison test block respectively; the echo height difference is calculated according to the first reflectivity and the second reflectivity, where the echo height difference is the difference between the echo heights of the matrix layer interface and the composite layer interface and the echo height of the composite layer interface and the air interface; the phased array probe is selected according to the echo height and the echo height difference to perform ultrasonic detection on the composite layer of the actual water turbine bearing to generate a detection result of the delamination defect. Through calibration of the comparison test block, calculation of acoustic parameters and integration of phased array technology, high-precision and high-efficiency detection of the delamination defect of the composite layer of the water turbine bearing is achieved.

[0018] Additional aspects and advantages of the present application will be given in part in the following description, become apparent in part from the following description, or be learned through the practice of the present application. Description of the Drawings

[0019] The above and / or additional aspects and advantages of the present application will become apparent and be readily understood from the following description of the embodiments in conjunction with the drawings, where:

[0020] Figure 1 is a flowchart of an ultrasonic detection method for delamination defects of the composite layer of a water turbine bearing according to an embodiment of the present application;

[0021] Figure 2 is a schematic diagram of a phased array ultrasonic detection method for delamination defects of the composite layer of a water turbine bearing according to an embodiment of the present application;

[0022] Figure 3 is an example diagram of an ultrasonic detection device for delamination defects of the composite layer of a water turbine bearing according to an embodiment of the present application;

[0023] Figure 4 is a schematic structural diagram of an electronic device according to an embodiment of the present application. Detailed Embodiments

[0024] The embodiments of the present application will be described in detail below. The examples of the embodiments are shown in the drawings, where the same or similar reference numerals denote the same or similar elements or elements with the same or similar functions from beginning to end. The embodiments described below with reference to the drawings are exemplary and are intended to explain the present application, but should not be construed as limiting the present application.

[0025] Currently, during each A / B-class maintenance of a water turbine unit, non-destructive testing needs to be carried out on the bearing to detect defects such as bearing wear and delamination of the composite layer in a timely manner and eliminate potential safety hazards of the equipment. Appearance inspection and penetrant testing methods can be used for bearing wear or delamination at the edge of the composite layer, but ultrasonic testing can only be used for delamination of the internal composite layer.

[0026] There is no ultrasonic detection standard for the inspection of the delamination of the overlay layer of the bearing bush of a hydro-generating unit, and only the standard for a thermal power generating unit can be referred to. However, this standard mainly targets the high-temperature bearing bushes of thermal power generating units, and the overlay layer is made of alloy materials such as Babbitt alloy and tungsten-lead alloy. In contrast, the temperature of the hydro-generating unit is relatively low, and the overlay layer mostly uses polymer materials such as polytetrafluoroethylene and polyamide. Since the acoustic properties of alloy materials and polymer materials differ greatly, the reflected echo differences between them are significant. If the ultrasonic detection standard for the bearing bushes of thermal power generating units with an alloy material overlay layer is used to detect the bearing bushes of hydro-generating units with a polymer material overlay layer, it will inevitably cause missed detection or misjudgment of defects, affecting the safe operation of the unit.

[0027] The following describes the ultrasonic detection method, device, electronic device, storage medium, and program for the delamination defect of the overlay layer of the bearing bush of a hydro-generating unit according to the embodiments of the present application with reference to the accompanying drawings.

[0028] Specifically, Figure 1 It is a schematic flowchart of an ultrasonic detection method for the delamination defect of the overlay layer of the bearing bush of a hydro-generating unit provided by an embodiment of the present application.

[0029] As Figure 1 shown, the ultrasonic detection method for the delamination defect of the overlay layer of the bearing bush of a hydro-generating unit includes the following steps:

[0030] In step S101, ultrasonic data reflected by the base layer and the overlay layer of the comparison test block of the bearing bush of the hydro-generating unit are obtained.

[0031] It can be understood that the embodiments of the present application can obtain the ultrasonic data reflected by the base layer and the overlay layer of the comparison test block of the bearing bush of the hydro-generating unit, so as to calculate the first reflectivity between the interface of the base layer and the overlay layer and the second reflectivity between the interface of the overlay layer and the air interface in the subsequent calculation of the ultrasonic data.

[0032] It should be noted that before obtaining the ultrasonic data reflected by the base layer and the overlay layer of the comparison test block of the bearing bush of the hydro-generating unit, a comparison test block with the same matrix material (such as alloy steel) and overlay layer material (such as polytetrafluoroethylene) as the actual bearing bush, the same test block thickness, and a good combination of the interface between the matrix and the overlay layer without delamination or bubbles needs to be made to avoid acoustic parameter deviation.

[0033] In step S102, the first reflectivity between the interface of the base layer and the overlay layer and the second reflectivity between the interface of the overlay layer and the air interface are calculated based on the ultrasonic data.

[0034] It can be understood that the embodiments of the present application can calculate the first reflectivity between the interface of the base layer and the overlay layer and the second reflectivity between the interface of the overlay layer and the air interface based on the ultrasonic data, so as to calculate the echo height difference in the subsequent calculation.

[0035] In the embodiment of the present application, calculating the first reflectivity between the matrix layer interface and the composite layer interface and the second reflectivity between the composite layer interface and the air interface according to the ultrasonic data includes: obtaining the density and sound velocity of the bearing bush matrix and the composite layer material of the hydro-generator unit from the ultrasonic data; calculating the corresponding acoustic impedances of the bearing bush matrix and the composite layer material according to the density and sound velocity respectively; calculating the first reflectivity between the matrix layer interface and the composite layer interface according to the acoustic impedances of the bearing bush matrix and the composite layer material, and calculating the second reflectivity between the composite layer interface and the air interface according to the acoustic impedance of the composite layer material and the acoustic impedance of air.

[0036] It can be understood that in the embodiment of the present application, the acoustic impedances of the bearing bush matrix and the composite layer material of the hydro-generator unit can be calculated according to the density and sound velocity of the bearing bush matrix and the composite layer material, and the first reflectivity between the matrix layer interface and the composite layer interface and the second reflectivity between the composite layer interface and the air interface can be calculated respectively according to the acoustic impedances, so as to improve the accuracy of subsequent detection.

[0037] Specifically, measuring the density and sound velocity of the bearing bush matrix and the composite layer material to calculate the acoustic impedance, specifically: Z = ρc, where Z is the acoustic impedance, ρ is the density, and c is the sound velocity.

[0038] Specifically, when measuring the acoustic characteristics of the bearing bush matrix and the composite layer material, the sound velocities of the bearing bush matrix and the composite layer can be measured by using an ultrasonic detector to measure two mutually parallel large flat bottom surfaces of the matrix and the composite layer, and calculated by using the first and second bottom surface echoes of the large flat bottom surface, or obtained from the Mth and Nth bottom waves, and the average value is taken after measuring 3 times to reduce errors; the density is obtained by the ratio of weight to volume, the weight is measured by the weighing method, and the volume of the irregular object is measured by the liquid immersion drainage method.

[0039] In step S103, calculating the echo height difference according to the first reflectivity and the second reflectivity, where the echo height difference is the echo height difference between the echo heights of the matrix layer interface and the composite layer interface and the echo height of the composite layer interface and the air interface.

[0040] It can be understood that in the embodiment of the present application, the echo height difference can be calculated according to the first reflectivity and the second reflectivity. By the direct correlation between the reflectivity and the echo height difference, replacing the manual experience judgment, and calculating the echo height difference based on the reflectivity, it provides a standardized and high-precision detection basis for the defect of the composite layer peeling off the bearing bush of the hydro-generator unit, and improves the reliability and efficiency of defect identification.

[0041] It should be noted that the echo heights of the matrix layer interface and the composite layer interface represent the echo heights in the normal bonding state; the echo height of the composite layer interface and the air interface represents the theoretical echo height in the completely peeled-off state.

[0042] Specifically, the interface reflectivity and the echo height difference ΔH are calculated based on acoustic parameters, specifically:

[0043] Reflectivity of the substrate - composite layer:

[0044] Reflectivity of the composite layer - air:

[0045] Echo height difference:

[0046] Wherein, R 基-覆 is the sound pressure reflectivity of the interface between the base layer and the composite layer; Z 基 is the acoustic impedance of the substrate; Z 覆 is the acoustic impedance of the composite layer, R 空-覆 is the sound pressure reflectivity of the interface between air and the composite layer; Z 空 is the acoustic impedance of air, ΔH is the difference between the echo height of the interface between the base layer and the composite layer and the echo height of the interface between the composite layer and air; H 基-覆 is the echo height of the interface between the base layer and the composite layer; H 空-覆 is the echo height of the interface between the composite layer and air; P0 is the sound pressure at the probe.

[0047] In step S104, phased array probes are selected according to the echo height and the echo height difference to perform ultrasonic detection on the composite layer of the actual hydro - generator bearing bush to generate the detection result of the delamination defect.

[0048] It can be understood that in the embodiments of the present application, phased array probes can be selected according to the echo height and the echo height difference to perform ultrasonic detection on the composite layer of the actual hydro - generator bearing bush to generate the detection result of the delamination defect. By selecting phased array probes based on the echo height and the echo height difference, combined with real - time imaging and automated analysis, the present invention realizes high - precision and high - efficiency detection of the delamination defect of the composite layer of the hydro - generator bearing bush.

[0049] In the embodiments of the present application, before phased array probes are selected according to the echo height and the echo height difference to perform ultrasonic detection on the composite layer of the actual hydro - generator bearing bush to generate the detection result of the delamination defect, it includes: calibrating the phased array process parameters of the phased array ultrasonic device by using the ultrasonic data of the reference block; wherein, the phased array process parameters include probe parameters, instrument setting parameters and scanning parameters. Among them, the probe parameters include probe type, frequency, probe diameter, aperture, number of wafers, size and arrangement mode, and the scanning parameters include scanning mode and encoder parameters; the instrument setting parameters are the detection thresholds for delamination defects, including the complete bonding threshold, partial delamination threshold and complete delamination threshold, and corresponding display colors are set according to different detection thresholds for delamination defects.

[0050] It can be understood that the embodiments of the present application can use the ultrasonic data of the reference block to correct the phased array process parameters of the phased array ultrasonic device, so as to improve the detection efficiency and accuracy.

[0051] It should be noted that the instrument parameters and focusing rules are adjusted according to the reference block, the sensitivity is calibrated, and three equivalent thresholds are set: the fully bonded area, the partially debonded area, and the debonded area.

[0052] In the embodiments of the present application, before screening the phased array probe according to the echo height and the echo height difference to perform ultrasonic detection on the actual water turbine bearing overlay layer to generate a debonding defect detection result, it further includes: obtaining the echo waveform, the projection imaging view of the actual water turbine bearing overlay layer, and the scanning path recorded by the two-dimensional encoder; generating the ultrasonic data of the actual water turbine bearing overlay layer according to the amplitude and time of the echo waveform, the projection imaging view, and the scanning path; generating the debonding defect detection result according to the ultrasonic data, the echo height, and the echo height difference.

[0053] It can be understood that the embodiments of the present application can generate a debonding defect detection result by integrating the echo waveform, the projection imaging, and the scanning path data, and combining the dynamic threshold determination rule, which improves the accuracy of generating the debonding defect detection result.

[0054] It should be noted that the present application can select real-time A-type wave amplitude display and C-type projection imaging display, add an encoder, and record the scanning path and the position and area of the debonding defect.

[0055] In the embodiments of the present application, generating the debonding defect detection result according to the ultrasonic data, the echo height, and the echo height difference includes: if the echo height of the matrix layer interface and the overlay layer interface of the actual water turbine bearing in the ultrasonic data is less than or equal to the echo height of the matrix layer and the overlay layer interface of the reference block, the current matrix and overlay layer interface is the fully bonded area; if the echo height of the matrix layer interface and the overlay layer interface of the actual water turbine bearing in the ultrasonic data is greater than the echo height of the matrix layer and the overlay layer interface of the reference block, and less than the sum of the echo height of the matrix layer and the overlay layer interface of the reference block and the echo height difference, the current matrix and overlay layer interface is the partially debonded area; if the echo height of the matrix layer interface and the overlay layer interface of the actual water turbine bearing in the ultrasonic data is greater than or equal to the sum of the echo height of the matrix layer and the overlay layer interface of the reference block and the echo height difference, the current matrix and overlay layer interface is the debonded area.

[0056] It can be understood that the embodiments of the present application can accurately identify the classification result of the debonding defect based on the threshold determination method calibrated by the reference block, and achieve high-precision, high-efficiency, and high-reliability detection of the debonding defect of the water turbine bearing overlay layer.

[0057] Specifically, for the complete bonding area: the equivalent of the reflected echo display ≤ the equivalent of the echo at the interface between the matrix and the clad layer of the reference block; for the partial delamination area: the equivalent of the echo at the interface between the matrix and the clad layer of the reference block < the equivalent of the reflected echo display < the equivalent of the echo at the interface between the clad layer and air (i.e., the equivalent of the echo at the interface between the matrix and the clad layer of the reference block + ΔH); for the delamination area: the equivalent of the reflected echo display ≥ the equivalent of the echo at the interface between the clad layer and air (i.e., the equivalent of the echo at the interface between the matrix and the clad layer of the reference block + ΔH).

[0058] In the embodiment of the present application, after generating the delamination defect detection result based on the ultrasonic data, echo height, and echo height difference, it further includes: analyzing the bonding state of the global interface of the actual hydro-generator bearing bush according to the amplitude of the echo waveform and the projection imaging view; calculating the defect depth according to the time of the echo waveform, and determining the defect position coordinates according to the scanning path; generating the delamination defect detection result based on the interface bonding state, defect depth, and defect position coordinates.

[0059] It can be understood that the embodiment of the present application can analyze the bonding state, defect depth, and defect position coordinates of the global interface of the actual hydro-generator bearing bush by fusing the echo amplitude, time, imaging, and position data, and realizes the standardized, intelligent, and high-precision detection of the delamination defect of the clad layer of the hydro-generator bearing bush.

[0060] Specifically, when discriminating the phased array interface echo imaging display, the wave height values within three threshold ranges are marked with different colors for distinction to identify the defect imaging display and the interface inherent echo display. The wave amplitude equivalent and area of the incomplete delamination area and the delamination area are respectively measured, and the results are comprehensively evaluated according to the design requirements.

[0061] According to the ultrasonic detection method for the delamination defect of the clad layer of the hydro-generator bearing bush proposed in the embodiment of the present application, the first reflectivity between the matrix layer interface and the clad layer interface and the second reflectivity between the clad layer interface and the air interface are calculated by using the ultrasonic data reflected by the base layer and the clad layer of the hydro-generator bearing bush reference block respectively; the echo height difference is calculated according to the first reflectivity and the second reflectivity, where the echo height difference is the difference between the echo heights of the matrix layer interface and the clad layer interface and the echo height of the clad layer interface and the air interface; the phased array probe is selected according to the echo height and the echo height difference to perform ultrasonic detection on the clad layer of the actual hydro-generator bearing bush to generate the delamination defect detection result. Through the calibration of the reference block, the calculation of acoustic parameters, and the integration of phased array technology, the high-precision and high-efficiency detection of the delamination defect of the clad layer of the hydro-generator bearing bush is realized.

[0062] Next, it will be combined with Figure 2 The ultrasonic detection method for the delamination defect of the clad layer of the hydro-generator bearing bush of the present application will be elaborated in detail as follows:

[0063] 1. Measure the acoustic properties of the bearing bush base and the cladding layer materials: The sound velocities of the bearing bush base and the cladding layer can be measured by using an ultrasonic detector to measure the two mutually parallel large flat bottom surfaces of the base and the cladding layer, and calculated by using the first and second bottom echoes of the large flat bottom surface; it can also be obtained by the Mth and Nth bottom waves. Measure 3 times and take the average value to reduce errors. The density is determined by the ratio of weight to volume. The weight is measured by the weighing method, and the volume of irregular objects is measured by the liquid immersion drainage method.

[0064] Calculate the acoustic impedance Z = ρc of the base and cladding layer materials, where ρ is the density of the bearing bush base and cladding layer materials, and c is the sound velocity.

[0065] 2. Calculate the interface reflectivity and the echo height difference between the base and the cladding layer materials: According to the measured acoustic properties of the base and the cladding layer, calculate the interface reflectivity (R base-clad) between the base and the cladding layer, the reflectivity (R air-clad) between the cladding layer and the air interface, and the interface reflection echo height between the base and the cladding layer and the echo height difference (ΔH) between the cladding layer and the air interface.

[0066] Calculate the interface reflectivity and the echo height difference ΔH based on the acoustic parameters. Specifically:

[0067] Reflectivity of the base - cladding layer:

[0068] Reflectivity of the cladding layer - air:

[0069] Echo height difference:

[0070] Among them, R 基-覆 is the sound pressure reflectivity of the interface between the base layer and the cladding layer; Z 基 is the acoustic impedance of the base; Z 覆 is the acoustic impedance of the cladding layer, R 空-覆 is the sound pressure reflectivity of the interface between the air and the cladding layer; Z 空 is the acoustic impedance of the air, ΔH is the difference between the echo height of the interface between the base layer and the cladding layer and the echo height of the interface between the cladding layer and the air; H 基-覆 is the echo height of the interface between the base layer and the cladding layer; H 空-覆 is the echo height of the interface between the cladding layer and the air; P0 is the sound pressure at the probe.

[0071] 3. Manufacture a bearing bush comparison test block: Select the remaining materials for manufacturing the bearing bush or the base and cladding layer of the same material, acoustic performance, and specifications to process the bearing bush comparison test block, ensuring that the base and cladding layer of the comparison test block are well combined and there is no delamination.

[0072] 4. Select a phased array probe: Select the probe frequency range according to the acoustic attenuation and sound field characteristics of the bearing bush base layer and the composite layer; select the probe model according to the shape of the bearing bush to ensure good coupling between the probe and the detection surface of the bearing bush, and determine the probe size; according to the thickness of the bearing bush base body and the composite layer, select to place the probe on the base body side or the composite layer side as the detection surface to avoid the composite layer thickness being small and within the blind area of the probe initial wave.

[0073] 5. Adjust parameters and set thresholds: Place the probe on the well-bonded area of the base body and the composite layer of the bearing bush comparison test block to make the interface echo reach 80% of the full screen, and increase the gain by 3 dB as coupling compensation. Set 3 equivalent thresholds: fully bonded area (≤80% wave height), partially debonded area (80% wave height - 80% wave height + ΔH), debonded area (≥80% wave height + ΔH). Select A-type amplitude display and C-type projection real-time imaging display, and connect a two-dimensional encoder to record the probe scanning path, defect position and area.

[0074] 6. Identify the phased array interface echo imaging display: Mark the wave height values within the 3 threshold ranges with different colors for distinction. Mark the debonded area, partially debonded area and intact area with red, yellow and green respectively to achieve visual and rapid discrimination, and identify the interface debonded area, incompletely debonded area and interface inherent echo imaging display.

[0075] 7. Evaluate the debonding defects of the base layer and the composite layer: Based on the measurement of the reflected echo height and defect area at the interface between the base body and the composite layer, comprehensively evaluate the echo height and area of the incompletely bonded area and the debonded area at the interface between the base body and the composite layer.

[0076] In summary, in this application, the composite layer of the bearing bush of the hydropower unit uses polymer materials such as polytetrafluoroethylene and polyamide, which have great differences in acoustic properties from the alloy materials such as babbit alloy and tungsten-lead alloy used in thermal power units. There is no standard to rely on for the ultrasonic detection of the bearing bush of the hydropower unit, and relying on the thermal power bearing bush detection standard is likely to cause missed detection or misjudgment of defects. Conventional ultrasonic detection is manually drawn when measuring the defect area. The defect area is extremely irregular and difficult to accurately measure, and the boundaries of the debonded area and the incompletely bonded area are not easy to define, making it difficult to comprehensively evaluate the quality of the bearing bush. The present invention adopts the phased array ultrasonic multi-channel technology, sets 3 interface echo height thresholds according to the calculated height difference of the interface echo of different materials, images and displays the 3 echo height situations and assigns different color marks, and cooperates with the encoder to record the scanning path, which is convenient for identifying different regions, defining boundaries, measuring the area of various situations, and thus comprehensively evaluating. Compared with the conventional method, the detection speed is increased by more than 50%, the measurement error of the defect area is <5%, and it can be adapted to the detection of composite layers with different thicknesses (1 - 50 mm) and materials (such as polytetrafluoroethylene and polyamide), with fast detection speed, high efficiency and high precision.

[0077] Next, a description will be given of an ultrasonic detection device for the defect of the overlay layer peeling off the bearing bush of a hydropower unit according to an embodiment of the present application with reference to the accompanying drawings.

[0078] Figure 3 It is a block schematic diagram of an ultrasonic detection device for the defect of the overlay layer peeling off the bearing bush of a hydropower unit according to an embodiment of the present application.

[0079] As Figure 3 shown, the ultrasonic detection device 10 for the defect of the overlay layer peeling off the bearing bush of a hydropower unit includes: an acquisition module 100, a first calculation module 200, a second calculation module 300, and a generation module 400.

[0080] Among them, the acquisition module 100 is used to acquire the ultrasonic data reflected by the bearing bush base layer and the overlay layer of the hydropower unit comparison test block respectively; the first calculation module 200 is used to calculate the first reflectivity between the matrix layer interface and the overlay layer interface and the second reflectivity between the overlay layer interface and the air interface according to the ultrasonic data; the second calculation module 300 is used to calculate the echo height difference according to the first reflectivity and the second reflectivity, where the echo height difference is the echo height difference between the echo heights of the matrix layer interface and the overlay layer interface and the echo height of the overlay layer interface and the air interface; the generation module 400 is used to screen the phased array probe according to the echo height and the echo height difference to perform ultrasonic detection on the actual overlay layer of the hydropower unit bearing bush to generate a detection result for the peeling defect.

[0081] It should be noted that the foregoing explanation of the embodiment of the ultrasonic detection method for the defect of the overlay layer peeling off the bearing bush of a hydropower unit also applies to the ultrasonic detection device for the defect of the overlay layer peeling off the bearing bush of a hydropower unit in this embodiment, and will not be elaborated here.

[0082] The ultrasonic detection device for the defect of the overlay layer peeling off the bearing bush of a hydropower unit according to an embodiment of the present application calculates the first reflectivity between the matrix layer interface and the overlay layer interface and the second reflectivity between the overlay layer interface and the air interface by using the ultrasonic data reflected by the base layer and the overlay layer of the hydropower unit bearing bush comparison test block respectively; calculates the echo height difference according to the first reflectivity and the second reflectivity, where the echo height difference is the echo height difference between the echo heights of the matrix layer interface and the overlay layer interface and the echo height of the overlay layer interface and the air interface; screens the phased array probe according to the echo height and the echo height difference to perform ultrasonic detection on the actual overlay layer of the hydropower unit bearing bush to generate a detection result for the peeling defect. Through calibration with a comparison test block, acoustic parameter calculation, and phased array technology integration, high-precision and high-efficiency detection of the defect of the overlay layer peeling off the bearing bush of a hydropower unit is achieved.

[0083] Figure 4 It is a schematic structural diagram of an electronic device provided by an embodiment of the present application. The electronic device may include:

[0084] A memory 401, a processor 402, and a computer program stored on the memory 401 and executable on the processor 402.

[0085] When the processor 402 executes the program, it implements the ultrasonic detection method for the defect of the water turbine bearing overlay peeling provided in the above embodiments.

[0086] Further, the vehicle further includes:

[0087] A communication interface 403 for communication between the memory 401 and the processor 402.

[0088] The memory 401 is used to store a computer program executable on the processor 402.

[0089] The memory 401 may include a high-speed RAM memory, and may also include a non-volatile memory, such as at least one disk memory.

[0090] If the memory 401, the processor 402, and the communication interface 403 are implemented independently, the communication interface 403, the memory 401, and the processor 402 can be interconnected through a bus and communicate with each other. The bus can be an Industry Standard Architecture (ISA) bus, a Peripheral Component Interconnect (PCI) bus, an Extended Industry Standard Architecture (EISA) bus, etc. The bus can be divided into an address bus, a data bus, a control bus, etc. For ease of representation, Figure 4 only a thick line is shown in the figure, but it does not mean that there is only one bus or one type of bus.

[0091] Optionally, in a specific implementation, if the memory 401, the processor 402, and the communication interface 403 are integrated on a chip, the memory 401, the processor 402, and the communication interface 403 can communicate with each other through an internal interface.

[0092] The processor 402 may be a Central Processing Unit (CPU), or an Application Specific Integrated Circuit (ASIC), or one or more integrated circuits configured to implement the embodiments of the present application.

[0093] An embodiment of the present application further provides a computer-readable storage medium, on which a computer program or instruction is stored. When the computer program or instruction is executed by a processor, the ultrasonic detection method for the defect of the overlay layer of the bearing bush of the hydraulic generator set as described above is implemented.

[0094] An embodiment of the present application further provides a computer program product, including a computer program or instruction. When the computer program or instruction is executed, the ultrasonic detection method for the defect of the overlay layer of the bearing bush of the hydraulic generator set as described above is implemented.

[0095] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples", etc. means 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 representations of the above terms are not necessarily directed to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any one or N embodiments or examples in a suitable manner. In addition, without conflict, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples.

[0096] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "N" is at least two, such as two, three, etc., unless otherwise specifically and clearly defined.

[0097] Any process or method description shown in the flowchart or described in other ways herein may be understood to represent a module, segment, or part of code including one or N executable instructions for implementing a customized logical function or process. The scope of the preferred embodiments of the present application includes additional implementations, where the functions may be executed in a substantially simultaneous manner or in a reverse order according to the functions involved, rather than in the order shown or discussed, which should be understood by those skilled in the art of the embodiments of the present application.

[0098] It should be understood that each part of the present application can be implemented by hardware, software, firmware, or a combination thereof. In the above embodiments, the N steps or methods can be implemented by software or firmware stored in a memory and executed by a suitable instruction execution system. For example, if implemented by hardware, as in another embodiment, any one or a combination of the following techniques well known in the art can be used: discrete logic circuits having logic gate circuits for implementing logical functions on data signals, application specific integrated circuits having appropriate combinational logic gate circuits, programmable gate arrays (PGAs), field programmable gate arrays (FPGAs), etc.

[0099] Those of ordinary skill in the art can understand that all or part of the steps carried by the methods of the above embodiments can be completed by instructing relevant hardware through a program, and the program can be stored in a computer-readable storage medium. When the program is executed, it includes one or a combination of the steps of the method embodiments.

Claims

1. An ultrasonic detection method for the defect of the separation of the overlay layer of the bearing bush of a hydraulic generator set, characterized in that, It includes the following steps: Obtain the ultrasonic data reflected by the base layer and the composite layer of the bearing bush comparison test block of the hydraulic generator unit respectively; Calculate the first reflectivity between the matrix layer interface and the composite layer interface and the second reflectivity between the composite layer interface and the air interface according to the ultrasonic data; Calculate the echo height difference according to the first reflectivity and the second reflectivity, where the echo height difference is the echo height difference between the matrix layer interface and the composite layer interface echo height and the composite layer interface and the air interface echo height; Screen the phased array probe according to the echo height and the echo height difference to perform ultrasonic detection on the composite layer of the actual bearing bush of the hydraulic generator unit to generate a detection result of the delamination defect.

2. The ultrasonic detection method for the defect of the water turbine unit bearing bush composite layer peeling according to claim 1, characterized in that, The calculating the first reflectivity between the matrix layer interface and the composite layer interface and the second reflectivity between the composite layer interface and the air interface according to the ultrasonic data includes: Obtain the density and sound velocity of the bearing bush matrix and the composite layer materials of the hydraulic generator unit in the ultrasonic data; Calculate the corresponding acoustic impedance of the bearing bush matrix and the composite layer materials according to the density and the sound velocity respectively; Calculate the first reflectivity between the matrix layer interface and the composite layer interface according to the acoustic impedance of the bearing bush matrix and the composite layer materials, and calculate the second reflectivity between the composite layer interface and the air interface according to the acoustic impedance of the composite layer material and the air acoustic impedance.

3. The ultrasonic detection method for the defect of the water turbine bearing overlay layer peeling according to claim 1, characterized in that, Before screening the phased array probe according to the echo height and the echo height difference to perform ultrasonic detection on the composite layer of the actual bearing bush of the hydraulic generator unit to generate a detection result of the delamination defect, it includes: Calibrate the phased array process parameters of the phased array ultrasonic equipment by using the ultrasonic data of the comparison test block; Among them, the phased array process parameters include probe parameters, instrument setting parameters and scanning parameters. Among them, the probe parameters include probe type, frequency, probe diameter, aperture, number of wafers, size and arrangement mode, and the scanning parameters include scanning mode and encoder parameters; the instrument setting parameters are the detection thresholds for delamination defects, including the complete bonding threshold, the partial delamination threshold and the complete delamination threshold, and corresponding display colors are set according to different detection thresholds for delamination defects.

4. The ultrasonic detection method for the defect of the water turbine bearing overlay layer peeling, according to claim 3, is characterized in that, Before screening the phased array probe according to the echo height and the echo height difference to perform ultrasonic detection on the composite layer of the actual bearing bush of the hydraulic generator unit to generate a detection result of the delamination defect, it also includes: Obtain the echo waveform, projection imaging view and scanning path recorded by the two-dimensional encoder of the composite layer of the actual bearing bush of the hydraulic generator unit; Generate the ultrasonic data of the composite layer of the actual bearing bush of the hydraulic generator unit according to the amplitude and time of the echo waveform, the projection imaging view and the scanning path; Generate a detection result of the delamination defect according to the ultrasonic data, the echo height and the echo height difference.

5. The ultrasonic detection method for the defect of the water turbine unit bearing bush composite layer peeling according to claim 4, characterized in that, The generating a detection result of the delamination defect according to the ultrasonic data, the echo height and the echo height difference includes: If the echo height of the matrix layer interface and the composite layer interface of the actual bearing bush of the hydraulic generator unit in the ultrasonic data is less than or equal to the echo height of the matrix layer and the composite layer interface of the comparison test block, the current matrix and composite layer interface is the complete bonding area; If the echo height of the interface between the matrix layer and the cladding layer of the actual hydro-generator bearing bush in the ultrasonic data is greater than the echo height of the interface between the matrix layer and the cladding layer of the reference block, and less than the sum of the echo height of the interface between the matrix and the cladding layer of the reference block and the echo height difference, then the current interface between the matrix and the cladding layer is a partial delamination area; If the echo height of the interface between the matrix layer and the cladding layer of the actual hydro-generator bearing bush in the ultrasonic data is greater than or equal to the sum of the echo height of the interface between the matrix and the cladding layer of the reference block and the echo height difference, then the current interface between the matrix and the cladding layer is a delamination area.

6. The ultrasonic detection method for the defect of the water turbine unit bearing overlay layer peeling, as claimed in claim 5, is characterized in that After generating the delamination defect detection result according to the ultrasonic data, the echo height, and the echo height difference, it further includes: Analyze the bonding state of the global interface of the actual hydro-generator bearing bush according to the amplitude of the echo waveform and the projection imaging view; Calculate the defect depth according to the time of the echo waveform, and determine the defect position coordinates according to the scanning path; Generate a delamination defect detection result according to the interface bonding state, defect depth, and defect position coordinates.

7. An ultrasonic detection device for the defect of the detachment of the overlay layer of the bearing bush of a hydro-generating unit, characterized in that, It includes: An acquisition module for acquiring the ultrasonic data reflected by the base layer and the cladding layer of the hydro-generator bearing bush reference block; A first calculation module for calculating the first reflectivity between the matrix layer interface and the cladding layer interface and the second reflectivity between the cladding layer interface and the air interface according to the ultrasonic data; A second calculation module for calculating the echo height difference according to the first reflectivity and the second reflectivity, where the echo height difference is the difference between the echo heights of the matrix layer interface and the cladding layer interface and the echo height of the cladding layer interface and the air interface; A generation module for screening phased array probes to perform ultrasonic detection on the cladding layer of the actual hydro-generator bearing bush according to the echo height and the echo height difference to generate a delamination defect detection result.

8. An electronic device, characterized in that, It includes: A memory, a processor, and a computer program stored on the memory and executable on the processor, and the processor executes the program to implement the ultrasonic detection method for delamination defects of the cladding layer of the hydro-generator bearing bush according to any one of claims 1-6.

9. A computer-readable storage medium having a computer program stored thereon, characterized in that, The program is executed by the processor to be used to implement the ultrasonic detection method for delamination defects of the cladding layer of the hydro-generator bearing bush according to any one of claims 1-6.

10. A computer program product, characterized in that, It includes a computer program, and when the computer program is executed by the processor, it is used to implement the ultrasonic detection method for delamination defects of the cladding layer of the hydro-generator bearing bush according to any one of claims 1-6.

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