Axle ultrasonic phased array water immersion automatic detection equipment and method

Abstract

The invention discloses an axle ultrasonic phased array water immersion automatic detection device and method. The device comprises a water immersion detection module, a phased array probe module, a multi-axis motion control module and an intelligent processing module. The phased array probe module is connected with the multi-axis motion control module through the waterproof support, and the intelligent processing module is connected with the water immersion detection module and the multi-axis motion control module. The water immersion detection module is used for providing a steady sound coupling environment and monitoring and adjusting the fluid state in real time; the multi-axis motion control module is used for driving the phased array probe module to realize rapid full-coverage lossless scanning and realize an automatic detection process; and the intelligent processing module is used for positioning and identifying defect types in combination with a pulse reflection method and a defect identification model, constructing a scanning image in real time and visually displaying a detection result. The axle detection quality and efficiency can be remarkably improved, the detection cost is reduced, rapid analysis and decision making are facilitated, and a reliable nondestructive detection scheme is provided for maintenance of the automobile axle.

Description

Technical Field

[0001] The present invention relates to the technical field of non-destructive testing of vehicle axles, and in particular to an axle ultrasonic phased array water immersion automated testing device and method. Background Art

[0002] As a key component of the vehicle's transmission system, the quality and performance of automotive axles are directly related to vehicle safety and reliability. Under high-intensity operating conditions, axles are prone to defects such as cracks, pores, and inclusions. These defects can lead to axle breakage and, in turn, serious traffic accidents. Nondestructive testing of axles to ensure their integrity and safety during use is a key research topic in automotive manufacturing and maintenance.

[0003] Traditional nondestructive testing methods, such as magnetic particle testing and penetrant testing, can detect some surface defects, but their ability to detect internal defects is limited and their efficiency is low. With the rapid development of the automotive industry, ultrasonic testing equipment has gradually been applied to axle inspection. This typically uses manual scanning with a single probe, resulting in low inspection efficiency and a strong reliance on operator experience, making it difficult to ensure consistent inspection results. On the other hand, while existing automated testing equipment can improve inspection efficiency, its accuracy and defect recognition capabilities still need improvement. Changes in the inspection environment may also affect the accuracy of the inspection results. These issues have limited the widespread application of existing technologies in actual production.

[0004] Therefore, there is an urgent need for a more efficient, accurate and stable axle non-destructive testing technology that can quickly and accurately detect defects inside and on the surface of the axle, and at the same time realize automatic classification and positioning of defects, so as to meet the strict requirements of modern automobile manufacturing and maintenance for axle testing and ensure the safe operation of vehicles. Summary of the Invention

[0005] In view of this, the present invention provides an axle ultrasonic phased array water immersion automated detection equipment and method to solve the technical problems that existing axle non-destructive testing equipment cannot quickly and accurately detect internal and surface defects of axles and cannot quickly locate and classify defects.

[0006] In order to achieve the above technical objectives, the present invention adopts the following technical solutions:

[0007] In a first aspect, the present invention provides an automated axle water immersion detection method using ultrasonic phased array technology, comprising:

[0008] It includes: a water immersion detection module, a phased array probe module, a multi-axis motion control module and an intelligent processing module; the phased array probe module is connected to the multi-axis motion control module through a waterproof bracket, and the intelligent processing module is connected to the water immersion detection module and the multi-axis motion control module;

[0009] The water immersion detection module is used to provide a stable acoustic coupling environment for the tested axle and the phased array probe module, and monitor the fluid status;

[0010] The phased array probe module is used to perform multi-angle electronic scanning and acoustic-to-electrical signal conversion on the axle under test according to preset tracks and angles under the drive of the multi-axis motion control module to obtain echo signals;

[0011] The multi-axis motion control module is used to drive the phased array probe module to perform a full-coverage scan of the tested axle based on a preset path and speed under the control of the intelligent processing module, and transmit the echo signal to the intelligent processing module;

[0012] The intelligent processing module is used to monitor and adjust the parameters of the water immersion detection module in real time. It is also used to digitally process the echo signal based on the pulse reflection method, combine the scanning position and angle information of the phased array probe module, construct the scanning image in real time, and identify the type and location information of the defect based on the preset defect recognition model.

[0013] Furthermore, the water immersion detection module includes a detection tank, a coupled water circulation module, a temperature control module and an axle fixture; the axle fixture is fixed to the bottom of the detection tank.

[0014] The test pool is the main container, used to provide a working space for measuring the axle under test; the axle fixture is installed at the bottom of the test pool, and the side is connected to the coupling water circulation module and temperature control module through pipes;

[0015] The coupled water circulation module is used to control the thickness of the water layer and circulate and filter the coupled water medium to keep the water clean and the water level stable;

[0016] The temperature control module is used to monitor the temperature of the coupled water medium in real time and maintain the water temperature stable through heaters and coolers;

[0017] The axle fixture includes a clamping claw and a driving mechanism. The clamping claw is used to clamp the axle under test to ensure that it remains stable during the test process; the driving mechanism is used to drive the axle under test to rotate around its own axis according to a preset direction and speed.

[0018] Furthermore, the water layer depth of the detection pool is determined according to the material of the axle to be tested, the parameters of the phased array probe and the real-time medium temperature. The calculation formula is:

[0019]

[0020]

[0021] in, Indicates the calibration temperature, represents the temperature coefficient of water sound velocity, represents the theoretical depth of the water layer, represents the focal length of the phased array probe, represents the phased array probe chip diameter, represents the speed of sound in water, Represents the speed of sound of the axle material.

[0022] Furthermore, the multi-axis motion control module includes a three-axis linear guide, a servo motor and a processor; the servo motor is connected to the three-axis linear guide, and the processor is electrically connected to the servo motor;

[0023] The three-axis linear guide is installed on the top of the detection tank to control the movement of the probe in the X, Y, and Z directions;

[0024] The servo motor is used to provide power for the movement of the phased array probe module, driving the phased array probe module to move along the three-axis linear guide rail;

[0025] The processor is used to receive instructions from the intelligent processing module and set the moving speed and end point position.

[0026] Furthermore, the processor adjusts the end point position of the phased array probe based on the PID method, and the adjustment method is expressed as follows:

[0027]

[0028] in, Indicates the target end position, represents the position error, represents the proportionality coefficient, represents the integral coefficient, represents the differential coefficient.

[0029] Furthermore, the intelligent processing module includes a phased array control module, a signal processing module, a defect recognition module and a detection result generation module connected in sequence;

[0030] The phased array control module is used to generate a focusing method based on the 3D model of the axle, control the time-sharing excitation of the probe elements, dynamically adjust the acoustic beam parameters and excitation sequence, and generate a scanning path based on the 3D model of the axle under test;

[0031] The signal processing module is used to perform signal filtering, sound velocity drift correction and adaptive gain control on the ultrasonic echo, and output the optimized echo signal;

[0032] Defect recognition module, used to use the preset defect analysis network to perform intelligent defect classification and quantitative analysis based on the optimized echo signal;

[0033] The detection result generation module is used to generate a multi-modal scanning composite image and output a detection report in a specified format.

[0034] Furthermore, the phased array control module includes a focus delay calculation unit;

[0035] The focusing delay calculation unit calculates the delay of each array element in real time based on the axle structure under test, realizes beam focusing, and completes defect directional detection;

[0036] The calculation formula for the delay of each array element is:

[0037]

[0038] Where F represents the focal length, represents the array element position, represents the deflection angle, Represents the temperature compensation term.

[0039] Furthermore, the defect recognition module includes an input layer, a feature extraction layer, a multi-task branching layer, a confidence assessment layer and an output layer connected in sequence;

[0040] The input layer preprocesses the echo signal, converts the time domain into time-frequency spectrum features, and performs normalization. The backbone network of the feature extraction layer includes an improved ResNet34 architecture and an attention module to extract defect features. The multi-task branch layer uses a Softmax network to output the probability of defect occurrence and a U-net segmentation network to output the defect outline. The confidence assessment layer verifies the reliability of defect identification using an anomaly detection algorithm based on the Mahalanobis distance.

[0041] Furthermore, the signal processing module also includes a beamforming unit for delaying and superimposing the echo signals to achieve receiving focusing.

[0042] On the other hand, the present invention further provides an axle ultrasonic phased array water immersion automated detection method, which is implemented using the axle ultrasonic phased array water immersion automated detection device described in the above solution, comprising:

[0043] The axle to be tested is fixed in the water immersion detection module, constant temperature coupling water is injected to immerse the axle to be tested, and the liquid level is monitored by the water level sensor;

[0044] Sending a scanning path signal to the multi-axis motion control module through the intelligent processing module and starting the phased array probe module;

[0045] The phased array probe is triggered in time, and multi-angle sound beams are sequentially excited to cover the entire cross section of the axle;

[0046] The intelligent processing module collects reflected echo signals in real time based on the phased array probe module, digitally processes the echo signals based on the pulse reflection method, and constructs a scanning image in real time based on the scanning position and angle information of the phased array probe module. The defect type and location information are identified based on the preset defect recognition model.

[0047] Compared with the existing technology, the axle ultrasonic phased array water immersion automated detection method proposed in this invention has the following advantages:

[0048] (1) Efficient automated testing: The multi-axis motion control module is used to drive the phased array probe module to perform full-coverage scanning of the axle under test according to the preset path and speed under the control of the intelligent processing module, thereby improving detection efficiency and reducing the time and labor intensity of manual operation. At the same time, the precise control capability of the multi-axis motion control module ensures the uniformity and comprehensiveness of the scan, avoids detection blind spots, and improves the reliability of detection.

[0049] (2) Accurate defect diagnosis: Driven by the multi-axis motion control module, the phased array probe module can perform multi-angle electronic scanning of the axle under test according to the preset trajectory and angle. The intelligent processing module digitizes the echo signal based on the pulse reflection method and, combined with the scanning position and angle information of the phased array probe module, can construct the scan image in real time. Based on the preset defect recognition model, the intelligent processing module can accurately identify the type and location information of the defect, thereby improving the accuracy of defect diagnosis. This efficient data processing capability enables timely feedback of the test results, facilitating subsequent analysis and decision-making by the operator.

[0050] (3) High flexibility and adaptability: The multi-axis motion control module and phased array probe module are highly flexible and can be adjusted according to the shape, size, and inspection requirements of the axle. This adaptability enables the equipment to be applied to various types of axle inspections, improving its versatility and practicality.

[0051] In summary, the equipment and method of the present invention have many advantages such as high efficiency, precision, stability, flexibility, and economy. They can significantly improve the quality and efficiency of axle detection, reduce detection costs, and provide a reliable detection solution for the automotive manufacturing and maintenance fields. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 This is a schematic diagram of the structure of the axle ultrasonic phased array water immersion automated detection equipment provided by the present invention;

[0053] Figure 2 A schematic structural diagram of a water immersion detection module provided by the present invention;

[0054] Figure 3A schematic diagram of the process of the automated axle water immersion detection method using ultrasonic phased array provided by the present invention;

[0055] In the figure, 1-detection pool, 2-tested axle, 3-drive motor, 4-encoder, 5-three-axis motion guide, 6-waterproof bracket, 7-phased array probe. DETAILED DESCRIPTION

[0056] The preferred embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings, wherein the accompanying drawings constitute a part of this application and are used together with the embodiments of the present invention to illustrate the principles of the present invention, and are not used to limit the scope of the present invention.

[0057] Example 1

[0058] See Figure 1 This embodiment provides an axle ultrasonic phased array water immersion automated detection device 100, comprising: a water immersion detection module 101, a phased array probe module 102, a multi-axis motion control module 103, and an intelligent processing module 104. The phased array probe module 102 is connected to the multi-axis motion control module 103 via a waterproof bracket, and the intelligent processing module 104 is connected to the water immersion detection module 101 and the multi-axis motion control module 103.

[0059] The water immersion detection module 101 is used to provide a stable acoustic coupling environment for the axle under test and the phased array probe module 102, and monitor the fluid state;

[0060] The phased array probe module 102 is used to perform multi-angle electronic scanning and acoustic-to-electrical signal conversion on the axle under test according to a preset trajectory and angle under the drive of the multi-axis motion control module 103 to obtain an echo signal;

[0061] The multi-axis motion control module 103 is used to drive the phased array probe module 102 to perform a full-coverage scan of the axle under test based on a preset path and speed under the control of the intelligent processing module 104, and transmit the echo signal to the intelligent processing module;

[0062] The intelligent processing module 104 is used to monitor and adjust the parameters of the water immersion detection module 101 in real time. It is also used to digitally process the echo signal based on the pulse reflection method, combine the scanning position and angle information of the phased array probe module 102, construct the scanning image in real time, and identify the type and location information of the defect based on a preset defect recognition model.

[0063] The equipment of this embodiment provides a constant acoustic coupling environment through the water immersion detection module and monitors and adjusts the fluid state in real time to ensure the reliability of the detection results. The multi-axis motion control module drives the phased array probe module to achieve rapid full-coverage non-destructive scanning, realizes an automated detection process, and improves detection efficiency. The intelligent processing module combines the pulse reflection method and the defect recognition model to accurately locate and identify the defect type. By constructing the scanning image in real time, the detection results can be intuitively displayed, facilitating rapid analysis and decision-making.

[0064] As a preferred embodiment, the water immersion detection module includes a detection tank, a coupled water circulation module, a temperature control module and an axle fixture; the axle fixture is fixed to the bottom of the detection tank;

[0065] The test pool is the main container, used to provide a working space for measuring the axle under test; the axle fixture is installed at the bottom of the test pool, and the side is connected to the coupling water circulation module and temperature control module through pipes;

[0066] The coupled water circulation module is used to control the thickness of the water layer and circulate and filter the coupled water medium to keep the water clean and the water level stable;

[0067] The temperature control module is used to monitor the temperature of the coupled water medium in real time and maintain the water temperature stable through heaters and coolers;

[0068] The axle fixture includes a clamping claw and a driving mechanism. The clamping claw is used to clamp the axle under test to ensure that it remains stable during the test process; the driving mechanism is used to drive the axle under test to rotate around its own axis according to a preset direction and speed.

[0069] In some embodiments, the hardware structure of the water immersion detection module can be: the detection pool is located in the center, used to accommodate the axle and coupling medium, and the axle clamp is located on one side of the detection pool, used to fix the axle; the coupling water circulation module is located on the side of the detection pool, including a water pump, a filter and a water tank, and is connected to the detection pool through a pipe; the temperature control module is located at the bottom of the detection pool, including a heater, a cooler and a temperature sensor, and is connected to the water circulation system through a pipe.

[0070] like Figure 2 As shown, Figure 2 It shows a possible structure of the water immersion detection module. Figure 2 In the image, the axle 2 under test is located at the bottom of the test tank 1. The axle fixture is installed on one side of the test tank and is connected to the drive motor 3 and encoder 4. During the test, the axle can be rotated along its own axis as needed. The phased array probe 7 is connected to the three-axis motion guide 5 via a waterproof bracket 6.

[0071] It should be noted that the cleanliness and uniformity of water quality directly affect the propagation characteristics of ultrasonic waves. The intelligent processing module needs to monitor the water quality in the water immersion detection module to ensure that there are no impurities, bubbles or suspended matter in the water to avoid these factors interfering with the propagation and reflection of ultrasonic signals. When the axle under test needs to rotate, the rotation of the axle will generate eddy currents, causing the dissolved gas in the water to precipitate and form microbubbles, which will scatter ultrasonic waves and cause signal attenuation. Therefore, the speed of axle rotation should not exceed 3r / min to avoid the generation of sudden changes in water flow. In some scenarios, radial guide plates can also be installed on the side walls of the detection pool to convert tangential eddies into laminar flows, thereby avoiding interference of the coupling medium on the detection accuracy and improving the accuracy of the detection.

[0072] When using ultrasonic phased array water immersion testing to detect defects on axles, controlling the water layer thickness is a key parameter to ensure detection accuracy and signal-to-noise ratio. As a preferred embodiment, the water layer depth of the detection pool is determined based on the material of the axle being tested, the parameters of the phased array probe, and the real-time medium temperature. The calculation formula is:

[0073]

[0074]

[0075] in, Indicates the calibration temperature, represents the temperature coefficient of water sound velocity, represents the theoretical depth of the water layer, represents the focal length of the phased array probe, represents the phased array probe chip diameter, represents the speed of sound in water, Represents the speed of sound of the axle material.

[0076] The above method ensures that the appropriate water layer thickness is always maintained between the probe and the axle during the detection process, and ensures that no abnormal echo occurs between the primary interface wave and the workpiece bottom wave or the shear wave echo at the maximum detection distance.

[0077] As a preferred embodiment, the multi-axis motion control module includes a three-axis linear guide, a servo motor and a processor; the servo motor is connected to the three-axis linear guide, and the processor is electrically connected to the servo motor;

[0078] The three-axis linear guide is installed on the top of the detection tank to control the movement of the probe in the X, Y, and Z directions;

[0079] The servo motor is used to provide power for the movement of the phased array probe module, driving the phased array probe module to move along the three-axis linear guide rail;

[0080] The processor is used to receive instructions from the intelligent processing module and set the moving speed and end point position.

[0081] As a preferred embodiment, the processor adjusts the end point position of the phased array probe based on the PID method. The adjustment method is expressed as follows:

[0082]

[0083] in, Indicates the target end position, represents the position error, represents the proportionality coefficient, represents the integral coefficient, represents the differential coefficient.

[0084] The PID control method adjusts the phased array probe position to accommodate different axle types and inspection environments. Even with changes in the test tank's water temperature and quality, or variations in axle shape and size, the PID controller maintains system stability and inspection accuracy by adjusting control parameters.

[0085] In some embodiments, the phased array probe module includes 128 chips with a center frequency of 5-10 MHz, which can be independently excited to form a variable sound beam angle of 0-70° to achieve full coverage detection of the tested axle.

[0086] As a preferred embodiment, the intelligent processing module includes a phased array control module, a signal processing module, a defect recognition module and a detection result generation module connected in sequence;

[0087] The phased array control module is used to generate a focusing method based on the 3D model of the axle, control the time-sharing excitation of the probe elements, dynamically adjust the acoustic beam parameters and excitation sequence, and generate a scanning path based on the 3D model of the axle under test;

[0088] The signal processing module is used to perform signal filtering, sound velocity drift correction and adaptive gain control on the ultrasonic echo, and output the optimized echo signal;

[0089] Defect recognition module, used to use the preset defect analysis network to perform intelligent defect classification and quantitative analysis based on the optimized echo signal;

[0090] The detection result generation module is used to generate a multi-modal scanning composite image and output a detection report in a specified format.

[0091] As a specific embodiment, the phased array control module generates a focusing law based on a three-dimensional model of the axle, controls the time-sharing excitation of the probe chip, realizes the sound beam deflection and dynamic focusing, and the focusing depth can be adaptively adjusted according to the axle material.

[0092] Determining the focal length of a phased array probe is a core aspect of ultrasonic testing process design. In some embodiments, the phased array control module includes a focus delay calculation unit;

[0093] The focusing delay calculation unit calculates the delay of each array element in real time based on the axle structure under test, realizes beam focusing, and completes defect directional detection;

[0094] The calculation formula for the delay of each array element is:

[0095]

[0096] Where F represents the focal length, represents the array element position, represents the deflection angle, Represents the temperature compensation term.

[0097] As a specific embodiment, the signal processing module performs signal filtering, sound velocity drift correction processing and adaptive gain control on the echo, specifically:

[0098] The signal-to-noise ratio is improved through bandpass and time domain windows, as well as Hilbert transform. The sound velocity drift caused by water temperature is dynamically corrected to correct the sound velocity drift phenomenon. Finally, the signal gain is adjusted in real time based on the fluctuation of water layer thickness to compensate for the sound energy attenuation.

[0099] As a preferred embodiment, the signal processing module further includes a beamforming unit for delaying and superimposing the echo signals to achieve receiving focusing.

[0100] By receiving and focusing, the echo signals are delayed and superimposed (such as the TFM total focusing algorithm), and the sound field is reconstructed by collecting data, providing a basis for the subsequent update of the sound path model.

[0101] As a preferred embodiment, the defect recognition module includes an input layer, a feature extraction layer, a multi-task branching layer, a confidence assessment layer and an output layer connected in sequence;

[0102] The input layer preprocesses the echo signal, converts the time domain into time-frequency spectrum features, and performs normalization. The backbone network of the feature extraction layer includes an improved ResNet34 architecture and an attention module to extract defect features. The multi-task branch layer uses a Softmax network to output the probability of defect occurrence and a U-net segmentation network to output the defect outline. The confidence assessment layer verifies the reliability of defect identification using an anomaly detection algorithm based on the Mahalanobis distance.

[0103] It should be noted that the defect recognition module can be pre-trained using transfer learning to identify common axle defects such as transverse cracks (45-70° orientation), axial fatigue cracks, and pitting corrosion pits (Ø0.5-2mm). If a single scan fails to identify a possible defect, a rescan command can be executed to refine the local grid to 0.1mm to determine the defect type.

[0104] As a specific example, inspection results typically include B-scan, C-scan, and D-scan images. The B-scan image reflects the depth-amplitude cross-section along the scanning path, the C-scan image displays an XY plane projection pseudo-color image with depth encoding and HSV color space-amplitude mapping, and the D-scan image displays the spatial morphology of the defect in 3D rendering. Finally, a PDF inspection report is automatically generated, integrating a 3D defect map, size statistics, and a compliance assessment (compliant with the TG / CL248-2013 standard).

[0105] Example 2

[0106] like Figure 3 As shown, an embodiment of the present invention further provides an axle ultrasonic phased array water immersion automated detection method, which is implemented using the axle ultrasonic phased array water immersion automated detection device described in Example 1, comprising:

[0107] Step S101: Fix the axle to be tested in the water immersion detection module, inject constant temperature coupling water to immerse the axle to be tested, and monitor the liquid level through the water level sensor;

[0108] Step S102: sending a scanning path signal to the multi-axis motion control module through the intelligent processing module, and starting the phased array probe module;

[0109] Step S103: triggering the phased array probe in time-sharing mode to sequentially stimulate multi-angle acoustic beams to cover the entire cross-section of the axle;

[0110] Step S104: The intelligent processing module collects the reflected echo signal in real time based on the phased array probe module, digitally processes the echo signal based on the pulse reflection method, and constructs a scanning image in real time in combination with the scanning position and angle information of the phased array probe module. The type and location information of the defect are identified based on the preset defect recognition model.

[0111] The ultrasonic phased array water immersion automated detection equipment and method for vehicle axles disclosed in the present invention provide a constant acoustic coupling environment and real-time monitoring and adjustment of the fluid state through the water immersion detection module to ensure the reliability of the detection results; a multi-axis motion control module drives the phased array probe module to achieve rapid full-coverage non-destructive scanning, realizes an automated detection process, and improves detection efficiency; utilizes an intelligent processing module combined with a pulse reflection method and a defect recognition model to accurately locate and identify defect types, and by constructing a scan image in real time, can intuitively display the detection results, facilitating rapid analysis and decision-making. The present invention has the advantages of high efficiency, precision, stability, flexibility, and economy, and can significantly improve the quality and efficiency of axle detection, reduce detection costs, and provide a reliable detection solution for automobile manufacturing and maintenance.

[0112] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by any technician familiar with this technical field within the technical scope disclosed by the present invention should be covered by the scope of protection of the present invention.

Claims

1. An axle ultrasonic phased array water immersion automatic detection equipment, characterized in that: include: Water immersion detection module, phased array probe module, multi-axis motion control module and intelligent processing module; the phased array probe module is connected to the multi-axis motion control module through a waterproof bracket, and the intelligent processing module is connected to the water immersion detection module and the multi-axis motion control module; The water immersion detection module is used to provide a stable acoustic coupling environment for the tested axle and the phased array probe module, and monitor the fluid status; The phased array probe module is used to perform multi-angle electronic scanning and acoustic-to-electrical signal conversion on the axle under test according to preset tracks and angles under the drive of the multi-axis motion control module to obtain echo signals; The multi-axis motion control module is used to drive the phased array probe module to perform a full-coverage scan of the tested axle based on a preset path and speed under the control of the intelligent processing module, and transmit the echo signal to the intelligent processing module; The intelligent processing module is used to monitor and adjust the parameters of the water immersion detection module in real time. It is also used to digitally process the echo signal based on the pulse reflection method, combine the scanning position and angle information of the phased array probe module, construct the scanning image in real time, and identify the type and location information of the defect based on the preset defect recognition model.

2. The axle ultrasonic phased array water immersion automatic detection equipment according to claim 1 is characterized in that: The water immersion detection module includes a detection tank, a coupled water circulation module, a temperature control module and an axle fixture; the axle fixture is fixed to the bottom of the detection tank. The test pool is the main container, used to provide a working space for measuring the axle under test; the axle fixture is installed at the bottom of the test pool, and the side is connected to the coupling water circulation module and temperature control module through pipes; The coupled water circulation module is used to control the thickness of the water layer and circulate and filter the coupled water medium to keep the water clean and the water level stable; The temperature control module is used to monitor the temperature of the coupled water medium in real time and maintain the water temperature stable through heaters and coolers; The axle fixture includes a clamping claw and a driving mechanism. The clamping claw is used to clamp the axle under test to ensure that it remains stable during the test process; the driving mechanism is used to drive the axle under test to rotate around its own axis according to a preset direction and speed.

3. The axle ultrasonic phased array water immersion automatic detection equipment according to claim 2, characterized in that: The water layer depth of the detection pool is determined according to the material of the axle to be tested, the parameters of the phased array probe and the real-time medium temperature. The calculation formula is: in, Indicates the calibration temperature, represents the temperature coefficient of water sound velocity, represents the theoretical depth of the water layer, represents the focal length of the phased array probe, represents the phased array probe chip diameter, represents the speed of sound in water, Represents the speed of sound of the axle material.

4. The axle ultrasonic phased array water immersion automatic detection equipment according to claim 2, characterized in that: The multi-axis motion control module includes a three-axis linear guide, a servo motor and a processor; the servo motor is connected to the three-axis linear guide, and the processor is electrically connected to the servo motor; The three-axis linear guide is installed on the top of the detection tank to control the movement of the probe in the X, Y, and Z directions; The servo motor is used to provide power for the movement of the phased array probe module, driving the phased array probe module to move along the three-axis linear guide rail; The processor is used to receive instructions from the intelligent processing module and set the moving speed and end point position.

5. The axle ultrasonic phased array water immersion automatic detection equipment according to claim 4 is characterized in that: The processor adjusts the end point position of the phased array probe based on the PID method. The adjustment method is expressed as follows: in, Indicates the target end position, represents the position error, represents the proportionality coefficient, represents the integral coefficient, represents the differential coefficient.

6. The axle ultrasonic phased array water immersion automatic detection equipment according to claim 1, characterized in that: The intelligent processing module includes a phased array control module, a signal processing module, a defect recognition module and a detection result generation module connected in sequence; The phased array control module is used to generate a focusing method based on the 3D model of the axle, control the time-sharing excitation of the probe elements, dynamically adjust the acoustic beam parameters and excitation sequence, and generate a scanning path based on the 3D model of the axle under test; The signal processing module is used to perform signal filtering, sound velocity drift correction and adaptive gain control on the ultrasonic echo, and output the optimized echo signal; Defect recognition module, used to use the preset defect analysis network to perform intelligent defect classification and quantitative analysis based on the optimized echo signal; The detection result generation module is used to generate a multi-modal scanning composite image and output a detection report in a specified format.

7. The axle ultrasonic phased array water immersion automatic detection equipment according to claim 6, characterized in that: The phased array control module includes a focus delay calculation unit. The focus delay calculation unit calculates the delay of each array element in real time based on the axle structure under test to achieve acoustic beam focusing to complete defect directional detection. The calculation formula for each array element delay is: Where F represents the focal length, represents the array element position, represents the deflection angle, Represents the temperature compensation term.

8. The axle ultrasonic phased array water immersion automatic detection equipment according to claim 6, characterized in that: The defect recognition module includes an input layer, a feature extraction layer, a multi-task branching layer, a confidence assessment layer and an output layer connected in sequence; The input layer preprocesses the echo signal, converts the time domain into time-frequency spectrum features, and performs normalization. The backbone network of the feature extraction layer includes an improved ResNet34 architecture and an attention module to extract defect features. The multi-task branch layer uses a Softmax network to output the probability of defect occurrence and a U-net segmentation network to output the defect outline. The confidence assessment layer verifies the reliability of defect identification using an anomaly detection algorithm based on the Mahalanobis distance.

9. The axle ultrasonic phased array water immersion automatic detection equipment according to claim 6, characterized in that: The signal processing module also includes a beamforming unit for delaying and superimposing the echo signals to achieve receiving focusing.

10. An axle ultrasonic phased array water immersion automatic detection method, characterized in that: The axle ultrasonic phased array water immersion automatic detection device according to any one of claims 1 to 9 is implemented, comprising: The axle to be tested is fixed in the water immersion detection module, constant temperature coupling water is injected to immerse the axle to be tested, and the liquid level is monitored by the water level sensor; Sending a scanning path signal to the multi-axis motion control module through the intelligent processing module and starting the phased array probe module; The phased array probe is triggered in time, and multi-angle sound beams are sequentially excited to cover the entire cross section of the axle; The intelligent processing module collects reflected echo signals in real time based on the phased array probe module, digitally processes the echo signals based on the pulse reflection method, and constructs a scanning image in real time based on the scanning position and angle information of the phased array probe module. The defect type and location information are identified based on the preset defect recognition model.

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