Ship plate thickness and uniformity analysis system based on ultrasonic detection

Abstract

The invention relates to the technical field of marine equipment, and provides a ship plate thickness and uniformity analysis system based on ultrasonic detection, which comprises a server, a detection station, a bidirectional roller guide module, a floating bridge type detection platform, a posture adaptive adjustment module, an ultrasonic thickness detection module, a thickness uniformity analysis module and a structure monitoring scoring module. The floating bridge type detection platform slides along the circumferential side of the detection station, is connected with the two-way roller through a sliding rail, and floats up and down when the curvature of the ship plate changes, so that probe coupling is ensured; the bidirectional roller guide module collects a contact angle and pressure and outputs local curvature data; the posture self-adaptive adjustment module dynamically adjusts the relative posture of the platform and the detection module accordingly; the ultrasonic detection module transmits and receives echo signals and calculates the plate thickness; and the thickness uniformity analysis module constructs a two-dimensional matrix for the plate thickness data on the server, calculates a variable coefficient CV according to a fixed sliding window, and evaluates local thickness fluctuation.

Description

Technical Field

[0001] The present invention relates to the technical field of marine equipment, and in particular to a ship plate thickness and uniformity analysis system based on ultrasonic detection. Background Art

[0002] In the field of hull thickness detection, commonly used methods include single-point measurement with a handheld ultrasonic probe or a track-based rigid scanning system. These methods generally have problems such as poor contact stability, uncontrollable fitting posture, low detection efficiency, sparse data, and lack of overall surface coverage. When detecting curved ship plates (such as the bow, side, and areas with large curvature), the probe often fails to couple or the echo signal is severely attenuated due to improper posture, resulting in significant thickness measurement errors and difficulty in obtaining reliable thickness distribution results. For example, the Chinese patent CN103419901A discloses an immersive ship acoustic platform, whose structure solves the problem of underwater transducer installation and adopts a rigid box and sound-transmitting plate structure to improve the stability and watertightness of sonar detection; however, this solution is mainly used for acoustic transducer positioning, and has no attitude adaptive design for hull thickness detection. It still relies on rigid devices and cannot achieve contact compensation during curved ship plate detection - and its structure cannot avoid measurement errors caused by position deviation.

[0003] In addition, the prior art also has the following defects:

[0004] 1. The lack of a continuous surface thickness distribution map and uniformity analysis model makes it impossible to provide quantitative and visual results of regional thickness variations;

[0005] 2. Most mechanical structures are rigidly fixed or unidirectionally adjustable, without a feedback control mechanism. They cannot adjust the probe posture in real time according to curvature changes, resulting in low detection accuracy and incomplete coverage.

[0006] 3. Inspection mostly relies on manual operation, which is inefficient, poorly repeatable, and high-risk. Especially in ship maintenance or on-site inspection environments, it is labor-intensive and poses safety hazards.

[0007] The present invention is made in order to solve the common problems in this field, such as difficulty in measuring and fitting the thickness of ship plates, low efficiency of manual operation, lack of automatic continuous detection, lack of thickness uniformity analysis and visual expression, etc. Summary of the Invention

[0008] The purpose of the present invention is to address the current deficiencies and propose a ship plate thickness and uniformity analysis system based on ultrasonic testing.

[0009] In order to overcome the deficiencies of the prior art, the present invention adopts the following technical solutions:

[0010] A shipboard thickness and uniformity analysis system based on ultrasonic testing, comprising a server and a testing station. The system also includes a bidirectional roller guide module, a floating bridge testing platform, a posture adaptive adjustment module, an ultrasonic thickness detection module, a uniformity analysis module, and a structure monitoring and scoring module.

[0011] The floating bridge type detection platform is arranged on the peripheral side of the detection station, and is connected to the bidirectional roller guide module. When the shipboard surface is deformed or the curvature changes, the floating bridge type detection platform generates a controlled vertical follow-up displacement to maintain effective coupling between the ultrasonic probe and the shipboard surface;

[0012] The bidirectional roller guide modules are arranged at the front and rear ends of the floating bridge-type detection platform, and are used to guide the detection platform to move bidirectionally along the surface of the shipboard, and to obtain contact posture information with the shipboard surface in real time during the movement, so as to output guidance data representing the local curvature;

[0013] The posture adaptive adjustment module is installed on the floating bridge detection platform and controls the relative posture adjustment of the floating bridge detection platform and the ultrasonic thickness detection module in real time based on the guidance data output by the bidirectional roller guidance module, so that the emission direction of the ultrasonic thickness detection module is always consistent with the local normal of the shipboard surface, thereby ensuring the coupling quality and measurement accuracy of the detection;

[0014] The ultrasonic thickness detection module is used to transmit and receive ultrasonic signals and obtain echo data, and calculate the thickness value of the ship plate at the corresponding position based on the echo data;

[0015] The thickness uniformity analysis module is deployed in the server and constructs the thickness data obtained by the ultrasonic thickness detection module into a two-dimensional thickness distribution matrix. The thickness distribution matrix is ​​divided into fixed-size sliding windows and the coefficient of variation (CV) value of each sliding window is calculated to evaluate the degree of local thickness fluctuation.

[0016] The structural monitoring and scoring module is deployed in the server to generate a thickness distribution heat map and an uneven area identification map based on the coefficient of variation CV value and the area ratio of the uneven area calculated by the thickness uniformity analysis module, calculate the ship plate health index PHI, and output the structural status evaluation result.

[0017] Optionally, the bidirectional roller guide module includes a roller assembly, an angle sensing subunit, a pressure sensing subunit, a signal conditioning and output interface, and the roller assembly is used to achieve mechanical guidance and support on the surface of the shipboard, and the roller assembly includes a roller body and a roller shaft;

[0018] The angle sensor subunit is fixedly mounted on the roller shaft and detects the tilt angle of the roller body relative to the vertical direction in real time;

[0019] The pressure sensing subunit is arranged in the force contact area between the roller body and the floating bridge detection platform. The force direction of the force contact area is consistent with the normal direction of the shipboard surface, and the pressure sensing subunit detects the contact pressure applied by the roller body in the direction perpendicular to the shipboard surface in real time.

[0020] The input end of the signal conditioning and output interface is respectively connected to the angle sensing subunit and the pressure sensing subunit, and the output end is electrically connected to the posture processing interface in the server through the data bus, and converts the angle detection signal and the pressure detection signal into digital contact posture information and sends it to the server in real time.

[0021] Optionally, the outer peripheral surface of the roller is a magnetic adsorption coating layer or a high-friction rubber layer to provide stable guiding adhesion under different metal materials or in humid environments.

[0022] Optionally, the floating bridge-type inspection platform includes a support seat, an adsorption unit, an auxiliary support unit, and a sliding unit. The support seat is provided with a sliding track. The sliding unit is arranged on the sliding track and adjusts the position of the adsorption unit arranged on the sliding track. The auxiliary support unit is arranged on one side of the inspection area and auxiliary supports the support seat so that the support seat can be erected on one side of the ship plate inspection area.

[0023] Optionally, the posture adaptive adjustment module includes a three-degree-of-freedom linkage arm installed between the floating bridge detection platform and the ultrasonic thickness detection module, and the linkage arm includes at least three independently controllable drive drives to adjust the pitch angle and yaw angle of the floating bridge detection platform and the ultrasonic thickness detection module in real time according to the guidance data output by the two-way roller guidance module, so that the emission direction of the ultrasonic thickness detection module is always consistent with the local normal of the shipboard surface.

[0024] Optionally, the ultrasonic thickness detection module includes an area array ultrasonic probe, a multi-channel pulse transmitter-receiver board connected to the area array ultrasonic probe, a time-to-digital converter unit connected to the signal end of the pulse transmitter-receiver board, an interface control processor connected to the data end of the time-to-digital converter unit, and a coupling agent automatic supply component arranged in the same direction as the area array ultrasonic probe;

[0025] Among them, the coupling agent automatic supply component is used to continuously provide an acoustic coupling medium between the array ultrasonic probe and the surface of the shipboard; the interface control processor is used to calculate the thickness value of the shipboard based on the echo flight time Δt output by the time-to-digital converter unit and the pre-stored sound velocity v of the shipboard material.

[0026] Optionally, after calculating the coefficient of variation CV value, the thickness uniformity analysis module further compares it with the global CV mean value. If the CV value of a sliding window is higher than a set threshold, the area corresponding to the window is marked as an uneven thickness area.

[0027] Optionally, the structure monitoring scoring module calculates the ship plate health index PHI according to the following formula:

[0028] PHI = 100-α·CV-β·Ad;

[0029] Where, CV - is the global average CV value of the two-dimensional thickness matrix, Ad is the ratio of the uneven thickness area to the total detection area, and α and β are preset weight coefficients.

[0030] Optionally, the coupling agent automatic supply component includes a coupling agent storage tank, a micro-metering pump, a distribution manifold and a drip nozzle arranged between the area array ultrasonic probe and the surface of the shipboard, and a flow sensor located at the outlet of the micro-metering pump;

[0031] The driving end of the micro-metering pump is communicatively connected to the interface control processor, and the feedback signal of the flow sensor is used to close-loop regulate the output flow of the micro-metering pump to keep the coupling layer thickness between the ultrasonic probe and the surface of the ship plate constant during the detection process.

[0032] The beneficial effects achieved by the present invention are:

[0033] 1. Through the interaction between the bidirectional roller guide module and the posture adaptive adjustment module, the system can sense the local surface curvature in real time and dynamically adjust the probe pitch and yaw angles to ensure position stability and continuity during the measurement process;

[0034] 2. Through the interaction between the floating bridge detection platform and the posture adaptive adjustment module, the probe position and posture can be quickly compensated for uneven or curved areas on the shipboard, ensuring that the detection accuracy is not reduced due to surface deformation.

[0035] 3. Through the cooperation between the ultrasonic thickness detection module and the uniformity analysis module, the real-time collected thickness data can automatically construct a two-dimensional thickness distribution matrix and calculate the coefficient of variation of each region, ensuring that local thickness unevenness can be identified quickly and accurately;

[0036] 4. Through the interaction between the uniformity analysis module and the structural monitoring and scoring module, the local coefficient of variation and the area ratio of the uneven area can be converted into the ship plate health index and presented in a visual report, ensuring that the test results are intuitive and supportive of decision-making;

[0037] 5. Through the mutual cooperation of seven modules including the bidirectional roller guide module, floating bridge detection platform, posture adaptive adjustment module, ultrasonic thickness detection module, thickness uniformity analysis module, automatic encryption scanning submodule and structure monitoring and scoring module, this system can complete the full process closed loop from mechanical guidance, dynamic coupling, real-time measurement, intelligent identification to precise re-measurement and comprehensive evaluation on the curved surface of shipboard. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The present invention can be further understood from the following description in conjunction with the accompanying drawings. The components in the figures are not necessarily drawn to scale, but rather the emphasis is placed on illustrating the principles of the embodiments. In different views, the same reference numerals designate the same parts.

[0039] Figure 1 It is an overall block diagram of the present invention.

[0040] Figure 2 It is a top view schematic diagram of the detection station and bidirectional roller guide module, floating bridge detection platform, posture adaptive adjustment module, and ultrasonic thickness detection module of the present invention.

[0041] Figure 3 for Figure 2 Enlarged schematic diagram of part B in the middle.

[0042] Figure 4 for Figure 3 Enlarged schematic diagram of part C in the middle.

[0043] Figure 5 for Figure 3 Enlarged schematic diagram of part D in the middle.

[0044] Figure 6 It is a schematic top view of the adsorption unit of the present invention.

[0045] Figure 7 for Figure 6 Schematic cross-sectional view at AA in the middle.

[0046] Figure 8 for Figure 7 Enlarged schematic diagram of part E in the middle.

[0047] Figure 9 for Figure 7 Enlarged schematic diagram of part F in the middle.

[0048] Figure 10 for Figure 7 Enlarged schematic diagram of the middle H part.

[0049] Figure 11 It is a partial cross-sectional schematic diagram of the posture adaptive adjustment module and the ultrasonic thickness detection module of the present invention.

[0050] Figure 12 for Figure 11 Enlarged schematic diagram of the middle G section.

[0051] Figure 13 It is a side structural schematic diagram of the auxiliary support unit of the present invention.

[0052] Explanation of the accompanying symbols: 1. Detection station; 2. Ship plate; 3. Adsorption seat; 4. Auxiliary moving track; 5. Auxiliary moving member; 6. Support rod; 7. Support seat; 8. Sliding seat; 9. Ultrasonic array; 10. Couplant liquid storage tank; 11. Fixed seat; 12. Support rod; 13. Support auxiliary rod; 14. Roller body; 15. Limiting movable rod; 16. Limiting protrusion; 17. Limiting spring; 18. Pulling spring; 19. Check valve; 20. Casing base; 21. First joint; 22. Second joint; 23. Transfer bottom plate; 24. Fixed seat; 25. Follow-up plate; 26. Servo drive; 27. Connecting seat; 28. Linkage arm ; 29. ​​Ultrasonic thickness detection module; 30. Automatic coupling agent supply component; 31. Limiting ring; 32. Guide column; 33. Compression spring; 34. Lithium battery; 35. Flexible electrode sheet; 36. Guide column hole; 37. Electrode sheet bracket; 38. Housing base; 39. DC-DC boost submodule; 40. High-voltage MOSFET switch; 41. Coupling liquid storage tank; 42. Water pump; 43. Annular vacuum groove; 44. Hydrogel microcolumn array; 45. Air inlet; 46. Vacuum pump; 47. Air path check valve; 48. Air outlet; 49. Distribution manifold; 50. Micro metering pump; 51. Drop nozzle; 52. Telescopic rod. DETAILED DESCRIPTION

[0053] The following is an explanation of the embodiments of the present invention through specific embodiments. Those skilled in the art can understand the advantages and effects of the present invention from the contents disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and the details in this specification can also be modified and changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. In addition, the drawings of the present invention are only simple schematic illustrations and are not depicted in actual size. It is stated in advance. The following embodiments will further explain the relevant technical content of the present invention in detail, but the disclosed content is not intended to limit the scope of protection of the present invention.

[0054] Example 1: According to Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figure 5、 Figure 6 、 Figure 7 、 Figure 8 、 Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 and Figure 13 As shown, this embodiment provides a shipboard 2 thickness and uniformity analysis system based on ultrasonic detection, the shipboard 2 thickness and uniformity analysis system includes a server, a detection station 1, and the shipboard 2 thickness and uniformity analysis system also includes a bidirectional roller guide module, a floating bridge detection platform, a posture adaptive adjustment module, an ultrasonic thickness detection module 29, a uniformity analysis module, and a structure monitoring and scoring module;

[0055] In this embodiment, the server is respectively connected to the bidirectional roller guide module, floating bridge detection platform, posture adaptive adjustment module, ultrasonic thickness detection module 29, uniformity analysis module and structure monitoring scoring module, and stores the intermediate data and control data of the bidirectional roller guide module, floating bridge detection platform, posture adaptive adjustment module, ultrasonic thickness detection module 29, uniformity analysis module and structure monitoring scoring module in the database of the server for query and call.

[0056] The floating bridge type detection platform is arranged on the peripheral side of the detection station 1, and is connected to the bidirectional roller guide module. When the surface of the shipboard 2 is deformed or the curvature changes, a controlled vertical follow-up displacement is generated to maintain effective coupling between the ultrasonic probe and the surface of the shipboard 2;

[0057] The bidirectional roller guide modules are arranged at the front and rear ends of the floating bridge type detection platform, and are used to guide the detection platform to move bidirectionally along the surface of the shipboard 2, and obtain contact posture information with the surface of the shipboard 2 in real time during the movement, so as to output guidance data representing the local curvature;

[0058] The posture adaptive adjustment module is installed on the floating bridge detection platform and controls the relative posture adjustment between the floating bridge detection platform and the ultrasonic thickness detection module 29 in real time according to the guidance data output by the bidirectional roller guidance module, so that the emission direction of the ultrasonic thickness detection module 29 is always consistent with the local normal of the surface of the shipboard 2, thereby ensuring the coupling quality and measurement accuracy of the detection;

[0059] The ultrasonic thickness detection module 29 is used to transmit and receive ultrasonic signals and obtain echo data, and calculate the thickness value of the ship plate 2 at the corresponding position according to the echo data;

[0060] The thickness uniformity analysis module is deployed in the server and constructs the thickness data obtained by the ultrasonic thickness detection module 29 into a two-dimensional thickness distribution matrix. The thickness distribution matrix is ​​divided into fixed-size sliding windows and the coefficient of variation (CV) value of each sliding window is calculated to evaluate the degree of local thickness fluctuation.

[0061] The structural monitoring and scoring module is deployed in the server to generate a thickness distribution heat map and an uneven area identification map based on the coefficient of variation CV value and the area ratio of the uneven area calculated by the thickness uniformity analysis module, calculate the health index PHI of the ship plate 2, and output the structural status evaluation result.

[0062] The ship plate 2 thickness and uniformity analysis system also includes a central processing unit, which is respectively controlled and connected with the two-way roller guide module, the floating bridge detection platform, the posture adaptive adjustment module, the ultrasonic thickness detection module 29, the uniformity analysis module and the structure monitoring and scoring module, and is based on the central processing unit to centrally control the two-way roller guide module, the floating bridge detection platform, the posture adaptive adjustment module, the ultrasonic thickness detection module 29, the uniformity analysis module and the structure monitoring and scoring module, and stores the control data of the central processing unit in the database of the server to improve the efficiency and reliability of the entire system in detecting the thickness of the ship plate 2.

[0063] When performing ultrasonic testing, the bidirectional roller guide module and the floating bridge type testing platform need to be placed on the outer wall of the shipboard 2. In this embodiment, the bidirectional roller guide module and the floating bridge type testing platform are detachably connected to the shipboard 2, that is, they are adsorbed in the testing area of ​​the shipboard 2 by an adsorption device.

[0064] Optionally, the bidirectional roller guide module includes a roller assembly, an angle sensing subunit, a pressure sensing subunit, a signal conditioning and output interface, the roller assembly is used to realize mechanical guidance and support on the surface of the shipboard 2, the roller assembly includes a roller body 14, a support rod 12, a support subrod 13, a pulling spring 18, a limit spring 17, a limit protrusion 16, a limit movable rod 15, and a roller shaft. One end of the support rod 12 is provided with an action cavity for placing the rolling shaft, the rolling shaft is nested on the roller body 14 and is coaxially arranged with the roller body 14, and the two ends of the rolling shaft are hinged to the side walls of the action cavity. The supporting rod 12 is a rolling portion, and the other end of the supporting rod 12 extends toward one end of the supporting sub-rod 13, and one end of the limiting spring 17 is nested on the end portion of the supporting rod 12 away from the rolling portion. The other end of the limiting spring 17 is connected to one end portion of the supporting sub-rod 13, and the other end of the supporting sub-rod 13 is hinged to the floating bridge type detection platform. One end of the pulling spring 18 is connected to the floating bridge type detection platform, and the other end of the pulling spring 18 is hinged to the rod body of the supporting sub-rod 13, so that a triangular structure is formed between the contact end surfaces of the supporting sub-rod 13, the floating bridge type detection platform and the shipboard 2.

[0065] The support rod 12 and the supporting sub-rod 13 are coaxially arranged and connected by the limiting spring 17. Furthermore, one end of the support rod 12 and one end of the supporting sub-rod 13 face each other and are spaced apart, with the ends connected by the limiting spring 17, as shown in the figure. The limiting spring 17 allows the rolling portion to be ejected from the surface of the shipboard 2 during contact with the surface of the shipboard 2, and to rest against the detection position of the shipboard 2, thereby obtaining angle data of the shipboard 2 and force data of the contact area.

[0066] In addition, the limiting protrusions 16 are symmetrically arranged on the outer periphery of the supporting auxiliary rod 13, and the limiting protrusions 16 are provided with limiting holes for the passage of the limiting movable rod 15. The limiting movable rod 15 is symmetrically arranged on the outer periphery of the supporting rod 12. One end of the limiting movable rod 15 is connected to the supporting rod 12, and the other end of the limiting movable rod 15 extends toward one side of the supporting auxiliary rod 13 and passes through the limiting hole. The diameter of the limiting hole is adapted to the circumference of the limiting movable rod 15, so that the two can be movable and limited.

[0067] When the support rod 12 and the supporting auxiliary rod 13 are approaching each other, the limiting movable rod 15 moves along the direction of the limiting hole, thereby limiting the moving direction of the support rod 12 and improving the stability and reliability of the movement.

[0068] The angle sensing subunit is fixedly mounted on the roller shaft, and detects the inclination angle of the roller body 14 relative to the vertical direction in real time; the pressure sensing subunit is arranged in the force contact area between the roller body 14 and the floating bridge-type detection platform, the force direction of the force contact area is consistent with the normal direction of the surface of the ship plate 2, and detects the contact pressure applied by the roller body 14 in the direction perpendicular to the surface of the ship plate 2 in real time; the input end of the signal conditioning and output interface is respectively connected to the angle sensing subunit and the pressure sensing subunit, and the output end is electrically connected to the posture processing interface in the server through the data bus, and converts the angle detection signal and the pressure detection signal into digital contact posture information and sends it to the server in real time.

[0069] Optionally, the outer peripheral surface of the roller is a magnetic adsorption coating layer or a high-friction rubber layer to provide stable guiding adhesion under different metal materials or in humid environments.

[0070] The angle sensing subunit includes a three-axis accelerometer, a three-axis gyroscope, and an attitude calculation processor. The three-axis accelerometer is used to measure the component of the gravity vector in the sensor coordinate system; the three-axis gyroscope is used to detect the angular velocity of the sensor coordinate system around its own axis; the attitude calculation processor is used to fuse the accelerometer and gyroscope data, execute a filtering algorithm, and calculate the tilt angle. The three-axis accelerometer continuously outputs the gravity component in the X, Y, and Z directions; the three-axis gyroscope outputs the angular velocity around the X, Y, and Z axes in real time. The attitude calculation processor combines the short-term tilt change obtained by integrating the angular velocity with the long-term attitude correction determined by the gravity vector using a complementary filtering or Kalman filtering algorithm to calculate the pitch and roll angles of the roller relative to the vertical direction.

[0071] The pressure sensing subunit includes a strain gauge bridge element, a Wheatstone bridge circuit, a differential amplifier and an analog-to-digital converter, wherein the strain gauge bridge element is used to convert the normal pressure of the roller on the ship plate 2 into a resistance change; the Wheatstone bridge circuit is used to convert the resistance change into a differential voltage signal; the differential amplifier is used to amplify the microvolt signal output by the bridge; the analog-to-digital converter (ADC) is used to convert the amplified analog signal into a digital quantity; the strain gauge bridge element senses the normal pressure of the roller on the ship plate 2 and generates a corresponding bridge unbalanced voltage; the Wheatstone bridge circuit outputs this unbalanced voltage as a measurable differential signal; the differential amplifier amplifies the signal to a level suitable for the ADC input; the analog-to-digital converter performs high-resolution sampling on the amplified signal and outputs a digital value; wherein the digital value output by the analog-to-digital converter can be subjected to a noise filtering operation through the noise filtering algorithm built into the central processing unit to obtain an accurate normal pressure value. The bridge circuit formed by the strain gauge bridge circuit elements is directly connected to the input end of the differential amplifier; the output end of the amplifier is connected to the analog input of the analog-to-digital converter; the digital output of the analog-to-digital converter is sent to the central processing unit via the SPI interface to perform noise filtering operations, thereby obtaining an accurate normal pressure value.

[0072] Optionally, the floating bridge-type detection platform includes a support seat 7, an adsorption unit, an auxiliary support unit, a detection seat, and a sliding unit. The support seat 7 is provided with a sliding track. The sliding unit is arranged on the sliding track, and the position of the adsorption unit arranged on the sliding track is adjusted. The auxiliary support unit is arranged on one side of the detection area, and auxiliary supports the support seat 7 so that the support seat 7 can be erected on one side of the detection area of ​​the shipboard 2; wherein, the detection seat is arranged on the adsorption unit.

[0073] In this embodiment, the adsorption unit provided on the sliding track slides along the direction of the sliding track.

[0074] During the thickness detection process, the adsorption unit is adsorbed in a specific detection area of ​​the shipboard 2 and cooperates with the ultrasonic thickness detection module 29 to detect the thickness of the shipboard 2 in the current detection area.

[0075] The auxiliary support unit includes a support rod 12, a support drive mechanism, an auxiliary movable member 5, an auxiliary seat, and an auxiliary movable rail 4. The auxiliary seat is arranged on one side of the detection station 1, and the upper end surface of the auxiliary seat is provided with an auxiliary movable rail 4, wherein the auxiliary movable rail 4 extends along the length direction of the detection station 1.

[0076] The auxiliary movable member 5 is arranged on the auxiliary movable track 4 and slides along the direction of the auxiliary movable track 4. One end of the support rod 12 is drivingly connected to the support drive mechanism to form a support portion, which is arranged on the auxiliary movable member 5. The other end of the support rod 12 is connected to the support seat 7, so that when the auxiliary movable member 5 slides along the extension direction of the auxiliary movable track 4, it can synchronously drive the support seat 7 to move.

[0077] In this embodiment, the support rod 12 is configured as a telescopic structure, and is driven by the support drive mechanism to absorb telescopic movements, so as to detect the thickness of different areas of the shipboard 2.

[0078] The auxiliary movable component 5 includes an auxiliary seat, an auxiliary driving mechanism, a positioning probe, and at least two positioning marking members arranged on the auxiliary movable track 4. The auxiliary seat is slidably connected to the auxiliary movable track 4. The positioning probe is arranged on the auxiliary seat and is arranged in the direction of at least two positioning marks. The auxiliary driving mechanism is arranged on the auxiliary seat and drives the auxiliary seat to slide along the extension direction of the auxiliary movable track 4.

[0079] Among them, at least two positioning marking members are distributed at equal intervals along the extension direction of the auxiliary movable track 4 , and at the same time, the positioning marking members at various positions correspond to different detection positions in different areas of the detection station 1 .

[0080] When the ship plate 2 is placed on the inspection station 1, the auxiliary driving mechanism drives the auxiliary seat, the support rod 12 arranged on the auxiliary seat, and the support seat 7 connected to the support rod 12 to slide, and the sliding direction is set to be along the direction of the auxiliary movable track 4, so that the ultrasonic thickness detection module 29 and the posture adaptive adjustment module arranged on the support seat 7 can perform thickness detection on the ship plate 2 according to the set detection parameters, thereby analyzing the thickness uniformity of the ship plate 2.

[0081] In this embodiment, the posture adaptive adjustment module is provided on the detection seat;

[0082] The sliding unit includes a sliding seat 8 and a sliding drive unit. The sliding seat 8 is slidably connected to the sliding track. The sliding drive mechanism is provided on the sliding seat 8 and drives the sliding seat 8 to slide along the extending direction of the sliding track.

[0083] The adsorption unit includes a fixed seat 24, an adsorption member, and a transfer member. The adsorption member and the transfer member are disposed on the fixed seat 24. The adsorption member is used to adsorb the posture adaptive adjustment module and the ultrasonic thickness detection module 29 disposed on the fixed seat 24 onto the shipboard 2. The transfer member is used to adjust the position of the fixed seat 24 so that the fixed seat 24 slides along the extension direction of the sliding track. The fixed seat 24 is connected to the sliding seat 8 and moves in accordance with the movement of the sliding seat 8.

[0084] In this embodiment, the adsorption component includes an adsorption seat 3, a coupling liquid storage tank 41, a water pump 42, a check valve 19, a micro-nozzle, a hydrogel micro-column array 44, an annular vacuum groove 43, a vacuum pump 46, and an air circuit check valve 47. The hydrogel micro-column array 44 is solidified in the center of the end face of the adsorption seat 3 facing the shipboard 2, and the annular vacuum groove 43 is concentrically surrounded by the adsorption seat 3; the adsorption seat 3 is provided with a storage cavity, and a coupling liquid storage tank 41 is installed on one side of the storage cavity. The coupling liquid storage tank 41 is used to store the coupling liquid; the fluid outlet at the bottom is connected to a It is connected to a normally closed check valve 19, and the liquid inlet of a micro water pump 42 is immediately connected downstream of the check valve 19. The liquid outlet of the water pump 42 is connected to one end of a micro nozzle, and the other end of the micro nozzle is distributed above the hydrogel microcolumn array 44, and the coupling liquid is quantitatively sprayed into the hydrogel microcolumn array 44; a vacuum pump 46 is installed on the other side of the inner cavity of the adsorption seat 3, and the air inlet 45 of the vacuum pump 46 is connected to the annular vacuum groove 43 through a vacuum pipe, and the air outlet 48 of the vacuum pump 46 passes through the adsorption seat 3 and is connected to the external environment; all pumps and valves are powered by the built-in battery of the adsorption seat 3.

[0085] During use, the central processing unit first opens the waterway check valve 19 and starts the water pump 42, allowing the coupling liquid in the liquid storage tank to enter the micro-nozzle through the hose and be evenly sprayed from the micro-nozzle hole onto the hydrogel micro-column array 44. At this time, the hydrogel micro-columns swell when they encounter the liquid, using their own capillary structure to quickly remove impurities from the array surface and the surface of the shipboard 2, and form a preliminary water film seal between the bottom end of the column and the surface of the shipboard 2. Next, the central processing unit turns off the water pump 42 and allows the waterway check valve 19 to close automatically, then starts the vacuum pump 46 and opens the airway check valve 47. The vacuum pump 46 rotates forward to extract the air in the annular vacuum groove 43, establishing a continuous negative pressure around the micro-column array. The expanded hydrogel micro-columns and the negative pressure groove work together to firmly and airtightly lock the adsorption seat 3 to the shipboard 2. After completing the thickness detection, the central processing unit turns off the vacuum pump 46 and the air circuit check valve 47 in sequence to restore normal pressure. The hydrogel microcolumns rebound quickly and use themselves to squeeze out excess coupling liquid, breaking the seal with the ship plate 2. The adsorption seat 3 automatically detaches, and the entire system can be moved to the next detection position for cyclic operation.

[0086] The transfer component includes a transfer base plate 23, an electric adsorption subunit, a crab-like driving subunit, a local control unit, and at least four adsorption legs. The transfer base plate 23 is nested on the periphery of the fixed base 24 and supports the electric adsorption subunit, the crab-like driving subunit, the local control unit, and at least four adsorption legs. The adsorption legs are divided into two groups symmetrically arranged on both sides of the transfer base plate 23. The electric adsorption subunit is arranged on the adsorption legs, and the crab-like driving subunit drives the adsorption legs so that the adsorption legs can move freely. The electric adsorption subunit is used to firmly lock the adsorption legs to the surface of the shipboard 2 to provide a stable fulcrum and sliding point conversion for the crab-like driving subunit.

[0087] Among them, the local control unit is responsible for receiving and parsing the displacement and adsorption instructions from the central processing unit, coordinating the action timing of the electric adsorption subunit and the crab-like drive subunit, realizing the adsorption------vibration------release------vibration cycle step, and combining the displacement sensor feedback to dynamically correct the actual moving distance of each step; at the same time, it also monitors the operating status and safety parameters of each subunit (such as leakage, current overload, displacement deviation, etc.), and quickly takes power-off or alarm measures in abnormal moments to ensure the accuracy, efficiency and safety of the transfer process.

[0088] In this embodiment, the adsorption legs are in a two-joint connection structure, such as Figure 7 or Figure 10 As shown, the first joint 21 and the second joint 22 of the adsorption leg are hinged to each other to form a hinged portion, one end of the first joint 21 is provided with an adsorption portion in contact with the shipboard 2, and the second joint 22 is connected to the transfer base plate 23.

[0089] The electric adsorption subunit is arranged inside the adsorption part where the adsorption leg contacts the ship plate 2, wherein the electric adsorption subunit includes a DC-DC boost submodule 39, a high-voltage MOSFET switch, a current limiting resistor, a flexible electrode sheet 35, a spring reset mechanism, and a built-in lithium battery 34. The DC-DC boost submodule 39 boosts the underlying 12V DC (or battery voltage) to the target 200V DC, and the high-voltage MOSFET switch quickly switches the high voltage on and off according to the control signal to achieve instantaneous power-on (locking) and power-off (release) of the flexible electrode; the current limiting resistor limits the current of the boost output to the order of 1-5μA to avoid any risk of electric shock or plate discharge; the flexible electrode sheet 35 forms a high-field strength capacitor structure with the surface of the ship plate 2 to generate electrostatic adsorption force; the spring reset mechanism slightly separates the electrode sheet from the ship plate 2 after the high voltage is powered off to ensure that there is no residual adsorption after release; the built-in lithium battery 34 provides an independent power supply to the DC-DC boost submodule 39 and the MOSFET driver. The lithium battery 34 is detachably loaded in the battery compartment and connected to the contact head in the battery compartment to supply power to the DC-DC boost submodule 39 , the high-voltage MOSFET switch, the current limiting resistor, and the flexible electrode sheet 35 .

[0090] Among them, the spring return mechanism includes a compression spring 33, an electrode sheet bracket 37, a guide column 32, a casing base 38, and a limit baffle. The casing base 38 is built into the adsorption part, and one end of the compression spring 33 is against the bottom of the electrode sheet bracket 37, and the other end of the compression spring 33 is against the casing base 38. The electrode sheet bracket 37 adopts an integrally molded plastic, and the flexible electrode sheet 35 is arranged on the electrode sheet bracket 37, and guide column 32 holes are opened at the four corners of the electrode sheet bracket 37 frame. The guide column 32 passes through the guide column 32 hole on the electrode sheet bracket 37 to ensure that the electrode sheet moves smoothly in the vertical direction when the spring is compressed and released, and no lateral jamming occurs.

[0091] In addition, limit rings 31 are provided above and below the electrode sheet bracket 37. When the spring is fully released or compressed to the limit, the limit rings 31 prevent the bracket or spring from overtravel, protecting the electrode and circuit from mechanical impact.

[0092] In this embodiment, the drain of the high-voltage MOSFET switch is connected to the high-voltage output of the DC-DC boost module through a current-limiting resistor, and the source of the high-voltage MOSFET switch is connected to the positive electrode welding point of the electrode sheet on the bracket; the gate of the high-voltage MOSFET switch is driven by the local control unit.

[0093] The local control unit enables the gate of the high-voltage MOSFET switch, and the high-voltage DC-DC output (≈200 V) flows into the electrode sheet through the current-limiting resistor. A strong electrostatic adsorption force is formed between the electrode sheet and the shipboard 2, overcoming the spring preload. The bracket is pulled down and tightened, and the spring is further compressed to the set travel limit, and the electrode sheet adheres to the shipboard 2.

[0094] The local control unit enables the gate of the high-voltage MOSFET switch, which turns off and disconnects the high voltage from the electrode. The electrostatic adsorption force disappears, leaving only the spring preload. The spring quickly pops up the bracket, lifting the electrode off the shipboard 2, completing the desorption process and preparing for the next step.

[0095] The crab driving subunit is arranged between the first joint 21 and the second joint 22. Figure 10 The crab-like driving subunit includes a telescopic driving mechanism and a telescopic rod 52 , one end of the telescopic rod 52 is connected to the first joint 21 , and the other end of the telescopic rod 52 is drivingly connected to the telescopic driving mechanism to form a telescopic portion, which is provided on the second joint 22 .

[0096] The local control unit includes a microcontroller, a MOSFET driver, a piezoelectric amplifier, an incremental grating scale receiver, and a CAN bus receiver. The microcontroller is used to receive CAN (field bus) instructions, execute step logic, drive peripherals, and process closed-loop feedback. The MOSFET driver (such as TI UCC27517) cooperates with the high-voltage MOSFET switch 40 to complete the on / off control of the four electrically bonded electrodes; the piezoelectric amplifier (such as Apex PA78) amplifies the PWM signal of the microcontroller to ±100V and drives the two sets of telescopic parts to move; the incremental grating scale receiver (such as Broadcom HEDS-9800 series) sends the micron-level displacement pulses of the guide rail or base plate to the timer counter of the microcontroller; the CAN bus transceiver is used for high-speed, interference-resistant bidirectional communication with the central processing unit;

[0097] In this embodiment, the transfer process of the transfer component includes the following process: when the central processing unit issues a movement and detection instruction, the local control unit first powers on and locks the two front adsorption legs and powers off and releases the two rear legs, and then starts the X-axis telescopic drive mechanism of the crab-walking drive subunit - the telescopic drive mechanism causes the telescopic rod 52 to push the first joint 21 outward, and the two rear legs slide Δd / 2 relative to the two front legs under the action of inertia (in this embodiment, Δd is the single sliding distance of the transfer base plate 23 relative to the locking legs in each extension → retraction cycle of the telescopic rod 52 of the crab-walking drive subunit, Δd = L 伸出 -L 复位 , L 伸出It is the length of the telescopic rod when the telescopic drive mechanism pushes it from the initial position to the maximum extension position; L 复位 It is the length of the telescopic rod when it returns to the initial (reset) position under the action of power-off or retraction control signal); then the leg group is switched and the telescopic drive mechanism is retracted to retract the telescopic rod, so that the two front legs slide Δd / 2 under the fixed two rear legs; after completing the whole step translation, the local control unit makes all four legs powered on and locked, and the posture adaptive adjustment module adjusts the ultrasonic probe posture according to the roller guide data. After aligning with the local normal, the ultrasonic thickness detection module 29 transmits pulses and receives echoes, and the interface control processor calculates the thickness of the ship plate 2 based on this and uploads it to the server; after the detection is completed, the same cycle of: adsorption → extension → switch → retraction → adsorption is pressed to step to the next sampling point to complete the full plate thickness and uniformity analysis.

[0098] Through the mutual cooperation of the bidirectional roller guide module and the floating bridge detection platform, the detection platform can roll smoothly along the curved surface of the ship plate 2 and achieve controlled vertical follow-up displacement when the curvature changes, ensuring that the ultrasonic probe is always effectively coupled with the surface of the ship plate 2.

[0099] Optionally, the posture adaptive adjustment module includes a three-degree-of-freedom linkage arm 28 installed between the floating bridge detection platform and the ultrasonic thickness detection module 29, and the linkage arm 28 includes at least three independently controllable drive drives to adjust the pitch angle and yaw angle of the floating bridge detection platform and the ultrasonic thickness detection module 29 in real time according to the guidance data output by the two-way roller guidance module, so that the emission direction of the ultrasonic thickness detection module 29 is always consistent with the local normal of the surface of the shipboard 2.

[0100] In this embodiment, the ultrasonic thickness detection module 29 is arranged on the posture adaptive adjustment module, and the posture adaptive adjustment module also includes a follower plate 25. The action end of the linkage arm 28 is connected to the follower plate 25. The ultrasonic thickness detection module 29 is arranged on the follower plate 25 and moves with the movement of the follower plate 25.

[0101] The posture adaptive adjustment module also includes a posture analysis unit and a posture adjustment unit. The posture analysis unit obtains the data collected by the angle sensing subunit and analyzes the data collected by the angle sensing subunit to obtain the pitch angle and the yaw angle; the posture adjustment unit adjusts the linkage arm 28 according to the pitch angle and the yaw angle.

[0102] In this embodiment, the posture analysis unit uses the geometric center of the accelerometer / gyroscope packaging module as the origin of the coordinate system, and points to the horizontal axis direction from the front end to the rear end of the floating bridge detection platform, that is, the projection direction of the roller assembly axis on the horizontal plane; in actual installation, the X-axis is consistent with the direction of longitudinal movement of the detection platform along the shipboard 2.

[0103] The Y axis is set to be perpendicular to the X axis in the horizontal plane, pointing to the normal direction of the outer peripheral surface of the roller, that is, the direction from the center of the roller axis to the surface of the ship plate 2; that is, the positive direction of the Y axis corresponds to the direction of the normal pressure applied by the roller to the ship plate 2. The Z axis is perpendicular to both the X and Y axes, pointing to the top of the detection platform, that is, opposite to the direction of the earth's gravity. The positive direction of the Z axis is opposite to the direction of gravity acceleration in inertial measurement, and is used to distinguish between pitch and roll posture changes. The SPI or I 2 The C pin is directly electrically connected to the central processing unit and enables the pitch angle and roll angle relative to the vertical direction to be processed by the central processing unit.

[0104] In addition, the X, Y, and Z channels measure linear acceleration in the three directions mentioned above. In the static state, only the Z-axis channel outputs approximately +1g (or -1g, depending on the definition of the positive direction), while the X and Y-axis channels output approximately 0g. At the same time, using the Z-axis gravity component and the X / Y-axis zero bias components, the posture analysis unit can calculate the pitch angle (Pitch) and roll angle (Roll) through simple trigonometric functions:

[0105] Where a X is the acceleration component measured by the triaxial accelerometer along the local X-axis, in the static state a X ≈0;a Y is the acceleration component measured by the triaxial accelerometer along the local Y axis, in the static state a Y ≈0;a Z is the acceleration component measured by the triaxial accelerometer along the local Z axis, in the static state a Z ≈+g (if the positive direction of the Z axis is defined as opposite to the center of the earth, then it is -g).

[0106] The posture adjustment unit includes a connecting base 27 and three independently controlled servo drivers 26, corresponding to the pitch joint, roll joint, and lift joint. The connecting base 27 is used to support the three independently controlled servo drivers 26. The connecting base 27 is connected to the fixed base 24 and moves with the movement of the fixed base 24. Based on the calculated pitch angle Pitch and roll angle Roll, the central processing unit sends target angle and displacement instructions to these three servo drivers 26 in sequence through the field control bus. This causes the pitch joint to adjust the probe's fore-aft tilt angle, the roll joint to adjust the probe's left-right yaw angle, and the lift joint to fine-tune the height along the normal axis. This ensures that the ultrasonic probe is always aligned with the local normal of the shipboard 2 and closely adheres to the plate surface, achieving high-precision thickness detection.

[0107] Optionally, the ultrasonic thickness detection module 29 includes an area array ultrasonic probe, a multi-channel pulse transmitter-receiver board connected to the area array ultrasonic probe, a time-to-digital converter unit connected to the signal end of the pulse transmitter-receiver board, an interface control processor connected to the data end of the time-to-digital converter unit, and a coupling agent automatic supply component 30 arranged in the same direction as the area array ultrasonic probe;

[0108] The automatic coupling agent supply component 30 is used to continuously provide an acoustic coupling medium between the area array ultrasonic probe and the surface of the shipboard 2. The interface control processor is used to calculate the thickness of the shipboard 2 based on the echo flight time Δt output by the time-to-digital converter unit and the pre-stored sound velocity v of the shipboard 2 material. The automatic coupling agent supply component 30 is disposed on the side of the follower plate 25 facing the shipboard 2 and continuously provides the acoustic coupling medium between the area array ultrasonic probe and the contact end surface of the shipboard 2.

[0109] The thickness value T is calculated according to the following formula: Where Δt is the round-trip flight time of the echo received by the interface control processor from the time-to-digital converter unit; v is the pre-stored sound velocity constant corresponding to the shipboard material;

[0110] Through the cooperation between the posture adaptive adjustment module and the ultrasonic thickness detection module, the ultrasonic signal emission direction is always consistent with the normal line of the shipboard surface, ensuring the signal-to-noise ratio of the echo signal and the thickness measurement accuracy.

[0111] Optionally, the coupling agent automatic supply component 30 includes a coupling agent storage tank 10, a micro-metering pump 50, a distribution manifold 49 and a drip nozzle 51 arranged between the array ultrasonic probe and the surface of the ship plate 2, and a flow sensor located at the outlet of the micro-metering pump 50; the driving end of the micro-metering pump 50 is communicatively connected to the interface control processor, and the feedback signal of the flow sensor is used to close-loop regulate the output flow of the micro-metering pump 50 to keep the coupling layer thickness between the ultrasonic probe and the surface of the ship plate 2 constant during the detection process.

[0112] Before testing each test point of the shipboard, the central processor first reads the coupling layer thickness h required for the test point from the server or local storage. target , and convert it into the corresponding flow setting value Q set . Then, it sends a start command to the micro-metering pump driver to start with an initial duty cycle of D0, and the water pump begins to pump liquid from the coupling agent storage tank at a constant speed with this duty cycle. The extracted liquid first passes through the flow sensor next to the pump outlet. The sensor converts the real-time flow Q(t) into a digital signal and feeds it back to the interface control processor. The central processor runs the PID closed-loop control algorithm internally and sends the new duty cycle D(t) back to the pump driver. Through the distribution manifold and the annular drip nozzle, the coupling agent drips at a constant rate and is injected between the ultrasonic probe and the ship plate, forming a thickness of about h target The closed loop operates continuously at a frequency of ≥20Hz, maintaining coupling layer thickness fluctuations within ±5μm. Simultaneously, the posture adaptive adjustment module corrects the probe's posture based on the data from the roller module, and the ultrasonic thickness detection module transmits pulses and receives echoes to complete the measurement. After each measurement, the central processor sequentially issues commands to stop the metering pump and close the nozzle. The coupling agent automatically flows back into the reservoir or naturally drains away. The area array ultrasonic probe separates from the shipboard and enters standby mode, preparing for the next measurement point cycle.

[0113] Through the cooperation between the bidirectional roller guide module and the posture adaptive adjustment module, the system can perceive the local surface curvature in real time and dynamically adjust the pitch and yaw angles of the probe to ensure position stability and continuity during the measurement process.

[0114] In addition, through the mutual cooperation between the floating bridge detection platform and the posture adaptive adjustment module, the probe position and posture can be quickly compensated in uneven or curved areas of the shipboard, ensuring that the detection accuracy is not reduced due to surface deformation.

[0115] Optionally, after calculating the coefficient of variation CV value, the thickness uniformity analysis module further compares it with the global CV mean value. If the CV value of a sliding window is higher than a set threshold, the area corresponding to the window is marked as an uneven thickness area.

[0116] Optionally, the structure monitoring scoring module calculates the ship plate health index PHI according to the following formula:

[0117] PHI = 100-α·CV′-β·Ad;

[0118] Wherein, CV' is the global average CV value of the two-dimensional thickness matrix, Ad is the ratio of the uneven thickness area to the total detection area, and α and β are preset weight coefficients.

[0119] The global average CV value CV of the two-dimensional thickness matrix - ', calculated according to the following formula:

[0120] Where M is the total number of sliding windows, that is, the number of windows obtained by dividing the entire detection area into fixed-size sliding windows, CV i is the coefficient of variation of the thickness of the i-th sliding window, which is defined as the standard deviation of the thickness samples in the window σ i With the average value μ i The ratio of

[0121] Among them, for the thickness sample {t i,1 ,t i,2 ,…,t i,ni}Standard deviation of thickness samples within the window σ i With the average value μ i Calculate according to the following formula:

[0122] Where, t i,j is the ship plate thickness value measured at the jth measuring point in the i-th sliding window, n i is the total number of measurement points contained in the i-th sliding window, μ i is the average thickness of the i-th sliding window, that is, all n i The sum of the thickness values ​​divided by n i , σi is the standard deviation of the i-th sliding window.

[0123] In this embodiment, the detection area is divided into M non-overlapping sliding windows according to a fixed size (in this embodiment, it is set to: 100mm×100mm); ni thickness values ​​{t i,1 ,…,t i,ni}.

[0124] And calculate the thickness coefficient of variation CV of the i-th sliding window i is, which is defined as the standard deviation of thickness samples in the window σ i With the average value μ i The ratio of:

[0125] Find the maximum coefficient of variation CVmax among all windows (M windows): CV max =max 1≤j≤M CV j ;

[0126] In addition, to ensure that the uneven thickness area can accurately reflect the local excessive fluctuations on the ship plate surface, and to take into account the detection noise and inherent material tolerance, we first conducted an offline calibration test on several standard steel plate samples (1.5m wide × 2.0m long, designed thickness 20mm) from the same batch and the same process: the sample plate surface was divided into sliding windows of size 100mm × 100mm according to this method, and a total of M = 280 windows were collected;

[0127] Thickness data is collected at 5mm intervals within each window, and each CV is calculated. i ; All window CVs were obtained by 30 repeated tests i The overall distribution of the std =1.2%, standard deviation σ std =0.8%; According to the three sigma criterion (3σ) in statistical process control (SPC), the unevenness threshold is set to CVth=CV std +3σ std =1.2%+3×0.8%≈3.6%;

[0128] According to the China Classification Society (CCS) - Steel Plate Tolerance Specification (GB / T 3270-2016), the thickness tolerance of medium and thick plates (>10mm) is within ±5% and is considered qualified, corresponding to a maximum coefficient of variation of about 5%. Therefore, in order to meet the strict SPC test and take into account the industry tolerance, the above threshold is rounded to CV. th =4.0%.

[0129] Get the preset threshold CV from calibration or specification th (This embodiment is set to CV th =4.0%), and for each window i press:

[0130] Calculate the overscaling coefficient ω of each window according to the above formula i ∈[0, 1];

[0131] Take the average weight of all windows and calculate the proportion Ad of the uneven thickness area to the total detection area:

[0132]

[0133] Among them, M is the total number of sliding windows, that is, the number of windows obtained by dividing the entire detection area into fixed-size sliding windows, ω iis the overscaling coefficient for each window;

[0134] In this embodiment, the preset weight coefficients α and β provide an example of values, specifically:

[0135] 1) For the initial inspection of new shipbuilding plates (pursuing balance without minor defects), the values ​​of the weight coefficients α and β are: α = 10, β = 50; that is, after α and β are set to the above values, they are more sensitive to uneven areas, and large uneven areas can be eliminated as early as possible. 2) In the scenario of mid-term routine inspections (taking into account local fluctuations and area proportions), the values ​​of the weight coefficients α and β are: α = 20, β = 30; that is, after α and β are set to the above values, equal attention is paid to overall jitter and area. 3) In the scenario of life assessment of old shipbuilding plates (focusing on overall fluctuations), the values ​​of the weight coefficients α and β are: α = 40, β = 10; that is, after α and β are set to the above values, a small amount of uneven areas are tolerated, but overall thickness fluctuations are strictly controlled. 4) In the scenario of acceptance of key load-bearing plates (double strictness), the weight coefficients α and β are set to: α = 30, β = 30; that is, setting α and β to the above values ​​results in equally strict requirements for both indicators, which is suitable for high-risk areas such as hatch covers and deck chords. In short, users can fine-tune α and β within the above range based on the thickness inspection requirements of the ship plate material, service life, and stress environment, and will not be detailed in this embodiment.

[0136] Through the cooperation between the ultrasonic thickness detection module and the uniformity analysis module, the real-time collected thickness data can automatically construct a two-dimensional thickness distribution matrix and calculate the coefficient of variation of each area, ensuring that local thickness unevenness can be identified quickly and accurately.

[0137] The coordinates of the uneven thickness region are determined according to the following steps:

[0138] S100, divide the detection surface into a matrix of M rows × N columns according to a fixed window (such as 100mm × 100mm); calculate the coefficient of variation CV of each grid (i, j) i,j , with the threshold CV th Compare and mark the excess:

[0139] S101, for each row i, scan b from left to right i,1 ,b i,2 ,…,b i,N , the continuous 1 segment [j min ,j max ] is recorded as a segment; each segment is represented by a triple (i, j min ,j max ) indicates that this is the coordinate range of an "uneven thickness area" in terms of row and column numbers.

[0140] S102. Since the size of each grid is known (side length d), the row and column segments can be directly mapped to physical intervals: x∈[(j min -1)d,j max d],y∈[(i-1)d,id];

[0141] In the above formula, (j min -1)d means multiplying the column offset by the grid side length d to get the starting coordinate of the grid segment in the x direction. The x coordinate of the right edge of the jth column is j×d, and the y coordinate of the bottom edge of the i-th row is (i-1)×d. The y coordinate of the top edge of the i-th row is i×d.

[0142] S103: Report the interval list formed above to the automatic encryption scanning submodule.

[0143] In this embodiment, the complete two-dimensional thickness matrix {t i,j}, and normalize the thickness value at each grid cell (i, j):

[0144]

[0145] Where, t min , t max Then, through the preset color table (set as blue-green-yellow-red gradient in this embodiment), each c i,j Convert it into the corresponding RGB value and render it to the corresponding image pixel position to obtain the thickness distribution heat map.

[0146] In addition, the binary mask {b i,j}(If CV i,j >CV th Then b i,j =1, otherwise 0), for all b on the heat map i,j = 1 is superimposed with a translucent red frame or red translucent fill to highlight the area of ​​uneven thickness.

[0147] In this embodiment, after completing the generation of the thermal map and the identification map, the structural monitoring and scoring module will output the following structural status evaluation results:

[0148] 1) Ship plate health index (PHI) (value range 0 to 100, higher values ​​indicate more uniform thickness distribution);

[0149] 2) A list of key uneven regions, including the row and column indexes of each uneven window and its corresponding physical coordinate interval;

[0150] 3) Comprehensive maintenance recommendations, automatically determining the patient's status based on PHI and maximum CV value: healthy, recommended for re-examination, or required for rework;

[0151] 4) The accompanying visual report includes a thickness distribution thermogram, an uneven area identification map, and the aforementioned indices and suggestions, allowing users to intuitively understand the structural status and guide subsequent inspection or maintenance work.

[0152] Through the cooperation between the uniformity analysis module and the structural monitoring and scoring module, the local coefficient of variation and the area ratio of the uneven area can be converted into the ship plate health index and presented in a visual report, ensuring that the detection results are intuitive and decision-making supportive.

[0153] In addition, in this embodiment, through the mutual cooperation of seven modules including a bidirectional roller guide module, a floating bridge detection platform, a posture adaptive adjustment module, an ultrasonic thickness detection module, a thickness uniformity analysis module, an automatic encryption scanning submodule and a structure monitoring and scoring module, the system can complete a full-process closed loop from mechanical guidance, dynamic coupling, real-time measurement, intelligent identification to precise re-measurement and comprehensive evaluation on the curved surface of the ship plate.

[0154] Embodiment 2: This embodiment should be understood to include all the features of any of the above embodiments and further improve upon them. Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figure 5 、 Figure 6 、 Figure 7 、 Figure 8 、 Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 and Figure 13 As shown, optionally, the ship plate thickness and uniformity analysis system also includes an automatic encrypted scanning submodule, which linearly adjusts the moving speed of the floating bridge detection platform and increases the sampling frequency when an uneven thickness area is detected, so as to perform a fine scan of the uneven thickness area.

[0155] The automatic encryption scanning submodule includes an unevenness recognition unit, a path planning unit, a motion control interface, a sampling scheduler, and a feedback detection unit. The unevenness recognition unit receives the row and column segments (i, j) corresponding to the sliding window CV value from the thickness uniformity analysis module. min ,j max ), and calculate the encryption multiple κ of each segment i ; The path planning unit is based on the row and column segment interval and the encryption multiple κ i , in each physical rectangular interval, the encrypted grid spacing D of the i-th segment i Automatically generate parallel raster paths;

[0156] The motion control interface converts the deceleration speed V0 / κ required for the encrypted grid path generated by the path planning unit into i The reference speed V0 of the ordinary grid path is sent in real time to the supporting drive mechanism, auxiliary drive mechanism, sliding drive unit and crab drive sub-unit of the floating bridge detection platform, so as to automatically decelerate during encrypted scanning and restore normal speed during ordinary scanning, thereby realizing seamless speed switching between different path types.

[0157] The reference speed V0 is usually pre-calibrated as a global configuration parameter of the system and stored in the server (or the parameter storage unit of the local controller).

[0158] The sampling scheduler switches the sampling frequency to the pulse sampling frequency f used for the i-th segment encrypted scan through the control interface of the ultrasonic thickness detection module. rep，i Or the reference sampling frequency f0 under conventional scanning (conventional area);

[0159] In this embodiment, the conventional sampling frequency f0 is calculated according to the following formula:

[0160] Wherein, V0 is the normal scanning speed (in this embodiment, it is set to 50 mm / s preset in the parameter library of the server or local controller); d is the normal grid step (i.e., the side length of the sliding window, such as 100 mm).

[0161] The pulse sampling frequency f used for the i-th segment encrypted scan rep，i :

[0162] When κ i =1 (no encryption), f rep,i =f0; when κ i When f > 1, rep,i >f0, the sampling rate increases with the square root of the encryption multiple, which not only matches the denser grid spacing but also avoids the system load caused by excessively high frequency.

[0163] The feedback monitoring unit monitors the completion of the encrypted scan in real time and transmits the data back to the uniformity analysis module.

[0164] The uneven identification unit calculates the encryption multiple κ of the i-th segment (or the i-th row and column segment) according to the following formula:

[0165]

[0166] Where, CV i is the local coefficient of variation of the i-th segment (row and column segment); is the global average variation coefficient; γ is the sensitivity adjustment coefficient (can be selected from 0.5 to 2.0), and its value is determined according to the actual situation. Specifically, when γ is less than 1, the encryption response is weakened, which is suitable for scenarios with high surface flatness but slight local deviation is allowed; when γ is greater than 1, the encryption response is increased, which is suitable for scenarios with high precision requirements or where the material is prone to local wear. In this embodiment, γ = 1.0 is used as the default value; κ min , κ max These are the minimum and maximum allowed values ​​of the encryption multiple (in this embodiment, they are set to 1.2 and 5, respectively), which are used to prevent the encryption from being too weak or excessive.

[0167] In this embodiment, the spacing D of the i-th determinant segment i Determined according to the following formula: Where d is the set original scanning step, κ i is the encryption multiple of the i-th segment (or the i-th row and column segment);

[0168] The path planning unit automatically generates a parallel grid path according to the following steps:

[0169] S200, by row and column segment (i, j min ,j max ) Determine the physical rectangular interval of the segment:

[0170] x∈[x L ,x R ]=[(j min -1)d,j max d],y∈[y B ,y T ]=[(i-1)d,id];

[0171] S201, using the encrypted grid spacing D i Calculate the number of horizontal lines that can be inserted:

[0172]

[0173] Where y B is the y coordinate of the lower boundary of the physical rectangular interval mapped by the row and column segments, that is, (i-1)d, m is the index of the horizontal line segment, increasing from the bottom edge (m=0) to the top edge (m=N), y m The ordinate of the mth scan line is equal to the lower boundary y of the interval B plus m times the grid spacing D i , making sure the lines are parallel and evenly spaced.

[0174] Through the cooperation between the automatic encryption scanning submodule and the thickness uniformity analysis module, the system can intelligently extract local uneven areas after the first scan and automatically plan the encryption grid path, ensuring that any tiny thickness fluctuations can be re-measured with high density for a second time without omission.

[0175] S203, arranging according to a zigzag scanning trajectory:

[0176] When m is an even number, the direction of travel is (x L ,y m )→(x R ,y m ); when m is an odd number, the direction is (x R ,y m )→(x L ,y m ).

[0177] S204. Encode the zigzag path into an ordered list:

[0178] [(x L ,y0)→(x R ,y0),(x R ,y1)→(x L ,y1),...,(x * ,y N )];

[0179] Each item is a starting point→end point coordinate pair where the aircraft head should travel.

[0180] In this embodiment, the sampling scheduler dynamically switches the transmit / receive frequency according to the following steps:

[0181] S300, before starting the encrypted scan, the path planning unit is for each s on the entire scanning path k Calculate the corresponding target frequency f(s k ):

[0182]

[0183] The discretized frequency sequence is obtained according to the above formula and is cached in the local memory.

[0184] S301, issue a signal to the next path point s under the platform motion controller k When the sampling scheduler receives the position arrival interrupt signal, the sampling scheduler immediately queries the corresponding target frequency f(s k) and writes this value into the pulse repetition frequency register of the area array ultrasonic probe. Through the interaction between the automatic encryption scanning submodule and the motion control interface, the deceleration speed and micro-step distance in the encryption section can be switched synchronously with the ultrasonic sampling frequency, ensuring accurate spatiotemporal synchronous sampling even on high-density paths.

[0185] Through the mutual cooperation of the automatic encryption scanning submodule and the posture adaptive adjustment module, the probe posture is continuously corrected during the encrypted re-measurement process, ensuring that the probe is always aligned with the normal of the shipboard surface at high frequency, thereby improving the coupling quality and data accuracy.

[0186] S302, the array ultrasonic probe starts to operate at the new frequency f(s) in the next clock cycle after the register is updated. k ) Transmit and receive; since the switching instructions between sections are precisely synchronized with the trip interruption signal, there is no jump or missed sampling in the transmission interval.

[0187] Among them, through the mutual cooperation of the automatic encryption scanning sub-module and the ultrasonic thickness detection module, the trigger frequency on the encrypted path is dynamically increased, ensuring that each micro-step movement corresponds to an echo measurement, thereby greatly improving the resolution of local thickness measurement.

[0188] S303. The sampling scheduler continuously monitors the trigger completion or FIFO empty interrupt of the board to ensure that the required number of pulses for each segment has been issued and the echo acquisition is completed; if a frequency switching failure or interrupt loss is detected, the same register write command is immediately resent and an alarm is issued.

[0189] S304 , repeat the process of segment trigger → frequency switching → sampling completion confirmation until the entire raster path scan is completed; after the scan is completed, the scheduler resets the frequency to f0 for the last time and enters standby mode.

[0190] In addition, the feedback monitoring unit continuously compares the sliding window index list {(i,j)} and the corresponding encryption segment flag issued by the path planning unit, monitors the stepping feedback of the encoder and crab driving sub-unit of the floating bridge detection platform, and confirms that the window area has completed a complete round-trip scan according to the set encryption grid; then, it reads the window CVi,j value calculated by the ultrasonic thickness detection module and {(i,j,CV i,j The set of CV values ​​(completion flag) is then transmitted back to the thickness uniformity analysis module via the field control bus. The module updates the internal CV value matrix based on the refined window CV data and determines whether any windows still exceed the threshold and require further intensive scanning.

[0191] In this embodiment, through the mutual cooperation of the automatic encryption scanning submodule and the structural monitoring scoring module, the encrypted data obtained from the secondary retest can be fed back in real time to update the health index and maintenance recommendations, ensuring that the detection process achieves closed-loop adaptive optimization and decision support.

[0192] The contents disclosed above are only preferred feasible embodiments of the present invention and do not limit the scope of protection of the present invention. Therefore, all equivalent technical changes made using the contents of the present invention description and drawings are included in the scope of protection of the present invention. In addition, the elements therein can be updated as technology develops.

Claims

1. A ship plate thickness and uniformity analysis system based on ultrasonic detection, comprising a server and a detection station, characterized in that: The ship plate thickness and uniformity analysis system also includes a bidirectional roller guide module, a floating bridge detection platform, a posture adaptive adjustment module, an ultrasonic thickness detection module, a uniformity analysis module and a structure monitoring and scoring module; The floating bridge type detection platform is arranged on the peripheral side of the detection station, and is connected to the bidirectional roller guide module. When the shipboard surface is deformed or the curvature changes, the floating bridge type detection platform generates a controlled vertical follow-up displacement to maintain effective coupling between the ultrasonic probe and the shipboard surface; The bidirectional roller guide modules are arranged at the front and rear ends of the floating bridge-type detection platform, and are used to guide the detection platform to move bidirectionally along the surface of the shipboard, and to obtain contact posture information with the shipboard surface in real time during the movement, so as to output guidance data representing the local curvature; The posture adaptive adjustment module is installed on the floating bridge detection platform and controls the relative posture adjustment between the floating bridge detection platform and the ultrasonic thickness detection module in real time according to the guidance data output by the bidirectional roller guidance module; The ultrasonic thickness detection module is used to transmit and receive ultrasonic signals and obtain echo data, and calculate the thickness value of the ship plate at the corresponding position based on the echo data; The thickness uniformity analysis module is deployed in the server and constructs the thickness data obtained by the ultrasonic thickness detection module into a two-dimensional thickness distribution matrix. The thickness distribution matrix is ​​divided into fixed-size sliding windows and the coefficient of variation (CV) value of each sliding window area is calculated to evaluate the degree of local thickness fluctuation. The structural monitoring and scoring module is deployed in the server to generate a thickness distribution heat map and an uneven area identification map based on the coefficient of variation CV value and the area ratio of the uneven area calculated by the thickness uniformity analysis module, calculate the ship plate health index PHI, and output the structural status evaluation result.

2. The ship plate thickness and uniformity analysis system based on ultrasonic detection according to claim 1 is characterized in that: The bidirectional roller guide module includes a roller assembly, an angle sensing subunit, a pressure sensing subunit, and a signal conditioning and output interface. The roller assembly is used to achieve mechanical guidance and support on the surface of the shipboard. The roller assembly includes a roller body and a roller shaft. The angle sensing subunit is fixedly installed on the roller shaft and detects the inclination angle of the roller body relative to the vertical direction in real time. The pressure sensing subunit is arranged in the force contact area between the roller body and the floating bridge-type detection platform. The force direction of the force contact area is consistent with the normal direction of the shipboard surface, and detects the contact pressure applied by the roller body in the direction perpendicular to the shipboard surface in real time. The input end of the signal conditioning and output interface is respectively connected to the angle sensing subunit and the pressure sensing subunit, and the output end is electrically connected to the posture processing interface in the server through the data bus, and converts the angle detection signal and the pressure detection signal into digital contact posture information and sends it to the server in real time.

3. The ship plate thickness and uniformity analysis system based on ultrasonic detection according to claim 2 is characterized in that: The outer peripheral surface of the roller is a magnetic adsorption coating layer or a high-friction rubber layer to provide stable guiding adhesion under different metal materials or in humid environments.

4. The ship plate thickness and uniformity analysis system based on ultrasonic detection according to claim 1 is characterized in that: The floating bridge-type inspection platform includes a support seat, an adsorption unit, an auxiliary support unit, and a sliding unit. The support seat is provided with a sliding track. The sliding unit is arranged on the sliding track and adjusts the position of the adsorption unit arranged on the sliding track. The auxiliary support unit is arranged on one side of the inspection area and assists in supporting the support seat so that the support seat can be erected on one side of the ship plate inspection area.

5. The ship plate thickness and uniformity analysis system based on ultrasonic detection according to claim 4 is characterized in that: The posture adaptive adjustment module includes a three-degree-of-freedom linkage arm installed between the floating bridge detection platform and the ultrasonic thickness detection module. The linkage arm includes at least three independently controllable drive drivers to adjust the pitch angle and yaw angle of the floating bridge detection platform and the ultrasonic thickness detection module in real time according to the guidance data output by the two-way roller guidance module, so that the emission direction of the ultrasonic thickness detection module is always consistent with the local normal of the shipboard surface.

6. The ship plate thickness and uniformity analysis system based on ultrasonic detection according to claim 4 is characterized in that: The ultrasonic thickness detection module includes an array ultrasonic probe, a multi-channel pulse transmitter-receiver board connected to the array ultrasonic probe, a time-to-digital converter unit connected to the signal end of the pulse transmitter-receiver board, an interface control processor connected to the data end of the time-to-digital converter unit, and a coupling agent automatic supply component arranged in the same direction as the array ultrasonic probe. Among them, the coupling agent automatic supply component is used to continuously provide an acoustic coupling medium between the array ultrasonic probe and the surface of the shipboard; the interface control processor is used to calculate the thickness value of the shipboard based on the echo flight time Δt output by the time-to-digital converter unit and the pre-stored sound velocity v of the shipboard material.

7. The ship plate thickness and uniformity analysis system based on ultrasonic detection according to claim 6, characterized in that: After calculating the coefficient of variation CV value, the thickness uniformity analysis module further compares it with the global CV mean. If the CV value of a sliding window is higher than a set threshold, the area corresponding to the window is marked as a thickness uneven area.

8. The ship plate thickness and uniformity analysis system based on ultrasonic detection according to claim 7, characterized in that: The structural monitoring scoring module calculates the ship plate health index PHI according to the following formula: PHI = 100-α·CV-β·Ad; Where, CV - is the global average CV value of the two-dimensional thickness matrix, Ad is the ratio of the uneven thickness area to the total detection area, and α and β are preset weight coefficients.

9. The ship plate thickness and uniformity analysis system based on ultrasonic detection according to claim 6 or 8, characterized in that: The coupling agent automatic supply component includes a coupling agent storage tank, a micro-metering pump, a distribution manifold and a drip nozzle arranged between the area array ultrasonic probe and the surface of the shipboard, and a flow sensor located at the outlet of the micro-metering pump; The driving end of the micro-metering pump is communicatively connected to the interface control processor, and the feedback signal of the flow sensor is used to close-loop regulate the output flow of the micro-metering pump to keep the coupling layer thickness between the ultrasonic probe and the surface of the ship plate constant during the detection process.

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