Anvil crack detection method and system for cubic press

Abstract

The invention relates to the technical field of anvil crack detection, and discloses an anvil crack detection method and system for a cubic press, and the system comprises a stress monitoring module which is configured to determine the initial ultrasonic emission frequency of an ultrasonic flaw detector according to stress abnormal coordinates; the judgment module is configured to judge whether to optimize the initial ultrasonic transmitting frequency or not based on the analysis result; the optimization module is configured to determine an optimization coefficient of the initial ultrasonic transmitting frequency based on the material type data and the temperature data and obtain an optimized ultrasonic transmitting frequency; the ultrasonic detection module is configured to perform ultrasonic scanning on the suspected crack area at the optimized ultrasonic emission frequency; and analyzing the ultrasonic scanning data, determining the actual crack condition of the suspected crack area based on an analysis result, and generating a detection report. According to the invention, the anvil crack can be rapidly and accurately detected, and the safety and the operation efficiency of equipment are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of top hammer crack detection, and in particular to a top hammer crack detection method and system for a six-sided top press. Background Art

[0002] Six-sided presses are commonly used in materials synthesis and processing. One of their core components is the anvil. Under prolonged high-pressure, high-temperature operation, the anvil is prone to cracking, which not only affects the normal operation of the equipment but can also cause safety accidents. Therefore, crack detection of the anvil in six-sided presses is particularly important. Traditional detection methods mostly rely on manual visual inspection, which is not only inefficient but also prone to missed detections.

[0003] Therefore, it is necessary to design a method and system for detecting cracks in the top hammer of a six-sided top press to solve the problems existing in the current technology. Summary of the Invention

[0004] In view of this, the present invention proposes a method and system for detecting cracks in the top hammer of a six-sided top press, aiming to achieve rapid and accurate detection of cracks in the top hammer and improve the safety and operating efficiency of the equipment.

[0005] In one aspect, the present invention provides a top hammer crack detection system for a six-sided top press, comprising: a stress monitoring module configured to identify a top hammer to be detected, collect surface stress data of the top hammer to be detected, plot a three-dimensional stress distribution diagram based on the surface stress data, and determine whether the top hammer to be detected has a suspected crack region based on the three-dimensional stress distribution diagram; if so, collect stress anomaly coordinates of the suspected crack region, and determine an initial ultrasonic emission frequency of the ultrasonic flaw detector based on the stress anomaly coordinates; a judgment module configured to collect temperature data of the suspected crack area, analyze the temperature data, and determine whether to optimize the initial ultrasonic emission frequency based on the analysis result; an optimization module configured to, when the judgment module determines that the initial ultrasonic emission frequency is to be optimized, collect material type data of the anvil to be detected, determine an optimization coefficient of the initial ultrasonic emission frequency based on the material type data and temperature data, and obtain an optimized ultrasonic emission frequency; The ultrasonic detection module is configured to perform ultrasonic scanning on the suspected crack area at the optimized ultrasonic transmission frequency and obtain ultrasonic scanning data; analyze the ultrasonic scanning data, determine the actual crack condition of the suspected crack area based on the analysis result, and generate a detection report.

[0006] Furthermore, when the stress monitoring module determines whether there is a suspected crack area in the anvil to be detected according to the three-dimensional stress distribution diagram, it includes: Dividing the three-dimensional stress distribution map into regions to obtain a plurality of monitoring regions; Collecting stress values ​​of each coordinate point in each monitoring area and calculating the average stress value of the area; Determine whether there is an abnormal stress area based on the average stress value of the area; If so, the stress abnormality area is regarded as the suspected crack area.

[0007] Furthermore, when the stress monitoring module determines whether there is a stress abnormality area according to the average stress value of the area, it includes: Comparing the regional average stress value with the regional average stress threshold, and determining whether there is a stress abnormality area based on the comparison result; When the regional average stress value is greater than the regional average stress threshold, the monitored area is determined to be the stress abnormality area; Otherwise, it is determined that the monitored area is not the stress abnormality area.

[0008] Furthermore, when the stress monitoring module determines the initial ultrasonic emission frequency of the ultrasonic flaw detector according to the stress anomaly coordinates, it includes: Calculating the difference between the stress value of each coordinate point in the suspected crack area and the standard stress value one by one, recording it as a stress difference, and constructing a stress difference value set; Classifying the corresponding stress difference values ​​within the stress difference threshold in the stress difference value set into a first set; classifying the corresponding stress difference values ​​outside the stress difference threshold in the stress difference value set into a second set; Count the number of stress difference values ​​in the first set, and record it as the first number; Count the number of stress difference values ​​in the second set, and record it as the second number; The initial ultrasonic wave transmitting frequency is determined according to a ratio of the first number to the second number.

[0009] Furthermore, when the stress monitoring module determines the initial ultrasonic emission frequency according to the ratio of the first quantity to the second quantity, it includes: Recording the ratio of the first quantity to the second quantity as a quantity ratio; Comparing the quantity ratio with a first quantity ratio and a second quantity ratio, and determining the initial ultrasonic emission frequency according to the comparison result; wherein the first quantity ratio is smaller than the second quantity ratio; When the quantity ratio is less than or equal to the first quantity ratio, determining the initial ultrasonic wave transmitting frequency to be the first ultrasonic wave transmitting frequency; When the quantity ratio is greater than the first quantity ratio and less than the second quantity ratio, determining the initial ultrasonic wave transmitting frequency to be the second ultrasonic wave transmitting frequency; When the quantity ratio is greater than or equal to the second quantity ratio, the initial ultrasonic wave transmitting frequency is determined to be a third ultrasonic wave transmitting frequency.

[0010] Furthermore, the judgment module analyzes the temperature data and determines whether to optimize the initial ultrasonic emission frequency based on the analysis result, including: Analyzing the temperature data to obtain a temperature characteristic value and obtaining a temperature standard value corresponding to the temperature characteristic value; Calculating the ratio of the temperature characteristic value to the temperature standard value and recording it as the temperature ratio; Comparing the temperature ratio with a temperature ratio threshold, and determining whether to optimize the initial ultrasonic emission frequency according to the comparison result; When the temperature ratio is greater than a temperature ratio threshold, determining that the initial ultrasonic wave transmission frequency needs to be optimized; Otherwise, it is determined that the initial ultrasonic wave transmitting frequency does not need to be optimized.

[0011] Furthermore, the optimization module determines the optimization coefficient of the initial ultrasonic emission frequency based on the material type data and the temperature data, and obtains the optimized ultrasonic emission frequency, including: Performing feature extraction on the material type data to obtain material characteristic factors; Combining the material characteristic factor and the temperature characteristic value into a characteristic combination; Comparing the feature combination with a historical feature group, and determining an optimization coefficient of the initial ultrasonic emission frequency according to the comparison result; When there is a historical feature combination identical to the feature combination in the historical feature group, the historical optimization coefficient corresponding to the historical feature combination is used as the optimization coefficient, and the product value of the historical optimization coefficient and the initial ultrasonic transmission frequency is used as the optimized ultrasonic transmission frequency; When there is no historical feature combination identical to the feature combination in the historical feature group, the overlap between the historical feature combination and the historical feature group is calculated, and the maximum overlap is extracted. The optimization coefficient of the initial ultrasonic emission frequency is determined based on the maximum overlap, and the optimized ultrasonic emission frequency is obtained.

[0012] Furthermore, the optimization module determines the optimization coefficient of the initial ultrasonic emission frequency according to the maximum overlap, and obtains the optimized ultrasonic emission frequency, including: Comparing the maximum overlap with a first maximum overlap and a second maximum overlap, and determining an optimization coefficient of the initial ultrasonic emission frequency according to the comparison result; wherein the first maximum overlap is smaller than the second maximum overlap; When the maximum overlap is greater than or equal to the second maximum overlap, determining the optimization coefficient of the initial ultrasonic transmission frequency to be a first optimization coefficient; When the maximum overlap is less than the second maximum overlap and greater than or equal to the first maximum overlap, determining the optimization coefficient of the initial ultrasonic transmission frequency to be the second optimization coefficient; When the maximum overlap is less than the first maximum overlap, determining the optimization coefficient of the initial ultrasonic transmission frequency to be a third optimization coefficient; The product value of the optimization coefficient and the initial ultrasonic wave transmitting frequency is used as the optimized ultrasonic wave transmitting frequency.

[0013] Furthermore, the ultrasonic detection module analyzes the ultrasonic scanning data, determines the actual crack condition of the suspected crack area based on the analysis result, and generates a detection report, including: Filtering the ultrasonic scanning data to remove noise interference and obtain a clear ultrasonic image; Determining the actual crack condition of the suspected crack area based on the ultrasonic reflection characteristics in the clear ultrasonic image, including the crack length, crack width, and crack depth; A detection report is generated based on the actual crack situation.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: the top hammer crack detection system for a six-sided top press provided by the present invention can quickly and accurately detect top hammer cracks, thereby improving the safety and operating efficiency of the equipment; by drawing a three-dimensional stress distribution diagram through the stress monitoring module, it is possible to intuitively judge whether there is a suspected crack area in the top hammer, providing a basis for subsequent detection work; the initial ultrasonic emission frequency of the ultrasonic flaw detector is determined according to the stress anomaly coordinates of the suspected crack area, and ultrasonic scanning can be performed in a targeted manner, thereby improving the detection efficiency; the initial ultrasonic emission frequency is optimized through the judgment module and the optimization module, thereby further improving the accuracy of the detection; the ultrasonic detection module performs ultrasonic scanning on the suspected crack area and generates a detection report, thereby providing an important reference basis for the maintenance and maintenance of the equipment.

[0015] In another aspect, the present invention further provides a method for detecting cracks in an anvil of a six-sided top press, comprising the following steps: Identify a hammer to be tested, collect surface stress data of the hammer to be tested, plot a three-dimensional stress distribution diagram based on the surface stress data, and determine whether the hammer to be tested has a suspected crack region based on the three-dimensional stress distribution diagram; if so, collect stress anomaly coordinates of the suspected crack region, and determine an initial ultrasonic emission frequency of the ultrasonic flaw detector based on the stress anomaly coordinates; collecting temperature data of the suspected crack area, analyzing the temperature data, and determining whether to optimize the initial ultrasonic emission frequency based on the analysis result; When it is determined that the initial ultrasonic emission frequency is to be optimized, collecting material type data of the anvil to be detected, determining an optimization coefficient of the initial ultrasonic emission frequency based on the material type data and temperature data, and obtaining an optimized ultrasonic emission frequency; The suspected crack area is ultrasonically scanned at the optimized ultrasonic emission frequency to obtain ultrasonic scanning data; the ultrasonic scanning data is analyzed, the actual crack condition of the suspected crack area is determined based on the analysis result, and a detection report is generated.

[0016] It is understandable that the above-mentioned method and system for detecting cracks in the top hammer of the six-sided top press have the same beneficial effects, which will not be described in detail here. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Various other advantages and benefits will become apparent to those skilled in the art upon reading the detailed description of the preferred embodiment below. The accompanying drawings are for illustration purposes only and are not to be considered as limiting the present invention. The same reference symbols are used throughout the drawings to represent the same components. In the drawings: Figure 1 A structural block diagram of a top hammer crack detection system for a six-sided top press provided by an embodiment of the present invention; Figure 2 A flow chart of a method for detecting cracks in a top hammer of a six-sided top press provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0018] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art. It should be noted that, unless there is a conflict, the embodiments of the present disclosure and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments.

[0019] See Figure 1 As shown, in some embodiments of the present application, this embodiment provides a top hammer crack detection system for a six-sided top press, comprising: The stress monitoring module is configured to identify a hammer to be inspected, collect surface stress data of the hammer to be inspected, plot a three-dimensional stress distribution diagram based on the surface stress data, and determine whether a suspected crack region exists in the hammer to be inspected based on the three-dimensional stress distribution diagram; if so, collect stress anomaly coordinates of the suspected crack region, and determine an initial ultrasonic emission frequency of the ultrasonic flaw detector based on the stress anomaly coordinates; a judgment module configured to collect temperature data of a suspected crack area, analyze the temperature data, and determine whether to optimize the initial ultrasonic emission frequency based on the analysis result; an optimization module configured to, when the judgment module determines that the initial ultrasonic emission frequency is to be optimized, collect material type data of the anvil to be detected, determine an optimization coefficient of the initial ultrasonic emission frequency based on the material type data and the temperature data, and obtain an optimized ultrasonic emission frequency; The ultrasonic detection module is configured to perform ultrasonic scanning on the suspected crack area at an optimized ultrasonic transmission frequency and obtain ultrasonic scanning data; analyze the ultrasonic scanning data, determine the actual crack condition of the suspected crack area based on the analysis results, and generate a detection report.

[0020] It can be understood that the top hammer crack detection system for the six-sided top press provided in this embodiment can quickly and accurately detect top hammer cracks, thereby improving the safety and operating efficiency of the equipment; by drawing a three-dimensional stress distribution diagram through the stress monitoring module, it can intuitively determine whether there is a suspected crack area in the top hammer, providing a basis for subsequent detection work; the initial ultrasonic emission frequency of the ultrasonic flaw detector is determined according to the stress anomaly coordinates of the suspected crack area, and ultrasonic scanning can be performed in a targeted manner, thereby improving the detection efficiency; the initial ultrasonic emission frequency is optimized through the judgment module and the optimization module, thereby further improving the detection accuracy; the ultrasonic detection module performs ultrasonic scanning on the suspected crack area and generates a detection report, which provides an important reference basis for the maintenance and maintenance of the equipment.

[0021] Specifically, when the stress monitoring module determines whether there is a suspected crack area in the anvil to be inspected based on the three-dimensional stress distribution diagram, it includes: Divide the three-dimensional stress distribution map into regions to obtain several monitoring areas; Collect the stress values ​​of each coordinate point in each monitoring area and calculate the regional average stress value; Determine whether there is an abnormal stress area based on the regional average stress value; If so, the abnormal stress area is regarded as a suspected crack area.

[0022] It's clear that by meticulously segmenting the 3D stress distribution map and analyzing its stress values, the system can accurately locate areas where cracks are likely to occur, providing critical information for subsequent inspection steps. This segmentation method not only improves inspection accuracy but also effectively reduces the likelihood of false positives and missed detections, making the entire inspection process more efficient and reliable.

[0023] Specifically, the stress monitoring module determines whether there is a stress abnormality area based on the regional average stress value, including: Compare the regional average stress value with the regional average stress threshold, and determine whether there is an abnormal stress area based on the comparison result; When the regional average stress value is greater than the regional average stress threshold, the monitoring area is determined to be a stress abnormal area; Otherwise, it is determined that the monitored area is not a stress abnormality area.

[0024] In this example, the regional average stress threshold is derived based on a large amount of experimental data and experience, and can accurately reflect the stress level of the anvil under normal working conditions.

[0025] As you can see, by setting a reasonable regional average stress threshold, the system can intelligently identify areas where stress values ​​exceed the normal range, which are often closely associated with the presence of cracks. When the regional average stress value exceeds the regional average stress threshold, it indicates that the stress level in the monitored area is abnormal, possibly indicating the presence of cracks or other defects. This stress data-based judgment method is more accurate and reliable than traditional visual inspections or simple physical tests, enabling timely detection of potential safety hazards and providing a scientific basis for equipment maintenance and servicing.

[0026] Specifically, when the stress monitoring module determines the initial ultrasonic emission frequency of the ultrasonic flaw detector according to the stress anomaly coordinates, it includes: Calculate the difference between the stress value and the standard stress value of each coordinate point in the suspected crack area one by one, record it as the stress difference, and construct a stress difference value set; The corresponding stress difference values ​​within the stress difference threshold in the stress difference value set are classified into a first set; The corresponding stress difference values ​​outside the stress difference threshold in the stress difference value set are classified into a second set; Count the number of stress difference values ​​in the first set, and record it as the first number; Count the number of stress difference values ​​in the second set, and record it as the second number; The initial ultrasonic wave transmitting frequency is determined according to the ratio of the first number to the second number.

[0027] Specifically, when the stress monitoring module determines the initial ultrasonic emission frequency according to the ratio of the first quantity to the second quantity, it includes: Recording the ratio of the first quantity to the second quantity as the quantity ratio; Comparing the quantity ratio with the first quantity ratio and the second quantity ratio, and determining the initial ultrasonic emission frequency according to the comparison result; wherein the first quantity ratio is smaller than the second quantity ratio; When the quantity ratio is less than or equal to the first quantity ratio, determining the initial ultrasonic wave transmitting frequency to be the first ultrasonic wave transmitting frequency; When the quantity ratio is greater than the first quantity ratio and less than the second quantity ratio, determining the initial ultrasonic wave transmitting frequency to be the second ultrasonic wave transmitting frequency; When the quantity ratio is greater than or equal to the second quantity ratio, the initial ultrasonic wave transmitting frequency is determined to be the third ultrasonic wave transmitting frequency.

[0028] As can be understood, by meticulously analyzing and classifying stress differences, the system can more accurately determine the ultrasonic flaw detector's initial ultrasonic transmission frequency. This stress difference-based frequency determination method not only improves detection targeting but also ensures the effectiveness of ultrasonic scanning. The first, second, and third ultrasonic transmission frequencies are set based on different ratios, each suitable for varying degrees of stress anomalies. When the ratio is small, the stress differences within the suspected crack region are generally small. In this case, a lower initial ultrasonic transmission frequency (the first ultrasonic transmission frequency) can meet detection requirements. When the ratio is large, the stress differences within the suspected crack region are large, requiring a higher initial ultrasonic transmission frequency (the second ultrasonic transmission frequency) to ensure detection accuracy. When the ratio is even larger, higher energy is required to penetrate the anvil material and obtain a clearer crack image. In this case, the highest initial ultrasonic transmission frequency (the third ultrasonic transmission frequency) is selected to ensure detection effectiveness. This method of dynamically adjusting the initial ultrasonic transmission frequency enables the detection system to adapt to varying stress anomalies, improving detection flexibility and accuracy.

[0029] Specifically, the judgment module analyzes the temperature data and determines whether to optimize the initial ultrasonic emission frequency based on the analysis result, including: Analyze the temperature data to obtain the temperature characteristic value and obtain the temperature standard value corresponding to the temperature characteristic value; Calculate the ratio of the temperature characteristic value to the temperature standard value and record it as the temperature ratio; Comparing the temperature ratio with the temperature ratio threshold, and judging whether to optimize the initial ultrasonic emission frequency according to the comparison result; When the temperature ratio is greater than the temperature ratio threshold, it is determined that the initial ultrasonic emission frequency needs to be optimized; Otherwise, it is determined that there is no need to optimize the initial ultrasonic wave transmitting frequency.

[0030] In this embodiment, the temperature characteristic values ​​include a maximum temperature value, a minimum temperature value and an average temperature value. These temperature characteristic values ​​can fully reflect the temperature state of the anvil to be detected.

[0031] In this embodiment, the temperature characteristic value is preferably an average temperature value.

[0032] In this embodiment, the temperature ratio threshold is obtained based on a large amount of experimental data and experience, and can accurately reflect the performance changes of the anvil under different temperature conditions.

[0033] As you can see, by calculating the temperature ratio and comparing it with the temperature ratio threshold, the system intelligently determines whether the ultrasonic flaw detector's initial ultrasonic transmission frequency needs to be adjusted. If the temperature ratio exceeds the threshold, it indicates that the anvil's temperature may be affecting ultrasonic wave propagation. In this case, the initial ultrasonic transmission frequency needs to be optimized to ensure detection accuracy. This temperature-based optimization method further improves the detection system's adaptability and accuracy in diverse operating environments.

[0034] Specifically, the optimization module determines the optimization coefficient of the initial ultrasonic emission frequency based on the material type data and the temperature data, and obtains the optimized ultrasonic emission frequency, including: Extract features from material type data to obtain material characteristic factors; Combining material characteristic factors and temperature characteristic values ​​into characteristic combinations; Compare the feature combination with the historical feature group, and determine the optimization coefficient of the initial ultrasonic emission frequency based on the comparison results; When there is a historical feature combination that is the same as the feature combination in the historical feature group, the historical optimization coefficient corresponding to the historical feature combination is used as the optimization coefficient, and the product value of the historical optimization coefficient and the initial ultrasonic emission frequency is used as the optimized ultrasonic emission frequency; When there is no historical feature combination identical to the feature combination in the historical feature group, the overlap between the historical feature combination and the historical feature group is calculated, and the maximum overlap is extracted. The optimization coefficient of the initial ultrasonic emission frequency is determined according to the maximum overlap, and the optimized ultrasonic emission frequency is obtained.

[0035] In this embodiment, the material characteristic factor refers to the quantitative value corresponding to each type of material, and the material types include high-strength alloy steel, cast iron, stainless steel, etc.; for example, the material characteristic factor corresponding to high-strength alloy is 1.5, the material characteristic factor corresponding to cast iron is 1.2, and the material characteristic factor corresponding to stainless steel is 1.0.

[0036] In this embodiment, the calculation formula of the overlap degree is obtained by the following formula: ; Among them, Si represents the overlap between the feature combination and the i-th historical feature group; a represents the material feature factor in the feature combination; b represents the temperature feature value in the feature combination; ci represents the material feature factor in the i-th historical feature combination in the historical feature group, and di represents the temperature feature value in the i-th historical feature combination in the historical feature group; i = 1, 2,…, n, where n represents the total number of historical feature combinations in the historical feature group.

[0037] It can be understood that by calculating the degree of overlap, the system can find the historical feature combination that is closest to the current feature combination, thereby more accurately determining the optimization coefficient of the initial ultrasonic emission frequency. When there is a historical feature combination in the historical feature group that is exactly the same as the current feature combination, it means that the previous detection conditions are exactly the same as the current conditions, so the previous historical optimization coefficient can be directly adopted, which greatly improves the detection efficiency and accuracy. When there is no historical feature combination in the historical feature group that is exactly the same as the current feature combination, by calculating the degree of overlap and finding the historical feature combination with the maximum overlap, the system can optimize the current initial ultrasonic emission frequency according to the optimization coefficient corresponding to the maximum overlap to obtain the optimized ultrasonic emission frequency. This optimization method based on historical data not only improves the accuracy of detection, but also enables the detection system to make adaptive adjustments according to different material types and temperature conditions, further improving the flexibility and practicality of the system.

[0038] Specifically, the optimization module determines the optimization coefficient of the initial ultrasonic emission frequency according to the maximum overlap, and obtains the optimized ultrasonic emission frequency, including: Comparing the maximum overlap with the first maximum overlap and the second maximum overlap, and determining an optimization coefficient of the initial ultrasonic emission frequency according to the comparison result; wherein the first maximum overlap is less than the second maximum overlap; When the maximum overlap is greater than or equal to the second maximum overlap, determining the optimization coefficient of the initial ultrasonic emission frequency as the first optimization coefficient; When the maximum overlap is less than the second maximum overlap and greater than or equal to the first maximum overlap, determining the optimization coefficient of the initial ultrasonic emission frequency to be the second optimization coefficient; When the maximum overlap is less than the first maximum overlap, determining the optimization coefficient of the initial ultrasonic wave transmitting frequency to be the third optimization coefficient; The product of the optimization coefficient and the initial ultrasonic emission frequency is used as the optimized ultrasonic emission frequency.

[0039] In this embodiment, the first maximum overlap and the second maximum overlap are obtained based on a large amount of experimental data and experience, and can accurately reflect the influence of material type and temperature state on ultrasonic propagation effect under different overlaps.

[0040] It can be understood that by setting reasonable first and second maximum overlaps, the system can more accurately determine the optimization coefficient for the initial ultrasonic transmission frequency. When the maximum overlap is high, it indicates a high similarity between the current feature combination and the historical feature combination. In this case, a larger optimization coefficient (the first optimization coefficient) can be selected to obtain a more optimized ultrasonic transmission frequency. When the maximum overlap is moderate, a moderate optimization coefficient (the second optimization coefficient) is selected. When the maximum overlap is low, it indicates a low similarity between the current feature combination and the historical feature combination. In this case, the optimization coefficient should be selected with caution to avoid over-adjustment that may lead to poor detection results. In this case, a smaller optimization coefficient (the third optimization coefficient) is selected. This method of determining the optimization coefficient based on maximum overlap not only improves detection accuracy but also ensures the stability and reliability of the detection system under different conditions.

[0041] Specifically, the ultrasonic detection module analyzes the ultrasonic scanning data, determines the actual crack condition of the suspected crack area based on the analysis results, and generates a detection report, including: Filter the ultrasonic scanning data to remove noise interference and obtain clear ultrasonic images; Determine the actual crack condition of the suspected crack area based on the ultrasonic reflection characteristics in the clear ultrasonic image, including the crack length, crack width and crack depth; Generate inspection reports based on actual crack conditions.

[0042] It can be understood that the specific steps for judging the actual crack situation of the suspected crack area based on the ultrasonic reflection characteristics in the clear ultrasonic image are: first, the clear ultrasonic image is enhanced to improve the image contrast and make the crack characteristics more obvious; then, the length, width and depth of the crack are automatically identified by image recognition technology, and the identification results are compared with the preset crack judgment criteria to determine the actual situation of the crack; finally, information such as crack length, crack width and crack depth are integrated into the test report to generate a complete and accurate test report.

[0043] It is understandable that this crack detection method based on ultrasonic scanning data not only improves the accuracy and reliability of detection, but also provides an important reference basis for equipment maintenance and care, helping to timely discover potential safety hazards and ensure the normal operation of the equipment.

[0044] See Figure 2 As shown, in some embodiments of the present application, this embodiment provides a method for detecting cracks in a top hammer of a six-sided top press, comprising the following steps: S100: Identify an anvil to be tested, collect surface stress data of the anvil to be tested, plot a three-dimensional stress distribution diagram based on the surface stress data, and determine whether there is a suspected crack region in the anvil to be tested based on the three-dimensional stress distribution diagram; if so, collect stress anomaly coordinates of the suspected crack region, and determine an initial ultrasonic emission frequency of the ultrasonic flaw detector based on the stress anomaly coordinates; S200: collecting temperature data of the suspected crack area, analyzing the temperature data, and determining whether to optimize the initial ultrasonic emission frequency based on the analysis results; S300: When it is determined that the initial ultrasonic emission frequency is to be optimized, material type data of the anvil to be tested is collected, an optimization coefficient of the initial ultrasonic emission frequency is determined based on the material type data and temperature data, and an optimized ultrasonic emission frequency is obtained; S400: Performing ultrasonic scanning on the suspected crack area with an optimized ultrasonic emission frequency and acquiring ultrasonic scanning data; analyzing the ultrasonic scanning data, determining the actual crack condition of the suspected crack area based on the analysis result, and generating a test report.

[0045] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware. Furthermore, the present application may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0046] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems) and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0047] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0048] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0049] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered by the scope of protection of the claims of the present invention.

Claims

1. A top hammer crack detection system for a six-sided top press, characterized in that: include: a stress monitoring module configured to identify a top hammer to be detected, collect surface stress data of the top hammer to be detected, plot a three-dimensional stress distribution diagram based on the surface stress data, and determine whether the top hammer to be detected has a suspected crack region based on the three-dimensional stress distribution diagram; if so, collect stress anomaly coordinates of the suspected crack region, and determine an initial ultrasonic emission frequency of the ultrasonic flaw detector based on the stress anomaly coordinates; a judgment module configured to collect temperature data of the suspected crack area, analyze the temperature data, and determine whether to optimize the initial ultrasonic emission frequency based on the analysis result; an optimization module configured to, when the judgment module determines that the initial ultrasonic emission frequency is to be optimized, collect material type data of the anvil to be detected, determine an optimization coefficient of the initial ultrasonic emission frequency based on the material type data and temperature data, and obtain an optimized ultrasonic emission frequency; The ultrasonic detection module is configured to perform ultrasonic scanning on the suspected crack area at the optimized ultrasonic transmission frequency and obtain ultrasonic scanning data; analyze the ultrasonic scanning data, determine the actual crack condition of the suspected crack area based on the analysis result, and generate a detection report.

2. The top hammer crack detection system for a six-sided top press according to claim 1, characterized in that: When the stress monitoring module determines whether there is a suspected crack area in the anvil to be detected according to the three-dimensional stress distribution diagram, it includes: Dividing the three-dimensional stress distribution map into regions to obtain a plurality of monitoring regions; Collecting stress values ​​of each coordinate point in each monitoring area and calculating the average stress value of the area; Determine whether there is an abnormal stress area based on the average stress value of the area; If so, the stress abnormality area is regarded as the suspected crack area.

3. The top hammer crack detection system for a six-sided top press according to claim 2, characterized in that: When the stress monitoring module determines whether there is a stress abnormality area based on the average stress value of the area, it includes: Comparing the regional average stress value with the regional average stress threshold, and determining whether there is a stress abnormality area based on the comparison result; When the regional average stress value is greater than the regional average stress threshold, the monitored area is determined to be the stress abnormality area; Otherwise, it is determined that the monitored area is not the stress abnormality area.

4. The top hammer crack detection system for a six-sided top press according to claim 3, characterized in that: When the stress monitoring module determines the initial ultrasonic emission frequency of the ultrasonic flaw detector according to the stress anomaly coordinates, it includes: Calculating the difference between the stress value of each coordinate point in the suspected crack area and the standard stress value one by one, recording it as a stress difference, and constructing a stress difference value set; Classifying the corresponding stress difference values ​​within the stress difference threshold in the stress difference value set into a first set; classifying the corresponding stress difference values ​​outside the stress difference threshold in the stress difference value set into a second set; Count the number of stress difference values ​​in the first set, and record it as the first number; Count the number of stress difference values ​​in the second set, and record it as the second number; The initial ultrasonic wave transmitting frequency is determined according to a ratio of the first number to the second number.

5. The top hammer crack detection system for a six-sided top press according to claim 4, characterized in that: When the stress monitoring module determines the initial ultrasonic wave transmitting frequency according to the ratio of the first quantity to the second quantity, the method includes: Recording the ratio of the first quantity to the second quantity as a quantity ratio; Comparing the quantity ratio with a first quantity ratio and a second quantity ratio, and determining the initial ultrasonic emission frequency according to the comparison result; wherein the first quantity ratio is smaller than the second quantity ratio; When the quantity ratio is less than or equal to the first quantity ratio, determining the initial ultrasonic wave transmitting frequency to be the first ultrasonic wave transmitting frequency; When the quantity ratio is greater than the first quantity ratio and less than the second quantity ratio, determining the initial ultrasonic wave transmitting frequency to be the second ultrasonic wave transmitting frequency; When the quantity ratio is greater than or equal to the second quantity ratio, the initial ultrasonic wave transmitting frequency is determined to be a third ultrasonic wave transmitting frequency.

6. The top hammer crack detection system for a six-sided top press according to claim 5, characterized in that: The judgment module analyzes the temperature data and determines whether to optimize the initial ultrasonic emission frequency based on the analysis result, including: Analyzing the temperature data to obtain a temperature characteristic value and obtaining a temperature standard value corresponding to the temperature characteristic value; Calculating the ratio of the temperature characteristic value to the temperature standard value and recording it as the temperature ratio; Comparing the temperature ratio with a temperature ratio threshold, and determining whether to optimize the initial ultrasonic emission frequency according to the comparison result; When the temperature ratio is greater than a temperature ratio threshold, determining that the initial ultrasonic wave transmission frequency needs to be optimized; Otherwise, it is determined that the initial ultrasonic wave transmitting frequency does not need to be optimized.

7. The top hammer crack detection system for a six-sided top press according to claim 6, characterized in that: The optimization module determines the optimization coefficient of the initial ultrasonic emission frequency based on the material type data and the temperature data, and obtains the optimized ultrasonic emission frequency, including: Performing feature extraction on the material type data to obtain material characteristic factors; Combining the material characteristic factor and the temperature characteristic value into a characteristic combination; Comparing the feature combination with a historical feature group, and determining an optimization coefficient of the initial ultrasonic emission frequency according to the comparison result; When there is a historical feature combination identical to the feature combination in the historical feature group, the historical optimization coefficient corresponding to the historical feature combination is used as the optimization coefficient, and the product value of the historical optimization coefficient and the initial ultrasonic transmission frequency is used as the optimized ultrasonic transmission frequency; When there is no historical feature combination identical to the feature combination in the historical feature group, the overlap between the historical feature combination and the historical feature group is calculated, and the maximum overlap is extracted. The optimization coefficient of the initial ultrasonic emission frequency is determined based on the maximum overlap, and the optimized ultrasonic emission frequency is obtained.

8. The top hammer crack detection system for a six-sided top press according to claim 7, characterized in that: The optimization module determines the optimization coefficient of the initial ultrasonic emission frequency according to the maximum overlap and obtains the optimized ultrasonic emission frequency, including: Comparing the maximum overlap with a first maximum overlap and a second maximum overlap, and determining an optimization coefficient of the initial ultrasonic emission frequency according to the comparison result; wherein the first maximum overlap is smaller than the second maximum overlap; When the maximum overlap is greater than or equal to the second maximum overlap, determining the optimization coefficient of the initial ultrasonic transmission frequency to be a first optimization coefficient; When the maximum overlap is less than the second maximum overlap and greater than or equal to the first maximum overlap, determining the optimization coefficient of the initial ultrasonic transmission frequency to be the second optimization coefficient; When the maximum overlap is less than the first maximum overlap, determining the optimization coefficient of the initial ultrasonic transmission frequency to be a third optimization coefficient; The product value of the optimization coefficient and the initial ultrasonic wave transmitting frequency is used as the optimized ultrasonic wave transmitting frequency.

9. The top hammer crack detection system for a six-sided top press according to claim 8, characterized in that: The ultrasonic detection module analyzes the ultrasonic scanning data, determines the actual crack condition of the suspected crack area based on the analysis result, and generates a detection report, including: Filtering the ultrasonic scanning data to remove noise interference and obtain a clear ultrasonic image; Determining the actual crack condition of the suspected crack area based on the ultrasonic reflection characteristics in the clear ultrasonic image, including the crack length, crack width, and crack depth; A detection report is generated based on the actual crack situation.

10. A method for detecting cracks in an anvil of a six-sided top press, applied to the anvil crack detection system for a six-sided top press according to any one of claims 1 to 9, characterized in that: include: Identify a hammer to be tested, collect surface stress data of the hammer to be tested, plot a three-dimensional stress distribution diagram based on the surface stress data, and determine whether the hammer to be tested has a suspected crack region based on the three-dimensional stress distribution diagram; if so, collect stress anomaly coordinates of the suspected crack region, and determine an initial ultrasonic emission frequency of the ultrasonic flaw detector based on the stress anomaly coordinates; collecting temperature data of the suspected crack area, analyzing the temperature data, and determining whether to optimize the initial ultrasonic emission frequency based on the analysis result; When it is determined that the initial ultrasonic emission frequency is to be optimized, collecting material type data of the anvil to be detected, determining an optimization coefficient of the initial ultrasonic emission frequency based on the material type data and temperature data, and obtaining an optimized ultrasonic emission frequency; The suspected crack area is ultrasonically scanned at the optimized ultrasonic emission frequency to obtain ultrasonic scanning data; the ultrasonic scanning data is analyzed, the actual crack condition of the suspected crack area is determined based on the analysis result, and a detection report is generated.

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