Probe center online adjusting system and method applied to ultrasonic flaw detection

Abstract

The invention discloses a probe center online adjusting system and method applied to ultrasonic flaw detection, and belongs to the technical field of ultrasonic nondestructive testing. Comprising a water tank, a bar linear conveying unit, four groups of ultrasonic flaw detection units, a signal acquisition unit and a software display unit, each group of ultrasonic flaw detection unit comprises two ultrasonic probes; the bar linear conveying unit is used for directionally conveying bars into the water tank in the axial direction of the bars, and the direction of detection beams emitted by the two ultrasonic probes in each ultrasonic flaw detection unit is parallel to the radial section of the bars. The two ultrasonic probes in each group of ultrasonic flaw detection unit can synchronously and vertically lift and horizontally move in a detection plane parallel to the radial section of the bar; and the bar and the ultrasonic probe can be immersed in water filled in the water tank. According to the probe center online adjusting system and method applied to ultrasonic flaw detection, the problems that in the prior art, an ultrasonic flaw detection system cannot be adjusted online and detection is incomplete are solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of ultrasonic non-destructive testing, and in particular relates to a probe center online adjustment system and method used in ultrasonic flaw detection. Background Art

[0002] In industrial production, ultrasonic flaw detection is an important means of detecting internal defects in metal materials. Especially in water immersion ultrasonic flaw detection operations, precise alignment of the center of the ultrasonic probe and the center of the workpiece is crucial to ensuring detection accuracy and stability. However, the existing technology has the following problems: 1. Insufficient adjustment accuracy: Traditional adjustment methods rely on manual experience and offline calibration, which is difficult to meet the requirements of modern industry for high-precision flaw detection, and it is impossible to control the center deviation of the ultrasonic probe within 0.5mm. 2. Lack of real-time adjustment capability: When the production line is running continuously, factors such as workpiece vibration and water flow fluctuations can easily cause the probe position to shift, but the existing system cannot monitor and adjust it dynamically in real time. 3. Incomplete detection coverage: The traditional probe layout makes it difficult to achieve full coverage detection of the periphery of the workpiece, and there are detection blind spots, which reduces the accuracy of flaw detection.

[0003] Therefore, there is an urgent need for an ultrasonic probe center online adjustment system and method that can be adjusted online in real time, with high precision control and comprehensive coverage. Summary of the Invention

[0004] The purpose of the present invention is to overcome the deficiencies in the prior art and provide a probe center online adjustment system and method for ultrasonic flaw detection, which solves the problems in the prior art that ultrasonic flaw detection systems cannot be adjusted online and have incomplete detection.

[0005] To achieve the above objectives, the present invention adopts the following technical solutions: a system and method for online probe center adjustment for ultrasonic flaw detection, comprising a water tank, a bar linear conveying unit, four sets of ultrasonic flaw detection units, a signal acquisition unit electrically connected to the four sets of ultrasonic flaw detection units and used to obtain and collect ultrasonic echo signals, and a software display unit electrically connected to the signal acquisition unit; Wherein, each group of the ultrasonic flaw detection units includes two ultrasonic probes, and the detection beams emitted by the two ultrasonic probes intersect and form a detection midpoint; The bar linear conveying unit is used to convey the bar into the water tank in an axially oriented manner, and the detection beams emitted by the two ultrasonic probes in each group of the ultrasonic flaw detection units are parallel to the radial cross-section of the bar, and the two ultrasonic probes in each group of the ultrasonic flaw detection units are capable of synchronously rising and falling vertically and moving horizontally along a detection plane parallel to the radial cross-section of the bar; Furthermore, the rod and the ultrasonic probe can be immersed in the water poured into the water tank.

[0006] Optionally, the four groups of ultrasonic flaw detection units are linearly distributed along the axial direction of the rod, and the projections of the ultrasonic probes on the four groups of ultrasonic flaw detection units perpendicular to the axial direction of the rod are arranged in a circular array.

[0007] Optionally, the angle between the detection beams of the two ultrasonic probes in each group of the ultrasonic flaw detection units is 30° to 60°.

[0008] Optionally, a water level control unit for controlling the water level is provided in the water tank.

[0009] Optionally, the water level control unit can adjust the water level to cover the rod by 650 mm to 100 mm.

[0010] A method for online adjustment of the center of a probe used in ultrasonic flaw detection is implemented using any of the aforementioned online adjustment systems for the center of a probe used in ultrasonic flaw detection, comprising the following steps: Step 1: The bar is conveyed into the water tank by the bar linear conveying unit, and the water level is adjusted by the water level control unit to cover the bar and the ultrasonic probe. Then, the ultrasonic probe, signal acquisition unit, and software display unit are activated to obtain the interface wave water layer distance from the ultrasonic probe in each group of ultrasonic flaw detection units along its detection direction to the surface of the bar; Step 2: By comparing the distance of the interface wave water layer from the ultrasonic probe in each group of ultrasonic flaw detection units along the detection direction to the surface of the bar with the preset interface wave scale line, the position deviation of the detection midpoint of each group of ultrasonic flaw detection units is determined; Step three: According to the position deviation of the detection midpoint of each group of ultrasonic flaw detection units, adjust the positions of the two ultrasonic probes in the detection plane of the group of ultrasonic flaw detection units until the difference between the interface wave water layer distance from the ultrasonic probe to the surface of the rod along its detection direction and the interface wave scale line meets the deviation range.

[0011] Optionally, the deviation range is -0.5mm to +0.5mm.

[0012] Optionally, step four is also included; after completing the adjustment of step three, the signal acquisition unit again obtains the distance of the interface wave water layer from the ultrasonic probe in each group of ultrasonic flaw detection units along its detection direction to the surface of the rod, and performs a second comparison with the interface wave scale line; if the difference does not meet the deviation range, repeat step three for fine-tuning; if the difference meets the deviation range, repeat step two for real-time monitoring.

[0013] Compared with existing technologies, the present invention achieves the following beneficial effects: through the layout of four ultrasonic testing units, full coverage of the workpiece perimeter is achieved, avoiding detection blind spots and significantly improving detection accuracy. Furthermore, the two ultrasonic probes in each set of ultrasonic testing units can be synchronously raised and lowered vertically and moved horizontally along a detection plane parallel to the radial cross-section of the bar. This allows for online adjustment of the detection midpoint of each set of ultrasonic testing units, ensuring that the detection midpoint of each set of ultrasonic testing units coincides with or is close to the central axis of the bar, thus ensuring the detection accuracy and stability of ultrasonic testing. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present invention will be further described below with reference to the accompanying drawings and examples.

[0015] Figure 1 It is a structural diagram of a probe center online adjustment system applied to ultrasonic flaw detection in a preferred embodiment of the present invention; Figure 2 2 is a schematic structural diagram of four groups of ultrasonic flaw detection units in a preferred embodiment of the present invention; Among them, 1. Water tank; 2. Bar linear conveying unit; 3. Ultrasonic flaw detection unit; 4. Software display unit; 5. Ultrasonic probe; 6. Bar. DETAILED DESCRIPTION

[0016] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. These drawings are simplified schematic diagrams that only illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0017] It should be noted that if there are directional indications (such as up, down, bottom, top, etc.) involved in this embodiment, the directional indication is only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly. The terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. Unless otherwise clearly specified and defined, the terms "set", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected, or indirectly connected through an intermediate medium, or it can be a communication between the internal parts of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances. Example 1

[0018] like Figure 1-Figure 2As shown, a probe center online adjustment system for ultrasonic flaw detection includes a water tank 1, a bar linear conveying unit 2, four groups of ultrasonic flaw detection units 3, a signal acquisition unit electrically connected to the four groups of ultrasonic flaw detection units 3 and used to obtain and collect ultrasonic echo signals, and a software display unit 4 electrically connected to the signal acquisition unit. The software display unit 4 is used to display various data information obtained by the signal acquisition unit and fed back by the ultrasonic flaw detection units 3.

[0019] Among them, the rod linear conveying unit 2 is used to convey the rod 6 into the water tank 1 along the axial direction of the rod 6. The rod linear conveying unit 2 is an existing technology, which can convey the rod in a straight line and ensure that the rod 6 can pass through the inspection area composed of four groups of ultrasonic testing units 3 at a stable speed and trajectory, thereby realizing the continuity detection of the rod 6.

[0020] At the same time, each group of ultrasonic flaw detection units 3 includes two ultrasonic probes 5, and the detection beams emitted by the two ultrasonic probes 5 in each group of ultrasonic flaw detection units 3 intersect ( Figure 2 The dashed line in the figure represents the detection beam emitted by the ultrasonic probe 5, forming a detection midpoint. It is important to note that the linear distances along the detection direction between the detection midpoints of the four groups of ultrasonic testing units 3 and the corresponding ultrasonic probes 5 are equal, and the detection beams emitted by the two ultrasonic probes 5 in each group of ultrasonic testing units 3 are parallel to the radial cross-section of the rod 6. Furthermore, the two ultrasonic probes 5 in each group of ultrasonic testing units 3 can be synchronously raised and lowered vertically and moved horizontally within a detection plane parallel to the radial cross-section of the rod 6 to adjust the detection midpoint position of each group of ultrasonic testing units 3 so that the detection midpoint coincides with or is close to the central axis of the rod 6, thereby ensuring the accuracy and stability of ultrasonic testing. Furthermore, the rod 6 and ultrasonic probes 5 described above can both be immersed in the water in the water tank 1. The water in the water tank 1 serves as a coupling medium for ultrasonic transmission, eliminating the air gap between the ultrasonic probes 5 and the surface of the rod 6, ensuring stable propagation of the ultrasonic waves generated by the ultrasonic probes 5, thereby reducing ultrasonic wave loss and improving ultrasonic testing accuracy.

[0021] It should be noted that when the axial direction of the rod 6 is used as the X-axis direction in the spatial rectangular coordinate system, the two ultrasonic probes 5 in each group of ultrasonic flaw detection units 3 can move along the Y-axis direction (including positive and negative directions) and the Z-axis direction (including positive and negative directions) in the same spatial rectangular coordinate system, so that the detection midpoint of the ultrasonic flaw detection unit 3 can coincide with or be close to the central axis of the rod 6 (depending on the accuracy of the synchronous movement of the two ultrasonic probes 5 in each group of ultrasonic flaw detection units 3).

[0022] As described above, the synchronized vertical lifting and horizontal movement of the two ultrasonic probes 5 in each ultrasonic flaw detection unit 3 can be achieved by, but not limited to, a multi-axis servo drive mechanism known in the prior art. For example, the two ultrasonic probes 5 in the same ultrasonic flaw detection unit 3 can be fixedly mounted on a mounting plate, which is vertically slidably connected to a vertical plate via a set of linear guides. The vertical plate is provided with a first linear drive unit (such as a linear motor, servo screw, servo slide, etc.) for driving the mounting plate in the vertical direction. Simultaneously, the vertical plate is horizontally slidably connected to a horizontal plate via another set of linear guides. The horizontal plate is provided with a second linear drive unit (such as a linear motor, servo screw, servo slide, etc.) for driving the vertical plate in the horizontal direction. The first and second linear drive units are both electrically connected to the ultrasonic probes 5, the signal acquisition unit, the software display unit 4, etc., to achieve online adjustment of the ultrasonic detection center, with an adjustment accuracy within 0.5 mm.

[0023] In the above, the rod linear conveying unit 2 can ensure the position uniqueness of the rod when it is inspected by the ultrasonic flaw detection unit 3 by including but not limited to adopting a phased array ultrasonic square and circle shared centering device as disclosed in the application number 202320338051.X.

[0024] Furthermore, the four sets of ultrasonic testing units 3 are linearly distributed along the axial direction of the rod 6, and the ultrasonic probes 5 on the four sets of ultrasonic testing units 3 are arranged in a circular array, projected perpendicularly to the axial direction of the rod 6. It is important to note that the angle between the detection beams of the two ultrasonic probes 5 in each set of ultrasonic testing units 3 is 30° to 60° to avoid detection blind spots. The coordinated operation of multiple sets of ultrasonic probes 5 allows for effective identification of defects across the entire cross-section of the rod 6.

[0025] Furthermore, a water level control unit for controlling the water level height is provided in the water tank 1. The water level control unit is composed of existing equipment such as a metering water pump, a control valve, a water pump, a water level detector, etc., which are electrically connected to structures such as the rod linear conveying unit 2 and the ultrasonic flaw detection unit 3, and can realize precise control of the water level in the water tank 1. Example 2

[0026] like Figure 1-Figure 2 As shown, based on the first embodiment, a method for online adjustment of the probe center applied to ultrasonic flaw detection is implemented by using the aforementioned online adjustment system for the probe center applied to ultrasonic flaw detection, and includes the following steps: Step 1: The rod 6 is conveyed into the water tank 1 by the rod linear conveying unit 2, and the water level is adjusted by the water level control unit to cover the rod 6 and the ultrasonic probe 5. Then, the ultrasonic probe 5, the signal acquisition unit, and the software display unit 4 are activated to obtain the interface wave water layer distance from the ultrasonic probe 5 in each group of ultrasonic flaw detection units 3 along its detection direction to the surface of the rod 6; Step 2: By comparing the interface wave water layer distance from the ultrasonic probe 5 in each group of ultrasonic flaw detection units 3 along its detection direction to the surface of the rod 6 with the preset interface wave scale line, the position deviation of the detection midpoint of each group of ultrasonic flaw detection units 3 is determined; Step three: According to the position deviation of the detection midpoint of each group of ultrasonic flaw detection units 3, adjust the positions of the two ultrasonic probes 5 in the group of ultrasonic flaw detection units 3 in the detection plane until the difference between the interface wave water layer distance from the ultrasonic probe to the surface of the rod 6 along its detection direction and the interface wave scale line meets the deviation range.

[0027] Furthermore, the water level control unit can adjust the water level to cover the rod by 650 mm to 100 mm.

[0028] Furthermore, a method for online adjustment of the probe center used for ultrasonic flaw detection also includes step four; after completing the adjustment of step three, the signal acquisition unit again obtains the interface wave water layer distance from the ultrasonic probe 5 in each group of ultrasonic flaw detection units 3 along its detection direction to the surface of the rod 6, and performs a secondary comparison with the interface wave scale line; if the difference does not meet the deviation range, repeat step three for fine-tuning; if the difference meets the deviation range, repeat step two for real-time monitoring.

[0029] Working principle: By setting up four groups of ultrasonic flaw detection units 3, and each group of ultrasonic flaw detection units 3 is composed of two ultrasonic probes 5, the detection beams emitted by the two ultrasonic probes 5 intersect and form a detection midpoint, and the ultrasonic probes 5 on the four groups of ultrasonic flaw detection units 3 are arranged in a circular array in the projection perpendicular to the axial direction of the rod 6. Multiple groups of ultrasonic probes 5 cooperate with each other to avoid the occurrence of detection blind spots and can effectively identify the transverse and longitudinal defects of the rod 6.

[0030] The direction of the detection beam emitted by the two ultrasonic probes 5 in each group of ultrasonic flaw detection units 3 is parallel to the radial cross-section of the rod 6, and the two ultrasonic probes 5 in each group of ultrasonic flaw detection units 3 can be synchronously raised and lowered vertically and moved horizontally along the detection plane parallel to the radial cross-section of the rod 6, so that the detection midpoint position of each group of ultrasonic flaw detection units 3 can be adjusted online, so that the detection midpoint of the four groups of ultrasonic flaw detection units 3 can coincide with or be close to the central axis of the rod 6, thereby ensuring the detection accuracy and stability of ultrasonic flaw detection.

[0031] The above description is based on the ideal embodiment of the present invention. Based on the above description, relevant personnel can make various changes and modifications without departing from the technical scope of this invention. The technical scope of this invention is not limited to the content of the specification and must be determined according to the scope of the claims.

Claims

1. A probe center online adjustment system for ultrasonic flaw detection, characterized in that: It comprises a water tank (1), a rod linear conveying unit (2), four groups of ultrasonic flaw detection units (3), a signal acquisition unit electrically connected to the four groups of ultrasonic flaw detection units (3) and used for acquiring and collecting ultrasonic echo signals, and a software display unit (4) electrically connected to the signal acquisition unit; Each group of ultrasonic flaw detection units (3) includes two ultrasonic probes (5), and detection beams emitted by the two ultrasonic probes (5) intersect and form a detection midpoint; The bar linear conveying unit (2) is used to convey the bar (6) into the water tank (1) along the axial direction of the bar (6), and the detection beam direction emitted by the two ultrasonic probes (5) in each group of the ultrasonic flaw detection units (3) is parallel to the radial cross section of the bar (6), and the two ultrasonic probes (5) in each group of the ultrasonic flaw detection units (3) can be synchronously vertically lifted and lowered and horizontally moved along a detection plane parallel to the radial cross section of the bar (6); Furthermore, the rod (6) and the ultrasonic probe (5) can both be immersed in the water poured into the water tank (1).

2. The probe center online adjustment system for ultrasonic flaw detection according to claim 1 is characterized in that: The four groups of ultrasonic flaw detection units (3) are linearly distributed along the axial direction of the rod (6), and the projections of the ultrasonic probes (5) on the four groups of ultrasonic flaw detection units (3) perpendicular to the axial direction of the rod (6) are arranged in a circular array.

3. The probe center online adjustment system for ultrasonic flaw detection according to claim 1 is characterized in that: The angle between the detection beams of the two ultrasonic probes (5) in each group of the ultrasonic flaw detection units (3) is 30° to 60°.

4. The probe center online adjustment system for ultrasonic flaw detection according to claim 3 is characterized in that: A water level control unit for controlling the water level is provided in the water tank (1).

5. The probe center online adjustment system for ultrasonic flaw detection according to claim 4 is characterized in that: The water level control unit can adjust the water level to cover the rod by 650 mm to 100 mm.

6. A method for online adjustment of the probe center for ultrasonic flaw detection, implemented by the online adjustment system for the probe center for ultrasonic flaw detection according to any one of claims 1 to 5, characterized in that: The following steps are included: Step 1: transporting the rod (6) into the water tank (1) through the rod linear transport unit (2), adjusting the water level to cover the rod (6) and the ultrasonic probe (5) through the water level control unit, and then starting the ultrasonic probe (5), the signal acquisition unit, and the software display unit (4) to obtain the interface wave water layer distance from the ultrasonic probe (5) in each group of ultrasonic flaw detection units (3) along its detection direction to the surface of the rod (6); Step 2: by comparing the distance of the interface wave water layer from the ultrasonic probe (5) in each group of ultrasonic flaw detection units (3) along the detection direction to the surface of the rod (6) with a preset interface wave scale line, the position deviation of the detection midpoint of each group of ultrasonic flaw detection units (3) is determined; Step three, according to the position deviation of the detection midpoint of each group of ultrasonic flaw detection units (3), adjust the positions of the two ultrasonic probes (5) in the group of ultrasonic flaw detection units (3) in the detection plane until the difference between the interface wave water layer distance from the ultrasonic probe along its detection direction to the surface of the rod (6) and the interface wave scale line meets the deviation range.

7. The system and method for online probe center adjustment for ultrasonic flaw detection according to claim 6, characterized in that: The deviation range is -0.5mm to +0.5mm.

8. The system and method for online adjustment of the probe center for ultrasonic flaw detection according to claim 7, characterized in that: The method further includes step 4; after completing the adjustment of step 3, the signal acquisition unit again obtains the interface wave water layer distance from the ultrasonic probe (5) in each group of ultrasonic flaw detection units (3) along its detection direction to the surface of the rod (6), and performs a secondary comparison with the interface wave scale line; if the difference does not meet the deviation range, step 3 is repeated for fine adjustment; if the difference meets the deviation range, step 2 is repeated for real-time monitoring.

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