Ultrasonic detection sensor

Abstract

The embodiment of the invention provides an ultrasonic detection sensor. The ultrasonic detection sensor comprises an ultrasonic probe assembly, a detection module and a flexible attaching clamp. The detection module is connected with the ultrasonic probe assembly; the two ends of the ultrasonic probe assembly are each provided with the corresponding flexible attaching clamp. The flexible attaching clamp is attached to the surface of the crimping position of the power transmission fitting. The ultrasonic probe assembly is focused at the crimping part of the power transmission fitting and transmits an ultrasonic signal; and the detection module is used for processing the received ultrasonic signals. According to the embodiment of the invention, the ultrasonic probe assembly is focused at the crimping part of the power transmission fitting, so that the ultrasonic signal can be accurately transmitted and received, and the detection precision is improved; the flexible fitting fixtures are arranged at the two ends of the ultrasonic probe assembly and are fitted to the surface of the crimping part of the power transmission fitting; the stability and reliability of the ultrasonic probe assembly during detection can be guaranteed, and the detection precision of the ultrasonic detection sensor is further improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of compression detection of power transmission fittings, and particularly relates to an ultrasonic detection sensor. BACKGROUND

[0002] In the field of compression quality detection of power transmission fittings, the existing general ultrasonic detection sensor has significant deficiencies. The existing general ultrasonic detection sensor has strong structural rigidity, and under the influence of environmental factors such as vibration of the power transmission fitting and external wind, the ultrasonic detection sensor is prone to displacement, resulting in deviation of detection data and difficulty in ensuring detection accuracy. SUMMARY

[0003] The present application provides an ultrasonic detection sensor, which can improve the compression quality detection accuracy of power transmission fittings.

[0004] In a first aspect, an embodiment of the present application provides an ultrasonic detection sensor, which comprises an ultrasonic probe assembly, a detection module and a flexible fitting clamp; the detection module is connected with the ultrasonic probe assembly; the ultrasonic probe assembly is provided with the flexible fitting clamp at both ends; the flexible fitting clamp is attached to the surface of the compression part of the power transmission fitting; the ultrasonic probe assembly focuses on the compression part of the power transmission fitting and emits ultrasonic signals; and the detection module is used for processing the received ultrasonic signals.

[0005] The technical scheme of the embodiment of the present application, the ultrasonic detection sensor comprises an ultrasonic probe assembly, a detection module and a flexible fitting clamp; the detection module is connected with the ultrasonic probe assembly; the ultrasonic probe assembly is provided with the flexible fitting clamp at both ends; the flexible fitting clamp is attached to the surface of the compression part of the power transmission fitting; the ultrasonic probe assembly focuses on the compression part of the power transmission fitting and emits ultrasonic signals; and the detection module is used for processing the received ultrasonic signals. In this embodiment, the ultrasonic probe assembly focuses on the compression part of the power transmission fitting, which can accurately emit and receive ultrasonic signals, improve detection accuracy, and the flexible fitting clamp is arranged at both ends of the ultrasonic probe assembly and attached to the surface of the compression part of the power transmission fitting, which can ensure the stability and reliability of the ultrasonic probe assembly during detection, further improving the detection accuracy of the ultrasonic detection sensor. BRIEF DESCRIPTION OF DRAWINGS

[0006] The above and other features, advantages, and aspects of the various embodiments of the present disclosure will become more apparent with reference to the following detailed description in conjunction with the accompanying drawings. Throughout the drawings, the same or similar reference numerals are used to represent the same or similar elements. It should be understood that the drawings are schematic, and the proportions of the elements and the sizes do not necessarily correspond to reality.

[0007] Figure 1A schematic diagram of an ultrasonic detection sensor structure provided by an embodiment of the present application is shown in FIG. 1.

[0008] Figure 2 A schematic diagram of a flexible fitting clamp structure provided by an embodiment of the present application is shown in FIG. 2. DETAILED DESCRIPTION

[0009] Embodiments of the present disclosure will be described in more detail with reference to the drawings. Although certain embodiments of the present disclosure are shown in the drawings, it is understood that the present disclosure can be implemented in various forms and should not be interpreted as being limited to the embodiments set forth herein, but rather these embodiments are provided so that the present disclosure can be more thoroughly and completely understood. It should be understood that the drawings and embodiments of the present disclosure are for exemplary purposes only and are not intended to limit the scope of protection of the present disclosure.

[0010] It should be understood that the various steps in the method embodiments of the present disclosure can be performed in different orders and / or in parallel. In addition, the method embodiments can include additional steps and / or omit the steps shown. The scope of the present disclosure is not limited in this respect. The term "comprising" and variations thereof as used in this document shall mean "including but not limited to". It should be noted that the concepts of "first", "second", etc. mentioned in the present disclosure are only used to distinguish different devices, modules or units, and are not intended to limit the order or interdependence of the functions performed by these devices, modules or units. It should be noted that the modification of "one" or "multiple" mentioned in the present disclosure is illustrative and not limiting, and those skilled in the art should understand that, unless otherwise explicitly stated in the context, it should be understood as "one or more". It can be understood that the data involved in the technical solution (including but not limited to the data itself, the acquisition or use of the data) should comply with the requirements of the relevant laws and regulations and the relevant provisions.

[0011] Figure 1 A schematic diagram of an ultrasonic detection sensor structure provided by an embodiment of the present application is shown in FIG. 1. An ultrasonic probe assembly, a detection module and a flexible fitting clamp; the detection module is connected with the ultrasonic probe assembly; the ultrasonic probe assembly has the flexible fitting clamp arranged at both ends; the flexible fitting clamp is attached to the surface of the compression joint of the power transmission fitting; the ultrasonic probe assembly focuses on the compression joint of the power transmission fitting and emits ultrasonic signals; the detection module is used to process the received ultrasonic signals.

[0012] It should be noted that the power transmission hardware, in the power transmission line, is a metal accessory used for connecting conductors, jointing pipes and other components, and plays a role in suspension, fixation, protection and jointing. The quality of the compression joint directly affects the reliability and safety of the power transmission line, and is the core object of the detection of the embodiments of the present application. Compression joint (process), by applying pressure, the connected parts produce plastic deformation at the contact site, so as to realize a firm connection of a process method. In actual operation, due to the influence of equipment parameters, personnel skills and environmental factors, the compression joint site is prone to defects. Ultrasonic detection, using the propagation characteristics of ultrasonic signals in different media, by analyzing the reflection, refraction, scattering and other signal changes when the ultrasonic wave encounters defects, to detect the internal defects of the object. The ultrasonic detection sensor provided by the embodiments of the present application can detect the compression joint quality of the power transmission hardware based on the principle of ultrasonic detection.

[0013] Among them, the ultrasonic probe assembly has an adjustable focal length function, which can accurately focus on the compression joint site of the power transmission hardware of different depths, so that the ultrasonic beam accurately acts on the compression joint interface of the power transmission hardware, and improves the detection accuracy.

[0014] Among them, the flexible fitting clamp and the lower part of the ultrasonic probe assembly are both power transmission hardware.

[0015] Optionally, the ultrasonic probe assembly includes a shell, a control circuit, a piezoelectric transducer element array and an acoustic lens; the piezoelectric transducer element array and the acoustic lens are arranged in the shell; the control circuit is used to adjust the working mode of the piezoelectric transducer element array; the piezoelectric transducer element array is used to emit the ultrasonic signal; and the acoustic lens is used to focus the ultrasonic beam formed by the ultrasonic signal on the compression joint of the power transmission hardware.

[0016] Among them, the shell is used to protect the internal elements, and the internal elements include a control circuit, a piezoelectric transducer element array and an acoustic lens. The piezoelectric transducer element array is used to convert electrical signals into ultrasonic signals, or convert ultrasonic signals into electrical signals. Among them, the piezoelectric transducer element array is composed of a plurality of piezoelectric ceramic chips, and the material of each piezoelectric ceramic chip in the plurality of piezoelectric ceramic chips is lead zirconate titanate piezoelectric ceramic. The piezoelectric transducer element array has high sensitivity and wide frequency band characteristics, can emit ultrasonic signals of multiple frequencies, meets the detection requirements of compression joint defects of power transmission hardware of different sizes, and can realize mutual conversion of electrical signals and ultrasonic signals during the detection process.

[0017] Among them, the acoustic lens adopts a composite material with gradually changing sound velocity, which is used to adjust the acoustic lens parameters according to the depth information of the compression joint of the power transmission hardware, so as to control the focusing depth and focusing range of the ultrasonic beam.

[0018] In this embodiment, the acoustic lens is made of a composite material with gradually changing sound velocity, and the focusing depth and range of the ultrasonic beam can be accurately controlled by adjusting the parameters of the acoustic lens according to the depth information of the compression joint, thereby improving the detection resolution and ensuring that the ultrasonic beam can be accurately focused on the key part of the compression interface of the power transmission hardware. The acoustic lens cooperates with the piezoelectric transducer element array to accurately focus on the compression joint of the power transmission hardware with different depth information, so that the ultrasonic beam can accurately act on the compression interface, thereby improving the detection accuracy.

[0019] For example, the shell of the ultrasonic probe assembly is made of aluminum alloy material, which has good mechanical strength and electromagnetic shielding performance. The piezoelectric transducer element array is composed of 64 lead zirconate titanate piezoelectric ceramic chips arranged in a matrix. The acoustic lens is made of an organic glass composite material with gradually changing sound velocity, and the initial focusing parameters are set according to the common compression depth range of the power transmission hardware.

[0020] In this embodiment, the ultrasonic probe assembly with adjustable focal length can accurately focus on the compression joint of the power transmission hardware with different depths by adjusting the working mode of the piezoelectric transducer element array through the control circuit and combining the acoustic lens made of the composite material with gradually changing sound velocity, so that the ultrasonic beam can accurately act on the compression interface, thereby significantly improving the detection resolution and clearly capturing the ultrasonic echo changes caused by subtle defects, thereby realizing high-precision detection.

[0021] The flexible fitting clamp is used to tightly fit the surface of the compression joint of the power transmission hardware with different curvatures, and to maintain stability during detection to prevent displacement of the ultrasonic probe assembly due to vibration of the power transmission hardware, external wind and other factors, thereby enhancing the adaptability of the ultrasonic detection sensor to the complex-shaped power transmission hardware.

[0022] The flexible fitting clamp includes an adaptive fitting body, a vacuum adsorption fixing assembly and a buffer rubber. The adaptive fitting body is used to fit the arc surface structure of the compression joint of the power transmission hardware (the shape of the compression joint of the power transmission hardware is an arc surface structure). The vacuum adsorption fixing assembly is distributed on the inner side of the adaptive fitting body. The buffer rubber is located on the upper surface of the adaptive fitting body. The vacuum adsorption fixing assembly and the buffer rubber are used to fix the power transmission hardware.

[0023] In this embodiment, the flexible fitting clamp has excellent adaptive fitting capability and stable fixing performance, which can ensure that the ultrasonic probe assembly can work accurately under complex working conditions.

[0024] The adaptive fitting body is made of a multi-layer composite flexible material, and includes an inner rubber layer, a middle fiber layer and an outer wear-resistant protective layer. The inner rubber layer has a Shore hardness range of 15A-30A. The middle fiber layer is woven from aramid fibers and has a net-like structure. The outer wear-resistant protective layer is made of polyurethane material.

[0025] The rubber layer of the inner layer has low hardness and high elasticity, and the Shore hardness is in the range of 15A-30A, which can automatically deform according to the curvature of the compression joint of the power transmission hardware and tightly fit the surface; the fiber layer of the middle layer is woven by high-strength aramid fiber and has a mesh structure, which provides necessary structural support strength for the flexible fitting clamp and prevents excessive deformation; the wear-resistant protective layer of the outer layer is made of polyurethane material, which can resist sand and rainwater erosion in outdoor environment and prolong the service life of the clamp.

[0026] In the embodiment, the multi-layer material of the adaptive fitting body is connected through a hot pressing composite process, which can ensure the tight combination between the layers, synergistically exert the performance advantages of each layer, and perform rounding treatment at the corner parts to avoid scratching the surface of the power transmission hardware.

[0027] In the embodiment, the adaptive fitting body with the unique multi-layer composite structure can perfectly fit the compression shapes of various power transmission hardware, effectively solve the detection errors caused by poor fitting, greatly improve the detection accuracy, and ensure that the ultrasonic detection signal accurately reflects the compression quality condition.

[0028] The vacuum adsorption fixing assembly is composed of a plurality of micro vacuum suction cups; each micro vacuum suction cup in the plurality of micro vacuum suction cups is connected to an external vacuum generating device through an air pipe to form a negative pressure between the flexible fitting clamp and the surface of the compression joint of the power transmission hardware; the external vacuum generating device is located above the buffer rubber; the plurality of micro vacuum suction cups are arrayed, and the aperture of each micro vacuum suction cup in the plurality of micro vacuum suction cups is between 0.3mm and 1.5mm; the material of the air pipe is rubber material.

[0029] In the embodiment, each micro vacuum suction cup in the plurality of micro vacuum suction cups is connected to an external vacuum generating device through an air pipe to form a negative pressure between the flexible fitting clamp and the surface of the compression joint of the power transmission hardware, thereby realizing vacuum adsorption on the surface of the compression part of the power transmission hardware.

[0030] In the embodiment, the plurality of micro vacuum suction cups are arrayed, and the aperture of each micro vacuum suction cup in the plurality of micro vacuum suction cups is between 0.3mm and 1.5mm, which can ensure that sufficient suction force can be generated on the surface of the power transmission hardware with different roughness, so that the flexible fitting clamp is firmly fixed at the compression part and will not be loosened or displaced even under harsh conditions such as strong wind and vibration.

[0031] The air pipe is a flexible air pipe, and the material of the air pipe is rubber material, specifically a rubber material resistant to bending and aging, which is internally provided with a steel wire reinforcing layer to ensure that the air pipe will not be broken or leak air under frequent bending and stretching operations, and stably transmit vacuum negative pressure.

[0032] Exemplary, Figure 2 A schematic diagram of a flexible fitting clamp structure is provided for the embodiments of the present application. The flexible fitting clamp includes an adaptive fitting body 101, a micro vacuum suction cup 102, an air pipe 103, a buffer rubber 104, and an external vacuum generating device 105. Figure 2 Only three micro vacuum suction cups 102 are shown.

[0033] Exemplary, the rubber layer of the adaptive fitting body is made of natural rubber material with a Shore hardness of 20A, which has excellent flexibility. The aramid fiber in the fiber layer of the middle layer is woven in a 45-degree twill pattern to form a tight network, providing balanced support. The wear-resistant protective layer of the outer layer is made of polyurethane with a thickness of 2mm, which can effectively protect against external wear and tear.

[0034] Exemplary, in the vacuum suction and fixing assembly, the micro vacuum suction cup has a diameter of 1mm and is arranged in a 3x3 array, the air pipe has an inner diameter of 4mm, and a steel wire reinforcement layer with a steel wire diameter of 0.5mm is built-in, which is connected to an external vacuum generating device (such as a small vacuum pump) to quickly generate stable negative pressure to adsorb the power transmission fitting.

[0035] In this embodiment, the vacuum suction and fixing assembly strongly adsorbs, and the buffer rubber keeps the flexible fitting clamp highly stable in complex outdoor power transmission line environments, creating stable detection conditions for the ultrasonic probe assembly, not affected by external interference, improving detection reliability and continuity, reducing the risk of detection misjudgment, and effectively ensuring the safe operation of the power transmission line.

[0036] The ultrasonic detection sensor further includes a buffer damping structure; the buffer damping structure is located between the ultrasonic probe assembly and the power transmission fitting; the buffer damping structure adopts a structure of a silica gel buffer pad combined with a spring; the spring is made of stainless steel.

[0037] In this embodiment, the silica gel buffer pad absorbs the fine vibrations transmitted by the clamp, and the spring further buffers the larger impact force, preventing the ultrasonic probe assembly from being damaged due to sudden strong vibration of the power transmission fitting, and ensuring smooth detection process.

[0038] In this embodiment, the spring in the buffer damping structure is made of stainless steel, which has good corrosion resistance and elastic recovery ability. The spring stiffness coefficient is optimized according to the weight of the ultrasonic probe assembly and the common vibration impact strength to adapt to different detection conditions.

[0039] Exemplary, the silica gel buffer pad in the buffer damping structure has a thickness of 5mm, and the spring is a stainless steel spring with a wire diameter of 2mm and an outer diameter of 10mm, and a stiffness coefficient of 5N / mm, which provides reliable buffer for the installed ultrasonic probe assembly.

[0040] The detection module comprises a signal acquisition and processing unit and a data transmission unit; the acquisition and processing unit is configured to pre-process the received ultrasonic signals to obtain pre-processed signals, and extract detection features from the pre-processed signals; and the data transmission unit is configured to upload the detection features to an upper computer, so that the upper computer generates a detection report according to the detection features.

[0041] The signal acquisition and processing unit is electrically connected with the ultrasonic probe assembly, receives ultrasonic echo signals, and pre-processes the ultrasonic echo signals, such as amplification, filtering, digitization, etc., to extract detection features (i.e., characteristic parameters) reflecting the compression quality of the power hardware, such as echo amplitude, time delay, etc.

[0042] The acquisition and processing unit comprises a noise amplifier.

[0043] The noise amplifier is a high-precision low-noise amplifier, which amplifies the ultrasonic echo signals by multiple times (e.g., 10 times), performs band-pass filtering processing, converts the analog signals into digital signals after removing noise interference, effectively improves the signal-to-noise ratio of the weak ultrasonic echo signals, and provides a guarantee for subsequent accurate analysis.

[0044] The data transmission unit uploads the detection features to an external upper computer in a wireless or wired manner, so that the upper computer generates a detection report according to the detection features. In this embodiment, the data transmission unit can support high-speed wireless transmission protocols such as 5G, and can quickly and stably upload a large amount of detection feature data in a complex power line site environment, thereby improving the detection efficiency.

[0045] The upper computer is a computer device loaded with intelligent analysis software, receives the detection features transmitted by the data transmission unit, analyzes and judges the detection features according to the preset compression quality standard of the power hardware (judges whether the power compression hardware part is qualified), finally generates a detection report, realizes the automation and intelligentization of the detection process, and greatly improves the detection efficiency.

[0046] The technical scheme of the embodiment of the application comprises: an ultrasonic detection sensor, which comprises an ultrasonic probe assembly, a detection module and flexible fitting clamps; the detection module is connected with the ultrasonic probe assembly; the two ends of the ultrasonic probe assembly are respectively provided with the flexible fitting clamps; the flexible fitting clamps are fitted to the surface of the compression joint of the power transmission fitting; the ultrasonic probe assembly focuses on the compression joint of the power transmission fitting and emits ultrasonic signals; the detection module is used for processing the received ultrasonic signals. In the embodiment, the ultrasonic probe assembly focuses on the compression joint of the power transmission fitting, so that the ultrasonic signals can be accurately emitted and received, and the detection precision is improved; the flexible fitting clamps are arranged at the two ends of the ultrasonic probe assembly and are fitted to the surface of the compression joint of the power transmission fitting, so that the stability and reliability of the ultrasonic probe assembly during detection can be ensured, and the detection precision of the ultrasonic detection sensor is further improved.

[0047] It should be noted that the above are only the preferred embodiments of the application and the technical principles applied. Those skilled in the art will understand that the application is not limited to the specific embodiments herein, and those skilled in the art can make various obvious changes, readjustments and substitutions without departing from the protection scope of the application. Therefore, although the application has been described in detail through the above embodiments, the application is not limited to the above embodiments, and can include more other equivalent embodiments without departing from the concept of the application, and the scope of the application is determined by the scope of the appended claims.

Claims

1. An ultrasonic detection sensor, characterized in that: The ultrasonic detection sensor includes: an ultrasonic probe assembly, a detection module and a flexible bonding clamp; the detection module is connected to the ultrasonic probe assembly; the flexible bonding clamp is provided at each end of the ultrasonic probe assembly; the flexible bonding clamp is bonded to the surface of the crimping part of the power transmission hardware; the ultrasonic probe assembly focuses on the crimping part of the power transmission hardware and emits an ultrasonic signal; the detection module is used to process the received ultrasonic signal.

2. The ultrasonic detection sensor according to claim 1, characterized in that: in, The ultrasonic probe assembly includes a housing, a control circuit, a piezoelectric transducer element array and an acoustic lens; the piezoelectric transducer element array and the acoustic lens are arranged in the housing; the control circuit is used to adjust the working mode of the piezoelectric transducer element array; the piezoelectric transducer element array is used to transmit the ultrasonic signal; the acoustic lens is used to focus the ultrasonic beam formed by the ultrasonic signal on the crimping point of the power transmission hardware.

3. The ultrasonic detection sensor according to claim 2, characterized in that: in, The piezoelectric transducer element array is composed of a plurality of piezoelectric ceramic chips, and the material used for each of the plurality of piezoelectric ceramic chips is lead zirconate titanate piezoelectric ceramic.

4. The ultrasonic detection sensor according to claim 2, characterized in that: in, The material used for the acoustic lens is a composite material with a gradually changing sound velocity, which is used to adjust the acoustic lens parameters according to the depth information of the crimping point of the power transmission fitting to control the focusing depth and focusing range of the ultrasonic beam.

5. The ultrasonic detection sensor according to claim 1, characterized in that: The flexible fitting fixture includes an adaptive fitting body, a vacuum adsorption fixing component and a buffer rubber; the adaptive fitting body is used to fit the arc surface structure of the crimping part of the power transmission hardware; the vacuum adsorption fixing component is distributed on the inner side of the adaptive fitting body; the buffer rubber is located on the upper side of the adaptive fitting body; the vacuum adsorption fixing component and the buffer rubber are used to fix the power transmission hardware.

6. The ultrasonic detection sensor according to claim 5, characterized in that: in, The adaptive fitting body includes an inner rubber layer, a middle fiber layer and an outer wear-resistant protective layer; the Shore hardness of the inner rubber layer ranges from 15A to 30A; the middle fiber layer is woven from aramid fibers and has a mesh structure; the outer wear-resistant protective layer is made of polyurethane material.

7. The ultrasonic detection sensor according to claim 5, characterized in that: in, The vacuum adsorption fixing component is composed of a plurality of micro vacuum suction cups; each of the plurality of micro vacuum suction cups is connected to an external vacuum generating device through an air tube, so that a negative pressure is formed between the flexible fitting clamp and the surface of the crimped joint of the power transmission hardware; wherein, the external vacuum generating device is located above the buffer rubber; the plurality of micro vacuum suction cups are distributed in an array, and the aperture of each of the plurality of micro vacuum suction cups is between 0.3 mm and 1.5 mm; wherein, the material of the air tube is rubber material.

8. The ultrasonic detection sensor according to claim 1, characterized in that: in, The ultrasonic detection sensor also includes a buffering and shock-absorbing structure; the buffering and shock-absorbing structure is located between the ultrasonic probe assembly and the power transmission hardware; the buffering and shock-absorbing structure adopts a structure combining a silicone cushion and a spring; the material of the spring is stainless steel.

9. The ultrasonic detection sensor according to claim 1, characterized in that: in, The detection module includes a signal acquisition and processing unit and a data transmission unit; the acquisition and processing unit is used to preprocess the received ultrasonic signal to obtain a preprocessed signal; extract the detection features in the preprocessed signal; the data transmission unit is used to upload the detection features to the host computer so that the host computer generates a detection report based on the detection features.

10. The ultrasonic detection sensor according to claim 9, characterized in that: in, The acquisition and processing unit includes a noise amplifier.

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