Ultrasonic Flaw Detection Method and Apparatus Based on Adaptive Adjustment of Flaw Detection Curve

Abstract

This invention relates to the field of copper pipe flaw detection technology, and particularly to an ultrasonic flaw detection method and apparatus based on adaptive adjustment of flaw detection curves. This method can adaptively adjust flaw detection parameters in real time, improving the accuracy and reliability of flaw detection results. The method includes: adjusting the flaw detection parameters of the ultrasonic flaw detection apparatus, including transmission power and receiving gain, based on a preset time interval; acquiring the currently collected flaw detection curve and its corresponding flaw detection parameters within a set time window before each adjustment node, and comparing and analyzing them with the flaw detection curve after the previous adjustment to calculate the flaw detection curve deviation value; calculating the continuous flaw detection duration for maintaining the current flaw detection parameters based on the current flaw detection parameters; inputting the continuous flaw detection duration, the flaw detection curve deviation value, and the preset time interval into a preset flaw detection parameter control function to obtain the optimal flaw detection parameters for the next adjustment, and using these parameters to perform flaw detection on internally threaded copper pipes.

Description

Technical Field

[0001] This invention relates to the technical field of copper pipe flaw detection, and in particular to an ultrasonic flaw detection method and apparatus based on adaptive adjustment of the flaw detection curve. Background Technology

[0002] With the continuous improvement of precision requirements in industrial manufacturing, internally threaded copper tubes, as key heat transfer elements, are widely used in high-end fields such as refrigeration equipment, aerospace, and nuclear power plant heat exchangers. The integrity of its internal thread structure directly determines the heat transfer efficiency and service life of the product. Ultrasonic flaw detection technology, due to its non-contact and high sensitivity characteristics, has become the core means of defect detection for internally threaded copper tubes.

[0003] Transmit power and receive gain are key parameters of ultrasonic flaw detection devices, directly affecting the transmission intensity and reception sensitivity of ultrasonic signals. Appropriate flaw detection parameters can ensure that ultrasonic waves propagate effectively inside copper tubes and accurately detect potential defects; while inappropriate parameters may lead to inaccurate flaw detection results and failure to effectively identify defects.

[0004] During long-term continuous operation, the performance of existing ultrasonic flaw detection devices can change. For example, the sensitivity of the probe may decrease with increasing usage time, and the stability of electronic components may be affected. These changes can also affect the transmission and reception of ultrasonic signals, thereby affecting the accuracy of flaw detection results. However, existing fixed or simple manual adjustment methods cannot detect these changes in real time and cannot adaptively adjust the flaw detection parameters in a timely manner, thus affecting the reliability of flaw detection results. Summary of the Invention

[0005] This invention provides an ultrasonic flaw detection method and apparatus based on adaptive adjustment of flaw detection curves, which improves the accuracy and reliability of flaw detection results by real-time adaptive adjustment of flaw detection parameters, and can effectively solve the problems in the background art.

[0006] To achieve the above objectives, in a first aspect, the present invention provides an ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve, comprising:

[0007] Based on a preset time interval, the flaw detection parameters of the ultrasonic flaw detection device are adjusted, including the transmission power and the receiving gain.

[0008] Within the set time window before each adjustment node, the currently collected flaw detection curve and its corresponding flaw detection parameters are acquired, and compared and analyzed with the flaw detection curve after the previous adjustment to calculate the flaw detection curve deviation value.

[0009] Based on the current flaw detection parameters, calculate the duration of continuous flaw detection while maintaining the current flaw detection parameters;

[0010] The continuous flaw detection duration, flaw detection curve deviation value, and preset time interval are input into the preset flaw detection parameter control function to obtain the optimal flaw detection parameters for the next adjustment, and then the internal threaded copper pipe is flawed.

[0011] In conjunction with the first aspect, in one possible design, within a set time window before each adjustment node, the currently acquired flaw detection curve and its corresponding flaw detection parameters are acquired, and compared and analyzed with the flaw detection curve after the previous adjustment. The flaw detection curve deviation value is calculated, including:

[0012] Define the time window before each adjustment node;

[0013] Within the set time window, ultrasonic signals are continuously acquired and converted into digital signals;

[0014] The digital signal is preprocessed by filtering, amplification, and noise reduction to remove interference signals, and the ultrasonic signal intensity value at each time point is calculated based on the processed digital signal.

[0015] Plot the signal intensity value at each time point with time on the horizontal axis and ultrasonic signal intensity on the vertical axis to obtain the flaw detection curve C within the current time window. i (x), where x represents the abscissa of the flaw detection curve, the abscissa is the time axis, and i represents the i-th adjustment;

[0016] The flaw detection curve C i (x) is matched one-to-one with the transmit power P and receive gain G recorded in the same time window to form a triplet (C). i (x), P, G);

[0017] The currently acquired flaw detection curve C i (x) and the flaw detection curve C after the previous adjustment i-1 (x) is compared to calculate the flaw detection curve deviation value ΔC. i .

[0018] In conjunction with the first aspect, in one possible design, the flaw detection curve deviation value ΔC i The calculation method is as follows:

[0019] ;

[0020] Where N is the number of sampling points on the flaw detection curve, x j This represents the x-coordinate value of the j-th sampling point.

[0021] In conjunction with the first aspect, in one possible design, the setting of the preset time interval should at least take into account the design specifications, material characteristics, and flaw detection accuracy requirements of the internally threaded copper pipe.

[0022] In conjunction with the first aspect, in one possible design, based on the current flaw detection parameters, the duration of continuous flaw detection to maintain the current flaw detection parameters is statistically calculated, including:

[0023] When the ultrasonic flaw detector starts to perform flaw detection on the internally threaded copper pipe using the current flaw detection parameters, the timer is started and the time is recorded; the initial time is set to t0, at which point t0=0.

[0024] During the flaw detection process, monitor in real time whether the flaw detection parameters change;

[0025] Determine whether the flaw detection parameters at the current moment are the same as those at the start of flaw detection;

[0026] If a change in the flaw detection parameters is detected during the flaw detection process, the timer is stopped and the time t1 is recorded. The duration of continuous flaw detection with the current flaw detection parameters is T = t1 - t0.

[0027] If the flaw detection parameters do not change during the flaw detection process, when the flaw detection ends, record the time t2 at this time, stop the timer, and then maintain the current flaw detection parameters for a continuous flaw detection duration of T = t2 - t0.

[0028] In conjunction with the first aspect, in one possible design, the flaw detection parameter control function is expressed as:

[0029] ;

[0030] Where T represents the duration of continuous flaw detection, ΔC i P represents the deviation value of the flaw detection curve during the i-th adjustment, Δt represents the preset time interval, and P represents the deviation value of the flaw detection curve during the i-th adjustment. t G represents the current transmit power. r P represents the current receive gain. t+1 G represents the transmit power at the next adjustment. r+1 This indicates the receive gain at the next adjustment.

[0031] In conjunction with the first aspect, in one possible design, the formula for calculating the transmit power during the next adjustment is:

[0032] ;

[0033] The formula for calculating the receiver gain during the next adjustment is:

[0034] ;

[0035] Where α, β, γ, and δ are the weighting coefficients of the control function.

[0036] Secondly, the present invention also provides an ultrasonic flaw detection device based on adaptive adjustment of the flaw detection curve, comprising:

[0037] The flaw detection parameter adjustment module is used to adjust the flaw detection parameters of the ultrasonic flaw detection device based on a preset time interval. The specific flaw detection parameters to be adjusted include the transmission power and the receiving gain.

[0038] The flaw detection curve analysis module is used to acquire the currently collected flaw detection curve and its corresponding flaw detection parameters within a set time window before each adjustment node, and compare and analyze it with the flaw detection curve after the previous adjustment to calculate the flaw detection curve deviation value.

[0039] The flaw detection duration statistics module is used to calculate the duration of continuous flaw detection while maintaining the current flaw detection parameters, based on the current flaw detection parameters.

[0040] The flaw detection parameter optimization module is used to input the continuous flaw detection duration, flaw detection curve deviation value, and preset time interval into the preset flaw detection parameter control function to obtain the optimal flaw detection parameters for the next adjustment, and to perform flaw detection on the internally threaded copper pipe.

[0041] In conjunction with the second aspect, in one possible design, the setting of the preset time interval should at least take into account the design specifications, material characteristics, and flaw detection accuracy requirements of the internally threaded copper pipe.

[0042] In conjunction with the second aspect, in one possible design, the flaw detection time statistics module is configured as follows:

[0043] When the ultrasonic flaw detector starts to perform flaw detection on the internally threaded copper pipe using the current flaw detection parameters, the timer is started and the time is recorded; the initial time is set to t0, at which point t0=0.

[0044] During the flaw detection process, monitor in real time whether the flaw detection parameters change;

[0045] Determine whether the flaw detection parameters at the current moment are the same as those at the start of flaw detection;

[0046] If a change in the flaw detection parameters is detected during the flaw detection process, the timer is stopped and the time t1 is recorded. The duration of continuous flaw detection with the current flaw detection parameters is T = t1 - t0.

[0047] If no change is detected in the flaw detection parameters during the flaw detection process, record the time t2 when the flaw detection ends, stop the timer, and then maintain the current flaw detection parameters for a continuous flaw detection duration of T = t2 - t0.

[0048] The technical solution of this invention can achieve the following technical effects:

[0049] This invention adjusts the flaw detection parameters based on a preset time interval, and combines factors such as flaw detection curve deviation and continuous flaw detection duration into the flaw detection parameter control function to obtain the optimal flaw detection parameters for the next adjustment. It can sense the impact of factors such as changes in equipment performance on flaw detection in real time, and make timely adaptive adjustments to the flaw detection parameters, thus making up for the shortcomings of existing fixed or simple manual adjustment methods that cannot sense changes in real time and make timely adjustments.

[0050] Timely adjustment of flaw detection parameters can ensure that ultrasonic waves can effectively propagate inside copper tubes and accurately detect defects. This invention adjusts flaw detection parameters in real time to continuously optimize them according to actual conditions, thereby improving the transmission and reception of ultrasonic signals and thus improving the accuracy of flaw detection results. It avoids the problem of inaccurate flaw detection results and inability to effectively identify defects due to unsuitable parameters.

[0051] During long-term continuous operation, changes in equipment performance can affect the accuracy of flaw detection results. This invention adjusts parameters in real time to ensure that the parameters are always in a reasonable state during the flaw detection process, reducing the interference of factors such as changes in equipment performance on the flaw detection results and effectively improving the reliability of the flaw detection results. Attached Figure Description

[0052] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0053] Figure 1 This is a flowchart of the ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve in this invention;

[0054] Figure 2 This is a structural block diagram of the ultrasonic flaw detection device based on adaptive adjustment of flaw detection curve in this invention; Detailed Implementation

[0055] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0056] This application will now be described with reference to the accompanying drawings.

[0057] like Figure 1 As shown, the ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve of the present invention specifically includes the following steps:

[0058] Step S1: Adjust the flaw detection parameters of the ultrasonic flaw detection device based on a preset time interval, including the transmission power and the receiving gain;

[0059] Step S2: Within the set time window before each adjustment node, acquire the currently collected flaw detection curve and its corresponding flaw detection parameters, and compare and analyze it with the flaw detection curve after the previous adjustment to calculate the flaw detection curve deviation value.

[0060] Step S3: Based on the current flaw detection parameters, calculate the duration of continuous flaw detection while maintaining the current flaw detection parameters;

[0061] Step S4: Input the continuous flaw detection duration, flaw detection curve deviation value, and preset time interval into the preset flaw detection parameter control function to obtain the optimal flaw detection parameters for the next adjustment, and use them to perform flaw detection on the internally threaded copper pipe.

[0062] In this embodiment, the preset time interval represents the time interval for adjusting the operating parameters of the ultrasonic flaw detection device. This preset time interval allows for real-time sensing of changes in the device's performance, avoiding the limitations of traditional fixed-parameter methods that cannot adapt to equipment changes, and ensuring the reliability of the flaw detection results. The flaw detection curve deviation value represents the deviation of the flaw detection curve between two adjacent parameter adjustments. By calculating and analyzing the deviation value, it is possible to accurately determine whether the current parameters are suitable, thereby dynamically optimizing the flaw detection parameters, ensuring effective propagation of the ultrasonic signal and accurate defect detection, and improving the accuracy of the flaw detection results. Furthermore, since excessively high adjustment frequencies of the flaw detection parameters may lead to decreased detection efficiency, while excessively low adjustment frequencies may fail to adapt to changes in equipment performance in a timely manner, by using the continuous flaw detection duration as one of the reference factors for parameter adjustment, the efficiency loss caused by frequent parameter adjustments is avoided while ensuring flaw detection accuracy, thus achieving optimal detection performance.

[0063] In some embodiments of the present invention, for step S1, the setting of the preset time interval takes into account at least the design specifications, material characteristics and flaw detection accuracy requirements of the internally threaded copper tube.

[0064] The design specifications of internally threaded copper pipes, such as pipe diameter, thread depth, and pitch, affect the propagation path and attenuation of ultrasonic waves within the pipe. Larger diameter copper pipes may require longer ultrasonic wave propagation distances, while complex thread structures can make ultrasonic wave scattering and reflection more complicated. Setting a preset time interval according to the design specifications allows the adjustment frequency of the flaw detection parameters to match the structural characteristics of the copper pipe. For copper pipes with complex structures that have a significant impact on ultrasonic wave propagation, appropriately shortening the preset time interval allows for more timely adjustment of flaw detection parameters to adapt to changes in ultrasonic wave propagation and improve the accuracy of flaw detection.

[0065] The material properties of internally threaded copper tubes, such as density and elastic modulus, affect the propagation speed and attenuation characteristics of ultrasonic waves. For example, high-purity copper and copper containing impurities have different degrees of absorption and scattering of ultrasonic waves. By considering the material properties and setting a preset time interval, the timing of adjusting the flaw detection parameters can be reasonably adjusted for copper tubes of different materials. For copper tubes whose material properties cause rapid ultrasonic wave attenuation or large changes in propagation speed, more frequent adjustment of flaw detection parameters can ensure that a clear and accurate ultrasonic signal is always obtained during the flaw detection process, thereby improving the reliability of the flaw detection results.

[0066] The required flaw detection accuracy varies depending on the application scenario. For example, high-end fields such as aerospace and nuclear power plant heat exchangers have extremely high quality requirements for internally threaded copper tubes, where even the smallest defects can lead to serious consequences, necessitating higher flaw detection accuracy. In contrast, some ordinary refrigeration equipment has relatively lower requirements for flaw detection accuracy. Setting a preset time interval based on the flaw detection accuracy requirements can optimize flaw detection efficiency while meeting the accuracy requirements. For flaw detection tasks with high accuracy requirements, shortening the preset time interval and increasing the adjustment frequency of flaw detection parameters helps to more accurately capture minute defects inside the copper tube and avoid missing defects due to inappropriate parameters. For situations with lower accuracy requirements, the preset time interval can be appropriately extended to reduce unnecessary parameter adjustments, improve flaw detection efficiency, and reduce costs.

[0067] In addition, the setting of the preset time interval can also take into account the performance of the flaw detection equipment, the ambient temperature, and the production cycle.

[0068] The performance of flaw detection equipment includes, but is not limited to, transmission power stability, receiving sensitivity, and signal processing capabilities. Higher-performance equipment may exhibit greater stability and more precise signal processing, maintaining relatively stable flaw detection results over longer periods. In contrast, lower-performance equipment may be more susceptible to various factors, requiring more frequent parameter adjustments to ensure accurate results. Setting preset time intervals based on equipment performance can fully leverage its strengths while compensating for its weaknesses. For high-performance equipment, appropriately extending the preset time interval reduces unnecessary parameter adjustments, improves detection efficiency, and lowers equipment wear. For relatively lower-performance equipment, shortening the preset time interval allows for timely adjustments to detection parameters based on equipment changes, ensuring reliable results.

[0069] Changes in ambient temperature affect the propagation speed and attenuation characteristics of ultrasonic waves in a medium, as well as the performance of flaw detection equipment. Increased temperature accelerates the propagation speed of ultrasonic waves in copper pipes and may also increase attenuation. Furthermore, temperature variations can alter the performance of electronic components in the flaw detection equipment, thus affecting the detection results. By incorporating ambient temperature into the preset time interval, the adjustment of flaw detection parameters becomes more adaptable to changes in the actual working environment. In environments with significant temperature variations, shortening the preset time interval and adjusting the flaw detection parameters promptly based on temperature-induced changes in ultrasonic wave propagation characteristics and equipment performance ensures the accuracy of the flaw detection results. Conversely, in relatively stable temperature environments, appropriately extending the preset time interval reduces the frequency of parameter adjustments and improves the efficiency of flaw detection work.

[0070] The production cycle time reflects the production speed and batch size of internally threaded copper tubes. By setting a preset time interval in conjunction with the production cycle time, the flaw detection work can be effectively integrated with the production process. When the production cycle time is fast, by reasonably setting the preset time interval, it is possible to ensure that the flaw detection parameters are adjusted in a timely manner to meet the flaw detection accuracy requirements, without affecting production efficiency due to frequent parameter adjustments. When the production cycle time is slow, the flaw detection parameters can be adjusted more meticulously to further improve the flaw detection accuracy, while avoiding increased equipment maintenance costs and labor costs due to excessively frequent parameter adjustments.

[0071] In some embodiments of the present invention, regarding step S2, within a set time window before each adjustment node, the currently acquired flaw detection curve and its corresponding flaw detection parameters are acquired, and compared and analyzed with the flaw detection curve after the previous adjustment to calculate the flaw detection curve deviation value, including:

[0072] Step S21: Define the set time window before each adjustment node; the length of the time window is determined according to actual needs and the characteristics of the flaw detection device, and is used to limit the time range for obtaining the current flaw detection curve;

[0073] Step S22: Within the set time window, continuously acquire ultrasonic signals and convert them into digital signals;

[0074] Step S23: Perform preprocessing operations such as filtering, amplification, and noise reduction on the digital signal to remove interference signals. Calculate the ultrasonic signal intensity value corresponding to each time point based on the processed digital signal.

[0075] Step S24: Plot the signal intensity value at each time point with time as the horizontal axis and ultrasonic signal intensity as the vertical axis to obtain the flaw detection curve C within the current time window. i (x), where x represents the abscissa of the flaw detection curve, the abscissa is the time axis, and i represents the i-th time;

[0076] Step S25: Apply the flaw detection curve Ci (x) is matched one-to-one with the transmit power P and receive gain G recorded in the same time window to form a triplet (C). i (x), P, G);

[0077] Step S26: Transfer the currently acquired flaw detection curve C i (x) and the flaw detection curve C after the previous adjustment i-1 (x) is compared to calculate the flaw detection curve deviation value ΔC. i .

[0078] Specifically, the flaw detection curve deviation value ΔC i Calculated using the following formula:

[0079] ;

[0080] Where N is the number of sampling points on the flaw detection curve, x j This represents the x-coordinate value of the j-th sampling point;

[0081] Under the above calculation method, the deviation of the flaw detection curve is quantified by calculating the root mean square of the difference between corresponding points on two adjacent flaw detection curves. This reflects the fluctuation of the flaw detection results between two adjacent adjustments of flaw detection parameters, which helps to promptly identify potential problems in the flaw detection process. If the deviation value exceeds a certain threshold, it indicates that the flaw detection state may have changed, and the flaw detection parameters need to be adjusted. In addition, by taking into account the information of multiple sampling points on the flaw detection curve, rather than judging based on the difference of individual points, it can more comprehensively reflect the overall deviation of the two flaw detection curves. Even if the flaw detection curves have small differences in some local areas but large differences in other areas, the deviation value can be accurately calculated by this formula, thereby more reliably evaluating the effect of flaw detection parameter adjustments and the impact of equipment performance changes on the flaw detection results, providing a strong basis for subsequent optimization of flaw detection parameters.

[0082] In some embodiments of the present invention, for step S3, based on the current flaw detection parameters, the duration of continuous flaw detection while maintaining the current flaw detection parameters is calculated, specifically as follows:

[0083] Step S31: When the ultrasonic flaw detection device starts to perform flaw detection on the internally threaded copper pipe using the current flaw detection parameters, start the timer and start recording the time; set the initial time to t0, at this time t0=0;

[0084] Step S32: During the flaw detection process, monitor in real time whether the flaw detection parameters change; set a certain time t during the flaw detection process, and define the flaw detection parameter as the transmission power P. t and receiver gain G t ;

[0085] Step S33: Determine whether the flaw detection parameters at the current moment are the same as the flaw detection parameters at the start of flaw detection, that is, determine P. t =P and G t Does =G hold true?

[0086] If a change in the flaw detection parameters is detected during the flaw detection process, i.e., P exists... t ≠P or G t When the value is not equal to G, the timer is stopped and the time t1 is recorded. The duration of continuous flaw detection with the current flaw detection parameters is T = t1 - t0.

[0087] If the flaw detection parameters do not change during the flaw detection process, when the flaw detection ends, record the time t2 at this time, stop the timer, and then maintain the current flaw detection parameters for a continuous flaw detection duration of T = t2 - t0.

[0088] In this embodiment, the cutoff point for the continuous flaw detection duration statistics is determined based on two scenarios: whether the flaw detection parameters have changed and whether the flaw detection has ended. This provides the flaw detection parameter control function with continuous flaw detection duration data that better reflects the actual flaw detection situation. Combined with the flaw detection curve deviation value and the preset time interval, the flaw detection parameter control function can more accurately calculate the optimal flaw detection parameters for the next adjustment. This enables adaptive adjustment of the flaw detection parameters, effectively addressing the impact of factors such as changes in equipment performance on the accuracy of flaw detection results, and improving the accuracy and reliability of adaptive adjustment of flaw detection parameters.

[0089] In some embodiments of the present invention, for step S4, the flaw detection parameter control function is a mathematical model that calculates the optimal flaw detection parameters based on the continuous flaw detection duration, the flaw detection curve deviation value, and a preset time interval. The specific form of the flaw detection parameter control function needs to be determined based on actual conditions through a large amount of experimental data and theoretical analysis. It can be a multivariate nonlinear function, and the flaw detection parameter control function is expressed as follows:

[0090] ;

[0091] Where T represents the duration of continuous flaw detection, ΔC i P represents the deviation value of the flaw detection curve during the i-th adjustment, Δt represents the preset time interval, and P represents the deviation value of the flaw detection curve during the i-th adjustment. t G represents the current transmit power. r P represents the current receive gain. t+1 G represents the transmit power at the next adjustment. r+1 Indicates the receive gain at the next adjustment;

[0092] Specifically, the transmission power during the next adjustment The receiving gain during the next adjustment ;

[0093] α, β, γ, and δ are the weighting coefficients of the control function, which need to be determined through experimental calibration or optimization algorithms. The weighting coefficients α, β, γ, and δ are used to balance the influence of different factors on the adjustment of flaw detection parameters. They can be customized according to different flaw detection scenarios and needs, making the control function more flexible and accurate.

[0094] Furthermore, in order to ensure P t+1 and G r+1 If the value is within a reasonable range, the result of the control function needs to be normalized. Let the range of the transmit power Pt be [Pmin, Pmax], and the range of the receive gain Gr be [Gmin, Gmax], then the normalization formula is:

[0095] ;

[0096] ;

[0097] in, and This is the unnormalized calculation result; Z P and Z G It is the normalization factor, defined as , , and The tolerance parameter is used to avoid the normalization factor being too small; Pmin is the minimum transmission power at which the equipment can operate stably, usually determined by the equipment's hardware design. If the transmission power is too low, the ultrasonic signal may be too weak to effectively detect defects; Pmax is the maximum allowable transmission power of the equipment, usually determined by the power amplifier or the tolerance capability of the ultrasonic probe. If the transmission power is too high, it may cause the equipment to overheat, the probe to be damaged, or damage to the object being inspected; Gmin is the minimum gain of the receiving signal amplifier, usually set to the lowest value that can amplify weak signals to avoid excessive amplification of noise; Gmax is the maximum gain of the receiving signal amplifier, usually set to the highest value that can amplify strong signals while avoiding signal saturation or distortion; the optimal flaw detection parameters (P) are obtained for the next adjustment after normalization. t+1 G r+1 This technology will be applied to ultrasonic flaw detection devices to detect flaws in internally threaded copper pipes. Through normalization, it avoids situations where the results exceed the equipment's capabilities due to calculation errors or excessive parameter adjustments. At the same time, by limiting the results to a reasonable range during the calculation stage, it reduces subsequent inspection steps, thereby helping to improve response speed.

[0098] In some solutions, multiple embodiments of this application can be combined, and the combined solution can be implemented. Optionally, some operations in the processes of each method embodiment may be combined, and / or the order of some operations may be changed. Furthermore, the execution order between the steps of each process is merely exemplary and does not constitute a limitation on the execution order between steps; other execution orders are also possible. It is not intended to indicate that the execution order is the only possible order in which these operations can be performed. Those skilled in the art will conceive of various ways to reorder the operations described herein. In addition, it should be noted that the process details involved in one embodiment of this document are similarly applicable to other embodiments, or different embodiments may be combined.

[0099] Furthermore, some steps in the method embodiments can be equivalently replaced with other possible steps. Alternatively, some steps in the method embodiments may be optional and can be deleted in certain use cases. Or, other possible steps may be added to the method embodiments. Moreover, the various method embodiments can be implemented individually or in combination.

[0100] like Figure 2 As shown, the present invention also provides an ultrasonic flaw detection device based on adaptive adjustment of flaw detection curve, which specifically includes the following modules;

[0101] The flaw detection parameter adjustment module is used to adjust the flaw detection parameters of the ultrasonic flaw detection device based on a preset time interval. The specific flaw detection parameters to be adjusted include the transmission power and the receiving gain.

[0102] The flaw detection curve analysis module is used to acquire the currently collected flaw detection curve and its corresponding flaw detection parameters within a set time window before each adjustment node, and compare and analyze it with the flaw detection curve after the previous adjustment to calculate the flaw detection curve deviation value.

[0103] The flaw detection duration statistics module is used to calculate the duration of continuous flaw detection while maintaining the current flaw detection parameters, based on the current flaw detection parameters.

[0104] The flaw detection parameter optimization module is used to input the continuous flaw detection duration, flaw detection curve deviation value, and preset time interval into the preset flaw detection parameter control function to obtain the optimal flaw detection parameters for the next adjustment, and to perform flaw detection on the internally threaded copper pipe.

[0105] In this embodiment, the flaw detection parameter adjustment module can adjust key flaw detection parameters such as transmit power and receive gain based on a preset time interval, which can actively adapt to changes in the flaw detection process and ensure the accuracy of flaw detection. The flaw detection curve analysis module compares the current flaw detection curve with the one after the previous adjustment before the adjustment node and calculates the deviation value, which can detect changes in the flaw detection curve in a timely manner and provide a basis for parameter adjustment. The flaw detection duration statistics module counts the duration of maintaining the current flaw detection parameters, providing time-dimensional reference information for parameter optimization. The flaw detection parameter optimization module inputs the continuous flaw detection duration, flaw detection curve deviation value and preset time interval into the control function to obtain the optimal flaw detection parameters, realizes adaptive adjustment, overcomes the defects of existing fixed or simple manual adjustment methods that cannot perceive changes in equipment performance in real time and cannot adjust parameters in a timely manner, can adapt to changes in equipment performance in real time, adjust parameters in a timely manner, and improve the reliability and accuracy of flaw detection results.

[0106] In a specific implementation, as one example, the setting of the preset time interval takes into account at least the design specifications, material characteristics, and flaw detection accuracy requirements of the internally threaded copper tube.

[0107] By considering the design specifications of internally threaded copper tubes, the adjustment frequency of flaw detection parameters can be rationally arranged according to copper tubes of different sizes and shapes. This ensures that the flaw detection process matches the structural characteristics of the copper tubes and avoids inaccurate flaw detection due to specification differences. Copper tubes with different material properties have different characteristics in the propagation and reflection of ultrasonic waves. By considering material characteristics, the preset time interval can be adapted to changes in material, ensuring that flaw detection parameters can be adjusted in a timely manner according to material characteristics, thereby improving the accuracy of flaw detection. By setting the preset time interval in combination with flaw detection accuracy requirements, unnecessary frequent adjustments or insufficient adjustments can be avoided while meeting the needs of high-precision flaw detection. This effectively balances flaw detection efficiency and accuracy, enabling the flaw detection device to operate stably and efficiently under different accuracy requirements, thus improving the adaptability and practicality of the device.

[0108] In a specific implementation, as one example, the flaw detection time statistics module is configured as follows:

[0109] When the ultrasonic flaw detector starts to perform flaw detection on the internally threaded copper pipe using the current flaw detection parameters, the timer is started and the time is recorded; the initial time is set to t0, at which point t0=0.

[0110] During the flaw detection process, monitor in real time whether the flaw detection parameters change;

[0111] Determine whether the flaw detection parameters at the current moment are the same as those at the start of flaw detection;

[0112] If a change in the flaw detection parameters is detected during the flaw detection process, the timer is stopped and the time t1 is recorded. The duration of continuous flaw detection with the current flaw detection parameters is T = t1 - t0.

[0113] If no change is detected in the flaw detection parameters during the flaw detection process, record the time t2 when the flaw detection ends, stop the timer, and then maintain the current flaw detection parameters for a continuous flaw detection duration of T = t2 - t0.

[0114] By accurately recording the usage duration of flaw detection parameters, a crucial basis for parameter optimization is provided. Real-time monitoring of parameter changes, whether parameters change or remain unchanged at the end of the flaw detection process, allows for accurate calculation of the continuous flaw detection duration. This enables the system to determine the optimal flaw detection parameters for the next adjustment more precisely based on the actual usage time of the parameters, combined with other factors such as flaw detection curve deviation. This helps the system adaptively adjust flaw detection parameters, compensating for the shortcomings of existing fixed or simple manual adjustment methods. It also enables timely responses to the impact of equipment performance changes on the accuracy of flaw detection results, thereby improving the reliability of the results and ensuring the accuracy and stability of defect detection in internally threaded copper pipes.

[0115] This embodiment divides functional modules according to the method example described above. For example, each function can be divided into its own functional modules, or two or more functions can be integrated into one processing module. The integrated modules can be implemented in hardware. It should be noted that the module division in this embodiment is illustrative and only represents one logical functional division; other division methods may be used in actual implementation.

[0116] The various variations and specific embodiments of the ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve in the aforementioned Embodiment 1 are also applicable to the ultrasonic flaw detection device based on adaptive adjustment of the flaw detection curve in this embodiment. Through the foregoing detailed description of the ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve, those skilled in the art can clearly understand the implementation method of the ultrasonic flaw detection device based on adaptive adjustment of the flaw detection curve in this embodiment. Therefore, for the sake of brevity, it will not be described in detail here.

[0117] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. An ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve, characterized in that, include: Based on a preset time interval, the flaw detection parameters of the ultrasonic flaw detection device are adjusted, including the transmission power and the receiving gain. Within the set time window before each adjustment node, the currently collected flaw detection curve and its corresponding flaw detection parameters are acquired, and compared and analyzed with the flaw detection curve after the previous adjustment to calculate the flaw detection curve deviation value. Based on the current flaw detection parameters, calculate the duration of continuous flaw detection while maintaining the current flaw detection parameters; The continuous flaw detection duration, the flaw detection curve deviation value, and the preset time interval are input into a preset flaw detection parameter control function to obtain the optimal flaw detection parameters for the next adjustment, and then the internally threaded copper pipe is subjected to flaw detection.

2. The ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve according to claim 1, characterized in that, Within a set time window before each adjustment node, the currently acquired flaw detection curve and its corresponding flaw detection parameters are acquired and compared with the flaw detection curve after the previous adjustment. The flaw detection curve deviation value is calculated, including: Define the time window before each adjustment node; Within the set time window, ultrasonic signals are continuously acquired and converted into digital signals; The digital signal is preprocessed by filtering, amplification, and noise reduction to remove interference signals, and the ultrasonic signal intensity value at each time point is calculated based on the processed digital signal. Plot the signal intensity value at each time point with time on the horizontal axis and ultrasonic signal intensity on the vertical axis to obtain the flaw detection curve C within the current time window. i (x), where x represents the abscissa of the flaw detection curve, the abscissa is the time axis, and i represents the i-th adjustment; The flaw detection curve C i (x) is matched one-to-one with the transmit power P and receive gain G recorded in the same time window to form a triplet (C). i (x), P, G); The currently acquired flaw detection curve C i (x) and the flaw detection curve C after the previous adjustment i−1 (x) is compared to calculate the flaw detection curve deviation value ΔC. i .

3. The ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve according to claim 2, characterized in that, The flaw detection curve deviation value ΔC i The calculation method is as follows: ； Where, ΔC i This represents the deviation value of the flaw detection curve after the i-th adjustment, where N is the number of sampling points on the flaw detection curve, and x... j This represents the x-coordinate value of the j-th sampling point.

4. The ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve according to claim 1, characterized in that, The preset time interval is set by taking into account at least the design specifications, material characteristics, and flaw detection accuracy requirements of the internally threaded copper pipe.

5. The ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve according to claim 1, characterized in that, Based on the current flaw detection parameters, the duration of continuous flaw detection while maintaining the current flaw detection parameters is calculated, including: When the ultrasonic flaw detector starts to perform flaw detection on the internally threaded copper pipe using the current flaw detection parameters, the timer is started and the time is recorded; the initial time is set to t0, at which point t0=0. During the flaw detection process, monitor in real time whether the flaw detection parameters change; Determine whether the flaw detection parameters at the current moment are the same as those at the start of flaw detection; If a change in the flaw detection parameters is detected during the flaw detection process, the timer is stopped and the time t1 is recorded. The duration of continuous flaw detection with the current flaw detection parameters is T = t1 - t0. If no change is detected in the flaw detection parameters during the flaw detection process, record the time t2 when the flaw detection ends, stop the timer, and then maintain the current flaw detection parameters for a continuous flaw detection duration T = t2 − t0.

6. The ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve according to claim 1, characterized in that, The flaw detection parameter control function is expressed as follows: ； Where T represents the duration of continuous flaw detection, ΔC i P represents the deviation value of the flaw detection curve during the i-th adjustment, Δt represents the preset time interval, and P represents the deviation value of the flaw detection curve during the i-th adjustment. t G represents the current transmit power. r P represents the current receive gain. t+1 G represents the transmit power at the next adjustment. r+1 This indicates the receive gain at the next adjustment.

7. The ultrasonic flaw detection method based on adaptive adjustment of the flaw detection curve according to claim 6, characterized in that, The formula for calculating the transmission power during the next adjustment is: ; The formula for calculating the receiver gain during the next adjustment is: ; Where α, β, γ, and δ are the weighting coefficients of the control function.

8. An ultrasonic flaw detection device based on adaptive adjustment of the flaw detection curve, characterized in that, The device includes: The flaw detection parameter adjustment module is used to adjust the flaw detection parameters of the ultrasonic flaw detection device based on a preset time interval, including the transmission power and the receiving gain. The flaw detection curve analysis module is used to acquire the currently collected flaw detection curve and its corresponding flaw detection parameters within a set time window before each adjustment node, and compare and analyze it with the flaw detection curve after the previous adjustment to calculate the flaw detection curve deviation value. The flaw detection duration statistics module is used to calculate the duration of continuous flaw detection while maintaining the current flaw detection parameters, based on the current flaw detection parameters. The flaw detection parameter optimization module is used to input the continuous flaw detection duration, flaw detection curve deviation value, and preset time interval into the preset flaw detection parameter control function to obtain the optimal flaw detection parameters for the next adjustment, and to perform flaw detection on the internally threaded copper pipe.

9. The ultrasonic flaw detection device based on adaptive adjustment of the flaw detection curve according to claim 8, characterized in that, The preset time interval is set by taking into account at least the design specifications, material characteristics, and flaw detection accuracy requirements of the internally threaded copper pipe.

10. The ultrasonic flaw detection device based on adaptive adjustment of the flaw detection curve according to any one of claims 8-9, characterized in that, The flaw detection time statistics module is configured as follows: When the ultrasonic flaw detector starts to perform flaw detection on the internally threaded copper pipe using the current flaw detection parameters, the timer is started and the time is recorded; the initial time is set to t0, at which point t0=0. During the flaw detection process, monitor in real time whether the flaw detection parameters change; Determine whether the flaw detection parameters at the current moment are the same as those at the start of flaw detection; If a change in the flaw detection parameters is detected during the flaw detection process, the timer is stopped and the time t1 is recorded. The duration of continuous flaw detection with the current flaw detection parameters is T = t1 - t0. If no change is detected in the flaw detection parameters during the flaw detection process, record the time t2 when the flaw detection ends, stop the timer, and then maintain the current flaw detection parameters for a continuous flaw detection duration of T = t2 - t0.

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