Workpiece ultrasonic detection method and system based on double-probe cooperation, electronic equipment and storage medium

Abstract

The invention discloses a workpiece ultrasonic detection method and system based on double-probe cooperation, electronic equipment and a storage medium, and relates to the technical field of workpiece detection. The double-probe cooperation-based workpiece ultrasonic detection method applied to the double-probe cooperation-based workpiece ultrasonic detection system comprises the following steps: performing single-side scanning on a to-be-detected position of a to-be-detected workpiece at a preset angle through a linear array probe and a bicrystal phased array probe, collecting a first reflection signal and a second reflection signal reflected by the to-be-detected workpiece, and transmitting the first reflection signal and the second reflection signal to a phase-controlled ultrasonic detection instrument; the first reflection signal and the second reflection signal are processed through the phase-controlled ultrasonic detection instrument, and detection data obtained through processing are sent to an upper computer; and generating a detection result of the to-be-detected workpiece according to the detection data through the upper computer. According to the invention, the full-range coverage detection of the near field and the middle-deep layer of the to-be-detected workpiece is realized, the defect detection rate and the quantitative precision are improved, and the detection efficiency is improved at the same time.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of workpiece detection, and particularly relates to a workpiece ultrasonic detection method and system based on double-probe cooperation, an electronic device and a computer readable storage medium. BACKGROUND

[0002] In the detection process of a workpiece (for example, duplex stainless steel weld detection), a traditional phased array ultrasonic testing (PAUT) scheme often adopts a single probe for detection, and has the problem that detection depth and resolution are difficult to balance. For near-surface defects, due to the characteristics of stainless steel materials, the attenuation of sound waves is relatively serious, so a single probe is difficult to achieve high-resolution identification; and for middle-deep defects, the probe needs to have better focusing characteristics and scanning range. Therefore, in order to cover defects of different depths, multiple scanning settings often need to be increased, or detection needs to be performed from both sides of the weld, which not only increases the complexity of detection steps and reduces detection efficiency, but also may cause too large detection errors due to multiple operations.

[0003] The above information disclosed in the background section of this document merely to provide background information for understanding the concepts of the present application, and therefore, it can contain information that is not prior art. SUMMARY

[0004] The main purpose of the present application is to provide a workpiece ultrasonic detection method and system based on double-probe cooperation, an electronic device and a computer readable storage medium, which aims to achieve full-range coverage detection of near-field and middle-deep defects of a workpiece to be detected, improve defect detection rate and quantitative accuracy, and improve detection efficiency.

[0005] To achieve the above purpose, the present application provides a workpiece ultrasonic detection method based on double-probe cooperation, which is applied to a workpiece ultrasonic detection system based on double-probe cooperation, and the workpiece ultrasonic detection system based on double-probe cooperation at least includes a phased ultrasonic detection instrument, a linear array probe and a double-crystal phased array probe connected with the phased ultrasonic detection instrument, and an upper computer connected with the phased ultrasonic detection instrument. The workpiece ultrasonic detection method based on double-probe cooperation includes the following steps. The linear array probe and the double-crystal phased array probe respectively perform unilateral scanning on a to-be-detected position of a workpiece to be detected at a preset angle, collect first reflected signals and second reflected signals reflected by the workpiece to be detected, and transmit the first reflected signals and the second reflected signals to the phased ultrasonic detection instrument; The phased ultrasonic detection instrument processes the first reflected signals and the second reflected signals, and sends detection data obtained by processing to the upper computer; The host computer generates a detection result of the workpiece to be detected according to the detection data, wherein the detection result at least includes a defect distribution of the workpiece to be detected.

[0006] In an embodiment, the detection result includes a workpiece defect map, and the step of generating the detection result of the workpiece to be detected according to the detection data includes: Screening, from the detection data, an indicative signal with a signal amplitude exceeding a preset reference level by a preset proportion; Screening, from the indicative signal, an indicative signal on the opposite bevel, and increasing a sensitivity calibration level corresponding to the indicative signal on the opposite bevel to obtain an updated indicative signal; Generating a workpiece defect map of the workpiece to be detected according to the updated indicative signal.

[0007] In an embodiment, before the step of performing unilateral scanning on the to-be-detected position of the workpiece to be detected by the linear array probe and the dual-crystal phased array probe at a preset angle, the method further includes: Performing performance verification on the probe wafer of the linear array probe and the dual-crystal phased array probe respectively based on a preset wafer verification rule; Calibrating the sound velocity parameter of the phased ultrasonic detection instrument according to a reference point corresponding to a preset calibration test block and a preset radius; Based on the circular arc reflecting surface of the preset calibration test block, performing bidirectional scanning on all preset refraction angles and focal length rates by the linear array probe and the dual-crystal phased array probe, and correcting the wedge delay parameter of the phased ultrasonic detection instrument when the amplitude of the reflected signal received by the phased ultrasonic detection instrument is within a preset threshold range; Performing full-angle and / or full-focal law scanning on each refraction angle and sound path of a test block with a preset side bore by the linear array probe and the dual-crystal phased array probe, determining the gain compensation value corresponding to each focal law, so that the amplitude of the reflected signal under each refraction angle reaches a preset reference level.

[0008] In an embodiment, the workpiece ultrasonic detection system based on dual-probe cooperation further includes an encoder connected to the phased ultrasonic detection instrument. Before the step of performing unilateral scanning on the to-be-detected position of the workpiece to be detected by the linear array probe and the dual-crystal phased array probe at a preset angle, the method further includes: Driving the encoder to move by the phased ultrasonic detection instrument, and recording the relative error between the sampling position corresponding to the encoder and the actual position of the encoder in real time; Calibrating the sampling position of the encoder until the relative error is lower than a preset error threshold.

[0009] In an embodiment, before the step of performing unilateral scanning on the to-be-tested position of the workpiece by the linear array probe and the dual-crystal phased array probe at a preset angle respectively, the method further comprises: smoothing a preset probe scanning path on the outer surface of the workpiece; drawing a scanning auxiliary line on the to-be-tested position of the workpiece, the scanning auxiliary line being used for positioning of the linear array probe and the dual-crystal phased array probe and indicating a scanning range; controlling a surface temperature of the workpiece within a preset temperature range, a temperature difference between the surface temperature and the calibration test block being within a preset temperature difference range.

[0010] In an embodiment, the frequency of the linear array probe is between 2-7.5 MHz, the linear array probe comprises at least 16 crystals, the dual-crystal phased array probe is a 1.5D structure, and the frequency of the dual-crystal phased array probe is 2-5 MHz.

[0011] In an embodiment, the preset angle is 90° or 270°.

[0012] In addition, the present application also provides a workpiece ultrasonic detection system based on dual-probe cooperation, which comprises at least a phased ultrasonic detection instrument, a linear array probe connected with the phased ultrasonic detection instrument, a dual-crystal phased array probe, an upper computer, and an encoder. The linear array probe and the dual-crystal phased array probe are respectively used for unilateral scanning on a to-be-tested position of a workpiece at a preset angle, collecting first reflected signals and second reflected signals reflected by the workpiece, and transmitting the first reflected signals and the second reflected signals to the phased ultrasonic detection instrument. The phased ultrasonic detection instrument is used for processing the first reflected signals and the second reflected signals, and sending detection data obtained by processing to the upper computer. The upper computer is used for generating a detection result of the workpiece according to the detection data, wherein the detection result at least comprises a defect distribution of the workpiece. The encoder is used for recording sampling positions of the linear array probe and the dual-crystal phased array probe respectively.

[0013] In addition, the present application also provides an electronic device, which comprises at least a memory, a processor, and a computer program stored on the memory and capable of running on the processor, the computer program being configured to implement the steps of the workpiece ultrasonic detection method based on dual-probe cooperation applied to the electronic device.

[0014] Further, to achieve the above object, the present application also provides a computer readable storage medium, wherein a computer program is stored on the computer readable storage medium, and the computer program is executed by a processor to implement the steps of the workpiece ultrasonic detection method based on the cooperation of double probes.

[0015] Further, to achieve the above object, the present application also provides a computer program product, comprising a computer program, wherein the computer program is executed by a processor to implement the steps of the workpiece ultrasonic detection method based on the cooperation of double probes.

[0016] The present application provides a workpiece ultrasonic detection method based on the cooperation of double probes, which is applied to a workpiece ultrasonic detection system based on the cooperation of double probes, and the workpiece ultrasonic detection system based on the cooperation of double probes at least comprises a phased ultrasonic detection instrument, a linear array probe and a double-crystal phased array probe connected with the phased ultrasonic detection instrument, and an upper computer connected with the phased ultrasonic detection instrument; the workpiece ultrasonic detection method based on the cooperation of double probes comprises: the linear array probe and the double-crystal phased array probe respectively perform unilateral scanning on a to-be-detected position of a to-be-detected workpiece at a preset angle, collect first reflected signals and second reflected signals reflected by the to-be-detected workpiece, and transmit the first reflected signals and the second reflected signals to the phased ultrasonic detection instrument; the phased ultrasonic detection instrument processes the first reflected signals and the second reflected signals, and sends detection data obtained by processing to the upper computer; and the upper computer generates a detection result of the to-be-detected workpiece according to the detection data, wherein the detection result at least comprises a defect distribution of the to-be-detected workpiece. Because the linear array probe has a wide scanning capability and flexible beam focusing characteristics, it can efficiently cover the deep area of a weld, accurately locate buried defects at different angles, and the double-crystal phased array probe has a near-field optimization design, which can effectively overcome the problem of acoustic wave attenuation existing in the near surface of a workpiece, and realize high-resolution identification of small defects on the surface and near surface of a weld. Therefore, the technical scheme of the present application combines the linear array probe and the double-crystal phased array probe, so that when the to-be-detected workpiece is detected, full-range coverage detection of the near field and the deep layer can be realized, the defect detection rate and quantitative accuracy of the workpiece are improved, and the detection efficiency is also improved. BRIEF DESCRIPTION OF DRAWINGS

[0017] The accompanying drawings, which are incorporated herein and form part of the specification, illustrate embodiments consistent with the present application and, together with the description, further serve to explain the principles of the application.

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, for those of ordinary skill in the art, other drawings can also be obtained based on these drawings without any creative effort.

[0019] Figure 1 A flowchart of a workpiece ultrasonic detection method based on double-probe cooperation applied to a workpiece ultrasonic detection system based on double-probe cooperation in the embodiments of the present application; Figure 2 A typical workpiece defect atlas of a stainless steel weld shown by a host computer in the embodiments of the present application; Figure 3 Front view, top view and side view of a verification test block in the embodiments of the present application; Figure 4 Front view and side view of a side drilling position of a test block in the embodiments of the present application; Figure 5 A principle diagram of scanning a workpiece to be measured by a preset angle in the embodiments of the present application; Figure 6 A device structure diagram of a hardware running environment of a device involved in the workpiece ultrasonic detection method based on double-probe cooperation in the embodiments of the present application.

[0020] The purposes, functional features and advantages of the present application will be further described with reference to the embodiments and the accompanying drawings. DETAILED DESCRIPTION

[0021] In order to make the above purposes, features and advantages of the present application more apparent and understandable, the technical solutions in the embodiments of the present application will be clearly and completely described with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without any creative effort fall within the scope of the present application.

[0022] It should be understood that the specific embodiments described herein are only used to explain the technical solutions of the present application, and are not used to limit the present application.

[0023] In order to better understand the technical solutions of the present application, the following will be described in detail with reference to the accompanying drawings and specific embodiments.

[0024] The embodiment of the application provides a workpiece ultrasonic detection method based on double-probe cooperation, which is applied to a workpiece ultrasonic detection system based on double-probe cooperation. The workpiece ultrasonic detection system based on double-probe cooperation comprises at least a phased ultrasonic detection instrument, a linear array probe and a double-crystal phased array probe connected with the phased ultrasonic detection instrument, and an upper computer connected with the phased ultrasonic detection instrument. Referring to Figure 1 , Figure 1 The embodiment of the application provides a workpiece ultrasonic detection method based on double-probe cooperation, which is applied to a workpiece ultrasonic detection system based on double-probe cooperation. The workpiece ultrasonic detection system based on double-probe cooperation comprises at least a phased ultrasonic detection instrument, a linear array probe and a double-crystal phased array probe connected with the phased ultrasonic detection instrument, and an upper computer connected with the phased ultrasonic detection instrument. Referring to In step S10, the linear array probe and the double-crystal phased array probe are used to perform unilateral scanning on the to-be-detected position of the workpiece at a preset angle, respectively. The first reflection signal and the second reflection signal reflected by the workpiece are collected, and the first reflection signal and the second reflection signal are transmitted to the phased ultrasonic detection instrument. In the technical scheme of the embodiment of the application, the linear array probe and the double-crystal phased array probe are combined, and the unilateral detection process is used to realize the full-range coverage detection of the to-be-detected position (for example, the stainless steel weld) of the workpiece. The linear array probe can cover the deep layer area of the weld by using the wide scanning and flexible sound beam focusing characteristics, and the double-crystal phased array probe overcomes the problem of near-surface acoustic wave attenuation by the near-field optimization design. The two probes work together to make up for the limitations of a single probe in detection depth and resolution, and break through the limitation of insufficient space for detecting both sides of a complex structure. Moreover, the technical scheme of the embodiment of the application does not need multiple probes to scan in sequence, thereby reducing the cumbersome steps such as multiple scanning settings and multiple side detection. The detection efficiency is greatly improved while the reliability of workpiece defect detection is ensured, and a more intelligent and efficient solution is provided for the quality control of stainless steel welds.

[0025] For example, when the workpiece is scanned, the phased ultrasonic detection instrument can send a control instruction to control the linear array probe and the double-crystal phased array probe to emit ultrasonic signals. After the ultrasonic signals emitted by the probes are reflected by the to-be-detected position of the workpiece, the first reflection signal (corresponding to the emission signal of the linear array probe) and the second reflection signal (corresponding to the emission signal of the double-crystal phased array probe) are generated. The frequency, wavelength, penetration depth and resolution of different probes are different, so when each probe receives the reflection signal, it only receives the reflection signal corresponding to the parameters of its own emission signal. Thus, the linear array probe and the double-crystal phased array probe receive the respective first reflection signal and second reflection signal, which are then transmitted back to the phased ultrasonic detection instrument. The first reflection signal and the second reflection signal are used to reflect the characteristics of the deep layer area of the workpiece and the characteristics of the surface layer and near-surface area of the workpiece, respectively.

[0026] Step S20, the first reflection signal and the second reflection signal are processed by the phased ultrasonic detection instrument, and the detection data obtained by processing is sent to the upper computer; After the phased ultrasonic detection instrument receives the first reflection signal and the second reflection signal, it processes them, converts the signal data such as the first reflection signal and the second reflection signal into detection data reflecting the structural characteristics (such as the existence of cavities, notches, etc.) of the surface, near-surface, middle layer, deep layer, etc. of the workpiece to be tested, so that the upper computer can analyze the defect condition of the workpiece to be tested through the detection data.

[0027] Step S30, the detection result of the workpiece to be tested is generated by the upper computer according to the detection data, wherein the detection result at least includes the defect distribution of the workpiece to be tested.

[0028] The upper computer can be a computer with a display. The upper computer can send the detection data reflecting the structural characteristics of the workpiece to be tested to the upper computer. The upper computer can evaluate and analyze the detection data to generate intuitive and visual detection results and display them through the display. The detection result can include a welding workpiece defect map, which is mainly used to identify and classify various defects generated in the welding process. Common types include pores, incomplete fusion, slag inclusion, cracks, etc. In addition, the detection result can also include a detection report containing instrument parameters, calibration records, defect information, evaluation conclusions, etc., to ensure completeness, accuracy and traceability.

[0029] The workpiece ultrasonic detection method based on the cooperation of the double probes provided by the embodiment of the application forms full-range detection coverage of the near field and the middle near layer through the cooperative work of the linear array probe and the double-crystal phased array probe, makes up for the limitations of single probe in detection depth and resolution, can accurately locate different angle buried defects in the deep layer of the weld, can efficiently identify small defects on the surface and near the surface, and improves the defect detection rate and quantitative accuracy. Moreover, by using the single-sided operation mode, the limitation of insufficient detection space on both sides of the complex structure is broken through, and the detection application range is expanded. The double-probe cooperative scanning reduces the cumbersome steps of increasing multiple scanning settings and multiple-side detection, improves the detection efficiency while ensuring the detection reliability, and provides a more intelligent and efficient solution for workpiece detection, especially for stainless steel weld quality control.

[0030] Further, the detection result includes a workpiece defect map, and the step of generating the detection result of the workpiece to be tested according to the detection data can include: Step S31, screening out indicative signals with signal amplitude exceeding a preset reference level by a preset proportion from the detection data; Step S32, screening the indicative signal on the opposite bevel groove from the indicative signal, and increasing the sensitivity calibration level corresponding to the indicative signal on the opposite bevel groove to obtain an updated indicative signal; Step S33, generating a workpiece defect map of the workpiece to be detected according to the updated indicative signal.

[0031] Exemplarily, the host computer can present the detection result of the workpiece to be detected in the form of a workpiece defect map. Specifically, in the process of evaluating and analyzing the detection data, the host computer first screens the indicative signal that needs to be analyzed in detail. In the embodiment of the present application, the signal whose signal amplitude exceeds the preset reference level by a preset proportion is taken as the indicative signal. The preset reference level can be determined in advance and reflects the minimum controllable level of the defect analysis and detection of the workpiece to be detected. The preset proportion is a fixed value (such as 20%). Only the signal exceeding the reference level by 20% has the value of further detailed analysis. The signals with relatively low amplitudes can be considered as interference signals or as having no analysis value.

[0032] Exemplarily, the host computer can use OmniPC (a kind of Olympus nondestructive testing software), WeldSight (for weld detection and nondestructive testing) and the like in the process of evaluating and analyzing the data.

[0033] In addition, in order to ensure that the reflection signals in each direction are analyzed in detail and key information is not missed, the sensitivity calibration level of the indicative signal on the opposite bevel groove which has relatively weak signal strength is increased (for example, by 6 dB). The opposite bevel groove refers to the direction opposite to the direction directly facing the probe when the probe is performing single-side scanning. Since the transmitted signal received by this part is weak, the reflected signal is also weak. Therefore, in order to overcome the influence of weak signal strength, the sensitivity calibration level needs to be increased so that the characteristics of the reflected signal are more obviously exhibited.

[0034] Finally, according to the indicative signal after adjusting the sensitivity calibration level and the indicative signal without adjusting the sensitivity calibration level, a workpiece defect map is generated. Exemplarily, in the process of generating the workpiece defect map, the echo amplitude, propagation time and the like corresponding to the indicative signal at each position on the workpiece to be detected are first recorded. Subsequently, these data are converted into image pixels, in which the brightness or color represents the echo intensity and the position corresponds to the defect spatial coordinates, and finally a direct two-dimensional or three-dimensional workpiece defect map is formed, such as S-scan (fan-shaped scanning) and C-scan (used to display the projection distribution of defects on the detection surface of the workpiece). Figure 2 As shown in the figure, the highlighted part (i.e. the part with red, green or yellow color) represents the workpiece defect, and the coordinates of the highlighted part are the position of the defect. The left map corresponds to C-scan, and the right fan-shaped map corresponds to S-scan.

[0035] Exemplarily, when the to-be-tested position of the to-be-tested workpiece is a stainless steel weld, the following steps can be included in the process of scanning, data collection, evaluation and report issuing of the to-be-tested workpiece by the probe and the instrument: reference surface setting, using a permanent marker arrow on one side of the to-be-tested workpiece to clearly indicate the reference point as the starting position of the probe scanning; base material integrity detection: before detection, use a straight probe to detect the base material on both sides of the weld for phased array detection position ultrasonic detection, and check for delamination defects, and if abnormal signals are found, detailed records need to be kept; transmission correction: when there is a difference in material acoustic properties between the calibration block and the to-be-tested workpiece, transmission correction is performed; scanning data collection: according to the pre-determined scanning plan, the detection range, weld identification and position information are clearly indicated, and scanning is performed from one side of the weld; setting and calibration verification: every 4 hours or after completing a batch of detection, use a standard reference block to verify the instrument settings, and if the parameter deviation exceeds the standard, recalibration and rescan or data correction need to be performed; data evaluation: investigate the indicative signals with signal amplitude exceeding the reference level by 20%, and the evaluation reference for the indicative signals on the relative slope is the sensitivity calibration level plus 6 dB; distinguish non-related signals, and if necessary, confirm the reflector properties by combining other non-destructive testing methods; defect analysis and size measurement: combine A-scan (amplitude scan), S-scan (three-dimensional imaging), B-scan (cross-section imaging) and C-scan (constant depth scanning) to analyze and measure the defects, and clearly indicate the position, length and depth of the unqualified defects; report preparation: issue a detection report containing instrument parameters, calibration records, defect information, evaluation conclusions and other contents, and ensure the integrity, accuracy and traceability.

[0036] Further, in a feasible embodiment, before the step of performing single-sided scanning on the to-be-tested position of the to-be-tested workpiece by the linear array probe and the dual-crystal phased array probe at a preset angle, the method can further include: Step A10, performing performance verification on the probe wafers of the linear array probe and the dual-crystal phased array probe based on a preset wafer verification rule; Before performing scanning on the to-be-tested workpiece by the linear array probe and the dual-crystal phased array probe and the phased array ultrasonic detection instrument, in order to ensure the accuracy of the probe and the instrument, performance verification and parameter calibration are needed. Specifically, in the wafer performance verification, it is necessary to ensure that the signal difference between adjacent wafers does not exceed 3 decibels (dB), the number of failed wafers does not exceed 10% of the total number of probe wafers, and no more than two adjacent wafers fail at the same time. Under the condition of meeting the above conditions, it is determined that the performance verification is passed. Otherwise, the linear array probe and the dual-crystal phased array probe need to be repaired or new linear array probes and dual-crystal phased array probes need to be replaced, so that subsequent detection can be performed.

[0037] Step A20, calibrating the sound velocity parameter of the phased array ultrasonic detection instrument according to the reference point corresponding to the preset calibration block and the preset radius; The calibration test block is used for calibrating the standard workpiece of the instrument, such as Figure 3 As shown in FIG. 1, (a), (b) and (c) are respectively the front view, top view and side view of the calibration test block, R30 and R50 are respectively different preset radii, and other values such as 350.00 mm, 300.00 mm and 250.00 mm are respectively the sizes of various reference points on the calibration test block, and 45° is the angle on the front view.

[0038] Exemplarily, the TWI (The Welding Institute, British Welding Institute) preset standard calibration test block can be selected for the acoustic velocity calibration, and the 30 mm and 50 mm radii on the test block are used as the acoustic coupling reference points, the two probes are stably coupled to the two points, and after the reflected signals are collected, the phased ultrasonic detection instrument automatically calculates and calibrates the acoustic velocity parameter through the built-in algorithm.

[0039] In step A30, based on the preset circular arc reflection surface of the calibration test block, the linear array probe and the double-crystal phased array probe are used to perform bidirectional scanning on all preset refraction angles and focal length rates, and when the amplitude of the reflected signal received by the phased ultrasonic detection instrument is within the preset threshold range, the wedge delay parameter of the phased ultrasonic detection instrument is corrected. Exemplarily, based on the circular arc reflection surface of the calibration test block (TWI), bidirectional scanning is performed on all preset refraction angles and focal length rates, and when the amplitudes of the reflected signals are within the threshold range, the system automatically corrects the wedge delay parameter.

[0040] In step A40, the linear array probe and the double-crystal phased array probe are used to perform full-angle and / or full-focal length rate scanning on the test block with the preset side drill hole for each refraction angle and acoustic path, and the gain compensation value corresponding to each focal length rate is determined to make the amplitude of the reflected signal under each refraction angle reach the preset reference level.

[0041] In the embodiment of the present application, for each refraction angle and acoustic path, the side drill hole (SDH, Side Drilled Hole) with a known depth is used as the test block (as shown in FIG. 2). Figure 4 As shown in FIG. 2, the circle represents the side drill hole position, 1 / 3T and 2 / 3T represent the drill hole depth, (a) represents the schematic diagram of the test block with the side drill hole in the front direction, and (b) represents the schematic diagram of the test block with the side drill hole in the side direction. Specifically, in the calibration process, the gain compensation value required by each focal length rate can be automatically calculated by full-angle or full-focal length rate scanning, so that the amplitudes of the SDH reflected signals under different angles reach the preset unified reference level.

[0042] In another possible embodiment, the phased array ultrasonic testing instrument can also be calibrated for time corrected gain (TCG): adjust the gain from the SDH reflected signal to make the amplitude of the target reflector reach 80% of the full screen height (FSH); move the probe forward and backward to keep the signal amplitudes corresponding to all focal laws and refraction angles consistent, and mark the first calibration point; control the probe to move to the symmetric bore on the other side of the test block, repeat the operation and mark the second calibration point; the phased array ultrasonic testing instrument automatically generates a gain compensation curve based on the two-point attenuation characteristics to complete the TCG calibration.

[0043] In a possible embodiment, the workpiece ultrasonic testing system based on dual-probe cooperation further comprises an encoder connected to the phased array ultrasonic testing instrument. Before the step of performing unilateral scanning on the to-be-tested position of the workpiece by the linear array probe and the dual-crystal phased array probe at preset angles, the method can further comprise: Step B10: Move the encoder by driving it through the phased array ultrasonic testing instrument, and record the relative error between the sampling position corresponding to the encoder and the actual position of the encoder in real time; Step B20: Calibrate the sampling position of the encoder until the relative error is lower than a preset error threshold.

[0044] Before formally scanning the to-be-tested workpiece, the encoder needs to be calibrated in addition to calibrating the probe and the instrument. Specifically, the displacement accuracy calibration process is included, and the displacement of the encoder is embodied by the sampling position, so the deviation between the displacement displayed by the instrument and the actual physical displacement can be recorded by driving the encoder to move a preset distance (e.g., more than 500 mm), and the relative error should not exceed 1%. If the error exceeds the threshold, the sampling position of the encoder needs to be recalibrated and the relative error needs to be verified until the relative error is lower than 1%.

[0045] In another possible embodiment, the resolution of the encoder can also be set. The resolution of the encoder can be set to a maximum of 1 mm to ensure the positioning accuracy of the probe scanning position.

[0046] In another possible embodiment, before the step of performing unilateral scanning on the to-be-tested position of the workpiece by the linear array probe and the dual-crystal phased array probe at preset angles, the method can further comprise: Step C10: Smooth the preset probe scanning path on the outer surface of the to-be-tested workpiece; It should be noted that before scanning the to-be-tested workpiece, the surface needs to be finished first. The preset probe scanning path needs to be polished to remove impurities such as splashes and rust, so as to ensure that the surface is smooth and flat, and the gap between the treated surface and the probe should not be greater than 0.5 mm.

[0047] Step C20, draw a scanning auxiliary line on the to-be-tested position of the to-be-tested workpiece, which is used for positioning and indicating the scanning range of the linear array probe and the dual-crystal phased array probe; It is also necessary to mark the to-be-tested workpiece, for example, draw a clear scanning auxiliary line on the to-be-tested position (such as the edge of a stainless steel weld), which is used as a reference for positioning and indicating the scanning range of the probe, to ensure that the entire weld area and heat affected zone (HAZ) are covered.

[0048] Step C30, control the surface temperature of the to-be-tested workpiece within a preset temperature range, and control the temperature difference between the calibration block and the surface of the workpiece within a preset temperature difference range.

[0049] It is necessary to control the surface temperature of the to-be-tested workpiece within the range of 0°C to 50°C, and the temperature difference between the calibration block and the surface of the workpiece within 14°C, to ensure the calibration accuracy.

[0050] It should be noted that after the to-be-tested workpiece (such as a stainless steel weld) is welded for 24 hours and passes the visual inspection (VI), it is confirmed that there are no macroscopic defects and surface discontinuities, and then the workpiece ultrasonic detection based on the dual-probe cooperation is carried out.

[0051] In a feasible embodiment, the frequency of the linear array probe is between 2-7.5 MHz, and the linear array probe contains at least 16 crystals. The dual-crystal phased array probe is a 1.5D structure, and the frequency of the dual-crystal phased array probe is 2-5 MHz.

[0052] By selecting a linear array probe with a frequency of 2-7.5 MHz and at least 16 crystals, the wide scanning capability and flexible beam focusing characteristics are used to efficiently cover the deep area of the weld and accurately locate the buried defects at different angles.

[0053] In addition, the linear array probe adopts a 1.5D structure, which is divided into transmitting and receiving parts, and has a frequency of 2-5 MHz. Through the unique near-field optimization design, the problem of near-surface acoustic wave attenuation of stainless steel materials can be effectively overcome, and high-resolution identification of small defects on the surface and near-surface of the weld can be achieved.

[0054] In a feasible embodiment, the preset angle is 90° or 270°.

[0055] Exemplarily, when the to-be-tested workpiece is scanned by the dual-probe on one side, the preset angle of the probe tilt can be set to 90° or 270° to ensure that the beam covers the entire cross-section of the weld and the heat affected zone; the scanning speed needs to meet the requirement that the number of data lines missing (drop-out) per 25 mm linear scanning length is less than 2, and there is no adjacent data line missing.

[0056] like Figure 5 As shown, the probe scans the workpiece under test in a scanning direction at a preset angle. The area covered by the transmitted and reflected signals is shown by the dotted line in the figure. -10.00mm is the distance between the weld center and the probe. The thickness of the workpiece under test is 9.53mm.

[0057] Based on the aforementioned embodiment of the workpiece ultrasonic testing method based on dual-probe collaboration, efficient detection of stainless steel welds in the "near field to medium-deep" range has been successfully achieved. According to practical data, the defect detection rate of stainless steel welds has been increased by 20% and the detection efficiency has been increased by 30% compared with traditional detection methods, achieving good application results.

[0058] This application embodiment also provides a workpiece ultrasonic testing system based on dual-probe collaboration. The workpiece ultrasonic testing system based on dual-probe collaboration includes at least a phased array ultrasonic testing instrument, a linear array probe connected to the phased array ultrasonic testing instrument, a dual-crystal phased array probe, a host computer, and an encoder. Linear array probes and dual-crystal phased array probes are used to scan the test position of the workpiece at a preset angle on one side, collect the first reflection signal and the second reflection signal reflected by the workpiece, and transmit the first reflection signal and the second reflection signal to the phased ultrasonic testing instrument. The phased-array ultrasonic testing instrument is used to process the first and second reflection signals and send the processed test data to the host computer. The host computer is used to generate the detection results of the workpiece under test based on the detection data. The detection results include at least the defect distribution of the workpiece under test. The encoder is used to record the sampling positions of the linear array probe and the dual-crystal phased array probe, respectively.

[0059] In one feasible embodiment, the workpiece ultrasonic testing system based on dual-probe collaboration also includes calibration blocks and reference blocks, such as TWI blocks, IIW blocks, etc., for calibrating phased-array ultrasonic testing instruments.

[0060] The ultrasonic testing system for workpieces based on dual-probe collaboration provided in this application adopts the ultrasonic testing method for workpieces based on dual-probe collaboration described in the above embodiments. It can achieve full-range coverage testing of the near-field and mid-to-deep layers of the workpiece under test, improving defect detection rate and quantitative accuracy, while also increasing testing efficiency. Compared with the prior art, the beneficial effects of the ultrasonic testing system for workpieces based on dual-probe collaboration provided in this application are the same as those of the ultrasonic testing method for workpieces based on dual-probe collaboration described in the above embodiments. Furthermore, other technical features of this ultrasonic testing system for workpieces based on dual-probe collaboration are the same as those disclosed in the methods of the above embodiments, and will not be repeated here.

[0061] The embodiments of the present application also provide an electronic device, including at least one processor, and a memory connected with the at least one processor in communication; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor to enable the at least one processor to perform the method for workpiece ultrasonic detection based on double-probe cooperation in the above embodiments.

[0062] Reference will be made to the following description Figure 6 which shows a structural schematic diagram of an electronic device suitable for implementing the embodiments of the present application. Figure 6 The electronic device shown is merely an example, and should not bring any limitation to the functions and use range of the embodiments of the present application.

[0063] As shown in Figure 6 , the electronic device can include a processing device 1001 (for example, a central processor, a graphics processor, etc.), which can perform various appropriate actions and processes according to programs stored in a read-only memory (ROM) 1002 or programs loaded from a storage device 1003 to a random access memory (RAM) 1004. In the RAM 1004, various programs and data required for the operation of the electronic device are also stored. The processing device 1001, the ROM 1002, and the RAM 1004 are connected to each other through a bus 1005. An input / output (I / O) interface 1006 is also connected to the bus. Generally, the following systems can be connected to the I / O interface 1006: an input device 1007 including, for example, a touch screen, a touchpad, a keyboard, a mouse, an image sensor, a microphone, an accelerometer, a gyroscope, etc.; an output device 1008 including, for example, a liquid crystal display (LCD), a speaker, a vibrator, etc.; a storage device 1003 including, for example, a magnetic tape, a hard disk, etc.; and a communication device 1009. The communication device 1009 can allow the electronic device to communicate with other devices wirelessly or by wire to exchange data. Although the electronic device with various systems is shown in the figure, it should be understood that it is not required to implement or have all the systems shown. More or fewer systems can be alternatively implemented or provided.

[0064] In particular, according to embodiments of the present disclosure, the processes described above with reference to the flowcharts can be implemented as a computer software program. For example, embodiments of the present disclosure include a computer program product comprising a computer program carried on a computer readable medium, the computer program containing program code for performing the methods illustrated by the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via a communication device, or installed from a storage device 1003, or installed from a ROM 1002. When the computer program is executed by the processing device 1001, the above-mentioned functions defined in the methods of the embodiments of the present application are performed.

[0065] The electronic device provided by the embodiments of the present application adopts the workpiece ultrasonic detection method based on double probe cooperation in the above embodiments, which can realize full-range coverage detection of near field and middle deep layer of the workpiece to be detected, improve the defect detection rate and quantitative accuracy, and improve the detection efficiency. Compared with the prior art, the electronic device provided by the embodiments of the present application has the same beneficial effects as the workpiece ultrasonic detection method based on double probe cooperation provided by the above embodiments, and other technical features in the electronic device are the same as the features disclosed in the above-mentioned embodiment method, which will not be repeated here.

[0066] It should be understood that parts of the embodiments of the present application can be realized by hardware, software, firmware or a combination thereof. In the description of the above embodiments, specific features, structures, materials or characteristics can be combined in any one or more embodiments or examples in a suitable manner.

[0067] The above describes only specific implementation of the embodiments of the present application, but the protection scope of the embodiments of the present application is not limited thereto. Any person skilled in the art can easily think of changes or replacements within the technical scope disclosed by the present application, which should be covered within the protection scope of the embodiments of the present application. Therefore, the protection scope of the embodiments of the present application should be subject to the protection scope of the above claims.

[0068] The embodiments of the present application also provide a computer readable storage medium storing a computer program capable of running on a processor, and the computer program is used to execute the workpiece ultrasonic detection method based on double probe cooperation in the above embodiments.

[0069] The computer readable storage medium provided by the embodiments of the present application may, for example, be a U disk, but is not limited to an electric, magnetic, optical, electromagnetic, infrared, or semiconductor system or device, or any combination thereof. More specific examples of the computer readable storage medium may include, but are not limited to, an electric connection with one or more conductive wires, a portable computer disk, a hard disk, a random access memory (RAM), a read only memory (ROM), an erasable programmable read only memory (EPROM or flash memory), an optical fiber, a portable compact disk read only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination thereof. In the embodiments, the computer readable storage medium may be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system, system, or device. The program code contained on the computer readable storage medium can be transmitted by any suitable medium, including but not limited to an electric wire, an optical cable, an RF (Radio Frequency), and the like, or any suitable combination thereof.

[0070] The computer readable storage medium described above may be contained in an electronic device, or may exist separately without being assembled into an electronic device.

[0071] The computer readable storage medium described above carries one or more programs, which, when executed by an electronic device, cause the electronic device to: perform unilateral scanning on a to-be-tested position of a to-be-tested workpiece at a preset angle by a linear array probe and a double-crystal phased array probe respectively, collect first and second reflection signals reflected by the to-be-tested workpiece, and transmit the first and second reflection signals to a phased ultrasonic detection instrument; process the first and second reflection signals by the phased ultrasonic detection instrument, and send detection data obtained by processing to an upper computer; and generate a detection result of the to-be-tested workpiece according to the detection data by the upper computer, wherein the detection result at least includes a defect distribution of the to-be-tested workpiece.

[0072] Computer program code for carrying out operations of the present disclosure can be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like, and conventional procedural programming languages, such as the "C" programming language or similar programming languages. The program code can execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer can be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection can be made to an external computer (for example, through the Internet using an Internet Service Provider).

[0073] The flow diagrams and the block diagrams in the drawings are illustrations of architectures, functionalities, and operations of possible implementations of systems, methods, and computer program products according to various embodiments of the present application. In this regard, each block in the flow diagrams or block diagrams can represent a module, a segment, or a portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that in some alternative implementations, the functions noted in the blocks can occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently or the blocks may

[0074] The modules involved in the embodiments of the present application can be implemented in the form of software or in the form of hardware. In some cases, the name of the module does not constitute a limitation on the module itself.

[0075] The computer readable storage medium provided by the embodiments of the present application stores computer readable program instructions for executing the above-mentioned workpiece ultrasonic detection method based on the cooperation of double probes, which can realize full-range coverage detection of near field and middle deep layer of the workpiece to be detected, improve the defect detection rate and quantitative accuracy, and improve the detection efficiency. Compared with the prior art, the computer readable storage medium provided by the embodiments of the present application has the same beneficial effects as the workpiece ultrasonic detection method based on the cooperation of double probes provided by the above-mentioned embodiments, and will not be described here.

[0076] The embodiment of the present application further provides a computer program product comprising a computer program, which, when executed by a processor, implements the steps of the workpiece ultrasonic detection method based on double-probe cooperation as described above.

[0077] The computer program product provided by the embodiment of the present application can realize full-range coverage detection of near field and deep layer of the workpiece to be detected, improve defect detection rate and quantitative accuracy, and improve detection efficiency. Compared with the prior art, the beneficial effects of the computer program product provided by the embodiment of the present application are the same as those of the workpiece ultrasonic detection method based on double-probe cooperation provided by the above-mentioned embodiment, and will not be repeated here.

[0078] The above is only the preferred embodiment of the present application, and does not limit the patent scope of the present application. Any equivalent structure or equivalent process transformation using the content of the specification and drawings, or direct or indirect application in other related technical fields, is also included in the patent processing scope of the present application.

Claims

1. A method for ultrasonic testing of a workpiece based on dual probe cooperation, characterized in that, The application is applied to a workpiece ultrasonic detection system based on double probe cooperation, which comprises a phased ultrasonic detection instrument, a linear array probe and a double crystal phased array probe connected with the phased ultrasonic detection instrument, and a host computer connected with the phased ultrasonic detection instrument. The workpiece ultrasonic detection method based on double probe cooperation comprises the following steps: The linear array probe and the double crystal phased array probe are used to perform unilateral scanning on a to-be-detected position of a to-be-detected workpiece at a preset angle, collect first reflected signals and second reflected signals reflected by the to-be-detected workpiece, and transmit the first reflected signals and the second reflected signals to the phased ultrasonic detection instrument; The first reflected signals and the second reflected signals are processed by the phased ultrasonic detection instrument, and detection data obtained by processing is sent to the host computer; The host computer generates a detection result of the to-be-detected workpiece according to the detection data, wherein the detection result at least comprises defect distribution of the to-be-detected workpiece.

2. The dual-probe collaboration based workpiece ultrasonic testing method of claim 1, wherein, The detection result comprises a workpiece defect map, and the step of generating the detection result of the to-be-detected workpiece according to the detection data comprises the following steps: Indicative signals with a signal amplitude exceeding a preset reference level by a preset proportion are screened from the detection data; Indicative signals on the opposite bevel are screened from the indicative signals, and a sensitivity calibration level corresponding to the indicative signals on the opposite bevel is improved to obtain updated indicative signals; According to the updated indicative signals, a workpiece defect map of the to-be-detected workpiece is generated.

3. The dual-probe collaboration based workpiece ultrasonic testing method of claim 1, wherein, Before the step of performing unilateral scanning on the to-be-detected position of the to-be-detected workpiece at a preset angle by the linear array probe and the double crystal phased array probe, the method further comprises the following steps: The probe wafers of the linear array probe and the double crystal phased array probe are respectively subjected to performance verification based on a preset wafer verification rule; The sound velocity parameter of the phased ultrasonic detection instrument is calibrated according to a reference point corresponding to a preset calibration test block and a preset radius; Based on the arc reflection surface of the preset calibration test block, the linear array probe and the double crystal phased array probe are used to perform bidirectional scanning on all preset refraction angles and focal length rates, and the wedge delay parameter of the phased ultrasonic detection instrument is corrected when the reflected signal amplitude received by the phased ultrasonic detection instrument is within a preset threshold range; The linear array probe and the double crystal phased array probe are used to perform full-angle and / or full-focal law scanning on a test block with a preset side borehole for each refraction angle and sound path, and gain compensation values corresponding to each focal law are determined so that the reflected signal amplitude under each refraction angle reaches a preset reference level.

4. The dual-probe collaboration based workpiece ultrasonic testing method of claim 3, wherein, The workpiece ultrasonic detection system based on double probe cooperation further comprises an encoder connected with the phased ultrasonic detection instrument. Before the step of performing unilateral scanning on the to-be-detected position of the to-be-detected workpiece at a preset angle by the linear array probe and the double crystal phased array probe, the method further comprises the following steps: drive the encoder to move by the phased ultrasonic detection instrument, and record the relative error between the sampling position corresponding to the encoder and the actual position of the encoder in real time; calibrate the sampling position of the encoder until the relative error is lower than a preset error threshold.

5. The dual-probe collaboration based workpiece ultrasonic testing method of claim 3, wherein, Before the step of performing unilateral scanning on the to-be-detected position of the workpiece by the linear array probe and the dual-crystal phased array probe at a preset angle respectively, the method further comprises: smooth the preset probe scanning path on the outer surface of the workpiece; draw a scanning auxiliary line on the to-be-detected position of the workpiece, the scanning auxiliary line being used for positioning of the linear array probe and the dual-crystal phased array probe and indicating a scanning range; control the surface temperature of the workpiece within a preset temperature range, and the temperature difference between the surface temperature and the calibration test block is within a preset temperature difference range.

6. The dual-probe collaboration based workpiece ultrasonic testing method according to any one of claims 1 to 5, wherein, The frequency of the linear array probe is 2-7.5 MHz, the linear array probe comprises at least 16 wafers, the dual-crystal phased array probe is a 1.5D structure, and the frequency of the dual-crystal phased array probe is 2-5 MHz.

7. The dual-probe collaboration based workpiece ultrasonic testing method according to any one of claims 1 to 5, wherein, The preset angle is 90° or 270°.

8. A dual-probe cooperative based workpiece ultrasonic testing system, characterized in that, The workpiece ultrasonic detection system based on dual-probe cooperation at least comprises a phased ultrasonic detection instrument, a linear array probe connected with the phased ultrasonic detection instrument, a dual-crystal phased array probe, an upper computer, and an encoder; The linear array probe and the dual-crystal phased array probe are respectively used for performing unilateral scanning on a to-be-detected position of a workpiece at a preset angle, collecting first reflected signals and second reflected signals reflected by the workpiece, and transmitting the first reflected signals and the second reflected signals to the phased ultrasonic detection instrument; The phased ultrasonic detection instrument is used for processing the first reflected signals and the second reflected signals, and sending detection data obtained by processing to the upper computer; The upper computer is used for generating a detection result of the workpiece according to the detection data, wherein the detection result at least comprises a defect distribution of the workpiece; The encoder is used for recording sampling positions of the linear array probe and the dual-crystal phased array probe respectively.

9. An electronic device, comprising: The electronic device at least comprises a memory, a processor, and a computer program stored on the memory and executable on the processor, the computer program being configured to implement the steps of the workpiece ultrasonic detection method based on dual-probe cooperation according to any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer readable storage medium stores a program for implementing the workpiece ultrasonic detection method based on dual-probe cooperation, and the program for implementing the workpiece ultrasonic detection method based on dual-probe cooperation is executed by the processor to implement the steps of the workpiece ultrasonic detection method based on dual-probe cooperation according to any one of claims 1 to 7.

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