A cascade cooperative measurement method of an electromagnetic ultrasonic thickness measurement module

Abstract

The application discloses a kind of electromagnetic ultrasonic thickness measurement module cascade cooperative measurement methods, it is characterized in comprising the following steps: (1) using multiple electromagnetic ultrasonic thickness measurement module to form cascade measurement system, each module is connected by cascade interface, each electromagnetic ultrasonic thickness measurement module is sequentially defined as first channel module, second channel module …… nth channel module along cascade order;(2) each channel module is sequentially staggered into ultrasonic wave emission and receiving work cycle;(3) each channel module is in ultrasonic wave emission and receiving work cycle, using the way of gradually increasing interval time interval transmission trigger pulse signal, carries out ultrasonic wave emission and receiving work.This cascade cooperative measurement method can realize the cooperative measurement of multiple channel modules, and can avoid the mutual interference of each channel module while improving the overall measurement efficiency, adapt to the multi-measurement point high-speed scanning demand of large component.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic testing, and in particular to a cascaded collaborative measurement method for electromagnetic ultrasonic thickness measurement modules. Background Technology

[0002] In the field of industrial non-destructive testing, the thickness measurement of large components (such as pipes, storage tanks, plates, etc.) is a key link to ensure the safe operation of equipment. These large components need to be rapidly scanned or simultaneously monitored by multiple preset measurement points using ultrasonic thickness measuring devices with multiple modules and multiple channels. However, traditional multi-channel thickness measurement devices have the following drawbacks: First, electromagnetic coupling interference is severe during synchronous transmission. The high-energy electromagnetic fields of each channel superimpose, which can easily lead to saturation or even damage of the receiving channel. The effective signal is overwhelmed by clutter, the signal-to-noise ratio drops sharply, and it becomes impossible to distinguish individual echoes. In addition, the instantaneous power consumption peak is extremely high, which places stringent requirements on the power supply. Second, the simple polling mode is inefficient. If each channel is allowed to work independently in sequence (A ends, then B ends, then C ends), although interference is avoided, the detection cycle increases linearly with the number of channels, making it difficult to meet the needs of high-speed detection. Third, in industrial scenarios, different measurement points of the same large component may have material differences and thickness gradients, and the scanning speed and measurement priority requirements are also different. The transmission parameters (such as excitation frequency and transmission cycle) of traditional multi-channel thickness measurement devices are mostly fixed settings and cannot be dynamically adjusted according to the actual situation of the specific measurement point. They lack intelligent coordination mechanisms and cannot dynamically adjust the transmission strategy according to the measurement scenario, resulting in extremely poor flexibility. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a cascaded collaborative measurement method for electromagnetic ultrasonic thickness measurement modules. This cascaded collaborative measurement method can realize the collaborative measurement of multiple channels and improve the overall measurement efficiency while avoiding mutual interference between the channels and modules, and is suitable for the high-speed scanning requirements of multiple measurement points of large components.

[0004] To solve the above technical problems, the following technical solution is adopted:

[0005] A cascaded collaborative measurement method for electromagnetic ultrasonic thickness measurement modules, characterized by the following steps:

[0006] (1) A cascaded measurement system is formed by multiple electromagnetic ultrasonic thickness measurement modules. Each module is connected through a cascade interface. Each electromagnetic ultrasonic thickness measurement module is sequentially designated as the first channel module, the second channel module, ... the nth channel module in the cascade order.

[0007] (2) Each channel module enters the ultrasonic transmission and reception cycle in a staggered manner;

[0008] (3) During the ultrasonic transmission and reception cycle, each channel module transmits trigger pulse signals at intervals with gradually increasing intervals to perform ultrasonic transmission and reception.

[0009] The aforementioned cascaded measurement system consists of multiple electromagnetic ultrasonic thickness measurement modules connected in series via a cascade interface. It is suitable for simultaneous measurement of multiple measurement points on large components (such as pipes, tanks, and plates), and the number of channel modules can be flexibly increased or decreased according to the measurement range to adapt to different scenarios. Secondly, each channel module enters its working cycle sequentially in a staggered manner. This solves the problem of simultaneous transmission interference between channel modules, avoids mutual coupling of high-energy electromagnetic fields between channel modules, and prevents the receiving channel from being saturated by strong transmitted signals. Compared to a simple polling mode, this method does not require waiting for the previous channel module to complete its full working cycle before starting the next channel module. The overall measurement efficiency can be as close as possible to the level of a single channel, meeting the requirements of high-speed scanning. Within their respective working cycles, each channel module transmits trigger pulse signals at incremental intervals. This avoids signal superposition interference caused by continuous transmission within a single module, improves the signal-to-noise ratio of the measurement signal, ensures accurate identification of the echo signal, and also adapts to the differences in ultrasonic propagation time for workpieces of different thicknesses.

[0010] In a preferred embodiment, the electromagnetic ultrasonic thickness measurement module includes a signal receiving board, an electromagnetic ultrasonic excitation board, a data processing and transmission board, and an electromagnetic ultrasonic thickness measurement probe, which are stacked sequentially from top to bottom. The signal receiving board is equipped with a first power supply circuit and an ultrasonic signal acquisition and analog signal receiving amplification circuit. The electromagnetic ultrasonic excitation board is equipped with a second power supply circuit, a probe interface circuit, and a high-voltage excitation circuit. The data processing and transmission board is equipped with an analog-to-digital conversion circuit, a digital processing circuit, a network communication interface, a serial communication interface, a WIFI communication circuit, and a cascading interface. The signal output terminal of the high-voltage excitation circuit is electrically connected to the corresponding signal input terminal of the probe interface circuit, and the signal output terminal of the probe interface circuit is electrically connected to the corresponding signal input terminal of the electromagnetic ultrasonic thickness measurement probe. The signal output terminal of the electromagnetic ultrasonic thickness measurement probe is connected to the ultrasonic signal acquisition and analog signal receiving amplification circuit. The signal input terminals of the circuit are electrically connected to the corresponding signal input terminals. The signal output terminal of the ultrasonic signal capture and analog signal receiving amplification circuit is electrically connected to the signal input terminal of the analog-to-digital conversion circuit. The signal output terminal of the analog-to-digital conversion circuit is electrically connected to the signal input terminal of the digital processing circuit. The signal output terminal of the digital processing circuit is electrically connected to the signal input terminals of the network communication interface, serial communication interface, WIFI communication circuit, and cascade interface, respectively. The power supply output terminal of the first power supply circuit is electrically connected to the power supply input terminals of the ultrasonic signal capture and analog signal receiving amplification circuit on the signal receiving board, the analog-to-digital conversion circuit on the data processing and transmission board, the digital processing circuit, the network communication interface, the serial communication interface, the WIFI communication circuit, and the cascade interface, respectively. The power supply output terminal of the second power supply circuit is electrically connected to the power supply input terminals of the probe interface circuit and the high-voltage excitation circuit on the electromagnetic ultrasonic excitation board, respectively.

[0011] The aforementioned electromagnetic ultrasonic thickness measurement module divides its circuits into transmission, reception, and data processing components, distributed across three separate modules. These modules are then stacked vertically for three-dimensional assembly. Compared to the traditional flat layout, this significantly reduces the overall module size (achieving a miniaturized size of approximately 150mm × 26mm × 25mm) and weight (approximately 150g including the probe). This allows it to fit into the limited installation space of small automated equipment such as crawlers and drones, meeting the needs of space-constrained applications. During thickness measurement, the high-frequency excitation signal generated by the high-voltage excitation circuit is transmitted to the electromagnetic ultrasonic thickness measurement probe via the probe interface circuit, driving the probe to excite ultrasonic waves. The returned ultrasonic echo signal is captured and amplified by the ultrasonic signal capture and analog signal receiving and amplification circuits, then converted from analog to digital by the analog-to-digital converter circuit. The digital processing circuit then calculates the thickness data, which is finally transmitted back in real time through multiple communication interfaces, ensuring lossless signal transmission and efficient data processing. In single-channel operation, a single module can operate. When multi-channel collaborative measurement is required, the cascading interface provides a connection basis for interconnecting multiple modules, allowing them to be connected and solving the problem of low measurement efficiency in traditional single-module measurements. Simultaneously, by employing a dual-power supply design, the first power supply circuit powers all circuits and interfaces on the signal receiving board and data processing transmission board, while the second power supply circuit focuses on powering the high-voltage excitation and probe operation. This avoids electromagnetic interference and voltage fluctuations caused by sharing power with different types of circuits (for example, the high-voltage excitation circuit needs to output a transient high-frequency high-voltage signal to drive the probe coil to induce eddy currents, resulting in drastic current changes, high peak power consumption, and strong electromagnetic radiation during operation; while the ultrasonic signal acquisition and analog signal receiving circuits process the weak echo signal at the microvolt level returned by the probe, which is extremely sensitive to electromagnetic interference and requires a stable low-voltage power supply environment). This ensures the signal-to-noise ratio of ultrasonic signal acquisition and the stability of data processing. The independent power supply structure also allows for flexible matching of power supply parameters according to the power consumption requirements of each circuit, reducing the overall system power consumption, improving the reliability of the module in complex industrial environments, and avoiding measurement interruptions due to unstable power supply.

[0012] Typically, the signal receiving board and the electromagnetic ultrasonic excitation board are equipped with matching transmit and receive signal plugs / sockets; the electromagnetic ultrasonic excitation board and the data processing and transmission board are equipped with matching signal control plugs / sockets; the signal receiving board and the data processing and transmission board are equipped with matching ultrasonic analog signal plugs / sockets; the signal receiving board and the data processing and transmission board are also equipped with matching system grounding and power supply plugs / sockets; the three boards are electrically connected to each other through the combination of these four plugs / sockets.

[0013] In a further preferred embodiment, the cascaded interface includes a synchronous input signal pin, a synchronous output signal pin, a reset input signal pin, a reset output signal pin, and a ground signal pin. In each electromagnetic ultrasonic thickness measurement module of the cascaded measurement system, the synchronous output signal pin of the preceding channel module is electrically connected to the synchronous input signal pin of the following channel module; the reset output signal pin of the preceding channel module is electrically connected to the reset input signal pin of the following channel module; the reset output signal pin of the last channel module is electrically connected to the reset input signal pin of the first channel module; and the ground signal pins of all channel modules are electrically connected to each other. This structure enables orderly collaboration among multiple modules, ensuring the overall stability of the system.

[0014] In a further preferred embodiment, the method in which each channel module enters the ultrasonic transmission and reception cycle in a staggered manner in step (2) specifically includes the following steps:

[0015] (2-1) The synchronous output signal pin of the first channel module repeatedly outputs a synchronous pulse signal S1 to the next channel module according to the set time period T, which serves as the synchronous clock of the system and simultaneously starts and enters the ultrasonic transmission and reception working cycle of this module.

[0016] (2-2) When the synchronization input signal pin of the second channel module receives the synchronization pulse signal S1 from the first channel module, the second channel module system starts timing, delaying by a fixed transmit pulse working time Δt. s Then, the synchronous output signal pin of the second channel module repeatedly outputs a synchronous pulse signal S2 to the next channel module according to the set time period T, and at the same time starts the ultrasonic transmission and reception working cycle of this channel module.

[0017] (2-3) Each subsequent channel module continues to transmit the synchronization pulse signal S to the next channel module in a repeated cycle according to the set time period T, as in (2-2). n At the same time, the ultrasonic transmission and reception cycle of this channel module is started.

[0018] With this setup, the synchronization pulse signal S1, repeatedly output by the first channel module according to a set cycle, triggers its own startup. Simultaneously, it serves as the unified time reference for the entire cascaded measurement system. The timing of all channel modules (startup, peak shaving, and cycling) is referenced to this signal, ensuring timing consistency across all modules and preventing timing disruptions. The second channel module, after capturing S1 through its synchronization input pin, does not start immediately but rather after a Δt interval... s After a delay, S2 is output and the module starts working. S2 then serves as the synchronization trigger signal for the third channel, and so on, achieving chained synchronization. Ultimately, all modules synchronize according to S1, S2, S3...S... nThe timing of each module is staggered to ensure that the transmission action of the previous module does not overlap with the transmission / reception action of the next module. The synchronization pulse signal is output in a cycle according to the time period T. Compared with the synchronization method without a fixed reference, the timing control accuracy is higher and the start interval of each channel module is more consistent, ensuring that each module works continuously and stably, avoiding timing disorder. In addition, the time period T can also be flexibly adjusted according to the measurement requirements to adapt to different scanning speed scenarios and improve the flexibility of the solution.

[0019] In a further preferred embodiment, the Δt s The ringing time is greater than that of the high-voltage excitation circuit. After the high-voltage excitation circuit outputs the high-voltage excitation signal, a ringing phenomenon will occur due to the resonance effect of components such as inductors and capacitors in the circuit. That is, there is a continuous decaying oscillation after the excitation signal ends (this oscillation signal is the ringing signal). Since the ringing signal of the high-voltage excitation circuit is a strong interference signal, if the subsequent channel module starts transmitting / receiving before the ringing of the previous channel module has ended, its receiving channel will be saturated by the ringing signal and unable to distinguish its own ultrasonic echo. Therefore, Δt s Setting it to be longer than the ringing time ensures that the ringing signal of the previous channel module has completely attenuated when the next channel module starts up, eliminating the influence of the ringing signal on the measurement, improving the recognition accuracy of the ultrasonic echo signal, and protecting the receiving channel from hardware damage caused by long-term impact of strong ringing signals, thus extending the service life of the channel module.

[0020] In a further preferred embodiment, in step (3), each channel module emits trigger pulse signals at gradually increasing intervals. Specifically, each channel module outputs a synchronization pulse signal S. n At time n=1, 2, 3...n, the ultrasonic transmission and reception cycle of this channel module begins. The high-voltage excitation circuit of this module channel operates according to t. n t n +Δt n t n +2Δt n t n +3Δt n ...t n +nΔt n The incrementing time interval generates a transmit trigger pulse signal C. n It performs ultrasonic transmission and reception operations, where t n Δt is the adjustable reference transmission time period for this module's channel. n This is the adjustable increment time for this module's channels. When each channel module outputs S... n Following the synchronization pulse signal, the corresponding high-voltage excitation circuit simultaneously initiates the transmit trigger pulse signal C. n Then at interval t nThen a second trigger pulse signal C is issued. n Then at interval t n +Δt n Then a third trigger pulse signal C is issued. n Δt increases sequentially thereafter n This generates trigger pulse signals transmitted in a progressively sequential manner. Since the thickness of the workpiece area measured by different modules may vary, the ultrasonic round-trip time will differ. This method can adapt to individual differences in ultrasonic propagation time, and the incremental interval can prevent the echo signal of the later transmission from overlapping with the echo signal of the previous transmission. At the same time, compared to a fixed interval, the incremental interval can shorten the transmission interval as much as possible while ensuring that the signals do not overlap, thereby increasing the measurement frequency of a single module and optimizing the transmission efficiency of a single-channel module. n and Δt n It can be independently adjusted according to the measurement area, workpiece thickness and other parameters corresponding to the module.

[0021] In a further preferred embodiment, in step (3), when the first channel module enters the ultrasonic transmission and reception working cycle, after reaching a set time period T, the first channel module restarts its ultrasonic transmission and reception working cycle, and so on; when each subsequent channel module enters the ultrasonic transmission and reception working cycle, after receiving the synchronization pulse signal from the previous channel module and after a delay of a fixed transmission pulse working time Δt, s Then, each channel module sends a synchronization pulse signal S. n n = 1, 2, 3...n, and each channel module restarts its own ultrasonic transmission and reception cycle, repeating in sequence.

[0022] The first channel module uses a time period T as its cycle reference, restarting its own working time cycle every T time interval, and simultaneously outputting a synchronization pulse signal S1; subsequent channel modules use the received S1... n The synchronization pulse signal is a cyclic trigger condition; each time S is captured... n The system restarts its own working cycle, forming a closed-loop timing sequence with the first channel module in a fixed cycle and subsequent channel modules in a synchronous cycle. This cyclic mechanism enables uninterrupted measurement, adapting to the needs of continuous scanning or long-term monitoring of large components. Furthermore, the cycle of subsequent channel modules is triggered by the synchronous pulse signal of the previous module, ensuring that the entire system always maintains staggered timing and will not cause timing deviation due to long-term operation, thus achieving continuous and stable collaborative measurement across multiple channels.

[0023] In a further preferred embodiment, the Δt n =t n / 1000. Use this ratio for Δt. n and t nBy configuring the settings, we can ensure the incremental characteristics of the trigger pulse signal transmission interval as much as possible, avoid signal overlap, and prevent the measurement efficiency of the single-channel module from decreasing due to excessively large intervals.

[0024] In a further preferred embodiment, the electromagnetic ultrasonic thickness gauge probe includes a shell, a permanent magnet, a sound insulation layer, an electromagnetic coil, and a heat insulation composite layer. The permanent magnet, sound insulation layer, and electromagnetic coil are sequentially installed inside the shell from top to bottom, with the permanent magnet and electromagnetic coil corresponding to each other. The shell has a lower opening communicating with the interior, and the heat insulation composite layer is installed at and covers the lower opening, positioned below the electromagnetic coil. The permanent magnet provides a stable static magnetic field, which interacts with the eddy currents induced in the electromagnetic coil to generate a Lorentz force, thereby exciting ultrasonic waves. The sound insulation layer can block the influence of external environmental noise and internal circuit interference on the electromagnetic coil, reducing noise interference in the ultrasonic echo signal and improving measurement accuracy. The heat insulation composite layer ensures that the probe can directly contact the high-temperature metal workpiece, effectively blocking high-temperature heat radiation from being conducted into the probe, protecting the permanent magnet, electromagnetic coil, and other core components from high-temperature damage, making the probe suitable for high-temperature measurement scenarios.

[0025] In a further preferred embodiment, the thermal insulation layer comprises, from top to bottom, a polyimide plate, a porous vacuum silicone insulation cotton, and an aluminum silicate ceramic plate. The thermal insulation layer consists of three layers: the bottom aluminum silicate ceramic plate directly contacts the high-temperature workpiece and possesses excellent high-temperature resistance; the middle porous vacuum silicone insulation cotton utilizes a vacuum structure to block heat conduction, while the silicone material also acts as a buffer, reducing mechanical impact when the probe contacts the workpiece; the top polyimide plate has good mechanical strength and insulation properties, both fixing the lower insulation material and preventing electrical interference between the electromagnetic coil and the insulation layer. The three-layer structure integrates high-temperature resistance, efficient thermal insulation, and structural support, resulting in a more significant thermal insulation effect compared to a single insulation material. This allows the probe to operate continuously and stably at 350°C, meeting the continuous thickness measurement requirements of high-temperature metal workpieces.

[0026] In a further preferred embodiment, the electromagnetic ultrasonic thickness measurement probe further includes a probe cover, a plug wire, and a lead wire. The outer casing is cylindrical, with the probe cover mounted on top and covering the upper opening of the casing. An outlet is located on the outer side of the casing, the plug wire is fixed at the outlet and extends outwards, and the lead wire is disposed inside the casing. One end of the lead wire is soldered to the electrode of the electromagnetic coil, and the other end extends to the outlet and connects to the plug wire. The lead wire connects the coil to the plug wire, and the plug wire allows the probe to interface with the probe interface circuit of the electromagnetic ultrasonic excitation board.

[0027] The beneficial effects of this invention are as follows: this cascaded collaborative measurement method can realize the collaborative measurement of multi-channel modules, and can improve the overall measurement efficiency while avoiding mutual interference between the various channel modules, thus adapting to the high-speed scanning requirements of multiple measurement points of large components. Attached Figure Description

[0028] Figure 1 This is a timing diagram of the operation of each channel module of the cascaded measurement system in an embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram of the electromagnetic ultrasonic thickness measurement module in an embodiment of the present invention;

[0030] Figure 3 This is an exploded view of the electromagnetic ultrasonic thickness measurement module in an embodiment of the present invention;

[0031] Figure 4 This is a schematic diagram of the signal receiving board in an embodiment of the present invention;

[0032] Figure 5 This is a schematic diagram of the electromagnetic ultrasonic excitation plate in an embodiment of the present invention;

[0033] Figure 6 This is a schematic diagram of the data processing and transmission board in an embodiment of the present invention;

[0034] Figure 7 This is a schematic diagram of the electromagnetic ultrasonic thickness measuring probe in an embodiment of the present invention. Detailed Implementation

[0035] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:

[0036] A cascaded collaborative measurement method for electromagnetic ultrasonic thickness measurement modules includes the following steps:

[0037] (1) A cascaded measurement system is formed by three electromagnetic ultrasonic thickness measurement modules. Each module is connected through the cascade interface 305. Each electromagnetic ultrasonic thickness measurement module is designated as the first channel module, the second channel module and the third channel module in the cascade sequence.

[0038] (2) Each channel module enters the ultrasonic transmission and reception cycle in a staggered manner;

[0039] (3) During the ultrasonic transmission and reception cycle, each channel module transmits trigger pulse signals at intervals with gradually increasing intervals to perform ultrasonic transmission and reception.

[0040] The aforementioned cascaded measurement system consists of multiple electromagnetic ultrasonic thickness measurement modules connected in series via a cascade interface 305. It is suitable for simultaneous measurement of multiple measurement points on large components (such as pipes, tanks, and plates), and the number of channel modules can be flexibly increased or decreased according to the measurement range to adapt to different scenarios. Secondly, each channel module enters its working cycle sequentially in a staggered manner. This solves the problem of simultaneous transmission interference between channel modules, avoids mutual coupling of high-energy electromagnetic fields between channel modules, and prevents the receiving channel from being saturated by strong transmitted signals. Compared to a simple polling mode, this method does not require waiting for the previous channel module to complete its full working cycle before starting the next channel module. The overall measurement efficiency can be as close as possible to the level of a single channel, meeting the requirements of high-speed scanning. Within their respective working cycles, each channel module transmits trigger pulse signals at incremental intervals. This avoids signal superposition interference caused by continuous transmission within a single module, improves the signal-to-noise ratio of the measurement signal, ensures accurate identification of the echo signal, and also adapts to the differences in ultrasonic propagation time for workpieces of different thicknesses.

[0041] In step (2), the various channel modules enter the ultrasonic transmission and reception cycle in a staggered manner, specifically including the following steps:

[0042] (2-1) The synchronous output signal pin of the first channel module repeatedly outputs a synchronous pulse signal S1 to the next channel module according to the set time period T, which serves as the synchronous clock of the system and simultaneously starts and enters the ultrasonic transmission and reception working cycle of this module.

[0043] (2-2) When the synchronization input signal pin of the second channel module receives the synchronization pulse signal S1 from the first channel module, the second channel module system starts timing, delaying by a fixed transmit pulse working time Δt. s Then, the synchronous output signal pin of the second channel module repeatedly outputs a synchronous pulse signal S2 to the next channel module according to the set time period T, and at the same time starts the ultrasonic transmission and reception working cycle of this module.

[0044] (2-3) When the synchronization input signal pin of the third channel module receives the synchronization pulse signal S2 from the second channel module, the third channel module system starts timing, delaying by a fixed transmit pulse working time Δt. s Then, the third channel module outputs a synchronization pulse signal S3, which simultaneously starts the ultrasonic transmission and reception cycle of this channel module.

[0045] With this setup, the synchronization pulse signal S1, repeatedly output by the first channel module according to a set cycle, triggers its own startup. Simultaneously, it serves as the unified time reference for the entire cascaded measurement system. The timing of all channel modules (startup, peak shaving, and cycling) is referenced to this signal, ensuring timing consistency across all modules and preventing timing disruptions. The second channel module, after capturing S1 through its synchronization input pin, does not start immediately but rather after a Δt interval... s After a delay, S2 is output and the module starts working. S2 then serves as the synchronization trigger signal for the third channel, and so on to achieve chain synchronization. Ultimately, all modules start up sequentially in the order of S1, S2, and S3, ensuring that the transmission action of the previous module does not overlap with the transmission / reception action of the next module. The synchronization pulse signal is output cyclically according to the time period T. Compared with synchronization methods without a fixed reference, the timing control accuracy is higher, the start interval of each channel module is more consistent, ensuring that each module works continuously and stably, avoiding timing disorder. Furthermore, the time period T can be flexibly adjusted according to measurement requirements to adapt to different scanning speed scenarios, improving the flexibility of the solution.

[0046] Δt s The ringing time is greater than that of the high-voltage excitation circuit 203. After the high-voltage excitation circuit 203 outputs the high-voltage excitation signal, a ringing phenomenon will occur due to the resonance effect of components such as inductors and capacitors in the circuit. That is, there is a continuous decaying oscillation after the excitation signal ends (this oscillation signal is the ringing signal). Since the ringing signal of the high-voltage excitation circuit 203 is a strong interference signal, if the subsequent channel module starts transmitting / receiving before the ringing of the previous channel module has ended, its receiving channel will be saturated by the ringing signal and will not be able to distinguish its own ultrasonic echo. Therefore, Δt s Setting it to be longer than the ringing time ensures that the ringing signal of the previous channel module has completely attenuated when the next channel module starts up, eliminating the influence of the ringing signal on the measurement, improving the recognition accuracy of the ultrasonic echo signal, and protecting the receiving channel from hardware damage caused by long-term impact of strong ringing signals, thus extending the service life of the channel module.

[0047] The working timing of each channel module is as follows Figure 1 As shown, in step (3), each channel module transmits trigger pulse signals at gradually increasing intervals. Specifically, each channel module outputs a synchronization pulse signal S. n When n=1, 2, 3, the ultrasonic transmission and reception cycle of this channel module begins, and the high-voltage excitation circuit 203 of this module channel starts according to t. n t n +Δt n t n +2Δt n t n +3Δt n...t n +nΔt n The incrementing time interval generates a transmit trigger pulse signal C. n It performs ultrasonic transmission and reception operations, where t n Δt is the adjustable reference transmission time period for this module's channel. n This is the adjustable increment time for this module's channels. When each channel module outputs S... n After the synchronization pulse signal, the corresponding high-voltage excitation circuit 203 simultaneously starts transmitting the trigger pulse signal C. n Then at interval t n Then a second trigger pulse signal C is issued. n Then at interval t n +Δt n Then a third trigger pulse signal C is issued. n Δt increases sequentially thereafter n This generates trigger pulse signals transmitted in a progressively sequential manner. Since the thickness of the workpiece area measured by different modules may vary, the ultrasonic round-trip time will differ. This method can adapt to individual differences in ultrasonic propagation time, and the incremental interval can prevent the echo signal of the later transmission from overlapping with the echo signal of the previous transmission. At the same time, compared to a fixed interval, the incremental interval can shorten the transmission interval as much as possible while ensuring that the signals do not overlap, thereby increasing the measurement frequency of a single module and optimizing the transmission efficiency of a single-channel module. n and Δt n It can be independently adjusted according to the measurement area, workpiece thickness and other parameters corresponding to the module.

[0048] In step (3), when the first channel module enters the ultrasonic transmission and reception cycle, after reaching a set time period T, the first channel module restarts its ultrasonic transmission and reception cycle, and so on. When each subsequent channel module enters the ultrasonic transmission and reception cycle, after receiving the synchronization pulse signal from the previous channel module and after a delay of a fixed transmission pulse working time Δt, s Then, a synchronization pulse signal S is emitted. n n=1, 2, 3, and each channel module restarts its ultrasonic transmission and reception cycle in sequence.

[0049] The first channel module uses a time period T as its cycle reference, restarting its own working time cycle every T time interval, and simultaneously outputting a synchronization pulse signal S1; subsequent channel modules use the received S1... n The synchronization pulse signal is a cyclic trigger condition; each time S is captured... nThe system restarts its own working cycle, forming a closed-loop timing sequence with the first channel module in a fixed cycle and subsequent channel modules in a synchronous cycle. This cyclic mechanism enables uninterrupted measurement, adapting to the needs of continuous scanning or long-term monitoring of large components. Furthermore, the cycle of subsequent channel modules is triggered by the synchronous pulse signal of the previous module, ensuring that the entire system always maintains staggered timing and will not cause timing deviation due to long-term operation, thus achieving continuous and stable collaborative measurement across multiple channels.

[0050] Δt n =t n / 1000. Use this ratio for Δt. n and t n By configuring the settings, we can ensure the incremental characteristics of the trigger pulse signal transmission interval as much as possible, avoid signal overlap, and prevent the measurement efficiency of the single-channel module from decreasing due to excessively large intervals.

[0051] like Figure 2-7As shown, the electromagnetic ultrasonic thickness measurement module includes a signal receiving board 1, an electromagnetic ultrasonic excitation board 2, a data processing and transmission board 3, and an electromagnetic ultrasonic thickness measurement probe 4. The signal receiving board 1, electromagnetic ultrasonic excitation board 2, and data processing and transmission board 3 are stacked sequentially from top to bottom. The signal receiving board 1 is equipped with a first power supply circuit 101 and an ultrasonic signal capture and analog signal receiving amplification circuit 102. The electromagnetic ultrasonic excitation board 2 is equipped with a second power supply circuit 201, a probe interface circuit 202, and a high-voltage excitation circuit 203. The data processing and transmission board 3 is equipped with an analog-to-digital conversion circuit 301, a digital processing circuit 302, a network communication interface 303, a serial communication interface 304, a WIFI communication circuit (located on the lower surface of the data processing and transmission board 3), and a cascading interface 305. The signal output terminal of the high-voltage excitation circuit 203 is electrically connected to the corresponding signal input terminal of the probe interface circuit 202, and the signal output terminal of the probe interface circuit 202 is electrically connected to the corresponding signal input terminal of the electromagnetic ultrasonic thickness measurement probe 4. The signal output terminal of the electromagnetic ultrasonic thickness measurement probe 4 is connected to the ultrasonic signal capture and analog signal receiving amplification circuit. The signal input terminal of circuit 102 is electrically connected to the signal output terminal of the ultrasonic signal capture and analog signal receiving amplification circuit 102, which is electrically connected to the signal input terminal of the analog-to-digital conversion circuit 301. The signal output terminal of the analog-to-digital conversion circuit 301 is electrically connected to the signal input terminal of the digital processing circuit 302, which is electrically connected to the signal input terminals of the network communication interface 303, the serial communication interface 304, the WIFI communication circuit, and the cascade interface 305, respectively. The power supply output terminal of the first power supply circuit 101 is electrically connected to the power supply input terminals of the ultrasonic signal capture and analog signal receiving amplification circuit 102 on the signal receiving board 1, the analog-to-digital conversion circuit 301 on the data processing and transmission board 3, the digital processing circuit 302, the network communication interface 303, the serial communication interface 304, the WIFI communication circuit, and the cascade interface 305, respectively. The power supply output terminal of the second power supply circuit 201 is electrically connected to the power supply input terminals of the probe interface circuit 202 and the high-voltage excitation circuit 203 on the electromagnetic ultrasonic excitation board 2, respectively.

[0052] The aforementioned electromagnetic ultrasonic thickness measurement module divides its circuits into transmission, reception, and data processing components, which are distributed across three separate modules. These modules are then stacked vertically for three-dimensional assembly. Compared to the traditional flat layout, this significantly reduces the overall module size (achieving a miniaturized size of approximately 150mm × 26mm × 25mm) and weight (approximately 150g including the probe). This allows it to fit into the limited installation space of small automated equipment such as crawlers and drones, meeting the needs of space-constrained applications. During thickness measurement, the high-frequency excitation signal generated by the high-voltage excitation circuit 203 is transmitted to the electromagnetic ultrasonic thickness measurement probe 4 via the probe interface circuit 202, driving the probe 4 to excite ultrasonic waves. The returned ultrasonic echo signal is captured and amplified by the ultrasonic signal capture and analog signal receiving amplification circuit 102, then converted from analog to digital by the analog-to-digital conversion circuit 301. The digital processing circuit 302 then calculates the thickness data, which is finally transmitted back in real time through multiple communication interfaces, ensuring lossless signal transmission and efficient data processing. When using a single channel, one module can work. When multiple channels need to be measured collaboratively, the cascade interface 305 provides a connection basis for the interconnection of multiple modules. Each module can be connected through the cascade interface 305, which solves the problem of low measurement efficiency in traditional single-module measurement. Meanwhile, by adopting a dual-power-circuit independent power supply design, the first power supply circuit 101 supplies power to various circuits and interfaces on the signal receiving board 1 and the data processing and transmission board 3, while the second power supply circuit 201 focuses on supplying power to the high-voltage excitation and probe operation. This avoids electromagnetic interference and voltage fluctuations caused by different types of circuits sharing the same power supply (for example, the high-voltage excitation circuit 203 needs to output an instantaneous high-frequency high-voltage signal to drive the probe coil to induce eddy currents, resulting in drastic current changes, high power consumption peaks, and strong electromagnetic radiation during operation; while the ultrasonic signal acquisition and analog signal receiving circuit processes the microvolt-level weak echo signal returned by the probe, which is extremely sensitive to electromagnetic interference and requires a stable low-voltage power supply environment), ensuring the signal-to-noise ratio of ultrasonic signal acquisition and the stability of data processing; the independent power supply structure can also flexibly match the power supply parameters according to the power consumption requirements of each circuit, reduce the overall power consumption of the system, improve the reliability of the module in complex industrial environments, and avoid measurement interruptions caused by unstable power supply.

[0053] The signal receiving board 1 and the electromagnetic ultrasonic excitation board 2 are respectively equipped with matching transmit and receive signal plugs / sockets 5; the electromagnetic ultrasonic excitation board 2 and the data processing and transmission board 3 are respectively equipped with matching signal control plugs / sockets 6; the signal receiving board 1 and the data processing and transmission board 3 are respectively equipped with matching ultrasonic analog signal plugs / sockets 7; the signal receiving board 1 and the data processing and transmission board 3 are also respectively equipped with matching system grounding and power supply plugs / sockets 8; the three boards are electrically connected to each other through the combination of these four plugs / sockets.

[0054] The cascade interface 305 includes a synchronization input signal pin, a synchronization output signal pin, a reset input signal pin, a reset output signal pin, and a ground signal pin. In each electromagnetic ultrasonic thickness measurement module of the cascaded measurement system, the synchronization output signal pin of the preceding channel module is electrically connected to the synchronization input signal pin of the following channel module; the reset output signal pin of the preceding channel module is electrically connected to the reset input signal pin of the following channel module; the reset output signal pin of the last channel module is electrically connected to the reset input signal pin of the first channel module; and the ground signal pins of all channel modules are electrically connected to each other. This structure enables orderly collaboration among multiple modules, ensuring the overall stability of the system.

[0055] The electromagnetic ultrasonic thickness measuring probe 4 includes a housing 401, a permanent magnet 402, a sound insulation layer 403, an electromagnetic coil 404, and a heat insulation composite layer 405. The permanent magnet 402, the sound insulation layer 403, and the electromagnetic coil 404 are installed sequentially from top to bottom inside the housing 401, and the permanent magnet 402 and the electromagnetic coil 404 are positioned correspondingly. The housing 401 has a lower opening that communicates with the interior. The heat insulation composite layer 405 is installed at the lower opening of the housing 401 and covers the lower opening. The heat insulation composite layer 405 is located below the electromagnetic coil 404. The permanent magnet 402 provides a stable static magnetic field, which interacts with the eddy currents induced by the electromagnetic coil 404 to generate Lorentz force, thereby exciting ultrasonic waves. The sound insulation layer 403 can block the influence of external environmental noise and internal circuit interference on the electromagnetic coil 404, reduce the noise interference of ultrasonic echo signals, and improve measurement accuracy. The heat insulation composite layer 405 ensures that the probe can directly contact the high-temperature metal workpiece, effectively blocking the conduction of high-temperature heat radiation into the probe, protecting the core components such as the permanent magnet 402 and the electromagnetic coil 404 from high-temperature damage, and making the probe suitable for high-temperature measurement scenarios.

[0056] The thermal insulation layer 405 comprises, from top to bottom, a polyimide plate 4051, a porous vacuum silicone insulation cotton 4052, and an aluminum silicate ceramic plate 4053. The thermal insulation layer 405 is composed of three layers. The bottom aluminum silicate ceramic plate 4053 directly contacts the high-temperature workpiece and possesses excellent high-temperature resistance. The middle layer, the porous vacuum silicone insulation cotton 4052, utilizes a vacuum structure to block heat conduction, while the silicone material also acts as a buffer, reducing mechanical impact when the probe contacts the workpiece. The top polyimide plate 4051 has good mechanical strength and insulation properties, both fixing the lower insulation material and preventing electrical interference between the electromagnetic coil 404 and the insulation layer. The three-layer structure integrates high-temperature resistance, efficient thermal insulation, and structural support, resulting in a more significant thermal insulation effect compared to a single insulation material. This allows the probe to operate continuously and stably at 350℃, meeting the continuous thickness measurement requirements of high-temperature metal workpieces.

[0057] The electromagnetic ultrasonic thickness measuring probe 4 also includes a probe cover 406, a plug wire 407, and a lead wire 408. The outer shell 401 is cylindrical, and the probe cover 406 is installed on the top of the outer shell 401, covering the upper opening of the outer shell 401. An outlet is opened on the outside of the outer shell 401, and the plug wire 407 is fixed at the outlet and extends outward. The lead wire 408 is disposed inside the outer shell 401, with one end of the lead wire 408 soldered to the electrode of the electromagnetic coil 404, and the other end of the lead wire 408 extending to the outlet and connecting to the plug wire 407. The lead wire 408 connects the coil to the plug wire 407, and the plug wire 407 allows the probe to interface with the probe interface circuit 202 of the electromagnetic ultrasonic excitation board 2.

Claims

1. A method for cascade synergistic measurement of electromagnetic ultrasonic thickness module, characterized by The method comprises the following steps: (1) a plurality of electromagnetic ultrasonic thickness measurement modules are used to form a cascade measurement system, each module is connected through a cascade interface, and each electromagnetic ultrasonic thickness measurement module is sequentially defined as a first channel module, a second channel module, and an nth channel module along the cascade order; (2) each channel module is sequentially staggered into an ultrasonic wave emission and reception work cycle: (2-1) the synchronization output signal pin of the first channel module repeatedly outputs a synchronization pulse signal S1 to the next channel module as a system synchronization clock at a set time period T, and simultaneously starts and enters the ultrasonic wave emission and reception work cycle of the module; (2-2) when the synchronization pulse signal S1 of the first channel module is received by the synchronization input signal pin of the second channel module, the system of the second channel module starts timing, delays a fixed transmission pulse working time Δts, and then the synchronization output signal pin of the second channel module repeatedly outputs a synchronization pulse signal S2 to the next channel module at a set time period T, and simultaneously starts and enters the ultrasonic wave emission and reception work cycle of the channel module; (2-3) each subsequent channel module continues to transmit a synchronization pulse signal Sn to the next channel module at a set time period T according to the mode of (2-2), and simultaneously starts and enters the ultrasonic wave emission and reception work cycle of the channel module; (3) each channel module uses an interval time gradually increasing mode to interval transmit a trigger pulse signal during the ultrasonic wave emission and reception work cycle, and performs ultrasonic wave emission and reception work; The electromagnetic ultrasonic thickness measurement module comprises a signal receiving plate, an electromagnetic ultrasonic excitation plate, a data processing and transmission plate and an electromagnetic ultrasonic thickness measurement probe, and the signal receiving plate, the electromagnetic ultrasonic excitation plate and the data processing and transmission plate are sequentially stacked from top to bottom; the signal receiving plate is provided with a first power supply circuit, an ultrasonic signal capturing and analog signal receiving and amplifying circuit; the electromagnetic ultrasonic excitation plate is provided with a second power supply circuit, a probe interface circuit and a high-voltage excitation circuit; the data processing and transmission plate is provided with an analog-digital conversion circuit, a digital processing circuit, a network communication interface, a serial communication interface, a WIFI communication circuit and a cascade interface; a signal output end of the high-voltage excitation circuit is electrically connected with a corresponding signal input end of the probe interface circuit, a signal output end of the probe interface circuit is electrically connected with a corresponding signal input end of the electromagnetic ultrasonic thickness measurement probe; a signal output end of the electromagnetic ultrasonic thickness measurement probe is electrically connected with a corresponding signal input end of the ultrasonic signal capturing and analog signal receiving and amplifying circuit, a signal output end of the ultrasonic signal capturing and analog signal receiving and amplifying circuit is electrically connected with a corresponding signal input end of the analog-digital conversion circuit, a signal output end of the analog-digital conversion circuit is electrically connected with a corresponding signal input end of the digital processing circuit, and corresponding signal output ends of the digital processing circuit are respectively electrically connected with corresponding signal input ends of the network communication interface, the serial communication interface, the WIFI communication circuit and the cascade interface; a power supply output end of the first power supply circuit is electrically connected with power supply input ends of the ultrasonic signal capturing and analog signal receiving and amplifying circuit on the signal receiving plate, the analog-digital conversion circuit, the digital processing circuit, the network communication interface, the serial communication interface, the WIFI communication circuit and the cascade interface on the data processing and transmission plate; a power supply output end of the second power supply circuit is electrically connected with power supply input ends of the probe interface circuit and the high-voltage excitation circuit on the electromagnetic ultrasonic excitation plate; the cascade interface comprises a synchronous input signal pin, a synchronous output signal pin, a reset input signal pin, a reset output signal pin and a ground signal pin; in each electromagnetic ultrasonic thickness measurement module of the cascade measurement system, the synchronous output signal pin of a previous channel module is electrically connected with the synchronous input signal pin of a subsequent channel module, the reset output signal pin of the previous channel module is electrically connected with the reset input signal pin of the subsequent channel module, the reset output signal pin of a last channel module is electrically connected with the reset input signal pin of the first channel module, and the ground signal pins of all the channel modules are electrically connected with each other.

2. The cascaded cooperative measurement method of an electromagnetic ultrasonic thickness measurement module according to claim 1, characterized in that: The Δt s greater than the high voltage excitation circuit ring time.

3. The cascaded cooperative measurement method of an electromagnetic ultrasonic thickness measurement module according to claim 1, characterized in that: In step (3), each channel module emits trigger pulse signals at gradually increasing intervals. Specifically, each channel module outputs a synchronization pulse signal S. n At time n=1, 2, 3...n, the ultrasonic transmission and reception cycle of this channel module begins. The high-voltage excitation circuit of this module channel operates according to t. n t n +Δt n t n +2Δt n t n +3Δt n ...t n +nΔt n The incrementing time interval generates a transmit trigger pulse signal C. n It performs ultrasonic transmission and reception operations, where t n Δt is the adjustable reference transmission time period for this module's channel. n This is the adjustable increment time for the channel in this module.

4. The cascaded cooperative measurement method of an electromagnetic ultrasonic thickness measurement module according to claim 3, characterized in that: In the step (3), when the first channel module enters the ultrasonic wave transmitting and receiving working period, after reaching a set time period T, the first channel module restarts the ultrasonic wave transmitting and receiving working period of the channel module, and the cycle is repeated; when each subsequent channel module enters the ultrasonic wave transmitting and receiving working period, after receiving the synchronization pulse signal of the previous channel module and delaying a fixed transmitting pulse working time Δt s , the channel module sends a synchronization pulse signal S n , n = 1, 2, 3, …, n, and each channel module restarts the ultrasonic wave transmitting and receiving working period of the channel module, and the cycle is repeated.

5. The cascaded cooperative measurement method of an electromagnetic ultrasonic thickness measurement module according to claim 3, characterized in that: said Δt n = t n / 1000.

6. The cascaded synergic measurement method of an electromagnetic ultrasonic thickness measurement module according to claim 1, characterized in that: The electromagnetic ultrasonic thickness measurement probe comprises a shell, a permanent magnet, a sound insulation layer, an electromagnetic coil and a heat insulation combined layer, the permanent magnet, the sound insulation layer and the electromagnetic coil are sequentially arranged in the interior of the shell from top to bottom, and the positions of the permanent magnet and the electromagnetic coil correspond to each other; the shell is provided with a lower opening communicating with the interior, the heat insulation combined layer is arranged at the lower opening of the shell and covers the lower opening, and the heat insulation combined layer is below the electromagnetic coil; the heat insulation combined layer comprises a polyimide plate, a porous vacuum silica gel heat insulation cotton and an aluminum silicate ceramic plate which are sequentially arranged from top to bottom.

7. The cascaded synergic measurement method of an electromagnetic ultrasonic thickness measurement module according to claim 6, characterized in that: The electromagnetic ultrasonic thickness measuring probe further comprises a probe upper cover, a plug wire and a lead wire, the shell is in a cylindrical shape, the probe upper cover is installed on the top of the shell and covers the upper opening of the shell, a wire outlet is formed on the outer side of the shell, the plug wire is fixed at the wire outlet and extends outward, the lead wire is arranged in the shell, one end of the lead wire is welded on the electrode of the electromagnetic coil, and the other end of the lead wire extends to the wire outlet and is connected with the plug wire.

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