Aluminum bar internal inclusion and pore detection system based on ultrasonic flaw detection technology

Abstract

This invention provides a system for detecting internal inclusions and porosity in aluminum rods based on ultrasonic flaw detection technology. It relates to the field of ultrasonic testing technology and includes: a construction module for constructing a dynamically adjustable detection coordinate system using the center point of the aluminum rod's end face as a first reference position, the center of the phased array ultrasonic probe array as a second reference position, and the reference positioning edge of the testing platform as a third reference position; and a calculation module for dividing the detection coordinate system into multiple hierarchical scanning sub-regions based on the two-dimensional spatial topological characteristics of the detection coordinate system and the actual size and shape distribution of the aluminum rod's end face; and calculating the focusing delay parameters and scanning path parameters corresponding to each sub-region based on the spatial position, area, and geometric distribution characteristics of the distance from the core region of the aluminum rod's end face. This invention achieves accurate and efficient detection of non-metallic inclusions and minute defects such as pores inside aluminum rods.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic testing technology, and in particular to a system for detecting inclusions and pores inside aluminum rods based on ultrasonic flaw detection technology. Background Technology

[0002] In aerospace, high-end equipment manufacturing and other fields, aluminum rods are used as key structural components. Defects such as non-metallic inclusions and pores inside the rods can seriously affect the mechanical properties and service safety of the products. Therefore, there is an urgent need for accurate testing. Existing ultrasonic flaw detection technologies mostly use fixed detection coordinate systems and lack targeted noise suppression solutions.

[0003] For example, when component manufacturers inspect aerospace-grade aluminum bars, the slight skew during the clamping process makes it impossible for traditional fixed coordinate systems to dynamically adapt to the actual position. At the same time, the multipath scattering noise generated by the coarse grains of the aluminum bar interferes with signal recognition, causing the system to miss a tiny non-metallic inclusion defect. This defect causes stress concentration during subsequent processing, ultimately leading to cracking and scrapping of the part. The shortcomings of traditional technologies in coordinate system adaptability and noise suppression make it difficult to meet the needs of accurate detection of tiny defects. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a system for detecting inclusions and pores inside aluminum rods based on ultrasonic flaw detection technology, so as to achieve accurate and efficient detection of non-metallic inclusions and micro-defects of pores inside aluminum rods.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows:

[0006] Firstly, a system for detecting internal inclusions and porosity in aluminum rods based on ultrasonic flaw detection technology includes:

[0007] The construction module is used to construct a dynamically adjustable detection coordinate system based on the center point of the end face of the aluminum rod as the first reference position, the center of the phased array ultrasonic probe array as the second reference position, and the reference positioning edge of the detection stage as the third reference position.

[0008] The calculation module is used to divide the detection coordinate system into multiple hierarchical scanning sub-regions based on the two-dimensional spatial topological characteristics of the detection coordinate system and the actual size and shape distribution of the aluminum rod end face; and to calculate the focusing delay parameters and scanning path parameters corresponding to each sub-region based on the spatial position, area size and geometric distribution characteristics of the distance from the core area of ​​the aluminum rod end face of each scanning sub-region.

[0009] The scanning module is used to drive the phased array ultrasonic probe array to perform multi-region dynamic focusing scanning of the aluminum rod based on the focusing delay parameter and scanning path parameter, and to transmit and receive ultrasonic signals to obtain the original ultrasonic echo signal of the defect information.

[0010] The suppression module is used to process the original ultrasonic echo signal to suppress multipath scattering noise caused by coarse material grains, and obtain a denoised ultrasonic signal with improved signal-to-noise ratio.

[0011] The extraction module is used to process the denoised ultrasonic signal and identify and extract the micron-level non-metallic inclusions and porosity defects from the denoised ultrasonic signal.

[0012] The processing module is used to process the extracted defect feature information, calculate the precise three-dimensional position and equivalent size of the defect in the aluminum rod in real time, and generate a final inspection report with defect position markings.

[0013] Furthermore, using the center point of the end face of the aluminum rod as the first reference position, the center of the phased array ultrasonic probe array as the second reference position, and the reference positioning edge of the testing stage as the third reference position, a dynamically adjustable testing coordinate system is constructed, including:

[0014] The image of the end face of the aluminum rod is acquired by a visual positioning sensor, and the image is processed by edge extraction and contour fitting. The center point of the fitted contour is established as the first reference position.

[0015] Based on the established first reference position, the phased array ultrasonic probe array is driven to perform a pre-positioning movement so that the center of the probe array is initially aligned with the first reference position on the two-dimensional plane, and the aligned position is established as the second reference position.

[0016] Based on the first and second reference positions, the relative spatial angle between the aluminum rod axis and the reference positioning edge of the detection stage is calculated, and the angle relationship is used as the quantitative parameter of the third reference position.

[0017] The quantification parameters of the first, second, and third reference positions are integrated to construct a unified detection coordinate system that can be dynamically adjusted according to the actual clamping state of the aluminum rod.

[0018] Furthermore, based on the two-dimensional spatial topological characteristics of the detection coordinate system and the actual size and shape distribution of the aluminum rod end face, the detection coordinate system is divided into multiple hierarchical scanning sub-regions. Based on the spatial location, area, and geometric distribution characteristics of each scanning sub-region relative to the core region of the aluminum rod end face, the focusing delay parameters and scanning path parameters corresponding to each sub-region are calculated, including:

[0019] A dynamically adjustable detection coordinate system is invoked, and a virtual geometric boundary that accurately represents the actual contour of the aluminum rod is defined in the coordinate system based on the preset diameter and tolerance parameters of the aluminum rod end face.

[0020] Based on virtual geometric boundaries, and according to the physical law that stress concentration and high defect probability are in the central region during aluminum rod manufacturing, the system adaptively divides the region into multiple concentric ring-shaped hierarchical scanning sub-regions from the inside out, and assigns a priority weight coefficient to each sub-region based on the distance between the scanning sub-region and the core region.

[0021] For each divided scanning sub-region, based on priority weight coefficients, spatial location and area size, combined with the known physical laws of ultrasonic wave propagation in aluminum and the sound beam focusing law, a set of dynamic focusing delay parameters for optimizing the detection sound field energy is calculated and generated.

[0022] Based on the dynamic focusing delay parameter set, an efficient scanning trajectory is planned for each scanning sub-region to achieve full coverage and maintain a smooth transition with the paths of adjacent regions, and the corresponding scanning path parameter set is generated.

[0023] Furthermore, based on the focusing delay parameter and scanning path parameter, the phased array ultrasonic probe array is driven to perform multi-region dynamic focusing scanning of the aluminum rod, transmitting and receiving ultrasonic signals to obtain the raw ultrasonic echo signal of the defect information, including:

[0024] Based on the scanning path parameter set, the mechanical movement mechanism of the phased array ultrasonic probe array is controlled so that the probe array moves sequentially to the designated position of each scanning sub-region according to the planned efficient scanning trajectory, and ensures that it maintains a constant coupling state with the end face of the aluminum rod during the movement, thereby establishing a physical position basis for the accurate scanning of each sub-region;

[0025] At each specified scanning position, the focusing delay parameter set corresponding to the sub-region is called to dynamically adjust the emission timing and phase of each element of the phased array ultrasonic probe array, thereby emitting a focused ultrasonic beam to achieve directional energy injection and precise scanning of a specific region inside the aluminum rod.

[0026] After the focused ultrasonic beam is emitted, the ultrasonic echo signal reflected or scattered from inside the aluminum rod is received synchronously by the phased array ultrasonic probe array. The received analog echo signal is amplified and filtered by the signal conditioning circuit and finally converted into a digital echo signal.

[0027] Furthermore, based on the scanning path parameter set, the mechanical movement mechanism of the phased array ultrasonic probe array is controlled, enabling the probe array to move sequentially to designated positions in each scanning sub-region according to a planned efficient scanning trajectory, while ensuring constant coupling with the aluminum rod end face during movement. This establishes a physical positional basis for precise scanning of each sub-region, including:

[0028] Call the scan path parameter set for each scan sub-region, and obtain the multi-axis cooperative motion control command of the mechanical moving mechanism based on the scan path parameter set;

[0029] By executing motion control commands, the phased array ultrasonic probe array is driven to move sequentially along a planned high-efficiency scanning trajectory, and the contact pressure between the probe and the end face of the aluminum rod is monitored in real time by a force control sensor during the movement.

[0030] Based on the real-time contact pressure data fed back by the force control sensor, the Z-axis position of the mechanical moving mechanism is dynamically adjusted so that the probe array and the end face of the aluminum rod maintain a constant coupling state throughout the scanning process.

[0031] Once the probe array reaches and stabilizes at a designated position in any scanning sub-region according to the control method, a precise physical location basis is established.

[0032] Furthermore, by processing the original ultrasonic echo signal to suppress multipath scattering noise caused by coarse material grains, a denoised ultrasonic signal with improved signal-to-noise ratio is obtained, including:

[0033] The original ultrasonic echo signal is received, and the signal in the original ultrasonic echo signal is subjected to joint time-frequency domain analysis to extract the dispersion and attenuation characteristic parameters that characterize the scattering properties of the material grains.

[0034] Based on the extracted dispersion and attenuation characteristic parameters, a multipath scattering noise characterization template matching the current aluminum rod material characteristics is established by querying a preset acoustic characteristic database.

[0035] By establishing a multipath scattering noise characterization template, noise component matching and estimation are performed on the original ultrasonic echo signal. An adaptive filtering algorithm is then used to separate and subtract the estimated noise components from the original signal to obtain the denoised signal.

[0036] The denoised signal is reconstructed by wavelet transform and envelope detection to obtain a denoised ultrasonic signal with improved signal-to-noise ratio.

[0037] Furthermore, the denoised ultrasonic signal is processed to identify and extract micron-level non-metallic inclusions and porosity defects, including:

[0038] The system receives the denoised ultrasonic signal with improved signal-to-noise ratio and performs statistical analysis on the amplitude distribution of the signal to calculate the dynamic threshold that adapts to the signal energy.

[0039] Based on the calculated dynamic threshold, the amplitude of the denoised ultrasonic signal is compared with the dynamic threshold to initially identify all potential defect echoes and obtain binarized label data of potential defect locations.

[0040] Signal morphology analysis is performed on the obtained binarized labeled data. By performing opening and closing operations, isolated noise points in the binarized labeled data are eliminated, adjacent small defect regions are connected, and finally the connected regions corresponding to non-metallic inclusions and pores are accurately segmented.

[0041] Based on the precisely segmented connected regions, the defect feature information of the echo signal of each connected region is extracted, including but not limited to the maximum amplitude, energy integral, time domain width and spectral center frequency.

[0042] Furthermore, the extracted defect feature information is processed to calculate the precise three-dimensional location and equivalent size of the defect in the aluminum rod in real time, and a final inspection report with defect location markers is generated, including:

[0043] Receive defect feature information, and based on the defect echo arrival time and the spatial position of the phased array probe in the detection coordinate system contained in the defect feature information, calculate the precise three-dimensional coordinates of each defect inside the aluminum rod in real time through ultrasonic propagation path calculation and spatial geometric transformation.

[0044] Based on the three-dimensional coordinates of the defect and the extracted defect feature information, combined with the principle of ultrasonic diffraction time difference, the equivalent size of each defect is calculated.

[0045] The obtained three-dimensional location information of all defects is integrated with the corresponding equivalent size information and associated with the identification information of the aluminum rod to generate a structured list of defect data.

[0046] Based on a structured defect data list, the location and size of defects are automatically marked on the 3D contour map of the aluminum rod, ultimately generating a final inspection report that integrates data tables and 3D visualization markers.

[0047] In a second aspect, a computing device includes:

[0048] One or more processors;

[0049] A storage device for storing one or more programs that, when executed by one or more processors, cause the one or more processors to execute the system.

[0050] Thirdly, a computer-readable storage medium storing a program that, when executed by a processor, performs the system.

[0051] The above-described solution of the present invention has at least the following beneficial effects:

[0052] This invention effectively overcomes the technical problems of traditional ultrasonic flaw detection technology, such as the inability of a fixed coordinate system to adapt to aluminum rod clamping deviation, severe interference from material grain scattering noise, easy missed or false detection of small defects, difficulty in balancing scanning efficiency and accuracy, inaccurate defect localization, and insufficient report visualization. It adopts a dynamic adjustable detection coordinate system with triple reference fusion, a hierarchical scanning sub-region division and dynamic focusing parameter optimization strategy, a targeted noise suppression scheme based on material property matching, a defect feature extraction method combining dynamic threshold and morphological analysis, and a three-dimensional positioning technology based on ultrasonic path calculation and geometric transformation. As a result, it achieves accurate identification, precise three-dimensional positioning, and size quantification of non-metallic inclusions and porosity defects inside aluminum rods, improving the accuracy and efficiency of detection. At the same time, the generated three-dimensional visualized inspection report provides reliable data support for the quality assessment of aluminum rods. Attached Figure Description

[0053] Figure 1 This is a schematic diagram of an aluminum rod internal inclusion and porosity detection system based on ultrasonic flaw detection technology provided in an embodiment of the present invention.

[0054] Figure 2 This is a schematic diagram of the process of a system for detecting inclusions and pores inside an aluminum rod based on ultrasonic flaw detection technology, provided by an embodiment of the present invention. The system processes the original ultrasonic echo signal to suppress multipath scattering noise caused by coarse material grains, thereby obtaining a denoised ultrasonic signal with improved signal-to-noise ratio. Detailed Implementation

[0055] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0056] like Figure 1 As shown, embodiments of the present invention propose a system for detecting internal inclusions and porosity in aluminum rods based on ultrasonic flaw detection technology, comprising:

[0057] The construction module is used to construct a dynamically adjustable detection coordinate system based on the center point of the end face of the aluminum rod as the first reference position, the center of the phased array ultrasonic probe array as the second reference position, and the reference positioning edge of the detection stage as the third reference position.

[0058] The calculation module is used to divide the detection coordinate system into multiple hierarchical scanning sub-regions based on the two-dimensional spatial topological characteristics of the detection coordinate system and the actual size and shape distribution of the aluminum rod end face; and to calculate the focusing delay parameters and scanning path parameters corresponding to each sub-region based on the spatial position, area size and geometric distribution characteristics of the distance from the core area of ​​the aluminum rod end face of each scanning sub-region.

[0059] The scanning module is used to drive the phased array ultrasonic probe array to perform multi-region dynamic focusing scanning of the aluminum rod based on the focusing delay parameter and scanning path parameter, and to transmit and receive ultrasonic signals to obtain the original ultrasonic echo signal of the defect information.

[0060] The suppression module is used to process the original ultrasonic echo signal to suppress multipath scattering noise caused by coarse material grains, and obtain a denoised ultrasonic signal with improved signal-to-noise ratio.

[0061] The extraction module is used to process the denoised ultrasonic signal and identify and extract the micron-level non-metallic inclusions and porosity defects from the denoised ultrasonic signal.

[0062] The processing module is used to process the extracted defect feature information, calculate the precise three-dimensional position and equivalent size of the defect in the aluminum rod in real time, and generate a final inspection report with defect position markings.

[0063] In this embodiment of the invention, the invention employs a three-tiered reference system: a dynamically adjustable detection coordinate system is constructed using the center point of the aluminum rod end face, the center of the phased array ultrasonic probe array, and the reference positioning edge of the detection stage. The system is then used to divide the detection coordinate system into hierarchical scanning sub-regions based on the characteristics of the aluminum rod end face and to calculate the corresponding focusing delay parameters and scanning path parameters. Based on these parameters, the probe array is driven to perform multi-region dynamic focusing scanning. The original ultrasonic echo signal is processed to suppress multipath scattering noise. Micrometer-level defect feature information is identified and extracted from the denoised signal. This defect feature information is processed, and the three-dimensional position and equivalent size of the defect are calculated, generating a label. The series of technical methods used in the testing report have overcome the technical problems of traditional ultrasonic flaw detection technology, such as the inability of the detection coordinate system to adapt to aluminum rod clamping deviations, lack of targeting and accuracy of scanning, noise interference affecting defect identification, difficulty in detecting small defects, inaccurate defect location and size quantification, and lack of intuitive defect marking in the testing report. As a result, it has achieved efficient and accurate detection of non-metallic inclusions and porosity defects inside aluminum rods, improved the accuracy and reliability of the test results, provided comprehensive, intuitive and reliable data support for aluminum rod quality assessment and application, and met the stringent quality requirements of aluminum rod raw materials in the high-end manufacturing field.

[0064] In a preferred embodiment of the present invention, a dynamically adjustable detection coordinate system is constructed based on the center point of the end face of the aluminum rod as the first reference position, the center of the phased array ultrasonic probe array as the second reference position, and the reference positioning edge of the detection stage as the third reference position, including:

[0065] The image of the end face of the aluminum rod is acquired by a visual positioning sensor, and edge extraction and contour fitting are performed on the image. The center point of the fitted contour is established as the first reference position. Specifically, when inspecting aerospace-grade aluminum rods, the visual positioning sensor is first activated to acquire an image of the end face of the aluminum rod. After obtaining a clear end face image, the image is processed. The contour edges of the end face of the aluminum rod are identified by edge extraction technology. Then, the contour fitting method is used to fit these edges into a complete end face contour. Finally, the center point of the fitted contour is determined and the center point is used as the first reference position.

[0066] Based on the established first reference position, the phased array ultrasonic probe array is driven to perform a pre-positioning movement so that the center of the probe array is initially aligned with the first reference position on a two-dimensional plane. The aligned position is then established as the second reference position. Specifically, after obtaining the first reference position, the moving mechanism of the phased array ultrasonic probe array is controlled to move the probe array toward the first reference position for pre-positioning adjustment. This allows the center of the probe array to gradually approach and eventually align with the first reference position on a two-dimensional plane. Once the two are precisely aligned, the position of the center of the probe array at this time is determined as the second reference position.

[0067] Based on the first and second reference positions, the relative spatial angle between the aluminum rod axis and the reference positioning edge of the testing platform is calculated, and the angle relationship is used as the quantitative parameter of the third reference position. Specifically, while establishing the first and second reference positions, the spatial posture of the aluminum rod is analyzed with reference to these two reference positions, and the relative spatial angle formed between the aluminum rod axis and the reference positioning edge of the testing platform is calculated. The specific value of this angle is used as the quantitative parameter of the third reference position to characterize the positional relationship between the aluminum rod and the reference edge of the testing platform.

[0068] The quantized parameters of the first, second, and third reference positions are fused to construct a unified detection coordinate system that can be dynamically adjusted according to the actual clamping state of the aluminum rod. Specifically, this involves integrating the coordinate information of the first, second, and third reference positions and the included angle quantized parameters of the third reference position, and linking the three together using a spatial coordinate fusion algorithm to construct a unified detection coordinate system. The coordinate system adjusts its parameters in real time according to the actual state such as skewness that occurs during the clamping process of the aluminum rod, ensuring that the coordinate system always maintains a precise correspondence with the actual position of the aluminum rod.

[0069] In this embodiment of the invention, the invention employs a technical approach that uses a visual positioning sensor to acquire an image of the aluminum rod's end face and determines a first reference position through edge extraction and contour fitting. This is followed by aligning the phased array ultrasonic probe array with the first reference position to establish a second reference position, calculating the relative spatial angle between the aluminum rod's axis and the reference positioning edge of the testing platform as a third reference quantification parameter, and then integrating these three parameters to construct a testing coordinate system. This effectively overcomes the technical problem of insufficient positioning accuracy caused by the inability of traditional fixed testing coordinate systems to adapt to deviations such as skewing that may occur during aluminum rod clamping. Furthermore, it achieves dynamic adaptation between the testing coordinate system and the actual clamping state of the aluminum rod, improving the accuracy and flexibility of the testing and positioning.

[0070] In a preferred embodiment of the present invention, based on the two-dimensional spatial topological characteristics of the detection coordinate system and the actual size and shape distribution of the aluminum rod end face, the detection coordinate system is divided into multiple hierarchical scanning sub-regions; based on the spatial location, area size, and geometric distribution characteristics of the distance from the core region of the aluminum rod end face of each scanning sub-region, the focusing delay parameters and scanning path parameters corresponding to each sub-region are calculated, including:

[0071] A dynamically adjustable detection coordinate system is invoked, and a virtual geometric boundary that accurately represents the actual contour of the aluminum rod is defined within the coordinate system based on the preset diameter and tolerance parameters of the aluminum rod end face. Specifically, this involves: invoking the dynamically adjustable detection coordinate system previously constructed based on a triple datum, which has the ability to respond in real time to changes in the aluminum rod clamping state. Regardless of slight skew or positional shift during clamping, the system can maintain compatibility with the actual position of the aluminum rod through parameter adjustments; simultaneously, the preset diameter parameter of the aluminum rod end face to be detected is introduced. This parameter is a standard size determined in advance according to the production specifications of the aluminum rod, and is also included in the allowable dimensional tolerance range during the production process, avoiding inaccurate detection boundaries due to slight deviations between the actual size of the aluminum rod and the standard size; in the dynamically adjustable detection coordinate system, the preset diameter and tolerance range are combined and calculated, using the diameter as the basic contour, and the boundary is adjusted inward and outward according to the tolerance range, ultimately accurately defining a virtual geometric boundary that can completely and precisely reflect the true shape of the aluminum rod end face.

[0072] Based on virtual geometric boundaries and the physical characteristics of stress concentration and high defect probability in the central region during aluminum rod manufacturing, the system adaptively divides the area into multiple concentric ring-shaped hierarchical scanning sub-regions from the inside out. Each sub-region is assigned a priority weight coefficient determined by its distance from the core region. Specifically, using the virtual geometric boundaries defined in the first step as the spatial range benchmark, and fully considering the physical characteristics of aluminum rod manufacturing, the molten metal in the central region cools faster and experiences more concentrated stress during casting and rolling processes. Compared to the edge regions, this makes it more prone to defects such as non-metallic inclusions and porosity. The probability of defects is significantly higher in the core area than in other areas. Based on this pattern, starting from the central core area on the end face of the aluminum rod, multiple independent and concentric ring-shaped scanning sub-regions are gradually and evenly divided from the inside out according to a preset width interval. The ring-shaped sub-regions form a clear hierarchical structure from the inside out. The inner sub-regions correspond to the core area where defects occur frequently, and the outer sub-regions correspond to the edge areas where the probability of defects is lower. On this basis, priority weight coefficients are assigned to each scanning sub-region according to its distance from the central core area. The closer the sub-region is to the core area, the higher the priority weight coefficient is assigned, and the farther away it is, the lower the weight coefficient is assigned.

[0073] For each defined scanning sub-region, based on priority weighting coefficients, spatial location, and area size, and combined with the known physical laws of ultrasonic wave propagation in aluminum and the beam focusing law, a dynamic focusing delay parameter set for optimizing the detection sound field energy is calculated and generated. Specifically, for each defined concentric ring-shaped scanning sub-region, a multi-factor comprehensive calculation process is initiated: first, the priority weighting coefficient of the sub-region is included; a higher weighting coefficient results in a larger basic energy allocation coefficient, ensuring stronger focusing energy for high-defect areas; then, the positional relationship relative to the phased array ultrasonic probe array is determined based on the specific spatial coordinates of the sub-region in the dynamic detection coordinate system; the focusing coverage is determined by combining the area size of the sub-region; a larger area results in a higher focal point density and a more refined delay parameter step size; subsequently, the core physical laws of ultrasonic wave propagation in aluminum are integrated, including the constant propagation speeds of longitudinal and transverse waves in aluminum, and the energy attenuation law that increases with propagation distance and is frequency-dependent; attenuation = attenuation coefficient × propagation distance × sound frequency, where the attenuation coefficient is in dB / (mm·MHz), the propagation distance is in mm, and the sound frequency... The rate unit is MHz. All three units can be directly calculated if they match. If there are differences in the parameter units in practical applications, each parameter must be normalized to a unified dimension before calculation. The final attenuation unit is dB. The propagation path geometry at different depths along a straight line is also considered. The propagation path length equals the spatial straight-line distance between the probe element coordinates and the target point coordinates in the sub-region. Simultaneously, the core principle of beam focusing is strictly followed. The core principle of beam focusing is to precisely control the emission time difference of each element in the probe array, compensating for the acoustic path difference between different elements and the target focal point in the sub-region. This ensures that the ultrasonic waves emitted by all elements arrive simultaneously at the focal point and achieve in-phase superposition, thus forming a narrow beam with highly concentrated energy, improving the detection sensitivity for minute defects. Finally, the energy allocation coefficient corresponding to the priority weight, the basic delay time calculated based on the acoustic path difference, the energy attenuation correction value calculated based on the propagation distance and attenuation coefficient, and the focal point distribution requirements determined by the coverage area are weighted and fused to generate a dedicated dynamic focusing delay parameter set for each scanning sub-region, containing the emission delay time and phase adjustment values ​​of each element.

[0074] Based on a dynamic focusing delay parameter set, an efficient scanning trajectory is planned for each scanning sub-region to achieve full coverage and maintain a smooth transition with the path of adjacent regions. A corresponding scanning path parameter set is generated. Specifically, this involves: using the calculated dynamic focusing delay parameter set as the core basis, planning a dedicated scanning trajectory for each scanning sub-region. During the planning process, it is first ensured that the trajectory can achieve full coverage of the sub-region without blind spots. For sub-regions of different sizes, spiral, grating, and other trajectory modes are flexibly adopted to ensure that every spatial point within the sub-region is scanned by the ultrasonic beam, eliminating any scanning omissions. Simultaneously, the continuity of the trajectory is emphasized. At the junction of the trajectories of two adjacent concentric ring-shaped sub-regions, the direction and speed of the trajectory are adjusted to ensure a smooth transition between the endpoint of the trajectory of the previous sub-region and the starting point of the trajectory of the next sub-region, avoiding trajectory breaks, overlaps, or sharp turns, reducing mechanical losses and time waste during the movement of the phased array ultrasonic probe array. After the trajectory planning is completed, the specific information of the trajectory is converted into the corresponding scanning path parameter set.

[0075] In this embodiment of the invention, by employing a dynamically adjustable detection coordinate system and defining precise virtual geometric boundaries using preset diameter and tolerance parameters of the aluminum rod end face, and adaptively dividing concentric ring-shaped hierarchical scanning sub-regions from the inside out based on the physical law that the aluminum rod's central region has a high probability of defects, and assigning priority weight coefficients related to the distance to the core region, and by calculating dynamic focusing delay parameter sets for each sub-region based on the propagation law of ultrasonic waves in aluminum and the sound beam focusing law, and then planning an efficient scanning trajectory that covers the entire area and smoothly transitions with adjacent areas based on this parameter set, and generating a scanning path parameter set, the technical means effectively overcome the technical problems of traditional ultrasonic flaw detection technology, such as lack of specificity in scanning area division, unreasonable sound field energy distribution, incomplete scanning path coverage or poor transition, resulting in insufficient detection of high-defect areas and difficulty in balancing detection accuracy and efficiency. This achieves differentiated key detection of the aluminum rod end face, optimizes the detection sound field energy distribution, ensures the comprehensiveness and continuity of the scan, and improves detection accuracy and efficiency.

[0076] In a preferred embodiment of the present invention, based on focusing delay parameters and scanning path parameters, a phased array ultrasonic probe array is driven to perform multi-region dynamic focusing scanning of an aluminum rod, transmitting and receiving ultrasonic signals to obtain the original ultrasonic echo signal of defect information, including:

[0077] Based on the scanning path parameter set, the mechanical movement mechanism of the phased array ultrasonic probe array is controlled to move the probe array sequentially to the designated positions of each scanning sub-region according to the planned efficient scanning trajectory, ensuring a constant coupling state with the aluminum rod end face during the movement. This establishes a physical positional basis for the accurate scanning of each sub-region. Specifically, this involves: acquiring the previously generated scanning path parameter set, which contains detailed information such as the coordinates, speed, and turning nodes of the phased array ultrasonic probe array to be moved; converting the parameters into control commands and transmitting them to the mechanical movement mechanism of the probe array; and driving the mechanical movement mechanism to move the probe array sequentially to the designated positions of each concentric ring scanning sub-region according to the planned efficient scanning trajectory. During the movement, the contact pressure between the probe array and the aluminum rod end face is monitored in real time by a force control sensor. If the pressure deviates from the preset constant coupling range, the Z-axis position of the mechanical movement mechanism is immediately adjusted. If the pressure is too high, the probe is controlled to move slightly away from the aluminum rod end face; if the pressure is too low, the probe is controlled to move slightly closer. This ensures that the probe array and the aluminum rod end face maintain a stable coupling state throughout the entire movement, providing a reliable physical positional basis for the accurate scanning of each scanning sub-region.

[0078] At each designated scanning position, the focusing delay parameter set corresponding to the sub-region is invoked to dynamically adjust the emission timing and phase of each element in the phased array ultrasonic probe array, thereby emitting a focused ultrasonic beam. This achieves directional energy injection and precise scanning of a specific region inside the aluminum rod. Specifically, after the phased array ultrasonic probe array moves to a designated position in a scanning sub-region and stabilizes, the focusing delay parameter set corresponding to that sub-region is invoked. The parameter set contains the emission time difference and phase adjustment value of each element in the probe array. According to the instructions of the parameter set, the emission timing of each element is dynamically adjusted, allowing some elements to emit earlier and some to emit later. At the same time, the phase of the emitted signal of each element is adjusted so that the ultrasonic waves emitted by different elements form superposition interference at a specific position in the sub-region inside the aluminum rod, thereby converging into a focused ultrasonic beam with concentrated energy. The directional focused beam can accurately act on the target area inside the aluminum rod, achieving directional energy injection into the area. This ensures that even tiny non-metallic inclusions or pore defects can reflect or scatter identifiable ultrasonic signals, completing a precise scan of the sub-region.

[0079] After the focused ultrasonic beam is emitted, the phased array ultrasonic probe array synchronously receives the ultrasonic echo signals reflected or scattered from inside the aluminum rod. The received analog echo signals are amplified and filtered by the signal conditioning circuit, and finally converted into digital echo signals. Specifically, while the focused ultrasonic beam is emitted, the phased array ultrasonic probe array switches to receiving mode to synchronously capture the ultrasonic echo signals reflected or scattered from inside the aluminum rod. The signals contain both useful signals reflected from defects and noise signals generated by scattering from material grains. The received echo signals are analog electrical signals, which are usually weak in amplitude and mixed with high-frequency interference. The analog signal is fed into the signal conditioning circuit, which first amplifies the signal to enhance the amplitude of the useful signal to achieve the strength required for subsequent processing. Then, the filtering circuit filters out high-frequency noise and low-frequency interference that are unrelated to the detection frequency. The amplified and filtered analog signal is then converted into a digital echo signal by the analog-to-digital converter module, finally obtaining the original ultrasonic echo signal containing defect information.

[0080] In this embodiment of the invention, because a mechanical movement mechanism based on a scanning path parameter set is used to move the probe array to the designated position in each sub-region according to the planned trajectory and maintain a constant coupling state, and the focusing delay parameter set is called at each position to adjust the transmission timing and phase of the array elements to transmit a focused beam, and the received echo is amplified, filtered and converted into a digital signal, the technical problems of inaccurate probe movement trajectory, unstable coupling state leading to unreliable scanning position, insufficient sound field focusing making it difficult to directionally scan specific areas, and poor raw data quality due to untreated echo signals are overcome in traditional technologies. Thus, accurate positioning and stable coupling of the probe scanning position are achieved, ensuring directional energy injection and accurate scanning of each sub-region inside the aluminum rod, while obtaining high-quality raw ultrasonic echo signals, improving the accuracy of micro-defect detection.

[0081] In a preferred embodiment of the present invention, based on a set of scanning path parameters, the mechanical movement mechanism of the phased array ultrasonic probe array is controlled so that the probe array moves sequentially to the designated position of each scanning sub-region according to a planned efficient scanning trajectory, and ensures that it maintains a constant coupling state with the end face of the aluminum rod during the movement, thereby establishing a physical position basis for the accurate scanning of each sub-region, including:

[0082] The scanning path parameter set for each scanning sub-region is invoked, and multi-axis coordinated motion control commands for the mechanical moving mechanism are obtained based on the scanning path parameter set. Specifically, this includes: invoking the scanning path parameter set pre-set for each scanning sub-region. These parameter sets record in detail the specific position of each sub-region, the trajectory direction of the probe to be moved, the moving speed, and the connection nodes between each region. Based on these parameters, the motion control algorithm is used to convert them into multi-axis coordinated motion control commands for the mechanical moving mechanism. The multi-axis coordinated motion control commands precisely specify the moving direction and distance of the X and Y axes, as well as the timing coordination of the movement of each axis, to ensure that the probe array can move accurately according to the planned trajectory.

[0083] By executing motion control commands, the phased array ultrasonic probe array is driven to move sequentially along a planned high-efficiency scanning trajectory. During the movement, the force control sensor monitors the contact pressure between the probe and the end face of the aluminum rod in real time. Specifically, the mechanical moving mechanism receives and executes multi-axis coordinated motion control commands, driving the phased array ultrasonic probe array to move sequentially to the designated position of each scanning sub-region along the planned high-efficiency scanning trajectory. Throughout the movement, the force control sensor installed on the probe array works continuously to detect the contact pressure between the probe array and the end face of the aluminum rod in real time.

[0084] Based on real-time contact pressure data fed back by the force control sensor, the Z-axis position of the mechanical moving mechanism is dynamically adjusted to maintain a constant coupling state between the probe array and the aluminum rod end face throughout the scanning process. Specifically, this includes: receiving real-time contact pressure data fed back by the force control sensor and comparing it with a preset optimal coupling pressure range. If the detected pressure is greater than the preset range, it indicates that the contact between the probe and the aluminum rod end face is too tight, and an adjustment command is immediately issued to control the Z-axis of the mechanical moving mechanism to rise, reducing the contact pressure between the probe and the aluminum rod. If the pressure is less than the preset range, it indicates that the contact is too loose, and the Z-axis is controlled to fall, increasing the contact pressure. Through dynamic adjustment, it is ensured that the probe array and the aluminum rod end face maintain a constant coupling state throughout the entire scanning movement.

[0085] Once the probe array reaches and stabilizes at the designated position in any scanning sub-region according to the control method, a precise physical position basis is established. Specifically, when the phased array ultrasonic probe array moves to the designated position in any scanning sub-region according to the control command, and the contact pressure fed back by the force control sensor is stable within the preset range, it indicates that the probe position and coupling state have met the requirements. At this time, the position is confirmed to be stable and reliable, which serves as the physical position basis for precise scanning of the sub-region.

[0086] In this embodiment of the invention, by employing a technique of calling the scanning path parameter set of each scanning sub-region to generate multi-axis coordinated motion control commands for the mechanical moving mechanism, executing the commands to drive the probe array to move sequentially along the planned trajectory, and monitoring the contact pressure in real time through a force control sensor, and dynamically adjusting the Z-axis position of the mechanical moving mechanism based on the pressure data to maintain a constant coupling state, and establishing a physical position basis after the probe array reaches a stable position, the technical problems of probe movement trajectory deviation and unstable coupling state with the aluminum rod end face in traditional ultrasonic flaw detection, which lead to unreliable scanning position basis and affect detection accuracy, are overcome. This achieves precise and controllable movement of the probe array and continuous stability of the coupling state, laying a solid physical position foundation for accurate scanning of each scanning sub-region and providing prerequisite support for the accurate detection of minute defects.

[0087] like Figure 2 As shown, in another preferred embodiment of the present invention, by processing the original ultrasonic echo signal to suppress multipath scattering noise caused by coarse material grains, a denoised ultrasonic signal with improved signal-to-noise ratio is obtained, including:

[0088] The process involves receiving the raw ultrasonic echo signal and performing a time-frequency domain joint analysis to extract dispersion and attenuation characteristic parameters that characterize the scattering properties of the material grains. Specifically, this includes receiving the raw ultrasonic echo signal obtained from previous scans, which contains useful signals reflected from internal defects in the aluminum rod and multipath scattering noise signals generated by coarse material grains. Subsequently, a time-frequency domain joint analysis is performed on the raw ultrasonic echo signal to analyze both the amplitude variation of the signal at different time points and the frequency distribution characteristics of the signal. Through this two-way analysis, the dispersion and attenuation characteristic parameters that reflect the scattering properties of the aluminum rod grains are accurately captured.

[0089] Based on the extracted dispersion and attenuation characteristic parameters, a multipath scattering noise characterization template matching the current aluminum rod material characteristics is established by querying a preset acoustic characteristic database. Specifically, this includes: calling the preset acoustic characteristic database, which stores acoustic characteristic data and corresponding noise performance patterns of aluminum rods with different materials and grain states; comparing and matching the dispersion and attenuation characteristic parameters extracted in the first step with the data in the database; selecting reference data that highly matches the current aluminum rod material characteristics; and constructing a multipath scattering noise characterization template specifically for the current aluminum rod grain scattering situation based on the successfully matched reference data.

[0090] By establishing a multipath scattering noise characterization template, noise components are matched and estimated in the original ultrasonic echo signal. An adaptive filtering algorithm is then used to separate and subtract the estimated noise components from the original signal to obtain the denoised signal. Specifically, the process involves comparing the constructed multipath scattering noise characterization template with the original ultrasonic echo signal segment by segment. Based on the noise characteristics of the template, the corresponding noise components are identified and matched in the original signal. At the same time, the amplitude, duration, and distribution location of these noise components are accurately estimated. Then, an adaptive filtering algorithm is used to dynamically adjust the filtering parameters according to the real-time changes of the original signal and the estimated noise components. The identified noise components are separated from the original ultrasonic echo signal and subtracted, thus initially eliminating most of the multipath scattering noise and obtaining the preliminarily denoised signal.

[0091] The denoised signal is reconstructed using wavelet transform and envelope detection to obtain a denoised ultrasonic signal with improved signal-to-noise ratio. Specifically, the process involves: first, wavelet transform reconstruction is performed on the initially denoised signal. Through decomposition and reconstruction, residual minor noise is further eliminated from the signal while preserving the waveform characteristics of the useful defect signal to avoid distortion. Then, envelope detection is performed on the reconstructed signal to extract the envelope curve, highlighting the amplitude variation characteristics of the useful defect signal and making the defect signal more clearly identifiable. After these two steps, a denoised ultrasonic signal with improved signal-to-noise ratio is finally obtained.

[0092] In this embodiment of the invention, because a joint time-frequency domain analysis of the original ultrasonic echo signal is performed to extract dispersion and attenuation characteristic parameters that characterize the scattering properties of the material grains, a multipath scattering noise characterization template matching the current aluminum rod material characteristics is established by querying a preset acoustic characteristic database, and the original signal is matched and estimated using this template, and the noise components are separated and subtracted using an adaptive filtering algorithm, and then the denoised signal is reconstructed by wavelet transform and envelope detection, the technical problems of traditional noise suppression schemes lacking specificity, failing to accurately suppress multipath scattering noise caused by coarse aluminum rod grains, and thus masking small defect signals are effectively overcome, thereby improving the signal-to-noise ratio of the ultrasonic echo signal and obtaining a denoised ultrasonic signal with significantly reduced noise interference and clearly highlighted defect characteristic signals.

[0093] In a preferred embodiment of the present invention, the denoised ultrasonic signal is processed to identify and extract micron-level feature information of non-metallic inclusions and porosity defects from the denoised ultrasonic signal, including:

[0094] The system receives a denoised ultrasonic signal with improved signal-to-noise ratio (SNR) and performs statistical analysis on its amplitude distribution to calculate a dynamic threshold that adapts to changes in signal energy. Specifically, it receives a denoised ultrasonic signal with significantly improved SNR after noise suppression processing. This signal has eliminated most of the multipath scattering noise caused by coarse aluminum rod grains, retaining only useful defect-related signals and a small amount of residual noise. Subsequently, a comprehensive statistical analysis of the amplitude distribution of this denoised ultrasonic signal is performed, detailing the amplitude variation range, peak density, and energy concentration trend at different time periods. By analyzing the real-time fluctuations in signal energy, a dynamic threshold that adapts to real-time signal energy changes is dynamically calculated. This threshold is not a fixed value but automatically adjusts with the strength of the signal energy. The threshold increases when the signal energy is high and decreases when the signal energy is low, ensuring that weak, minute defect signals are captured while avoiding misjudging residual noise as defects due to an excessively low threshold.

[0095] Based on the calculated dynamic threshold, the amplitude of the denoised ultrasonic signal is compared with the dynamic threshold to initially identify all potential defect echoes and obtain binary marker data for the potential defect locations. Specifically, after obtaining the dynamic threshold, the amplitude value of the denoised ultrasonic signal at each moment is compared with the dynamic threshold point by point. When the amplitude value of the signal at a certain moment is higher than the dynamic threshold, the signal is determined to be a potential defect echo signal, and the location is marked as having a potential defect. When the signal amplitude value is lower than the dynamic threshold, it is determined to be a background signal or residual noise, and no defect marking is performed. Through point-by-point comparison, the entire denoised ultrasonic signal is comprehensively screened to initially identify all possible corresponding defect echoes, and the location information of potential defects is converted into binary marker data.

[0096] Signal morphological analysis is performed on the obtained binarized marked data. Opening and closing operations are executed to eliminate isolated noise points and connect adjacent small defect regions, ultimately accurately segmenting the connected regions corresponding to non-metallic inclusions and pores. Specifically, this involves: performing signal morphological analysis on the generated binarized marked data; firstly, performing an opening operation to erode the binarized data, reducing the boundaries of potential defect regions, thereby eliminating small isolated noise points in the data. These noise points are mostly minor interferences remaining after denoising and are not actual defects; then, expansion processing is performed... The process involves restoring the original outline of the potential defect area to ensure that the shape of the actual defect is not destroyed. After the opening operation is completed, the closing operation is performed. First, the binarized data is dilated to expand the range of the potential defect area, connecting the originally adjacent but unconnected small defect areas into a whole. Then, erosion is performed to correct the boundary shape of the defect area and remove the redundant edges caused by the dilation. Through the combination of opening and closing operations, the connected areas corresponding one-to-one with the non-metallic inclusions and porosity defects inside the aluminum rod are finally accurately segmented, completely eliminating the interference of residual noise and clarifying the specific range of the actual defect.

[0097] Based on the precisely segmented connected regions, defect feature information of the echo signal in each connected region is extracted, including but not limited to maximum amplitude, energy integral, time domain width, and spectral center frequency. Specifically, for each precisely segmented defect connected region, the corresponding echo signal characteristics are analyzed in depth to extract core feature information that accurately characterizes the defect attributes. Among them, the maximum amplitude refers to the highest intensity value of the echo signal in the connected region, reflecting the defect's ability to reflect ultrasonic waves; the energy integral is the cumulative calculation of the amplitude of the echo signal in the region, reflecting the total energy of the defect's reflected signal; the time domain width refers to the duration of the defect echo signal from its appearance to its disappearance, which is related to the extension range of the defect; the spectral center frequency is the frequency distribution of the defect echo signal analyzed to determine the main frequency of its energy concentration, reflecting the material and structural characteristics of the defect. By extracting key feature information, the core attributes of each defect are fully understood.

[0098] In this embodiment of the invention, because a dynamic threshold that adapts to changes in signal energy is calculated by receiving a denoised ultrasonic signal and statistically analyzing its amplitude distribution, and then comparing the signal amplitude based on the dynamic threshold to initially identify potential defect echoes and obtain binarized labeled data, morphological opening and closing operations are performed on the binarized data to eliminate isolated noise points, connect adjacent micro-defect regions, and accurately segment the defect connected regions, and then defect feature information such as the maximum amplitude and energy integral are extracted based on the connected regions, this invention effectively overcomes the technical problems in traditional technologies, such as the difficulty of adapting fixed thresholds to changes in signal energy, the tendency of residual noise to lead to false detections and missed detections, and the difficulty of accurately segmenting micro-defect regions, which makes it impossible to effectively identify and extract micron-level non-metallic inclusions and porosity defect features. This achieves accurate screening of micro-defect echoes and precise definition of defect regions, successfully extracting core feature information that can accurately characterize defect attributes, and improving the accuracy and reliability of micro-defect detection.

[0099] In a preferred embodiment of the present invention, the extracted defect feature information is processed to calculate the precise three-dimensional position and equivalent size of the defect in the aluminum rod in real time, and a final inspection report with defect location markers is generated, including:

[0100] The system receives defect feature information and, based on the arrival time of the defect echo and the spatial position of the phased array probe in the detection coordinate system contained in the defect feature information, calculates the precise three-dimensional coordinates of each defect inside the aluminum rod in real time through ultrasonic propagation path calculation and spatial geometric transformation. Specifically, this includes: receiving the extracted defect feature information, which contains the time data of the echo signal of each potential defect arriving at the phased array probe, and the real-time spatial position coordinates of the phased array probe in the dynamically adjustable detection coordinate system; calculating the propagation path of the ultrasonic wave from the probe to the defect and back to the probe based on the known speed of ultrasonic wave propagation in aluminum material, and then estimating the straight-line distance between the probe and the defect; combining the spatial position of the phased array probe in the detection coordinate system, converting the relative distance between the probe and the defect into the three-dimensional coordinates of the defect inside the aluminum rod through spatial geometric transformation, namely the depth along the axis of the aluminum rod, the radial radius, and the circumferential angular position, thereby calculating the precise three-dimensional coordinates of each defect in real time.

[0101] Based on the three-dimensional coordinates of the defect and the extracted defect feature information, combined with the ultrasonic diffraction time-of-flight principle, the equivalent size of each defect is calculated. Specifically, after obtaining the precise three-dimensional coordinates of the defect, the previously extracted defect feature information, including the maximum amplitude of the defect echo, energy integral, and other data reflecting the defect's reflection characteristics, is analyzed using the ultrasonic diffraction time-of-flight principle. The ultrasonic diffraction time-of-flight principle is based on the fact that the defect edge diffracts ultrasonic waves, and the diffracted signals at different locations arrive at the probe at different times. By calculating this time difference and combining it with the ultrasonic wave propagation speed, the actual size of the defect can be deduced. The calculation results are compared with data in a standard defect database, converting the complex shape of the actual defect into an equivalent size, that is, the size of a standard-shaped defect with the same diffraction characteristics as the defect, thus achieving precise quantification of the size of non-metallic inclusions and porosity defects.

[0102] The obtained 3D location information of all defects is integrated with the corresponding equivalent size information and associated with the identification information of the aluminum rod to generate a structured defect data list. Specifically, this includes: summarizing the precise 3D coordinate information of all defects with the corresponding equivalent size information, sorting them according to the order of discovery or spatial location of the defects, and associating them with the unique identification information of the aluminum rod, including basic information such as the model, specifications, production batch, and serial number of the aluminum rod, to ensure that each defect data can correspond to a specific aluminum rod. Through data integration, a structured defect data list is generated, which clearly presents the serial number, 3D coordinates, equivalent size, and corresponding aluminum rod identification of each defect.

[0103] Based on a structured defect data list, the location and size of defects are automatically marked in the 3D contour map of the aluminum rod. This results in a final inspection report integrating data tables and 3D visualization markers. Specifically, the process includes: using the generated structured defect data list, accessing the 3D contour map of the aluminum rod (constructed based on the rod's actual dimensions and a dynamic detection coordinate system to accurately reflect its true shape), reading the 3D coordinates of each defect one by one, locating the precise position corresponding to those coordinates in the 3D contour map, and automatically marking the defect. Furthermore, different symbols or depths are used based on the defect's equivalent size. The defects are distinguished and marked with different colors, and larger defects are marked with more conspicuous or larger symbols, making the spatial distribution and actual size of the defects intuitively identifiable. Based on this, the structured defect data list is converted into a standardized data table, which clearly lists the serial number, three-dimensional coordinates, equivalent size and related aluminum rod information of each defect. This data table is integrated with the three-dimensional contour map with defect markings to generate a complete inspection report. The report contains detailed and accurate defect data, has intuitive and easy-to-understand three-dimensional visualization markings, and clearly presents the specific location, actual size and overall distribution of defects inside the aluminum rod.

[0104] In this embodiment of the invention, by employing a technical approach that combines the arrival time of the defect echo with the spatial position of the probe after receiving defect feature information, calculates the precise three-dimensional coordinates of the defect through ultrasonic propagation path calculation and spatial geometric transformation, calculates the equivalent size based on the three-dimensional coordinates, feature information, and ultrasonic diffraction time difference principle, and integrates the three-dimensional position of the defect, the equivalent size, and the aluminum rod identification information to generate a structured defect data list, and automatically marks the defect in the three-dimensional contour map of the aluminum rod and generates an inspection report with integrated data tables and three-dimensional visualization marks, this invention effectively overcomes the technical problems of inaccurate three-dimensional positioning of defects, inaccurate quantification of equivalent sizes, and lack of structured and intuitive visualization in inspection reports in traditional technologies, which lead to an inability to accurately grasp the actual situation of defects. This achieves precise three-dimensional positioning and precise equivalent size quantification of non-metallic inclusions and porosity defects inside the aluminum rod. The generated inspection report combines structured data with intuitive three-dimensional markings, clearly presenting the location, size, and related information of the aluminum rod, providing a comprehensive and reliable basis for aluminum rod quality assessment, qualification determination, and subsequent processing optimization, and improving the practicality and traceability of the inspection results.

[0105] Embodiments of the present invention also provide a computing device, including: a processor and a memory storing a computer program, wherein the computer program, when executed by the processor, performs the system as described above. All implementations in the above system embodiments are applicable to this embodiment and can achieve the same technical effects.

[0106] Embodiments of the present invention also provide a computer-readable storage medium storing instructions that, when executed on a computer, cause the computer to perform the system as described above. All implementations in the above system embodiments are applicable to this embodiment and can achieve the same technical effects.

[0107] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. An aluminum bar internal inclusion and pore detection system based on ultrasonic flaw detection technology, characterized in that, The application relates to a method for detecting defects in an aluminum rod end face, comprising the following steps: A construction module is used to construct a dynamic adjustable detection coordinate system with the center point of the end face of the aluminum rod as a first reference position, the center of the phased array ultrasonic probe array as a second reference position, and the reference positioning edge of the detection table as a third reference position, which comprises the following steps: An image of the aluminum rod end face is acquired through a visual positioning sensor, and edge extraction and contour fitting processing are performed on the image, so that the contour center point obtained through fitting is determined as the first reference position; Based on the determined first reference position, the phased array ultrasonic probe array is driven to move in a predetermined position, so that the center of the probe array is preliminarily aligned with the first reference position in a two-dimensional plane, and the aligned position is determined as the second reference position; According to the first reference position and the second reference position, the relative spatial included angle between the aluminum rod axis and the reference positioning edge of the detection table is calculated, and the included angle relationship is taken as the quantitative parameter of the third reference position; The first reference position, the second reference position and the quantitative parameter of the third reference position are fused to construct a unified detection coordinate system which can be dynamically adjusted according to the actual clamping state of the aluminum rod; A calculation module is used to divide the detection coordinate system into multiple hierarchical scanning sub-regions according to the two-dimensional space topological characteristics of the detection coordinate system and the actual size and shape distribution law of the aluminum rod end face, and to calculate the focusing delay parameter and the scanning path parameter corresponding to each sub-region according to the spatial position, area size and distance geometric distribution characteristics of each scanning sub-region and the core region of the aluminum rod end face; A scanning module is used to drive the phased array ultrasonic probe array to perform multi-region dynamic focusing scanning on the aluminum rod based on the focusing delay parameter and the scanning path parameter, to emit and receive ultrasonic signals, and to obtain original ultrasonic echo signals of defect information; An inhibition module is used to process the original ultrasonic echo signals to inhibit the multi-path scattering noise caused by the coarse material grain, and to obtain denoised ultrasonic signals with improved signal-to-noise ratio; An extraction module is used to process the denoised ultrasonic signals to identify and extract the feature information of micron-level non-metallic inclusions and pore defects from the denoised ultrasonic signals; A processing module is used to process the extracted defect feature information, to calculate the accurate three-dimensional position and equivalent size of the defects in the aluminum rod in real time, and to generate a final detection report with defect position marking.

2. The system for detecting internal inclusion and porosity in an aluminum rod based on ultrasonic flaw detection technology according to claim 1, wherein According to the two-dimensional space topological characteristics of the detection coordinate system and the actual size and shape distribution law of the aluminum rod end face, the detection coordinate system is divided into multiple hierarchical scanning sub-regions; according to the spatial position, area size and distance geometric distribution characteristics of each scanning sub-region and the core region of the aluminum rod end face, the focusing delay parameter and the scanning path parameter corresponding to each sub-region are calculated, which comprises the following steps: The dynamic adjustable detection coordinate system is called, and a virtual geometric boundary accurately representing the actual contour of the aluminum rod is defined in the coordinate system based on the preset diameter and tolerance parameters of the aluminum rod end face. Based on the virtual geometric boundary, according to the physical law of stress concentration and high defect probability in the center area of the aluminum bar during the manufacturing process, the area is adaptively divided into multiple hierarchical scanning sub-areas from the inside to the outside in a concentric ring shape, and each sub-area is assigned a priority weight coefficient determined based on the distance between the scanning sub-area and the core area; For each divided scanning sub-area, according to the priority weight coefficient, spatial position and area size, combined with the known physical law of ultrasonic wave propagation in aluminum material and the sound beam focusing rule, a set of dynamic focusing delay parameters for optimizing the detection sound field energy is calculated and generated respectively; Based on the set of dynamic focusing delay parameters, an efficient scanning trajectory for each scanning sub-area is planned to achieve global coverage and smooth transition with adjacent area paths, and the corresponding scanning path parameter set is generated.

3. The system for detecting internal inclusion and porosity in an aluminum rod based on ultrasonic flaw detection technology according to claim 2, characterized in that, Based on the focusing delay parameters and scanning path parameters, the phased array ultrasonic probe array is driven to perform multi-region dynamic focusing scanning on the aluminum bar, emit and receive ultrasonic signals, and obtain the original ultrasonic echo signal of the defect information, including: Based on the scanning path parameter set, the mechanical moving mechanism of the phased array ultrasonic probe array is controlled to move the probe array to the specified position of each scanning sub-area according to the planned efficient scanning trajectory, and to ensure constant coupling with the end face of the aluminum bar during the movement, thereby establishing a physical position basis for accurate scanning of each sub-area; At each specified scanning position, the corresponding focusing delay parameter set of the sub-area is called to dynamically adjust the emission timing and phase of each element of the phased array ultrasonic probe array, and then a focused ultrasonic beam is emitted to realize directional energy injection and accurate scanning of the specific area inside the aluminum bar. After the focused ultrasonic beam is emitted, the phased array ultrasonic probe array synchronously receives the ultrasonic echo signals reflected or scattered from the inside of the aluminum bar, and the received analog echo signals are amplified and filtered by a signal conditioning circuit, and finally converted into digital echo signals.

4. The system for detecting internal inclusion and porosity of an aluminum bar based on ultrasonic flaw detection technology according to claim 3, wherein Based on the scanning path parameter set, the mechanical moving mechanism of the phased array ultrasonic probe array is controlled to move the probe array to the specified position of each scanning sub-area according to the planned efficient scanning trajectory, and to ensure constant coupling with the end face of the aluminum bar during the movement, thereby establishing a physical position basis for accurate scanning of each sub-area, including: Calling the scanning path parameter set for each scanning sub-area, obtaining the multi-axis coordinated motion control instruction of the mechanical moving mechanism based on the scanning path parameter set; By executing the motion control instruction, the phased array ultrasonic probe array is driven to move according to the planned efficient scanning trajectory, and the contact pressure between the probe and the end face of the aluminum bar is monitored in real time by the force control sensor during the movement; According to the real-time contact pressure data fed back by the force control sensor, the Z-axis position of the mechanical moving mechanism is dynamically adjusted to maintain a constant coupling state between the probe array and the end face of the aluminum bar during the entire scanning process; When the probe array reaches the specified position of any scanning sub-area according to the control mode and stabilizes, an accurate physical position basis is established.

5. The system for detecting internal inclusion and porosity in an aluminum rod based on ultrasonic flaw detection technology according to claim 4, wherein By processing the original ultrasonic echo signal, the multi-path scattering noise caused by coarse material grains is suppressed, and a denoised ultrasonic signal with improved signal-to-noise ratio is obtained, including: The original ultrasonic echo signal is received, and the signal in the original ultrasonic echo signal is analyzed in time-frequency domain to extract dispersion and attenuation characteristic parameters representing material grain scattering characteristics; Based on the extracted dispersion and attenuation characteristic parameters, a multi-path scattering noise representation template matched with the current aluminum bar material characteristics is established by querying a preset acoustic characteristic database; Through the established multi-path scattering noise representation template, noise component matching and estimation are performed on the original ultrasonic echo signal, and an adaptive filtering algorithm is used to separate and subtract the estimated noise component from the original signal to obtain a denoised signal; The denoised signal is subjected to wavelet transform reconstruction and envelope detection processing, and finally a denoised ultrasonic signal with improved signal-to-noise ratio is obtained.

6. The system for detecting internal inclusion and porosity of an aluminum bar based on ultrasonic flaw detection technology according to claim 5, wherein, The denoised ultrasonic signal is processed to identify and extract the characteristic information of micron-level non-metallic inclusions and porosity defects from the denoised ultrasonic signal, including: The signal-to-noise ratio improved denoised ultrasonic signal is received, and the amplitude distribution of the signal is statistically analyzed to calculate a dynamic threshold that changes adaptively with the signal energy; Based on the calculated dynamic threshold, the amplitude of the denoised ultrasonic signal is compared with the dynamic threshold to preliminarily identify all potential defect echoes and obtain binary labeled data of the potential defect positions; Signal morphology analysis is performed on the obtained binary labeled data to eliminate isolated noise points in the binary labeled data, connect adjacent small defect regions, and finally accurately segment the connected regions corresponding to non-metallic inclusions and pores; Based on the accurately segmented connected regions, the echo signal defect characteristic information of each connected region is extracted, including but not limited to maximum amplitude, energy integral, time domain width, and spectral center frequency.

7. The system for detecting internal inclusion and porosity in an aluminum rod based on ultrasonic flaw detection technology according to claim 6, wherein The extracted defect characteristic information is processed to calculate the accurate three-dimensional position and equivalent size of the defect in the aluminum bar in real time, and a final detection report with defect position marking is generated, including: The defect characteristic information is received, and based on the defect echo arrival time contained in the defect characteristic information and the spatial position of the phased array probe in the detection coordinate system, the accurate three-dimensional coordinates of each defect inside the aluminum bar are calculated in real time through ultrasonic propagation range calculation and spatial geometric transformation; Based on the three-dimensional coordinates of the defects and the extracted defect characteristic information, the equivalent size of each defect is calculated based on the ultrasonic diffraction time difference principle; All the three-dimensional position information and corresponding equivalent size information of the defects are integrated, and the identification information of the aluminum bar is associated to generate a structured defect data list; Based on the structured defect data list, the positions and sizes of the defects are automatically labeled in the three-dimensional profile of the aluminum bar to finally generate a final detection report integrating the data table and three-dimensional visual marking.

8. A computing device, comprising: Comprise: One or more processors; A storage device for storing one or more programs, when the one or more programs are executed by the one or more processors, so that the one or more processors execute the system as claimed in any one of claims 1 to 7.

9. A computer-readable storage medium, characterized in that, The computer readable storage medium stores a program, and the program is executed by the processor to perform the system of any one of claims 1 to 7.

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