Phased array ultrasonic flexible detection device for multiple types of welding seams and detection method of phased array ultrasonic flexible detection device

Abstract

The invention discloses a phased array ultrasonic flexible detection device and detection method for multiple types of welding seams. The phased array ultrasonic flexible detection device comprises a device mounting plate, and a butt welding seam detection module and a corner welding seam detection module which are mounted on the device mounting plate, each of the butt weld detection module and the fillet weld detection module comprises a probe clamping module used for fixing a phased array ultrasonic probe; the pressure maintaining module is connected with the probe clamping module and the device mounting plate, an adjustable elastic mechanism is arranged in the pressure maintaining module, and the pressure maintaining module is used for providing elastic force for pressing the probe to the surface of the detected welding seam; the coupling agent filling module is arranged at the tail end of the probe clamping module and is used for supplying a coupling agent between the probe and the surface of the detected welding seam; and the electromagnet is arranged on the probe clamping module or the device mounting plate and is used for generating magnetic force when being electrified and overcoming the elastic force to lift the probe so as to be in a storage preparation state. According to the invention, automatic detection of various welding seam types such as corner joint, butt joint, bent plate objects, flat plate objects and the like is realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of industrial non-destructive testing, and in particular to a phased array ultrasonic flexible detection device for multiple types of welds and a detection method thereof. BACKGROUND

[0002] Phased array ultrasonic detection is a detection technology based on phased array transducers for imaging the inside of the detected object. Due to its high precision and high flexibility, it has been widely used in the field of industrial non-destructive testing. Welding is a widely used connection method in the manufacturing industry of ships, automobiles, high-speed rails, etc. How to detect the quality of a large number of welds in the product with high precision is a key problem to ensure product quality. The core requirement of non-destructive testing of welds is to comprehensively cover all possible orientations of defects in the weld, adapt to complex geometric structures, efficiently complete the detection, and intuitively and accurately locate, quantify and qualitatively defects. Phased array ultrasonic detection meets the requirements of weld detection through electronic beam deflection, focusing and real-time imaging capabilities.

[0003] In order to increase the detection angle of phased array ultrasonic inside the detected weld, the phased array probe needs to be used with a wedge, and the wedge made of wear-resistant material is also beneficial to protect the probe wafer and reduce wear. However, there is an air gap between the probe and the surface of the detected weld. Since the acoustic impedance of air does not match the probe and the steel plate, it will isolate most of the acoustic energy from entering the inside of the weld. Therefore, a coupling agent needs to be added between the wedge and the detected weld to ensure the close contact of the wedge and the weld, so as to realize the propagation and reflection of phased array acoustic waves inside the weld. The commonly used coupling agent is water, oil or glycerol. Therefore, the key to using phased array ultrasonic to detect the internal quality of the weld is the close contact and good coupling of the wedge and the detected weld.

[0004] At present, the common way to detect the internal quality of the weld using phased array ultrasonic is manual detection or custom-made special scanning frame. For manual detection, the operator needs to manually operate the probe to contact the surface of the weld and ensure the appropriate pressure. Excessive pressure or damage to the wedge, and insufficient pressure will damage the imaging effect. At the same time, it is necessary to add coupling agent continuously to ensure the good coupling of the wedge and the surface of the weld. In the process of long-distance detection, it is difficult to operate. The use of custom-made special scanning frame can ensure the contact of the phased array probe and the surface of the weld, and only needs to add coupling agent manually. However, the existing scanning frame is developed for specific types of welds, for example, the scanning frame suitable for plate welding cannot detect longitudinal bone corner joint weld. For products with multiple complex weld types, it is necessary to frequently replace the scanning device during detection, which reduces the detection efficiency.

[0005] Therefore, it is necessary to develop a high-flexibility phased array ultrasonic detection device to realize automatic detection of multiple types of welds such as corner joint, butt joint, curved plate object and flat plate object. SUMMARY

[0006] In view of the above defects of the prior art, the technical problem to be solved by the present application is the problem of the close contact and coupling of the phased array ultrasonic probe with the surface of the detected weld in the detection process of the phased array ultrasonic probe and various types of welds.

[0007] To achieve the above-mentioned purpose, the present application provides a phased array ultrasonic flexible detection device for multiple types of welds, comprising a device mounting plate, and a butt joint weld detection module and an angle joint weld detection module mounted on the device mounting plate. The butt joint weld detection module and the angle joint weld detection module each comprise: A probe clamping module for fixing a phased array ultrasonic probe; A pressure maintaining module connected between the probe clamping module and the device mounting plate, wherein an adjustable elastic mechanism is arranged in the pressure maintaining module for providing an elastic force for pressing the probe against the surface of the detected weld; A coupling agent filling module arranged at the end of the probe clamping module for supplying coupling agent between the probe and the surface of the detected weld; An electromagnet arranged on the probe clamping module or the device mounting plate for generating a magnetic force to overcome the elastic force and lift the probe to a storage preparation state when energized.

[0008] The present application realizes phased array ultrasonic detection of various types of welds such as plate butt joint and longitudinal bone angle joint by developing a detection device, wherein a probe clamping module, a pressure maintaining module and a coupling agent filling module are integrated in the device to ensure close contact and complete coupling of the probe with the surface of the detected weld.

[0009] Further, the butt joint weld detection module and the angle joint weld detection module are arranged perpendicular to each other.

[0010] In the present application, two probe clamping modules perpendicular to each other are included in the device, and mode switching is realized by controlling the storage and release of the probe, wherein a single probe mode is used for detecting plate butt joint welds, and a double probe mode is used for detecting longitudinal bone angle joint welds.

[0011] Further, the adjustable elastic mechanism is a torsion spring.

[0012] Further, the pressure of the probe applied to the surface of the detected weld is adjusted by replacing the torsion spring or adjusting the compression amount of the torsion spring.

[0013] Further, the probe and the probe clamping module are connected by a rotating shaft, so that the probe has a rotating degree of freedom perpendicular to the surface of the detected weld to realize adaptive angle contact.

[0014] Further, a damping adjusting device is arranged between the pressure maintaining module and the probe clamping module, for controlling the probe pressing speed and preventing impact between the probe and the detected surface.

[0015] In the present application, the connection between each probe clamping module and the device mounting plate comprises a pressure maintaining module, which ensures the close contact between the probe and the weld surface in the working state through an adjustable elastic mechanism, and guarantees the proper working pressure of the probe through the elastic force provided by the adjustable elastic mechanism.

[0016] Further, the end of the coupling agent filling module is provided with a protrusion, which forms a cavity for accommodating the coupling agent between the lower surface of the probe and the detected weld surface; and the coupling agent filling module is connected to an external liquid pressurizing device through a pipeline.

[0017] In the present application, the end of the probe clamping module and the connection with the probe comprise a coupling agent filling module, which is connected to a liquid pressurizing device such as a water pump through a pipeline, and realizes the complete coupling between the probe and the detected weld surface by continuously transmitting the coupling agent to spray on the surface of the probe.

[0018] Further, the external liquid pressurizing device comprises a water pump system with automatic flow rate adjusting function, for automatically adjusting the supply rate of the coupling agent according to the probe posture and the weld direction.

[0019] Further, the device mounting plate is used for connecting with an external motion mechanism, and the device body adopts a modular structure design, and the butt joint weld detection module and the fillet joint weld detection module can be independently detached or replaced, so as to adapt to different probe sizes and weld types.

[0020] The device of the present application is suitable for phased array ultrasonic automatic scanning of various weld forms such as plate butt joint and longitudinal bone joint, solves the problem that the previous phased array ultrasonic scanning frame can only be developed in a customized manner and is suitable for specific working conditions, has high universality, and at the same time, the device ensures the close contact and complete coupling between the probe and the weld surface in the scanning process through adjusting the probe clamping pressure and the automatic spraying of the coupling agent, solves the problem that the probe pressure and the coupling agent need to be manually adjusted in the previous phased array ultrasonic detection process, improves the detection efficiency, and has high practical value.

[0021] On the other hand, the present application provides a weld detection method according to the device, comprising the following steps: (1) Mode selection step: according to the type of the weld to be detected, the on-off of the electromagnet in the butt joint weld detection module and the fillet joint weld detection module is selectively controlled, so that the corresponding probe is pressed to the detected surface under the elastic force of the pressure maintaining module; (2) Coupling agent supply step: start the coupling agent filling module, continuously supply coupling agent between the pressed probe and the detected surface, and control the coupling agent supply rate through the automatic flow rate adjusting system; (3) Scanning detection step: drive the external motion mechanism connected with the device mounting plate to move the device along the weld extension direction, and collect and analyze the phased array ultrasonic signal.

[0022] Technical effects

[0023] The device realizes automatic scanning of various weld forms such as butt joint of spliced plates and longitudinal bone corner joint through mechanism design and innovation, and has higher working flexibility compared with the traditional phased array ultrasonic scanning frame developed for a single weld form. Since the device can be applied to various weld detection conditions, it has higher application value in scenes such as shipbuilding industry, nuclear industry, and new energy industry, where weld forms are diversified and complex. At the same time, the main structure of the device is simple and effective, the processing and manufacturing cost is low, and the parts can be replaced quickly. Through modular design, the universality of spare parts is improved, so as to effectively reduce the processing and maintenance cost of the device, which is beneficial to the scale application of enterprises.

[0024] The pressure maintaining module in the device ensures the close contact between the probe and the weld surface during weld detection through the elastic mechanism, replacing the method of manually controlling the probe pressure in the traditional manual phased array ultrasonic detection process. The adjustable mechanism finely sets the probe detection pressure, avoiding invalid detection data caused by too small pressure or serious probe wear caused by too large pressure. The coupling agent filling module in the device ensures the complete coupling between the probe and the weld surface during weld detection by adaptively supplying coupling agent at the end of the probe, replacing the method of manually applying coupling agent in the traditional manual phased array ultrasonic detection process. The module avoids detection data loss caused by too little coupling agent and contamination of the detected object caused by too much coupling agent. The mechanical device replaces manual operation to improve the stability of the device during detection, reducing the operation difficulty of phased array ultrasonic detection. On the one hand, it can reduce the learning threshold of related industry practitioners, and on the other hand, it can improve the work efficiency of operators, which has a promoting effect on cost reduction and efficiency improvement of phased array ultrasonic detection industry.

[0025] The device is suitable for phased array ultrasonic detection process of various weld types in various manufacturing industries. Since the device has high universality, convenient operation, and low manufacturing cost, it has high practical value in the field of non-destructive testing.

[0026] The concept, specific structure and technical effects of the present application will be further described in conjunction with the accompanying drawings to fully understand the purpose, features and effects of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 is a structural schematic diagram of a phased array ultrasonic flexible detection device for multi-type welds of a preferred embodiment of the present application; Figure 2 is a work flow diagram of a phased array ultrasonic flexible detection device for multi-type welds of a preferred embodiment of the present application.

[0028] wherein: 1 - device mounting plate, 2 - butt joint detection module electromagnet, 3 - butt joint detection pressure maintaining module, 4 - butt joint detection probe clamping module, 5 - butt joint detection probe, 6 - butt joint detection couplant filling module, 7 - fillet joint detection probe, 8 - fillet joint detection couplant filling module, 9 - fillet joint detection probe clamping module, 10 - fillet joint detection pressure maintaining module, 11 - fillet joint detection module electromagnet. DETAILED DESCRIPTION

[0029] The following reference to the drawings introduces several preferred embodiments of the present application, making its technical content more clear and easy to understand. The present application can be embodied in many different forms of embodiments, and the scope of protection of the present application is not limited to the embodiments mentioned herein.

[0030] In the drawings, components of the same structure are denoted by the same reference numerals, and components having similar structures or functions are denoted by similar reference numerals. The size and thickness of each component shown in the drawings are arbitrarily shown, and the present application does not limit the size and thickness of each component. In order to make the drawing clearer, the thickness of some components is appropriately exaggerated in some places in the drawing.

[0031] As Figure 1 shown, it is a schematic diagram of a phased array ultrasonic flexible detection device for multi-type welds of the present application, which is suitable for phased array ultrasonic detection of two working conditions of butt joint and longitudinal bone joint, and is composed of three parts, which are device mounting plate 1, butt joint detection module and fillet joint detection module. Among them, the butt joint detection module includes butt joint detection module electromagnet 2, butt joint detection pressure maintaining module 3, butt joint detection probe clamping module 4, butt joint detection probe 5, and butt joint detection couplant filling module 6; the fillet joint detection module includes fillet joint detection probe 7, fillet joint detection couplant filling module 8, fillet joint detection probe clamping module 9, fillet joint detection pressure maintaining module 10, and fillet joint detection module electromagnet 11.

[0032] The device mounting plate is used for connecting the butt joint detection module, the corner joint detection module and the motion mechanism; the butt joint detection module is used for butt joint detection of the plate and detection from the bottom plate direction during longitudinal rib corner joint detection; the corner joint detection mechanism is used for detection of the weld joint from the rib plate direction during longitudinal rib corner joint detection.

[0033] As shown in the workflow diagram of the phased array ultrasonic flexible detection device for the butt joint of the plate and the longitudinal rib corner joint, before detection starts, the butt joint detection module electromagnet 2 and the corner joint detection module electromagnet 11 are both in the energized state, and the two detection modules are lifted to a certain angle by electromagnetic attraction and are separated from the surface of the detected object, which is the storage preparation state. Figure 2

[0034] After detection starts, the type of the weld joint of the detected object is first determined. If the plate butt joint is detected, the butt joint detection module electromagnet 2 is de-energized, and the butt joint detection module falls and closely adheres to the upper surface of the detected weld joint. If the detected object is a longitudinal rib corner joint, the butt joint detection module electromagnet 2 and the corner joint detection module electromagnet 11 are both de-energized, and the two weld joint detection modules are rotated under the elastic force of the pressure maintaining module, the butt joint detection probe 5 adheres to the upper surface of the bottom plate of the corner joint, and the corner joint detection probe 7 adheres to the side surface of the rib plate of the corner joint.

[0035] After the corresponding probe is released according to the type of the detected weld joint, the probe clamping module is rotated to the surface of the detected object under the control of the torsional spring in the pressure maintaining module, and the probe is adhered to the surface of the detected object. Since the probe is connected to the probe clamping module as a rotating shaft, the probe has one degree of rotational freedom relative to the probe clamping module, so the pressure in the tangential direction of the motion direction of the end of the probe clamping module can be converted into the pressure perpendicular to the surface of the detected object, thereby ensuring the close adhesion of the probe to the surface of the detected object. At the same time, the pressure in the pressure maintaining module can be adjusted by replacing the torsional spring or adjusting the compression amount of the torsional spring, so as to ensure that the adhesion pressure of the probe to the surface of the detected object meets the optimal working condition.

[0036] After the detection probe is adhered to the surface of the detected object, the end of the coupling agent filling module starts to release the coupling agent. Since the coupling agent filling module has a protrusion relative to the lower surface of the probe, a cavity is formed between the probe and the surface of the detected object. When the coupling agent is filled through the small hole at the end, it can be ensured that the air is completely discharged and the probe is completely coupled to the surface of the detected object. At the same time, the coupling agent input port of the coupling agent filling module is connected to the water pump, and the filling amount of the coupling agent is adjusted by adjusting the pressure and flow rate of the water pump, so as to adapt to different detection objects. For example, when detecting the longitudinal rib corner joint from the rib plate direction, the coupling agent will slide down along the rib plate due to gravity, so the flow rate can be appropriately increased to ensure the coupling quality.

[0037] ​After each module of the device starts to work, the motion mechanism connected with the device mounting plate can move along the direction of the weld seam, and at this time, the embodiment can ensure that the phased array ultrasonic probe is closely attached to and fully coupled with the surface of the object under inspection, so that a high-quality phased array ultrasonic detection result is obtained.

[0038] The preferred embodiments of the present application are described in detail above. It should be understood that those of ordinary skill in the art can make many modifications and variations without departing from the concept of the present application. Therefore, any technical solution obtained by logical analysis, reasoning or limited experiments based on the concept of the present application and the prior art should be within the protection scope defined by the claims.

Claims

1. A phased array ultrasonic flexible inspection device for multiple types of welds, characterized in that, It includes a device mounting plate, and a butt weld detection module and a fillet weld detection module mounted on the device mounting plate; Both the butt weld inspection module and the fillet weld inspection module include: Probe clamping module for fixing phased array ultrasonic probes; A pressure holding module connects the probe clamping module and the device mounting plate. The pressure holding module is equipped with an adjustable elastic mechanism to provide an elastic force that presses the probe against the surface of the weld being inspected. A coupling agent filling module, located at the end of the probe clamping module, is used to supply coupling agent between the probe and the surface of the weld being inspected; An electromagnet, mounted on the probe clamping module or device mounting plate, is used to generate magnetic force when energized, overcoming the elastic force to lift the probe and put it into a storage ready state.

2. The phased array ultrasonic flexible inspection device for multiple types of welds as described in claim 1, characterized in that, The butt weld detection module and the corner weld detection module are arranged perpendicular to each other.

3. The phased array ultrasonic flexible inspection device for multiple types of welds as described in claim 1, characterized in that, The adjustable elastic mechanism is a torsion spring.

4. The phased array ultrasonic flexible inspection device for multiple types of welds as described in claim 3, characterized in that, The pressure applied by the probe to the surface of the weld being inspected can be adjusted by replacing the torsion spring or adjusting the compression of the torsion spring.

5. The phased array ultrasonic flexible inspection device for multiple types of welds as described in claim 1, characterized in that, The probe and the probe clamping module are connected by a rotating shaft, giving the probe a degree of rotational freedom perpendicular to the surface of the weld being inspected, so as to achieve adaptive angle fitting.

6. The phased array ultrasonic flexible inspection device for multiple types of welds as described in claim 1, characterized in that, A damping adjustment device is provided between the pressure holding module and the probe clamping module to control the probe pressing speed and prevent impact between the probe and the surface being inspected.

7. The phased array ultrasonic flexible inspection device for multiple types of welds as described in claim 1, characterized in that, The end of the coupling agent filling module is provided with a protrusion, which forms a cavity between the lower surface of the probe and the surface of the weld to be inspected for accommodating the coupling agent; the coupling agent filling module is connected to an external liquid pressurization device through a pipe.

8. The phased array ultrasonic flexible inspection device for multiple types of welds as described in claim 1, characterized in that, The external liquid pressurization device includes a water pump system with automatic flow rate adjustment function, which is used to automatically adjust the supply rate of coupling agent according to the probe posture and weld direction.

9. The phased array ultrasonic flexible inspection device for multiple types of welds as described in claim 1, characterized in that, The mounting plate of the device is used to connect with an external motion mechanism. The main body of the device adopts a modular structure design. The butt weld detection module and the corner weld detection module can be disassembled or replaced independently to adapt to different probe sizes and weld types.

10. A weld inspection method based on the apparatus of any one of claims 1 to 9, characterized in that, Includes the following steps: (1) Mode selection steps: According to the type of weld to be inspected, selectively control the on and off of the electromagnets in the butt weld detection module and the fillet weld detection module, so that the corresponding probe is pressed against the surface to be inspected under the elastic force of the pressure holding module. (2) Coupling agent supply step: Start the coupling agent filling module to continuously supply coupling agent between the pressed probe and the surface under test, and control the coupling agent supply rate through the automatic flow rate adjustment system; (3) Scanning and inspection steps: Drive the external motion mechanism connected to the device mounting plate to move the device along the weld extension direction, and at the same time perform phased array ultrasonic signal acquisition and imaging analysis.

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