Automatic review system, method and apparatus for detection sensitivity in phased array detection

Abstract

This invention discloses an automatic sensitivity verification system, method, and device for phased array testing. It can solve the problems of inconvenience in carrying and using physical comparison test blocks and the inability to monitor sensitivity deviation in real time during the testing process in related technologies. By combining a virtual test block model with a sensitivity verification algorithm, it realizes automatic sensitivity comparison and alarm prompts during the testing process, effectively avoiding defect misjudgment and missed detection and re-testing, improving the convenience of on-site testing, and ensuring the accuracy and reliability of test results.

Description

Technical Field

[0001] This application belongs to the field of nondestructive testing, specifically relating to an automatic verification system for detection sensitivity in phased array testing, an automatic verification method for detection sensitivity in phased array testing, an automatic verification device for detection sensitivity in phased array testing, an electronic device, and a computer-readable storage medium. Background Technology

[0002] With the widespread application of ultrasonic phased array testing technology in the field of nondestructive testing, sensitivity verification is a crucial step in ensuring the accuracy and reliability of test results. However, sensitivity verification relies on physical comparison blocks, which are large and heavy, making them inconvenient to carry and use on-site. Real-time verification is not possible during the testing process; verification can only be performed at specific points or when the tester has a subjective suspicion. This can lead to sensitivity deviations being difficult to detect in a timely manner, potentially resulting in misjudgments or missed detections. If a subsequent verification reveals that the sensitivity has deviated from the preset threshold, repeated testing is required, affecting testing efficiency and accuracy. Therefore, there is an urgent need for a technical solution that can automatically verify the sensitivity of phased array testing. Summary of the Invention

[0003] This application aims to address at least one of the technical problems existing in the prior art. To this end, this application proposes an automatic sensitivity verification system for phased array testing, which solves the problems of inconvenience in carrying and using physical comparison test blocks and the inability to monitor sensitivity deviations in real time during testing. By combining a virtual test block model with a sensitivity verification algorithm, automatic sensitivity comparison and alarm prompts are achieved during testing, effectively avoiding false defect judgments, missed detections, and re-testing, improving the convenience of on-site testing, and ensuring the accuracy and reliability of test results.

[0004] To achieve the above objectives, a first aspect of the present invention proposes an automatic verification system for detection sensitivity in phased array testing, comprising: a phased array testing device for performing phased array ultrasonic testing operations and acquiring signals, configured to: acquire parameter information of a physical comparison test block for sensitivity calibration and detection process parameters; and generate a corresponding virtual comparison test block model based on the parameter information and detection process parameters; wherein the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; and during initial sensitivity detection, the ultrasonic echoes corresponding to each artificial reference reflector in the physical comparison test block are recorded. The amplitude serves as the reference amplitude value. During phased array ultrasonic testing of the workpiece, the same ultrasonic testing signal is simultaneously transmitted to both the workpiece and the virtual comparison test block model, and the virtual echo amplitude generated by each virtual reference reflector module in the virtual comparison test block model is acquired in real time. The sensitivity verification algorithm module, which is connected to the phased array testing equipment, is configured to: receive the virtual echo amplitude, compare the virtual echo amplitude with the reference amplitude value, calculate the real-time detection sensitivity deviation value; compare the detection sensitivity deviation value with a preset alarm threshold, and trigger an alarm when the detection sensitivity deviation value exceeds the alarm threshold.

[0005] In some embodiments, the parameter information of the physical comparison test block includes at least the geometric dimensions of the physical comparison test block, the acoustic performance parameters of the material, and the type, size, and spatial coordinates of each artificial reference reflector.

[0006] In some embodiments, the transmission parameters of the ultrasonic detection signal include pulse waveform, excitation voltage, focal position, and transmission frequency.

[0007] In some embodiments, the automatic verification system for detection sensitivity in phased array detection further includes: a human-machine interface for receiving a preset alarm threshold input by the user and displaying the real-time detection sensitivity deviation value and alarm prompts.

[0008] In some embodiments, the phased array detection device and the sensitivity verification algorithm module are integrated into the same instrument or connected in a distributed manner via wired or wireless communication.

[0009] An automatic sensitivity verification system for phased array testing according to an embodiment of the present invention includes: a phased array testing device, configured to perform phased array ultrasonic testing operations and acquire signals, and configured to: acquire parameter information of a physical comparison test block for sensitivity calibration and testing process parameters; and generate a corresponding virtual comparison test block model based on the parameter information and testing process parameters; wherein the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; and at the initial sensitivity detection, the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block is recorded as a reference. Amplitude value; During phased array ultrasonic testing of the workpiece under inspection, the same ultrasonic testing signal is simultaneously emitted to both the workpiece and the virtual comparison test block model, and the virtual echo amplitude generated by each virtual reference reflector module in the virtual comparison test block model is acquired in real time; The sensitivity verification algorithm module, which is connected to the phased array testing equipment, is configured to: receive the virtual echo amplitude, compare the virtual echo amplitude with the reference amplitude value, calculate the real-time detection sensitivity deviation value; compare the detection sensitivity deviation value with a preset alarm threshold, and trigger an alarm when the detection sensitivity deviation value exceeds the alarm threshold. Therefore, this application can solve the problems of inconvenience in carrying and using physical comparison test blocks and the inability to monitor sensitivity deviation in real time during testing in related technologies. By combining the virtual test block model with the sensitivity verification algorithm, automatic sensitivity comparison and alarm prompts are achieved during the testing process, effectively avoiding misjudgment and missed detection of defects and re-testing, improving the convenience of on-site testing, and ensuring the accuracy and reliability of the test results.

[0010] To achieve the above objectives, a second aspect of the present invention proposes an automatic verification method for detection sensitivity in phased array testing, applicable to an automatic verification system for detection sensitivity in phased array testing as described in any of the above claims. The method includes: acquiring parameter information of a physical comparison test block used for sensitivity calibration and detection process parameters; generating a corresponding virtual comparison test block model in the phased array testing equipment based on the parameter information and detection process parameters; wherein the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; and recording the sensitivity of the phased array testing equipment during initial sensitivity testing. The ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block is used as the reference amplitude value. During the phased array ultrasonic testing of the workpiece under test using the phased array testing equipment, the same ultrasonic testing signal is simultaneously transmitted to the workpiece under test and the virtual comparison test block model, and the virtual echo amplitude generated by each virtual reference reflector module in the virtual comparison test block model is collected in real time. The virtual echo amplitude is compared with the reference amplitude value to calculate the real-time detection sensitivity deviation value. The detection sensitivity deviation value is compared with the preset alarm threshold. When the detection sensitivity deviation value exceeds the alarm threshold, an alarm is triggered.

[0011] In some embodiments, recording the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block as a reference amplitude value includes: acquiring ultrasonic echo amplitudes from each artificial reference reflector in the physical comparison test block, measuring and storing the absolute value or normalized value of the ultrasonic echo amplitude, and forming a reference amplitude value that corresponds one-to-one with each artificial reference reflector.

[0012] In some embodiments, comparing the virtual echo amplitude with the reference amplitude value to calculate the real-time detection sensitivity deviation value includes: calculating the difference between the virtual echo amplitude and the reference amplitude value, and using the difference as the detection sensitivity deviation value.

[0013] In some embodiments, the method further includes: recording the alarm position of the workpiece being inspected when the detection sensitivity deviation exceeds the alarm threshold.

[0014] The automatic verification method for detection sensitivity in phased array testing according to embodiments of the present invention is applied to an automatic verification system for detection sensitivity in phased array testing as described above. The method includes: acquiring parameter information of a physical comparison test block for sensitivity calibration and detection process parameters; generating a corresponding virtual comparison test block model in the phased array testing equipment based on the parameter information and detection process parameters; wherein the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; when initially testing the sensitivity of the phased array testing equipment, recording the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block as a reference amplitude value; during the phased array ultrasonic testing of the workpiece under test using the phased array testing equipment, simultaneously transmitting the same ultrasonic detection signal to the workpiece under test and the virtual comparison test block model, and acquiring the virtual echo amplitude generated based on each virtual reference reflector module in the virtual comparison test block model in real time; comparing the virtual echo amplitude with the reference amplitude value to calculate the real-time detection sensitivity deviation value; comparing the detection sensitivity deviation value with a preset alarm threshold, and triggering an alarm when the detection sensitivity deviation value exceeds the alarm threshold. Therefore, this application can solve the problems of inconvenience in carrying and using physical comparison test blocks and the inability to monitor sensitivity deviation in real time during the testing process in related technologies. By combining virtual test block models with sensitivity verification algorithms, automatic sensitivity comparison and alarm prompts can be realized during the testing process, effectively avoiding defect misjudgment and missed detection and retesting, improving the convenience of on-site testing, and ensuring the accuracy and reliability of test results.

[0015] To achieve the above objectives, a third aspect of the present invention provides an automatic verification device for detection sensitivity in phased array testing, comprising: an acquisition module configured to acquire parameter information and detection process parameters of a physical comparison test block used for sensitivity calibration, and to generate a corresponding virtual comparison test block model in the phased array testing equipment based on the parameter information and detection process parameters; wherein the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; and an initial detection module configured to record the ultrasound corresponding to each artificial reference reflector in the physical comparison test block during the initial detection of the sensitivity of the phased array testing equipment. The echo amplitude serves as the reference amplitude value. The formal detection module is configured to simultaneously transmit the same ultrasonic detection signal to both the workpiece and the virtual comparison test block model during phased array ultrasonic testing of the workpiece using a phased array testing device, and to acquire the virtual echo amplitude generated in real time based on each virtual reference reflector module in the virtual comparison test block model. The comparison module is configured to compare the virtual echo amplitude with the reference amplitude value to calculate the real-time detection sensitivity deviation value. The alarm module is configured to compare the detection sensitivity deviation value with a preset alarm threshold, and to trigger an alarm when the detection sensitivity deviation value exceeds the alarm threshold.

[0016] An automatic sensitivity verification device for phased array detection according to an embodiment of the present invention includes: an acquisition module configured to acquire parameter information and detection process parameters of a physical comparison test block used for sensitivity calibration, and to generate a corresponding virtual comparison test block model in the phased array detection equipment based on the parameter information and detection process parameters; wherein the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; and an initial detection module configured to record the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block as a reference when initially detecting the sensitivity of the phased array detection equipment. The system comprises a reference amplitude value; a formal detection module configured to simultaneously transmit the same ultrasonic detection signal to both the workpiece and the virtual comparison test block model during phased array ultrasonic testing of the workpiece using a phased array testing device, and to acquire virtual echo amplitudes generated in real time based on each virtual reference reflector module in the virtual comparison test block model; a comparison module configured to compare the virtual echo amplitude with the reference amplitude value to calculate the real-time detection sensitivity deviation value; and an alarm module configured to compare the detection sensitivity deviation value with a preset alarm threshold, triggering an alarm when the detection sensitivity deviation value exceeds the alarm threshold. Therefore, this application solves the problems of inconvenience in carrying and using physical comparison test blocks and the inability to monitor sensitivity deviation in real time during testing in related technologies. By combining the virtual test block model with the sensitivity verification algorithm, automatic sensitivity comparison and alarm prompts are achieved during the testing process, effectively avoiding misjudgment and missed detection of defects and the need for re-testing, improving the convenience of on-site testing, and ensuring the accuracy and reliability of the test results.

[0017] To achieve the above objectives, a fourth aspect of the present invention provides an electronic device, comprising: a processor and a memory, wherein the memory stores a program or instructions executable on the processor, and when the program or instructions are executed by the processor, implements the steps of the automatic verification method for detection sensitivity in phased array detection as described above.

[0018] The electronic device according to embodiments of the present invention, by executing the above-described automatic verification method for detection sensitivity in phased array detection, can solve the problems of inconvenience in carrying and using physical comparison test blocks and the inability to monitor sensitivity deviation in real time during the detection process in related technologies. By combining the virtual test block model with the sensitivity verification algorithm, automatic sensitivity comparison and alarm prompts are realized during the detection process, effectively avoiding defect misjudgment and missed detection and re-detection, improving the convenience of on-site detection, and ensuring the accuracy and reliability of the detection results.

[0019] To achieve the above objectives, a fifth aspect of the present invention provides a computer-readable storage medium storing a program or instructions, which, when executed by a processor, implement the steps of the automatic verification method for detection sensitivity in phased array detection as described in any of the preceding claims.

[0020] According to the computer-readable storage medium of the present invention, by executing the above-described automatic verification method for detection sensitivity in phased array detection, the problems of inconvenience in carrying and using physical comparison test blocks and the inability to monitor sensitivity deviation in real time during the detection process can be solved in related technologies. By combining the virtual test block model with the sensitivity verification algorithm, automatic sensitivity comparison and alarm prompts can be realized during the detection process, effectively avoiding defect misjudgment and missed detection and re-detection, improving the convenience of on-site detection, and ensuring the accuracy and reliability of the detection results.

[0021] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0022] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0023] Figure 1 This is a schematic diagram of an automatic verification system for detection sensitivity in phased array detection according to an embodiment of this application;

[0024] Figure 2 This is a flowchart illustrating an automatic verification method for detection sensitivity in phased array detection according to an embodiment of this application.

[0025] Figure 3 This is a schematic diagram of the overall process of an automatic verification method for detection sensitivity in phased array detection according to an embodiment of this application.

[0026] Figure 4 This is a schematic diagram of an automatic verification device for detection sensitivity in phased array detection according to an embodiment of this application;

[0027] Figure 5 This is a schematic diagram of the structure of an electronic device according to an embodiment of this application.

[0028] Reference numerals: Automatic sensitivity verification system 100, phased array detection device 101, sensitivity verification algorithm module 102, human-machine interface 103, automatic sensitivity verification device 400, acquisition module 401, initial detection module 402, formal detection module 403, comparison module 404, alarm module 405, processor 510, memory 520, input / output interface 530, communication interface 540, bus 550. Detailed Implementation

[0029] Embodiments of this application will now be described in more detail with reference to the accompanying drawings. While some embodiments of this application are shown in the drawings, it should be understood that this application can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of this application. It should be understood that the drawings and embodiments of this application are for illustrative purposes only and are not intended to limit the scope of protection of this application.

[0030] It should be understood that the steps described in the method embodiments of this application may be performed in different orders and / or in parallel. Furthermore, the method embodiments may include additional steps and / or omit the steps shown. The scope of this application is not limited in this respect.

[0031] As described in the background section, with the increasing demands for accuracy and efficiency in the field of nondestructive testing, phased array testing technology is widely used in the testing of key components such as pressure equipment and pipelines. In actual testing, the relevant phased array sensitivity verification methods rely on large and heavy physical comparison test blocks, which are inconvenient to carry and use on site. Verification can only be carried out when continuous work exceeds the specified time, the test is completed, or when the tester has subjective suspicion. Real-time monitoring cannot be carried out during the test. If the sensitivity deviates from the preset threshold and is not detected in time, it will lead to misjudgment and missed detection. Moreover, the tested parts need to be tested repeatedly, resulting in a waste of manpower and resources. At the same time, manual verification is prone to subjective errors, resulting in low overall testing efficiency and potential safety hazards due to sensitivity drift.

[0032] To address the shortcomings of the aforementioned phased array sensitivity verification methods, the automatic sensitivity verification system for phased array testing in this invention replaces the physical test block with a virtual comparison test block model. Combined with a sensitivity verification algorithm module, it achieves real-time monitoring throughout the entire testing process. It accurately compares the initial calibration reference amplitude with the virtual echo amplitude synchronously acquired during the testing process to calculate the deviation value. When the deviation exceeds the standard, an automatic alarm is triggered. This effectively solves the problem of balancing the convenience of on-site testing with the reliability of results in related methods. It avoids the problems of repeated testing and quality risks caused by the inconvenience of carrying physical test blocks and the lack of real-time monitoring, thus ensuring the accuracy of the test results.

[0033] The following is for reference. Figure 1 This application describes an automatic verification system for detection sensitivity in phased array detection, provided by an embodiment of the present application.

[0034] like Figure 1The diagram shows an automatic sensitivity verification system for phased array testing in an embodiment of this application. The automatic sensitivity verification system 100 includes: a phased array testing device 101, used to perform phased array ultrasonic testing and acquire signals, configured to: acquire parameter information and testing process parameters of a physical comparison test block for sensitivity calibration; and generate a corresponding virtual comparison test block model based on the parameter information and testing process parameters; wherein the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; during initial sensitivity detection, the ultrasonic waves corresponding to each artificial reference reflector in the physical comparison test block are recorded. The echo amplitude serves as the reference amplitude value. During phased array ultrasonic testing of the workpiece under inspection, the same ultrasonic testing signal is simultaneously transmitted to both the workpiece and the virtual comparison test block model, and the virtual echo amplitude generated by each virtual reference reflector module in the virtual comparison test block model is acquired in real time. The sensitivity verification algorithm module 102, which is communicatively connected to the phased array testing device 101, is configured to: receive the virtual echo amplitude, compare the virtual echo amplitude with the reference amplitude value, calculate the real-time detection sensitivity deviation value, compare the detection sensitivity deviation value with a preset alarm threshold, and trigger an alarm when the detection sensitivity deviation value exceeds the alarm threshold.

[0035] Specifically, due to the size and weight limitations of physical test blocks, which cannot accompany the entire testing process, virtual models can accurately replicate the acoustic characteristics of physical test blocks, avoiding the inconvenience of carrying and placing them. Sensitivity can be checked in real time during the testing process. Since artificial reflectors of different positions and types correspond to different ultrasonic propagation paths and reflection characteristics, the reference amplitude values ​​of each artificial reference reflector are recorded during the initial calibration. Establishing multiple sets of reference data can comprehensively cover various sensitivity deviation scenarios that may occur during the testing process. During the testing process, factors such as equipment heating and changes in the state of the coupling agent may cause sensitivity fluctuations. Synchronous signal transmission and real-time algorithm transmission can achieve millisecond-level response and can capture sensitivity deviations in real time. When testing personnel continuously scan, it is difficult to pay attention to changes in sensitivity in real time. However, the automatic judgment and alarm prompts of the algorithm module can avoid deviations caused by human negligence and ensure that the sensitivity remains within a stable and controllable range during the testing process.

[0036] It should be noted that physical comparison test blocks are standardized physical workpieces used to calibrate the performance of testing equipment and establish testing benchmarks. Their material and acoustic properties are consistent with or close to those of the workpiece being inspected. The internal parts are machined with artificial reference reflectors (such as flat-bottomed holes, horizontal holes, slots, stepped surfaces, etc.) with clear dimensions, shapes and positions according to preset specifications. These reflectors are used to simulate the actual defects that may exist in the workpiece being inspected.

[0037] As an optional embodiment, the parameter information of the physical comparison test block includes at least the geometric dimensions of the physical comparison test block, the acoustic performance parameters of the material, and the type, size, and spatial coordinates of each artificial reference reflector.

[0038] Specifically, the geometric dimensions of the physical comparison test block include the length, width, and thickness of the test block. The acoustic performance parameters of the material are collected, including the longitudinal wave velocity, transverse wave velocity, and sound attenuation coefficient of the material used in the test block. In addition to the above parameters, the surface state parameters, processing tolerance parameters, test block identification and traceability parameters (test block standard number, production batch, calibration validity period), temperature characteristic correlation parameters, etc., should also be covered to ensure that the virtual model can accurately replicate the propagation characteristics of ultrasound in the physical test block. If the artificial reference reflector is a blind hole type reflector, the depth of the hole and the perpendicularity of the hole wall need to be recorded. If it is a slot type reflector, the included angle of the slot and the radius of the bottom fillet need to be marked, and the surface roughness of the reflector needs to be specified. These parameters can determine the intensity and waveform of the ultrasound reflection.

[0039] It should be noted that the artificial reference reflector refers to a reflective structure with specific acoustic reflection characteristics, which is processed inside the physical comparison test block according to preset specifications and positions. Types include flat-bottomed holes, horizontal holes, and slots. The material is the same as the test block body. The difference in shape and size forms an interface that can stably reflect ultrasonic waves. The system determines the reference amplitude value by recording the ultrasonic echo amplitude reflected by the artificial reference reflector. The virtual reference reflector module in the virtual comparison test block model must completely replicate its acoustic reflection characteristics to ensure that the virtual echo amplitude collected during the detection process is comparable to the reference amplitude.

[0040] As an optional embodiment, the transmission parameters of the ultrasonic detection signal include pulse waveform, excitation voltage, focal position, and transmission frequency.

[0041] Specifically, the pulse waveform (such as square wave or sine wave) affects the propagation stability of ultrasonic waves and the waveform shape of the echo signal. It should be selected and kept consistent according to the material of the workpiece under inspection and the inspection requirements to ensure that the signal characteristics received by the virtual comparison block and the workpiece under inspection are consistent. The stability of the excitation voltage is related to the amplitude reference of the echo signal. Emitting the same excitation voltage can avoid echo amplitude deviation caused by energy differences. The focal position should match the inspection area of ​​the workpiece under inspection (such as the weld center or defect-prone areas). The virtual comparison block model needs to replicate the focal parameters to ensure that the focusing state of the ultrasonic wave is consistent in both, so that the intensity distribution of the reflected signal matches the propagation path. The transmission frequency affects the penetration and resolution of ultrasonic waves. It needs to be combined with the thickness of the workpiece under inspection and the size of the artificial reference reflector to avoid echo signal distortion caused by frequency differences and ensure the accuracy of the sensitivity deviation calculation.

[0042] As an optional embodiment, the automatic verification system for detection sensitivity in phased array detection further includes: a human-machine interface 103, used to receive preset alarm thresholds input by the user and display real-time detection sensitivity deviation values ​​and alarm prompts.

[0043] Specifically, the interface supports receiving user-preset alarm thresholds (adapting to different detection standards' threshold requirements) through touch input, button settings, etc., and displays the specific value and trend of the deviation of the detection sensitivity in real time. When the deviation exceeds the threshold, the interface outputs alarm prompts in the form of sound and light prompts, pop-up flashing, etc., allowing operators to quickly detect abnormalities without having to check the background data.

[0044] As an optional embodiment, the phased array detection device and the sensitivity verification algorithm module are integrated into the same instrument, or distributed through wired or wireless communication.

[0045] Among them, distributed connection can be flexibly selected according to actual testing needs. Wired methods (such as Ethernet, dedicated data cable) can ensure the anti-interference and reliability of signal transmission and are suitable for fixed testing stations and other scenarios. Wireless methods (such as WiFi, Bluetooth) facilitate flexible equipment layout and are suitable for scenarios that require long-distance operation, such as the testing of large workpieces.

[0046] like Figure 2 The diagram shown is a flowchart illustrating an automatic verification method for detection sensitivity in phased array detection according to an embodiment of this application. The automatic verification method for detection sensitivity in phased array detection according to an embodiment of this invention may include the following steps:

[0047] Step S201: Obtain parameter information and detection process parameters of the physical comparison test block used for sensitivity calibration. Based on the parameter information and detection process parameters, generate a corresponding virtual comparison test block model in the phased array detection equipment. The physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules.

[0048] Specifically, based on the testing scenario, acoustic parameters such as geometric dimensions and sound velocity of the physical comparison test block are collected, as well as the type, size, and spatial coordinates of the artificial reference reflector within the test block. For the Type II standard test block commonly used in pipeline testing, the geometric dimension measurement accuracy must reach 0.01mm. Material acoustic parameters need to be measured, including longitudinal wave velocity and attenuation coefficient, and temperature correction curves need to be recorded. The spatial coordinates and detailed features such as borehole roughness of the artificial reference reflector need to be determined. The testing process parameters need to be simultaneously entered, including key parameters affecting ultrasonic wave propagation such as the number of probe array elements, wedge angle, and type of coupling agent. During the modeling process, the geometric shape and reflector distribution of the physical test block need to be replicated. Furthermore, the propagation path, reflection law, and energy attenuation characteristics of ultrasonic waves in the test block need to be matched using acoustic simulation algorithms to ensure that the echo signal amplitude and waveform of the virtual reference reflector module are consistent with those of the physical reflector. After modeling, equivalence verification needs to be performed through small-scale ultrasonic testing to confirm that the echo deviation between the virtual and physical test blocks is ≤0.1dB, ensuring the accuracy of subsequent sensitivity verification.

[0049] Step S202: When initially testing the sensitivity of the phased array detection device, record the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block as the reference amplitude value.

[0050] As an optional embodiment, the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block is recorded as a reference amplitude value. This includes: acquiring ultrasonic echo amplitudes from each artificial reference reflector in the physical comparison test block, measuring and storing the absolute or normalized value of the ultrasonic echo amplitude, and forming a reference amplitude value that corresponds one-to-one with each artificial reference reflector.

[0051] Specifically, the probe of the phased array testing equipment is attached to the physical comparison test block according to preset process parameters (such as probe angle and coupling pressure). The scanning path accurately covers each artificial reference reflector (such as flat-bottomed holes and slots of different depths). The acquisition module captures the ultrasonic echo amplitude of each reflector. During the acquisition process, the ambient temperature must be kept stable and the coupling agent must be applied evenly to avoid signal fluctuations caused by external interference. After the acquisition is completed, the storage method is selected according to the needs of the testing scenario. If it is a routine test with the same equipment and the same process, the absolute value of the ultrasonic echo amplitude (in dB) can be stored directly. If it is necessary to adapt to a unified benchmark for different equipment or different batches of tests, the amplitude is converted into a normalized value to eliminate the influence of differences in equipment hardware.

[0052] Step S203: During the phased array ultrasonic testing of the workpiece under test using the phased array testing equipment, the same ultrasonic testing signal is simultaneously transmitted to the workpiece under test and the virtual comparison test block model, and the virtual echo amplitude generated by each virtual reference reflector module in the virtual comparison test block model is collected in real time.

[0053] Specifically, during the phased array ultrasonic testing of the workpiece by the phased array testing equipment, the equipment's signal transmission module outputs two sets of ultrasonic testing signals with completely identical parameters, including the same pulse waveform, excitation voltage, transmission frequency, and focal position. One set is applied to the workpiece to complete defect detection, while the other set is synchronously input to the virtual comparison test block model to ensure the homogeneity of the two sets of signals and avoid deviations in sensitivity judgment due to differences in signal parameters. During synchronous transmission, the equipment's signal acquisition module captures the virtual echo amplitudes fed back by each virtual reference reflector module in the virtual comparison test block model in real time. The acquisition frequency is synchronized with the scanning frequency of the workpiece, and the acquired virtual echo amplitudes are associated and stored one by one with the corresponding virtual reference reflectors.

[0054] Step S204: Compare the virtual echo amplitude with the reference amplitude value to calculate the real-time detection sensitivity deviation value.

[0055] As an optional embodiment, the virtual echo amplitude is compared with the reference amplitude value to calculate the real-time detection sensitivity deviation value, including: calculating the difference between the virtual echo amplitude and the reference amplitude value, and using the difference as the detection sensitivity deviation value.

[0056] Specifically, if the reference amplitude is stored as an absolute value, this method can preserve the original energy characteristics of the amplitude, making it easier to trace the original state of signal transmission and reception of the equipment. The calculation can be completed directly by subtracting the absolute value of the virtual echo amplitude from the reference amplitude. If the reference amplitude is stored as a normalized value (i.e., the ratio relative to the standard reference), the difference between the normalized value of the virtual echo amplitude and the normalized value of the reference amplitude is calculated. This method can effectively eliminate the influence of hardware differences between different equipment and different testing batches.

[0057] To avoid calculation errors caused by instantaneous signal noise, a smoothing mechanism can be embedded in the difference calculation process. By collecting data from multiple consecutive frames, a field fluctuation value can be filtered out. The calculated deviation value needs to be associated and stored with the corresponding reflector feature information, detection timestamp, etc., so as to facilitate subsequent tracing of the specific scenario of sensitivity change.

[0058] Step S205: Compare the detection sensitivity deviation value with the preset alarm threshold. When the detection sensitivity deviation value exceeds the alarm threshold, trigger an alarm prompt.

[0059] As an optional embodiment, the method further includes: recording the alarm position of the workpiece scanned by the phased array detection device when the detection sensitivity deviation exceeds the alarm threshold.

[0060] Specifically, such as Figure 3As shown, the system combines deviation data from multiple consecutive frames for trend analysis, filtering out false deviation signals caused by instantaneous electromagnetic interference and brief fluctuations in the coupling agent. When an anomaly is detected, in on-site detection scenarios, an audible and visual alarm (such as a flashing red warning light) is used to quickly alert the operator. In remote monitoring scenarios, an alarm message is sent to the backend management terminal via pop-ups, message pushes, etc., while simultaneously locking the current detection status to prevent operators from missing anomalies and continuing detection. If the sensitivity frequently exceeds the preset threshold at the same location, the system can also trace back the equipment status (such as probe wear or signal transmission module failure), further improving the overall rigor of the detection.

[0061] In summary, this application provides an automatic verification method for detection sensitivity in phased array testing, applicable to an automatic verification system for detection sensitivity in phased array testing as described above. The method includes: acquiring parameter information of a physical comparison test block used for sensitivity calibration and detection process parameters; generating a corresponding virtual comparison test block model in the phased array testing equipment based on the parameter information and detection process parameters; wherein the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; when initially testing the sensitivity of the phased array testing equipment, recording the physical comparison test... The ultrasonic echo amplitude corresponding to each artificial reference reflector in the block serves as the reference amplitude value. During phased array ultrasonic testing of the workpiece under inspection using phased array testing equipment, the same ultrasonic testing signal is simultaneously transmitted to both the workpiece and the virtual comparison test block model, and the virtual echo amplitude generated by each virtual reference reflector module in the virtual comparison test block model is acquired in real time. The virtual echo amplitude is compared with the reference amplitude value to calculate the real-time detection sensitivity deviation value. The detection sensitivity deviation value is compared with a preset alarm threshold, and an alarm is triggered when the detection sensitivity deviation value exceeds the alarm threshold. Therefore, this application can solve the problems of inconvenience in carrying and using physical comparison test blocks and the inability to monitor sensitivity deviation in real time during the testing process in related technologies. By combining the virtual test block model with the sensitivity verification algorithm, automatic sensitivity comparison and alarm prompts are realized during the testing process, effectively avoiding defect misjudgment and missed detection, and re-testing, improving the convenience of on-site testing, and ensuring the accuracy and reliability of the test results.

[0062] It should be noted that the method of this embodiment can be executed by a single device, such as a computer or server. The method of this embodiment can also be applied to a distributed scenario, where multiple devices cooperate to complete the task. In such a distributed scenario, one of these devices may execute only one or more steps of the method of this embodiment, and the multiple devices will interact with each other to complete the above method.

[0063] It should be noted that the above description describes some embodiments of the present invention. Other embodiments are within the scope of the appended claims. In some cases, the actions or steps described in the claims may be performed in a different order than that shown in the above embodiments and still achieve the desired results. Furthermore, the processes depicted in the drawings do not necessarily require a specific or sequential order to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0064] refer to Figure 4 This is a schematic diagram of an automatic verification device for detection sensitivity in phased array detection according to an embodiment of this application.

[0065] The automatic sensitivity verification device 400 includes: an acquisition module 401, an initial detection module 402, a formal detection module 403, a comparison module 404, and an alarm module 405.

[0066] The acquisition module 401 is configured to acquire parameter information and detection process parameters of the physical comparison test block used for sensitivity calibration, and generate a corresponding virtual comparison test block model in the phased array detection equipment based on the parameter information and detection process parameters; wherein, the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; the initial detection module 402 is configured to record the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block as a reference amplitude value when initially detecting the sensitivity of the phased array detection equipment; the formal detection module 403 is configured to... The system is configured to simultaneously transmit the same ultrasonic detection signal to both the workpiece and the virtual comparison test block model during phased array ultrasonic testing of the workpiece using a phased array testing device, and to acquire the virtual echo amplitude generated in real time based on each virtual reference reflector module in the virtual comparison test block model. The comparison module 404 is configured to compare the virtual echo amplitude with the reference amplitude value to calculate the real-time detection sensitivity deviation value. The alarm module 405 is configured to compare the detection sensitivity deviation value with a preset alarm threshold, and to trigger an alarm when the detection sensitivity deviation value exceeds the alarm threshold.

[0067] The initial detection module 402 is also configured as follows:

[0068] Record the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block as the reference amplitude value, including:

[0069] Ultrasonic echo amplitudes are collected from each artificial reference reflector of the physical comparison test block. The absolute or normalized values ​​of the ultrasonic echo amplitudes are measured and stored to form a reference amplitude value that corresponds one-to-one with each artificial reference reflector.

[0070] The comparison module 404 is also configured as follows:

[0071] The virtual echo amplitude is compared with the reference amplitude value to calculate the real-time detection sensitivity deviation, including:

[0072] Calculate the difference between the virtual echo amplitude and the reference amplitude, and use the difference as the detection sensitivity deviation value.

[0073] Alarm module 405 is also configured as follows:

[0074] Record the alarm position of the workpiece scanned by the phased array detection equipment when the detection sensitivity deviation exceeds the alarm threshold.

[0075] The automatic sensitivity verification device for phased array testing provided in this application can solve the problems of inconvenience in carrying and using physical comparison test blocks and the inability to monitor sensitivity deviation in real time during the testing process in related technologies. By combining the virtual test block model with the sensitivity verification algorithm, automatic sensitivity comparison and alarm prompts are realized during the testing process, which effectively avoids defect misjudgment and missed detection and re-testing, improves the convenience of on-site testing, and ensures the accuracy and reliability of the test results.

[0076] refer to Figure 5 The diagram below is a block diagram of an electronic device according to some embodiments of the present invention. It illustrates a more specific hardware structure of an electronic device provided in this application embodiment. The device may include: a processor 510, a memory 520, an input / output interface 530, a communication interface 540, and a bus 550. The processor 510, memory 520, input / output interface 530, and communication interface 540 are interconnected internally via the bus 550.

[0077] The processor 510 can be implemented using a general-purpose CPU (Central Processing Unit), microprocessor, application-specific integrated circuit (ASIC), or one or more integrated circuits, and is used to execute relevant programs to implement the technical solutions provided in the embodiments of this specification.

[0078] The memory 520 can be implemented in the form of ROM (Read Only Memory), RAM (Random Access Memory), static storage device, dynamic storage device, etc. The memory 520 can store the operating system and other applications. When the technical solutions provided in the embodiments of this specification are implemented by software or firmware, the relevant program code is stored in the memory 520 and is called and executed by the processor 510.

[0079] Input / output interface 530 is used to connect input / output modules to realize information input and output. Input / output modules can be configured as components in the device (not shown in the figure) or externally connected to the device to provide corresponding functions. Input devices may include keyboards, mice, touch screens, microphones, various sensors, etc., and output devices may include displays, speakers, vibrators, indicator lights, etc.

[0080] The communication interface 540 is used to connect a communication module (not shown in the figure) to enable communication between this device and other devices. The communication module can communicate via wired means (such as USB, Ethernet cable, etc.) or wireless means (such as mobile network, WIFI, Bluetooth, etc.).

[0081] Bus 550 includes a pathway for transmitting information between various components of the device, such as processor 510, memory 520, input / output interface 530, and communication interface 540.

[0082] It should be noted that although the above-described device only shows the processor 510, memory 520, input / output interface 530, communication interface 540, and bus 550, in specific implementations, the device may also include other components necessary for normal operation. Furthermore, those skilled in the art will understand that the above-described device may only include the components necessary for implementing the embodiments of this specification, and not necessarily all the components shown in the figures.

[0083] The electronic device described above is used to implement the automatic verification method for detection sensitivity in phased array detection in any of the foregoing embodiments, and has the beneficial effects of the corresponding automatic verification method for detection sensitivity in phased array detection, which will not be elaborated here.

[0084] Based on the same concept, corresponding to the automatic verification method for detection sensitivity in phased array detection provided in any of the above embodiments, this application also provides a computer-readable storage medium storing a program or instructions, which, when executed by a processor, implements the automatic verification method for detection sensitivity in phased array detection as described above.

[0085] The aforementioned computer-readable storage media can be any available medium or data storage device that a computer can access, including but not limited to magnetic storage (e.g., floppy disks, hard disks, magnetic tapes, magneto-optical disks (MOs), etc.), optical storage (e.g., CDs, DVDs, BDs, HVDs, etc.), and semiconductor storage (e.g., ROMs, EPROMs, EEPROMs, non-volatile memory (NAND flash), solid-state drives (SSDs)).

[0086] The computer instructions stored in the storage medium of the above embodiments are used to cause the computer to execute the automatic verification method for detection sensitivity in the corresponding phased array detection in any of the foregoing embodiments, and have the beneficial effects of the corresponding automatic verification method for detection sensitivity in phased array detection embodiments, which will not be repeated here.

[0087] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, it should be noted that the scope of the methods and apparatuses in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Additionally, features described with reference to certain examples may be combined in other examples.

[0088] From the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of computer software products plus necessary general-purpose hardware platforms, and of course, they can also be implemented by hardware. The computer software product is stored in a storage medium (such as ROM, RAM, magnetic disk, optical disk, etc.) and includes several instructions to cause the terminal or network-side device to execute the methods described in the various embodiments of this application.

[0089] The embodiments of this application have been described above with reference to the accompanying drawings. However, this application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other implementations under the guidance of this application without departing from the spirit and scope of the claims. All of these implementations are within the protection scope of this application.

Claims

1. An automatic verification system for detection sensitivity in phased array detection, characterized in that, include: The phased array testing equipment, used to perform phased array ultrasonic testing operations and acquire signals, is configured as follows: Obtain parameter information and detection process parameters of the physical comparison test block used for sensitivity calibration, and generate a corresponding virtual comparison test block model based on the parameter information and the detection process parameters; wherein, the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; the virtual reference reflector modules in the virtual comparison test block model must completely replicate the acoustic reflection characteristics of the artificial reference reflectors; During the initial detection sensitivity, the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block is recorded as the reference amplitude value. During the phased array ultrasonic testing of the workpiece under inspection, the same ultrasonic testing signal is simultaneously transmitted to the workpiece under inspection and the virtual comparison test block model, and the virtual echo amplitude generated by each virtual reference reflector module in the virtual comparison test block model is collected in real time. The sensitivity verification algorithm module, which is communicatively connected to the phased array detection device, is configured as follows: The virtual echo amplitude is received, and the virtual echo amplitude is compared with the reference amplitude value to calculate the real-time detection sensitivity deviation value. The detection sensitivity deviation value is compared with a preset alarm threshold. When the detection sensitivity deviation value exceeds the alarm threshold, an alarm is triggered.

2. The automatic verification system for detection sensitivity in phased array detection according to claim 1, characterized in that, The parameter information of the physical comparison test block includes at least the geometric dimensions of the physical comparison test block, the acoustic performance parameters of the material, and the type, size, and spatial coordinates of each artificial reference reflector.

3. The automatic verification system for detection sensitivity in phased array detection according to claim 1, characterized in that, The transmission parameters of the ultrasonic detection signal include pulse waveform, excitation voltage, focal position, and transmission frequency.

4. The automatic verification system for detection sensitivity in phased array detection according to claim 1, characterized in that, Also includes: The human-computer interaction interface is used to receive the preset alarm threshold input by the user and to display the real-time detection sensitivity deviation value and the alarm signal.

5. The automatic verification system for detection sensitivity in phased array detection according to claim 1, characterized in that, The phased array detection device and the sensitivity verification algorithm module are integrated into the same instrument, or are distributedly connected via wired or wireless communication.

6. An automatic verification method for detection sensitivity in phased array detection, characterized in that, The method, applied to the automatic detection sensitivity verification system in phased array detection as described in any one of claims 1-5, comprises: Obtain parameter information and detection process parameters of the physical comparison test block used for sensitivity calibration. Based on the parameter information and the detection process parameters, generate a corresponding virtual comparison test block model in the phased array detection equipment. The physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules. The virtual reference reflector modules in the virtual comparison test block model must completely replicate the acoustic reflection characteristics of the artificial reference reflectors. When initially testing the sensitivity of the phased array detection device, the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block is recorded as the reference amplitude value. During the phased array ultrasonic testing of the workpiece under test using the phased array testing equipment, the same ultrasonic testing signal is simultaneously transmitted to the workpiece under test and the virtual comparison test block model, and the virtual echo amplitude generated by each virtual reference reflector module in the virtual comparison test block model is collected in real time. The virtual echo amplitude is compared with the reference amplitude value to calculate the real-time detection sensitivity deviation value. The detection sensitivity deviation value is compared with a preset alarm threshold. When the detection sensitivity deviation value exceeds the alarm threshold, an alarm is triggered.

7. The automatic verification method for detection sensitivity in phased array detection according to claim 6, characterized in that, The recording of the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block, as the reference amplitude value, includes: Ultrasonic echo amplitudes are collected from each artificial reference reflector of the physical comparison test block, and the absolute or normalized values ​​of the ultrasonic echo amplitudes are measured and stored to form the reference amplitude values ​​that correspond one-to-one with each artificial reference reflector.

8. The automatic verification method for detection sensitivity in phased array detection according to claim 6, characterized in that, The step of comparing the virtual echo amplitude with the reference amplitude value to calculate the real-time detection sensitivity deviation value includes: Calculate the difference between the virtual echo amplitude and the reference amplitude value, and use the difference as the detection sensitivity deviation value.

9. The automatic verification method for detection sensitivity in phased array detection according to claim 6, characterized in that, The method further includes: The alarm position of the workpiece being inspected, scanned by the phased array detection device, is recorded when the deviation value of the detection sensitivity exceeds the alarm threshold.

10. An automatic verification device for detection sensitivity in phased array detection, characterized in that, The automatic detection sensitivity verification device in phased array detection is used to implement the automatic detection sensitivity verification method in phased array detection as described in any one of claims 6 to 9, including: The acquisition module is configured to acquire parameter information and detection process parameters of a physical comparison test block used for sensitivity calibration, and based on the parameter information and the detection process parameters, generate a corresponding virtual comparison test block model in the phased array detection equipment; wherein, the physical comparison test block includes multiple artificial reference reflectors, and the virtual comparison test block model includes multiple virtual reference reflector modules; the virtual reference reflector modules in the virtual comparison test block model must completely replicate the acoustic reflection characteristics of the artificial reference reflectors; The initial detection module is configured to record the ultrasonic echo amplitude corresponding to each artificial reference reflector in the physical comparison test block as a reference amplitude value when initially detecting the sensitivity of the phased array detection device. The formal testing module is configured to simultaneously transmit the same ultrasonic testing signal to the workpiece under test and the virtual comparison test block model during the phased array ultrasonic testing process performed on the workpiece under test using the phased array testing equipment, and to collect the virtual echo amplitude generated in real time based on each virtual reference reflector module in the virtual comparison test block model. The comparison module is configured to compare the virtual echo amplitude with the reference amplitude value and calculate the real-time detection sensitivity deviation value. The alarm module is configured to compare the detection sensitivity deviation value with a preset alarm threshold, and trigger an alarm when the detection sensitivity deviation value exceeds the alarm threshold.

11. An electronic device, characterized in that, include: A processor and a memory, the memory storing a program or instructions executable on the processor, the program or instructions being executed by the processor to implement the steps of the automatic verification method for detection sensitivity in phased array detection as described in any one of claims 6 to 9.

12. A computer-readable storage medium, characterized in that, The readable storage medium stores a program or instructions that, when executed by a processor, implement the steps of the automatic verification method for detection sensitivity in phased array detection as described in any one of claims 6 to 9.

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