Ultrasonic probe self-adaptive clamping detection device based on adsorption type workpiece and detection method of ultrasonic probe self-adaptive clamping detection device
By designing an adaptive clamping and testing device for ultrasonic probes based on adsorption workpieces, and utilizing a combination of magnetic wheels and springs, the stability and adaptability issues of traditional ultrasonic probe clamping devices are solved, achieving high-precision and high-efficiency testing results.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-08
- Publication Date
- 2026-03-27
AI Technical Summary
Traditional ultrasonic probe clamping devices suffer from insufficient mechanical stability, poor clamping stability, contact mechanical mismatch, limited adaptability, and low level of intelligence, resulting in inaccurate test results and low efficiency.
An adaptive clamping and detection device for ultrasonic probes based on adsorption workpieces was designed. It uses a combination of magnetic wheels and springs to maintain a constant contact force between the probe and the workpiece surface. Real-time pressure monitoring and automatic compensation are achieved through a motor and pressure sensor. It is suitable for various types of probes. The connection line angle is optimized by combining temperature detection and universal joint to improve detection stability.
It achieves constant contact force between the probe and the workpiece surface, improving detection accuracy and efficiency. It has wide applicability, good signal consistency, and improves detection efficiency by more than 40%, with signal error less than 3%.
Smart Images
Figure CN121741007A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to an adaptive clamping and testing device and method for an ultrasonic probe based on an adsorption-type workpiece, belonging to the field of non-destructive testing technology. Background Technology
[0002] In ultrasonic testing, stable probe clamping and good contact with the workpiece surface are key factors in ensuring accurate and reliable test results. Traditional ultrasonic probe clamping methods have many drawbacks, and existing typical ultrasonic probe clamping devices suffer from four major technical bottlenecks: 1. Insufficient mechanical stability: Traditional mechanical clamping is prone to μm-level displacement due to vibration, resulting in a decrease in signal-to-noise ratio; poor clamping stability: some clamping devices cannot firmly fix the probe, and the probe is prone to displacement or shaking during the detection process, resulting in unstable detection signal and affecting detection accuracy.
[0003] 2. Contact mechanical mismatch: Uneven pressure distribution between the planar probe and the curved workpiece (standard deviation σ>8N); during scanning, it is difficult to ensure that the probe and the workpiece surface maintain a consistent contact force. Excessive contact force may damage the probe or workpiece surface, while insufficient contact force will lead to signal attenuation and inaccurate acquisition of internal defect information of the workpiece.
[0004] 3. Limited adaptability: The replacement of dedicated fixtures is time-consuming (average replacement time > 15 min / time); existing clamping fixtures can usually only be adapted to specific types of ultrasonic probes. For different types of probes (such as single crystal straight probes, single crystal angle probes, dual crystal straight probes, dual crystal angle probes, etc.), different clamping devices need to be replaced, which increases the testing cost and operational complexity.
[0005] 4. Low level of intelligence: Lack of real-time pressure monitoring and automatic compensation functions. Some clamping devices have complex structures, and the process of installing and removing probes is cumbersome, reducing detection efficiency.
[0006] Therefore, it is necessary to conduct in-depth research on existing ultrasonic probe clamping and testing devices to solve the above problems. Summary of the Invention
[0007] To overcome the above problems, in-depth research was conducted, and an adaptive clamping and detection device for ultrasonic probes based on adsorption workpieces was designed. The device includes an ultrasonic detector, an ultrasonic probe, and a probe clamping mechanism. The probe clamping mechanism includes a clamp for clamping the probe and a tooling housing. The clamp is clamped on the outer circumference of the ultrasonic probe. The fixture housing is located on the outside of the clamp and can slide up and down relative to the clamp. Magnetic wheels are provided on the fixture housing, allowing it to adhere to the surface of the workpiece to be measured. The clamp has a fixing mechanism that holds the ultrasonic probe inside the clamp.
[0008] In a preferred embodiment, a spring is provided between the clamp and the tooling housing.
[0009] In a preferred embodiment, the spring is a spring with a gradient change in stiffness coefficient.
[0010] In a preferred embodiment, the detection device is further provided with a digital pre-compression adjustment mechanism, including a motor and a pressure sensor. The motor is used to provide downward pressure to adjust the spring preload, and the pressure sensor is used to detect the current spring preload.
[0011] In a preferred embodiment, the magnetic chucks are multiple in number, and the multiple magnetic chucks are arranged with Halbach magnetic poles to form a gradient magnetic field distribution.
[0012] In a preferred embodiment, a temperature detector is provided in the detection device for detecting the ambient temperature; The magnetic chuck uses an electromagnet.
[0013] In a preferred embodiment, a linear slide rail is provided between the clamp and the tooling housing.
[0014] In a preferred embodiment, the linear guide rail includes a guide rail mounted on the outside of the fixture and a slider mounted on the inside of the tooling housing.
[0015] In a preferred embodiment, a universal joint is provided at the top of the tooling housing, and the ultrasonic probe connecting wire is disposed in the universal joint.
[0016] The present invention also provides a detection method using an adaptive clamping detection device for an ultrasonic probe based on an adsorption workpiece, comprising the following steps: S1. Place the ultrasonic probe to be used into the fixture, clamp the ultrasonic probe inside the fixture using the fixing mechanism, and assemble the detection device. S2. The detection device is attached to the surface of the workpiece to be tested by magnetic suction wheels; S3. Move the detection device to observe the ultrasonic signal echo and detect the workpiece to be tested.
[0017] The beneficial effects of this invention include: 1) It can maintain a constant contact force between the probe and the workpiece surface within a pressure fluctuation range of ±0.5N; 2) Verified according to ASTM E317 standard, the detection efficiency is improved by more than 40%, and the signal consistency error is less than 3%; 3) Applicable to various types of probes such as single-crystal straight probes, single-crystal angle probes, dual-crystal straight probes, and dual-crystal angle probes, which can improve detection accuracy and efficiency; 4) It solves the technical problems of poor stability, uneven adhesion, limited applicability and complicated operation in the traditional ultrasonic probe clamping process. Attached Figure Description
[0018] Figure 1 A schematic diagram of an adaptive clamping and detection device for an ultrasonic probe based on an adsorption workpiece, according to a preferred embodiment of the present invention, is shown. Figure 2 A schematic diagram of the clamping structure in an ultrasonic probe adaptive clamping detection device based on an adsorption workpiece according to a preferred embodiment of the present invention is shown. Figure 3 A schematic diagram of an adaptive clamping and detection device for an ultrasonic probe based on an adsorption workpiece, according to a preferred embodiment of the present invention, is shown.
[0019] Explanation of icon numbers: 1- Fixture; 2- Tooling housing; 3-Linear guide rail; 11-Slide rail; 12-Slider; 13- Bolt; 21-Magnetic roller. Detailed Implementation
[0020] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Through these descriptions, the features and advantages of the present invention will become clearer and more apparent.
[0021] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments. Although various aspects of embodiments are shown in the accompanying drawings, the drawings are not necessarily drawn to scale unless specifically indicated otherwise.
[0022] An adaptive clamping and detection device for an ultrasonic probe based on an adsorption-type workpiece, provided by the present invention, includes an ultrasonic detector, an ultrasonic probe, and a probe clamping mechanism. The ultrasonic detector is used to process the signals emitted and received by the ultrasonic probe and display the detection results. The ultrasonic probe is used to emit and receive ultrasonic waves. The probe clamping mechanism is used to fix the probe to the surface of the workpiece to be tested.
[0023] The probe clamping mechanism includes a clamp 1 for clamping the probe and a tooling housing 2, such as Figure 1 , Figure 2 As shown, where, The clamp 1 is held on the outer circumference of the ultrasonic probe; The tooling housing 2 is located on the outside of the clamp 1 and can slide up and down relative to the clamp 1. A magnetic roller 21 is provided on the tooling housing 2 so that the tooling housing 2 can be adsorbed onto the surface of the workpiece to be tested. A spring is provided between the fixture 1 and the tooling housing 2. The spring provides downward pressure to the fixture, so that the ultrasonic probe can fit against the surface of the workpiece to be tested.
[0024] In a preferred embodiment, a linear slide rail 3 is provided between the clamp 1 and the tooling housing 2, so that the clamp 1 and the tooling housing 2 can only move up and down.
[0025] Preferably, the linear guide rail 3 includes a guide rail 11 mounted on the outside of the fixture 1 and a slider 12 mounted on the inside of the tooling housing.
[0026] Preferably, an anti-drop stop is provided at the end of the slide rail to prevent the slider from detaching from the slide rail. For example, a large pad is provided at the upper end of the slide rail to prevent the slider from detaching from the slide rail and to prevent the fixture from falling out of the tooling housing.
[0027] The magnetic rollers allow the detection device to automatically adhere to the surface of a ferromagnetic workpiece, while the springs ensure the contact force between the probe and the workpiece surface. This combination ensures both the stability of the tooling and the accuracy of the detection.
[0028] According to a preferred embodiment of the present invention, there are multiple magnetic chucks 21, which are arranged with Halbach magnetic poles to form a gradient magnetic field distribution. Preferably, there are four magnetic chucks 21, and the magnetic pole angle is optimized through finite element simulation to reduce eddy current losses while ensuring the attraction force, so that the fixture can be stably held on the workpiece for inspection. Preferably, the magnetic pole angle is 75°.
[0029] According to a preferred embodiment of the present invention, by selecting a suitable magnetic chuck material, the magnetic flux density on the surface of the magnetic chuck is ≥0.8T and the adsorption torque is ≥20Nm.
[0030] More preferably, a temperature detector is provided in the detection device to detect the ambient temperature. The magnetic suction wheel is an electromagnet. When the ambient temperature changes beyond the preset temperature, the magnetic flux density attenuation is compensated by PWM voltage regulation to ensure the stability of the adsorption torque.
[0031] Preferably, when the ambient temperature change exceeds ±5℃, the magnetic flux density attenuation ΔB = 0.1T is automatically compensated.
[0032] In a preferred embodiment, the clamp 1 has a fixing mechanism that holds the ultrasonic probe inside the clamp.
[0033] In a preferred embodiment, the clamp 1 is a box structure with an open lower end, such as... Figure 3 As shown.
[0034] More preferably, there are two slide rails 11, arranged on opposite sides of the clamp, such as... Figure 2 As shown, the fixing mechanism is located on the opposite side of the clamp. Preferably, the fixing mechanism is a bolt 13, which is used to fix the probe by tightening the bolt 13.
[0035] The above-mentioned fixing mechanism is simple and effective, and can fix different types of probes, such as single crystal straight probes, single crystal angle probes, dual crystal straight probes, and dual crystal angle probes.
[0036] In a preferred embodiment, the springs are multiple, preferably two, and are disposed at the top of the clamp 1.
[0037] In a preferred embodiment, the spring is a spring with a gradient design of stiffness coefficient. In this invention, the manufacturing process of the spring is not limited. For example, it can be manufactured using a variable pitch winding process to improve the responsiveness under low vibration conditions and improve the stability of the detection device.
[0038] Preferably, the spring stiffness coefficient is k = 50~150 N / mm.
[0039] In a preferred embodiment, the detection device is further provided with a digital pre-compression adjustment mechanism, including a motor and a pressure sensor. The motor is used to provide downward pressure to adjust the spring preload, and the pressure sensor is used to detect the current spring preload.
[0040] Preferably, the motor is a ball screw motor, equipped with an RV reducer and an absolute encoder to precisely adjust the spring preload.
[0041] Preferably, the pressure sensor is a piezoelectric pressure sensor.
[0042] In a preferred embodiment, a PID control method is used to regulate the spring preload, which is adjusted according to the actual detection requirements to control the magnitude of the adhesion force between the probe and the surface of the ferromagnetic workpiece.
[0043] More preferably, the PID control method adopts the Ziegler-Nichols tuning method, setting the proportional coefficient Kp=2.5, integral time Ti=0.8s, and derivative time Td=0.1s. These parameters can ensure the pressure control accuracy of ±0.2N, ensure that the probe maintains a consistent contact force with the workpiece surface during scanning, and improve the stability of the detection signal.
[0044] In a preferred embodiment, a universal joint is provided at the top of the tooling housing 2, and the ultrasonic probe connecting line is disposed in the universal joint. When the surface of the workpiece to be tested is curved, the universal joint compensates for the bending angle of the connecting line, avoiding the connection line from affecting the test pressure and thus reducing the detection stability.
[0045] Preferably, the universal joint is a three-degree-of-freedom spherical hinge, and a locking screw is provided on the hinge for adjusting the angle of the universal joint. More preferably, the bending angle of the connecting wire is adjusted according to the surface curvature of the workpiece to be tested, so as to avoid the connecting wire affecting the test pressure and thus affecting the test results.
[0046] Preferably, the universal joint is supported by a silicon nitride bearing with a friction coefficient ≤0.05.
[0047] More preferably, an elastic damping bushing made of polyurethane composite material with a Shore hardness of 85A±5 is also provided on the outside of the universal joint to further reduce the influence of the connecting wire on the test pressure.
[0048] This invention also discloses a detection method for an ultrasonic probe adaptive clamping detection device based on an adsorption workpiece, comprising the following steps: S1. Place the ultrasonic probe to be used into the fixture, clamp the ultrasonic probe inside the fixture using the fixing mechanism, and assemble the detection device. S2. The detection device is attached to the surface of the workpiece to be tested by magnetic suction wheels; S3. Move the detection device to observe the ultrasonic signal echo and detect the workpiece to be tested.
[0049] Preferably, in step S2, zero-point calibration is also performed on the pressure sensor to ensure that the spring preload is at a preset value.
[0050] Preferably, in step S2, the current ambient temperature is detected, and the magnetic flux of the magnetic chuck is adjusted according to the ambient temperature. The specific adjustment value can be set by those skilled in the art based on experience.
[0051] Preferably, in S2, when the surface of the workpiece to be tested is curved, the universal joint angle is adjusted according to the curvature of the surface. The specific adjustment value can be set by those skilled in the art based on experience. Example
[0052] Example 1 According to ASTM E317 standard, an adaptive clamping and testing device based on an ultrasonic probe for adsorption workpieces was used for testing and verification. The results were compared with the original ultrasonic testing fixtures, and the results are shown in Table 1.
[0053] The adaptive clamping detection device includes an ultrasonic detector, an ultrasonic probe, and a probe clamping mechanism. The probe clamping mechanism includes a clamp 1 for clamping the probe and a tooling housing 2. The clamp 1 clamps the ultrasonic probe on the outer circumferential side. The tooling housing 2 is located on the outside of the clamp 1 and can slide up and down relative to the clamp 1. A magnetic roller 21 is provided on the tooling housing 2 so that the tooling housing 2 can be adsorbed onto the surface of the workpiece to be tested. A spring is provided between the clamp 1 and the tooling housing 2 to provide downward pressure on the clamp. A linear slide rail 3 is provided between the clamp 1 and the tooling housing 2. The linear slide rail 3 includes a slider 11 installed on the outside of the clamp 1 and a slide rail installed on the inside of the tooling housing.
[0054] The magnetic chuck 21 has four poles arranged in a Halbach magnetic pole configuration with a pole angle of 75°. A temperature detector is installed in the detection device to detect the ambient temperature. The magnetic chuck uses an electromagnet. When the ambient temperature changes beyond the preset temperature, PWM voltage regulation is used to compensate for the attenuation of magnetic flux density.
[0055] The spring has two springs, designed with a gradient change in stiffness coefficient, and the spring stiffness coefficient is k=50~150N / mm.
[0056] The detection device is also equipped with a digital adjustment mechanism for pre-compression, including a motor and a pressure sensor. The pressure sensor is a piezoelectric pressure sensor, and the spring preload is regulated by a PID control method. The PID control method adopts the Ziegler-Nichols tuning method, with the proportional coefficient Kp=2.5, integral time Ti=0.8s, and derivative time Td=0.1s set.
[0057] A universal joint is provided at the top of the tooling housing 2, and the ultrasonic probe connecting wire is located in the universal joint.
[0058] Table 1. Detection and Verification Results
[0059] As can be seen from Table 1, the ultrasonic probe adaptive clamping detection device based on adsorption workpiece has significant improvements in probe repeatability, contact force uniformity, defect detection rate, single detection time, and environmental adaptability.
[0060] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship in the working state of this invention, and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. Furthermore, the terms "first," "second," "third," and "fourth" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0061] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0062] The present invention has been described above with reference to preferred embodiments; however, these embodiments are merely exemplary and illustrative. Various substitutions and modifications can be made to the present invention based on these embodiments, all of which fall within the scope of protection of the present invention.
Claims
1. An adaptive clamping and detection device for an ultrasonic probe based on an adsorption-type workpiece, comprising an ultrasonic detector, an ultrasonic probe, and a probe clamping mechanism, characterized in that, The probe clamping mechanism includes a clamp for clamping the probe and a tooling housing, wherein the clamp is clamped on the outer circumference of the ultrasonic probe; The fixture housing is located on the outside of the clamp and can slide up and down relative to the clamp. Magnetic wheels are provided on the fixture housing, allowing it to adhere to the surface of the workpiece to be measured. The clamp has a fixing mechanism that holds the ultrasonic probe inside the clamp.
2. The adaptive clamping and detection device for ultrasonic probes based on adsorption-type workpieces according to claim 1, characterized in that, A spring is installed between the fixture and the tooling housing.
3. The adaptive clamping and detection device for ultrasonic probes based on adsorption-type workpieces according to claim 1, characterized in that, The spring is a spring with a gradient change in stiffness coefficient.
4. The adaptive clamping and detection device for ultrasonic probes based on adsorption-type workpieces according to claim 1, characterized in that, The detection device also includes a digital pre-compression adjustment mechanism, comprising a motor and a pressure sensor. The motor provides downward pressure to adjust the spring preload, and the pressure sensor detects the current spring preload.
5. The adaptive clamping and detection device for ultrasonic probes based on adsorption-type workpieces according to claim 1, characterized in that, The magnetic chuck has multiple magnetic wheels, which are arranged with Halbach magnetic poles to form a gradient magnetic field distribution.
6. The adaptive clamping and detection device for ultrasonic probes based on adsorption-type workpieces according to claim 1, characterized in that, The detection device is equipped with a temperature detector to detect the ambient temperature; The magnetic chuck uses an electromagnet.
7. The adaptive clamping and detection device for ultrasonic probes based on adsorption-type workpieces according to claim 1, characterized in that, A linear slide rail is provided between the fixture and the tooling housing.
8. The adaptive clamping and detection device for ultrasonic probes based on adsorption-type workpieces according to claim 1, characterized in that, The linear guide rail includes a guide rail mounted on the outside of the fixture and a slider mounted on the inside of the tooling housing.
9. The adaptive clamping and detection device for ultrasonic probes based on adsorption-type workpieces according to claim 1, characterized in that, A universal joint is provided at the top of the tooling housing, and the ultrasonic probe connection cable is located in the universal joint.
10. A detection method, employing the adaptive clamping detection device for an ultrasonic probe based on an adsorption-type workpiece as described in any one of claims 1-9, characterized in that, Includes the following steps: S1. Place the ultrasonic probe to be used into the fixture, clamp the ultrasonic probe inside the fixture using the fixing mechanism, and assemble the detection device. S2. The detection device is attached to the surface of the workpiece to be tested by magnetic suction wheels; S3. Move the detection device to observe the ultrasonic signal echo and detect the workpiece to be tested.