A fault detection system and method based on ultrasonic imaging

Abstract

This invention discloses an ultrasonic imaging-based fault detection system and method. The ultrasonic imaging-based fault detection system includes a base plate, a vertical plate fixedly mounted on the top of the base plate, a horizontal plate fixedly mounted on one end of the vertical plate, a threaded rod rotatably mounted on the bottom of the horizontal plate, a sleeve rod threaded onto the surface of the threaded rod, a lifting motor fixedly mounted on the top of the horizontal plate, the output end of the lifting motor penetrating the horizontal plate and fixedly connected to the top of the threaded rod, a sliding groove formed inside the vertical plate, a slider movably mounted inside the sliding groove, one end of the slider being fixedly connected to one end of the sleeve rod, and top plates fixedly mounted on both sides of the top of the sleeve rod. This invention allows for automatic adjustment of the detection height via the sleeve rod and lifting motor, and adjustment of the horizontal position of the detection via a push plate and pneumatic cylinder, thereby expanding the detection range to replace single-point detection and improving detection efficiency.

Description

Technical Field

[0001] This invention relates to the field of aircraft maintenance technology, specifically to a fault detection system and method based on ultrasonic imaging. Background Technology

[0002] An airplane is a heavier-than-air aircraft with wings and one or more engines that can fly in the atmosphere by its own power. Aircraft structures (such as fuselage skin, wing spars, landing gear joints, engine blades, etc.) are subjected to harsh conditions such as high altitude, high pressure, vibration, shock, and temperature fluctuations for a long time, which can easily lead to latent faults such as fatigue cracks, corrosion, delamination, and debonding. These faults are characterized by their high degree of concealment and high degree of harm. If they are not detected in time, they may lead to flight safety accidents. Therefore, there is a need for a fault detection system based on ultrasonic imaging.

[0003] When operators perform maintenance work on aircraft, they often use corresponding ultrasonic imaging fault detection systems. Although existing systems can achieve the purpose of detection, in actual detection processes, they are mostly single-point detections, which have drawbacks such as low detection efficiency, blurry images, inaccurate fault location, and high dependence on the experience of the inspectors. In addition, the aircraft inspection parts are uneven and have different curvatures, and since the probe is not adjustable, blind spots may occur, which may reduce the accuracy of the detection. Summary of the Invention

[0004] The purpose of this invention is to provide an ultrasonic imaging-based fault detection system and method to address the shortcomings mentioned in the background art. While existing ultrasonic imaging fault detection systems can achieve the detection purpose, in actual testing, they are mostly single-point detections, resulting in low detection efficiency, blurred images, inaccurate fault location, and high dependence on the experience of the testing personnel. Furthermore, the varying heights and curvatures of the aircraft's testing areas, coupled with the non-adjustable probes, can easily lead to blind spots, potentially reducing detection accuracy.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an ultrasonic imaging-based fault detection system, comprising a base plate, a vertical plate fixedly mounted on the top of the base plate, a horizontal plate fixedly mounted on one end of the vertical plate, a threaded rod rotatably mounted on the bottom of the horizontal plate, a sleeve rod threaded onto the surface of the threaded rod, a lifting motor fixedly mounted on the top of the horizontal plate, the output end of the lifting motor penetrating the horizontal plate and fixedly connected to the top of the threaded rod, a sliding groove being formed inside the vertical plate, a slider being movably mounted inside the sliding groove, one end of the slider being fixedly connected to one end of the sleeve rod, top plates fixedly mounted on both sides of the top of the sleeve rod, a connecting plate fixedly mounted on one end of the top plate, a horizontal groove being formed inside the connecting plate, a connecting rod being movably mounted inside the horizontal groove, and a push plate fixedly mounted on one end of the connecting rod.

[0006] Preferably, a pneumatic cylinder is fixedly installed on one side of the top plate, and the output end of the pneumatic cylinder passes through the top plate and is fixedly connected to one side of the push plate.

[0007] Preferably, an extension plate is fixedly installed at the other end of the connecting rod. A strip groove is formed inside the extension plate, and a lead screw is rotatably installed inside the strip groove. A threaded sleeve is threaded onto the surface of the lead screw, and an adjustment plate is fixedly installed on the top of the threaded sleeve. An adjustment motor is fixedly installed at one end of the extension plate, and the output end of the adjustment motor passes through the extension plate and is fixedly connected to one end of the lead screw.

[0008] Preferably, an installation block is fixedly installed at one end of the adjustment plate, a slot is provided at one end of the installation block, an insert plate is movably installed inside the slot, a fixing plate is fixedly installed at one end of the insert plate, and an ultrasonic probe is fixedly installed at one end of the fixing plate.

[0009] Preferably, an intelligent control console is fixedly installed on the top of the base plate, an imaging display is fixedly installed on the surface of the intelligent control console, and control buttons are equidistantly installed on the surface of the intelligent control console.

[0010] Preferably, a protective box is fixedly installed at one end of the intelligent control console. A signal conditioning module, a data acquisition and processing module, a wireless communication module, and a power supply module are fixedly installed inside the protective box at one end. A movable door is hinged to one end of the protective box. Heat dissipation slots are provided at equal intervals at one end of the movable door, and a handle is fixedly installed at one end of the movable door.

[0011] A fault detection method based on ultrasonic imaging includes the following steps: S1. First, the operator slides the fixing plate, which in turn causes the insertion plate to slide. Then, the insertion plate is slid into the slot to install the ultrasonic probe. Different ultrasonic probes, such as straight probes, angle probes, and array probes, can be replaced according to different detection conditions. Next, the lifting motor is started. The operation of the lifting motor will cause the threaded rod to rotate, which in turn causes the sleeve rod to slide. Then, the sleeve rod will cause the slider to slide, and the slider will slide inside the groove.

[0012] S2. Then, start the pneumatic cylinder. The operation of the pneumatic cylinder will push the push plate to slide, and the push plate will then drive the connecting rod to slide. Subsequently, the connecting rod will slide inside the transverse groove. The detection height can be automatically adjusted by the sleeve rod and lifting motor, and the horizontal position of the detection can be adjusted by the push plate and pneumatic cylinder. Then, start the adjusting motor. The operation of the adjusting motor will cause the lead screw to rotate, and the lead screw will then drive the lead sleeve to slide. Subsequently, the lead sleeve will slide inside the strip groove. At this time, the lead sleeve will drive the adjusting plate to slide, and the adjusting plate will then drive the mounting block to slide. Subsequently, the mounting block 21 will drive the fixing plate to slide, and then the fixing plate will drive the ultrasonic probe to slide, so that the ultrasonic probe can be inserted into different detection parts.

[0013] S3. Finally, the ultrasonic probe emits ultrasonic waves into the aircraft structure. When the ultrasonic waves encounter a defect, they are reflected and the reflected signal is received by the ultrasonic probe. The signal conditioning module then filters out noise and amplifies the signal. Subsequently, the data acquisition and processing module converts the acquired signal into a digital signal and performs signal noise reduction, defect extraction, and feature analysis. At this point, the data detected by the ultrasonic waves can be imaged on the imaging display. The data can then be processed via the control buttons or transmitted to the background for processing and storage via the wireless communication module.

[0014] Compared with the prior art, the beneficial effects of the present invention are: This invention relates to an ultrasonic imaging-based fault detection system and method. During daily use, the operator starts the lifting motor, which causes the threaded rod to rotate. This rotation, in turn, causes the sleeve rod to slide, which in turn causes the slider to slide. The slider then slides within the groove. At this point, the pneumatic cylinder is activated, pushing a push plate to slide. This push plate then causes a connecting rod to slide, which in turn slides within the transverse groove. This invention automatically adjusts the detection height using the sleeve rod and lifting motor, and adjusts the horizontal position of the detection using the push plate and pneumatic cylinder. This expands the detection range, replacing single-point detection, thereby improving detection efficiency, image clarity, and fault location accuracy. It also eliminates the drawback of high reliance on operator experience.

[0015] This ultrasonic imaging-based fault detection system and method, during daily use, involves the operator starting an adjustment motor. The operation of the adjustment motor causes the lead screw to rotate, which in turn causes the lead screw to slide. The lead screw then slides inside the slot, causing the lead screw to slide. This causes the adjustment plate to slide, which in turn causes the mounting block to slide. The mounting block then causes the fixing plate to slide, and finally the fixing plate causes the ultrasonic probe to slide. This allows the ultrasonic probe to be inserted into different detection locations, thereby improving the accuracy of the detection. Attached Figure Description

[0016] Figure 1 This is the front view of the present invention; Figure 2 This is a cross-sectional view of the present invention; Figure 3 For the present invention Figure 2 Enlarged view of a portion of point A in the middle; Figure 4 For the present invention Figure 2 Enlarged view of a section at point B in the middle; Figure 5 For the present invention Figure 2 Enlarged view of a section at point C; Figure 6 This is a schematic diagram of the top structure of the base plate of the present invention.

[0017] In the diagram: 1. Base plate; 2. Vertical plate; 3. Horizontal plate; 4. Threaded rod; 5. Sleeve rod; 6. Lifting motor; 7. Slide groove; 8. Sliding block; 9. Top plate; 10. Connecting plate; 11. Horizontal groove; 12. Connecting rod; 13. Push plate; 14. Pneumatic cylinder; 15. Extension plate; 16. Strip groove; 17. Lead screw; 18. Threaded sleeve; 19. Adjusting plate; 20. Adjusting motor; 21. Mounting block; 22. Slot; 23. Insert plate; 24. Fixing plate; 25. Ultrasonic probe; 26. Intelligent control console; 27. Imaging display; 28. Control button; 29. ​​Protective box; 30. Signal conditioning module; 31. Data acquisition and processing module; 32. Wireless communication module; 33. Power supply module; 34. Movable door; 35. Heat dissipation groove; 36. Pull handle. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Example 1: Please see Figures 1-6An ultrasonic imaging-based fault detection system includes a base plate 1, a vertical plate 2 fixedly mounted on the top of the base plate 1, a horizontal plate 3 fixedly mounted on one end of the vertical plate 2, a threaded rod 4 rotatably mounted on the bottom of the horizontal plate 3, a sleeve rod 5 threadedly fitted onto the surface of the threaded rod 4, a lifting motor 6 fixedly mounted on the top of the horizontal plate 3, the output end of the lifting motor 6 passing through the horizontal plate 3 and fixedly connected to the top of the threaded rod 4, a groove 7 being formed inside the vertical plate 2, a slider 8 being movably mounted inside the groove 7, one end of the slider 8 being fixedly connected to one end of the sleeve rod 5, and the sleeve rod 5 sliding causing the slider 8 to slide inside the groove 7. Both the inner surface of the slide and the outer surface of the slider 8 are smooth, which allows the slider 8 to slide more smoothly inside the slide groove 7 and reduces the occurrence of jamming. Due to the design of the slide groove 7 and the slider 8, the sliding of the sleeve rod 5 is more stable. Top plates 9 are fixedly installed on both sides of the top of the sleeve rod 5. A connecting plate 10 is fixedly installed at one end of the top plate 9. A transverse groove 11 is opened inside the connecting plate 10. A connecting rod 12 is movably installed inside the transverse groove 11, and a push plate 13 is fixedly installed at one end of the connecting rod 12. A pneumatic cylinder 14 is fixedly installed on one side of the top plate 9, and the output end of the pneumatic cylinder 14 passes through the top plate 9 and is fixedly connected to one side of the push plate 13.

[0020] In this invention, the operator starts the lifting motor 6, which causes the threaded rod 4 to rotate. The threaded rod 4 then drives the sleeve rod 5 to slide, which in turn drives the slider 8 to slide. The slider 8 then slides inside the slide groove 7. At this point, the pneumatic cylinder 14 is activated, which pushes the push plate 13 to slide. The push plate 13 then drives the connecting rod 12 to slide, which then slides inside the transverse groove 11. This invention automatically adjusts the detection height using the sleeve rod 5 and the lifting motor 6, and adjusts the horizontal position of the detection using the push plate 13 and the pneumatic cylinder 14, thereby expanding the detection range to replace single-point detection. This improves detection efficiency, image clarity, and fault location accuracy, while also eliminating the drawback of high reliance on the experience of the detection personnel.

[0021] Example 2: Please see Figures 1-6An ultrasonic imaging-based fault detection system includes an extension plate 15 fixedly mounted on the other end of a connecting rod 12. A slotted groove 16 is formed inside the extension plate 15, and a lead screw 17 is rotatably mounted inside the slotted groove 16. A threaded sleeve 18 is threaded onto the surface of the lead screw 17, and an adjusting plate 19 is fixedly mounted on the top of the threaded sleeve 18. An adjusting motor 20 is fixedly mounted on one end of the extension plate 15, and the output end of the adjusting motor 20 passes through the extension plate 15 and is fixedly connected to one end of the lead screw 17. A mounting block 21 is fixedly mounted on one end of the adjusting plate 19, and a slot 22 is formed on one end of the mounting block 21. An insert plate 23 is movably mounted inside the slot 22. The slot 22 and the insert plate 23 are connected. 3. The design features quick plug-in and hot-swap, supporting probe hot-switching. Operators can quickly change probes according to the inspection location without restarting the system, improving maintenance and inspection efficiency. Straight probes can be used to inspect internal defects in aircraft fuselage skin and wing flat structures, while angled probes are used to inspect transverse cracks in irregular structures such as landing gear joints and engine blades. Array probes are used for large-area rapid inspection, achieving scanning imaging through array element switching, improving inspection efficiency and reducing the risk of missed detections. One end of the plug plate 23 is fixedly mounted with a fixing plate 24, and the other end of the fixing plate 24 is fixedly mounted with an ultrasonic probe 25. The head of the ultrasonic probe 25 adopts a flexible design, which can conform to curved structures to ensure coupling effect.

[0022] In this invention, the operator slides the fixing plate 24, which in turn causes the insertion plate 23 to slide. The insertion plate 23 is then slid into the slot 22, allowing the ultrasonic probe 25 to be installed. Different ultrasonic probes 25, such as straight probes, angle probes, and array probes, can be replaced according to different detection conditions. Simultaneously, the adjusting motor 20 is activated, causing the lead screw 17 to rotate. The lead screw 17 then causes the lead sleeve 18 to slide, which then slides inside the strip groove 16. At this point, the lead sleeve 18 causes the adjusting plate 19 to slide, which in turn causes the mounting block 21 to slide. The mounting block 21 then causes the fixing plate 24 to slide, which in turn causes the ultrasonic probe 25 to slide. This allows the ultrasonic probe 25 to be inserted into different detection locations, thereby improving detection accuracy.

[0023] Example 3: Please see Figures 1-6An ultrasonic imaging-based fault detection system includes an intelligent control console 26 fixedly mounted on the top of a base plate 1. An imaging display 27 is fixedly mounted on the surface of the intelligent control console 26, and control buttons 28 are equidistantly mounted on the surface of the intelligent control console 26. The system can image the data detected by ultrasonic waves through the imaging display 27 and process the data through the control buttons 28. A protective box 29 is fixedly mounted on one end of the intelligent control console 26. Inside the protective box 29, a signal conditioning module 30, a data acquisition and processing module 31, a wireless communication module 32, and a power supply module 33 are fixedly mounted on one end. The signal conditioning module 30 acts as a bridge connecting the ultrasonic probe 25 and the data acquisition and processing module 31, and its main function is to further process the received reflected signals to eliminate interference and optimize signal quality. To improve signal quality and ensure the accuracy of data acquisition, the data acquisition and processing module 31 is responsible for completing the digital acquisition of signals, data processing, defect identification, and feature extraction, ensuring processing speed and accuracy. The wireless communication module 32 can transmit the processed information to the background, thereby realizing remote processing. The power module 33 can provide power support, allowing it to standby for a long time. One end of the protective box 29 is hinged to a movable door 34, and one end of the movable door 34 is provided with heat dissipation slots 35 at equal intervals. The heat dissipation slots 35 can dissipate the heat generated by the signal conditioning module 30, data acquisition and processing module 31, wireless communication module 32, and power module 33 during operation, thereby extending their service life. A handle 36 is fixedly installed on one end of the movable door 34, and the design of the handle 36 makes it easy to pull the movable door 34.

[0024] In this invention, the ultrasonic probe 25 emits ultrasonic waves into the interior of the aircraft structure. When the ultrasonic waves encounter a defect, they are reflected and the reflected signal is received by the ultrasonic probe 25. The signal conditioning module 30 then filters noise and amplifies the signal. Subsequently, the data acquisition and processing module 31 converts the acquired signal into a digital signal and performs signal noise reduction, defect extraction, and feature analysis. At this time, the data detected by the ultrasonic waves can be imaged on the imaging display 27. The data can then be processed via the control button 28 or transmitted to the background for processing and storage via the wireless communication module 32.

[0025] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fault detection system based on ultrasonic imaging, comprising a base plate (1), characterized in that: A vertical plate (2) is fixedly installed on the top of the base plate (1). A horizontal plate (3) is fixedly installed on one end of the vertical plate (2). A threaded rod (4) is rotatably installed on the bottom of the horizontal plate (3). A sleeve rod (5) is threaded onto the surface of the threaded rod (4). A lifting motor (6) is fixedly installed on the top of the horizontal plate (3). The output end of the lifting motor (6) passes through the horizontal plate (3) and is fixedly connected to the top of the threaded rod (4). A sliding groove (7) is opened inside the vertical plate (2). A slider (8) is movably installed inside the sliding groove (7). One end of the slider (8) is fixedly connected to one end of the sleeve rod (5). Top plates (9) are fixedly installed on both sides of the top of the sleeve rod (5). A connecting plate (10) is fixedly installed on one end of the top plate (9). A horizontal groove (11) is opened inside the connecting plate (10). A connecting rod (12) is movably installed inside the horizontal groove (11). A push plate (13) is fixedly installed on one end of the connecting rod (12).

2. The fault detection system based on ultrasonic imaging according to claim 1, characterized in that: A pneumatic cylinder (14) is fixedly installed on one side of the top plate (9), and the output end of the pneumatic cylinder (14) passes through the top plate (9) and is fixedly connected to one side of the push plate (13).

3. The fault detection system based on ultrasonic imaging according to claim 1, characterized in that: An extension plate (15) is fixedly installed at the other end of the connecting rod (12). A strip groove (16) is provided inside the extension plate (15). A lead screw (17) is rotatably installed inside the strip groove (16). A threaded sleeve (18) is threaded onto the surface of the lead screw (17). An adjusting plate (19) is fixedly installed on the top of the threaded sleeve (18). An adjusting motor (20) is fixedly installed at one end of the extension plate (15). The output end of the adjusting motor (20) passes through the extension plate (15) and is fixedly connected to one end of the lead screw (17).

4. The fault detection system based on ultrasonic imaging according to claim 3, characterized in that: An installation block (21) is fixedly installed at one end of the adjustment plate (19). A slot (22) is provided at one end of the installation block (21). An insert plate (23) is movably installed inside the slot (22). A fixing plate (24) is fixedly installed at one end of the insert plate (23), and an ultrasonic probe (25) is fixedly installed at one end of the fixing plate (24).

5. The fault detection system based on ultrasonic imaging according to claim 1, characterized in that: A smart console (26) is fixedly installed on the top of the base plate (1). An imaging display (27) is fixedly installed on the surface of the smart console (26), and control buttons (28) are equidistantly installed on the surface of the smart console (26).

6. The fault detection system based on ultrasonic imaging according to claim 5, characterized in that: A protective box (29) is fixedly installed at one end of the intelligent control console (26). A signal conditioning module (30), a data acquisition and processing module (31), a wireless communication module (32) and a power supply module (33) are fixedly installed inside the protective box (29). A movable door (34) is hinged to one end of the protective box (29). Heat dissipation slots (35) are opened at equal intervals at one end of the movable door (34), and a handle (36) is fixedly installed at one end of the movable door (34).

7. A fault detection method based on ultrasonic imaging as described in claims 1-6, characterized in that: Its detection method includes the following steps: S1. First, the operator slides the fixed plate (24), which then drives the insert plate (23) to slide. The insert plate (23) is then slid into the slot (22) to install the ultrasonic probe (25). Different ultrasonic probes (25) can be replaced according to different detection conditions, such as straight probes, angle probes and array probes. Next, the lifting motor (6) is started. The operation of the lifting motor (6) will cause the threaded rod (4) to rotate. The threaded rod (4) then drives the sleeve rod (5) to slide. The sleeve rod (5) then drives the slider (8) to slide. The slider (8) then slides inside the groove (7). S2. Then start the pneumatic cylinder (14). The operation of the pneumatic cylinder (14) will push the push plate (13) to slide. Subsequently, the push plate (13) will drive the connecting rod (12) to slide. Then the connecting rod (12) will slide inside the transverse groove (11). The detection height can be automatically adjusted by the sleeve rod (5) and the lifting motor (6), and the detection horizontal position can be adjusted by the push plate (13) and the pneumatic cylinder (14). Then start the adjustment motor (20). The operation of the adjustment motor (20) will make When the lead screw (17) rotates, the lead screw (17) will drive the sleeve (18) to slide. Then the sleeve (18) will slide inside the strip groove (16). At this time, the sleeve (18) will drive the adjusting plate (19) to slide. Then the adjusting plate (19) will drive the mounting block (21) to slide. Then the mounting block (21) will drive the fixing plate (24) to slide. Then the fixing plate (24) will drive the ultrasonic probe (25) to slide, so that the ultrasonic probe (25) can be inserted into different detection parts. S3. Finally, the ultrasonic probe (25) will emit ultrasonic waves into the aircraft structure. When the ultrasonic waves encounter a defect, they will be reflected and the reflected signal will be received by the ultrasonic probe (25). Then, the signal conditioning module (30) will filter the noise and amplify the signal. Subsequently, the data acquisition and processing module (31) will convert the acquired signal into a digital signal and complete the signal noise reduction, defect extraction and feature analysis. At this time, the data detected by the ultrasonic waves can be imaged through the imaging display (27). Then, the data can be processed through the control button (28). The data can also be transmitted to the background for processing and storage through the wireless communication module (32).

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