An ultrasonic flaw detection tool suitable for gear

Abstract

This application discloses an ultrasonic flaw detection fixture for gears, comprising a contour clamping block assembly, including a first clamping block and a second clamping block; an intermediate block disposed between the first and second clamping blocks, with its lower end face having a contact surface for contacting the tooth tip of the gear; an internal mounting cavity for accommodating an ultrasonic phased array probe; an elastic adjustment component disposed between the contour clamping block assembly and the intermediate block; an anti-detachment connector for connecting the contour clamping block assembly and the intermediate block to form a slidable locking connection; and an operating lever, one end of which is movably connected to the intermediate block via a ball joint, and the other end extending to the outside of the maintenance viewing window of the wind turbine gearbox. The solution of this application, by setting the elastic adjustment component structure, can adapt to different gear thicknesses, achieve automatic centering and alignment, and make the clamping force adjustable and uniform; at the same time, by setting the anti-detachment connector structure, it effectively ensures that the components do not loosen or fall off during the flaw detection process, improving operational safety and reliability.

Description

Technical Field

[0001] This application generally relates to the field of nondestructive testing equipment technology. More specifically, this application relates to an ultrasonic flaw detection fixture suitable for gears. Background Technology

[0002] The gearbox in a wind turbine generator set is one of the most valuable and potentially most serious core components in the entire unit. The gears inside the gearbox, especially the planetary gears and sun gear, are subjected to complex alternating loads over long periods, making them prone to internal damage such as fatigue cracks and metallurgical defects during service. If not detected in time, this can lead to catastrophic gear breakage, causing enormous economic losses and safety risks.

[0003] Currently, ultrasonic testing is commonly used for gear inspection in wind turbine gearboxes. However, due to structural limitations, there are many technical bottlenecks: the probe cannot adaptively clamp and position itself according to different tooth thicknesses, it is prone to displacement and cannot maintain a centered detection position, resulting in unstable ultrasonic coupling, signal distortion, and poor repeatability of test results; when operating inside the gearbox, the tooling is prone to loosening and falling off, posing a safety hazard of damaging the gears and gearbox.

[0004] In view of this, there is an urgent need to provide an ultrasonic flaw detection fixture solution for gears, so that it can be extended into the interior through the inspection window of the wind turbine gearbox, can be stably clamped on gears of different specifications, and has a reliable anti-disengagement locking function, thereby realizing efficient and reliable in-service inspection of gears inside the wind turbine gearbox. Summary of the Invention

[0005] In order to solve at least one or more of the technical problems mentioned above, this application proposes an ultrasonic flaw detection fixture for gears that can be clamped onto gears of different specifications and has a reliable anti-disengagement locking function.

[0006] In some embodiments, this application provides an ultrasonic flaw detection fixture suitable for gears, comprising: a contour clamping block assembly, including a first clamping block and a second clamping block that fit against the tooth surface of the gear; an intermediate block disposed between the first clamping block and the second clamping block, the lower end face of which is provided with a fitting surface for contacting the tooth tip of the gear; the intermediate block having an internal mounting cavity for accommodating an ultrasonic phased array probe; an elastic adjustment assembly disposed between the contour clamping block assembly and the intermediate block; an anti-detachment connector for connecting the contour clamping block assembly and the intermediate block to form a slidable locking connection; and an operating lever, one end of which is movably connected to the intermediate block via a ball joint, and the other end extending to the outside of the maintenance viewing window of the wind turbine gearbox.

[0007] In some embodiments, the elastic adjustment assembly includes two springs, respectively clamped between the first clamping block and the intermediate block and between the second clamping block and the intermediate block; the first clamping block and the second clamping block are provided with a first annular groove on their sides facing the intermediate block, and the two sides of the intermediate block are provided with a second annular groove; the two ends of the springs are respectively embedded in the corresponding first annular groove and second annular groove.

[0008] In some embodiments, the second end face of the first clamping block and / or the second clamping block is provided with a mounting groove, the bottom wall of the mounting groove has a preset thickness, and is provided with a plurality of positioning grooves and a through hole penetrating the bottom wall; the anti-detachment connector includes a rod-shaped mounting part for passing through the through hole, a limiting part provided at one end of the mounting part, and an external thread provided at the other end; the end face of the limiting part is provided with a plurality of protrusions that cooperate with the positioning grooves to limit the rotation or detachment of the anti-detachment connector.

[0009] In some embodiments, a gap is reserved between the first clamping block, the intermediate block, and the second clamping block; when the first clamping block and the second clamping block are pressed to reduce the gap, the protrusion is dislodged from the positioning groove, and the clamping distance is adjusted by rotating the anti-disengagement connector; after the first clamping block and the second clamping block are released, the gap is restored, and the protrusion is re-embedded into the positioning groove to achieve anti-disengagement locking.

[0010] In some embodiments, the first clamping block and the second clamping block are respectively provided with a tooth-shaped surface at one end away from the intermediate block. The shape of the tooth-shaped surface is adapted to the tooth surface of the gear to be tested, and is used to fit against the gear tooth surface during flaw detection.

[0011] In some embodiments, the intermediate block is formed by splicing a first intermediate block and a second intermediate block; the first intermediate block and the second intermediate block are respectively provided with L-shaped mounting grooves, and the two sides of the L-shaped mounting grooves extend to two adjacent sidewalls of the intermediate block and are flush with the edges of the two sidewalls; when the first intermediate block and the second intermediate block are spliced ​​together, the two L-shaped mounting grooves together form a mounting cavity for accommodating an ultrasonic phased array probe.

[0012] In some embodiments, each edge of the L-shaped mounting groove is provided with an anti-interference hole, and its inner corner is provided with a chamfer.

[0013] In some embodiments, the upper ends of the first intermediate block and the second intermediate block are each provided with a hemispherical cavity, and the two hemispherical cavities are spliced ​​together to form a spherical cavity; the ball joint includes a ball head, a connecting part and a screw part connected in sequence, the ball head is rotatably accommodated in the spherical cavity, and the connecting part has two opposing planes.

[0014] In some embodiments, countersunk holes are provided on both the first intermediate block and the second intermediate block below the L-shaped mounting groove, and the two countersunk holes together form a receiving cavity, which contains a magnetic adsorption element, wherein the magnetic pole direction of the magnetic adsorption element is perpendicular to the top surface of the gear tooth.

[0015] In some embodiments, the operating lever is provided with a semi-circular groove along its axial direction, and the semi-circular groove contains a signal line; one end of the signal line is connected to the probe, and the other end is connected to a portable ultrasonic flaw detector.

[0016] The ultrasonic flaw detection fixture for gears described above, with its elastic adjustment component structure, can adapt to different gear thicknesses, achieve automatic centering and alignment, and ensure adjustable and uniform clamping force. Simultaneously, the sliding and locking anti-detachment connector structure effectively ensures that components do not loosen or fall during flaw detection, improving operational safety and reliability. Furthermore, the operating rod structure, with one end connected to the intermediate block via a ball joint and the other end extending to the inspection window, enables remote control of flaw detection without disassembling the gearbox, allowing for flexible adjustment of the probe angle and eliminating blind spots in the detection process. Attached Figure Description

[0017] The above and other objects, features, and advantages of exemplary embodiments of this application will become readily understood by reading the following detailed description with reference to the accompanying drawings. In the drawings, several embodiments of this application are illustrated by way of example and not limitation, and the same or corresponding reference numerals denote the same or corresponding parts, wherein:

[0018] Figure 1 This illustration shows a partial structural diagram of the ultrasonic flaw detection fixture assembled on a gear according to an embodiment of this application; Figure 2 A top view of an ultrasonic flaw detection fixture for gears according to an embodiment of this application is shown; Figure 3 A side view of an ultrasonic flaw detection fixture for gears according to an embodiment of this application is shown; Figure 4 A cross-sectional view along the length of the operating lever is shown of an ultrasonic flaw detection fixture for gears according to an embodiment of this application; Figure 5 A cross-sectional view of an ultrasonic flaw detection fixture for gears according to an embodiment of this application is shown along the width direction of the operating lever at the conformal clamping block assembly. Figure 6 An exploded view of the ultrasonic flaw detection fixture for gears according to an embodiment of this application is shown, excluding the operating lever. Figure 7An exploded view of the ultrasonic flaw detection tooling operating lever for gears according to an embodiment of this application is shown; Figure 8 A structural diagram of the first clamping block according to an embodiment of this application is shown; Figure 9 A front view of the first side of the first clamping block according to an embodiment of this application is shown; Figure 10 A front view of the second side of the first clamping block according to an embodiment of this application is shown; Figure 11 It shows Figure 10 A cross-sectional view along the AA direction; Figure 12 It shows Figure 10 A cross-sectional view along the BB direction; Figure 13 A schematic diagram of the anti-detachment connector according to an embodiment of this application is shown; Figure 14 This diagram shows the first intermediate block, the ball joint, and the second intermediate block in an assembled state according to an embodiment of this application. Figure 15 A schematic diagram of the ball joint structure according to an embodiment of this application is shown; Figure 16 An exploded view of the inter-block in an embodiment of this application is shown; Figure 17 A schematic diagram of the structure of the first intermediate block according to an embodiment of this application is shown; Figure 18 A schematic diagram of the structure of the first intermediate block in an embodiment of this application is shown.

[0019] In the diagram: 100, ultrasonic testing fixture for gears; 200, gear; 201, tooth tip; 202, tooth surface; 300, inspection window; 1. First clamping block; 1-1. First annular groove; 1-2. Mounting groove; 1-3. Positioning groove; 1-4. Tooth-shaped surface; 1-5. Bottom wall; 1-6. Through hole; 2. Second clamping block; 2-1. Threaded hole; 2-2. Second annular groove; 3. Intermediate block; 3-1. First intermediate block; 311. L-shaped mounting groove; 312. Anti-interference hole; 313. Chamfer; 314. Countersunk hole; 315. Hemispherical cavity; 317. Bolt hole; 318. Through hole; 3-2. Second intermediate block; 4. Ball joint; 4-1. Ball head; 4-2. Connecting part; 4-3. Screw part; 5. Anti-detachment connector; 5-1. Limiting part; 5-2. Protrusion; 5-3. Mounting part; 6. Spring; 7. Operating lever; 7-1. First section; 7-2. Second section; 7-3. Second threaded hole; 7-4. Semi-circular groove; 8. Magnetic adsorption element; 9. Phased array probe; 10. Portable ultrasonic flaw detector; 11. Signal line; 12. Bolt; 13. Gap. Detailed Implementation

[0020] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0021] It should be understood that the terms "comprising" and "including" used in the specification and claims of this application indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0022] It should also be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application. As used in this specification and claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used in this specification and claims refers to any combination and all possible combinations of one or more of the associated listed items, and includes such combinations.

[0023] As used in this specification and claims, the term "if" may be interpreted, depending on the context, as "when," "once," "in response to determination," or "in response to detection." Similarly, the phrase "if determined" or "if [described condition or event] is detected" may be interpreted, depending on the context, as "once determined," "in response to determination," "once [described condition or event] is detected," or "in response to detection of [described condition or event]."

[0024] The specific embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0025] like Figure 1-7As shown, in some embodiments, this application provides an ultrasonic flaw detection fixture 100 suitable for gears, comprising: a contour clamping block assembly, which includes a first clamping block 1 and a second clamping block 2 that fit against the tooth surface 202 of the gear 200; an intermediate block 3, which is disposed between the first clamping block 1 and the second clamping block 2, and whose lower end face is provided with a fitting surface for contacting the tooth tip 201 of the gear 200; an installation cavity for accommodating an ultrasonic phased array probe 9 is provided inside the intermediate block 3; an elastic adjustment component, which is disposed between the contour clamping block assembly and the intermediate block 3; an anti-detachment connector 5, which is used to connect the contour clamping block assembly and the intermediate block 3 to form a slidable locking connection; and an operating lever 7, one end of which is provided with a threaded hole 7-3, and a ball joint 4 is connected to the threaded hole, that is, one end of which is movably connected to the intermediate block 3 through the ball joint 4, and the other end extends to the outside of the inspection window 300 of the wind turbine gear 200 box.

[0026] like Figure 1 and Figure 6 As shown, in the scheme of this application, the ultrasonic flaw detection fixture 100 for gears includes a contour clamping block assembly, an intermediate block 3, an elastic adjustment component, an anti-detachment connector 5, and an operating lever 7. The contour clamping block assembly includes a first clamping block 1 and a second clamping block 2, which are used to engage with the two opposing tooth surfaces 202 of the gear 200 during flaw detection to achieve initial positioning of the fixture on the gear 200. The intermediate block 3 is disposed between the first clamping block 1 and the second clamping block 2, and its lower end face has a contact surface for contacting the tooth tip 201 of the gear 200; simultaneously, the interior of the intermediate block 3 also has a mounting cavity for accommodating the ultrasonic phased array probe 9, allowing the probe to be close to the tooth tip 201 for flaw detection.

[0027] An elastic adjustment component is positioned between the contour clamping block assembly and the intermediate block 3 to provide elastic force during clamping, enabling the first clamping block 1 and the second clamping block 2 to adaptively conform to the tooth surfaces 202 of the gears 200 with different tooth thicknesses, ensuring clamping stability and adaptability. An anti-detachment connector 5 connects the contour clamping block assembly and the intermediate block 3. During adjustment, it allows relative sliding between the contour clamping block assembly and the intermediate block 3 to adjust the clamping distance according to the gear 200 thickness. In the clamping state, it restricts relative rotation or axial movement between the two to prevent loosening due to vibration or other reasons, thereby improving the safety and reliability of the tooling.

[0028] One end of the operating lever 7 is movably connected to the intermediate block 3 via a ball joint 4, allowing the intermediate block 3 to swing freely relative to the operating lever 7. This allows the intermediate block 3 to automatically adjust its posture when the extension angle of the operating lever 7 is limited, ensuring that the lower end face of the intermediate block 3 is parallel and in contact with the tooth tip 201. The other end of the operating lever 7 extends to the outside of the maintenance window 300 of the wind turbine gearbox 200, allowing operators to control the tooling outside the gearbox 200 and conveniently inspect the internal gear 200.

[0029] During flaw detection, the operator first inserts the contour clamping block assembly, the intermediate block 3, and the ultrasonic phased array probe 9 installed inside it into the wind turbine gearbox 200 through the inspection window 300. Then, the operator holds the operating lever 7 located outside the inspection window 300 and adjusts the posture of the intermediate block 3 and the contour clamping block assembly via the ball joint 4, so that the first clamping block 1 and the second clamping block 2 straddle both sides of the tooth of the gear 200 to be tested. The operator applies pressure to the contour clamping block assembly via the operating lever 7, compressing the elastic adjustment component, causing the first clamping block 1 and the second clamping block 2 to open to both sides; when the opening size of the contour clamping block assembly is larger than the tooth thickness, the fixture is pushed further in, so that the lower end face of the intermediate block 3 contacts the tooth tip 201 of the gear 200. At this time, the pressure on the operating lever 7 is released, and the elastic force of the elastic adjustment component drives the first clamping block 1 and the second clamping block 2 to reset, so that their contour surfaces are tightly fitted with the two opposite tooth surfaces 202 of the gear 200, and at the same time, the intermediate block 3 is pressed against the tooth tip 201, realizing the initial positioning of the tooling on the gear 200.

[0030] Based on this, the operator fine-tunes the position of the fixture using the operating lever 7, ensuring stable coupling between the ultrasonic phased array probe 9, installed in the intermediate block 3, and the gear tip 201 via the contact surface and the gear 200 lubricant. With the fixture clamped on the gear 200, the anti-detachment connector 5 is locked, restricting relative rotation or axial movement between the contour clamping block assembly and the intermediate block 3 to prevent the fixture from loosening due to vibration or other reasons during testing. After completing the inspection of one tooth, the operator pulls the operating lever 7, compressing the elastic adjustment component to open the first clamping block 1 and the second clamping block 2, removing the fixture from the current tooth and moving it to the next tooth to be tested, repeating the above operation until all gears 200 to be tested have undergone flaw detection.

[0031] The solution of this application, by setting an elastic adjustment component structure, can adapt to different thicknesses of gears 200, achieve automatic centering and alignment, and make the clamping force adjustable and uniform. At the same time, by setting a sliding and locking anti-detachment connector 5 structure, it effectively ensures that the parts do not loosen or fall off during the flaw detection process, improving the safety and reliability of the operation. In addition, by setting an operating rod 7 structure with one end connected to the intermediate block 3 via a ball joint 4 and the other end extending to the outside of the inspection window 300, it is possible to remotely control the flaw detection without disassembling the gear box 200, making the probe angle flexibly adjustable, thereby eliminating the detection blind spot.

[0032] like Figure 6 and Figure 11 As shown, in a specific implementation, the first clamping block 1 and the second clamping block 2 are respectively provided with tooth-shaped surfaces 1-4 at the ends away from the intermediate block 3. The shape of the tooth-shaped surfaces 1-4 is adapted to the tooth surface 202 of the gear 200 to be tested, and is used to fit against the tooth surface 202 of the gear 200 during flaw detection.

[0033] In this application, the first clamping block 1 and the second clamping block 2 are respectively provided with tooth-like surfaces 1-4 at their ends away from the intermediate block 3. These tooth-like surfaces 1-4 are machined according to the contour of the tooth surface 202 of the gear 200 to be tested, and their shape is adapted to the involute contour or tooth profile curve of the gear 200 tooth surface 202. During flaw detection, these tooth-like surfaces 1-4 are used to fit against the tooth surface 202 of the gear 200, allowing the first clamping block 1 and the second clamping block 2 to be stably clamped on both sides of the tooth surface 202 of the gear 200. Through the surface contact or line contact between the tooth-like surfaces 1-4 and the tooth surface 202, the fit between the clamping blocks and the gear 200 is improved, thereby ensuring the positioning accuracy and clamping stability of the tooling on the gear 200.

[0034] like Figure 6 , 10 As shown in Figure 11, in a specific embodiment, the elastic adjustment component includes two springs 6, which are respectively clamped between the first clamping block 1 and the intermediate block 3, and between the second clamping block 2 and the intermediate block 3; the first clamping block 1 and the second clamping block 2 are provided with a first annular groove 1-1 on their sides facing the intermediate block 3, and the two sides of the intermediate block 3 are respectively provided with a second annular groove 2-2; the two ends of the springs 6 are respectively embedded in the corresponding first annular groove 1-1 and second annular groove 2-2.

[0035] In this application, the elastic adjustment assembly includes two springs 6. One spring 6 is clamped between the first clamping block 1 and the intermediate block 3, and the other spring 6 is clamped between the second clamping block 2 and the intermediate block 3. To achieve stable installation of the springs 6, the first clamping block 1 and the second clamping block 2 are respectively provided with a first annular groove 1-1 on their sides facing the intermediate block 3, and the intermediate block 3 is respectively provided with a second annular groove 2-2 on its two sides facing the first clamping block 1 and the second clamping block 2. The two ends of the two springs 6 are respectively embedded in the corresponding first annular groove 1-1 and second annular groove 2-2, thereby keeping the springs 6 in a compressed state between the first clamping block 1 and the intermediate block 3 and between the second clamping block 2 and the intermediate block 3.

[0036] like Figure 8 , 9 As shown in Figure 12, in a specific embodiment, the second end faces of the first clamping block 1 and the second clamping block 2 are provided with mounting grooves 1-2. The bottom wall 1-5 of the mounting groove 1-2 has a preset thickness and is provided with multiple positioning grooves 1-3 and through holes 1-6 penetrating the bottom wall 1-5. The anti-detachment connector 5 includes a rod-shaped mounting part 5-3 for passing through the through hole 1-6, a limiting part 5-1 provided at one end of the mounting part 5-3, and an external thread provided at the other end. The end face of the limiting part 5-1 is provided with multiple protrusions 5-2 that cooperate with the positioning grooves 1-3 to limit the rotation or detachment of the anti-detachment connector 5.

[0037] In this application, the second end faces of the first clamping block 1 and the second clamping block 2 are respectively provided with mounting grooves 1-2. The mounting groove 1-2 is formed by a cavity recessed into the first clamping block 1 or the second clamping block 2, and its bottom wall 1-5 has a predetermined thickness. A through hole 1-6 is formed on the bottom wall 1-5 of the mounting groove 1-2 for the rod-shaped mounting portion 5-3 of the anti-detachment connector 5 to pass through; simultaneously, multiple positioning grooves 1-3 are also formed on the bottom wall 1-5, arranged around the through hole 1-6. It is worth noting that this application does not limit the number of positioning grooves 1-3; it can be four or other numbers.

[0038] like Figure 13 As shown, this solution includes two anti-detachment connectors 5. One anti-detachment connector 5 connects the first clamping block 1 and the intermediate block 3, and the other anti-detachment connector 5 connects the second clamping block 2 and the intermediate block 3. Specifically, the anti-detachment connector 5 includes a rod-shaped mounting part 5-3, a limiting part 5-1, and an external thread. The rod-shaped mounting part 5-3 is a slender rod-shaped structure. The limiting part 5-1 is located at one end of the rod-shaped mounting part 5-3, and its end face has multiple protrusions 5-2. The external thread is located at the other end of the rod-shaped mounting part 5-3 and is used to connect with the threaded hole on the intermediate block 3.

[0039] When the anti-detachment connector 5, the first clamping block 1, and the intermediate block 3 are in the assembled state, the limiting part 5-1 of the anti-detachment connector 5 is accommodated in the mounting groove 1-2 of the first clamping block 1, and the protrusion 5-2 on its end face is embedded in the positioning groove 1-3 of the bottom wall 1-5 of the mounting groove 1-2; after the rod-shaped mounting part 5-3 passes through the through hole 1-6 of the bottom wall 1-5 of the mounting groove 1-2, the external thread at its end is connected to the corresponding threaded hole on the intermediate block 3. The connection method between the second connecting block and the intermediate block 3 is the same as the above connection method, and will not be described in detail here.

[0040] The solution of this application, through the aforementioned structure, connects the first clamping block 1 and the second clamping block 2 to the intermediate block 3 via two anti-detachment connectors 5. In the clamping state, the protrusion 5-2 is embedded in the positioning groove 1-3, restricting the rotation of the anti-detachment connector 5 relative to the first clamping block 1 or the second clamping block 2; simultaneously, since the mounting part 5-3 is threadedly connected to the intermediate block 3, the axial movement of the anti-detachment connector 5 is also restricted, thereby achieving the anti-detachment locking function. When it is necessary to adjust the clamping distance, the protrusion 5-2 is disengaged from the positioning groove 1-3 by pressing the first clamping block 1 and the second clamping block 2, allowing the anti-detachment connector 5 to be rotated for adjustment.

[0041] It is worth noting that the solution in this application does not limit the number of anti-detachment connectors 5. That is to say, in other embodiments, only one anti-detachment connector 5 can be provided, so that only the mounting groove 1-2 is provided on the first clamping block 1, and the threaded hole 2-1 is provided on the second clamping block 2 (e.g., Figure 6(As shown). During installation, the anti-detachment connector 5 passes through the through hole 318 of the first clamping block 1 and the intermediate part in sequence and is then threadedly connected to the second clamping block 2.

[0042] like Figure 5 As shown, in a specific implementation, a gap 13 is reserved between the first clamping block 1, the intermediate block 3, and the second clamping block 2; when the first clamping block 1 and the second clamping block 2 are pressed to reduce the gap 13, the protrusion 5-2 is dislodged from the positioning groove 1-3, and the clamping distance is adjusted by rotating the anti-disengagement connector 5; after the first clamping block 1 and the second clamping block 2 are released, the gap 13 is restored, and the protrusion 5-2 is re-embedded into the positioning groove 1-3 to achieve anti-disengagement locking.

[0043] In the solution of this application, a gap 13 is reserved between the first clamping block 1, the intermediate block 3 and the second clamping block 2. The setting of the gap 13 allows the first clamping block 1 and the second clamping block 2 to generate a certain displacement relative to the intermediate block 3, thereby providing conditions for the adjustment operation of the anti-detachment connector 5.

[0044] When it is necessary to adjust the clamping distance, the operator can press the first clamping block 1 and the second clamping block 2 towards the middle block 3 to reduce the gap 13 between the three. During this process, as the first clamping block 1 is displaced relative to the limiting part 5-1 of the anti-detachment connector 5, the protrusion 5-2 that was originally embedded in the positioning groove 1-3 is dislodged from the positioning groove 1-3. At this time, the rotation constraint of the anti-detachment connector 5 is released, and the operator can freely rotate the anti-detachment connector 5 and adjust the span between the first clamping block 1 and the second clamping block 2 through the thread engagement between its external thread and the second clamping block 2 to accommodate gears 200 with different tooth thicknesses.

[0045] After the clamping distance is adjusted to the appropriate position, the operator releases the first clamping block 1 and the second clamping block 2. Under the elastic force of the elastic adjustment component, the first clamping block 1 and the second clamping block 2 reset, and the gap 13 between them returns to its initial state. At the same time, the position of the first clamping block 1 relative to the limiting part 5-1 of the anti-detachment connector 5 also resets, causing the protrusion 5-2 to re-embed in the positioning groove 1-3. The cooperation between the protrusion 5-2 and the positioning groove 1-3 again forms a rotational constraint, restricting the relative rotation of the anti-detachment connector 5; at the same time, due to the threaded connection between the anti-detachment connector 5 and the second clamping block 2, its axial movement is also restricted, thereby achieving anti-detachment locking. This structural design enables the tooling to effectively resist external interference such as vibration in the clamping state, preventing the anti-detachment connector 5 from loosening or falling out, thus improving the safety and reliability of the tooling.

[0046] like Figure 6 , 14As shown in Figure 18, in a specific implementation, the intermediate block 3 is formed by splicing a first intermediate block 3-1 and a second intermediate block 3-2; the first intermediate block 3-1 and the second intermediate block 3-2 are respectively provided with L-shaped mounting grooves 311, and the two sides of the L-shaped mounting grooves 311 extend to two adjacent side walls of the intermediate block 3 and are flush with the edges of the two side walls; when the first intermediate block 3-1 and the second intermediate block 3-2 are spliced, the two L-shaped mounting grooves 311 together form a mounting cavity for accommodating the ultrasonic phased array probe 9.

[0047] In this application, the intermediate block 3 is formed by splicing together a first intermediate block 3-1 and a second intermediate block 3-2. The first intermediate block 3-1 and the second intermediate block 3-2 are made of antimagnetic materials such as copper, aluminum, and non-metals. Each has bolt holes 317, and they are fastened together with bolts 12. The first intermediate block 3-1 and the second intermediate block 3-2 each have L-shaped mounting grooves 311. The two sides of each L-shaped mounting groove 311 extend to two adjacent sidewalls of the intermediate block 3 and are flush with the edges of these sidewalls. When the first intermediate block 3-1 and the second intermediate block 3-2 are spliced ​​together, the two L-shaped mounting grooves 311 together form a complete mounting cavity, which is used to accommodate the ultrasonic phased array probe 9.

[0048] The solution proposed in this application designs the intermediate block 3 as a split structure, with L-shaped mounting grooves 311 on each of the two halves. This not only facilitates the machining and forming of the mounting grooves 1-2, but also facilitates the installation and removal of the probe. The design of the mounting grooves 1-2 extending to the sidewall edges of the intermediate block 3 allows the probe to be inserted as close as possible to the outer side of the intermediate block 3, thereby reducing the overall size of the intermediate block 3 and making it easier for the tooling to reach into the gearbox 200 through the narrow inspection window 300. At the same time, the mounting cavity, formed by the L-shaped grooves on the two halves, provides good positioning and constraint for the probe, ensuring that the probe maintains a stable contact with the tooth tip 201 during flaw detection.

[0049] like Figure 18 As shown, in a specific embodiment, each edge of the L-shaped mounting groove 311 is provided with an anti-interference hole 312, and its inner corner is provided with a chamfer 313.

[0050] In this application, each edge of the L-shaped mounting groove 311 is provided with an anti-interference hole 312. The anti-interference hole 312 is a partially enlarged recessed structure opened at the edge of the mounting groove 1-2. Its shape and position correspond to the edge contour of the ultrasonic phased array probe 9. It is used to provide clearance space for the edge of the probe when the ultrasonic phased array probe 9 is installed, so as to avoid the edge of the probe being squeezed or scratched by the hard edge of the mounting groove 1-2, thereby protecting the probe from damage.

[0051] Meanwhile, a chamfer 313 is provided at the inner corner of the L-shaped mounting groove 311. The chamfer 313 is a bevel or arc surface machined at the inner corner of the mounting groove 1-2, which is used to further eliminate sharp corners, facilitate the smooth installation of the probe, and prevent stress concentration or damage to the probe due to contact with sharp corners during installation.

[0052] The solution proposed in this application, through the combination of anti-interference hole 312 and chamfer 313, not only reduces the operational difficulty and improves the assembly efficiency during probe assembly, but also effectively protects the structural integrity of the probe, a precision component, and ensures the stability and reliability of flaw detection operations.

[0053] like Figure 18 As shown, in a specific embodiment, the upper ends of the first intermediate block 3-1 and the second intermediate block 3-2 are both provided with hemispherical cavities 315, and the two hemispherical cavities 315 are spliced ​​together to form a spherical cavity; the ball hinge 4 includes a ball head 4-1, a connecting part 4-2 and a screw part 4-3 connected in sequence, the ball head 4-1 is rotatably accommodated in the spherical cavity, and the connecting part 4-2 has two oppositely arranged planes.

[0054] In the scheme of this application, the upper ends of the first intermediate block 3-1 and the second intermediate block 3-2 are both provided with hemispherical cavities 315. When the first intermediate block 3-1 and the second intermediate block 3-2 are spliced ​​together, the two hemispherical cavities 315 are aligned to form a complete spherical cavity. This spherical cavity is used to accommodate the ball joint 4 and to provide space for the multi-degree-of-freedom rotation of the ball head 4-1.

[0055] In this application, a ball joint 4 movably connects the operating lever 7 and the intermediate block 3. Specifically, the ball head 4-1 of the ball joint 4 can be rotatably accommodated within a spherical cavity with multiple degrees of freedom, allowing the intermediate block 3 to freely swing in multiple directions such as pitch, yaw, and roll relative to the operating lever 7 in space. During flaw detection, when the operating lever 7 is restricted by the opening position of the wind turbine gearbox inspection window 300 or by obstacles inside the gearbox and cannot be inserted at the optimal angle, the intermediate block 3 can automatically adjust its posture under the action of the ball joint 4, ensuring that the lower end face of the intermediate block 3 always tends to remain parallel and in contact with the tooth tip 201 surface of the gear 200. This adaptive adjustment function is particularly suitable for helical gear inspection: the tooth tip surface of the helical gear has an inclination angle relative to the insertion direction of the operating lever 7. If the intermediate block 3 is rigidly connected to the operating lever 7, it is difficult to guarantee complete contact of the contact surfaces; however, through the multi-degree-of-freedom swing of the ball joint 4, the intermediate block 3 can conform to the actual inclination direction of the helical gear tooth tip, achieving surface contact contact. In addition, in scenarios where the inspection window 300 has a narrow opening or the internal space of the gearbox is cramped, the operator does not need to forcibly change the grip angle of the operating lever 7. The operator can flexibly adjust the relative angle and direction between the head of the flaw detection tool 100 and the operating lever 7 through the ball joint 4, thereby greatly reducing the difficulty of operation and avoiding probe positioning deviation or poor coupling caused by interference between the operating lever 7 and the housing.

[0056] Through the above structure, the ball joint 4 not only ensures stable and uniform ultrasonic coupling between the ultrasonic phased array probe 9 and the tooth tip 201, but also significantly improves the tooling's adaptability to different tooth shapes and different working spaces, eliminates blind spots in the detection, and improves the reliability and repeatability of the flaw detection results.

[0057] like Figure 15 As shown, in this design, the ball joint 4 includes a ball head 4-1, a connecting part 4-2, and a screw part 4-3 connected in sequence. The ball head 4-1 is a spherical structure, rotatably housed within a spherical cavity formed by the splicing of the first intermediate block 3-1 and the second intermediate block 3-2, thereby achieving a movable connection between the intermediate block 3 and the operating rod 7. The connecting part 4-2 is located between the ball head 4-1 and the screw part 4-3, and its outer surface has two opposing planes. The screw part 4-3 has external threads for connecting with the threaded hole at the end of the operating rod 7, thus fixing the ball joint 4 to the operating rod 7.

[0058] The solution of this application, through the aforementioned structure, uses a ball joint 4 to movably connect the operating lever 7 and the intermediate block 3, allowing the intermediate block 3 to swing freely relative to the operating lever 7. This automatically adjusts its posture when the extension angle of the operating lever 7 is limited, ensuring the parallel fit between the lower end face of the intermediate block 3 and the tooth tip 201. Simultaneously, the planar design on the connecting part 4-2 facilitates the assembly and disassembly of the ball joint 4.

[0059] like Figure 18As shown, in a specific embodiment, countersunk holes 314 are provided on the first intermediate block 3-1 and the second intermediate block 3-2, below the L-shaped mounting groove 311. The two countersunk holes 314 together form a receiving cavity, which contains a magnetic adsorption element 8, wherein the magnetic pole direction of the magnetic adsorption element 8 is perpendicular to the tooth tip 201 surface of the gear 200.

[0060] In this application, countersunk holes 314 are provided on the first intermediate block 3-1 and the second intermediate block 3-2, respectively, below the L-shaped mounting groove 311. The two countersunk holes 314 are formed by recesses downwards from the interior of the first intermediate block 3-1 and the second intermediate block 3-2. When the first intermediate block 3-1 and the second intermediate block 3-2 are joined together, the two countersunk holes 314 align to form a complete receiving cavity. This receiving cavity is located below the L-shaped mounting groove 311, i.e., near the lower end face of the intermediate block 3. A magnetic adsorption element 8 is provided inside the receiving cavity. This magnetic adsorption element 8 is used to adsorb and fix the intermediate block 3 onto the tooth tip 201 surface of the gear 200 during flaw detection operations.

[0061] It is worth noting that the magnetic pole direction of the magnetic adsorption element 8 is set to be perpendicular to the tooth tip 201 surface of the gear 200, that is, the magnetic field line direction is perpendicular to the tooth tip 201 surface, thereby generating an adsorption force perpendicular to the tooth tip 201 surface, so that the lower end surface of the intermediate block 3 can be tightly attached to the tooth tip 201, ensuring that the ultrasonic phased array probe 9 installed inside the intermediate block 3 and the tooth tip 201 form a stable coupling state.

[0062] The solution of this application not only achieves rapid positioning and reliable fixation of the intermediate block 3 on the tooth tip 201 by embedding the magnetic adsorption element 8 in the receiving cavity inside the intermediate block 3, but also avoids the interference of exposed parts to the tooling when passing through the inspection window 300, which is conducive to the flexible operation of the tooling in a narrow space.

[0063] like Figure 4 and Figure 7 As shown, in a specific embodiment, the operating lever 7 is provided with a semi-circular groove 7-4 along its axial direction, and the semi-circular groove 7-4 contains a signal line 11; one end of the signal line 11 is connected to the probe, and the other end is connected to the portable ultrasonic flaw detector 10.

[0064] In this application, the operating lever 7 consists of two sections: a first section 7-1 and a second section 7-2. The two sections are detachably connected as one unit using a threaded connection. This modular structure allows the operating lever 7 to be assembled into a single unit of the required length before use, and to be disassembled into two sections after use, thereby reducing the overall size for single-use and facilitating carrying and storage for the operator.

[0065] In addition, the operating lever 7 in this design has a semi-circular groove 7-4 along its axial direction. This semi-circular groove 7-4 is formed by an inward indentation from the surface of the operating lever 7 and extends along the length of the lever. The semi-circular groove 7-4 is used to accommodate the signal line 11, so that the signal line 11 is embedded in the groove and laid along the length of the operating lever 7. One end of the signal line 11 is connected to the ultrasonic phased array probe 9 installed inside the intermediate block 3, and the other end is connected to the portable ultrasonic flaw detector 10, which is used to transmit the ultrasonic signal collected by the probe to the flaw detector for processing and display. By setting a semi-circular groove 7-4 on the operating lever 7 and accommodating the signal line 11 in the groove, the signal line 11 can be effectively prevented from dangling or being hooked by external components during operation, thereby protecting the signal line 11 from damage. At the same time, it makes the overall structure of the fixture more compact and neat, and facilitates flexible operation in the narrow space inside the wind turbine gearbox 200.

[0066] While numerous embodiments of this application have been shown and described herein, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Many modifications, alterations, and alternatives will arise for those skilled in the art without departing from the spirit and intent of this application. It should be understood that various alternatives to the embodiments of this application described herein may be employed in the practice of this application. The appended claims are intended to define the scope of protection of this application and therefore cover equivalents or alternatives within the scope of these claims.

Claims

1. An ultrasonic inspection tool (100) for a gear, characterized in that, include: The contour clamping block assembly includes a first clamping block (1) and a second clamping block (2) that are in contact with the tooth surface (202) of the gear (200); An intermediate block (3) is disposed between the first clamping block (1) and the second clamping block (2), and its lower end face is provided with a contact surface for contacting the tooth tip (201) of the gear (200); the intermediate block (3) is provided with a mounting cavity for accommodating an ultrasonic phased array probe (9); An elastic adjustment component is disposed between the contour clamping block assembly and the intermediate block (3); Anti-detachment connector (5), which is used to connect the contoured clamping block assembly and the intermediate block (3) to form a slidable locking connection; and The operating lever (7) is movably connected at one end to the intermediate block (3) via a ball joint (4), and at the other end extends to the outside of the maintenance window (300) of the wind turbine gearbox (200).

2. The ultrasonic inspection tool of claim 1, wherein, The elastic adjustment assembly includes two springs (6), which are respectively clamped between the first clamping block (1) and the intermediate block (3) and between the second clamping block (2) and the intermediate block (3); The first clamping block (1) and the second clamping block (2) are provided with a first annular groove (1-1) on the side facing the middle block (3), and the two sides of the middle block (3) are provided with a second annular groove (2-2). The two ends of the spring (6) are respectively embedded in the first annular groove (1-1) and the second annular groove (2-2).

3. The ultrasonic inspection tool of claim 2, wherein, The second end face of the first clamping block (1) and / or the second clamping block (2) is provided with a mounting groove (1-2). The bottom wall (1-5) of the mounting groove (1-2) has a preset thickness and is provided with multiple positioning grooves (1-3) and through holes (1-6) penetrating the bottom wall (1-5). The anti-detachment connector (5) includes a rod-shaped mounting part (5-3) for passing through the through hole (1-6), a limiting part (5-1) at one end of the mounting part (5-3), and an external thread at the other end; the end face of the limiting part (5-1) is provided with a plurality of protrusions (5-2) that cooperate with the positioning groove (1-3) to restrict the rotation or detachment of the anti-detachment connector (5).

4. The ultrasonic inspection tool of claim 3, wherein, A gap (13) is reserved between the first clamping block (1), the middle block (3), and the second clamping block (2); When the first clamping block (1) and the second clamping block (2) are pressed together to reduce the gap (13), the protrusion (5-2) is dislodged from the positioning groove (1-3), and the anti-dislodgement connector (5) is rotated to adjust the clamping distance; After the first clamping block (1) and the second clamping block (2) are released, the gap (13) is restored, and the protrusion (5-2) is re-embedded in the positioning groove (1-3) to achieve anti-loosening locking.

5. The ultrasonic inspection tool of claim 3, wherein, The first clamping block (1) and the second clamping block (2) are respectively provided with a tooth-shaped surface (1-4) at one end away from the middle block (3). The shape of the tooth-shaped surface (1-4) is adapted to the tooth surface (202) of the gear (200) to be tested, and is used to fit with the tooth surface (202) of the gear (200) during flaw detection.

6. The ultrasonic inspection tool of any one of claims 1-5, wherein, The intermediate block (3) is formed by splicing together the first intermediate block (3-1) and the second intermediate block (3-2); The first intermediate block (3-1) and the second intermediate block (3-2) are respectively provided with L-shaped mounting grooves (311), and the two sides of the L-shaped mounting grooves (311) extend to the two adjacent side walls of the intermediate block (3) and are flush with the edges of the two side walls; When the first intermediate block (3-1) and the second intermediate block (3-2) are joined together, the two L-shaped mounting slots (311) together form a mounting cavity for accommodating the ultrasonic phased array probe (9).

7. The ultrasonic inspection tool of claim 6, wherein, Each edge of the L-shaped mounting groove (311) is provided with an anti-interference hole (312), and its inner corner is provided with a chamfer (313).

8. The ultrasonic inspection tool of claim 6, wherein, The upper ends of the first intermediate block (3-1) and the second intermediate block (3-2) are provided with hemispherical cavities (315), and the two hemispherical cavities (315) are spliced ​​together to form a spherical cavity; The ball joint (4) includes a ball head (4-1), a connecting part (4-2), and a screw part (4-3) connected in sequence. The ball head (4-1) is rotatably accommodated in the spherical cavity, and the connecting part (4-2) has two opposing planes.

9. The ultrasonic inspection tool of claim 7, wherein, Both the first intermediate block (3-1) and the second intermediate block (3-2) are provided with countersunk holes (314) located below the L-shaped mounting groove (311). The two countersunk holes (314) together form a receiving cavity, which contains a magnetic adsorption element (8). The magnetic pole direction of the magnetic adsorption element (8) is perpendicular to the tooth tip (201) surface of the gear (200).

10. The ultrasonic inspection tool of claim 1, wherein, The operating lever (7) is provided with a semi-circular groove (7-4) along its axial direction, and the semi-circular groove (7-4) contains a signal line (11). One end of the signal line (11) is connected to the probe, and the other end is connected to the portable ultrasonic flaw detector (10).

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