A phased array ultrasonic detection system and method based on multi-modal data joint positioning

Abstract

The application is suitable for the field of ultrasonic scanning equipment, and provides a phased array ultrasonic detection system and method based on multi-modal data joint positioning. The scheme takes a vehicle body as a mobile carrier, integrates an ultrasonic phased array probe, a ranging sensor, a detection probe and a multi-degree-of-freedom adjusting mechanism, firstly positions the edge of a workpiece through initial scanning and marks coordinates, then controls the probe to switch to a vertical state, performs adaptive follow-up scanning along the workpiece contour, and generates a complete contour model by fusing multi-modal data; then automatically plans a grid-shaped global serpentine scanning path, completes full-area detection, finally integrates data to generate a detection report, and automatically identifies a missed area to perform supplementary scanning. Therefore, the application solves the problem of the detection blind area existing in the edge of a large-thickness workpiece of the existing scanning vehicle, realizes full-range blind area-free detection, has the advantages of high automation degree, accurate positioning and comprehensive coverage, and can be widely applied to efficient nondestructive detection of large-volume workpieces of different sizes.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic scanning equipment and provides a phased array ultrasonic testing system and method based on multimodal data joint localization. Background Technology

[0002] The phased array ultrasonic scanning vehicle is an automated non-destructive testing (NDT) device equipped with an ultrasonic phased array probe. It is primarily used for detecting internal defects in large-volume metal components, composite material plates, and other workpieces, and is widely applied in aerospace, heavy equipment manufacturing, and pressure vessel industries. Its core testing principle is based on the piezoelectric effect and the Huygens-Fresnel principle: multiple independent array elements in the probe array can achieve electronic focusing, deflection, and scanning of the sound beam by precisely controlling the transmission and reception delay times. This enables accurate localization and imaging of defects such as cracks, inclusions, and pores at different depths and locations within the workpiece. Compared to traditional single-probe ultrasonic testing, it offers advantages such as high detection efficiency, intuitive imaging, and strong adaptability.

[0003] Currently, mainstream phased array ultrasonic scanning vehicles generally adopt a structure with a mobile vehicle body and a multi-degree-of-freedom motion mechanism: the mobile vehicle body serves as the support, and the probe moves planarly on the surface of the workpiece under test through a motor drive; the ultrasonic phased array probe is fixed to the end of the motion by a rigid or semi-rigid clamping mechanism. This type of equipment can realize automated scanning of large planar areas and is the mainstream equipment form for efficient non-destructive testing in the current industrial field.

[0004] However, existing phased array ultrasonic scanning vehicles have significant blind zone problems when applied to large-volume, thick-walled test pieces: when the edge thickness of the test piece is large, due to the travel limitations of the ultrasonic phased array and the limitations of the probe installation structure, the ultrasonic phased array probe cannot match the thick edge surface of the test piece, resulting in the sound beam being unable to detect the edge area of ​​the test piece, forming a detection blind zone, which cannot meet the requirement of full-range, blind-zone-free detection of large-volume test pieces. Summary of the Invention

[0005] To address the aforementioned deficiencies, the present invention aims to provide a phased array ultrasonic detection system and method based on multimodal data joint positioning, in order to solve the problems raised in the background art. The system includes a vehicle body, an ultrasonic phased array probe installed on the front side of the vehicle body in the direction of travel and capable of lateral displacement and angle adjustment, a ranging sensor installed on the ultrasonic phased array probe, and a visual detection probe installed on the bottom of the vehicle body and near the ultrasonic phased array probe.

[0006] The vehicle body is equipped with a walking drive assembly that enables the vehicle body to move in all directions, and an ultrasonic phased array instrument that is electrically connected to the ultrasonic phased array probe.

[0007] It also includes a system processor, which controls the vehicle to move, adjust its spatial position, and adjust the angle of the ultrasonic phased array probe from the horizontal to the vertical direction.

[0008] Furthermore, a lateral displacement seat is installed on the vehicle body, and an outer frame and a lifting seat that can be raised and lowered are fixedly connected to the lateral displacement seat. A movable seat that can move back and forth along the forward direction of the vehicle body is installed on the outer frame.

[0009] The ultrasonic phased array probe is mounted on a movable base and a lifting base at both ends via finger hinges; the ultrasonic phased array probe can be angled by the movable base and the lifting base.

[0010] Furthermore, adjustment seats are installed on both outer walls of the ultrasonic phased array probe, and the ultrasonic phased array probe is hinged to two sets of mounting fingers through the adjustment seats on both sides.

[0011] The ultrasonic phased array probe can be positioned along the length of the adjustment base under the control of the drive device.

[0012] Furthermore, the lifting seat includes a vertical frame installed on the output end of the lateral displacement seat, and a vertical slide seat that can be lifted and lowered by a driving device is installed on the vertical frame.

[0013] The bottom of the vertical frame is equipped with an outer frame that extends horizontally away from the vertical frame, and a movable slide block that can move along the length of the outer frame is installed on the side of the outer frame away from the vertical frame.

[0014] The adjusting seat includes an adjusting slider that can be displaced under the drive of a driving device;

[0015] The two sets of mounting fingers are fixed on the vertical slide and the movable slide, respectively. Each set of mounting fingers is equipped with a hinge shaft, and the mounting fingers are hinged to the adjustment sliders on both sides of the ultrasonic phased array probe through the hinge shaft.

[0016] Furthermore, the ultrasonic phased array probe is equipped with a tilt angle sensor inside.

[0017] Furthermore, two ranging sensors are provided on the ultrasonic phased array probe, and the two ranging sensors are respectively located on both sides of the detection area of ​​the ultrasonic phased array probe.

[0018] A phased array ultrasonic testing method based on multimodal data joint localization includes the following steps:

[0019] S1: Pre-test preparation and parameter initialization; This step places the vehicle body in the initial position A;

[0020] S2: Perform the initial scan; including the following steps:

[0021] S2.1 The ultrasonic probe moves laterally in front of the vehicle body to complete a single lateral scan of the upper surface of the workpiece; during the process, the ultrasonic phased array instrument collects ultrasonic echo data.

[0022] S2.2 After a single transverse scan is completed, the system drives the vehicle to move forward one preset step distance in the longitudinal direction; during the movement, the detection probe acquires images of the workpiece surface in real time, and the distance sensor detects the distance between the vehicle and the edge of the workpiece in real time.

[0023] S2.3 Repeat steps S2.1-S2.2 until the detection probe identifies the workpiece edge contour and the distance sensor detects a sudden change in distance. The system determines that it has reached the next edge position B of the workpiece. At this time, the vehicle moves, and the system processor controls the marking device to physically mark position B and record the coordinate data of the point.

[0024] S3: Probe orientation conversion for edge contour scanning; includes the following steps:

[0025] S3.1 The system controls the ultrasonic phased array probe to extend a specified distance from the edge of the test piece, and controls its rotation around the axis until the probe detection surface is in a vertical state or parallel to the edge surface of the test piece; at the same time, the system controls the ultrasonic phased array probe to lower, ensuring that the detection surface of the detection probe covers the entire edge area of ​​the test piece.

[0026] S3.2 Edge contour scanning; the system processor controls the vehicle body to move along the outer contour of the workpiece;

[0027] S3.3 Contour Data Integration: The system integrates the visual contour data collected by the detection probe, the distance data collected by the ranging sensor, and the edge defect data collected by the ultrasonic phased array instrument to generate the contour model of the test piece and related defect data.

[0028] When the vehicle body returns to position B along the contour, the edge scanning stops and the contour model is uploaded to the terminal.

[0029] S4: Overall scan path generation;

[0030] S5: Overall scanning of the entire workpiece area;

[0031] S6: Final data integration.

[0032] Furthermore, during the movement in step S3.2, the ultrasonic phased array probe remains vertical and performs continuous ultrasonic scanning on the edge surface of the workpiece. The detection probe synchronously acquires contour images, and the distance sensor detects the changes in distance data between the vehicle body and the edge in real time. Based on the changes in distance data, the system adjusts the movement path of the vehicle body in a timely manner through the universal wheels at the bottom of the vehicle body to ensure that the vehicle body always travels along the contour.

[0033] Furthermore, step S4 specifically includes the following sub-steps:

[0034] S4.1 Automatically generate the overall scanning path;

[0035] Based on the workpiece contour model obtained by S3.3, the host computer terminal automatically generates a grid-like scanning path covering the entire area of ​​the workpiece, combined with the preset horizontal scanning interval and vertical step distance parameters. The path takes the position C inside the workpiece as the overall scanning starting point, and the path direction is a "snake" traversal mode.

[0036] S4.2 Probe attitude reset; The system processor controls the ultrasonic phased array probe to reset from a vertical state to a horizontal state;

[0037] S4.3 The vehicle body moves to the overall scan starting point C and enters the overall scan.

[0038] Furthermore, step S5 specifically includes the following sub-steps:

[0039] S5.1 Repeat steps S2.1-S2.2 to complete multiple horizontal and vertical scans of the current straight path until the edge is reached;

[0040] S5.2, Change vehicle direction and perform serpentine scanning;

[0041] During the reversing process, the system processor controls the omnidirectional wheels at the bottom of the vehicle to quickly reverse direction and continues to execute the scanning cycle of steps S2.1-S2.2 until the ultrasonic phased array probe covers the entire area within the workpiece contour model, at which point the system determines that the overall scanning is complete.

[0042] The beneficial effects of this invention are as follows:

[0043] 1. Solved the problem of blind spots in edge detection of large-volume and thick workpieces, achieving full-range blind-spot-free scanning;

[0044] This invention achieves automatic switching between horizontal and vertical orientations of the ultrasonic phased array probe through a multi-degree-of-freedom adjustment mechanism. It can flip the probe detection surface from a horizontal state to a vertical state, perfectly matching thick workpieces or shell facades with edges, fundamentally eliminating blind spots in detection, and meeting the requirements for non-destructive testing of large-volume workpieces across the entire area without dead angles.

[0045] 2. Enables automatic recognition, positioning, and adaptive following scanning of workpiece edge contours;

[0046] This invention integrates a ranging sensor and a detection probe, which can identify the edge contour of the workpiece in real time, capture distance change signals, and complete edge coordinate marking. With the help of the vehicle's universal wheels and steering servo, it can automatically walk and continuously scan along the outer contour of the workpiece without manual intervention to adjust the probe position and vehicle path, which greatly improves the automation and positioning accuracy of thick edge area detection.

[0047] 3. Multimodal data fusion to generate a high-precision complete workpiece contour model;

[0048] This invention integrates visual contour data and distance detection data in real time to accurately construct a three-dimensional contour model of the workpiece under test, providing a reliable data foundation for subsequent global scanning path planning. This solves the problem that existing scanning equipment cannot obtain the complete contour in advance and is prone to incomplete scanning coverage.

[0049] 4. Automatically generate a global grid serpentine scanning path and generate a scanning plan, resulting in more comprehensive scanning coverage;

[0050] Based on the generated complete contour model, the system can automatically generate a grid-like serpentine scanning path that adapts to the actual shape of the workpiece, replacing the traditional fixed-stroke scanning method and achieving a high degree of matching between the scanning path and the workpiece contour.

[0051] 5. It has the ability to automatically identify missed areas and perform supplementary local scanning;

[0052] After the overall scan is completed, this invention automatically identifies uncovered or missed areas by comparing the coordinates of the scanned areas with the contour model in a rasterized manner, and autonomously generates supplementary scan paths and completes supplementary scanning, thereby improving the reliability of detection.

[0053] 7. From system initialization, edge positioning, contour scanning, path generation, global scanning to supplementary scanning and report generation, this invention realizes fully automated closed-loop operation, eliminating the need for manual adjustment of probes, path planning, or position marking, significantly reducing human intervention and greatly improving the efficiency of automated non-destructive testing of large-volume workpieces. Attached Figure Description

[0054] Figure 1 This is a schematic diagram of the overall structure of the device;

[0055] Figure 2 This is an exploded view of the vehicle body;

[0056] Figure 3 This is a schematic diagram of the installation structure of the lateral displacement seat and the outer frame;

[0057] Figure 4 This is a schematic diagram of the installation structure of the lifting platform and the outer frame from a first-person perspective.

[0058] Figure 5This is a schematic diagram of the installation structure of the lifting platform and the outer frame from a second-person perspective.

[0059] Figure 6 A diagram demonstrating the path for initial scanning and contour scanning of the vehicle body;

[0060] Figure 7 A diagram illustrating the path for a comprehensive vehicle body scan;

[0061] In the diagram: 01-Vehicle body; 02-Ultrasonic phased array device; 03-Shell; 04-Vehicle chassis; 041-Wheel seat; 05-Steering servo; 051-Universal wheel axle; 052-Wheel frame; 06-Wheel; 07-Walking motor;

[0062] 1- Lateral displacement seat; 10- Cable chain; 11- Lateral guide rail; 12- Lateral slider; 13- Scanning motor;

[0063] 2-Outer frame; 3-Lifting seat; 301-First lead screw motor; 31-Vertical frame; 32-Vertical guide rail; 33-Vertical slide block;

[0064] 4-Moving seat; 401-Second lead screw motor; 402-Threaded seat; 41-Moving slide rail; 42-Moving slide block;

[0065] 5- Install the finger; 6- Adjust the seat;

[0066] 7-Ultrasonic phased array probe; 701-Third lead screw motor; 71-Adjusting slide rail; 72-Adjusting slider;

[0067] 8-Distance sensor; 9-Detection probe. Detailed Implementation

[0068] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0069] It should be noted that, in the description of this invention, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, 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," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0070] Furthermore, in the description of this invention, unless otherwise explicitly specified and limited, the terms "connected" and "linked" 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. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0071] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0072] See Figure 1-5 The purpose of this invention is to provide a phased array ultrasonic testing system and method based on multimodal data joint positioning. The system includes a vehicle body 01, on which a lateral displacement seat 1 is mounted. An outer frame 2 and a lifting seat 3 are fixedly connected to the lateral displacement seat 1. A movable seat 4 is mounted on the outer frame 2. Installation fingers 5 are mounted on both the movable seat 4 and the lifting seat 3; that is, two sets of installation fingers 5 are arranged on the lateral displacement seat 1, and an ultrasonic phased array probe 7 is installed between the two sets of installation fingers 5. A ranging sensor 8 is provided on the ultrasonic phased array probe 7. In addition, a detection probe 9 is mounted on the bottom of the outer frame 2.

[0073] Vehicle body 01 serves as the mobile load-bearing foundation for the entire scanning vehicle; see appendix for details. Figure 1 and attached Figure 2 It includes an ultrasonic phased array device 02, a housing 03, a chassis 04, and omnidirectionally rolling wheels 06 mounted on the chassis 04.

[0074] The housing 03 is fixedly mounted on the top of the chassis 04. The ultrasonic phased array instrument 02 is located on the top of the housing 03 and is used to output ultrasonic detection signals and receive feedback signals for defect analysis. The chassis 04 is equipped with a walking drive assembly, which includes wheel seats 041, steering servo motor 05, universal wheel axle 051, wheel frame 052, wheels 06, and walking motor 07.

[0075] Wheel seat 041 is fixedly connected to chassis 04. Steering servo 05 is fixedly mounted on wheel seat 041. Universal wheel axle 051 is mounted on the output end of steering servo 05. Wheel frame 052 is mounted on the bottom end of universal wheel axle 051. Wheel 06 is rotatably mounted on the inner side of wheel frame 052. Travel motor 07 is fixedly mounted on the outer side of wheel frame 052, and the output end of travel motor 07 is connected to wheel 06 in a transmission connection.

[0076] When the walking motor 07 is working, it can drive the wheel 06 to rotate, causing the vehicle body 01 to move on the upper surface of the workpiece to be tested. The steering servo motor 05 can adjust the moving direction of the vehicle body 01 by driving the universal wheel axle 051 to rotate, so as to meet the movement requirements of different detection paths.

[0077] In other words, there are four sets of wheels 06, which are respectively installed under the four wheel seats 041 at the bottom of the chassis 04. Each set of wheels 06 is independently equipped with a set of travel motors 07 and steering servos 05. The four sets of travel motors 07 and steering servos 05 can drive the corresponding wheels 06 to rotate independently and adjust their direction; that is, the steering servo 05 drives the universal wheel axle 051 and drives the wheels 06 to rotate in all directions. With the cooperation of the four sets of independently driven and omnidirectionally rotating wheels 06, the vehicle body 01 can not only achieve straight-line travel and conventional steering, but also complete complex movements such as diagonal movement in any direction, zero-radius U-turns, and lateral translation, which greatly improves the mobility and position adjustment accuracy in a narrow detection space.

[0078] Understandably, the system also includes supporting hardware such as a system processor. The system processor adopts an embedded microprocessor architecture, integrating a multi-channel PWM drive module and motion control algorithm unit. Through preset control programs and communication protocols, the system processor establishes electrical connections with four sets of travel motors 07, each steering servo motor 05, and subsequent scanning motors 13, first lead screw motor 301, second lead screw motor 401, and third lead screw motor 701. After the operator issues motion commands through the host computer, the system processor analyzes the commands in real time, adjusting the speed, direction, and motion sequence of each motor, thereby precisely controlling the vehicle body 01 to complete the movement along the specified path and spatial position adjustment, achieving automated and intelligent collaborative control of the entire detection system.

[0079] Example 1

[0080] Based on the basic structure of the vehicle body 01 described above, this embodiment presents a structure capable of performing a horizontal sweep scan of the front area of ​​the vehicle. See the appendix for details. Figure 1 and attached Figure 3 The lateral displacement seat 1 is fixedly installed on the front side of the vehicle body 01 in the forward direction. The lateral displacement seat 1 includes a lateral guide rail 11, a lateral slider 12 and a matching scanning motor 13.

[0081] The transverse guide rail 11 extends along the width direction of the vehicle body 01, and its fixed end is fixedly connected to the side of the chassis 04 of the vehicle body 01. A transverse slider 12 is slidably connected to the transverse guide rail 11. A scanning motor 13 is fixedly installed at one end of the transverse guide rail 11, and a lead screw is driven to the output end of the scanning motor 13. The lead screw passes through the transverse guide rail 11 and is threadedly connected to the transverse slider 12. When the scanning motor 13 rotates forward and backward, it drives the lead screw to rotate, thereby causing the transverse slider 12 to slide back and forth along the length direction of the transverse guide rail 11, thus adjusting the position of the probe in the width direction of the vehicle body 01.

[0082] The lifting seat 3 is fixedly installed on the horizontal slider 12 and moves horizontally synchronously with the horizontal slider 12. See the appendix for details. Figure 1 Appendix Figure 4 and attached Figure 5 The lifting seat 3 includes a vertical frame 31, a vertical guide rail 32, a vertical slide 33, and a first lead screw motor 301. The fixed end of the vertical frame 31 is fixedly connected to the horizontal slider 12. The vertical guide rail 32 is fixedly connected to the vertical frame 31 and extends vertically. The vertical slide 33 is slidably connected to the vertical guide rail 32. The first lead screw motor 301 is fixedly installed on the top of the vertical frame 31. The output end of the first lead screw motor 301 is connected to a lead screw, which extends downward and passes through the vertical frame 31 before being threadedly connected to the vertical slide 33. When the first lead screw motor 301 rotates forward and backward, it drives the lead screw to rotate, causing the vertical slide 33 to move up and down along the length of the vertical guide rail 32.

[0083] The outer frame 2 is fixedly connected to one side of the horizontal slider 12, as detailed in the appendix. Figure 3-5 The outer frame 2 is a frame structure, and its fixed end is fixedly connected to the bottom of the vertical frame 31. The outer frame 2 extends horizontally on the side away from the vertical frame 31 to provide an installation support base for the ultrasonic phased array probe 7.

[0084] The movable base 4 is installed on the side of the outer frame 2 away from the vertical frame 31, as detailed in the appendix. Figure 4 and attached Figure 5 .

[0085] The movable seat 4 includes a movable slide rail 41, a movable slide block 42, a second lead screw motor 401, and a threaded seat 402. The movable slide rail 41 is fixedly connected to the side wall of the outer frame 2 away from the vertical frame 31, and extends horizontally. The movable slide block 42 is slidably connected to the movable slide rail 41. The second lead screw motor 401 is fixedly installed at one end of the outer frame 2, and a lead screw is connected to the output end of the second lead screw motor 401. The lead screw is threadedly connected to the threaded seat 402, and the threaded seat 402 is fixedly connected to the side wall of the movable slide block 42. When the second lead screw motor 401 rotates forward and backward, it drives the lead screw to rotate, causing the threaded seat 402 and the movable slide block 42 to slide back and forth along the length of the movable slide rail 41.

[0086] Two sets of mounting fingers 5 are used to hold and fix the ultrasonic phased array probe 7. The specific mounting structure is as follows:

[0087] The ultrasonic phased array probe 7 is kept in a horizontal position. One set of mounting fingers 5 is fixedly mounted on the vertical slide 33 of the lifting seat 3, and the other set of mounting fingers 5 is fixedly mounted on the movable slide 42. The two sets of mounting fingers 5 are arranged opposite each other to form a clamping structure for holding the ultrasonic phased array probe 7.

[0088] Specifically, each set of mounting fingers 5 is equipped with a hinge axis. The mounting fingers 5 are hinged to the ultrasonic phased array probe 7 through the hinge axis, so that the ultrasonic phased array probe 7 can be adjusted by angular swing around the hinge axis.

[0089] Example 2

[0090] Based on the above embodiment 1, see details below. Figure 4 , Figure 5 The ultrasonic phased array probe 7 is clamped and positioned between two sets of mounting fingers 5, with its front and rear ends hinged to the two sets of mounting fingers 5 respectively. Both sets of mounting fingers 5 are U-shaped structures. The end of the ultrasonic phased array probe 7 is hinged within the bifurcation of the U-shaped structure. The detection end of the ultrasonic phased array probe 7 faces downwards, used to emit ultrasonic beams and receive ultrasonic echoes reflected from the workpiece.

[0091] In other words, in this scheme, when the ultrasonic phased array probe 7 is in a horizontal position, both sets of mounting fingers 5 are on the same horizontal plane. When the lifting seat 3 moves upward, it drives one set of mounting fingers 5 to rise, causing the end of the ultrasonic phased array probe 7 to move upward, and the ultrasonic phased array probe 7 tilts as a whole. The other set of mounting fingers 5 is driven, or the second lead screw motor 401 matched with the other set of mounting fingers 5 operates synchronously, driving the moving slide 42 to move towards the lifting seat 3, coordinating with the tilting of the ultrasonic phased array probe 7, so that the end emitting surface of the ultrasonic phased array probe 7 faces the vehicle body 01.

[0092] When the lifting seat 3 raises one end of the ultrasonic phased array probe 7 to its upper limit, the other set of mounting fingers 5 is driven, or synchronously driven by the second lead screw motor 401, causing the sliding seat 42 to move to its limit position close to the vehicle body 01. At this time, the ultrasonic phased array probe 7 is in a vertical state. Ultrasonic detection is then performed on the edge surface of the object to be tested at the bottom of the vehicle body.

[0093] Example 3

[0094] Based on the above embodiment 2, see details. Figure 4 , Figure 5 Adjustment seats 6 are installed on both outer walls of the ultrasonic phased array probe 7. The adjustment seats 6 are fixedly connected to the corresponding two sides of the ultrasonic phased array probe 7, and are hinged to the two sets of mounting fingers 5. That is to say, the ultrasonic phased array probe 7 is hinged to the mounting fingers 5 through the two sets of adjustment seats 6.

[0095] The adjustment base 6 includes an adjustment slide rail 71, an adjustment slider 72, and a third lead screw motor 701. The adjustment slide rail 71 is fixedly connected to the side wall of the ultrasonic phased array probe 7 and extends along the length of the ultrasonic phased array probe 7. The adjustment slider 72 is slidably connected to the adjustment slide rail 71. The third lead screw motor 701 is fixedly installed at one end of the adjustment slide rail 71, and a lead screw is connected to the output end of the third lead screw motor 701. The lead screw is threadedly engaged with the adjustment slider 72. When the third lead screw motor 701 is working, it drives the lead screw to rotate, thereby causing the adjustment slider 72 to slide along the adjustment slide rail 71.

[0096] Two sets of mounting fingers 5 are hinged to adjusting sliders 72. Specifically, the two forked ends of the mounting fingers 5 with a "U"-shaped structure are respectively hinged to one end of the two adjusting sliders 72, and the other ends of the two adjusting sliders 72 are hinged to the two forked ends of the "U"-shaped structure of another mounting finger 5. Thus, with the upward movement of the lifting seat 3 and the lateral displacement of the moving slide 42, the overall angle of the adjusting seat 6 can be adjusted, and the ultrasonic phased array probe 7 fixedly connected to it is also driven to rotate.

[0097] Meanwhile, the operation of the two third lead screw motors 701 enables the ultrasonic phased array probe 7 to be adjusted in height. See appendix for details. Figure 5 After the angle is adjusted, the detection surface of the ultrasonic phased array probe 7 is in a vertical state. At this time, the third lead screw motor 701 runs, driving the ultrasonic phased array probe 7 to move downward. When it is at the lower limit, the ultrasonic phased array probe 7 can perform the detection of thick test pieces. In particular, when ultrasonically detecting square shell test pieces, traditional inspection vehicles only detect on the upper surface of the test piece and cannot obtain ultrasonic data on the edge surface of the test piece. However, this device can run along the upper edge of the test piece and detect from the edge surface of the test piece inward, which can complete a more accurate detection task.

[0098] Example 4

[0099] Based on any one or more of the above embodiments, the ultrasonic phased array probe 7 is equipped with a tilt angle sensor inside. The angle sensor is electrically connected to the ultrasonic phased array instrument 02 and is used to detect the tilt angle of the ultrasonic phased array probe 7 in real time and transmit the angle signal to the ultrasonic phased array instrument 02, so that the operator can monitor the probe posture in real time.

[0100] See appendix Figure 1 Appendix Figure 4 and attached Figure 5 A ranging sensor 8 is fixedly installed on the side of the ultrasonic phased array probe 7 away from the vehicle body 01. Specifically, two ranging sensors 8 are provided on the ultrasonic phased array probe 7, and the two ranging sensors 8 are respectively located on both sides of the detection area of ​​the ultrasonic phased array probe 7. The ranging sensors 8 are set towards the workpiece to be measured, and are used to detect the distance between the vehicle body 01 and the workpiece in real time, providing data reference for the movement and positioning of the vehicle body 01 and the adjustment of the probe position.

[0101] Both the front bottom of the vehicle body 01 and the front bottom of the outer frame 2 are equipped with detection probes 9. The detection probes 9 are visual detection probes used to acquire surface images of the workpiece to be tested, and to assist in the preliminary positioning and edge contour recognition of the workpiece surface, providing a basis for the scanning path planning of the ultrasonic phased array probe 7.

[0102] Understandably, the ranging sensor 8, detection probe 9, angle sensor, etc., are all electrically connected to the controller of this system. The controller is a PLC controller. Simultaneously, the controller is also electrically connected to the walking motor 07, scanning motor 13, first lead screw motor 301, second lead screw motor 401, and third lead screw motor 701 to achieve programmed control of each motor. Based on the workpiece contour data collected by the detection probe 9, the distance data transmitted by the ranging sensor 8, and the angle data from the angle sensor, the controller can automatically plan the scanning path and control the coordinated movement of each motor to achieve automatic position and angle adjustment of the ultrasonic phased array probe 7.

[0103] In the above embodiments, the start-stop, forward and reverse rotation, and movement stroke of the scanning motor 13, the first lead screw motor 301, the second lead screw motor 401, and the third lead screw motor 701 are all programmed and controlled by conventional controllers in the art. The cooperative motion logic, parameter settings, and signal transmission between the motors are all existing technologies and will not be described in detail here.

[0104] Based on any one of the above embodiments 4, see details. Figure 1-7 Based on the above system, this invention proposes a phased array ultrasonic detection method based on multimodal data joint localization, comprising the following steps:

[0105] See Figure 1-7 This detection method uses the vehicle body 01 as a moving carrier, and combines an ultrasonic phased array probe 7, a ranging sensor 8, a detection probe 9, and a multi-degree-of-freedom adjustment mechanism to achieve contour recognition and full-range blind-spot-free scanning of the workpiece under test. The specific steps are as follows:

[0106] S1: Preparation and parameter initialization before detection;

[0107] S1.1 Place the vehicle body 01 at the initial position A on the edge of the workpiece to be tested, so that the detection surface of the ultrasonic phased array probe 7 faces the upper surface of the workpiece; send an initialization command to the system processor through the host computer, including setting the initial position coordinates (coordinates corresponding to position A), longitudinal displacement step value, lateral displacement step value, probe attitude initial parameters, etc.

[0108] S1.2 System self-test;

[0109] The system processor drives the ranging sensor 8, detection probe 9, and angle sensor to perform self-tests, collect initial distance, workpiece surface image, and probe initial angle data, and enters the automatic detection process after confirming that each module is working properly.

[0110] S2: Perform initial scan (corresponding to...) Figure 7 (A→B path in the middle), edge localization is performed after the initial scan. This includes the following steps:

[0111] S2.1 Initial scan with horizontal probe;

[0112] The system processor controls the scanning motor 13 to start, driving the transverse slider 12 to move unidirectionally along the transverse guide rail 11, which in turn drives the ultrasonic phased array probe 7 to perform a single transverse scan on the upper surface of the workpiece; during the process, the ultrasonic phased array instrument 02 synchronously collects ultrasonic echo data to complete the preliminary defect detection of the current transverse area.

[0113] S2.2 Vehicle body stepping and edge detection;

[0114] After a single transverse scan is completed, the scanning motor 13 stops, and the system processor controls the walking motor 07 to start, driving the vehicle body 01 to move forward one preset step distance in the longitudinal direction; during the movement, the detection probe 9 acquires images of the workpiece surface in real time, and the distance sensor 8 detects the distance between the vehicle body and the edge of the workpiece in real time.

[0115] S2.3, Repeat the scan until the edge is triggered;

[0116] Repeat steps S2.1-S2.2 until the detection probe 9 identifies the workpiece edge contour and the distance sensor 8 detects a sudden change in distance. The system determines that it has reached the next edge position B of the workpiece. At this time, the vehicle moves, and the system processor controls the marking device to physically mark position B and record the coordinate data of the point.

[0117] S3: Probe orientation change, performing edge contour scanning (corresponding to...) Figure 7 (The dashed outline path from B to A to B in the middle).

[0118] S3.1 Ultrasonic phased array probe attitude switching;

[0119] The system processor controls the coordinated movement of the first lead screw motor 301 and the second lead screw motor 401:

[0120] The first lead screw motor 301 drives the vertical slide block 33 to rise along the vertical guide rail 32, thereby lifting the corresponding mounting finger 5; the second lead screw motor 401 drives the movable slide block 42 to move along the movable slide rail 41 towards the vertical frame 31, thereby bringing the corresponding mounting finger 5 closer to the vehicle body; and drives the ultrasonic phased array probe 7 to rotate around the axis until the probe detection surface is in a vertical state.

[0121] The angle sensor collects the probe tilt angle in real time. When the angle reaches 90°, the first lead screw motor 301 and the second lead screw motor 401 stop, completing the attitude conversion.

[0122] S3.2 Edge contour scanning;

[0123] The system processor controls the walking motor 07 and the steering servo motor 05 to work together to drive the vehicle body 01 to move along the outer contour of the workpiece.

[0124] During the movement, the ultrasonic phased array probe 7 remains vertical and performs continuous ultrasonic scanning on the edge surface of the workpiece. The detection probe 9 simultaneously acquires contour images, and the distance sensor 8 detects the distance between the vehicle body and the edge in real time. The system adjusts the movement path of the vehicle body in a timely manner through the universal wheels at the bottom of the vehicle body to ensure that the vehicle body always travels along the contour.

[0125] S3.3 Contour Data Integration;

[0126] The system processor performs multimodal fusion on the visual contour data collected by the detection probe 9, the distance data collected by the ranging sensor 8, and the edge defect data collected by the ultrasonic phased array instrument 02 to generate a complete contour model of the workpiece to be tested.

[0127] When the vehicle body 01 returns to the initial position B along the contour, the edge scanning stops and the contour model is uploaded to the host computer terminal.

[0128] S4: Overall scan path generation; includes the following steps:

[0129] S4.1 automatically generates the overall scanning path;

[0130] Based on the workpiece contour model obtained by S3.3, the host computer terminal automatically generates a grid-like scanning path covering the entire area of ​​the workpiece, combined with the preset horizontal scanning interval and vertical step distance parameters. The path takes the position C inside the workpiece as the overall scanning starting point, and the path direction is a "snake" traversal mode.

[0131] S4.2, Probe attitude reset;

[0132] The system processor controls the first lead screw motor 301 and the second lead screw motor 401 to move in opposite directions, resetting the ultrasonic phased array probe 7 from a vertical state to a horizontal state, in preparation for overall scanning.

[0133] S4.3, The vehicle moves to the overall scanning starting point; the system processor controls the walking motor 07 and the steering servo motor 05 to work together to drive the vehicle 01 from position B to the overall scanning starting point C.

[0134] S5: Overall scanning of the entire workpiece area (corresponding appendix) Figure 7 (The serpentine scanning path starting from point C). S5.1 Repeat steps S2.1-S2.2 to complete the horizontal and vertical scanning of the current straight path multiple times until the edge.

[0135] S5.1 Repeat steps S2.1-S2.2 to complete the horizontal and vertical scanning of the current straight path multiple times until the edge.

[0136] S5.2, Change vehicle direction and perform serpentine scanning;

[0137] During the reversal process, the system processor controls the steering servo 05 to drive the wheel 06 to turn 90°, and then controls the travel motor 07 to drive the vehicle body 01 to move laterally by a preset step distance. After the lateral movement is completed, the steering servo 05 drives the wheel 06 to turn 90° again to restore the original longitudinal direction and continues to execute the scanning cycle of steps S2.1-S2.2 until the ultrasonic phased array probe 7 covers the entire area within the workpiece contour model, and the system determines that the overall scanning is complete.

[0138] S6: Data integration process;

[0139] The system processor integrates the initial scan data, edge contour scan data, and overall scan data, and combines them with the visual positioning data of the detection probe 9 and the distance data of the ranging sensor 8 to generate a complete non-destructive testing report for the workpiece.

[0140] It is worth noting that after the overall scan is completed, the system processor performs a rasterized comparison between the scanned area coordinate library and the workpiece contour model generated by S3.3, automatically identifying any uncovered or missed areas. If any missed areas exist, the system extracts the boundary and center coordinates of the missed areas and generates a local supplementary scan path. The system then controls the travel motor 07 and steering servo motor 05 to drive the vehicle body 01 precisely to the missed area to complete the supplementary scan; thus ensuring that all areas are covered and that no areas are missed during the scan.

[0141] Of course, the present invention may have other various embodiments. Without departing from the spirit and essence of the present invention, those skilled in the art can make various corresponding changes and modifications according to the present invention, but these corresponding changes and modifications should all fall within the protection scope of the appended claims.

Claims

1. A phased array ultrasonic testing system based on multimodal data joint localization, characterized in that, Includes vehicle body (01), ultrasonic phased array probe (7) installed on the front side of vehicle body (01) in the forward direction and capable of lateral displacement and angle adjustment, ranging sensor (8) installed on ultrasonic phased array probe (7), and visual detection probe installed on the bottom of vehicle body (01) and near ultrasonic phased array probe (7). The vehicle body (01) is provided with a walking drive assembly that can drive the vehicle body (01) to move in all directions, and an ultrasonic phased array instrument (02) electrically connected to the ultrasonic phased array probe (7). It also includes a system processor for controlling the vehicle body (01) to complete movement, spatial position adjustment, and controlling the angle of the ultrasonic phased array probe (7) to be adjusted from the horizontal direction to the vertical direction.

2. The phased array ultrasonic testing system based on multimodal data joint localization according to claim 1, characterized in that, A lateral displacement seat (1) is installed on the vehicle body (01). An outer frame (2) and a lifting seat (3) that can be raised and lowered are fixedly connected to the lateral displacement seat (1). A movable seat (4) that can move back and forth along the forward direction of the vehicle body (01) is installed on the outer frame (2). The two ends of the ultrasonic phased array probe (7) are respectively hinged to the movable seat (4) and the lifting seat (3) by mounting fingers (5); the ultrasonic phased array probe (7) can be adjusted in angle by the movable seat (4) and the lifting seat (3).

3. The phased array ultrasonic testing system based on multimodal data joint localization according to claim 2, characterized in that, The ultrasonic phased array probe (7) is equipped with adjustment seats (6) on both outer walls. The ultrasonic phased array probe (7) is hinged to two sets of installation fingers (5) through the adjustment seats (6) on both sides. The ultrasonic phased array probe (7) can be positioned along the length of the adjustment seat (6) under the control of the drive device.

4. The phased array ultrasonic testing system based on multimodal data joint localization according to claim 3, characterized in that, The lifting seat (3) includes a vertical frame (31) installed on the output end of the horizontal displacement seat (1), and a vertical slide (33) that can be lifted and lowered by a drive device is installed on the vertical frame (31). The bottom of the vertical frame (31) is equipped with an outer frame (2) that extends horizontally away from the vertical frame (31), and a movable slide (42) that can move along the length of the outer frame (2) is installed on the side of the outer frame (2) away from the vertical frame (31). The adjusting seat (6) includes an adjusting slider (72) that can be displaced under the drive of the driving device; The two sets of mounting fingers (5) are fixed on the vertical slide (33) and the movable slide (42) respectively. Each set of mounting fingers (5) is provided with a hinge shaft. The mounting fingers (5) are hinged to the adjustment sliders (72) on both sides of the ultrasonic phased array probe (7) through the hinge shaft.

5. The phased array ultrasonic testing system based on multimodal data joint localization according to claim 1, characterized in that, The ultrasonic phased array probe (7) is equipped with a tilt angle sensor inside.

6. The phased array ultrasonic testing system based on multimodal data joint localization according to claim 1, characterized in that, Two ranging sensors (8) are provided on the ultrasonic phased array probe (7), and the two ranging sensors (8) are respectively located on both sides of the detection area of ​​the ultrasonic phased array probe (7).

7. A phased array ultrasonic testing method based on multimodal data joint localization, characterized in that, Includes the following steps: S1: Pre-test preparation and parameter initialization; This step places the vehicle body in the initial position A; S2: Perform initial scanning; It includes the following steps: S2.1 The ultrasonic probe moves laterally in front of the vehicle body to complete a single lateral scan of the upper surface of the workpiece; during the process, the ultrasonic phased array instrument collects ultrasonic echo data. S2.2 After a single transverse scan is completed, the system drives the vehicle to move forward one preset step distance in the longitudinal direction; during the movement, the detection probe acquires images of the workpiece surface in real time, and the distance sensor detects the distance between the vehicle and the edge of the workpiece in real time. S2.3 Repeat steps S2.1-S2.2 until the detection probe identifies the workpiece edge contour and the distance sensor detects a sudden change in distance. The system determines that it has reached the next edge position B of the workpiece. At this time, the vehicle moves, and the system processor controls the marking device to physically mark position B and record the coordinate data of the point. S3: Probe orientation change to perform edge contour scanning; It includes the following steps: S3.1 The system controls the ultrasonic phased array probe to extend a specified distance from the edge of the test piece, and controls its rotation around the axis until the probe detection surface is in a vertical state or parallel to the edge surface of the test piece; at the same time, the system controls the ultrasonic phased array probe to lower, ensuring that the detection surface of the detection probe covers the entire edge area of ​​the test piece. S3.2 Edge contour scanning; the system processor controls the vehicle body to move along the outer contour of the workpiece; S3.3 Contour Data Integration: The system integrates the visual contour data collected by the detection probe, the distance data collected by the ranging sensor, and the edge defect data collected by the ultrasonic phased array instrument to generate the contour model of the test piece and related defect data. When the vehicle body returns to position B along the contour, the edge scanning stops and the contour model is uploaded to the terminal. S4: Overall scan path generation; S5: Overall scanning of the entire workpiece area; S6: Final data integration.

8. The phased array ultrasonic testing method based on multimodal data joint localization according to claim 7, characterized in that, During the movement in step S3.2, the ultrasonic phased array probe remains vertical and performs continuous ultrasonic scanning on the edge surface of the workpiece. The detection probe synchronously acquires contour images, and the distance sensor detects the changes in distance data between the vehicle body and the edge in real time. Based on the changes in distance data, the system adjusts the movement path of the vehicle body in a timely manner through the universal wheels at the bottom of the vehicle body to ensure that the vehicle body always travels along the contour.

9. The phased array ultrasonic testing method based on multimodal data joint localization according to claim 7, characterized in that, Step S4 specifically includes the following sub-steps: S4.1 Automatically generate the overall scanning path; Based on the workpiece contour model obtained by S3.3, the host computer terminal automatically generates a grid-like scanning path covering the entire area of ​​the workpiece, combined with the preset horizontal scanning interval and vertical step distance parameters. The path takes the position C inside the workpiece as the overall scanning starting point, and the path direction is a "snake" traversal mode. S4.2 Probe attitude reset; The system processor controls the ultrasonic phased array probe to reset from a vertical state to a horizontal state; S4.3 The vehicle body moves to the overall scan starting point C and enters the overall scan.

10. The phased array ultrasonic testing method based on multimodal data joint localization according to claim 7, characterized in that, Step S5 specifically includes the following sub-steps: S5.1 Repeat steps S2.1-S2.2 to complete the horizontal and vertical scanning of the current straight path multiple times until the edge is reached; S5.2, Change vehicle direction and perform serpentine scanning; During the reversing process, the system processor controls the omnidirectional wheels at the bottom of the vehicle to quickly reverse direction and continues to execute the scanning cycle of steps S2.1-S2.2 until the ultrasonic phased array probe covers the entire area within the workpiece contour model, at which point the system determines that the overall scanning is complete.

Images