A calibration tool for phased array ultrasonic testing

Abstract

The application discloses a kind of calibration tool for phased array ultrasonic testing, it is related to phased array ultrasonic testing technical field, including guide rail support plate, the side of guide rail support plate is equipped with C-shaped fixing frame;The side of C-shaped fixing frame is equipped with pull rope encoder, guide rail connecting plate is slidably connected at the rear end of guide rail support plate, and the front end of guide rail connecting plate is equipped with linear guide rail.The calibration tool for phased array ultrasonic testing, calibration precision is greatly improved, so that detection data is more stable, can eliminate human operation error, replace artificial hand-held probe, avoid probe deviation, angle skew, coupling pressure big and small problem, echo amplitude, sound path data stability, reduce positioning, angle, delay deviation from source;Positioning and attitude high consistency tool uses precision mechanical positioning, limit structure, each time calibration probe attitude, relative test block position is completely unified, and repeat calibration consistency is far superior to manual operation.

Description

Technical Field

[0001] This invention relates to the field of phased array ultrasonic testing technology, specifically to a calibration fixture for phased array ultrasonic testing. Background Technology

[0002] Phased array ultrasonic testing (PAUT) calibration is the core step to ensure consistent detection positioning accuracy and sensitivity. The core is to calibrate three major parameters: wedge delay, refraction angle, and wedge sound velocity, in order to eliminate systematic errors in the propagation of sound waves within the wedge.

[0003] Driven by the demand for high precision and efficiency in industrial non-destructive testing, traditional ultrasonic (UT) fixed-angle probes cannot meet the requirements for inspecting complex workpieces. Phased array ultrasonic testing achieves multi-angle coverage through electronic focusing and fan-shaped scanning. The wedge is a key coupling component between the probe and the workpiece. In use, the mainstream calibration method mainly involves manually moving the probe on the test block to find the SDH echo peak and manually recording the delay, angle, and gain parameters. This relies on operational experience. However, handheld probes are prone to deflection and swaying, resulting in uneven coupling pressure, which leads to echo amplitude fluctuations (exceeding the ±5% standard requirement), depth deviations (> ±1mm), and distortion in positioning and sensitivity calibration. Summary of the Invention

[0004] The purpose of this invention is to provide a calibration fixture for phased array ultrasonic testing, in order to solve the problems mentioned in the background art. The mainstream calibration method mainly involves manually moving the probe on the test block to find the SDH echo peak and manually recording the delay, angle, and gain parameters. This method relies on operational experience, and the handheld probe is prone to deflection and swing, resulting in uneven coupling pressure, which leads to echo amplitude fluctuations (exceeding the ±5% standard requirement), depth deviations (> ±1mm), and distortion in positioning and sensitivity calibration.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a calibration fixture for phased array ultrasonic testing, comprising a guide rail support plate, a C-shaped fixing frame installed on the side of the guide rail support plate; a pull-rope encoder installed on the side of the C-shaped fixing frame; a guide rail connecting plate slidably connected to the rear end of the guide rail support plate, and a linear guide rail installed at the front end of the guide rail connecting plate; a spring support arm assembly disposed inside the linear guide rail; a limit block installed at the bottom end of the spring support arm assembly; a wedge block frame assembly disposed inside the linear guide rail, and a fisheye bearing disposed on the surface of the wedge block frame assembly; and a test block body disposed at the bottom end of the guide rail support plate.

[0006] Furthermore, the pull-cord encoder is installed inside the guide rail support plate via a C-shaped fixing bracket, and the C-shaped fixing bracket is used to adjust the height of the pull-cord encoder.

[0007] Furthermore, the guide rail connecting plate and the guide rail support plate are arranged in parallel by a linear guide rail, and the positions of the guide rail connecting plate and the wedge block frame assembly correspond to each other.

[0008] Furthermore, the spring arm assembly and the linear guide rail are connected by a guide rail connecting plate.

[0009] Furthermore, a test block base is provided on the side of the bottom end of the test block body, and the guide rail support plate, the test block base and the linear guide rail are connected by screws.

[0010] Furthermore, the function of the pull-cord encoder is to calibrate the position recording.

[0011] Compared with the prior art, the beneficial effects of the present invention are: The significantly improved calibration accuracy results in more stable test data, eliminating human error and replacing manual probe handling. This avoids issues such as probe offset, angle misalignment, and fluctuating coupling pressure. Echo amplitude and sound path data are stable, reducing positioning, angle, and delay deviations at the source. The positioning and posture are highly consistent. The fixture uses precision mechanical positioning and limiting structures, ensuring that the probe posture and relative position to the test block are completely consistent each time it is calibrated. The consistency of repeated calibration is far superior to manual operation. The parameter calibration is more accurate. Combined with the constant temperature and constant coupling pressure design, the interference caused by temperature and coupling state is weakened. The calibration accuracy of wedge delay, refraction angle, sound velocity, and TCG curve fully meets the standards, effectively reducing defect misjudgment and missed detection.

[0012] Furthermore, the efficiency of operations is significantly improved, labor costs are reduced, and calibration speed is increased. It can be combined with automated scanning mechanisms and intelligent recognition algorithms, greatly shortening the time required for a single probe + wedge calibration. Compared to 10-15 minutes per manual calibration, tooling calibration can usually be completed in tens of seconds. It supports batch continuous calibration, which can continuously complete the calibration of multiple probes and wedges of different specifications. It is suitable for centralized calibration before shifts and batch verification of equipment, greatly reducing auxiliary operation time. The operation threshold is lowered. No operator needs to have extensive PAUT calibration experience. It can be completed with simple clamping. Even novices can operate in a standardized manner, reducing skill dependence. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of the present invention viewed from below.

[0014] Figure 2 This is a top view of the structure of the present invention.

[0015] In the figure: 1. C-type fixing frame; 2. Pull rope encoder; 3. Guide rail connecting plate; 4. Spring support arm assembly; 5. Fish eye bearing; 6. Linear guide rail; 7. Limit block; 8. Guide rail support plate; 9. Wedge block frame assembly; 10. Test block body. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] Example 1: As Figure 1-2 The technical solution shown addresses the problem that mainstream calibration methods primarily involve manually moving a handheld probe on a test block to locate the SDH echo peak and manually recording delay, angle, and gain parameters. This relies heavily on operational experience, and the handheld probe is prone to deflection and swaying, resulting in uneven coupling pressure, which leads to echo amplitude fluctuations (exceeding ±5% of the standard requirement), depth deviations (> ±1mm), and distortion in positioning and sensitivity calibration. This phased array ultrasonic testing calibration fixture discloses a calibration method for phased array ultrasonic testing, including a guide rail support plate 8, a C-type fixing frame 1 mounted on the side of the guide rail support plate 8, a pull-cord encoder 2 mounted on the side of the C-type fixing frame 1, a guide rail connecting plate 3 slidably connected to the rear end of the guide rail support plate 8, and a linear guide rail 6 mounted at the front end of the guide rail connecting plate 3. A spring support arm assembly 4 is installed inside the linear guide rail 6, a limit block 7 is mounted at the bottom end of the spring support arm assembly 4, and a wedge block frame assembly 9 is mounted on the inner side of the linear guide rail 6. A fisheye bearing 5 is provided on the surface, and a test block body 10 is provided at the bottom end of the guide rail support plate 8; a pull rope encoder 2 is installed inside the guide rail support plate 8 through a C-shaped fixing bracket 1, and the C-shaped fixing bracket 1 is used to adjust the height of the pull rope encoder 2; the guide rail connecting plate 3 and the guide rail support plate 8 are arranged parallel to each other through a linear guide rail 6, and the guide rail connecting plate 3 corresponds to the position of the wedge block frame assembly 9; the spring support arm assembly 4 and the linear guide rail 6 are connected through the guide rail connecting plate 3; a test block base is provided on the side of the bottom end of the test block body 10, and the guide rail support plate 8, the test block base and the linear guide rail 6 are connected by screws; the function of the pull rope encoder 2 is to calibrate the position recording.

[0018] In this example, the calibration principle of the calibration method is wedge delay calibration, which compensates for the instrument time baseline by measuring the propagation time of the sound wave in the wedge and avoids depth positioning drift; the delay is calculated by the echo from the bottom surface of the wedge or the echo from the standard reflector of the test block (such as the side-drilled SDH).

[0019] Then, by refraction angle calibration, the consistency between the actual refraction angle and the nominal angle, such as 45° and 60°, is verified. The true angle is determined by the arc surface of the test block or the SDH echo peak value to ensure accurate scanning coverage.

[0020] Next, sensitivity (TCG / DAC) calibration was performed. Time gain compensation curves were created using echoes from standard reflectors at different depths as a reference to ensure consistent sensitivity in detecting defects at different depths.

[0021] Based on the ISO19675 (IIWPAUT) standard test block, the system integrates mechanical positioning, uniform force scanning, and intelligent algorithms to achieve one-click automatic calibration of wedge block delay, refraction angle, sensitivity (TCG / DAC), sound velocity, and zero point, eliminating human error and improving testing consistency and efficiency.

[0022] Fully automated calibration of five core parameters: wedge delay, refraction angle, sound velocity, null point, and TCG / DAC. Repeatability: Angle ≤ ±0.2°, delay ≤ ±0.05μs, depth ≤ ±0.1mm; Single probe-wedge calibration time ≤ 90 seconds, supports batch continuous calibration; It is compatible with flat / curved (COD / AOD) wedge blocks and mainstream PAUT instruments; Automatically generate calibration reports and traceability data to meet quality assurance and audit requirements; The hardware platform includes: Automatic calibration worktable: precision slide and rotary axis, repeatability ±0.02mm; constant force clamping mechanism, coupled pressure closed-loop control; Sensing and Control: Real-time positioning using an encoder; Coupling and temperature control: manual spray / immersion coupling, constant temperature base to suppress temperature drift.

[0023] By utilizing this phased array ultrasonic testing calibration method, the following advantages are achieved: calibration accuracy is significantly improved, test data is more reliable; work efficiency is significantly increased, and labor costs are reduced; the adaptability to working conditions is strong; quality control is standardized, and data is traceable and verifiable; the stability of equipment and workpiece testing is improved, and maintenance risks are reduced; and safety and on-site management are optimized.

[0024] The significantly improved calibration accuracy makes the detection data more stable, eliminates human operation errors, replaces manual hand-held probes, and avoids problems such as probe offset, angle tilt, and fluctuating coupling pressure. The echo amplitude and sound path data are stable, reducing positioning, angle, and delay deviations from the source. The positioning and attitude-consistent fixture adopts a precision mechanical positioning and limiting structure, ensuring that the probe attitude and relative position to the test block are completely consistent each time the calibration is performed. The consistency of repeated calibration is far superior to manual operation. With more precise parameter calibration and constant temperature and constant coupling pressure design, interference caused by temperature and coupling state is weakened. The calibration accuracy of wedge delay, refraction angle, sound velocity and TCG curve fully meets the standards, effectively reducing defect misjudgment and missed detection.

[0025] The efficiency of operation is significantly improved, the labor cost is reduced, and the calibration speed is fast. It can be used with automated scanning mechanism and intelligent recognition algorithm. The time for a complete set of calibration of a single probe + wedge block is greatly shortened. Compared with 10 to 15 minutes per manual calibration, tool calibration can usually be completed in tens of seconds. It supports batch continuous calibration and can continuously complete the calibration of multiple sets of probes and wedges of different specifications. It is suitable for centralized pre-shift calibration by work teams and batch equipment verification, which greatly reduces auxiliary operation time. The operation threshold is lowered, and operators do not need to have extensive PAUT calibration experience. It can be completed with simple clamping, and even novices can operate in a standardized manner, reducing the reliance on skills.

[0026] It has strong adaptability to working conditions and standardized coupling state. It adopts constant pressure clamping and automatic coupling method, and the coupling layer thickness is uniform and stable, eliminating echo distortion and sensitivity drift caused by uneven manual coupling. The modular fixture is compatible with various types of wedges / probes and can accommodate flat wedges, curved wedges (COD / AOD), wedges of different angles, and conventional / high-temperature probes. One set of fixtures covers the mainstream configurations on site, eliminating the need for multiple sets of auxiliary tools.

[0027] Standardized quality control ensures data traceability and accountability; unified processes and standardized procedures strictly adhere to standards such as ISO19675 to implement fixed calibration procedures, eliminating the chaos of different personnel and work groups using different calibration methods, and achieving unified calibration standards across the entire plant and all projects. The system automatically retains and records the original A-scan waveform, calibration parameters, time, ambient temperature, and equipment number, generating an electronic calibration report. The data is tamper-proof and meets the requirements of quality inspection, internal audit, third-party audit, and special equipment certification. It facilitates wedge condition management, and multiple calibration data can be compared and analyzed. By observing the trends in delay and sensitivity changes, wedge wear, aging, and cracking can be predicted in advance, enabling wedge life management and preventive replacement.

[0028] Improved stability of equipment and workpiece testing reduces maintenance risks. Long-term stable and accurate calibration of phased array ultrasonic testing (PAUT) equipment reduces frequent deviations in instrument parameters, decreases the frequency of repeated fine-tuning and on-site temporary recalibration, and extends the stable operation cycle of the equipment. The test results are highly comparable; the test data of the same equipment, different time periods, and different operators have very small deviations, and the test results of the same batch of workpieces are consistent, which facilitates defect comparison, defect rating, and re-inspection judgment. The mechanical limiting and flexible clamping of the probe and wedge block prevent the probe from being bumped or scratched by the wedge block during manual operation, reducing the damage rate of consumables and lowering the cost of use.

[0029] Safety and on-site management are optimized, reducing on-site labor intensity and eliminating the need for long periods of manual operation involving holding the probe and repeated alignment. It is especially suitable for large-scale, high-frequency calibration scenarios in workshops and construction sites.

[0030] The protective fixture for the test block effectively limits the probe's range of motion, preventing scratches and impacts to the surface of the standard test block, protecting metrological standards, extending the lifespan of the standard test block, and ensuring the accuracy of the metrological benchmark. Real-time monitoring of the wedge block's condition protects both the standard test block and testing consumables, resulting in lower overall operating costs.

[0031] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A calibration fixture for phased array ultrasonic testing, comprising a guide rail support plate (8), wherein a C-type fixing frame (1) is installed on the side of the guide rail support plate (8). Its features are: A pull-rope encoder (2) is installed on the side of the C-type fixing frame (1). A guide rail connecting plate (3) is slidably connected to the rear end of the guide rail support plate (8). A linear guide rail (6) is installed at the front end of the guide rail connecting plate (3). A spring support arm assembly (4) is provided inside the linear guide rail (6). A limit block (7) is installed at the bottom end of the spring support arm assembly (4). A wedge block frame assembly (9) is installed on the inner side of the linear guide rail (6). A fisheye bearing (5) is provided on the surface of the wedge block frame assembly (9). A test block body (10) is provided at the bottom end of the guide rail support plate (8).

2. The calibration fixture for phased array ultrasonic testing according to claim 1, characterized in that: The pull-rope encoder (2) is installed inside the guide rail support plate (8) by a C-type fixing bracket (1), and the C-type fixing bracket (1) is used to adjust the height of the pull-rope encoder (2).

3. The calibration fixture for phased array ultrasonic testing according to claim 2, characterized in that: The guide rail connecting plate (3) and the guide rail support plate (8) are arranged in parallel by a linear guide rail (6), and the guide rail connecting plate (3) and the wedge block frame assembly (9) are positioned corresponding to each other.

4. The calibration fixture for phased array ultrasonic testing according to claim 3, characterized in that: The spring arm assembly (4) and the linear guide rail (6) are connected by a guide rail connecting plate (3).

5. The calibration fixture for phased array ultrasonic testing according to claim 4, characterized in that: The test block body (10) is provided with a test block base on the side of its bottom end, and the guide rail support plate (8), the test block base and the linear guide rail (6) are connected by screws.

6. The calibration fixture for phased array ultrasonic testing according to claim 5, characterized in that: The function of the pull-rope encoder (2) is to calibrate the position record.

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