An experimental device simulating an automated flaw detection environment for aluminum parts

Abstract

This utility model relates to the field of ultrasonic flaw detection technology, specifically an experimental device for simulating the automatic flaw detection environment of aluminum parts. It includes an environment simulation module, a flaw detection execution module, and a signal generation and acquisition module. The environment simulation module, as the main structure of the experimental device, simulates the experimental environment of the aluminum parts. The flaw detection execution module, located inside the environment simulation module, scans the aluminum parts. The signal generation and acquisition module, connected to the flaw detection execution module, generates excitation signals and acquires echo signals. The flaw detection execution module includes a dual-crystal probe and a mechanical transmission module that drives the dual-crystal probe; the signal generation and acquisition module is connected to the dual-crystal probe. This utility model, by integrating a silicone rubber heating plate and a misting humidifier, simulates the temperature and humidity in the working environment of the aluminum parts, evaluating their reliability in real-world scenarios. Utilizing the built-in ultrasonic probe and mechanical transmission structure, it achieves omnidirectional automated scanning of the aluminum parts, improving detection efficiency and comprehensiveness.

Description

Technical Field

[0001] This utility model relates to the field of ultrasonic flaw detection technology, specifically an experimental device that simulates an automatic flaw detection environment for aluminum parts. Background Technology

[0002] Aluminum, due to its lightweight, high strength, and ease of processing, is widely used in aerospace vehicle structural components, automotive engine parts, and marine engineering equipment. However, aluminum components must withstand complex environmental loads during actual service. For example, aerospace engine components face high-temperature thermal cycling conditions, automotive chassis parts may be in high-humidity corrosive environments, and marine platform structural components are subject to long-term salt spray corrosion. These complex conditions can easily lead to hidden defects such as fatigue cracks, thermal stress damage, and intergranular corrosion within aluminum components. If these defects are not detected in time, they may cause serious safety accidents.

[0003] Traditional aluminum component flaw detection technology mainly relies on ultrasonic testing, but existing experimental equipment has significant limitations. Firstly, most devices can only perform tests under normal temperature and pressure conditions, failing to simulate the complex environments of high temperature and high humidity encountered in actual service, thus hindering accurate assessment of defect initiation and propagation behavior under real-world operating conditions. Secondly, traditional flaw detection experiments still rely on manual operation, lacking efficient mechanical transmission structures and automated control systems. This makes it difficult to achieve comprehensive automatic scanning of aluminum components, and manual scanning at a constant speed results in significant waveform fluctuations on the oscilloscope, leading to low detection efficiency and insufficient comprehensiveness.

[0004] To address the aforementioned problems, this invention proposes an experimental device that simulates an automatic flaw detection environment for aluminum parts. Utility Model Content

[0005] The purpose of this invention is to provide an experimental device that simulates the environment of automatic flaw detection for aluminum parts. By integrating environmental simulation, it solves the technical difficulties of traditional devices in simulating complex environments, provides a reliable experimental platform for the detection of aluminum parts, and thus solves the technical problems in the background art.

[0006] To achieve the above objectives, this utility model provides the following technical solution: an experimental device for simulating an automatic flaw detection environment for aluminum parts, comprising an environment simulation module, a flaw detection execution module, and a signal generation and acquisition module;

[0007] The environmental simulation module serves as the main structure of the experimental device and is used to simulate the experimental environment of the aluminum parts; the flaw detection execution module is used to scan the aluminum parts and is located inside the environmental simulation module; the signal generation and acquisition module is connected to the flaw detection execution module and is used to generate excitation signals and acquire echo signals.

[0008] The flaw detection execution module includes a dual-crystal probe and a mechanical transmission module that drives the movement of the dual-crystal probe. The signal generation and acquisition module is connected to the dual-crystal probe.

[0009] Furthermore, the environmental simulation module includes a soundproof and heat-insulating box, a silicone rubber heating plate, a water cup, and a misting humidifier; the soundproof and heat-insulating box is connected to the box body via a hinged hinge; the silicone rubber heating plate is connected to a temperature controller via a wire; the water cup is connected to the water inlet of the misting humidifier via a hose; the misting humidifier is used to atomize water and spray it into the box, and is installed on the inner side wall of the box body.

[0010] Furthermore, the environmental simulation module also includes a temperature and humidity sensor, a DHTC temperature display, and an OLED humidity display;

[0011] The DHTC temperature display screen is installed on the door of the enclosure; the temperature and humidity sensor is connected to the DHTC temperature display screen and is installed near the soundproof platform to collect temperature and humidity data inside the enclosure in real time and transmit the signal to the DHTC temperature display screen.

[0012] The OLED humidity display screen is installed on the top wall of the soundproof and heat-insulating box; it is used to display temperature and humidity data.

[0013] Furthermore, the mechanical transmission module includes a driver, a DC power supply, a dual-axis ball screw slide, and a Z-axis lifting platform;

[0014] The dual-axis ball screw slide is installed inside the soundproof and heat-insulating box along the X-axis direction and near the top wall.

[0015] The top of the Z-axis lifting platform is connected to the dual-axis ball screw slide; the bottom is connected to the dual-crystal probe by bolts, and the distance between the probe and the surface of the aluminum part is adjusted by the Z-axis lifting platform.

[0016] The driver is connected to the servo motors of the dual-axis ball screw slide and the Z-axis lifting platform via wires, and is used to drive the movement of the mechanical transmission module;

[0017] The DC power supply powers the driver, the dual-axis ball screw slide, the Z-axis lifting platform, and the temperature and humidity sensor.

[0018] Furthermore, the mechanical transmission module also includes a soundproof platform and a dual-axis linear guide rail;

[0019] The soundproof platform is used to support aluminum parts and is positioned above the dual-axis linear guide rail;

[0020] A dual-axis linear guide is set at the bottom of the soundproof and heat-insulating box along the Y-axis direction; the dual-axis linear guide is connected to the soundproof platform; the aluminum parts on the soundproof platform move along the Y-axis direction through the dual-axis linear guide.

[0021] Furthermore, the signal generation and acquisition module includes a digital signal generator, an oscilloscope, and an RF adapter;

[0022] The digital signal generator is a desktop device that connects to the transmitter of a dual-crystal probe via an RF adapter.

[0023] The oscilloscope is a desktop device that connects to the receiver of a dual-crystal probe via an RF adapter.

[0024] Beneficial effects

[0025] This invention integrates a silicone rubber heating plate and a misting humidifier to simulate the temperature and humidity conditions in the working environment of aluminum parts, thus evaluating their reliability in real-world scenarios. Utilizing a built-in ultrasonic probe and mechanical transmission structure, it achieves omnidirectional automated scanning of aluminum parts, improving inspection efficiency and comprehensiveness. Combined with a digital signal generator and oscilloscope, it generates stable excitation signals and analyzes the flaw detection echoes in real time, accurately identifying the location of defects. This invention solves the problem that traditional devices cannot reproduce complex working conditions such as high temperature and high humidity, providing a possibility for studying the influence of environmental factors on the formation of defects in aluminum parts. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this utility model. For those skilled in the art, other drawings can be obtained based on these drawings.

[0027] Figure 1 This is a schematic diagram of the overall structure of the experimental device disclosed in this utility model;

[0028] Figure 2 This is a schematic diagram of the external structure of the experimental device disclosed in this utility model;

[0029] Figure 3 This is a partial enlarged view of the experimental apparatus disclosed in this utility model.

[0030] In the picture:

[0031] 1. Soundproof and heat-insulating box; 2. Water cup; 3. Soundproof platform; 4. Dual-axis linear guide rail; 5. Silicone rubber heating plate; 6. RF adapter; 7. Driver; 8. DC power supply; 9. DHTC temperature display screen; 10. Temperature and humidity sensor; 11. Hinge; 12. OLED humidity display screen; 13. Dual-axis ball screw slide; 14. Z-axis lifting platform; 15. Dual-crystal probe; 16. Atomizing humidifier. Detailed Implementation

[0032] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0033] To achieve the above objectives, this utility model provides the following technical solution, such as... Figure 1-3 As shown, an experimental device simulating an automatic flaw detection environment for aluminum parts includes an environment simulation module, a flaw detection execution module, and a signal generation and acquisition module.

[0034] The environmental simulation module, as the main structure of the experimental device, is used to simulate the experimental environment of the aluminum parts; the flaw detection execution module is used to scan the aluminum parts and is located inside the environmental simulation module; the signal generation and acquisition module is connected to the flaw detection execution module and is used to generate excitation signals and acquire echo signals.

[0035] The flaw detection execution module includes a dual-crystal probe 15 and a mechanical transmission module that drives the dual-crystal probe 15 to move. The signal generation and acquisition module is connected to the dual-crystal probe 15, and the dual-crystal probe 15 detects aluminum parts. The signal generation and acquisition module outputs and receives detection signals through the dual-crystal probe 15.

[0036] The dual-crystal probe 15 is connected to a digital signal generator and an oscilloscope via an RF adapter 6 for transmitting and receiving ultrasonic waves.

[0037] Furthermore, the environmental simulation module includes a soundproof and heat-insulating box 1, a silicone rubber heating plate 5, a water cup 2, and a misting humidifier 16. The soundproof and heat-insulating box 1 is a double-layered rectangular box filled with polyurethane foam insulation material. The box door is connected to the box body via a hinge 11, and the edges are equipped with sealing strips to isolate the external environment and maintain stable temperature and humidity inside the box. The silicone rubber heating plate 5 is a thin sheet that can fit against the inner wall of the box. The surface is covered with an insulating silicone layer and is connected to a temperature controller via wires to regulate the temperature inside the box. The water cup 2 is a cylindrical container that is connected to the water inlet of the misting humidifier 16 via a hose to provide water to the misting humidifier 16. The misting humidifier 16 contains an ultrasonic vibrating plate and a water level sensor, which is installed on the inner side wall of the box to atomize water and spray it into the box to regulate humidity.

[0038] Furthermore, the environmental simulation module also includes a temperature and humidity sensor 10, a DHTC temperature display 9, and an OLED humidity display 12;

[0039] The DHTC temperature display screen 9 is installed on the door of the enclosure; the temperature and humidity sensor 10 is connected to the DHTC temperature display screen 9 and is installed near the soundproof platform 3. It is used to collect the temperature and humidity data inside the enclosure in real time and transmit the signal to the DHTC temperature display screen 9.

[0040] An OLED humidity display screen 12 is installed on the top wall of the soundproof and heat-insulating box 1; it is used to display temperature and humidity data.

[0041] Furthermore, the mechanical transmission module includes a driver 7, a DC power supply 8, a dual-axis ball screw slide 13, and a Z-axis lifting platform 14;

[0042] The dual-axis ball screw slide 13 is installed inside the soundproof and heat-insulating box 1 and near the top wall along the X-axis direction. The dual-axis ball screw slide 13 is a ball screw drive structure to realize the rapid movement of the dual crystal probe 15 in the X-axis direction.

[0043] The Z-axis lifting platform 14 has a vertical structure and an internal worm gear drive. The top of the Z-axis lifting platform 14 is connected to the dual-axis ball screw slide 13; the bottom is connected to the dual-crystal probe 15 by bolts. The Z-axis lifting platform 14 is used to adjust the distance between the probe and the surface of the aluminum part to ensure uniform contact of the coupling agent, and has a self-locking function to prevent the probe from sliding down.

[0044] The driver 7 is fixed on the door of the soundproof and heat-insulating box 1, and has control buttons and keys on its exterior. The driver 7 contains a servo motor drive circuit, which is connected to the servo motors of the dual-axis linear guide rail 4, the dual-axis ball screw slide 13 and the Z-axis lifting platform 14 through wires, and is used to drive the movement of the mechanical transmission module.

[0045] DC power supply 8 is a power adapter that outputs DC power to power devices such as driver 7, dual-axis ball screw slide 13, Z-axis lifting platform 14, and temperature and humidity sensor 10.

[0046] Furthermore, the mechanical transmission module also includes a soundproof platform 3 and a dual-axis linear guide rail 4;

[0047] The soundproof platform 3 is a rectangular flat plate used to support aluminum parts and reduce vibration and noise; it is made of soundproof material and is set above the dual-axis linear guide rail 4.

[0048] The dual-axis linear guide 4 is set at the bottom of the soundproof and heat-insulating box 1 along the Y-axis direction; the dual-axis linear guide 4 is connected to the soundproof platform 3; the aluminum parts on the soundproof platform 3 are driven to move along the Y-axis direction through the dual-axis linear guide 4.

[0049] Furthermore, the signal generation and acquisition module includes a digital signal generator, an oscilloscope, and an RF adapter 6;

[0050] The digital signal generator is a desktop device that connects to the transmitter of the dual-crystal probe 15 via an RF adapter 6 to output excitation signals.

[0051] The oscilloscope is a benchtop device and is connected to the receiver of the dual crystal probe 15 via an RF adapter 6.

[0052] The working principle and process are as follows:

[0053] First, clean the surface of the aluminum part to be tested, removing impurities such as oil and oxide film. Then, evenly apply a layer of ultrasonic coupling agent such as glycerin or machine oil to reduce the sound energy loss of ultrasonic waves between the probe and the surface of the aluminum part.

[0054] Then open the door of the soundproof and heat-insulating box 1, place the aluminum part on the soundproof platform 3, and move the aluminum part to the appropriate detection position by adjusting the knob of the dual-axis linear guide rail 4. Adjust the knob of the Z-axis lifting platform 14 to make the dual crystal probe 15 slowly descend until it just touches the surface of the aluminum part. At this time, observe the initial echo signal on the oscilloscope to ensure good coupling effect.

[0055] According to the experimental requirements, the target temperature and humidity inside the chamber are set through the control software, and the type, frequency and amplitude of the excitation signal are set.

[0056] The silicone rubber heating plate 5 is activated to start heating the inside of the soundproof and heat-insulating box 1. The temperature and humidity sensor 10 monitors the temperature inside the box in real time to ensure that the temperature reaches the set value.

[0057] When the atomizing humidifier 16 is turned on, the water in the water cup 2 flows into the atomizing humidifier 16 through the pipe, is atomized into tiny water droplets and sprayed into the box. The temperature and humidity sensor 10 monitors the humidity change. When the humidity reaches the set value, the atomizing humidifier 16 stops working.

[0058] The scanning speed is set by the button on the driver 7, and the driver 7 controls the mechanical transmission module to drive the dual crystal probe 15 to perform omnidirectional scanning on the surface of the aluminum part.

[0059] The excitation signal output by the digital signal generator is transmitted to the dual crystal probe 15 through the RF adapter 6, which excites the probe to generate ultrasonic waves. After the ultrasonic waves enter the aluminum part, they are reflected when they encounter a defect. The echo signal is received by the dual crystal probe 15 and transmitted to the oscilloscope through another RF adapter 6.

[0060] The oscilloscope displays the waveform of the echo signal in real time. When a significant change is detected in the oscilloscope signal, the experimenter can mark the defect location and the corresponding echo characteristics. After the experiment, the experimenter can further analyze the defect location and the corresponding echo characteristics to generate a detailed test report.

[0061] This device addresses the shortcomings of traditional aluminum component flaw detection experiments, such as the lack of multi-field coupled environment simulation, insufficient automated detection coverage, weak signal feature extraction capabilities, and poor adaptability to complex operating conditions. It innovatively constructs a multi-dimensional defect detection environment simulation system. By integrating a heating module and humidity control components, it can dynamically reproduce the complex service environment of aluminum components, ranging from 200℃ to 5%-95% humidity gradient. Employing a dual-crystal ultrasonic probe mounted on a guide rail, it achieves omnidirectional dynamic scanning of aluminum components. This device provides a controllable experimental platform for experimental research on the thermal fatigue damage evolution and corrosion failure mechanisms of aluminum alloy components.

[0062] The embodiments of this utility model are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the utility model to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical applications of this utility model, and to enable those skilled in the art to understand this utility model and design various embodiments with various modifications suitable for a particular purpose.

Claims

1. An experimental apparatus for simulating an automated flaw detection environment for aluminum parts, characterized in that, It includes an environmental simulation module, a flaw detection execution module, and a signal generation and acquisition module; The environmental simulation module serves as the main structure of the experimental device and is used to simulate the experimental environment of the aluminum parts; the flaw detection execution module is used to scan the aluminum parts and is located inside the environmental simulation module; the signal generation and acquisition module is connected to the flaw detection execution module and is used to generate excitation signals and acquire echo signals. The flaw detection execution module includes a dual-crystal probe (15) and a mechanical transmission module that drives the dual-crystal probe (15) to move. The signal generation and acquisition module is connected to the dual-crystal probe (15).

2. The experimental apparatus for simulating an automatic flaw detection environment of an aluminum member according to claim 1, characterized by, The environmental simulation module includes a soundproof and heat-insulating box (1), a silicone rubber heating plate (5), a water cup (2), and a misting humidifier (16); the soundproof and heat-insulating box (1) is connected to the box body via a hinge (11); the silicone rubber heating plate (5) is connected to a temperature controller via a wire; the water cup (2) is connected to the water inlet of the misting humidifier (16) via a hose; the misting humidifier (16) is used to atomize water and spray it into the box, and is installed on the inner side wall of the box body.

3. The experimental apparatus for simulating an automatic flaw detection environment for aluminum members according to claim 2, characterized by, The environmental simulation module also includes a temperature and humidity sensor (10), a DHTC temperature display (9), and an OLED humidity display (12); The DHTC temperature display screen (9) is installed on the door of the enclosure; the temperature and humidity sensor (10) is connected to the DHTC temperature display screen (9), and the temperature and humidity sensor (10) is installed near the soundproof platform (3) to collect temperature and humidity data inside the enclosure in real time and transmit the signal to the DHTC temperature display screen (9). The OLED humidity display screen (12) is installed on the top wall of the soundproof and heat-insulating box (1) to display temperature and humidity data.

4. The experimental apparatus for simulating an automatic flaw detection environment for aluminum members according to claim 2, characterized by The mechanical transmission module includes a driver (7), a DC power supply (8), a dual-axis ball screw slide (13), and a Z-axis lifting platform (14); The dual-axis ball screw slide (13) is installed inside the soundproof and heat-insulating box (1) along the X-axis direction and near the top wall; The top of the Z-axis lifting platform (14) is connected to the dual-axis ball screw slide (13); the bottom is connected to the dual-crystal probe (15) by bolts, and the distance between the probe and the surface of the aluminum part is adjusted by the Z-axis lifting platform (14). The driver (7) is connected to the servo motors of the dual-axis ball screw slide (13) and the Z-axis lifting platform (14) via wires, and is used to drive the mechanical transmission module to move. The DC power supply (8) provides power to the driver (7), the dual-axis ball screw slide (13), the Z-axis lifting platform (14), and the temperature and humidity sensor (10).

5. The experimental apparatus for simulating an automatic flaw detection environment of an aluminum member according to claim 1, wherein The mechanical transmission module also includes a soundproof platform (3) and a dual-axis linear guide rail (4); The sound insulation platform (3) is used to support aluminum parts and is positioned above the dual-axis linear guide rail (4); A dual-axis linear guide (4) is set at the bottom of the soundproof and heat-insulating box (1) along the Y-axis direction; the dual-axis linear guide (4) is connected to the soundproof platform (3); the aluminum parts on the soundproof platform (3) are driven to move along the Y-axis direction through the dual-axis linear guide (4).

6. The experimental apparatus for simulating an automatic flaw detection environment for aluminum members according to claim 1, wherein The signal generation and acquisition module includes a digital signal generator, an oscilloscope, and an RF adapter (6); The digital signal generator is a desktop device, which is connected to the transmitter of the dual crystal probe (15) via an RF adapter (6); The oscilloscope is a desktop device and is connected to the receiver of a dual-crystal probe (15) via an RF adapter (6).

Images