A crack detection sensor

Abstract

A crack detection sensor utilizes ultrasonic waves to detect cracks in a test object. It includes a main unit, a transducer, and a coupling layer. The transducer is communicatively connected to the main unit, and the coupling layer abuts against the detection face of the transducer and is used to remove gas from the detection face. This invention, by setting a coupling layer between the transducer detection face and the test object, effectively removes gas between them, ensuring efficient transmission of the ultrasonic signal and thus improving the sensitivity and accuracy of ultrasonic detection.

Description

Technical Field

[0001] This utility model relates to the field of flaw detection, and in particular to a crack detection sensor. Background Technology

[0002] In the production of industrial products such as automotive brake pads and refractory bricks, gases can easily be introduced into the raw materials during the molding and sintering stages, leading to cracks or cavities inside the products. These defects have a significant impact on the performance and safety of the products. For example, under stress and friction conditions, tiny internal cracks in brake pads can easily expand into large cracks, causing braking failure and posing a serious safety hazard. Similarly, if refractory bricks have internal cavities in high-temperature environments, they may crack due to localized stress concentration, affecting their service life and reliability in high-temperature furnaces.

[0003] Currently, the most common crack detection method is manual tapping and sound identification. This involves an operator tapping the object being tested and judging the presence of cracks or cavities based on changes in the sound. This method relies heavily on the operator's experience and auditory sensitivity, resulting in highly subjective results and a high risk of misjudgment or missed detection. Furthermore, the tapping method is a contact-based inspection method, which can easily cause mechanical damage to the surface of the object being tested, making it unsuitable for precision products or materials with high requirements for surface integrity. Utility Model Content

[0004] The technical problem to be solved by this invention is to provide a crack detection sensor that solves the problem of easy interference in ultrasonic detection.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows:

[0006] A crack detection sensor that uses ultrasonic waves to detect cracks in a test object includes a main unit, a transducer, and a coupling layer.

[0007] The transducer is communicatively connected to the host, and the coupling layer abuts against the detection end face of the transducer and is used to remove gas from the detection end face of the transducer.

[0008] In some embodiments, the host includes a signal amplification circuit board and a data acquisition circuit board, wherein the signal amplification circuit board is communicatively connected to the transducer, and the data acquisition circuit board is communicatively connected to the signal amplification circuit board.

[0009] In some embodiments, the host computer further includes an RS485 interface, which is communicatively connected to the data acquisition circuit board.

[0010] In some embodiments, the host also includes a housing with heat dissipation holes, and the signal amplification circuit board and the data acquisition circuit board are both assembled and connected to the inner wall of the housing.

[0011] In some embodiments, the coupling layer is a replaceable coupling plate, which is assembled and connected to the transducer.

[0012] In some embodiments, the transducer includes a transmitting transducer and a receiving transducer, the detection end faces of the transmitting and receiving transducers abutting against the opposite sides of the object being tested to form an ultrasonic beam detection channel.

[0013] In some embodiments, the coupling layer is a gel coupling layer, which is disk-shaped and covers the detection end face of the transducer.

[0014] In some embodiments, the transducer is communicatively connected to the host via a connecting cable, and the connecting cable is covered with a shielding layer, which is a woven metal mesh.

[0015] The beneficial effects of this invention are as follows: by setting a coupling layer between the transducer detection end face and the object being tested, the gas between the transducer end face and the surface of the object being tested is effectively eliminated, ensuring efficient transmission of ultrasonic signals, thereby improving the sensitivity and accuracy of ultrasonic testing. Compared with the traditional method of manually tapping to identify sounds, this solution achieves truly non-destructive testing and can significantly improve the detection rate of micro-cracks and internal cavities, ensuring more stable and reliable test results. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of a crack detection sensor according to an embodiment of the present invention;

[0017] Figure 2 This is a schematic diagram of the operation of a crack detection sensor according to an embodiment of the present invention;

[0018] Figure 3 This is a schematic diagram of the communication architecture of a crack detection sensor according to an embodiment of the present invention;

[0019] Label Explanation:

[0020] 1. Main unit; 11. Housing; 12. Heat dissipation holes; 2. Transducer; 21. Transmitting transducer; 22. Receiving transducer; 3. Coupling layer; 4. Object under test. Detailed Implementation

[0021] To explain in detail the technical content, objectives, and effects of this utility model, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0022] Please refer to Figures 1 to 3 A crack detection sensor that uses ultrasonic waves to detect cracks in a test object 4 includes a main unit 1, a transducer 2, and a coupling layer 3.

[0023] The transducer 2 is communicatively connected to the host 1, and the coupling layer 3 abuts against the detection end face of the transducer 2 and is used to remove gas from the detection end face of the transducer 2.

[0024] As described above, by setting a coupling layer 3 between the detection end face of transducer 2 and the object under test 4, the gas between the end face of transducer 2 and the surface of the object under test 4 is effectively eliminated, ensuring efficient transmission of ultrasonic signals and thus improving the sensitivity and accuracy of ultrasonic detection. Compared with the traditional method of manually tapping to identify sounds, this solution achieves truly non-destructive testing and can significantly improve the detection rate of micro-cracks and internal cavities, ensuring more stable and reliable test results.

[0025] In some embodiments, the host 1 includes a signal amplification circuit board and a data acquisition circuit board, wherein the signal amplification circuit board is communicatively connected to the transducer 2, and the data acquisition circuit board is communicatively connected to the signal amplification circuit board.

[0026] As described above, by incorporating a signal amplification circuit board and a data acquisition circuit board into the host unit 1, the received weak ultrasonic signal can be effectively amplified first, and then the data acquisition circuit board completes the digital acquisition and processing, ensuring the integrity and stability of the detection signal. This structure helps improve detection resolution, reduce signal interference, and enhance the sensor's ability to identify small cracks.

[0027] In some embodiments, the host 1 further includes an RS485 interface, which is communicatively connected to the data acquisition circuit board.

[0028] As described above, by adding an RS485 interface to host computer 1, stable communication with the host computer can be achieved. The RS485 interface has advantages such as strong anti-interference capability, long transmission distance, and high reliability, enabling the sensor to maintain stable data transmission even in complex industrial environments, ensuring the real-time performance and accuracy of the detection data.

[0029] In some embodiments, the host 1 further includes a housing 11 with heat dissipation holes 12, and the signal amplification circuit board and the data acquisition circuit board are both assembled and connected to the inner wall of the housing 11.

[0030] As can be seen from the above description, by setting heat dissipation holes 12 on the housing 11 of the host 1 and fixing the signal amplification circuit board and the data acquisition circuit board on the inner wall of the housing 11, it not only helps to dissipate heat from the internal circuit and extend the service life of the circuit board, but also enhances the stability and vibration resistance of the structure, thereby improving the reliability of the whole machine under high temperature and harsh working conditions.

[0031] In some embodiments, the coupling layer 3 is a replaceable coupling plate, which is assembled and connected to the transducer 2.

[0032] As described above, using a replaceable coupling plate as the coupling layer 3 facilitates replacement based on different surface conditions of the measured object 4, improving adaptability and simplifying maintenance. When the coupling plate wears down or its performance deteriorates due to long-term use, it can be directly replaced, reducing operating costs and ensuring that the detection sensitivity remains at its optimal level.

[0033] In some embodiments, the transducer 2 includes a transmitting transducer 21 and a receiving transducer 22, the detection end faces of the transmitting transducer 21 and the receiving transducer 22 abutting against the opposite sides of the object under test 4 to form an ultrasonic beam detection channel.

[0034] As described above, by setting up transmitting transducers 21 and receiving transducers 22, and attaching them to opposite sides of the object under test 4 to form an ultrasonic through-beam detection channel, the internal structure of the object under test 4 can be inspected via transmission. This method can effectively identify internal cracks or cavities that are not visible on the surface, significantly improving detection accuracy, and is especially suitable for materials with large thickness or hidden internal defects.

[0035] In some embodiments, the coupling layer 3 is a gel coupling layer 3, which is disc-shaped and covers the detection end face of the transducer 2.

[0036] As described above, by using a disc-shaped gel coupling layer 3 to cover the end face of the transducer 2, both a tight fit between the transducer 2 and the surface of the object under test 4 is ensured, while maintaining good flexibility and adaptability during the detection process. The gel material can effectively isolate air and reduce sound wave reflection, thereby improving the transmission efficiency of ultrasonic energy and enhancing the intensity and stability of the detection signal.

[0037] In some embodiments, the transducer 2 is communicatively connected to the host 1 via a connecting line, and the connecting line is covered with a shielding layer, which is a woven metal mesh.

[0038] As described above, by setting a shielding layer on the connection line between transducer 2 and host 1, and using a woven metal mesh as the shielding structure, the influence of external electromagnetic interference and environmental noise on the detection signal is effectively suppressed. This ensures more stable and reliable transmission of the ultrasonic detection signal, improves data accuracy, and is suitable for use in complex electromagnetic environments.

[0039] The embodiments of this utility model are as follows:

[0040] A crack detection sensor utilizes ultrasonic waves to detect cracks in a test object 4. The sensor includes a main unit 1, a transducer 2, and a coupling layer 3. The transducer 2 is communicatively connected to the main unit 1. The coupling layer 3 abuts against the detection end face of the transducer 2 and is used to expel gas from the detection end face of the transducer 2, thereby ensuring that the ultrasonic signal can be efficiently transmitted to the test object 4.

[0041] The host unit 1 internally houses a signal amplification circuit board and a data acquisition circuit board. The signal amplification circuit board is communicatively connected to the transducer 2 and is used to amplify the received weak ultrasonic signals. The data acquisition circuit board is communicatively connected to the signal amplification circuit board and is used to complete the digital acquisition and preliminary processing of the signals. The host unit 1 also includes an RS485 interface, which is communicatively connected to the data acquisition circuit board and used to establish a stable data transmission link with the host computer. To ensure the system's heat dissipation and stability, the host unit 1 uses a housing 11 with heat dissipation holes 12. Both the signal amplification circuit board and the data acquisition circuit board are fixedly mounted on the inner wall of the housing 11. Through natural convection via the heat dissipation holes 12, the circuit operating temperature can be effectively reduced, the service life of electronic components can be extended, and the overall reliability of the device in high-temperature environments can be enhanced.

[0042] The coupling layer 3 is a replaceable coupling plate, which is assembled and connected to the transducer 2 via snap-fit ​​or threaded connection. When the coupling plate's performance deteriorates due to long-term use, it can be quickly replaced to ensure detection sensitivity. In another specific form, the coupling layer 3 can be a gel coupling layer 3. The gel coupling layer 3 is disc-shaped and covers the detection end face of the transducer 2, maintaining a flexible fit during detection, effectively isolating air and reducing reflection, thereby improving ultrasonic energy transmission efficiency and enhancing signal stability.

[0043] Transducer 2 includes a transmitting transducer 21 and a receiving transducer 22. The detection ends of the two transducers abut against the opposite sides of the object under test 4, thereby forming an ultrasonic through-beam detection channel. The ultrasonic signal enters the object under test 4 through the transmitting transducer 21 and is received by the receiving transducer 22, realizing transmission detection and enabling the identification of cracks or cavities inside the object under test 4.

[0044] The transducer 2 is connected to the host 1 via a connecting cable. The connecting cable is covered with a shielding layer, which is a woven metal mesh structure. This shielding layer is used to suppress the influence of external electromagnetic interference and environmental noise on signal transmission, and to ensure the stability and accuracy of ultrasonic detection signal transmission.

[0045] Through the above structure, the entire crack detection sensor achieves a comprehensive effect of high sensitivity, strong anti-interference, non-destructive operation, and maintainability. This device can be applied to crack detection in materials such as automotive brake pads and refractory bricks, and is particularly suitable for detecting micro-cracks and internal cavities that are difficult to detect using traditional manual methods.

[0046] The above description is merely an embodiment of this utility model and does not limit the patent scope of this utility model. Any equivalent modifications made based on the content of this utility model specification and drawings, or direct or indirect applications in related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. A crack detection sensor that uses ultrasonic waves to detect cracks in a test object, characterized in that: Includes the host, transducer, and coupling layer; The transducer is communicatively connected to the host, and the coupling layer abuts against the detection end face of the transducer and is used to remove gas from the detection end face of the transducer.

2. The crack detection sensor according to claim 1, characterized in that: The host includes a signal amplification circuit board and a data acquisition circuit board. The signal amplification circuit board is communicatively connected to the transducer, and the data acquisition circuit board is communicatively connected to the signal amplification circuit board.

3. The crack detection sensor according to claim 2, characterized in that: The host also includes an RS485 interface, which is communicatively connected to the data acquisition circuit board.

4. The crack detection sensor according to claim 3, characterized in that: The host also includes a housing with heat dissipation holes, and the signal amplification circuit board and the data acquisition circuit board are both assembled and connected to the inner wall of the housing.

5. The crack detection sensor according to claim 1, characterized in that: The coupling layer is a replaceable coupling plate, which is assembled and connected to the transducer.

6. The crack detection sensor according to claim 1, characterized in that: The transducer includes a transmitting transducer and a receiving transducer, and the detection end faces of the transmitting and receiving transducers abut against the opposite sides of the object being tested to form an ultrasonic beam detection channel.

7. The crack detection sensor according to claim 1, characterized in that: The coupling layer is a gel coupling layer, which is disc-shaped and covers the detection end face of the transducer.

8. The crack detection sensor according to claim 1, characterized in that: The transducer is connected to the host via a connecting cable, and the connecting cable is covered with a shielding layer, which is a woven metal mesh.

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