Method and apparatus for optimizing parameters of pulsed eddy current probe, device, and medium

Abstract

A method includes establishing three-dimensional finite element models of a probe and a detected weldment by electromagnetic simulation software. Setting an inner diameter, an outer diameter, a height

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the technical field of non-destructive detection, and in particular, to a method and apparatus for optimizing parameters of a pulsed eddy current probe, a device, and a medium. BACKGROUND

[0002] Laser welding is an efficient precision welding method using a high energy density laser beam as a heat source. In order to ensure the quality of laser welding, a non-destructive detection approach is typically employed to detect a welded seam. It can detect a defect in the welded seam rapidly and accurately without damaging the quality of the welded seam.

[0003] At present, a pulsed eddy current detection system is generally employed to detect laser welding defects, including surface, near surface, and deep-lying defects of a weldment. This technique is characterized by rich signals, a large effective detection range, fast detection speed, etc., and has been widely used in laser welding detection.

[0004] However, due to limited precision of a probe for conventional laser welding defect detection, when the probe is used for defect detection on a special weldment involving complicated local welding and abrupt local material attribute changes, acquired detected signals are complex with weak features. It is hard to obtain accurate detection results. Therefore, a problem to be solved urgently is to develop a method for optimizing parameters of a pulsed eddy current probe to assist in designing a high precision probe and realize defect detection on a special weldment. SUMMARY

[0005] In view of the above problems, the present disclosure is proposed to provide a method and apparatus for optimizing parameters of a pulsed eddy current probe, a device, and a medium that can overcome or at least partially solve the above problems. Three-dimensional finite element models for pulsed eddy current detection established by electromagnetic simulation software may be employed to simulate magnetically-induced voltages of a detection point under different excitation coil parameters by an orthogonal test method, and optimal values of the excitation coil parameters can be obtained rapidly and accurately. A great assistance may be provided for the optimized design of the pulsed eddy current probe, and a pulsed eddy current probe with higher precision can be designed. Defect detection on a special weldment can be realized.

[0006] In a first aspect, the present disclosure provides a method for optimizing parameters of a pulsed eddy current probe, including:

[0007] establishing three-dimensional finite element models for pulsed eddy current detection by electromagnetic simulation software, where the three-dimensional finite element models include a probe model and a detected weldment model, and the detected weldment model includes a welded seam structure having a welding defect;

[0008] setting excitation coil parameters of the probe model to global variables according to the three-dimensional finite element models, where the excitation coil parameters include an inner diameter, an outer diameter, a height, a number of turns, a lift-off height, an excitation frequency, and an excitation current of an excitation coil;

[0009] determining a detection point for the pulsed eddy current detection according to the welded seam structure having the welding defect;

[0010] determining target optimization ranges of the excitation coil parameters;

[0011] determining second magnetically-induced voltages of the detection point under different excitation coil parameters by an orthogonal test method according to the target optimization ranges; and

[0012] determining optimal values of the excitation coil parameters according to the second magnetically-induced voltages.

[0013] Optionally, the establishing three-dimensional finite element models for pulsed eddy current detection by electromagnetic simulation software may include:

[0014] determining property parameters of a detected weldment, where the property parameters include a geometrical parameter, a defect parameter, a welded seam parameter, a material parameter, and an electromagnetic parameter of the detected weldment;

[0015] establishing a three-dimensional finite element model of the detected weldment by the electromagnetic simulation software according to the property parameters, where the detected weldment model includes the welded seam structure having the welding defect;

[0016] determining feature parameters of an eddy current probe, where the feature parameters include the excitation coil parameters and detection coil parameters; and

[0017] establishing a three-dimensional finite element model of the eddy current probe by the electromagnetic simulation software according to the feature parameters.

[0018] Optionally, the determining target optimization ranges of the excitation coil parameters may include:

[0019] determining an initial optimization range of each parameter of the excitation coil parameters;

[0020] analyzing influences of a variation of a single parameter of the excitation coil parameters on a magnetic induction intensity and a first magnetically-induced voltage of the detection point by a target optimization function in the electromagnetic simulation software according to the initial optimization range, and determining a target optimization range of each parameter of the excitation coil parameters; and

[0021] determining the target optimization ranges of the excitation coil parameters according to the target optimization range of each parameter,

[0022] where the initial optimization range is greater than the target optimization range.

[0023] Optionally, the analyzing influences of a variation of a single parameter of the excitation coil parameters on a magnetic induction intensity and a first magnetically-induced voltage of the detection point by a target optimization function in the electromagnetic simulation software according to the initial optimization range, and determining a target optimization range of each parameter of the excitation coil parameters may include:

[0024] determining, by the target optimization function in the electromagnetic simulation software, the magnetic induction intensity and the first magnetically-induced voltage of the detection point when one parameter of the excitation coil parameters varies in the corresponding initial optimization range while other parameters remain unchanged; and

[0025] determining the target optimization range of each parameter of the excitation coil parameters according to the initial optimization range of each parameter, the magnetic induction intensity, and the first magnetically-induced voltage.

[0026] Optionally, the determining second magnetically-induced voltages of the detection point under different excitation coil parameters by an orthogonal test method according to the target optimization ranges may include:

[0027] designing an orthogonal test table according to the target optimization ranges;

[0028] determining a plurality of sets of the excitation coil parameters of different magnitudes according to the orthogonal test table; and

[0029] inputting each set of the excitation coil parameters to the three-dimensional finite element model and outputting the second magnetically-induced voltage of the detection point under each set of the excitation coil parameters.

[0030] Optionally, the determining optimal values of the excitation coil parameters according to the second magnetically-induced voltages may include:

[0031] determining differential induced voltage peaks at the welding defect and a normal welded seam according to the second magnetically-induced voltages; and

[0032] determining the optimal values of the excitation coil parameters according to the differential induced voltage peaks.

[0033] Optionally, the determining a detection point for the pulsed eddy current detection according to the welded seam structure having the welding defect may include:

[0034] setting a first detection point for the pulsed eddy current detection at the welding defect; and

[0035] setting a second detection point for the pulsed eddy current detection at a normal structure of a welded seam.

[0036] In a second aspect, the present disclosure provides an apparatus for optimizing parameters of a pulsed eddy current probe, including:

[0037] a model establishment module configured to establish three-dimensional finite element models for pulsed eddy current detection by electromagnetic simulation software, where the three-dimensional finite element models include a probe model and a detected weldment model, and the detected weldment model includes a welded seam structure having a welding defect;

[0038] a global variable setting module configured to set excitation coil parameters of the probe model to global variables according to the three-dimensional finite element models, where the excitation coil parameters include an inner diameter, an outer diameter, a height, a number of turns, a lift-off height, an excitation frequency, and an excitation current of an excitation coil;

[0039] a detection point setting module configured to determine a detection point for the pulsed eddy current detection according to the welded seam structure having the welding defect;

[0040] a target optimization range determination module configured to determine target optimization ranges of the excitation coil parameters;

[0041] a second magnetically-induced voltage determination module configured to determine second magnetically-induced voltages of the detection point under different excitation coil parameters by an orthogonal test method according to the target optimization ranges; and

[0042] an optimal value determination module configured to determine optimal values of the excitation coil parameters according to the second magnetically-induced voltages.

[0043] Optionally, the model establishment module may be further configured to:

[0044] determine property parameters of a detected weldment, where the property parameters include a geometrical parameter, a defect parameter, a welded seam parameter, a material parameter, and an electromagnetic parameter of the detected weldment;

[0045] establish a three-dimensional finite element model of the detected weldment by the electromagnetic simulation software according to the property parameters, where the detected weldment model includes the welded seam structure having the welding defect;

[0046] determine feature parameters of the pulsed eddy current probe, where the feature parameters include the excitation coil parameters and detection coil parameters; and

[0047] establish a three-dimensional finite element model of the pulsed eddy current probe by the electromagnetic simulation software according to the feature parameters.

[0048] Optionally, the target optimization range determination module may include:

[0049] a first determination unit configured to determine an initial optimization range of each parameter of the excitation coil parameters;

[0050] a second determination unit configured to analyze influences of a variation of a single parameter of the excitation coil parameters on a magnetic induction intensity and a first magnetically-induced voltage of the detection point by a target optimization function in the electromagnetic simulation software according to the initial optimization range, and determine a target optimization range of each parameter of the excitation coil parameters; and

[0051] a third determination unit configured to determine the target optimization ranges of the excitation coil parameters according to the target optimization range of each parameter,

[0052] where the initial optimization range is greater than the target optimization range.

[0053] Optionally, the second determination unit may be further configured to:

[0054] determine, by the target optimization function in the electromagnetic simulation software, the magnetic induction intensity and the first magnetically-induced voltage of the detection point when one parameter of the excitation coil parameters varies in the corresponding initial optimization range while other parameters remain unchanged; and

[0055] determine the target optimization range of each parameter of the excitation coil parameters according to the initial optimization range of each parameter, the magnetic induction intensity, and the first magnetically-induced voltage.

[0056] Optionally, the second magnetically-induced voltage determination module may be further configured to:

[0057] design an orthogonal test table according to the target optimization ranges;

[0058] determine a plurality of sets of the excitation coil parameters of different magnitudes according to the orthogonal test table; and

[0059] input each set of the excitation coil parameters to the three-dimensional finite element model and output the second magnetically-induced voltage of the detection point under each set of the excitation coil parameters.

[0060] Optionally, the optimal value determination module may be further configured to:

[0061] determine differential induced voltage peaks at the welding defect and a normal welded seam according to the second magnetically-induced voltages; and

[0062] determine the optimal values of the excitation coil parameters according to the differential induced voltage peaks.

[0063] Optionally, the detection point setting module may be further configured to:

[0064] set a first detection point for the pulsed eddy current detection at the welding defect; and

[0065] set a second detection point for the pulsed eddy current detection at a normal structure of a welded seam.

[0066] In a third aspect, the present disclosure provides an electronic device, including a memory and a processor, where the memory and the processor are in communication connection with each other; the memory stores computer instructions, and the processor executes the computer instructions to perform the method as described in the first aspect.

[0067] In a fourth aspect, the present disclosure provides a computer-readable storage medium, storing computer instructions which cause a computer to perform the method as described in the first aspect.

[0068] The technical solutions provided in embodiments of the present disclosure have at least the following technical effects or advantages:

[0069] According to a method and apparatus for optimizing parameters of a pulsed eddy current probe, a device, and a medium provided in the embodiments of the present disclosure, three-dimensional finite element models for pulsed eddy detection may be established using electromagnetic simulation software, where the three-dimensional finite element models include a probe model and a detected weldment model having a welding defect; excitation coil parameters of the probe model are set to global variables according to the three-dimensional finite element models, and factors influencing the sensitivity of the probe are taken into full consideration; a detection point for the pulsed eddy current detection is determined according to characteristics of the welding defect and a welded seam structure; second magnetically-induced voltages of the detection point under different excitation coil parameters are determined accurately by an orthogonal test method through a small number of tests according to the determined target optimization ranges of the excitation coil parameters; and optimal values of the excitation coil parameters may be determined according to the second magnetically-induced voltages. The method obtains the optimal parameters of the pulsed eddy current probe rapidly and accurately by the electromagnetic simulation software and the orthogonal test method, provides a great assistance for the optimized design of the pulsed eddy current probe, and is conducive to designing a pulsed eddy current probe with higher precision. Defect detection on a special weldment is realized.

[0070] The above description is merely a summary of the technical solutions of the present disclosure. In order to make the technical means of the present disclosure to be understood more clearly and implemented in accordance with the content of the specification, and in order to make the above and other objectives, features and advantages of the present disclosure more obvious and easier to understand, specific implementations of the present disclosure are described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0071] By reading the detailed description of the following preferred embodiments, various other advantages and benefits will become apparent to those of ordinary skill in the art. The accompanying drawings are provided merely for illustrating the specific examples, rather than to limit the present disclosure. Throughout the accompanying drawings, the same reference numerals represent the same components. In the accompanying drawings:

[0072] FIG. 1 is a flowchart of a method for optimizing parameters of a pulsed eddy current probe provided by an embodiment of the present disclosure;

[0073] FIG. 2 is a structural schematic diagram of a coil of an eddy current probe provided by an embodiment of the present disclosure;

[0074] FIG. 3 is a schematic diagram of a position of a pulsed eddy current detection point provided by an embodiment of the present disclosure;

[0075] FIG. 4 is a diagram of relation between an inner diameter of an excitation coil and a magnetic induction intensity provided by an embodiment;

[0076] FIG. 5 is a diagram of relation between an inner diameter of an excitation coil and a first differential induced voltage peak provided by an embodiment; and

[0077] FIG. 6 is a structural block diagram of an apparatus for optimizing parameters of a pulsed eddy current probe provided by an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0078] To make the objective, technical solutions, and advantages of the present application clearer, embodiments of the present application will be further described in detail with reference to the accompanying drawings.

[0079] FIG. 1 is a flowchart of a method for optimizing parameters of a pulsed eddy current probe provided by an embodiment of the present disclosure. As shown in FIG. 1, the method includes the following steps.

[0080] Step SI 10, three-dimensional finite element models for pulsed eddy current detection are established by electromagnetic simulation software.

[0081] The three-dimensional finite element models include a probe model and a detected weldment model, and the detected weldment model includes a welded seam structure having a welding defect.

[0082] In this embodiment, in consideration of an actual situation of the pulsed eddy current detection and the efficiency of modeling, the three-dimensional finite element models of a probe and a detected weldment are established separately. Moreover, a welded seam having a welding defect is also designed on the model of the detected weldment.

[0083] In this embodiment, parameterized three-dimensional finite element models may be established by the electromagnetic simulation software to simulate the pulsed eddy current detection. Influences on a detection result by noise in an environment and the like when a physical device is used to perform the pulsed eddy current detection can be avoided, and a test cost can be reduced. The electromagnetic simulation software may be Ansys Maxwell electromagnetic simulation software.

[0084] In this embodiment, since a weldment body detected actually is made of an electrically conductive material, and both of a size and a position of the electrically conductive material can affect a magnitude of a magnetic field and a magnitude of a detected signal of a detection coil. Therefore, a 1:1 model may be established so that the accuracy of optimization can be guaranteed as much as possible.

[0085] Optionally, step SI 10 includes the following steps.

[0086] At a first step, property parameters of a detected weldment are determined, where the property parameters include a geometrical parameter, a defect parameter, a welded seam parameter, a material parameter, and an electromagnetic parameter of the detected weldment.

[0087] In this embodiment, a suitable laser weldment may be selected according to an actual working condition, and the property parameters of the detected weldment may be determined according to the characteristics of the detected weldment such as an actual structure and a material. That is, with consideration of a geometrical parameter, a defect parameter, a welded seam parameter, a material parameter, and an electromagnetic parameter of the detected weldment, the simulated model may be closer to the actual detected weldment with respect to properties. The welded seam parameter may include a weld width, a penetration, and an excess weld metal of the welded seam.

[0088] At a second step, a three-dimensional finite element model of the detected weldment is established by the electromagnetic simulation software according to the property parameters, where the detected weldment model includes the welded seam structure having the welding defect.

[0089] In this embodiment, the property parameters of the detected weldment are input to corresponding parameter settings of the electromagnetic simulation software so that the three-dimensional finite element model of the detected weldment can be simulated.

[0090] At a third step, feature parameters of an eddy current probe are determined, where the feature parameters include the excitation coil parameters and detection coil parameters.

[0091] FIG. 2 is a structural schematic diagram of a coil of an eddy current probe provided by an embodiment of the present disclosure. As shown in FIG. 2, the coil of the eddy current probe generally includes an excitation coil 1 and a detection coil 2. Therefore, the determined feature parameters need to include the excitation coil parameters and detection coil parameters. Specifically, the excitation coil parameters and the detection coil parameters of the eddy current probe may be determined according to the property parameters of the detected weldment and the characteristics of an actual structure of an existing eddy current detection probe. As can be seen from FIG. 2, the excitation coil parameters may include: geometrical parameters of the excitation coil, i.e., an inner diameter rl, an outer diameter RI, a height H, and a number of turns N; and excitation parameters of the excitation coil, i.e., a lift-off height (not shown in the figure), an excitation frequency f, and an excitation current A.

[0092] At a fourth step, a three-dimensional finite element model of the eddy current probe is established by the electromagnetic simulation software according to the feature parameters.

[0093] In this embodiment, the feature parameters are input to corresponding parameter settings of the electromagnetic simulation software so that the three-dimensional finite element model of the eddy current probe can be simulated.

[0094] Exemplarily, when the detected weldment is a cell connector, initial values of geometrical parameters of a cell connector model and an eddy current probe model are determined according to properties of the cell connector and structural characteristics of an existing eddy current probe, and initial geometries of simulation models are drawn by the AnsysMaxwell electromagnetic simulation software. The specific geometrical parameters are as shown in Table 1 below:

[0095] Table 1

[0096] Excitation Coil (mm) Detection Coil (mm) Connector (mm) Post (mm) Welded Seam (mm) Plastic Ring (mm) Inner diameter 10 Inner diameter 2 Length 60 Diameter 18 Weld width 2.25 Inner diameter 18 Outer diameter 14 Outer diameter 6 Width 60 / / Outer diameter 24 Height 7 Height 4 Height 1 Height 10 Penetration 1.62 Height 9.2

[0097] It needs to be noted that the geometrical parameters of the excitation coil and the detection coil may be determined according to an eddy current detection principle and technical experience and geometrical parameters of the connector. Numerical values in Table 1 are merely example values for convenience of understanding. Specifically, other values may be set according to an actual situation, which will not be defined herein.

[0098] In this embodiment, the data in Table 1 may be used as initial values of the geometrical parameters for drawing a simulation model, and an initial three-dimensional finite element models may be drawn according to these initial values. After the completion of drawing, the material parameter and the electromagnetic parameter of the cell connector model and the excitation parameters of the probe model may be set. The material parameter of the cell connector is set with reference to plastic attributes. An eddy current effect is produced at the cell connector and the post and a welded seam region, and the excitation coil is excited by an external circuit. After the completion of setting the parameters, the model is gridded. To provide a more accurate simulation result, different regions of the model may be gridded differently. Specifically, the excitation coil, the detection coil, and the plastic ring may be divided with a maximum grid size and a maximum number of grids. For the connector, the post, and the welded seam region, a penetration depth division manner may be set additionally to perform layered encryption of grids, ensuring the accuracy of detection regions.

[0099] In this embodiment, a cuboid 2-3 times the size of the model may be set as a solution domain. For example, the solution domain is sized in the electromagnetic simulation software to offset 150% in x, y, and z directions.

[0100] Step S120, excitation coil parameters of the probe model are set to global variables according to the three-dimensional finite element models.

[0101] The excitation coil parameters include an inner diameter, an outer diameter, a height, a number of turns, a lift-off height, an excitation frequency, and an excitation current of an excitation coil.

[0102] In this embodiment, since the eddy current detection probe induces an eddy current field on a surface of the detected weldment, near the surface, and deeply by using a varying magnetic field generated by the excitation coil. A size and a shape of the eddy current field may be influenced by the excitation coil parameters, the property parameters of the detected weldment, and the like. When the detection probe passes through a defect, the original eddy current bypasses the defect. Thus, the eddy current is disturbed, which in turn affects the magnetic field generated by the eddy current. A variation of the magnetic field is detected by the detection coil or a magnetic sensor. Features such as a phase and an amplitude of a detected signal are extracted to perform qualitative and quantitative analysis on the defect.

[0103] It may be construed as the measurement sensitivity of the eddy current probe being mainly influenced by the excitation coil parameters. Therefore, the excitation coil parameters of the probe model are set to the global variables. That is, research is focused on the influences of the magnitudes of the inner diameter, the outer diameter, the height, the number of turns, the lift-off height, the excitation frequency, and the excitation current of the excitation coil on the detected signal, i.e., on a magnetic field distribution and an induced voltage of the detected weldment.

[0104] That is to say, optimization and adjustment of the initial probe model are realized by adjusting the magnitudes of the inner diameter, the outer diameter, the height, the number of turns, the lift-off height, the excitation frequency, and the excitation current of the excitation coil.

[0105] Step S130, a detection point for the pulsed eddy current detection is determined according to the welded seam structure having the welding defect.

[0106] Optionally, step SI30 includes:

[0107] set a first detection point for the pulsed eddy current detection at the welding defect; and set a second detection point for the pulsed eddy current detection at a normal structure of a welded seam.

[0108] FIG. 3 is a schematic diagram of a position of a pulsed eddy current detection point provided by an embodiment of the present disclosure. As shown in FIG. 3, the detection point includes a first detection point a and a second detection point b. Since the center of the coil is a common placement position for the magnetic sensor, the detection point may further include a third detection point c at the bottom center of the excitation coil to facilitate extraction of a magnetic induction intensity change rule at the third detection point c.

[0109] In this embodiment, coordinates of the first detection point a, the second detection point b, and the third detection point c may be determined according to a coordinate system of the three-dimensional finite element model, the defect parameter, the welded seam parameter, and the structure parameter of the excitation coil parameters. A number of the detection points may be also set as needed. For example, one first detection point a is disposed at the center of a defect structure, or a plurality of first detection points a may be disposed according to a specific size of the defect structure. Since the welded seam of the detected weldment in the figure is circular, a detection line Xh parallel to the X axis and passing through the bottom circle of the coil is set on the surface of the detected weldment, and 100 second detection points b in the detection line 4 are averagely selected. The 100 points had better avoid the defect structure. One third detection point c may be disposed at the bottom circle of the excitation coil.

[0110] It needs to be noted that when the welded seam is in other shapes such as a strip shape, the second detection point may be determined according to a specific shape; and a number of detection points may be set according to an actual requirement, which will not be defined in the present disclosure.

[0111] Step S140, target optimization ranges of the excitation coil parameters are determined.

[0112] Optionally, step SI40 includes the following steps.

[0113] At a first step, an initial optimization range of each parameter of the excitation coil parameters is determined.

[0114] In this embodiment, the initial optimization range of each parameter of the excitation coil parameters may be determined according to the property parameters of the detected weldment and feature parameters of an existing pulsed eddy current probe.

[0115] It needs to be noted that a lower limit value of the initial optimization range may be set as small as possible while an upper limit value set as large as possible, guaranteeing that the influences of a variation of each parameter on the magnetic induction intensity and the magnetically-induced voltage can be obtained when a simulation test is conducted. If a test result is not ideal, the initial optimization range may be re-adjusted.

[0116] Specifically, the lower limit values of the initial optimization ranges of the inner diameter and the outer diameter may be determined according to the weld width and the penetration of the welded seam, with a region between the inner diameter and the outer diameter being capable of covering the welded seam as a minimum standard. The lower limit values of the initial optimization ranges of the height and the number of turns may be set according to an actual situation. The lower limit value of the initial optimization range of the lift-off height is set as small as possible. The lower limit value of the initial optimization range of the excitation current may be set according to an excitation circuit disposed. The lower limit value of the initial optimization range of the excitation frequency may be determined according to the electromagnetic parameter of the weldment, which may be specifically determined according to the following formula:

[0117] F=l / 7tpo52,

[0118] where f represents the excitation frequency; p represents a magnetic conductivity of the detected weldment, o represents an electric conductivity of the detected weldment; and 5 represents a detection depth.

[0119] In this embodiment, the magnetic conductivity and the electric conductivity may be set with reference to the electromagnetic parameter used when the initial three-dimensional finite element model is established; and the detection depth should be greater than a depth of the welded seam and smaller than a structural depth of the weldment.

[0120] Exemplarily, the lower limit values of the initial optimization ranges of the parameters may be set according to calculation and analysis as follows: 5 mm for the inner diameter, 13 mm for the outer diameter, 4 mm for the height, 200 for the number of turns, 0.5 A for the current, 0.5 mm for the lift-off height, and 1000 Hz for the frequency.

[0121] In this embodiment, to enable a more comprehensive detection result, the upper limit values may be set as large as possible and may be specifically set according to detection experience, thereby guaranteeing that the point having the greatest influence on the magnetic induction intensity or the magnetically-induced voltage may be observed from a change curve between each parameter and the magnetic induction intensity or the magnetically-induced voltage.

[0122] At a second step, influences of a variation of a single parameter of the excitation coil parameters on a magnetic induction intensity and a first magnetically-induced voltage of the detection point are analyzed by a target optimization function in the electromagnetic simulation software according to the initial optimization range, and a target optimization range of each parameter of the excitation coil parameters is determined.

[0123] The initial optimization range is greater than the target optimization range.

[0124] In this embodiment, the influences of the variation of each parameter on the detected magnetic induction intensity and the first magnetically-induced voltage need to be studied, and the target optimization range may be determined according to an extent of the influences.

[0125] Optionally, the second step includes:

[0126] determine, by the target optimization function in the electromagnetic simulation software, the magnetic induction intensity and the first magnetically-induced voltage of the detection point when one parameter of the excitation coil parameters varies in the corresponding initial optimization range while other parameters remain unchanged; and determine the target optimization range of each parameter of the excitation coil parameters according to the target optimization range of each parameter, the magnetic induction intensity, and the first magnetically-induced voltage.

[0127] In this embodiment, only one parameter of the excitation coil parameters is set to gradually increase from the lower limit value of the initial optimization range to the upper limit value at a set step size by the target optimization function of the Ansys Maxwell electromagnetic simulation software, while other parameters are fixed at selected values, and the magnetic induction intensity and the magnetically-induced voltage corresponding to the detection point at each value of the parameter are collected. For example, the inner diameter is set to gradually increase from 5 mm to 20 mm at the step size of 1 mm, and the other parameters are set to corresponding lower limit values, and simulation is performed to output the magnetic induction intensity and the magnetically-induced voltage corresponding to the detection point.

[0128] In this embodiment, the magnetic induction intensities and the first magnetically-induced voltages at the welding defect and the normal welded seam may be extracted according to the magnetic induction intensity and the first magnetically-induced voltage, and the influence of each parameter on the magnetic field is analyzed according to the variation of the magnetic induction intensities at the welding defect; and the influence of each parameter on the detected signal is analyzed according to a peak of a difference of the first magnetically-induced voltages at the welding defect and the normal welded seam, i.e., a first differential induced voltage peak. In order to more intuitively analyze the extent of the influences, a data table or curve may be drawn with values of the parameters respectively corresponding to the magnetic induction intensity and the first differential induced voltage peak. Thus, the variations of the magnetic induction intensities and the first differential induced voltage peak at the welding defect and the normal welded seam when each parameter varies are observed.

[0129] FIG. 4 is a diagram of relation between an inner diameter of an excitation coil and a magnetic induction intensity provided by this embodiment, and FIG. 5 is a diagram of relation between an inner diameter of an excitation coil and a first differential induced voltage peak provided by this embodiment. It needs to be noted that the curves in FIG. 4 and FIG. 5 are drawn with part of data in the above test, which are for the purpose of facilitating understanding of the present disclosure and do not limit the present disclosure.

[0130] As shown in FIG. 4, the magnetic induction intensity at the normal welded seam decreases as the inner diameter increases, and the induction intensity at the welding defect increases as the inner diameter increases. As shown in FIG. 5, the first differential induced voltage peak at the normal structure of the welded seam and the welding defect increases firstly and then decreases as the inner diameter increases. As can be known from the above analysis, when the inner diameter changes, the corresponding magnetic field and detected signal are both influenced. The target optimization range of the inner diameter may be determined from the initial optimization range of the inner diameter according to the change rules of the inner diameter and the magnetic induction intensity as well as the differential induced voltage peak. For example, as can be seen from FIG. 4 and FIG. 5, when the inner diameter is 7 mm, the influences on the magnetic induction intensity and the first differential induced voltage are maximum. Therefore, the target optimization range of the inner diameter may be selected as 6-10 mm. The other excitation coil parameters may be determined using the same method. That is, the change rules of other parameters and the magnetic induction intensity as well as the differential induced voltage peak are studied to determine the target optimization range of the other parameters, and each target optimization range should include a parameter value corresponding to the point having the maximum influences.

[0131] At a third step, the target optimization ranges of the excitation coil parameters are determined according to the target optimization range of each parameter.

[0132] In this embodiment, the target optimization range of each parameter may be gathered so that the target optimization ranges of the excitation coil parameters can be obtained.

[0133] Step SI50, second magnetically-induced voltages of the detection point under different excitation coil parameters are determined by an orthogonal test method according to the target optimization ranges.

[0134] In this embodiment, by the orthogonal test method, an accurate test result may be obtained by a small number of tests, thereby greatly saving the optimization time and improving optimization efficiency.

[0135] Optionally, step SI50 includes the following steps.

[0136] At a first step, an orthogonal test table is designed according to the target optimization ranges.

[0137] Specifically, a level and a factor of an orthogonal table are determined according to the target optimization range of each parameter; and an orthogonal test table is designed according to the level and the factor.

[0138] Exemplarily, to facilitate understanding, an orthogonal test is performed with only the inner diameter, the outer diameter, the height, and the number of turns as study objects, and it is determined there are 4 factors. A set step size of the inner diameter, the outer diameter, and the height may be set to 1 mm, and a set step size of the number of turns may be set to 100. The target optimization range may be then determined as follows: 6-10 mm for the inner diameter, 14-18 mm for the outer diameter, 5-9 mm for the height, 300-700 for the number of turns, and it is determined that there are 5 levels. Therefore, a 4-factor 5-level orthogonal table may be established, and the established orthogonal table is as shown in Table 2 below:

[0139] Table 2

[0140] Factor Level 1 2 3 4 5 Inner diameter (mm) 6 7 8 9 10 Outer diameter (mm) 14 15 16 17 18 Height (mm) 5 6 7 8 9 Number of turns 300 400 500 600 700

[0141] It needs to be noted that the orthogonal test needs to be actually performed in the present disclosure with the inner diameter, the outer diameter, the height, the number of turns, the lift-off height, the excitation frequency, and the excitation current as study objects. In this example, only part of the excitation coil parameters are selected as the study objects, which are only for facilitating understanding rather than limiting the present disclosure.

[0142] At a second step, a plurality of sets of the excitation coil parameters of different magnitudes are determined according to the orthogonal test table.

[0143] In this embodiment, 25 sets of the excitation coil parameters may be determined according to Table 2. The orthogonal table may be input to Statistical Package for the Social Sciences (SPSS) software. After processing by the software, detailed data of 25 sets of test data may be obtained.

[0144] At a third step, each set of the excitation coil parameters is input to the three-dimensional finite element model and the second magnetically-induced voltage of the detection point under each set of the excitation coil parameters is output.

[0145] In this embodiment, 25 sets of the excitation coil parameters may be separately input to the three-dimensional finite element model, and the second magnetically-induced voltage of the detection point is output by using a transient solver function.

[0146] In this embodiment, when the orthogonal test is performed, the set step size may be subdivided according to the test result. That is, the number of levels of the orthogonal test is adjusted continuously such that the test result is better.

[0147] Step SI60, optimal values of the excitation coil parameters are determined according to the second magnetically-induced voltages.

[0148] Optionally, step S160 includes:

[0149] determine differential induced voltage peaks at the welding defect and a normal welded seam according to the second magnetically-induced voltages; and determine the optimal values of the excitation coil parameters according to the differential induced voltage peaks.

[0150] In this embodiment, when the differential induced voltage peak is greater, it indicates that the detected signal is stronger, and the qualitative and quantitative analysis on the defect is more accurate. Therefore, the values of the excitation coil parameters corresponding to the maximum differential induced voltage peak are the optimal values of the excitation coil parameters.

[0151] In this embodiment, a calculation formula for the differential induced voltage peak at the welding defect and the normal welded seam may be edited using the transient solver function. When simulation is performed, the electromagnetic simulation software may directly output the differential induced voltage peak according to the calculation formula, thereby improving the test efficiency. The calculation formula for the differential induced voltage peak is as follows:

[0152] V=max(Vf-Vn),

[0153] where V represents the differential induced voltage peak; Vf represents a magnetically-induced voltage at the welding defect; and Vn represents a magnetically-induced voltage at the normal welded seam.

[0154] In this embodiment, the differential induced voltage data at the welding defect and the normal welded seam obtained by simulation may be analyzed by using the SPSS software. The software may calculate the magnetically-induced voltage at each welding defect and a mean value of the differential induced voltage peak at each normal welded seam, and determine a range according to the mean value of the peaks. Which excitation coil parameter has the greatest influence on the signal detected by the probe may be determined according to the range.

[0155] Exemplarily, the orthogonal test is performed on the data in Table 2. The test data is analyzed by the SPSS software to obtain a range analysis Table 3 as follows:

[0156] Table 3

[0157] Level\ Meari\. Factor \ Value Inner Diameter Outer Diameter Height Number of Turns 1 1.2548 0.2252 0.8588 0.5046 2 1.643 0.7634 0.5324 1.377 3 0.499 1..8998 0.5558 0.868 4 0.495 0.8606 0.9362 0.4758 5 0.3992 0.542 1.4078 1.0656 Range 1.2438 1.6746 0.8754 0.9012 Ranking 2 1 4 3

[0158] As can be seen from Table 3, the outer diameter has the greatest influence on the detected signal. The level corresponding to the maximum mean value of each factor is the optimal level, and the parameter value corresponding to the optimal level is the optimal value. Therefore, the optimal values of the excitation coil parameters may be intuitively determined in combination with Table 2 and Table 3 as follows: 7 mm for the inner diameter, 16 mm for the outer diameter, 9 mm for the height, and 400 for the number of turns.

[0159] It needs to be noted that when the orthogonal test is performed with the inner diameter, the outer diameter, the height, the number of turns, the lift-off height, the excitation frequency, and the excitation current as the study objects, i.e., with all the excitation coil parameters as the study objects, the optimal values of the excitation coil parameters are determined using the above-mentioned method, which will not be described here redundantly.

[0160] In this embodiment, the differential induced voltage peaks may be ranked in a descending order, and 5 top ranked differential induced voltage peaks are selected therefrom, and the values of 5 sets of the excitation coil parameters corresponding to each differential induced voltage peak are separately input to the electromagnetic simulation software for simulation verification. The optimal set of values are selected from five sets of values as the optimal values.

[0161] Based on the same inventive concept, an embodiment of the present disclosure further provides an apparatus for optimizing parameters of a pulsed eddy current probe. FIG. 6 is a structural block diagram of an apparatus for optimizing parameters of a pulsed eddy current probe provided by an embodiment of the present disclosure. As shown in FIG. 6, the apparatus 600 includes a model establishment module 601, a global variable setting module 602, a detection point setting module 603, a target optimization range determination module 604, a second magnetically-induced voltage determination module 605, and an optimal value determination module 606.

[0162] The model establishment module 601 is configured to establish three-dimensional finite element models for pulsed eddy current detection by electromagnetic simulation software, where the three-dimensional finite element models include a probe model and a detected weldment model, and the detected weldment model includes a welded seam structure having a welding defect.

[0163] The global variable setting module 602 is configured to set excitation coil parameters of the probe model to global variables according to the three-dimensional finite element models, where the excitation coil parameters include an inner diameter, an outer diameter, a height, a number of turns, a lift-off height, an excitation frequency, and an excitation current of an excitation coil.

[0164] The detection point setting module 603 is configured to determine a detection point for the pulsed eddy current detection according to the welded seam structure having the welding defect.

[0165] The target optimization range determination module 604 is configured to determine target optimization ranges of the excitation coil parameters.

[0166] The second magnetically-induced voltage determination module 605 is configured to determine second magnetically-induced voltages of the detection point under different excitation coil parameters by an orthogonal test method according to the target optimization ranges.

[0167] The optimal value determination module 606 is configured to determine optimal values of the excitation coil parameters according to the second magnetically-induced voltages.

[0168] Optionally, the model establishment module 601 is further configured to:

[0169] determine property parameters of a detected weldment, where the property parameters include a geometrical parameter, a defect parameter, a welded seam parameter, a material parameter, and an electromagnetic parameter of the detected weldment;

[0170] establish a three-dimensional finite element model of the detected weldment by the electromagnetic simulation software according to the property parameters, where the detected weldment model includes the welded seam structure having the welding defect;

[0171] determine feature parameters of the pulsed eddy current probe, where the feature parameters include the excitation coil parameters and detection coil parameters; and

[0172] establishing a three-dimensional finite element model of the eddy current probe by the electromagnetic simulation software according to the feature parameters.

[0173] Optionally, the target optimization range determination module 604 includes:

[0174] a first determination unit configured to determine an initial optimization range of each parameter of the excitation coil parameters;

[0175] a second determination unit configured to analyze influences of a variation of a single parameter of the excitation coil parameters on a magnetic induction intensity and a first magnetically-induced voltage of the detection point by a target optimization function in the electromagnetic simulation software according to the initial optimization range, and determine a target optimization range of each parameter of the excitation coil parameters; and

[0176] a third determination unit configured to determine the target optimization ranges of the excitation coil parameters according to the target optimization range of each parameter,

[0177] where the initial optimization range is greater than the target optimization range.

[0178] Optionally, the second determination unit is further configured to:

[0179] determine, by the target optimization function in the electromagnetic simulation software, the magnetic induction intensity and the first magnetically-induced voltage of the detection point when one parameter of the excitation coil parameters varies in the corresponding initial optimization range while other parameters remain unchanged; and

[0180] determine the target optimization range of each parameter of the excitation coil parameters according to the initial optimization range of each parameter, the magnetic induction intensity, and the first magnetically-induced voltage.

[0181] Optionally, the second magnetically-induced voltage determination module 605 is further configured to:

[0182] design an orthogonal test table according to the target optimization ranges;

[0183] determine a plurality of sets of the excitation coil parameters of different magnitudes according to the orthogonal test table; and

[0184] input each set of the excitation coil parameters to the three-dimensional finite element model and output the second magnetically-induced voltage of the detection point under each set of the excitation coil parameters.

[0185] Optionally, the optimal value determination module 606 is further configured to:

[0186] determine differential induced voltage peaks at the welding defect and a normal welded seam according to the second magnetically-induced voltages; and

[0187] determine the optimal values of the excitation coil parameters according to the differential induced voltage peaks.

[0188] Optionally, the detection point setting module 603 is further configured to:

[0189] set a first detection point for the pulsed eddy current detection at the welding defect; and

[0190] set a second detection point for the pulsed eddy current detection at a normal structure of a welded seam.

[0191] It will be appreciated that division of the above-mentioned function modules of the apparatus provided in the foregoing embodiments is merely used as an example. In practical application, the foregoing functions may be allocated to and completed by different function modules as required, that is, an internal structure of the apparatus is divided into different function modules to complete all or some of the foregoing functions.

[0192] An embodiment of the present disclosure provides an electronic device. The electronic device may include a processor and a memory, where the processor and the memory may be in communication connection with each other by a bus or otherwise.

[0193] The processor may be a central processing unit (CPU) or an application specific integrated circuit (ASIC), or may be configured as one or more integrated circuits for implementing the embodiments of the present disclosure.

[0194] The memory may include a mass memory for data or instructions. By way of example but not limitation, the memory may include a hard disk drive (HDD), a floppy disk drive, a flash memory, an optical disk, a magneto-optical disk, a magnetic tape, or a universal serial bus (USB) drive, or a combination of two or more of them. If appropriate, the memory may include a removable or non-removable (or fixed) medium. If appropriate, the memory may be inside or outside of an electronic device. In a particular embodiment, the memory may be a nonvolatile solid-state memory.

[0195] In one example, the memory may be a read only memory (ROM). In one example, the ROM may be a mask programmed ROM, a programmable ROM (PROM), an erasable PROM (EPROM), an electrically erasable PROM (EEPROM), electrically alterable ROM (EAROM), or a flash memory, or a combination of two or more of them.

[0196] The processor is configured to implement any method for optimizing parameters of a pulsed eddy current probe in the above embodiments by reading and executing computer program instructions stored in the memory.

[0197] In one example, the electronic device may further include a communication interface and a bus. The processor, the memory, and the communication interface are connected by the bus and complete communication with one another. The communication interface is mainly configured to implement communications between the modules, apparatuses, units, and / or devices in the embodiments of the present disclosure. If appropriate, the bus may include one or more buses.

[0198] In addition, an embodiment of the present disclosure may provide a computer-readable storage medium to implement the method for optimizing parameters of a pulsed eddy current probe in the above embodiments. The computer-readable storage medium stores computer program instructions. When the computer program instructions are executed by a processor, any method for optimizing parameters of a pulsed eddy current probe in the above embodiments is implemented.

[0199] The above-mentioned technical solutions in the embodiments of the present disclosure have at least the following technical effects or advantages:

[0200] According to a method and apparatus for optimizing parameters of a pulsed eddy current probe, a device, and a medium provided in the embodiments of the present disclosure, three-dimensional finite element models for pulsed eddy detection may be established using electromagnetic simulation software, where the three-dimensional finite element models include a probe model and a detected weldment model having a welding defect; excitation coil parameters of the probe model are set to global variables according to the three-dimensional finite element models, and factors influencing the sensitivity of the probe are taken into full consideration; a detection point for the pulsed eddy current detection is determined according to characteristics of the welding defect and a welded seam structure; second magnetically-induced voltages of the detection point under different excitation coil parameters are determined accurately by an orthogonal test method through a small number of tests according to the determined target optimization ranges of the excitation coil parameters; and optimal values of the excitation coil parameters may be determined according to the second magnetically-induced voltages. The method obtains the optimal parameters of the pulsed eddy current probe rapidly and accurately by the electromagnetic simulation software and the orthogonal test method, provides a great assistance for the optimized design of the pulsed eddy current probe, and is conducive to designing a pulsed eddy current probe with higher precision. Defect detection on a special weldment is realized.

[0201] In the specification provided herein, a large quantity of specific details are described. However, it can be understood that the embodiments of the present disclosure can be practiced without the specific details. In some embodiments, well-known methods, structures and techniques are not shown in detail to avoid obscuring the understanding of this specification.

[0202] Similarly, it should be understood that in order to simplify the present disclosure and help understand one or more of the aspects of the present disclosure, in the above description of the exemplary embodiments of the present disclosure, various features of the present disclosure are sometimes grouped together into a single embodiment, figure, or description thereof. However, the method of the present disclosure should not be interpreted as reflecting an intention that the claimed disclosure requires more features than those explicitly recited in each claim. More precisely speaking, as reflected in the following claims, the inventive aspects have fewer features than all the features of a single previously disclosed embodiment. Therefore, the claims following the detailed description of the embodiments are hereby explicitly incorporated into the detailed description of the embodiments, where each claim itself is used as an independent embodiment of the present disclosure.

[0203] It should be noted that the above examples illustrate rather than limit the disclosure, and those skilled in the art can design alternative examples without departing from the scope of the appended claims. In the claims, any reference sign between brackets should not be construed as a limitation on to the claims. The word “contain” does not exclude the presence of components or steps not listed in the claims. The word “one” or “a / an” preceding a component does not exclude the existence of a plurality of such components. The present disclosure can be implemented with the assistance of hardware including several different components and the assistance of a properly programmed computer. In the unit claims where several apparatuses are listed, several of the apparatuses may be embodied by a same hardware item. The use of words such as first, second, and third does not indicate any order. The words may be interpreted as names.

Claims

1. A method for optimizing parameters of a pulsed eddy current probe, comprising:establishing three-dimensional finite element models for pulsed eddy current detection by electromagnetic simulation software, wherein the three-dimensional finite element models comprise a probe model and a detected weldment model, and the detected weldment model comprises a welded seam structure having a welding defect;setting excitation coil parameters of the probe model to global variables according to the three-dimensional finite element models, wherein the excitation coil parameters comprise an inner diameter, an outer diameter, a height, a number of turns, a lift-off height, an excitation frequency, and an excitation current of an excitation coil;determining a detection point for the pulsed eddy current detection according to the welded seam structure having the welding defect;determining target optimization ranges of the excitation coil parameters;determining second magnetically-induced voltages of the detection point under different excitation coil parameters by an orthogonal test method according to the target optimization ranges; anddetermining optimal values of the excitation coil parameters according to the second magnetically-induced voltages.

2. The method according to claim 1, wherein the establishing three-dimensional finite element models for pulsed eddy current detection by electromagnetic simulation software comprises:determining property parameters of a detected weldment, wherein the property parameters comprise a geometrical parameter, a defect parameter, a welded seam parameter, a material parameter, and an electromagnetic parameter of the detected weldment;establishing a three-dimensional finite element model of the detected weldment by the electromagnetic simulation software according to the property parameters, wherein the detected weldment model comprises the welded seam structure having the welding defect;determining feature parameters of an eddy current probe, wherein the feature parameters comprise the excitation coil parameters and detection coil parameters; andestablishing a three-dimensional finite element model of the eddy current probe by the electromagnetic simulation software according to the feature parameters.

3. The method according to claim 1, wherein the determining target optimization ranges of the excitation coil parameters comprises:determining an initial optimization range of each parameter of the excitation coil parameters;analyzing influences of a variation of a single parameter of the excitation coil parameters on a magnetic induction intensity and a first magnetically-induced voltage of the detection point by a target optimization function in the electromagnetic simulation software according to the initial optimization range, and determining a target optimization range of each parameter of the excitation coil parameters; anddetermining the target optimization ranges of the excitation coil parameters according to the target optimization range of each parameter,wherein the initial optimization range is greater than the target optimization range.

4. The method according to claim 3, wherein the analyzing influences of a variation of a single parameter of the excitation coil parameters on a magnetic induction intensity and a first magnetically-induced voltage of the detection point by a target optimization function in the electromagnetic simulation software according to the initial optimization range, and determining a target optimization range of each parameter of the excitation coil parameters comprise:determining, by the target optimization function in the electromagnetic simulation software, the magnetic induction intensity and the first magnetically-induced voltage of the detection point when one parameter of the excitation coil parameters varies in the corresponding initial optimization range while other parameters remain unchanged; anddetermining the target optimization range of each parameter of the excitation coil parameters according to the initial optimization range of each parameter, the magnetic induction intensity, and the first magnetically-induced voltage.

5. The method according to claim 1, wherein the determining second magnetically-induced voltages of the detection point under different excitation coil parameters by an orthogonal test method according to the target optimization ranges comprises:designing an orthogonal test table according to the target optimization ranges;determining a plurality of sets of the excitation coil parameters of different magnitudes according to the orthogonal test table; andinputting each set of the excitation coil parameters to the three-dimensional finite element model and outputting the second magnetically-induced voltage of the detection point under each set of the excitation coil parameters.

6. The method according to claim 1, wherein the determining optimal values of the excitation coil parameters according to the second magnetically-induced voltages comprises:determining differential induced voltage peaks at the welding defect and a normal welded seam according to the second magnetically-induced voltages; anddetermining the optimal values of the excitation coil parameters according to the differential induced voltage peaks.

7. The method according to claim 1, wherein the determining a detection point for the pulsed eddy current detection according to the welded seam structure having the welding defect comprises:setting a first detection point for the pulsed eddy current detection at the welding defect; andsetting a second detection point for the pulsed eddy current detection at a normal structure of a welded seam.

8. An apparatus for optimizing parameters of a pulsed eddy current probe, comprising:a model establishment module configured to establish three-dimensional finite element models for pulsed eddy current detection by electromagnetic simulation software, wherein the three-dimensional finite element models comprise a probe model and a detected weldment model, and the detected weldment model comprises a welded seam structure having a welding defect;a global variable setting module configured to set excitation coil parameters of the probe model to global variables according to the three-dimensional finite element models, wherein the excitation coil parameters comprise an inner diameter, an outer diameter, a height, a number of turns, a lift-off height, an excitation frequency, and an excitation current of an excitation coil;a detection point setting module configured to determine a detection point for the pulsed eddy current detection according to the welded seam structure having the welding defect;a target optimization range determination module configured to determine target optimization ranges of the excitation coil parameters;a second magnetically-induced voltage determination module configured to determine second magnetically-induced voltages of the detection point under different excitation coil parameters by an orthogonal test method according to the target optimization ranges; andan optimal value determination module configured to determine optimal values of the excitation coil parameters according to the second magnetically-induced voltages.

9. An electronic device, comprising a memory and a processor, wherein the memory and the processor are in communication connection with each other; the memory stores computer instructions, and the processor executes the computer instructions to perform the method according to any one of claims 1 to 7.

10. A computer-readable storage medium, storing computer instructions which cause a computer to perform the method according to any one of claims 1 to 7.27

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