Detection device, detection system, propagation member, fixing device, program, and storage medium
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- KK TOSHIBA
- Filing Date
- 2025-06-03
- Publication Date
- 2026-08-04
Smart Images
Figure 0007900563000001 
Figure 0007900563000002 
Figure 0007900563000003
Abstract
Description
Technical Field
[0001] Embodiments of the present invention relate to a detection device, a detection system, a propagation member, a fixture, a program, and a storage medium.
Background Art
[0002] There is a detection device that transmits ultrasonic waves to an object and detects reflected waves. Development of a detection device that does not require a coupling liquid is desired.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] The problem to be solved by the present invention is to provide a detection device, a detection system, a propagation member, a fixture, a program, and a storage medium that do not require a coupling liquid.
Means for Solving the Problems
[0005] The detection device according to the embodiment includes a detector, a first propagation member, a second propagation member, and a fixture. The detector includes a plurality of detection elements that transmit and detect ultrasonic waves. The first propagation member is attached to the detector and the ultrasonic waves propagate therethrough. The second propagation member is where the ultrasonic waves propagate and is softer than the first propagation member. The fixture detachably fixes the second propagation member to the first propagation member.
Brief Description of the Drawings
[0006] [Figure 1] It is a perspective view and a front view showing the detection device according to the embodiment. [Figure 2] It is a perspective view and a bottom view showing the second propagation member. [Figure 3] This is a side view showing the second propagation member. [Figure 4] These are a bottom view and a side view showing a part of the detection device according to the embodiment. [Figure 5] This is a side view showing a detection device according to an embodiment. [Figure 6] These are a bottom view and a side view showing a part of the detection device according to the embodiment. [Figure 7] These are a side view and a perspective view showing the detection device according to the embodiment. [Figure 8] This is a schematic side view of another fastener. [Figure 9] This is a side view showing the tip of the detection device according to the embodiment. [Figure 10] This is a perspective view showing the tip of the detection device according to the embodiment. [Figure 11] This is a schematic diagram illustrating the three-dimensional detection results obtained through exploration. [Figure 12] This is a schematic diagram representing the detection system according to the embodiment. [Figure 13] This is a schematic diagram representing another detection system according to the embodiment. [Figure 14] This is a schematic diagram illustrating an inspection method using a detection device according to an embodiment. [Figure 15] This is a schematic diagram showing a part of the detection device according to the embodiment. [Figure 16] This is a flowchart illustrating the method for determining health. [Figure 17] This is a schematic diagram illustrating the second intensity data. [Figure 18] This is a schematic diagram showing each unit for replacing the second propagation member. [Figure 19] This is a schematic diagram illustrating the operation of each unit for replacing the second propagation member. [Figure 20] This is a schematic diagram illustrating the operation of each unit for replacing the second propagation member. [Figure 21] This is a schematic diagram representing the hardware configuration.
Best Mode for Carrying Out the Invention
[0007] Hereinafter, each embodiment of the present invention will be described with reference to the drawings. The drawings are schematic or conceptual, and the relationship between the thickness and width of each part, the ratio of the sizes between parts, etc. are not necessarily the same as the actual ones. Even when representing the same part, there are cases where their dimensions and ratios are represented differently in the drawings. In the specification of the present application and each figure, the same reference numerals are given to the same elements as those already described, and the detailed description will be omitted as appropriate.
[0008] FIG. 1 is a perspective view showing a detection device according to an embodiment. As shown in FIG. 1, the detection device 10 according to the embodiment includes a first propagation member 11, a second propagation member 12, a fixture 13, and a detector 15.
[0009] The detector 15 includes an element array 15a. The element array 15a includes a plurality of detection elements. Each detection element transmits ultrasonic waves. Also, each detection element detects the reflected wave of the ultrasonic wave. Here, the transmission of the ultrasonic wave by the detector 15 and the detection of the reflected wave are called probing. The side of the element array 15a is surrounded by the housing 15h of the detector 15. The side is a direction intersecting the transmission direction of the ultrasonic wave.
[0010] The first propagation member 11 is attached to the detector 15 (housing 15h). The first propagation member 11 is capable of propagating ultrasonic waves. For example, the first propagation member 11 contacts the detector 15. Or, another member capable of propagating ultrasonic waves may be provided between the first propagation member 11 and the detector 15.
[0011] The second propagation member 12 is attached to the first propagation member 11 by the fixture 13. The first propagation member 11 is located between the detector 15 and the second propagation member 12. The second propagation member 12 is capable of propagating ultrasonic waves. The ultrasonic wave that has propagated through the first propagation member 11 propagates through the second propagation member 12 and is emitted outside the detection device 10.
[0012] The first propagation member 11 is solid. The first propagation member 11 has sufficient hardness so that no substantial changes occur even when the detection device 10 is in operation. This suppresses damage to the element array 15a. The second propagation member 12 is gel-like and not liquid. The second propagation member 12 is softer than the first propagation member 11. That is, the hardness of the second propagation member 12 is less than that of the first propagation member 11. For this reason, the second propagation member 12 deforms more easily than the first propagation member 11. The second propagation member 12 has sufficient softness so that it can deform according to the surface shape of the object being inspected when the detection device 10 is in operation.
[0013] The fixing device 13 fixes the second propagation member 12 in a state where the second propagation member 12 is in contact with the first propagation member 11. The fixing device 13 detachably fixes the second propagation member 12 to the first propagation member 11.
[0014] In the example shown in Figure 1, the fixture 13 includes a plate member 13a and a fastener 13b. The plate member 13a includes a first end E1 and a second end E2. The first end E1 is fastened and secured to the housing 15h by the fastener 13b. The fastener 13b is, for example, a screw. The plate member 13a extends along the direction from the housing 15h toward the second propagation member 12. The second end E2, opposite to the first end E1, is bent so that the second propagation member 12 is positioned between the first propagation member 11 and the second end E2. A portion of the second propagation member 12 is sandwiched between the second end E2 and the first propagation member 11.
[0015] The plate member 13a may be an elastic leaf spring. An elastic force is generated in the plate member 13a in a direction that presses the second propagation member 12 toward the first propagation member 11. Alternatively, the second propagation member 12 may be pressed by a linear member such as a hard steel wire instead of the plate member 13a. The specific structure of the fixing device 13 can be modified as appropriate, as long as it is equipped with a pressing member that can be fixed to the housing 15h at one end and press the second propagation member 12 toward the first propagation member 11 at the other end.
[0016] For example, the first propagation member 11 and the second propagation member 12 include resin. Specifically, the first propagation member 11 includes acrylic, and the second propagation member 12 includes segmented polyurethane.
[0017] For example, the detection device 10 transmits ultrasonic waves to the joint and detects the reflected waves. The acoustic impedance of a typical steel plate used for joining is 4.5 × 10⁻⁶. 7 The impedance is approximately (Pa·s / m). To ensure that ultrasonic waves propagate sufficiently between the detection device 10 and the joint, the acoustic impedances of the first propagation member 11 and the second propagation member 12 are set to 1.0 × 10⁻¹⁰. 5 Larger than (Pa·s / m), 1.0 × 10 8 It is preferable that the acoustic impedance is less than (Pa·s / m). The acoustic impedance can be measured according to JIS A1405-1 (ISO 10534-1). The acoustic impedance may also be measured according to JIS A 1409 (ISO 354).
[0018] To suppress deformation of the first propagation member 11, the Rockwell hardness (M scale) of the first propagation member 11 is preferably greater than 80 and less than 110. The Rockwell hardness can be measured according to JIS Z 2245 (ISO 2039-2). To allow for easy deformation according to the surface shape of the target, the hardness of the second propagation member 12, measured by an Asker rubber hardness tester type F, is preferably greater than 40 and less than 60.
[0019] Here, the direction from the first propagation member 11 to the second propagation member 12 is defined as the Z direction (first direction). One direction intersecting the Z direction is defined as the X direction (second direction). One direction intersecting the ZX plane is defined as the Y direction (third direction). For example, the X, Y, and Z directions are mutually orthogonal.
[0020] Figures 2(a) and 2(b) are perspective and bottom views, respectively, of the second propagation member. As shown in Figures 2(a) and 2(b), the second propagation member 12 includes a first portion 12a and a second portion 12b.
[0021] The first portion 12a is located on the outer periphery of the second propagation member 12 and is held in place by the fastener 13. The second portion 12b is surrounded by the first portion 12a. The first portion 12a is located around the second portion 12b along the XY plane. For example, the second portion 12b is located in the center of the second propagation member 12.
[0022] The second portion 12b protrudes more than the first portion 12a in the Z direction. For example, as shown in Figure 2(a), the thickness T2 of the second portion 12b is greater than the thickness T1 of the first portion 12a. The thickness corresponds to the length in the Z direction.
[0023] Figures 3(a) and 3(b) are side views representing the second propagation member. An example of the specific structure of the second propagation member 12 will be described. As shown in Figure 3(a), the first part 12a and the second part 12b each have a first surface S1 and a second surface S2 that intersect with the Z direction. The first part 12a and the second part 12b also have a common third surface S3 that intersects with the Z direction. The third surface S3 is located on the opposite side of the first surface S1 and the second surface S2. For example, the first surface S1, the second surface S2, and the third surface S3 are parallel to each other. The position of the first surface S1 in the Z direction is between the position of the second surface S2 in the Z direction and the position of the third surface S3 in the Z direction.
[0024] As another example, as shown in Figure 3(b), the first part 12a and the second part 12b may each have a third face S3 and a fourth face S4 intersecting the Z direction. The third face S3 is located on the opposite side of the first face S1. The fourth face S4 is located on the opposite side of the second face S2. For example, the first face S1, the second face S2, the third face S3, and the fourth face S4 are parallel to each other. The positions of the first face S1 and the fourth face S4 in the Z direction are between the positions of the second face S2 and the third face S3 in the Z direction.
[0025] Figures 4(a) and 4(b) are a bottom view and a side view, respectively, showing a part of the detection device according to the embodiment. Figures 5(a) and 5(b) are side views showing a detection device according to an embodiment. As shown in Figures 4(a) and 4(b), the first portion 12a is pressed against the first propagation member 11 by the fixing device 13. As a result, the second propagation member 12 adheres tightly to the first propagation member 11 so that there is no gap between the first propagation member 11 and the second propagation member 12. For example, the first portion 12a deforms and its thickness decreases.
[0026] An opening OP is formed at the second end E2 of the plate member 13a. In the examples of Figures 4(a) and 4(b), the opening OP is a hole that penetrates the second end E2 in the thickness direction of the second end E2. The thickness direction of the second end E2 is parallel to the Z direction when the second end E2 is pressing against the second propagation member 12.
[0027] The fixing device 13 fixes the second propagation member 12 such that the second portion 12b protrudes in the Z direction beyond the first portion 12a and the second end E2. Specifically, the second portion 12b of the second propagation member 12 is inserted into the opening OP. As a result, when the first portion 12a is pressed against the fixing device 13, the second portion 12b protrudes in the Z direction beyond the second end E2 of the fixing device 13, as shown in Figures 4(b), 5(a), and 5(b). That is, as shown in Figure 4(b), the position of the second end E2 in the Z direction is between the position of the second surface S2 in the Z direction and the position of the third surface S3 in the Z direction.
[0028] By having the second portion 12b protrude more than the first portion 12a, the volume of the second portion 12b protruding from the second end E2 of the fixing device 13 can be increased. In other words, the volume of the second portion 12b that deforms to conform to the surface shape of the object can be increased. This makes it easier for the space between the first propagation member 11 and the object to be filled with the second propagation member 12.
[0029] Figures 6(a) and 6(b) are bottom views showing a part of the detection device according to the embodiment. As shown in Figure 6(a), the opening OP may extend in one direction in a slit shape. As shown in Figure 6(b), the plate member 13a may be composed of multiple wires W. The opening OP is formed at a position where no wires W are provided.
[0030] Figures 7(a) and 7(b) are a side view and a perspective view, respectively, of the detection device according to the embodiment. The fixing device 13 detachably secures the second propagation member 12 to the first propagation member 11. In other words, by using the fixing device 13, it is possible to switch between a state in which the second propagation member 12 is fixed to the first propagation member 11 and a state in which the second propagation member 12 is not fixed to the first propagation member 11.
[0031] For example, as shown in Figures 7(a) and 7(b), the plate member 13a can be removed from the housing 15h by loosening the fastener 13b. When the plate member 13a is removed from the housing 15h, the second end E2 moves away from the first propagation member 11. That is, the distance between the second end E2 and the first propagation member 11 increases. As a result, the pressure from the second end E2 on the second propagation member 12 is eliminated. The second propagation member 12 becomes removable. The second propagation member 12 can be removed and a new, different second propagation member 12 can be installed.
[0032] Alternatively, the plate member 13a may be a leaf spring. In this case, the second end E2 may be moved away from the first propagation member 11 by deforming the plate member 13a. This eliminates the pressure from the second end E2 on the second propagation member 12, making the second propagation member 12 removable.
[0033] Figures 8(a) to 8(d) are schematic side views of other fasteners. Figures 8(a) and 8(b) show the state in which the second propagation member 12 is fixed to the first propagation member 11. Figures 8(c) and 8(d) show the state in which the second propagation member 12 is not fixed to the first propagation member 11. Figures 8(b) and 8(d) show the view of the fixing device 13 from a viewpoint opposite to that of Figures 8(a) and 8(c), respectively.
[0034] As shown in Figures 8(a) to 8(d), a slit S may be provided in the plate member 13a. The slit S extends along the Z direction. When the fastener 13b is loosened, the plate member 13a becomes slidable along the direction in which the slit S extends. As the plate member 13a slides, as shown in Figures 8(c) and 8(d), the second end E2 of the plate member 13a moves away from the first propagation member 11. The pressure from the second end E2 on the second propagation member 12 is removed, and the second propagation member 12 becomes removable.
[0035] The advantages of the embodiment will be explained. When using ultrasound for inspection, it is preferable that there is no air between the detection device and the object. This improves the propagation of ultrasound and makes it easier to detect reflected waves. As a result, for example, the accuracy of the inspection is improved. Conventionally, to improve the propagation of ultrasound, a couplant solution with good acoustic impedance has been used. By applying the detection device to an object that has been pre-coated with the couplant solution, the space between the detection device and the object is filled with the couplant solution.
[0036] When using a couplant solution, it is necessary to wipe it off after inspection. If the couplant solution remains on the object, it may cause alteration (e.g., rust) or deterioration of the object's surface. However, wiping off the couplant solution is time-consuming. To shorten inspection time, there is a need for a technology that eliminates the need to apply and wipe off the couplant solution.
[0037] To address this issue, the detection device 10 according to this embodiment can utilize a second propagation member 12 instead of the couplant liquid. The second propagation member 12 is softer than the first propagation member 11 and can deform according to the surface shape of the object when the detection device 10 is in operation. As the second propagation member 12 deforms and fills the space between the first propagation member 11 and the object, the amount of air between the first propagation member 11 and the object can be reduced.
[0038] On the other hand, the second propagation member 12 is soft and therefore easily damaged. Also, foreign matter (such as metal powder) attached to the target can easily become embedded in the second propagation member 12. If damage or other abnormalities such as the attachment of foreign matter occur on the surface of the second propagation member 12, ultrasonic waves will not propagate easily between the second propagation member 12 and the target. The accuracy of ultrasonic wave detection will decrease. For this reason, it is preferable to replace the second propagation member 12 at an appropriate time. In the detection device 10, the second propagation member 12 is detachably fixed by a fixing device 13. Therefore, the second propagation member 12 can be easily replaced.
[0039] According to this embodiment, a detection device 10 can be provided that does not require a couplant liquid and allows for easy replacement of the second propagation member 12.
[0040] Figures 9(a) and 9(b) are side views showing the tip of the detection device according to the embodiment. Figure 9(a) shows the state of the second propagation member 12 before it contacts the target O. Figure 9(b) shows the state of the second propagation member 12 after it contacts the target O. As shown in Figures 9(a) and 9(b), the second portion 12b of the second propagation member 12 deforms and collapses upon contact with the target O. The thickness of the second portion 12b decreases.
[0041] The second part 12b deforms so that the fixing device 13 also comes into contact with the target O. The fixing device 13 is harder than the second propagation member 12 and has sufficient rigidity. Therefore, unlike the second propagation member 12, the fixing device 13 does not deform substantially even when it comes into contact with the target O. Also, the first part 12a, which is already held down by the fixing device 13, is less prone to deformation than the second part 12b. The contact of the fixing device 13 with the target O makes it easier to determine the distance D between the first propagation member 11 and the target O. This suppresses variations in the distance D due to the degree of deformation of the second propagation member 12.
[0042] The fixing device 13 has a first contact surface C1 that contacts the object O. The first contact surface C1 is oriented in the Z direction. For example, the second end E2 of the plate member 13a includes the first contact surface C1. In this example, the first contact surface C1 is composed of a single surface. The first contact surface C1 may be composed of multiple lines or multiple points. The first propagation member 11 has a second contact surface C2 that contacts the second propagation member 12. Preferably, the first contact surface C1 is parallel to the second contact surface C2. For example, the first contact surface C1 and the second contact surface C2 are parallel to the X and Y directions, which are the arrangement directions of the multiple detection elements described later.
[0043] When the second part 12b comes into contact with the target O and collapses, the first contact surface C1 of the fixing device 13 comes into contact with the target O. When the first contact surface C1 and the second contact surface C2 are parallel, the distance D is determined by the thickness T3 of the deformed first part 12a and the thickness T4 of the second end E2. For example, the distance D can be set to a predetermined value by pressing the detection device 10 toward the target O until the first contact surface C1 makes surface contact with the target O. Furthermore, the variation in distance D at each point in the XY plane can be reduced. This reduces the variation in reflected wave intensity for each exploration and reduces the variation in reflected wave intensity at each point in the XY plane.
[0044] Furthermore, "parallel" does not mean strictly parallel, but may include variations in the manufacturing process, for example. There may be a slight inclination between the first contact surface C1, the second contact surface C2, and the alignment direction, as long as it does not cause problems with detection. For example, if the angle between any two of the first contact surface C1, the second contact surface C2, and the alignment direction is greater than -5 degrees and less than +5 degrees, then those two can be considered substantially parallel.
[0045] The following sections will provide a detailed explanation of the structure of the detector 15, the detection system including the detection device 10, the inspection using ultrasound, and the determination of the integrity of the detection device 10.
[0046] (Detector structure) Figure 10 is a perspective view showing the tip of the detection device according to this embodiment. Inside the detector 15, an element array 15a is provided, as shown in Figure 10. The element array 15a includes a plurality of detection elements 15b. The detection elements 15b are, for example, transducers that emit ultrasonic waves with a frequency of 1 MHz to 100 MHz. The plurality of detection elements 15b are arranged along the X and Y directions.
[0047] Figure 10 shows the inspection of the joint 50. The joint 50 is made by spot welding a metal member 51 (first member) and a metal member 52 (second member) at a weld 53. At the weld 53, a solidified area 54 is formed where a portion of the metal member 51 and a portion of the metal member 52 have melted, mixed together, and solidified. Each detection element 15b transmits ultrasonic waves US towards the joint 50 and receives reflected waves RW from the joint 50.
[0048] As a more specific example, as shown in Figure 10, one detection element 15b transmits ultrasonic waves (US) toward the weld 53. A portion of the ultrasonic waves (US) is reflected from the upper or lower surface of the joint 50. Each of the multiple detection elements 15b receives (detects) this reflected wave (RW). Each detection element 15b sequentially transmits ultrasonic waves (US), and each reflected wave (RW) is detected by the multiple detection elements 15b. This provides a detection result of the reflected wave indicating the condition near the weld 53.
[0049] Figure 11 is a schematic diagram illustrating the three-dimensional detection results obtained from the exploration. In the exploration, as described above, each detection element 15b sequentially transmits ultrasonic waves, and each reflected wave is detected by multiple detection elements 15b. In the specific example shown in Figure 11, 64 detection elements 15b are provided in an 8x8 configuration. In this case, the 64 detection elements 15b sequentially transmit ultrasonic waves. One detection element 15b repeatedly detects the reflected wave 64 times. From one detection element 15b, the detection result of the reflected wave intensity distribution in the Z direction is output 64 times. The intensity distributions of the 64 reflected waves output from one detection element 15b are summed up. The summed intensity distribution becomes the intensity distribution at the coordinate where one detection element 15b is provided in one exploration. The same processing is performed for the detection results from each of the 64 detection elements 15b. As a result, the intensity distribution of the reflected wave in the Z direction is generated at each point in the XY plane. Figure 11 shows this three-dimensional intensity distribution as an image. In Figure 11, areas with high brightness correspond to areas with high ultrasonic wave intensity. Three-dimensional intensity distribution data is used for the inspection.
[0050] (Detection system) Figure 12 is a schematic diagram showing a detection system according to an embodiment. The detection system 1a comprises a detection device 10 and a processing device 90. In the detection system 1a, the detection device 10 has a shape that can be grasped by a person's hand. The inspector, holding the detection device 10, brings the second propagation member 12 at the tip of the detection device 10 into contact with the weld 53 and inspects the weld 53. At this time, the inspector presses the second propagation member 12 against the joint 50 so that the second propagation member 12 deforms to conform to the shape of the weld 53. For example, the inspector presses the second propagation member 12 against the joint 50 until the first contact surface C1 of the fixing device 13 comes into contact with the joint 50. With the detection device 10 in contact with the weld 53, the inspector performs the search.
[0051] The processing unit 90 controls the element array 15a. During the exploration, electrical signals are transmitted from the processing unit 90 to each detection element 15b, and ultrasonic waves are transmitted from each detection element 15b. Each detection element 15b also outputs an electrical signal in response to the detection of reflected waves. The magnitude of the electrical signal corresponds to the intensity of the reflected wave. Each detection element 15b transmits intensity data indicating the intensity of the detected reflected wave to the processing unit 90. The processing unit 90 performs various processes based on the intensity data.
[0052] Figure 13 is a schematic diagram representing another detection system according to the embodiment. The detection system 1b shown in Figure 13 includes a robot 20 and a processing unit 90. The robot 20 includes a manipulator 21 and a control unit 22.
[0053] In the example shown in Figure 13, the manipulator 21 is a vertical articulated type. The manipulator 21 may also be a horizontal articulated type or a parallel link type. The control device 22 controls the movement of the manipulator 21. The control device 22 is a so-called robot controller.
[0054] As shown in Figure 13, a detection device 10 and an imaging device 25 are provided at the tip of the manipulator 21. The imaging device 25 photographs the welded member and acquires an image. The processing device 90 extracts the weld marks from the obtained image and detects the position of the weld 53. The control device 22 operates the manipulator 21 so that the tip of the detection device 10 comes into contact with the weld 53.
[0055] (inspection) Figure 14 is a schematic diagram illustrating an inspection method using a detection device according to an embodiment. The detection results (intensity data) of the reflected waves obtained by the detection system 1a or 1b shown in Figure 12 or Figure 13 can be applied to the inspection of the welded joint 53. The processing device 90 may perform the following processing using the intensity data.
[0056] As shown in Figure 14(a), some of the ultrasonic waves US are reflected by the upper surface 51a of the metal member 51 or the upper surface 53a of the welded portion 53. Another portion of the ultrasonic waves US enters the joint 50 and is reflected by the lower surface 51b of the metal member 51 or the lower surface 53b of the welded portion 53.
[0057] The positions of the upper surface 51a, lower surface 51b, upper surface 53a, and lower surface 53b in the Z direction are different from each other. That is, the distances in the Z direction between these surfaces and the detection element 15b are different from each other. When the detection element 15b detects reflected waves from these surfaces, the peaks of the reflected wave intensity are detected. By calculating the time from the transmission of the ultrasonic wave US until each peak is detected, it is possible to determine which surface the ultrasonic wave US is being reflected from.
[0058] Figures 14(b) and 14(c) are graphs illustrating the relationship between the time elapsed after transmitting an ultrasonic wave (US) and the intensity of the reflected wave (RW). Here, the intensity of the reflected wave (RW) is expressed as an absolute value. The graph in Figure 14(b) illustrates the detection results of reflected waves (RW) from the upper surface 51a and lower surface 51b of the metal member 51. The graph in Figure 14(c) illustrates the detection results of reflected waves (RW) from the upper surface 53a and lower surface 53b of the welded joint 53.
[0059] In the graphs of Figures 14(b) and 14(c), peak Pe10 is based on the reflected wave RW from the first propagation member 11 and the second propagation member 12. Peak Pe11 is based on the reflected wave RW from the upper surface 51a. Peak Pe12 is based on the reflected wave RW from the lower surface 51b. The time from the transmission of the ultrasonic US until the detection of peaks Pe11 and Pe12 corresponds to the positions of the upper surface 51a and lower surface 51b of the metal member 51 in the Z direction, respectively.
[0060] Similarly, peak Pe13 is based on the reflected wave RW from the upper surface 53a. Peak Pe14 is based on the reflected wave RW from the lower surface 53b. The time from the transmission of the ultrasonic US until peaks Pe13 and Pe14 are detected corresponds to the positions of the upper surface 53a and lower surface 53b of the weld 53 in the Z direction, respectively.
[0061] The processing unit 90 determines whether a peak Pe12 exists in the reflected wave intensity distribution in the Z direction at each point within the first plane. The first plane is parallel to the X and Y directions. As a specific example, the processing unit 90 detects peaks in a predetermined range in the Z direction where a peak Pe12 can be detected. The predetermined range is set in advance according to the length of the first propagation member 11 in the Z direction, the distance between the first propagation member 11 and the metal member 51, etc. The processing unit 90 compares the intensity of the peak with a predetermined threshold. When the peak exceeds the threshold, the processing unit 90 determines that the peak is a peak Pe12. The presence of a peak Pe12 indicates that the lower surface 51b exists at the location of the peak and that the metal members 51 and 52 are not joined. The processing unit 90 determines that the point where a peak Pe12 is detected is not joined. The processing unit 90 sequentially determines whether each point within the first plane is joined. The set of points determined to be joined corresponds to the welded joint 53. For example, the inspection checks whether a weld 53 has been formed. The inspection also checks the diameter of the weld 53 and whether the diameter is sufficient.
[0062] The intensity of the reflected wave may be expressed in any manner. For example, the reflected wave intensity output from the detection element 15b includes positive and negative values depending on the phase. Various processing may be performed based on the reflected wave intensity, which includes both positive and negative values. The reflected wave intensity, which includes both positive and negative values, may be converted to an absolute value. The average value of the reflected wave intensity may be subtracted from the reflected wave intensity at each time point. Alternatively, a weighted average value, a weighted moving average value, etc., of the reflected wave intensity may be subtracted from the reflected wave intensity at each time point. Even when using the results of these processing steps applied to the reflected wave intensity, the various processing described in this application can still be performed.
[0063] (Assessment of health) The processing device 90 may also determine the integrity of the detection device 10. Specifically, the processing device 90 will determine as appropriate whether the reflected wave is properly detected. The reflected wave will not be properly detected if the second propagation member 12 is not properly fixed by the fixing device 13, or if there are scratches or foreign matter on the surface (second surface S2) of the second propagation member 12. An inappropriate detection result of the reflected wave can lead to an incorrect inspection result.
[0064] Figure 15 is a schematic diagram showing a part of the detection device according to the embodiment. When the detection device 10 is brought into contact with the object to be inspected, foreign matter F may adhere to the second propagation member 12, as shown in Figure 15. Foreign matter F is, for example, fine particles of metal. When foreign matter F adheres to the second propagation member 12, the ultrasonic waves US are scattered by the foreign matter F on the surface of the second propagation member 12. The reflected waves RW that travel toward the element array 15a decrease, and the intensity of the reflected waves detected by the element array 15a decreases. In addition to foreign matter F, if there are scratches on the surface, the ultrasonic waves US will also be scattered by those scratches. If there are abnormalities such as foreign matter or scratches on the surface, the intensity of the detected reflected waves decreases. If the detection result obtained at this time is used for inspecting the welded part 53, an appropriate inspection result regarding the welded part 53 cannot be obtained. In determining soundness, the processing device 90 determines whether there are any abnormalities on the surface of the second propagation member 12.
[0065] Figure 16 is a flowchart illustrating the method for determining health. The detection device 10 performs a scan (step St1). Through the scan, multiple first intensity data are acquired by multiple detection elements 15b. The scan may be performed on the object to be inspected or on a sample (test piece) for determining its integrity. The processing device 90 receives the multiple first intensity data. The processing device 90 generates second intensity data using at least a portion of the multiple first intensity data (step St2). The second intensity data is the sum of at least a portion of the multiple intensity data. The second intensity data may be the average or weighted average of at least a portion of the multiple intensity data.
[0066] Figure 17 is a schematic diagram illustrating the second intensity data. In Figure 17, the horizontal axis represents the elapsed time after the transmission of the ultrasound. The elapsed time corresponds to the position in the Z direction. The vertical axis represents the intensity of the reflected wave at each time point. In Figure 17, the intensity is expressed as an absolute value.
[0067] As a specific example, each time one detection element 15b, as shown in Figure 10, transmits an ultrasonic wave (US), 64 detection elements 15b detect the reflected wave (RW). When each of the 64 detection elements 15b transmits an ultrasonic wave (US), a total of 4096 detection results (first intensity data) are obtained. The processing unit 90 sums the intensity distributions in the Z direction of the 4096 first intensity data. This generates second intensity data.
[0068] The processing unit 90 detects the intensity of a portion of the reflected wave in the second intensity data (step St3). For example, as shown in Figure 17, a range Ra in the Z direction in which the reflected wave from the second surface S2 can be detected is set in advance. The processing unit 90 compares the intensity of the reflected wave in range Ra with a preset threshold (step St4). If the intensity is greater than or equal to the threshold, the processing unit 90 determines that the second propagation member 12 is normal. If the intensity is less than the threshold, the processing unit 90 determines that the second propagation member 12 is abnormal.
[0069] As a specific example, the processing unit 90 detects the peak Pe with the highest intensity within the range Ra, as shown in Figure 17. The processing unit 90 compares the intensity of peak Pe with a threshold Th. When the intensity of peak Pe is equal to or greater than the threshold Th, the processing unit 90 determines that the second propagation member 12 is normal. When the intensity of peak Pe is less than the threshold Th, the processing unit 90 determines that the second propagation member 12 is abnormal. In addition to peak intensity, the processing unit 90 may also determine the state of the second propagation member 12 by comparing the cumulative or average value of the intensity within the range Ra with the threshold Th.
[0070] If the second propagation member 12 is determined to be abnormal, the processing unit 90 transmits first information (step St5). The first information indicates that the second propagation member 12 is abnormal. By transmitting the first information, the inspector can be prompted to replace the second propagation member 12 or inspect the detection device 10. After transmitting the first information or when the second propagation member 12 is normal, the processing unit 90 terminates the determination.
[0071] The specific details of the processing in the determination can be changed as appropriate. For example, when the second propagation member 12 is determined to be normal, the processing device 90 may transmit information indicating that there is no abnormality in the second propagation member 12. Also, the second intensity data may be generated using only a portion of the multiple first intensity data. For example, if the foreign matter F mainly adheres to the outer periphery of the second surface S2, the second intensity data may be generated using the first intensity data from the detection element 15b located on the outer periphery of the element array 15a.
[0072] The range Ra is set based on the length of the first propagation member 11 in the Z direction and the distance between the first propagation member 11 and the joint 50. The threshold Th is set based on the intensity of the reflected wave from the second surface S2 when the second propagation member 12 is in a normal state and the variability of the detected reflected wave intensity. As shown in Figure 9, once the distance D between the first propagation member 11 and the target O is determined, the peak of the reflected wave from the second surface S2 is more likely to appear in the range Ra. This improves the accuracy of the health determination.
[0073] When the first information is transmitted from the processing unit 90, the user replaces the second propagation member 12. The detection system 1a or 1b may perform a health check after the second propagation member 12 has been replaced and before the search is performed. This allows the system to check whether there is any abnormality in the replaced second propagation member 12. The processing unit 90 may perform a health check at a predetermined time, after a predetermined period has elapsed since the last check, or when the search is performed.
[0074] The second propagation member 12 may be automatically replaced. The following describes the units for automatically replacing the second propagation member 12.
[0075] Figure 18 is a schematic diagram showing each unit for replacing the second propagation member 12. The detection system 1a or 1b includes a release unit 31, an extrusion unit 32, and a transport unit 33, as shown in Figure 18.
[0076] The release unit 31 includes a bar 31a, a drive unit 31x, and a drive unit 31y. The bar 31a is a member that extends in a direction intersecting the Z direction. The drive unit 31x moves the bar 31a in the X direction. The drive unit 31y moves the bar 31a and the drive unit 31x in the Y direction along the guide 31g. The bar 31a is hooked onto the plate member 13a and deforms the plate member 13a. This releases the fixing of the second propagation member 12 by the fixing device 13. The specific shape of the bar 31a is arbitrary, as long as it extends in one direction. For example, the tip of the bar 31a may be curved and hook-shaped.
[0077] The extrusion unit 32 includes a bar 32a, an extrusion section 32b, a drive section 32x, and a drive section 32z. The bar 32a is a member extending in a direction intersecting the Z direction. The extrusion section 32b is attached to the end of the bar 32a via the drive section 32z. The drive section 32z moves the extrusion section 32b in the Z direction. The drive section 32x moves the bar 32a in the X direction.
[0078] With the extrusion portion 32b positioned below the second propagation member 12 which is placed on the second end E2, the extrusion portion 32b moves in the Z direction. The extrusion portion 32b comes into contact with the second propagation member 12. The second propagation member 12 is pushed out by the extrusion portion 32b and lifts off the second end E2. As a result, the second propagation member 12 becomes removable from the second end E2.
[0079] The transport unit 33 includes a holding part 33a, a drive part 33x, and a drive part 33z. The holding part 33a extends in a direction intersecting the Z direction. The tip of the holding part 33a has a structure capable of holding the second propagation member 12. In the example shown in Figure 18, a claw is provided at the tip of the holding part 33a. The holding part 33a holds the second propagation member 12 by hooking it onto the claw. An air intake port is provided at the tip of the holding part 33a, and the second propagation member 12 may also be held by vacuum suction.
[0080] The drive unit 33x moves the holding unit 33a in the X direction. The drive unit 33z moves the drive unit 33x and the holding unit 33a in the Z direction. The transport unit 33 holds and transports the second propagation member 12. The transport unit 33 transports one new second propagation member 12 from the placement location where a new second propagation member 12 is placed to the second end E2.
[0081] For example, the drive units 31x, 32x, and 33x include air cylinders. The drive units 31y, 32z, and 33z include motors.
[0082] For example, as shown in Figure 18, the release unit 31, the extrusion unit 32, and the transport unit 33 may be configured as a single exchange device 30. Alternatively, the release unit 31, the extrusion unit 32, and the transport unit 33 may each be provided independently and separately. In this case, the movement directions of the bars 31a, 32a, and 33a may be different from each other.
[0083] Figures 19(a) to 19(d) and 20(a) to 20(d) are schematic diagrams illustrating the operation of each unit for replacing the second propagation member. As shown in Figure 19(a), the bar 31a of the release unit 31 is inserted between the first propagation member 11 and the plate member 13a. As shown in Figure 19(b), the release unit 31 moves the bar 31a away from the first propagation member 11. This deforms the plate member 13a and releases the fixing of the second propagation member 12. The second propagation member 12 moves away from the first propagation member 11. The extrusion unit 32 positions the tip of the extrusion section 32b below the second end E2 and raises it. As a result, as shown in Figure 19(c), the second propagation member 12 is pushed out from the second end E2.
[0084] As shown in Figure 19(d), the transport unit 33 holds the second portion 12b by clamping it with the holding portion 33a, thereby holding the extruded second propagation member 12. When the opening OP of the second end E2 is slit-shaped, as shown in Figure 6(a), the amount of the second propagation member 12 extruded by the extrusion unit 32 may be smaller than that shown in Figure 19(b). This is because the second propagation member 12 can be removed from the second end E2 by sliding the second propagation member 12 along the direction in which the opening OP extends.
[0085] As shown in Figure 20(a), the transport unit 33 transports the held second propagation member 12 to another location. As shown in Figure 20(b), the transport unit 33 transports a new second propagation member 12 onto the second end E2. The new second propagation member 12 is placed on the extrusion unit 32b. As shown in Figure 20(c), the extrusion unit 32 lowers the extrusion unit 32b and places the second propagation member 12 on the second end E2. As shown in Figure 20(d), the release unit 31 brings the bar 31a closer to the first propagation member 11 and releases the deformation of the plate member 13a. Through these operations, the second propagation member 12 is replaced.
[0086] The processing unit 90 controls the operation of the release unit 31, the extrusion unit 32, and the transport unit 33. For example, if the processing unit 90 determines that the second propagation member 12 is abnormal, it causes each unit to replace the second propagation member 12. This makes it possible to obtain more appropriate reflected wave detection results.
[0087] Figure 21 is a schematic diagram representing the hardware configuration. As the processing unit 90, for example, the computer 90a shown in Figure 21 can be used. The computer 90a includes a CPU 91, ROM 92, RAM 93, storage device 94, input interface 95, output interface 96, and communication interface 97.
[0088] ROM92 stores programs that control the operation of computer 90a. ROM92 contains the programs necessary for computer 90a to perform each of the processes described above. RAM93 functions as a memory area where the programs stored in ROM92 are deployed.
[0089] The CPU 91 includes processing circuits. The CPU 91 uses the RAM 93 as work memory and executes programs stored in at least one of the ROM 92 or the storage device 94. During program execution, the CPU 91 controls each component via the system bus 98 and performs various processes.
[0090] The memory device 94 stores data necessary for program execution and data obtained through program execution.
[0091] The input interface (I / F) 95 connects the processing unit 90 and the input device 95a. The input I / F 95 is, for example, a serial bus interface such as USB. The CPU 91 can read various data from the input device 95a via the input I / F 95.
[0092] The output interface (I / F) 96 connects the processing unit 90 and the output device 96a. The output I / F 96 is a video output interface such as a Digital Visual Interface (DVI) or a High-Definition Multimedia Interface (HDMI®). The CPU 91 can transmit data to the output device 96a via the output I / F 96 and display an image on the output device 96a.
[0093] The communication interface (I / F) 97 connects the processing unit 90 to a server 97a located outside the processing unit 90. The communication I / F 97 is, for example, a network card such as a LAN card. The CPU 91 can read various data from the server 97a via the communication I / F 97.
[0094] The storage device 94 includes one or more selected from Hard Disk Drives (HDDs) and Solid State Drives (SSDs). The input device 95a includes one or more selected from a mouse, keyboard, microphone (voice input), and touchpad. The output device 96a includes one or more selected from a monitor and a projector. Devices that have the functions of both input device 95a and output device 96a, such as a touch panel, may also be used.
[0095] The processing of the various data described above may be recorded as a program that can be executed by a computer on a magnetic disk (flexible disk and hard disk, etc.), an optical disk (CD-ROM, CD-R, CD-RW, DVD-ROM, DVD±R, DVD±RW, etc.), a semiconductor memory, or another non-transitory computer-readable storage medium.
[0096] For example, information recorded on a recording medium can be read by a computer (or embedded system). The recording format (storage format) of the recording medium is arbitrary. For example, a computer reads a program from the recording medium and has the CPU execute the instructions written in the program based on this program. In a computer, program acquisition (or reading) may be performed via a network.
[0097] According to the detection device 10, detection system 1a, or detection system 1b described above, the couplant fluid can be eliminated and the second propagation member 12 can be easily replaced. By using the second propagation member 12 or fixing device 13 according to the embodiment, the couplant fluid is not required. The second propagation member 12 according to the embodiment is easily replaceable. Furthermore, by using a program that causes the computer to replace the second propagation member 12, more appropriate detection results can be obtained.
[0098] Although several embodiments of the present invention have been illustrated above, these embodiments are presented as examples only and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims of the invention and its equivalents. Furthermore, the embodiments described above can be implemented in combination with each other. [Explanation of symbols]
[0099] 1a,1b: Detection system, 10: Detection device, 11: First propagation member, 12: Second propagation member, 12a: First part, 12b: Second part, 13: Fixing device, 13a: Plate member, 13b: Fastener, 15: Detector, 15a: Element array, 15b: Detection element, 15h: Housing, 20: Robot, 21: Manipulator, 22: Control device, 25: Imaging device, 30: Exchange device, 31: Release unit, 31a: Bar, 31g: Guide, 31x: Drive unit, 31y: Drive unit, 32: Extrusion unit, 32a: Bar, 32b: Extrusion unit, 32x: Drive unit, 32z: Drive unit, 33: Conveying unit, 33a: Holding unit, 33x: Drive unit, 33z: Drive unit, 50: Joint, 51: Metal member, 51a: Top surface, 51b: Bottom surface, 52: Metal member, 53: Welded part, 53a: Top surface, 53b: Bottom surface, 54: Solidification part, 90: Processing unit, 90a: Computer, 91: CPU, 92: ROM, 93: RAM, 94: Storage device, 95: Input interface, 95a: Input device, 96: Output interface, 96a: Output device, 97: Communication interface, 97a: Server, 98: System bus, 223: Propagation unit, C1: First contact surface, C2: Second contact surface, D: Distance, E1: First end, E2: Second end, F: Foreign matter, H: Hole, O: Target, Pe: Peak, Pe10~Pe14: Peak, RW: Reflected wave, Ra: Range, S: Slit, S1: First surface, S2: Second surface, S3: Third surface, S4: Fourth surface, T1~T4: Thickness, Th: Threshold, US: Ultrasound
Claims
1. A detector comprising multiple detection elements configured to transmit ultrasonic waves toward a target and detect reflected waves, A first propagation member attached to the detector and configured to propagate the ultrasonic waves, A second propagation member through which the ultrasonic waves propagate and which is softer than the first propagation member, A fixing device configured to detachably fix the second propagation member to the first propagation member, Equipped with, A portion of the second propagation member protrudes beyond the fixing device in a first direction from the first propagation member toward the second propagation member, The fixing device includes a first contact surface configured to contact the object, The first propagation member includes a second contact surface configured to contact the second propagation member when the second propagation member is fixed by the fastener, A detection device wherein, when a portion of the second propagation member comes into contact with the object, the portion of the second propagation member deforms to conform to the surface shape of the object, reducing its thickness in the first direction, so that the first contact surface comes into contact with the surface of the object in a state where it is substantially parallel to the second contact surface.
2. A detector comprising a plurality of detection elements configured to transmit ultrasonic waves toward an object and detect reflected waves, A first propagation member attached to the detector and configured to propagate the ultrasonic waves, A second propagation member through which the ultrasonic waves propagate, which is softer than the first propagation member, and whose hardness, as measured by an Asker rubber hardness tester type F, is greater than 40 and less than 60, A fixing device configured to detachably fix the second propagation member to the first propagation member, Equipped with, A portion of the second propagation member protrudes beyond the fixing device in a first direction from the first propagation member toward the second propagation member, The fixing device includes a first contact surface configured to contact the object, A detection device wherein, when a portion of the second propagation member comes into contact with the object, the portion of the second propagation member deforms to conform to the surface shape of the object, reducing its thickness in the first direction, thereby causing the first contact surface to come into contact with the surface of the object.
3. The first propagation member includes a second contact surface configured to contact the second propagation member, The detection device according to claim 2, wherein the first contact surface contacts the surface of the target in a manner substantially parallel to the second contact surface.
4. The second propagation member is The first part is held in place by the aforementioned fixing device, A second portion surrounded by the first portion, protruding beyond the first portion and in contact with the object, Includes, The detection device according to any one of claims 1 to 3, wherein the second part deforms to conform to the surface shape of the object when it comes into contact with the object, thereby reducing its thickness.
5. The detector includes a housing that houses the plurality of detection elements, The detection device according to any one of claims 1 to 4, wherein the fixing device includes a pressing member, one end of which is fixable to the housing and the other end of which presses the second propagation member toward the first propagation member.
6. The detection device according to claim 5, wherein the fixing device is detachable from the housing.
7. The detection device according to claim 5 or 6, wherein the fixing device can move in the first direction relative to the first propagation member to increase the distance between the pressing member and the first propagation member.
8. The detection device according to claim 5 or 6, wherein the fixing device can increase the distance between the pressing member and the first propagation member by rotating the fixing device around one end of the pressing member.
9. The detection device according to any one of claims 1 to 8, wherein the acoustic impedance of the second propagation member is greater than 1.0 × 10⁵ (Pa·s / m) and less than 1.0 × 10⁸ (Pa·s / m).
10. The detection device according to any one of claims 1 to 9, wherein the target is a welded joint formed by welding a plurality of members.
11. A detection device according to any one of claims 1 to 10, A processing device configured to determine an abnormality in the second propagation member based on intensity data indicating the intensity of the reflected wave detected by the plurality of detection elements, A detection system equipped with [the following features].
12. A detection device according to any one of claims 1 to 10, A robot including a manipulator, The detection device is a detection system provided at the tip of the manipulator.
13. The detection system according to claim 11 or 12, further comprising an exchange device configured to remove the second propagation member from the fixing device and to supply another second propagation member.
14. A release unit configured to release the fixing of the second propagation member by the fixing device, An extrusion unit configured to push out the second propagation member placed on the fixing device, A transport unit configured to transport the second propagation member, The detection system according to claim 11 or 12, further comprising the above.
15. A detector including a plurality of detection elements that transmit ultrasonic waves and detect reflected waves, A first propagation member attached to the detector, through which the ultrasonic waves propagate, and A second propagation member is attached to the first propagation member, through which the ultrasonic waves propagate, and is softer than the first propagation member. A detection device including, A replacement device configured to replace the second propagation member, A processing device configured to determine an abnormality in the second propagation member based on intensity data indicating the intensity of the reflected wave detected by the plurality of detection elements, A detection system equipped with [the following features].
16. The detection system according to claim 15, wherein the detection device includes a fixing device configured to detachably fix the second propagation member to the first propagation member.
17. A release unit configured to release the fixing of the second propagation member by the fixing device, An extrusion unit configured to push out the second propagation member placed on the fixing device, A transport unit configured to transport the second propagation member, The detection system according to claim 16, further comprising the above.