CN103969336A - Automatic detecting and imaging method of hyper-acoustic phased array of weld joint in complex space - Google Patents
Automatic detecting and imaging method of hyper-acoustic phased array of weld joint in complex space Download PDFInfo
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Abstract
The invention relates to an automatic detecting and imaging method of a hyper-acoustic phased array of a weld joint in a complex space. The automatic detecting and imaging method comprises the following steps: 11) determining a scanning trace according to a three-dimensional CAD model of the complex space; 12) clamping a hyper-acoustic phased array transducer with a six-shaft manipulator to track and scan the weld joint along the determined scanning trace, so as to obtain detected data and a detected result of the weld joint, and displaying the detecting result of the weld joint in a three-dimensional weld joint figure. As the manipulator is used in the weld joint detection, high-efficient automatic detection is realized; the detected result is displayed visually into the three-dimensional geometric figure of a workpiece by applying the computer three-dimensional visualization technology, so that detectors can position and quantify defects conveniently.
Description
Technical field
The present invention relates to ultrasound examination, automation control area, be specially a kind of ultrasonic phase array robotization detection and formation method of complex space weld seam.
Background technology
At present, the ultrasonic detection method of curve surface work pieces is mainly pulse reflection method and the pulse through transmission technique of utilizing conventional transducer.Development Techniques difficulty for the ultrasonic wave detecting system of curve surface work pieces is larger, and curve surface work pieces detection system needs multi-shaft interlocked scanning and searching mechanism, therefore needs the combination of the technology such as Robotics, automatic control technology, CAD/CAM and ultrasonic detecting technology.Simultaneously aspect flaw indication processing, testing result demonstration, this future development showing towards defect automatic ration, Classifcation of flaws and three-D ultrasonic C image.On the other hand, due to the development of digital and electronic and DSP technology, make accurate delay more and more convenient, therefore in recent years, ultrasonic phased array technology development particularly rapid, this technology, compared with traditional handicraft UT (Ultrasonic Testing) technology, has a lot of advantages, such as detection speed is fast, defect location is accurate, and detection sensitivity is high, and testing result is directly perceived, can realize real-time demonstration etc., it is also a development trend that this technology is applied in curve surface work pieces Non-Destructive Testing.Introduce respectively the application in Non-Destructive Testing of Robotics and ultrasonic phased array technology below.
Robotics be combine computing machine, robot topology, kybernetics, mechanics, information and sensing technology, artificial intelligence, bionics, mechanics, electronics and microelectronics and systems engineering etc. multidisciplinary and form new and high technology.Robot is that one has automatic control operation and locomotive function, can complete the programmable operations machine of various operations, is generally made up of topworks, drive unit, pick-up unit and control system etc.Adopt widely in the world robot to carry out testing.As magnetically adsorbed wall-climbing robot, simple in structure, action flexibly, can complete the Non-Destructive Testing task of some storage tanks and hull surface.As spider-shaped climbing robot, self assemble dozens of detection probe, can scan detection to the point of effective range on pressure vessel.As creepage robot, the thrust that can form by gas-liquid pressure differential in pipeline is advanced, and can detect oil-gas pipeline corrosion situation, and its accuracy of detection can reach 1mm.Domestic aspect, because the industrial robot of China is just started to walk since " the Seventh Five-Year Plan " the tackling of key scientific and technical problems eighties, the design and manufacturing technology of robot manipulator, control system hardware and software designing technique, kinematics and trajectory planning technology cannot not take the time longly, can only production department divide robot key components, the level of Industrial Robot Technology and engineering application thereof and external than also having certain distance, in Ultrasonic NDT field, a lot of research institutions are also carrying out exploration and the development work of robot automation's ultrasonic testing system, but at present Ultrasonic NDT field to the application of mechanical arm still all in reduced levels.
Ultrasonic phased array technology has developed more than 20 year, and its key concept comes from phased array technology.In phased-array radar, a large amount of sub antenna unit is arranged by definite shape, by controlling time delay and the amplitude of each subelement emitting electromagnetic wave bundle, just can within the scope of certain space, synthesize the radar beam of flexible focusing scanning.Ultrasonic phased array technology is in the early stage of development, because the reason such as complicacy and cost height of wave propagation in its system complexity, solid makes its application in industrial nondestructive testing limited.But along with the fast development of electronic technology and computer technology, ultrasonic phased array technology is applied to industrial nondestructive testing gradually.In recent years, digital and electronic and DSP technology were greatly developed, and made accurate delay more and more convenient, and this makes the particularly rapid of ultrasonic phased array technology development.
Two technological incorporation in Non-Destructive Testing of Robotics and ultrasonic phase array detection technique were carried out to curved surface weld defect afterwards to be detected and will bring huge progress.
Given this present invention is proposed.
Summary of the invention
Object of the present invention is for overcoming the deficiencies in the prior art, a kind of ultrasonic phase array robotization detection and formation method of complex space weld seam are provided, realize efficient robotization and detect, and show three-dimensional picture, make that testing staff is convenient, the location of carrying out intuitively weld defect and quantitatively.
In order to realize this object, the present invention adopts following technical scheme: a kind of ultrasonic phase array robotization detection and formation method of complex space weld seam, and step is:
11) determine track while scan according to the three-dimensional CAD model of complex space;
12) utilize six axis robot clamping ultrasonic phased array transducer along definite track while scan butt welded seam spotting scaming, obtain the detection data of weld seam, obtain weld seam detection result, and weld seam detection result is presented in three-dimensional weld seam figure.
Step 11) if in the three-dimensional CAD model of complex space known, directly this three-dimensional CAD model is inputed to main control computer, main control computer obtains the position of weld seam to three-dimensional CAD model analysis, determine track while scan.
Step 11) if in three-dimensional CAD model the unknown of complex space, the curved surface of complex space is measured, obtained surface data, then curve reestablishing obtains its three-dimensional CAD model, the position that the three-dimensional CAD model analysis obtaining is obtained to weld seam, obtains track while scan.
Step 12) described in weld seam detection result be the ultrasonic C-scan Image that can show weld seam inherent vice, it is corresponding with the three-dimensional structure of three-dimensional geometrical structure in three-dimensional CAD model and weld seam that described three-dimensional weld seam figure is ultrasonic C-scan Image, the three-dimensional weld seam model image showing by Computerized three-dimensional visualization technique.
Step 11) and step 12) between the process of a man-machine interaction can also be set: main control computer is shown to testing staff after obtaining track while scan, testing staff judges that whether scanning result is correct, directly enter step 12 if correctly need not revise), after track while scan being modified if incorrect, enter step 12); Or testing staff according to actual needs situation determines whether to modify.
Described track while scan is the movement locus of position, the motor point composition of six axis robot, and what in some position, carry is the welding seam position information on complex space surface.
Described six axis robot is six axle chain type mechanical arms.
Three-dimensional CAD model and track while scan corresponding to three-dimensional CAD model that the three-dimensional CAD model of input or curve reestablishing are obtained store in computing machine, while having the weld seam detection of same model next time, directly transfer track while scan, and butt welded seam scans.
Adopt after technical solutions according to the invention, bring following beneficial effect:
1, mechanical arm is introduced in weld seam detection, realized efficient robotization and detect.
2, adopt six axle chain type mechanical arms, dirigibility is good, and cost is low, and precision is high.
3, appliance computer three-dimensional visualization technique, allows testing result be shown to more intuitively in workpiece three-dimensional geometric shapes, facilitates testing staff to locate and quantitative defect.
4, the process that increases man-machine interaction, can detect as required.
5, three-dimensional CAD model and track while scan corresponding to three-dimensional CAD model are stored in computing machine, directly call while use next time, can simplify step, saves time.
Below in conjunction with accompanying drawing, the specific embodiment of the present invention is described in further detail.
Brief description of the drawings
Fig. 1: detection system principle schematic of the present invention
Fig. 2: detection system structural representation of the present invention
Fig. 3: ultrasonic C-scan Image of the present invention
Fig. 4: three-dimensional weld seam model image of the present invention
Fig. 5: the three-dimensional weld seam model image of further embodiment of this invention
Wherein: 1, six axis robot, 2, ultrasonic phased array transducer, 3, workpiece, 4, main control computer.
Embodiment
Ultrasonic phase array robotization detection and the formation method of a kind of complex space weld seam of the present invention, step is:
11) determine track while scan according to the three-dimensional CAD model of complex space;
12) utilize six axis robot 1 to clamp ultrasonic phased array transducer 2 along definite track while scan butt welded seam 5 spotting scamings, obtain the detection data of weld seam 5, obtain weld seam detection result, and weld seam detection result is presented in three-dimensional weld seam figure.Mechanical arm is introduced in weld seam detection, realized efficient robotization and detect.Appliance computer three-dimensional visualization technique, allows testing result be shown to more intuitively in workpiece three-dimensional geometric shapes, facilitates testing staff to locate and quantitative defect, and testing staff can observe the defect situation of weld seam very intuitively.
Above-mentioned steps 11) if in the three-dimensional CAD model of complex space known, directly this three-dimensional CAD model is inputed to main control computer 4, main control computer 4 obtains the position of weld seam to three-dimensional CAD model analysis, determine track while scan.If three-dimensional CAD model the unknown of complex space, measures the curved surface of complex space, obtain surface data, then curve reestablishing obtains its three-dimensional CAD model, the three-dimensional CAD model analysis obtaining is obtained to the position of weld seam, obtains track while scan.Therefore no matter whether the model of complex space is known, method of the present invention all can realize the detection to its weld seam.
Above-mentioned steps 12) described in weld seam detection result be the ultrasonic C-scan Image that can show weld seam inherent vice, it is corresponding with the three-dimensional structure of three-dimensional geometrical structure in three-dimensional CAD model and weld seam that described three-dimensional weld seam figure is ultrasonic C-scan Image, the three-dimensional weld seam model image showing by Computerized three-dimensional visualization technique.Compared with the signal or planar graph that showed, testing staff can observe the defect situation of weld seam very intuitively in the past.
Above-mentioned steps 11) and step 12) between the process of a man-machine interaction can also be set: main control computer 4 is shown to testing staff after obtaining track while scan, testing staff judges that whether scanning result is correct, directly enter step 12 if correctly need not revise), after track while scan being modified if incorrect, enter step 12); Or testing staff according to actual needs situation determines whether to modify.Increase human-computer interaction function, make operation more flexible, if when sometimes track while scan has deviation, testing staff can also finely tune, when sometimes the weld seam at some position is without detection, can be manually deleted, or can be detected according to testing staff's actual needs.
Described track while scan is the movement locus of position, the motor point composition of six axis robot, and what in some position, carry is the welding seam position information on complex space surface.
Described six axis robot 1 is six axle chain type mechanical arms (consulting Fig. 2), and six axle chain type mechanical arm dirigibilities are good, conveniently complex space surface is scanned, and cost is low, and precision is high.
The three-dimensional CAD model and track while scan corresponding to three-dimensional CAD model that while having new weld seam detection, the three-dimensional CAD model of input or curve reestablishing are obtained store in computing machine at every turn, while having the weld seam detection of same model next time, directly transfer track while scan, butt welded seam scans.If while having so a collection of identical workpiece to carry out weld seam detection, only need input for the first time three-dimensional CAD model or carry out curve reestablishing and obtain three-dimensional CAD model, analyze and generate track while scan, later this track while scan of direct use scans, so greatly simplify detecting step, save detection time
As shown in Figure 1 and Figure 2, in the ultrasonic phase array robotization detection of a kind of complex space weld seam of the present invention and formation method, adopt phased array automated detection system, this system comprises six axis robot 1, main control computer 4 and display section, excite and reception & disposal part, and ultrasonic phased array transducer 2.Six axis robot, according to the shape difference of workpiece 3, is responsible for driving ultrasonic phased array transducer 2 to complete different scanning paths; The function of main control computer and display section is: user arranges testee correlation parameter by man-machine software interface according to concrete Detection task, by bus, configuration information is transferred to the electronic installation that signal excitation receives and processes, in the time that detection information exchange is crossed bus transfer to main control computer, detection information visualization is exported to user simultaneously; Signal excitation receiving processing system task has been the overall process of the transmitting of phased ultrasound signal, reception, processing.
As shown in Figure 3, the ultrasonic phase array robotization detection of a kind of complex space weld seam of the present invention and formation method measurement V-type weld seam sidewall do not merge the C scan image obtaining.The testing result of current ultrasonic phase array can only be a two-dimentional plane scanning result images, is just difficult to be mapped like this with the result on actual inclined-plane.The present invention is by three-dimensional visualization technique and Ultrasonic C-Scan result in conjunction with computing machine, ultrasonic C-scan Image is corresponding with the three-dimensional structure of three-dimensional geometrical structure in three-dimensional CAD model and weld seam, the three-dimensional weld seam model image showing by Computerized three-dimensional visualization technique.Show the Ultrasonic C-Scan result of to be detected.
As shown in Figure 4, Figure 5, three-dimensional weld seam model image is the weld seam three-dimensional model generating in conjunction with ultrasonic C-scan Image and the Computerized three-dimensional visualization technique of testing result.Three-dimensional weld seam solid images is the weld seam sidewall image that fusion detection result is not carried out corresponding demonstration with workpiece three-dimensional geometrical structure.
Phased array ultrasonic detection system is made up of phased array probe, data acquisition unit, pulse generation unit, electric-motor drive unit, industrial computer, display etc. conventionally.System is moved special function software on windows platform, and the scanning, in real time demonstration and the result that complete tested workpiece are passed judgment on.Described phased array probe is phase array transducer.
Wherein, ultrasonic phased array transducer is made up of multiple piezoelectric crystals, and separate piezoelectric chip is wrapped in a standard probe box.Its lead-in wire cable rolling is conventionally tied up and is formed by the fine concentric cable well shielding, and is connected with instrument by commercial hyperchannel connector.Each piezoelectric crystal is called an array element, control the time delay of each array element excitation (or reception) pulse in transducer by pulse generation unit, data acquisition unit etc., phase relation when changing each array element transmitting (or reception) sound wave and arriving certain point in (or from) object, realizes dynamic focusing and (or) the deflection of wave beam.
In addition, function software is also an extremely important ingredient in phased array ultrasonic detection system.Because can phased-array technique provide considerable application adaptability to depend on the multifunctionality of software.Application software wants to manage forcefully the collection of ultrasound detection signal.Focus on rule except processing to calculate, require software to there is powerful code capacity, all data and store, show result and good data-handling capacity etc.
Phased array ultrasonic detection technology detects and has obvious technical advantage with respect to conventional single Probe Ultrasonic Searching:
Speed: in phased array probe, selecteed wafer alternately excites, make electron scanning (E-scanning) can realize high precision, profile scanning (fan-shaped S scanning), A sweep, rolling B scanning and L (linearity) scanning fast, even can realize C scanning, covering member very rapidly, more faster than routine list probe mechanical system, better covering is provided in same time.Due to can all detected parts of one-time detection, greatly shorten detection time, alleviate testing staff's labour intensity, improve accuracy of detection and reliability.
Adaptability: setting can change within a few minutes, can adapt to very multimember size and geometric configuration and change, and can be suitable for complex-shaped member inspection.
Inspection angle: depend on detection needs and array structure, the wave beam forming can be selected beam angle (inspection angle) in wide region, for example makes ultrasonic orientation optimization, perpendicular to the defect of expecting, the incomplete fusion in weld seam.
Wave beam control (be generally sector display, S-scanning) can and be drawn components pattern with suitable and more angle scanning and be reached optimal detection.S scanning is also useful for the situation that only has very little scanning area, thereby more adapts to the limited occasion of scanning contact area than conventional transducer.
Electron focusing can make beam shape and size reach optimization at the defective locations of expection, obtains maximum coverage territory, and highest resolution, and best detection probability, obtain optimum signal and high quality image.Focus on and improve significantly signal to noise ratio (S/N ratio), and can allow to work under lower pulse voltage.
Imaging: defects detection and graphic plotting are had to high resolution, image that can display defect " real depth ", thereby show more easily and explain than conventional waveform, can the data analysis evaluation to scanning collection by the special software of programming in advance, reduce the impact of testing staff's factor.Data can be preserved and be reappeared on demand, even can video mode record and playback.
In addition, phased array ultrasonic detection system has also possessed the examining report of writing, has supported the functions such as USB exterior storage medium and Internet Transmission.
The foregoing is only the preferred embodiment of the present invention, it should be pointed out that for the ordinary skill in the art, without departing from the principles of the present invention, can also make various deformation and improvement, this also should be considered as protection scope of the present invention.
Claims (8)
1. ultrasonic phase array robotization detection and the formation method of complex space weld seam, is characterized in that: step is:
11) determine track while scan according to the three-dimensional CAD model of complex space;
12) utilize six axis robot clamping ultrasonic phased array transducer along definite track while scan butt welded seam spotting scaming, obtain the detection data of weld seam, obtain weld seam detection result, and weld seam detection result is presented in three-dimensional weld seam figure.
2. ultrasonic phase array robotization detection and the formation method of a kind of complex space weld seam according to claim 1, it is characterized in that: step 11) if in the three-dimensional CAD model of complex space known, directly this three-dimensional CAD model is inputed to main control computer, main control computer obtains the position of weld seam to three-dimensional CAD model analysis, determine track while scan.
3. ultrasonic phase array robotization detection and the formation method of a kind of complex space weld seam according to claim 1, it is characterized in that: step 11) if in three-dimensional CAD model the unknown of complex space, the curved surface of complex space is measured, obtain surface data, then curve reestablishing obtains its three-dimensional CAD model, the position that the three-dimensional CAD model analysis obtaining is obtained to weld seam, obtains track while scan.
4. ultrasonic phase array robotization detection and the formation method of a kind of complex space weld seam according to claim 1, it is characterized in that: step 12) described in weld seam detection result be the ultrasonic C-scan Image that can show weld seam inherent vice, it is corresponding with the three-dimensional structure of three-dimensional geometrical structure in three-dimensional CAD model and weld seam that described three-dimensional weld seam figure is ultrasonic C-scan Image, the three-dimensional weld seam model image showing by Computerized three-dimensional visualization technique.
5. according to ultrasonic phase array robotization detection and the formation method of the arbitrary described a kind of complex space weld seam of claim 1-4, it is characterized in that: step 11) and step 12) between the process of a man-machine interaction can also be set: main control computer is shown to testing staff after obtaining track while scan, testing staff judges that whether scanning result is correct, directly enter step 12 if correctly need not revise), after track while scan being modified if incorrect, enter step 12); Or testing staff according to actual needs situation determines whether to modify.
6. ultrasonic phase array robotization detection and the formation method of a kind of complex space weld seam according to claim 5, it is characterized in that: the movement locus of position, the motor point composition that described track while scan is six axis robot, what in some position, carry is the welding seam position information on complex space surface.
7. ultrasonic phase array robotization detection and the formation method of a kind of complex space weld seam according to claim 5, is characterized in that: described six axis robot is six axle chain type mechanical arms.
8. according to ultrasonic phase array robotization detection and the formation method of the arbitrary described a kind of complex space weld seam of claim 1-7, it is characterized in that: three-dimensional CAD model and track while scan corresponding to three-dimensional CAD model that the three-dimensional CAD model of input or curve reestablishing are obtained store in computing machine, while having the weld seam detection of same model next time, directly transfer track while scan, butt welded seam scans.
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