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CN115343360A - Laser ultrasonic layered self-adaptive mode scanning method and system - Google Patents

Laser ultrasonic layered self-adaptive mode scanning method and system Download PDF

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CN115343360A
CN115343360A CN202210956078.5A CN202210956078A CN115343360A CN 115343360 A CN115343360 A CN 115343360A CN 202210956078 A CN202210956078 A CN 202210956078A CN 115343360 A CN115343360 A CN 115343360A
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CN115343360B (en
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赵纪元
王琛玮
王磊
韩瑞
颜江涛
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Xian Jiaotong University
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    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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    • G01N29/22Details, e.g. general constructional or apparatus details
    • G01N29/26Arrangements for orientation or scanning by relative movement of the head and the sensor
    • G01N29/265Arrangements for orientation or scanning by relative movement of the head and the sensor by moving the sensor relative to a stationary material
    • GPHYSICS
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    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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    • G01N29/44Processing the detected response signal, e.g. electronic circuits specially adapted therefor
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    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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Abstract

The invention discloses a laser ultrasonic layered self-adaptive mode scanning method and a system, wherein a scanning area is set according to a metal additive part model; scanning the scanned area in an M1 mode to obtain a laser ultrasonic signal; judging whether the laser ultrasonic signal has defect information or not through time domain analysis; if no defect information exists in the laser ultrasonic signal, scanning in an M1 mode is carried out until a defect is encountered or a set scanning area edge is reached; if the laser ultrasonic signals contain defect information, scanning in an M2 mode to obtain all ultrasonic signals in the region where the defect is located; and obtaining the position of the defect and the diameter of the defect for all ultrasonic signals in the area where the defect is located. The invention can realize the real-time detection of defects in the additive manufacturing process, intervene the manufacturing process according to the real-time detection result, and interrupt the current manufacturing process and repair small defects when the defects are detected; if the detected defect can not be repaired, the manufacturing process can be stopped, and waste is avoided.

Description

一种激光超声分层自适应模式扫查方法及系统A laser ultrasonic layered adaptive mode scanning method and system

技术领域technical field

本发明属于增材制造技术领域,具体涉及一种激光超声分层自适应模式扫查方法及系统。The invention belongs to the technical field of additive manufacturing, and in particular relates to a laser ultrasonic layered adaptive mode scanning method and system.

背景技术Background technique

增材制造技术又称3D打印技术,是通过CAD设计数据,采用材料逐层累加的方法制造实体零件的技术,相对于传统的、对原材料切削的加工模式不同,是一种“自下而上”材料累加的制造方法,实现制件从无到有的制造。增材制造技术近些年快速发展,其优势在于三维结构的快速和自由制造,使得过去受到传统制造方式的约束,而无法实现的复杂结构件制造变为可能,被广泛应用于航空航天、医疗卫生等领域。Additive manufacturing technology, also known as 3D printing technology, is a technology that uses CAD design data and the method of accumulating materials layer by layer to manufacture solid parts. Compared with the traditional processing mode of cutting raw materials, it is a "bottom-up "The manufacturing method of material accumulation realizes the manufacture of parts from scratch. Additive manufacturing technology has developed rapidly in recent years. Its advantage lies in the rapid and free manufacturing of three-dimensional structures, which has made it possible to manufacture complex structural parts that were restricted by traditional manufacturing methods in the past. It is widely used in aerospace, medical health and other fields.

但是金属增材制件的质量控制一直是目前的研究重点,因为增材制造的特点,使用高能束进行制造,制造过程中能源消耗巨大,而且制造时间较长,成本高,如果制造完成之后发现制件有内部缺陷无法使用,会造成巨大的经济损失和时间浪费。考虑到其“自下而上”的制造特点,可以在制造过程中进行质量检测。激光超声是一种非接触、无损伤、耐高温、高精度的检测技术,可以应用于金属增材制造过程的在线实时检测,如果发现有缺陷,即可进行暂停制造进行补偿操作或者提前终止制造,减小损失。However, the quality control of metal additive parts has always been the current research focus. Because of the characteristics of additive manufacturing, high-energy beams are used for manufacturing, and the energy consumption in the manufacturing process is huge, and the manufacturing time is long and the cost is high. If the parts have internal defects and cannot be used, it will cause huge economic losses and waste of time. Considering its "bottom-up" manufacturing feature, quality inspection can be carried out during the manufacturing process. Laser ultrasound is a non-contact, non-damaging, high-temperature-resistant, high-precision detection technology that can be applied to the online real-time detection of the metal additive manufacturing process. If a defect is found, the manufacturing can be suspended for compensation or terminated in advance. , to reduce losses.

在制造过程中,高能束移动速度快,而为了达到高精度扫查,激光超声探头组移动扫查的点密集,扫查速度较慢,如果层与层间制造时间相差太久,会影响制件力学性能,因此需要研究一种高效的扫查技术以实现效率和精度兼顾的效果。本发明依据增材制造“逐层增加”的特点和“高效、高精度”的检测需求,结合激光超声非接触的特点,提出一种金属增材制造过程的激光超声分层自适应模式扫查方法,并设计对应的硬件系统。In the manufacturing process, the high-energy beam moves fast, but in order to achieve high-precision scanning, the moving scanning points of the laser ultrasonic probe group are dense, and the scanning speed is slow. If the manufacturing time difference between layers is too long, it will affect the manufacturing process. Therefore, it is necessary to study an efficient scanning technology to achieve both efficiency and accuracy. Based on the characteristics of "layer-by-layer increase" of additive manufacturing and the detection requirements of "high efficiency and high precision", combined with the characteristics of laser ultrasonic non-contact, a laser ultrasonic layered self-adaptive mode scan is proposed in the process of metal additive manufacturing method, and design the corresponding hardware system.

针对增材制造过程的激光超声检测,申请公布号CN106018288A的专利文献公布了一种激光超声在线无损检测增材制造零件的方法,但该方法采用固定步长的分层逐点扫查,使得扫描点数过多,数据量大,检测时间长,降低了实际增材制造的制件质量和检测效率。Aiming at the laser ultrasonic inspection of the additive manufacturing process, the patent document of application publication number CN106018288A discloses a method for laser ultrasonic online non-destructive inspection of additively manufactured parts, but the method adopts layered and point-by-point scanning with a fixed step length, so that the scanning Too many points, large amount of data, and long detection time reduce the quality and detection efficiency of the actual additive manufacturing parts.

申请公布号CN202110973449.6的专利文献公布了基于激光超声及振镜协同的金属增材同步检测系统及方法,但该方法对于新成形层的扫查未作路径规划,在新成形层全区域进行固定步长的二维扫查,存在数据量大,检测、计算耗时长,检测效率低的问题。The patent document with application publication number CN202110973449.6 discloses a metal additive synchronous detection system and method based on laser ultrasound and vibrating mirror synergy, but this method does not make path planning for the scanning of the new forming layer, and it is carried out in the entire area of the new forming layer Two-dimensional scanning with a fixed step size has the problems of large amount of data, long detection and calculation time, and low detection efficiency.

发明内容Contents of the invention

为克服现有技术中的问题,本发明提供一种金属增材制造过程的激光超声分层自适应模式扫查方法及系统,该方法能够有效提升缺陷检测精度,提高检测效率。In order to overcome the problems in the prior art, the present invention provides a laser ultrasonic layered self-adaptive mode scanning method and system in the metal additive manufacturing process. The method can effectively improve the defect detection accuracy and improve the detection efficiency.

为实现上述目的,本发明采用的技术方案如下:To achieve the above object, the technical scheme adopted in the present invention is as follows:

一种激光超声分层自适应模式扫查方法,包括以下步骤:A laser ultrasound layered adaptive mode scanning method, comprising the following steps:

步骤1:根据金属增材制件模型生成制造机器人移动路径,依据制造机器人移动路径设置扫查区域;Step 1: Generate the moving path of the manufacturing robot according to the metal additive part model, and set the scanning area according to the moving path of the manufacturing robot;

步骤2:对扫查区域进行M1模式扫查,得到激光超声信号;Step 2: scan the scanning area in M1 mode to obtain laser ultrasonic signals;

步骤3:通过时域分析,判断激光超声信号中是否有缺陷信息;Step 3: Through time domain analysis, determine whether there is defect information in the laser ultrasonic signal;

步骤4:若激光超声信号中无缺陷信息,则进行M1模式扫查,直到遇到缺陷或达到设定的扫查区域边缘;若激光超声信号中包含缺陷信息,则进行M2模式扫查,得到缺陷所在区域内的所有超声信号;其中,M2模式扫查的步长小于M1模式扫查的步长;Step 4: If there is no defect information in the laser ultrasonic signal, scan in M1 mode until a defect is encountered or reach the edge of the set scanning area; if the laser ultrasonic signal contains defect information, scan in M2 mode to obtain All ultrasonic signals in the area where the defect is located; wherein, the step size of M2 mode scan is smaller than the step size of M1 mode scan;

步骤5:对步骤4中的缺陷所在区域内的所有超声信号,根据C扫信号处理的方法,得到缺陷位置和缺陷直径。Step 5: For all ultrasonic signals in the area where the defect is located in step 4, the defect position and defect diameter are obtained according to the C-scan signal processing method.

优选的,步骤1中的,扫查区域为矩形。Preferably, in step 1, the scanning area is rectangular.

优选的,步骤3的具体过程为:Preferably, the specific process of step 3 is:

提取激光超声信号中第一个表面波传播时间TR和激光超声信号中第一个纵波传播时间TL,求解时域误差ΔT;Extract the first surface wave propagation time T R in the laser ultrasonic signal and the first longitudinal wave propagation time T L in the laser ultrasonic signal, and solve the time domain error ΔT;

若时域误差满足

Figure BDA0003791420170000031
判断此时激光超声信号中无缺陷信息,其中,f为干涉仪采样频率;If the time domain error satisfies
Figure BDA0003791420170000031
Judging that there is no defect information in the laser ultrasonic signal at this time, where f is the sampling frequency of the interferometer;

若时域误差满足

Figure BDA0003791420170000032
判断此时激光超声信号中包含缺陷信息。If the time domain error satisfies
Figure BDA0003791420170000032
It is judged that the laser ultrasonic signal contains defect information at this time.

优选的,时域误差ΔT通过下式计算:Preferably, the time domain error ΔT is calculated by the following formula:

ΔT=|(TR-tR)-(TL-tL)|ΔT=|(T R -t R )-(T L -t L )|

式中,tR为表面直达波理论传播时间,tL为纵波的底面回波理论传播时间。In the formula, t R is the theoretical propagation time of the surface direct wave, and t L is the theoretical propagation time of the bottom echo of the longitudinal wave.

优选的,表面直达波理论传播时间tR通过下式计算:Preferably, the theoretical propagation time t R of the surface direct wave is calculated by the following formula:

Figure BDA0003791420170000033
Figure BDA0003791420170000033

式中,d为激励点和接收点之间的距离,vR为表面波在金属增材制件模型的材料中传播的速度。In the formula, d is the distance between the excitation point and the receiving point, and v R is the speed of the surface wave propagating in the material of the metal additive part model.

优选的,纵波的底面回波理论传播时间tL通过下式计算:Preferably, the theoretical propagation time t L of the bottom echo of the longitudinal wave is calculated by the following formula:

Figure BDA0003791420170000034
Figure BDA0003791420170000034

式中,d为激励点和接收点之间的距离,h为增材制件整体高度,vL为纵波在该种材料中传播的速度。In the formula, d is the distance between the excitation point and the receiving point, h is the overall height of the additive product, and v L is the speed of longitudinal wave propagation in this material.

优选的,步骤4的具体过程如下:Preferably, the specific process of step 4 is as follows:

1)在激励点位置不变的情况下,在以激励点为圆心,在以M2模式扫查的步长为半径的圆上进行逐点扫查,采集信号,实时分析采集到的信号,以缺陷回波出现时刻最早、缺陷回波幅值最大的方向为缺陷所在方向;1) Under the condition that the location of the excitation point remains unchanged, scan point by point on a circle with the excitation point as the center and the step length of the scan in M2 mode as the radius, collect signals, analyze the collected signals in real time, and use The direction where the defect echo appears earliest and the defect echo amplitude is the largest is the direction of the defect;

2)在缺陷所在方向上进行变步长的直线扫查,采集信号,实时分析采集到的信号,以缺陷回波消失和缺陷透射波第一次出现的两个位置的连线为对角线,M1模式扫查方向为一条边绘制矩形,矩形为缺陷所在区域;2) Carry out linear scanning with variable step length in the direction of the defect, collect signals, analyze the collected signals in real time, and take the line connecting the two positions where the defect echo disappears and the defect transmission wave first appears as the diagonal line , the scanning direction of M1 mode is to draw a rectangle along one side, and the rectangle is the area where the defect is located;

3)在缺陷所在区域内进行型M2模式扫查,采集缺陷所在区域内的所有超声信号。3) Carry out type M2 mode scanning in the area where the defect is located, and collect all ultrasonic signals in the area where the defect is located.

优选的,M1模式的扫查步长为0.5mm、1mm、1.5mm或2mm;Preferably, the scanning step of M1 mode is 0.5mm, 1mm, 1.5mm or 2mm;

M2模式的扫查步长为0.1mm、0.2mm或0.5mm。The scanning step of M2 mode is 0.1mm, 0.2mm or 0.5mm.

优选的,进行步骤5后,进行如下步骤:判断M1模式和M2模式扫查的范围是否已覆盖扫查区域,如果已全部覆盖,则扫查结束,如果未覆盖,则跳转到步骤2。Preferably, after performing step 5, the following steps are performed: judge whether the scanning ranges of the M1 mode and the M2 mode have covered the scanning area, if they are all covered, the scanning ends, and if not covered, then jump to step 2.

上述方法采用的激光超声分层自适应模式扫查系统,包括脉冲激光器探头、干涉仪探头、45°平面镜以及X-Y光学透镜;The laser ultrasonic layered adaptive mode scanning system adopted by the above method includes a pulsed laser probe, an interferometer probe, a 45° plane mirror and an X-Y optical lens;

其中,脉冲激光器探头射出的脉冲激光,照射在金属增材制件上,在金属增材制件表面和内部激励出超声波;金属增材制件表面的超声波经X-Y光学透镜、45°平面镜传播回干涉仪探头。Among them, the pulse laser emitted by the pulse laser probe is irradiated on the metal additive part, and the ultrasonic wave is excited on the surface and inside of the metal additive part; the ultrasonic wave on the surface of the metal additive part propagates back through the X-Y optical lens and 45° plane mirror. Interferometer probe.

与现有技术相比,本发明具有的有益效果:Compared with the prior art, the present invention has the beneficial effects:

本发明的自适应模式扫查方法,可以在无缺陷区域进行大步长的M1模式扫查,实时分析采集的信号,若判断激光超声信号中包含缺陷信息,则进行小步长的M2模式扫查,同时兼顾检测速度和检测精度,且不会出现漏检的情况,克服了现有技术中检测速度和检测精度在固定步长的全区域扫查中无法兼顾的问题。本发明中提出的自适应模式扫查方法中,对信号进行实时分析,对于无缺陷区域信号进行简单时域分析,节约计算资源;对于缺陷区域信号根据C扫信号处理的方法,按照时间进行切片,输出缺陷回波时刻的切片,输出缺陷信息,将计算资源用在重点关注的缺陷区域中,相较于现有方法,有效降低了计算量。本发明可以实现增材制造过程中缺陷实时检测,根据实时检测结果对制造过程进行干预,当检测到缺陷时,可中断目前制造过程,对小缺陷进行修复;若检测的缺陷无法修复时,可终止制造过程,避免从缺陷产生到制造完成带来的浪费。The self-adaptive mode scanning method of the present invention can perform large-step M1 mode scanning in defect-free areas, analyze the collected signals in real time, and perform small-step M2 mode scanning if it is judged that the laser ultrasonic signal contains defect information. Inspection, while taking into account the detection speed and detection accuracy, and there will be no missed detection, which overcomes the problem in the prior art that the detection speed and detection accuracy cannot be considered in the full-area scanning with a fixed step size. In the adaptive mode scanning method proposed in the present invention, the signal is analyzed in real time, and the signal in the non-defective area is analyzed in the simple time domain to save computing resources; the signal in the defective area is processed according to the method of C-scan signal, and sliced according to time , output the slice of the defect echo time, output the defect information, and use the computing resources in the defect area that is focused on. Compared with the existing method, the calculation amount is effectively reduced. The invention can realize real-time detection of defects in the process of additive manufacturing, and intervene in the manufacturing process according to the real-time detection results. When a defect is detected, the current manufacturing process can be interrupted and small defects can be repaired; if the detected defect cannot be repaired, it can be Terminate the manufacturing process and avoid waste from defect generation to manufacturing completion.

进一步的,本发明可根据不同制件的用途和对缺陷的容忍度,设置不同的扫查步长,以实现高效、高精度检测。Further, the present invention can set different scan step lengths according to the usage of different parts and the tolerance to defects, so as to realize efficient and high-precision detection.

附图说明Description of drawings

图1是本发明的实施例的激光超声分层自适应模式扫查系统示意图;1 is a schematic diagram of a laser ultrasonic layered adaptive mode scanning system according to an embodiment of the present invention;

图2是本发明的实施例的实现流程图;Fig. 2 is the realization flowchart of the embodiment of the present invention;

图3是本发明的实施例中M1模式扫查示意图和特殊点信号的示意图;其中,(a)为M1模式扫查示意图,(b)为A点(无缺陷区域)信号示意图,(c)为B点(靠近缺陷区域)信号示意图。Fig. 3 is a schematic diagram of M1 mode scanning and a schematic diagram of a special point signal in an embodiment of the present invention; wherein, (a) is a schematic diagram of M1 mode scanning, (b) is a schematic diagram of a point A (defect-free area) signal, (c) It is a schematic diagram of the signal at point B (close to the defect area).

图4是本发明的实施例中M2模式中的圆形扫查示意图和特殊点信号的示意图;其中,(a)为M2模式中圆形扫查示意图,(b)为A点(靠近缺陷方向)信号示意图,(c)为其余点(远离缺陷位置)信号示意图。Fig. 4 is a schematic diagram of a circular scan in the M2 mode and a schematic diagram of a special point signal in an embodiment of the present invention; wherein, (a) is a schematic diagram of a circular scan in the M2 mode, and (b) is a point A (close to the defect direction ) signal schematic diagram, (c) is the signal schematic diagram of other points (away from the defect position).

图5是本发明的实施例中M2模式中的直线扫查示意图和特殊点信号的示意图;其中,(a)为M2模式中直线扫查示意图,(b)为A点(激励与接收位于缺陷同侧)信号示意图,(c)为B点(接收点位于缺陷区域内)信号示意图,(d)为C点(激励与接收位于缺陷异侧)信号示意图。Fig. 5 is a schematic diagram of a straight-line scan in the M2 mode and a schematic diagram of a special point signal in an embodiment of the present invention; wherein, (a) is a schematic diagram of a straight-line scan in the M2 mode, and (b) is point A (the excitation and reception are located at the defect Signal diagram on the same side), (c) is a schematic diagram of the signal at point B (the receiving point is located in the defect area), (d) is a schematic diagram of the signal at point C (the excitation and reception are located on the opposite side of the defect).

图6是本发明的实施例中M2模式中的矩形扫查示意图。FIG. 6 is a schematic diagram of a rectangular scan in the M2 mode in an embodiment of the present invention.

图1中,1是基板,2是连接装置,3是脉冲激光器探头,4是干涉仪探头,5是45°平面镜,6是X-Y光学透镜。In Figure 1, 1 is the substrate, 2 is the connection device, 3 is the pulse laser probe, 4 is the interferometer probe, 5 is the 45° plane mirror, and 6 is the X-Y optical lens.

具体实施方式Detailed ways

下面结合附图和实施例对本发明的方法进行进一步的说明。The method of the present invention will be further described below in conjunction with the drawings and embodiments.

本实施例提供了一种金属增材制造过程的激光超声分层自适应模式扫查系统,如图1所示。通过程序可实现圆形、直线、矩形扫查。脉冲激光器探头作为整个扫查系统的超声波激励装置,脉冲激光由脉冲激光器探头3射出,照射在待测物体上,在物体表面和内部激励出超声波;干涉仪探头4、45°平面镜5、X-Y光学透镜6构成超声波信号接收装置,干涉仪探头4发射连续激光到45°平面镜5,光路产生90°偏转,照射进入X-Y光学透镜6,再通过X-Y光学透镜6中光路偏转,照射在物体表面,当制件表面有超声波传播时,表面振动信息由连续激光沿X-Y光学透镜6、45°平面镜5逆向传播回干涉仪探头4,干涉仪探头4输出超声波信号,实现超声波信号的非接触式采集,干涉仪探头4采样频率为f。干涉仪探头4、45°平面镜5、X-Y光学透镜6、脉冲激光器探头3均固定在设备安装的基板1上,进行扫查时,将整个扫查系统的基板1通过连接装置2固定在机器人末端,在机器人运动过程中实现扫查。图中虚线标注为脉冲激光和用于检测的连续激光的光路。This embodiment provides a laser ultrasonic layered adaptive mode scanning system for metal additive manufacturing process, as shown in FIG. 1 . Circular, linear and rectangular scanning can be realized through the program. The pulse laser probe is used as the ultrasonic excitation device of the entire scanning system. The pulse laser is emitted by the pulse laser probe 3 and irradiated on the object to be tested, and the ultrasonic wave is excited on the surface and inside of the object; interferometer probe 4, 45° plane mirror 5, X-Y optics The lens 6 constitutes an ultrasonic signal receiving device. The interferometer probe 4 emits continuous laser light to the 45° plane mirror 5, and the optical path generates a 90° deflection, and then irradiates into the X-Y optical lens 6, and then deflects the optical path through the X-Y optical lens 6, and irradiates on the surface of the object. When there is ultrasonic wave propagation on the surface of the workpiece, the surface vibration information is transmitted back to the interferometer probe 4 by the continuous laser along the X-Y optical lens 6 and the 45° plane mirror 5, and the interferometer probe 4 outputs ultrasonic signals to realize the non-contact acquisition of ultrasonic signals. The sampling frequency of instrument probe 4 is f. The interferometer probe 4, 45° plane mirror 5, X-Y optical lens 6, and pulse laser probe 3 are all fixed on the substrate 1 installed on the equipment. When scanning, the substrate 1 of the entire scanning system is fixed on the end of the robot through the connecting device 2 , to realize the scanning during the robot movement. The dotted lines in the figure indicate the optical paths of the pulsed laser and the continuous laser used for detection.

参见图2,本发明的一种金属增材制造过程的激光超声分层自适应模式扫查方法,包括以下步骤:Referring to Fig. 2, a laser ultrasonic layered adaptive mode scanning method for a metal additive manufacturing process of the present invention includes the following steps:

步骤1:根据金属增材制件模型生成制造机器人移动路径,依据制造机器人移动路径设置扫查区域,扫查区域设置成矩形。Step 1: Generate the moving path of the manufacturing robot according to the metal additive part model, set the scanning area according to the moving path of the manufacturing robot, and set the scanning area as a rectangle.

步骤2:设置M1模式的扫查步长。M1模式为大步长扫查模式,一般步长可设置为0.5mm、1mm、1.5mm或2mm等;Step 2: Set the scanning step of M1 mode. M1 mode is a large-step scan mode, and the general step size can be set to 0.5mm, 1mm, 1.5mm or 2mm;

步骤3:设置M2模式的扫查步长。M2模式为小步长扫查模式。一般步长可设置为0.1mm、0.2mm或0.5mm。M2模式的步长需小于M1模式的步长。Step 3: Set the scanning step of M2 mode. The M2 mode is a scan mode with a small step size. The general step length can be set to 0.1mm, 0.2mm or 0.5mm. The step size of the M2 mode needs to be smaller than the step size of the M1 mode.

步骤4:设置最小可检缺陷尺寸。本发明中设计的激光超声分层自适应模式扫查系统中,最小可检缺陷直径为0.1mm,可根据增材制件用途设置最小可检缺陷尺寸。Step 4: Set the minimum detectable defect size. In the laser ultrasonic layered self-adaptive mode scanning system designed in the present invention, the minimum detectable defect diameter is 0.1 mm, and the minimum detectable defect size can be set according to the application of the additive part.

步骤5:依据当前增材制件整体高度h,表面波在金属增材制件模型的材料中传播的速度vR,纵波在该种材料中传播的速度vL,激励点和接收点之间的距离d等参数,依据如下公式求出当前表面直达波理论传播时间tR、纵波的底面回波理论传播时间tLStep 5: According to the overall height h of the current additive part, the speed v R of the surface wave propagating in the material of the metal additive part model, the speed v L of the longitudinal wave propagating in the material, and the distance between the excitation point and the receiving point According to the following formulas, calculate the theoretical propagation time t R of the current surface direct wave and the theoretical propagation time t L of the bottom echo of the longitudinal wave.

Figure BDA0003791420170000061
Figure BDA0003791420170000061

Figure BDA0003791420170000062
Figure BDA0003791420170000062

步骤6:控制机器人将如图1所示的扫查系统置于扫查起始位置,并开启扫查系统,确定超声波激励装置和超声波信号接收装置自动对焦。参见图3中(a)、(b)和(c),启动扫查系统,进行M1模式扫查,采集得到激光超声信号S。Step 6: Control the robot to place the scanning system as shown in Figure 1 at the scanning start position, and turn on the scanning system to ensure that the ultrasonic excitation device and the ultrasonic signal receiving device are automatically focused. Referring to (a), (b) and (c) in Fig. 3, start the scanning system, scan in the M1 mode, and acquire the laser ultrasonic signal S.

步骤7:实时分析采集到的激光超声信号S,通过时-频域、时域分析,判断激光超声信号S中是否有缺陷。具体包括以下步骤:Step 7: Analyze the collected laser ultrasonic signal S in real time, and judge whether there is a defect in the laser ultrasonic signal S through time-frequency domain and time domain analysis. Specifically include the following steps:

步骤7.1:激光超声信号S时-频域分析。提取激光超声信号S中出现的第一个波峰传播时刻T1和第二个波峰传播时刻T2,对采集到的激光超声信号S进行短时傅里叶变换,得到第一个波峰传播时刻T1的瞬时频率f1和第二个波峰传播时刻T2的瞬时频率f2Step 7.1: time-frequency domain analysis of the laser ultrasound signal S. Extract the first peak propagation time T 1 and the second peak propagation time T 2 in the laser ultrasonic signal S, and perform short-time Fourier transform on the collected laser ultrasonic signal S to obtain the first peak propagation time T The instantaneous frequency f 1 of 1 and the instantaneous frequency f 2 of the second peak propagation moment T 2 .

若f1<f2,则第一个波峰传播时刻T1的瞬时频率f1对应的超声波为表面波,TR=T1;第二个波峰传播时刻T2的瞬时频率f2对应的超声波为纵波,TL=T2If f 1 < f 2 , the ultrasonic wave corresponding to the instantaneous frequency f 1 at the first peak propagation time T 1 is a surface wave, T R = T 1 ; the ultrasonic wave corresponding to the instantaneous frequency f 2 at the second peak propagation time T 2 is longitudinal wave, T L = T 2 ;

若f1≥f2,则第一个波峰传播时刻T1的瞬时频率f1对应的超声波为纵波,TL=T1;第二个波峰传播时刻T2的瞬时频率f2对应的超声波为表面波,TR=T2If f 1 ≥ f 2 , the ultrasonic wave corresponding to the instantaneous frequency f 1 at the first peak propagation time T 1 is a longitudinal wave, T L = T 1 ; the ultrasonic wave corresponding to the instantaneous frequency f 2 at the second peak propagation time T 2 is surface wave, T R = T 2 ;

其中,TR为信号S中第一个表面波传播时间;TL为信号S中第一个纵波传播时间;Among them, T R is the propagation time of the first surface wave in the signal S; T L is the propagation time of the first longitudinal wave in the signal S;

步骤7.2:激光超声信号S时域分析。提取激光超声信号S中出现的第一个表面波传播时间TR和第一个纵波传播时刻和TL,求解时域误差ΔT。Step 7.2: Time domain analysis of the laser ultrasound signal S. Extract the first surface wave propagation time T R and the first longitudinal wave propagation time T L in the laser ultrasonic signal S, and solve the time domain error ΔT.

ΔT=|(TR-tR)-(TL-tL)|ΔT=|(T R -t R )-(T L -t L )|

若时域误差满足

Figure BDA0003791420170000071
判断此时检测点采集到的激光超声信号S中无缺陷信息。其中,f为干涉仪采样频率。If the time domain error satisfies
Figure BDA0003791420170000071
It is judged that there is no defect information in the laser ultrasonic signal S collected by the detection point at this time. Among them, f is the interferometer sampling frequency.

若时域误差满足

Figure BDA0003791420170000072
判断此时检测点采集到的激光超声信号S中包含缺陷信息。If the time domain error satisfies
Figure BDA0003791420170000072
It is judged that the laser ultrasonic signal S collected by the detection point at this time contains defect information.

参见图3中(a),当扫查起始位置A点周围无缺陷时,采集到的信号如图3中(b),信号中只有表面直达波信号和纵波底面回波信号;当扫查到缺陷附近B点位置时,信号中出现缺陷回波与纵波叠加的情况,通过步骤7.2判断出B点周围有缺陷,需要进行M2模式扫查。Referring to (a) in Figure 3, when there is no defect around point A at the starting position of the scan, the collected signal is shown in (b) in Figure 3, in which there are only surface direct wave signals and longitudinal wave bottom echo signals; when scanning When arriving at point B near the defect, the defect echo and longitudinal wave superimpose in the signal, and it is judged that there is a defect around point B through step 7.2, and M2 mode scanning is required.

步骤8:若采集到的激光超声信号S中无缺陷信息,则继续进行M1模式扫查,直到遇到缺陷或达到设定的扫查区域边缘;若采集到的信号中包含缺陷信息,则进行M2模式扫查,得到缺陷所在区域内的所有超声信号。具体包括以下步骤:Step 8: If there is no defect information in the collected laser ultrasonic signal S, continue to scan in M1 mode until a defect is encountered or reaches the edge of the set scanning area; if the collected signal contains defect information, proceed to Scan in M2 mode to obtain all ultrasonic signals in the area where the defect is located. Specifically include the following steps:

步骤8.1:在激励点位置不变的情况下,由X-Y光学透镜改变接收点的光路,接收点在以激励点为圆心,参见图4中(a)、(b)和(c),M2模式扫查(圆形扫查)的步长为半径的圆上进行逐点扫查,实时分析采集到的信号,以缺陷回波出现时刻最早、缺陷回波幅值最大的方向为缺陷所在方向。参见图4中(b)和(c),A点采集到的信号是圆形扫查采集到的所有信号中缺陷回波出现时刻最早,缺陷回波幅值最大的点,因此激励点和A点的连线即为缺陷所在方向。Step 8.1: With the position of the excitation point unchanged, the optical path of the receiving point is changed by the X-Y optical lens, and the receiving point is centered on the excitation point, see (a), (b) and (c) in Figure 4, M2 mode Scanning (circular scanning) scans point by point on a circle whose step length is the radius, analyzes the collected signals in real time, and takes the direction where the defect echo appears earliest and the defect echo amplitude is the largest as the direction of the defect. See (b) and (c) in Figure 4, the signal collected at point A is the point where the defect echo appears the earliest and the defect echo amplitude is the largest among all the signals collected by circular scanning, so the excitation point and A The line connecting the points is the direction of the defect.

步骤8.2:在激励点位置不变,缺陷所在方向确定的情况下,参见图5中(a)、(b)、(c)和(d),由X-Y光学透镜改变接收点的光路,接收点在缺陷方向上进行M2模式扫查,M2模式扫查为变步长(第n个接收点位于激励点n×M2步长的位置处)的直线扫查,实时分析采集到的信号,以缺陷回波消失和缺陷透射波第一次出现的两个位置的连线为对角线,M1模式扫查方向为其中一条边绘制矩形,矩形为缺陷所在区域。参见图5中(b)、(c)和(d),当接收点位于图5中(a)中A点位置时,图5中(b)信号中缺陷回波明显;当接收点移动到B位置时,因为接收点位于缺陷之中,缺陷内部粗糙度大导致干涉仪射出的连续激光无法聚焦,因此图5中(c)中信号只有噪声没有超声波信息;当接收点移动到C位置时,图5中(d)信号中出现缺陷透射波,因此由A点和C点的连线确定对角线,以M1模式扫查方向为一条边绘制的矩形如图5中(a)中虚线所示,该矩形为缺陷所在区域。Step 8.2: When the position of the excitation point remains unchanged and the direction of the defect is determined, refer to (a), (b), (c) and (d) in Figure 5, change the optical path of the receiving point by the X-Y optical lens, and the receiving point Carry out M2 mode scanning in the direction of the defect. The M2 mode scan is a linear scan with variable step length (the nth receiving point is located at the position of the excitation point n×M2 step length), and the collected signal is analyzed in real time to identify the defect. The line connecting the two positions where the echo disappears and the defect transmission wave appears for the first time is a diagonal line, and the scanning direction of the M1 mode is one of the sides to draw a rectangle, and the rectangle is the area where the defect is located. Referring to (b), (c) and (d) in Figure 5, when the receiving point is located at point A in Figure 5 (a), the defect echo in the signal (b) in Figure 5 is obvious; when the receiving point moves to At position B, because the receiving point is located in the defect, the internal roughness of the defect causes the continuous laser emitted by the interferometer to be unable to focus, so the signal in (c) in Figure 5 has only noise and no ultrasonic information; when the receiving point moves to position C , the defect transmission wave appears in the signal of (d) in Figure 5, so the diagonal line is determined by the line connecting point A and point C, and the rectangle drawn with the scanning direction of M1 mode as a side is shown as the dotted line in (a) of Figure 5 As shown, the rectangle is the area where the defect is located.

当图5中(a)中A点和C点的连线长度大于等于步骤4中的最小可检缺陷尺寸时,表明这个区域内有需要检出的缺陷,因此进入到步骤8.3进行矩形扫查;如果AC连线长度小于最小可检缺陷尺寸时,表面这个缺陷是可以接收的,因此不需要继续进行M2模式扫查,跳转到步骤6继续进行M1模式扫查。When the length of the line connecting point A and point C in (a) in Figure 5 is greater than or equal to the minimum detectable defect size in step 4, it indicates that there are defects that need to be detected in this area, so go to step 8.3 for rectangular scanning ; If the AC connection length is less than the minimum detectable defect size, the defect is acceptable on the surface, so there is no need to continue to scan in M2 mode, skip to step 6 and continue to scan in M1 mode.

步骤8.3:参见图6,图6中虚线方框为扫查区域,实线方框为金属增材制件,保持激励点位置不变,由X-Y光学透镜改变接收点的光路,接收点在缺陷所在区域内进行“S”型M2模式扫查,采集缺陷所在区域内的所有超声信号。Step 8.3: See Figure 6. The dotted line box in Figure 6 is the scanning area, and the solid line box is the metal additive product. Keep the position of the excitation point unchanged, and change the optical path of the receiving point by the X-Y optical lens. The receiving point is in the defect Carry out "S" type M2 mode scan in the area to collect all ultrasonic signals in the area where the defect is located.

步骤9:对步骤8.3采集到的信号,依据C扫信号处理的方法,将所有信号存于矩阵中,按照时间进行切片,输出缺陷回波时刻的切片,切片中超声波传播路径断开的位置即为缺陷位置,超声波断开的距离为缺陷直径,缺陷位置和缺陷直径为缺陷信息。Step 9: For the signals collected in step 8.3, according to the C-scan signal processing method, store all the signals in the matrix, slice according to time, and output the slice at the time of the defect echo. The position where the ultrasonic propagation path is disconnected in the slice is is the defect position, the ultrasonic disconnection distance is the defect diameter, and the defect position and defect diameter are defect information.

步骤10:判断M1和M2模式扫查的范围是否已覆盖扫查区域,如果已全部覆盖,则扫查结束。如果未覆盖,则跳转到步骤6,继续进行M1模式扫查。Step 10: Determine whether the scanning range of the M1 and M2 modes has covered the scanning area, and if it has been completely covered, the scanning ends. If it is not covered, skip to step 6 and continue to scan in M1 mode.

现有激光超声扫查方法多采用固定步长的全区域扫查,为了保证检测精度,扫查步长设置的很小,因此导致采集的数据量巨大,而且数据采集过程较长,影响制造效率与质量;当要保证检测效率时,扫查步长必须设置较大,导致漏检小尺寸缺陷。检测速度和检测精度在固定步长的全区域扫查中无法兼得,而本发明提出的自适应模式扫查方法,可以在无缺陷区域进行大步长扫查,在有缺陷区域进行小步长扫查,同时兼顾检测速度和检测精度,且不会出现漏检的情况。Existing laser ultrasonic scanning methods mostly use full-area scanning with a fixed step size. In order to ensure the detection accuracy, the scanning step size is set very small, resulting in a huge amount of collected data, and the data collection process is long, which affects manufacturing efficiency. and quality; when the detection efficiency is to be ensured, the scanning step length must be set larger, resulting in missed detection of small-sized defects. The detection speed and detection accuracy cannot be achieved in the whole-area scanning with a fixed step length, but the adaptive mode scanning method proposed by the present invention can perform large-step scanning in non-defective areas and small-step scanning in defective areas. Long scan, taking into account the detection speed and detection accuracy at the same time, and there will be no missed detection.

现有的激光超声全区域固定步长扫查采集到的数据量大,待采集完成之后进行信号处理的计算量大。而本发明中提出的自适应模式扫查方法中,对信号进行实时分析,对于无缺陷区域信号进行简单计算,节约计算资源;对于缺陷区域信号进行重点计算,将计算资源用在重点关注区域中,相较于现有方法,有效降低了计算量。The amount of data collected by the existing laser ultrasonic full-area fixed-step scanning scan is large, and the amount of calculation for signal processing after the acquisition is completed is large. However, in the self-adaptive mode scanning method proposed in the present invention, the signal is analyzed in real time, and the signal in the non-defect area is simply calculated to save computing resources; the signal in the defect area is focused on calculation, and the computing resources are used in the key attention area , compared with existing methods, effectively reducing the amount of computation.

Claims (10)

1. A laser ultrasonic layered self-adaptive mode scanning method is characterized by comprising the following steps:
step 1: generating a manufacturing robot moving path according to the metal additive product model, and setting a scanning area according to the manufacturing robot moving path;
step 2: scanning the scanned area in an M1 mode to obtain a laser ultrasonic signal;
and step 3: judging whether the laser ultrasonic signal has defect information or not through time domain analysis;
and 4, step 4: if no defect information exists in the laser ultrasonic signal, scanning in an M1 mode is carried out until a defect is encountered or a set scanning area edge is reached; if the laser ultrasonic signals contain defect information, scanning in an M2 mode to obtain all ultrasonic signals in the region where the defect is located; wherein the step length of the M2 mode scanning is smaller than that of the M1 mode scanning;
and 5: and (5) obtaining the position and the diameter of the defect of all the ultrasonic signals in the region where the defect is located in the step (4) according to a C-scan signal processing method.
2. The laser ultrasonic layered adaptive mode scanning method according to claim 1, wherein in the step 1, the scanned area is rectangular.
3. The laser ultrasonic layered adaptive mode scanning method according to claim 1, characterized in that the specific process of step 3 is as follows:
extracting the first surface wave propagation time T in the laser ultrasonic signal R And the propagation time T of the first longitudinal wave in the laser ultrasonic signal L Solving a time domain error delta T;
if the time domain error is satisfied
Figure FDA0003791420160000011
Judging non-defective information in the laser ultrasonic signal at the moment, wherein f is the sampling frequency of the interferometer;
if the time domain error is satisfied
Figure FDA0003791420160000012
And judging that the laser ultrasonic signal contains defect information at the moment.
4. The laser ultrasonic layered adaptive mode scanning method according to claim 3, wherein the time-domain error Δ T is calculated by the following formula:
ΔT=|(T R -t R )-(T L -t L )|
in the formula, t R Is the theoretical propagation time of the surface direct wave, t L The theoretical propagation time of the bottom echo of the longitudinal wave is shown.
5. The laser ultrasonic layered adaptive mode scanning method according to claim 4, characterized in that the surface direct wave theoretical propagation time t R Calculated by the following formula:
Figure FDA0003791420160000021
where d is the distance between the excitation point and the reception point and v R Is the speed of propagation of the surface wave in the material of the metallic additive product model.
6. The laser ultrasonic layered adaptive mode scanning method according to claim 5, wherein the theoretical propagation time t of the bottom echo of the longitudinal wave is t L Calculated by the following formula:
Figure FDA0003791420160000022
wherein d is the distance between the excitation point and the receiving point, h is the overall height of the additive product, and v L Is the speed at which longitudinal waves propagate in such a material.
7. The laser ultrasonic layered adaptive mode scanning method according to claim 1, characterized in that the specific process of step 4 is as follows:
1) Under the condition that the position of an excitation point is not changed, scanning point by point on a circle which takes the excitation point as the center of a circle and takes the step length of scanning in an M2 mode as the radius, acquiring signals, analyzing the acquired signals in real time, and taking the direction with the earliest defect echo occurrence time and the largest defect echo amplitude as the direction of a defect;
2) Performing linear scanning with variable step length in the direction of the defect, acquiring signals, analyzing the acquired signals in real time, and drawing a rectangle by taking a connecting line of two positions where the defect echo disappears and the defect transmission wave appears for the first time as a diagonal line and the scanning direction of the M1 mode as a side, wherein the rectangle is an area where the defect is located;
3) And scanning the defect in the region in which the defect is positioned in a M2 mode, and acquiring all ultrasonic signals in the region in which the defect is positioned.
8. The laser ultrasonic layered adaptive mode scanning method according to claim 1, characterized in that the scanning step length of the M1 mode is 0.5mm, 1mm, 1.5mm or 2mm;
the scanning step length of the M2 mode is 0.1mm, 0.2mm or 0.5mm.
9. The laser ultrasonic layered adaptive mode scanning method according to claim 1, characterized in that after step 5, the following steps are performed: and (3) judging whether the scanning ranges of the M1 mode and the M2 mode cover the scanning area, if so, finishing the scanning, and if not, skipping to the step 2.
10. A laser ultrasonic layered adaptive mode scanning system used in the method of any one of claims 1-9, which comprises a pulse laser probe (3), an interferometer probe (4), a 45 ° plane mirror (5) and an X-Y optical lens (6);
pulse laser emitted by the pulse laser probe (3) irradiates on the metal additive manufacturing part, and ultrasonic waves are excited on the surface and inside of the metal additive manufacturing part; ultrasonic waves on the surface of the metal additive workpiece are transmitted back to the interferometer probe (4) through the X-Y optical lens (6) and the 45-degree plane mirror (5), and the interferometer probe (4) outputs ultrasonic signals.
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