CN117589861A - A non-destructive testing system based on magnetic sensors - Google Patents
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Abstract
Description
技术领域Technical field
本发明涉及磁性材料损伤检测技术领域,尤其涉及一种基于磁传感器的无损检测系统。The invention relates to the technical field of magnetic material damage detection, and in particular to a non-destructive detection system based on magnetic sensors.
背景技术Background technique
无损检测可以在不损坏待测构件的前提下对其进行性能和工作状态评估,是保障设备安全运行的关键技术,在工业领域有广泛应用。金属构件在生产、生活中的应用相当普遍,对金属构件的损伤与失效进行精确有效的检测,对国家和人民的生命财产安全具有重要意义。在金属构件无损检测方面,常规无损检测技术(如漏磁检测、磁粉检测、渗透检测、涡流检测、超声检测、射线检测等)大多效率低、体积庞大、或只能对金属构件表面缺陷进行检测(如涡流检测和磁粉检测),涉及到内部损伤时一般检测繁琐(如漏磁检测需要加复杂的磁化装置、超声检测需要添加耦合剂等),或难以进行内部检测,目前技术大部分都是必须与待测磁性样品接触的接触式检测,难以实现自动化检测,导致检测的人力成本居高不下。现有的几种非接触式无损检测技术如涡流检测、机器视觉等则只能检测待测磁性样品的表面缺陷和损伤,因此目前还没有一种简单便捷的可以对待测磁性样品进行内部和表面同时检测的非接触式无损检测技术。Non-destructive testing can evaluate the performance and working status of the components to be tested without damaging them. It is a key technology to ensure the safe operation of equipment and is widely used in the industrial field. Metal components are widely used in production and life. Accurate and effective detection of damage and failure of metal components is of great significance to the safety of life and property of the country and people. In terms of non-destructive testing of metal components, conventional non-destructive testing technologies (such as magnetic flux leakage testing, magnetic particle testing, penetrant testing, eddy current testing, ultrasonic testing, radiographic testing, etc.) are mostly inefficient, bulky, or can only detect surface defects of metal components. (such as eddy current testing and magnetic particle testing), when it comes to internal damage, the detection is generally cumbersome (such as magnetic flux leakage testing requires a complex magnetization device, ultrasonic testing requires the addition of couplant, etc.), or it is difficult to perform internal testing. Most of the current technologies are Contact detection, which must be in contact with the magnetic sample to be tested, is difficult to implement automated detection, resulting in high labor costs for detection. Several existing non-contact non-destructive testing technologies, such as eddy current testing, machine vision, etc., can only detect surface defects and damage of the magnetic samples to be tested. Therefore, there is currently no simple and convenient method that can detect the interior and surface of the magnetic samples to be tested. Non-contact non-destructive testing technology that detects simultaneously.
磁无损检测技术是一种重要的无损检测技术手段,原理是通过探测磁性物体表面的磁场分布来检测其表面和内部的裂纹或损伤。但目前的磁无损检测技术如漏磁和磁粉检测等都带有复杂的磁化装置导致体积庞大,检测程序复杂、成本高昂,尤其是目前的无损检测技术都无法检测形状不规则的物品。目前为止,还没有一种简单便捷、检测快速以及非接触式的磁无损检测技术和手段。Magnetic non-destructive testing technology is an important non-destructive testing technology. The principle is to detect cracks or damage on the surface and inside of magnetic objects by detecting the magnetic field distribution on the surface. However, current magnetic non-destructive testing technologies, such as magnetic flux leakage and magnetic particle testing, all have complex magnetizing devices, which result in bulky, complex testing procedures and high costs. In particular, current non-destructive testing technologies cannot detect irregularly shaped items. So far, there is no simple, convenient, fast and non-contact magnetic non-destructive testing technology and means.
因此,亟需一种基于磁传感器的无损检测系统。Therefore, a non-destructive testing system based on magnetic sensors is urgently needed.
发明内容Contents of the invention
本发明的目的是提供一种基于磁传感器的无损检测系统,以解决上述现有技术中的问题,能够实现待测磁性样品的快速及非接触式检测。The purpose of the present invention is to provide a non-destructive testing system based on a magnetic sensor to solve the above-mentioned problems in the prior art and enable rapid and non-contact detection of magnetic samples to be tested.
本发明提供了一种基于磁传感器的无损检测系统,包括:磁传感器、信息处理模块、上位机和样品驱动装置,其中,所述样品驱动装置用于驱动待测磁性样品与所述磁传感器的相对位置发生变化;所述磁传感器用于在所述磁传感器相对于待测磁性样品发生位置变化的过程中,实时采集所述磁传感器所在位置的磁场强度信息;所述信息处理模块用于对所述磁传感器的磁场强度检测信号进行采集、记录、存储和处理,并将信号处理结果上传到所述上位机;所述上位机用于对所述信息处理模块所得到的信号处理结果以可视化的界面显示,并与标准样品所对应的信号进行对比,以得到待测磁性样品的检测结果。The invention provides a non-destructive testing system based on a magnetic sensor, which includes: a magnetic sensor, an information processing module, a host computer and a sample driving device, wherein the sample driving device is used to drive the magnetic sample to be tested and the magnetic sensor. The relative position changes; the magnetic sensor is used to collect the magnetic field intensity information of the position of the magnetic sensor in real time during the position change of the magnetic sensor relative to the magnetic sample to be measured; the information processing module is used to The magnetic field intensity detection signal of the magnetic sensor is collected, recorded, stored and processed, and the signal processing results are uploaded to the host computer; the host computer is used to visualize the signal processing results obtained by the information processing module The interface is displayed and compared with the signal corresponding to the standard sample to obtain the detection result of the magnetic sample to be tested.
如上所述的基于磁传感器的无损检测系统,其中,优选的是,所述基于磁传感器的无损检测系统还包括控制器,与所述磁传感器和所述样品驱动装置连接,用于控制待测磁性样品和所述磁传感器之间的相对运动。The non-destructive testing system based on the magnetic sensor as described above, preferably, the non-destructive testing system based on the magnetic sensor further includes a controller connected to the magnetic sensor and the sample driving device for controlling the test object. Relative motion between the magnetic sample and the magnetic sensor.
如上所述的基于磁传感器的无损检测系统,其中,优选的是,所述待测磁性样品与所述磁传感器的相对位置发生变化包括:待测磁性样品和磁传感器的位置均发生变化,具体是待测磁性样品旋转,在旋转过程中,磁传感器相对于待测磁性样品的高度保持不变,在待测磁性样品旋转一圈后,磁传感器相对于待测磁性样品的高度变化一次,以使磁传感器的检测信息能够覆盖待测磁性样品的所有高度。As described above, in the non-destructive testing system based on a magnetic sensor, preferably, the change in the relative position of the magnetic sample to be measured and the magnetic sensor includes: the positions of both the magnetic sample to be measured and the magnetic sensor change, specifically is the rotation of the magnetic sample to be measured. During the rotation, the height of the magnetic sensor relative to the magnetic sample to be measured remains unchanged. After the magnetic sample to be measured rotates once, the height of the magnetic sensor relative to the magnetic sample to be measured changes once. The detection information of the magnetic sensor can cover all heights of the magnetic sample to be measured.
如上所述的基于磁传感器的无损检测系统,其中,优选的是,所述样品驱动装置包括底座,所述底座上设置有旋转平台和第一安装支架,所述待测磁性样品设置在所述旋转平台上,所述旋转平台一侧设置有旋转电机,用于驱动所述旋转平台旋转;所述待测磁性样品可随所述旋转平台旋转,所述第一安装支架上沿竖直方向设置有导轨,所述信息处理模块设置在所述导轨上,所述导轨连接有升降电机,并且所述信息处理模块可沿所述导轨升降,所述磁传感器设置在所述信息处理模块的侧壁,所述磁传感器可随所述信息处理模块沿所述导轨升降。As described above, in the non-destructive testing system based on magnetic sensors, it is preferable that the sample driving device includes a base, a rotating platform and a first mounting bracket are provided on the base, and the magnetic sample to be tested is provided on the On the rotating platform, a rotating motor is provided on one side of the rotating platform for driving the rotating platform to rotate; the magnetic sample to be measured can rotate with the rotating platform, and the first mounting bracket is arranged in a vertical direction. There is a guide rail, the information processing module is arranged on the guide rail, the guide rail is connected with a lifting motor, and the information processing module can be lifted and lowered along the guide rail, and the magnetic sensor is arranged on the side wall of the information processing module , the magnetic sensor can move up and down along the guide rail along with the information processing module.
如上所述的基于磁传感器的无损检测系统,其中,优选的是,所述导轨一侧设置有用于检测所述磁传感器升降位置的第一位置检测传感器,所述磁传感器的下端停止点与所述待测磁性样品的下端位置对应,所述磁传感器的上端停止点与所述待测磁性样品的顶端位置对应。As described above, in the non-destructive testing system based on magnetic sensors, it is preferable that a first position detection sensor for detecting the lifting position of the magnetic sensor is provided on one side of the guide rail, and the lower end stop point of the magnetic sensor is in contact with the The lower end position of the magnetic sample to be measured corresponds to the upper end stop point of the magnetic sensor corresponding to the top position of the magnetic sample to be measured.
如上所述的基于磁传感器的无损检测系统,其中,优选的是,所述待测磁性样品与所述磁传感器的相对位置发生变化包括:待测磁性样品的位置保持不变,磁传感器相对于待测磁性样品发生横向和/或竖向移动,以使磁传感器相对于待测磁性样品的一个平面进行全部覆盖。As described above, the non-destructive testing system based on the magnetic sensor, preferably, the change in the relative position of the magnetic sample to be measured and the magnetic sensor includes: the position of the magnetic sample to be measured remains unchanged, and the magnetic sensor is relative to the magnetic sensor. The magnetic sample to be measured moves laterally and/or vertically, so that the magnetic sensor fully covers a plane of the magnetic sample to be measured.
如上所述的基于磁传感器的无损检测系统,其中,优选的是,所述样品驱动装置包括第二安装支架,所述信息处理模块设置在所述第二安装支架上,所述磁传感器设置在所述信息处理模块的下方,所述信息处理模块连接有电机单元,所述电机单元用于驱动所述信息处理模块带动所述磁传感器在待测磁性样品表面沿水平方向和/或垂直方向运动。As described above, the non-destructive testing system based on magnetic sensors, preferably, the sample driving device includes a second mounting bracket, the information processing module is arranged on the second mounting bracket, and the magnetic sensor is arranged on Below the information processing module, the information processing module is connected to a motor unit. The motor unit is used to drive the information processing module to drive the magnetic sensor to move in the horizontal direction and/or vertical direction on the surface of the magnetic sample to be measured. .
如上所述的基于磁传感器的无损检测系统,其中,优选的是,所述电机单元包括水平电机、垂直电机和竖直电机,其中,所述水平电机用于驱动所述信息处理模块带动所述磁传感器在待测磁性样品表面沿x轴方向移动,所述垂直电机用于驱动所述信息处理模块带动所述磁传感器在待测磁性样品表面沿y轴方向移动,所述竖直电机用于驱动所述信息处理模块带动所述磁传感器沿z轴方向移动。As described above, the non-destructive testing system based on magnetic sensors, preferably, the motor unit includes a horizontal motor, a vertical motor and a vertical motor, wherein the horizontal motor is used to drive the information processing module to drive the The magnetic sensor moves along the x-axis direction on the surface of the magnetic sample to be measured. The vertical motor is used to drive the information processing module to drive the magnetic sensor to move along the y-axis direction on the surface of the magnetic sample to be measured. The vertical motor is used to The information processing module is driven to drive the magnetic sensor to move along the z-axis direction.
如上所述的基于磁传感器的无损检测系统,其中,优选的是,所述磁传感器包括各向异性磁传感器、巨磁电阻、隧道结磁传感器和霍尔传感器中的至少一个;并且,所述磁传感器包括具有单探头的单个传感器,或者具有多探头的多个传感器。The non-destructive testing system based on magnetic sensors as described above, wherein preferably, the magnetic sensors include at least one of anisotropic magnetic sensors, giant magnetoresistance, tunnel junction magnetic sensors and Hall sensors; and, Magnetic sensors include a single sensor with a single probe, or multiple sensors with multiple probes.
如上所述的基于磁传感器的无损检测系统,其中,优选的是,所述信息处理模块包括信号放大电路,所述信号放大电路包括运算放大器、A/D芯片、单片机、电阻和电容。As described above, in the non-destructive testing system based on magnetic sensors, preferably, the information processing module includes a signal amplification circuit, and the signal amplification circuit includes an operational amplifier, an A/D chip, a microcontroller, a resistor and a capacitor.
本发明的基于磁传感器的无损检测系统,通过样品驱动装置驱动待测磁性样品与磁传感器的相对位置发生变化;通过磁传感器实时其所在位置的磁场强度信息;通过信息处理模块对磁传感器的磁场强度检测信号进行采集、记录、存储和处理,并将信号处理结果上传到上位机;通过上位机对信号处理结果以可视化的界面显示,并与标准样品所对应的信号进行对比,从而得到待测磁性样品的检测结果;通过探测待测磁性样品表面的磁场大小和分布情况,来判断待测磁性样品内部和表面是否存在缺陷、材质、均匀性和残余应力等;针对有磁性的材料进行检测,无需对样品进行磁化,去除了复杂的磁化装置,极大地降低了成本;无需任何耦合剂或磁粉液体,操作简单、检测快速便捷;非接触式检测,可以完全实现自动化或半自动化检测,减少人力成本;可以检测任何形状不规则的待测磁性样品。The non-destructive testing system based on the magnetic sensor of the present invention drives the relative position of the magnetic sample to be measured and the magnetic sensor to change through the sample driving device; real-time magnetic field strength information of its location through the magnetic sensor; and the magnetic field of the magnetic sensor through the information processing module. The intensity detection signal is collected, recorded, stored and processed, and the signal processing results are uploaded to the host computer; the signal processing results are displayed on a visual interface through the host computer and compared with the signals corresponding to the standard samples to obtain the results to be measured Detection results of magnetic samples; by detecting the size and distribution of the magnetic field on the surface of the magnetic sample to be tested, it is possible to determine whether there are defects, materials, uniformity and residual stress inside and on the surface of the magnetic sample to be tested; for testing magnetic materials, There is no need to magnetize the sample, eliminating the complex magnetization device, which greatly reduces the cost; no coupling agent or magnetic powder liquid is required, the operation is simple, and the detection is fast and convenient; the non-contact detection can fully realize automatic or semi-automatic detection, reducing manpower Low cost; can detect any irregularly shaped magnetic sample to be tested.
附图说明Description of drawings
为使本发明的目的、技术方案和优点更加清楚,下面将结合附图对本发明作进一步描述,其中:In order to make the purpose, technical solutions and advantages of the present invention clearer, the present invention will be further described below in conjunction with the accompanying drawings, in which:
图1为本发明提供的基于磁传感器的无损检测系统的第一实施例的结构示意图;Figure 1 is a schematic structural diagram of a first embodiment of a non-destructive testing system based on magnetic sensors provided by the present invention;
图2为本发明提供的基于磁传感器的无损检测系统的第二实施例的结构示意图。FIG. 2 is a schematic structural diagram of a second embodiment of a magnetic sensor-based non-destructive testing system provided by the present invention.
附图标记说明:1-磁传感器,2-待测磁性样品,3-底座,4-旋转平台,5-第一安装支架,6-导轨,7-信息处理模块,8-上位机,9-控制器,10-电机单元,11-第二安装支架。Explanation of reference symbols: 1-magnetic sensor, 2-magnetic sample to be measured, 3-base, 4-rotating platform, 5-first mounting bracket, 6-guide rail, 7-information processing module, 8-host computer, 9- Controller, 10-motor unit, 11-second mounting bracket.
具体实施方式Detailed ways
现在将参照附图来详细描述本公开的各种示例性实施例。对示例性实施例的描述仅仅是说明性的,决不作为对本公开及其应用或使用的任何限制。本公开可以以许多不同的形式实现,不限于这里所述的实施例。提供这些实施例是为了使本公开透彻且完整,并且向本领域技术人员充分表达本公开的范围。应注意到:除非另外具体说明,否则在这些实施例中阐述的部件和步骤的相对布置、材料的组分、数字表达式和数值应被解释为仅仅是示例性的,而不是作为限制。Various exemplary embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. The description of the exemplary embodiments is illustrative only and is in no way intended to limit the disclosure, its application or uses. The present disclosure may be implemented in many different forms and is not limited to the embodiments described herein. These embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. It should be noted that, unless specifically stated otherwise, the relative arrangements of parts and steps, compositions of materials, numerical expressions, and numerical values set forth in these examples are to be construed as illustrative only and not as limitations.
本公开中使用的“第一”、“第二”:以及类似的词语并不表示任何顺序、数量或者重要性,而只是用来区分不同的部分。“包括”或者“包含”等类似的词语意指在该词前的要素涵盖在该词后列举的要素,并不排除也涵盖其他要素的可能。“上”、“下”等仅用于表示相对位置关系,当被描述对象的绝对位置改变后,则该相对位置关系也可能相应地改变。The terms "first," "second," and similar words used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. Similar words such as "include" or "include" mean that the elements before the word include the elements listed after the word, and do not exclude the possibility of also covering other elements. "Up", "down", etc. are only used to express relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.
在本公开中,当描述到特定部件位于第一部件和第二部件之间时,在该特定部件与第一部件或第二部件之间可以存在居间部件,也可以不存在居间部件。当描述到特定部件连接其它部件时,该特定部件可以与所述其它部件直接连接而不具有居间部件,也可以不与所述其它部件直接连接而具有居间部件。In this disclosure, when a specific component is described as being between a first component and a second component, there may or may not be an intervening component between the specific component and the first component or the second component. When a specific component is described as being connected to other components, the specific component may be directly connected to the other components without intervening components, or may not be directly connected to the other components but have intervening components.
本公开使用的所有术语(包括技术术语或者科学术语)与本公开所属领域的普通技术人员理解的含义相同,除非另外特别定义。还应当理解,在诸如通用字典中定义的术语应当被解释为具有与它们在相关技术的上下文中的含义相一致的含义,而不应用理想化或极度形式化的意义来解释,除非这里明确地这样定义。All terms (including technical terms or scientific terms) used in this disclosure have the same meanings as understood by one of ordinary skill in the art to which this disclosure belongs, unless otherwise specifically defined. It should also be understood that terms defined in, for example, general dictionaries should be construed to have meanings consistent with their meanings in the context of the relevant technology and should not be interpreted in an idealized or highly formalized sense, except as expressly stated herein. Define it this way.
对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论,但在适当情况下,技术、方法和设备应当被视为说明书的一部分。Techniques, methods and devices known to those of ordinary skill in the relevant art may not be discussed in detail, but where appropriate, the techniques, methods and devices should be considered a part of the specification.
如图1和图2所示,本实施例提供的基于磁传感器的无损检测系统,包括:磁传感器1、信息处理模块7、上位机8(图2未示出)和样品驱动装置,其中,所述样品驱动装置用于驱动待测磁性样品2与所述磁传感器1的相对位置发生变化;所述磁传感器1用于在所述磁传感器1相对于待测磁性样品2发生位置变化的过程中,实时采集所述磁传感器1所在位置的磁场强度信息;所述信息处理模块7用于对所述磁传感器1的磁场强度检测信号进行采集、记录、存储和处理,并将信号处理结果上传到所述上位机8;所述上位机8用于对所述信息处理模块7所得到的信号处理结果以可视化的界面心思,并与标准样品所对应的信号进行对比,以得到待测磁性样品2的检测结果。As shown in Figures 1 and 2, the magnetic sensor-based non-destructive testing system provided by this embodiment includes: a magnetic sensor 1, an information processing module 7, a host computer 8 (not shown in Figure 2) and a sample driving device, where, The sample driving device is used to drive the relative position of the magnetic sample 2 to be measured to the magnetic sensor 1 to change; the magnetic sensor 1 is used to change the position of the magnetic sensor 1 relative to the magnetic sample 2 to be measured. , the magnetic field strength information of the location of the magnetic sensor 1 is collected in real time; the information processing module 7 is used to collect, record, store and process the magnetic field strength detection signal of the magnetic sensor 1, and upload the signal processing results to the host computer 8; the host computer 8 is used to visualize the signal processing results obtained by the information processing module 7 and compare them with the signals corresponding to the standard samples to obtain the magnetic samples to be measured. 2 test results.
其中,标准样品指的是形状、材料、工艺等参数均与待测磁性样品相同的无缺陷产品,可通过XRD检测等检测手段来得到标准样品。待测磁性样品2指的是大量具有磁性的构件,如碳钢、金属汽车零部件、轴承以及其他磁性材料等。Among them, the standard sample refers to a defect-free product with the same shape, material, process and other parameters as the magnetic sample to be tested. The standard sample can be obtained through detection methods such as XRD detection. The magnetic sample 2 to be tested refers to a large number of magnetic components, such as carbon steel, metal auto parts, bearings and other magnetic materials.
进一步地,所述磁传感器1为各向异性磁传感器(AMR)、巨磁电阻(GMR)、隧道结磁传感器(TMR)和霍尔传感器(Hall)中的至少一个。进一步,所述磁传感器1包括具有单探头的单个传感器,或者具有多探头的多个传感器。需要说明的是,本发明对磁传感器的类型、数量及探头类型不作具体限定。Further, the magnetic sensor 1 is at least one of anisotropic magnetic sensor (AMR), giant magnetoresistance (GMR), tunnel junction magnetic sensor (TMR) and Hall sensor (Hall). Further, the magnetic sensor 1 includes a single sensor with a single probe, or multiple sensors with multiple probes. It should be noted that the present invention does not specifically limit the type, quantity and probe type of magnetic sensors.
进一步地,所述信息处理模块7包括信号放大电路,所述信号放大电路包括运算放大器、A/D芯片、单片机以及各种电阻和电容。在具体实现中,信号放大电路可以布置在PCB板上。具体而言,信息处理模块7对磁传感器1的检测信号进行采集、处理、数字化以及数据传输和通讯到上位机8,以供后端的上位机8对采集到的数据进行分析、处理和显示。上位机8为计算机或工控机等,用来对采集到的数据进行处理和显示。Further, the information processing module 7 includes a signal amplification circuit, which includes an operational amplifier, an A/D chip, a microcontroller, and various resistors and capacitors. In specific implementation, the signal amplification circuit can be arranged on the PCB board. Specifically, the information processing module 7 collects, processes, digitizes, and transmits and communicates the detection signals of the magnetic sensor 1 to the host computer 8 so that the back-end host computer 8 can analyze, process, and display the collected data. The host computer 8 is a computer or an industrial computer, which is used to process and display the collected data.
在工作中,通过样品驱动装置驱动待测磁性样品2与磁传感器1的相对位置发生变化,在此过程中,通过磁传感器1实时其所在位置的磁场强度信息;通过信息处理模块7对磁传感器1的磁场强度检测信号进行处理,并将信号处理结果上传到上位机8;通过上位机8对信号处理结果与标准样品所对应的信号进行对比,从而得到待测磁性样品2的检测结果。其中,检测结果包括待测磁性样品2的内部和表面是否存在缺陷、材质、均匀性和残余应力等。During work, the relative position of the magnetic sample 2 to be measured and the magnetic sensor 1 is driven by the sample driving device to change. During this process, the magnetic field intensity information of its location is real-timely obtained through the magnetic sensor 1; the magnetic sensor is processed through the information processing module 7 The magnetic field strength detection signal of 1 is processed, and the signal processing result is uploaded to the host computer 8; the host computer 8 compares the signal processing result with the signal corresponding to the standard sample, thereby obtaining the detection result of the magnetic sample 2 to be tested. Among them, the test results include whether there are defects, material, uniformity, residual stress, etc. inside and on the surface of the magnetic sample 2 to be tested.
考虑到任何磁性物体的内部性能都与其表面磁场分布密切相关,无论当其内部成分、缺陷、孔洞以及应力的变化都会导致其表面磁场分布的异常,因此本发明通过检测待测磁性样品2表面磁场的分布就可以对待测磁性样品2的内部性能进行判断,通过与标准样品进行对比,来得到样品检测结果,可以作为一种新型的无损检测手段。Considering that the internal performance of any magnetic object is closely related to its surface magnetic field distribution, changes in its internal composition, defects, holes and stress will cause abnormalities in its surface magnetic field distribution. Therefore, the present invention detects the surface magnetic field of the magnetic sample 2 to be measured. The distribution can be used to judge the internal performance of the magnetic sample 2 to be tested. By comparing it with the standard sample, the sample test result can be obtained, which can be used as a new non-destructive testing method.
进一步地,本发明提供的基于磁传感器的无损检测系统可以用于对钢管缺陷及壁厚的无损检测;对磁环缺陷及壁厚的无损检测;对磁性材料的性能检测,如检测绝缘体磁性材料磁导率和磁损耗等;对各种不同材料材质的检测;对芯片,太阳能硅片等材料进行表面平整度及粗糙度检测;对污水、农药残留物进行检测;对铁路车轮、桥梁、地下管道等应用领域的目标检测物进行实时监测和检测;对焊缝进行检测;对PCB板进行检测等。需要说明的是,本发明对无损检测系统的应用场景不作具体限定。Furthermore, the non-destructive testing system based on magnetic sensors provided by the present invention can be used for non-destructive testing of steel pipe defects and wall thickness; non-destructive testing of magnetic ring defects and wall thickness; and performance testing of magnetic materials, such as testing of insulator magnetic materials. Magnetic permeability and magnetic loss, etc.; detection of various materials; surface flatness and roughness detection of chips, solar silicon wafers and other materials; detection of sewage and pesticide residues; detection of railway wheels, bridges, underground Real-time monitoring and detection of target detection objects in pipelines and other application fields; detection of welds; detection of PCB boards, etc. It should be noted that the present invention does not specifically limit the application scenarios of the non-destructive testing system.
更进一步地,所述基于磁传感器的无损检测系统还包括控制器9(图2未示出),与所述磁传感器1和所述样品驱动装置连接,用于控制待测磁性样品2和所述磁传感器1之间的相对运动。示例性地,控制器9为可编程逻辑控制器(PLC),在本发明的一种实施方式中,控制器9的型号为S7-300,需要说明的是,本发明对控制器9的类型及型号不作具体限定。Furthermore, the magnetic sensor-based non-destructive testing system also includes a controller 9 (not shown in Figure 2), which is connected to the magnetic sensor 1 and the sample driving device, and is used to control the magnetic sample 2 to be tested and the magnetic sample 2. The relative motion between the magnetic sensors 1. Illustratively, the controller 9 is a programmable logic controller (PLC). In one embodiment of the present invention, the model of the controller 9 is S7-300. It should be noted that the present invention does not specify the type of the controller 9 and models are not specifically limited.
如图1所示,在本发明的一种实施方式中,所述待测磁性样品2与所述磁传感器1的相对位置发生变化包括:待测磁性样品2和磁传感器1的位置均发生变化,具体是待测磁性样品2旋转,在旋转过程中,磁传感器1相对于待测磁性样品2的高度保持不变,在待测磁性样品2旋转一圈后,磁传感器1相对于待测磁性样品2的高度变化一次,以使磁传感器1的检测信息能够覆盖待测磁性样品2的所有高度。As shown in Figure 1, in one embodiment of the present invention, the change in the relative position of the magnetic sample 2 to be measured and the magnetic sensor 1 includes: the positions of both the magnetic sample 2 to be measured and the magnetic sensor 1 change. , specifically, the magnetic sample 2 to be measured rotates. During the rotation process, the height of the magnetic sensor 1 relative to the magnetic sample 2 to be measured remains unchanged. After the magnetic sample 2 to be measured rotates once, the height of the magnetic sensor 1 relative to the magnetic sample 2 to be measured remains unchanged. The height of the sample 2 changes once so that the detection information of the magnetic sensor 1 can cover all heights of the magnetic sample 2 to be measured.
具体而言,如图1所示,所述样品驱动装置包括底座3,所述底座3上设置有旋转平台4和第一安装支架5,所述待测磁性样品2设置在所述旋转平台4上,所述旋转平台4一侧设置有旋转电机(未示出),用于驱动所述旋转平台4旋转;所述待测磁性样品2可随所述旋转平台4旋转,所述第一安装支架5上沿竖直方向设置有导轨6,所述信息处理模块7设置在所述导轨6上,所述导轨6连接有升降电机(未示出),并且所述信息处理模块7可沿所述导轨6升降,所述磁传感器1设置在所述信息处理模块7的侧壁,所述磁传感器1可随所述信息处理模块7沿所述导轨6升降。具体而言,控制器9用于控制旋转电机的旋转方向、转速、升降电机的升降方向、升降速度及升降启停等。在本发明的一种实施方式中,旋转平台4可以为放置待测磁性样品的三维移动平台。Specifically, as shown in Figure 1, the sample driving device includes a base 3. A rotating platform 4 and a first mounting bracket 5 are provided on the base 3. The magnetic sample 2 to be measured is arranged on the rotating platform 4. On one side of the rotating platform 4, a rotating motor (not shown) is provided for driving the rotating platform 4 to rotate; the magnetic sample 2 to be measured can rotate with the rotating platform 4, and the first installation The bracket 5 is provided with a guide rail 6 in a vertical direction, and the information processing module 7 is provided on the guide rail 6. The guide rail 6 is connected to a lifting motor (not shown), and the information processing module 7 can move along the The guide rail 6 rises and falls, and the magnetic sensor 1 is arranged on the side wall of the information processing module 7 . The magnetic sensor 1 can rise and fall along the guide rail 6 with the information processing module 7 . Specifically, the controller 9 is used to control the rotation direction and speed of the rotating motor, the lifting direction, lifting speed, lifting start and stop of the lifting motor, etc. In one embodiment of the present invention, the rotating platform 4 may be a three-dimensional moving platform on which the magnetic sample to be measured is placed.
进一步地,所述导轨6一侧设置有用于检测所述磁传感器1升降位置的第一位置检测传感器(未示出),所述磁传感器1的下端停止点与所述待测磁性样品2的下端位置对应,所述磁传感器1的上端停止点与所述待测磁性样品2的顶端位置对应。Further, a first position detection sensor (not shown) for detecting the lifting position of the magnetic sensor 1 is provided on one side of the guide rail 6 , and the lower end stop point of the magnetic sensor 1 is in contact with the magnetic sample 2 to be measured. The lower end position corresponds to the upper end stop point of the magnetic sensor 1 and the top position of the magnetic sample 2 to be measured.
在具体实现中,将待测磁性样品2放置在旋转平台4上,通过控制器9控制旋转电机旋转,当待测磁性样品2随着旋转平台4旋转时,就可以检测出待测磁性样品2表面的磁场分布;通过控制器9控制升降电机的高度,进而调节待测磁性样品2的高度,就可以对待测磁性样品2不同高度处的周边磁场进行探测并获得待测磁性样品2的全部信息,依据磁传感器1输出信号的变化与预先存储在上位机8中的标准数据进行对比,就可以判断出待测磁性样品2内部的缺陷或损伤。而且,通过上位机8对相关数据进行分析,就可以检测出待测磁性样品2的内部相关信息,如材质、形状、缺陷大小和位置以及厚度等。在本发明的另一种实施方式中,也可以将多个磁传感器1放置在靠近待测磁性样品2不同高度的位置,可以加快检测速率,磁传感器与待测磁性样品2之间的距离可以依据不同的场景调节,本发明对此不作具体限定。In a specific implementation, the magnetic sample 2 to be measured is placed on the rotating platform 4, and the rotation of the rotating motor is controlled by the controller 9. When the magnetic sample 2 to be measured rotates with the rotating platform 4, the magnetic sample 2 to be measured can be detected. The magnetic field distribution on the surface; by controlling the height of the lifting motor through the controller 9 and then adjusting the height of the magnetic sample 2 to be measured, the surrounding magnetic field at different heights of the magnetic sample 2 to be measured can be detected and all information of the magnetic sample 2 to be measured can be obtained. , based on comparing the changes in the output signal of the magnetic sensor 1 with the standard data pre-stored in the host computer 8, the internal defects or damage of the magnetic sample 2 to be measured can be determined. Moreover, by analyzing the relevant data through the host computer 8, the internal relevant information of the magnetic sample 2 to be tested can be detected, such as material, shape, defect size and location, thickness, etc. In another embodiment of the present invention, multiple magnetic sensors 1 can also be placed at different heights close to the magnetic sample 2 to be measured, which can speed up the detection rate. The distance between the magnetic sensors and the magnetic sample 2 to be measured can be According to different scene adjustments, the present invention does not specifically limit this.
更进一步地,如图2所示,所述待测磁性样品2与所述磁传感器1的相对位置发生变化包括:待测磁性样品2的位置保持不变,磁传感器1相对于待测磁性样品2发生横向和/或竖向移动,以使磁传感器1相对于待测磁性样品2的一个平面进行全部覆盖。Furthermore, as shown in Figure 2, the change in the relative position of the magnetic sample 2 to be measured and the magnetic sensor 1 includes: the position of the magnetic sample 2 to be measured remains unchanged, and the magnetic sensor 1 is relative to the magnetic sample to be measured. 2 moves laterally and/or vertically so that the magnetic sensor 1 fully covers a plane of the magnetic sample 2 to be measured.
具体而言,如图2所示,所述样品驱动装置包括第二安装支架11,所述信息处理模块7设置在所述第二安装支架11上,所述磁传感器1设置在所述信息处理模块7的下方,所述信息处理模块7连接有电机单元10,所述电机单元10用于驱动所述信息处理模块7带动所述磁传感器1在待测磁性样品2表面沿水平方向和/或垂直方向运动。Specifically, as shown in Figure 2, the sample driving device includes a second mounting bracket 11, the information processing module 7 is disposed on the second mounting bracket 11, and the magnetic sensor 1 is disposed on the information processing module. Below the module 7, the information processing module 7 is connected to a motor unit 10. The motor unit 10 is used to drive the information processing module 7 to drive the magnetic sensor 1 on the surface of the magnetic sample 2 to be measured in the horizontal direction and/or vertical movement.
进一步地,所述电机单元10包括水平电机、垂直电机和竖直电机,其中,所述水平电机用于驱动所述信息处理模块7带动所述磁传感器1在待测磁性样品2表面沿x轴方向移动,所述垂直电机用于驱动所述信息处理模块7带动所述磁传感器1在待测磁性样品2表面沿y轴方向移动,所述竖直电机用于驱动所述信息处理模块7带动所述磁传感器1沿z轴方向移动。具体而言,控制器9用于控制水平步进电机、垂直步进电机和竖直步进电机的运行方向、运行速度等。通过水平电机和垂直电机,可以控制磁传感器1对待测磁性样品2的扫描方向、扫描速度等;通过竖直电机,可以控制磁传感器1相对于待测磁性样品2的高度,以适应不同厚度的待测磁性样品及不同场景的检测。在本发明的一种实施方式中,水平电机、垂直电机和竖直电机均为步进电机,需要说明的是,本发明对水平电机、垂直电机和竖直电机的类型、型号、数量及分布位置等不作具体限定。Further, the motor unit 10 includes a horizontal motor, a vertical motor and a vertical motor, wherein the horizontal motor is used to drive the information processing module 7 to drive the magnetic sensor 1 on the surface of the magnetic sample 2 to be measured along the x-axis. The vertical motor is used to drive the information processing module 7 to drive the magnetic sensor 1 to move in the y-axis direction on the surface of the magnetic sample 2 to be measured. The vertical motor is used to drive the information processing module 7 to drive the magnetic sensor 1 to move along the y-axis direction. The magnetic sensor 1 moves along the z-axis direction. Specifically, the controller 9 is used to control the running direction, running speed, etc. of the horizontal stepper motor, the vertical stepper motor, and the vertical stepper motor. Through the horizontal motor and the vertical motor, the scanning direction and scanning speed of the magnetic sensor 1 to the magnetic sample 2 to be measured can be controlled; through the vertical motor, the height of the magnetic sensor 1 relative to the magnetic sample 2 to be measured can be controlled to adapt to different thicknesses. Detection of magnetic samples to be tested and different scenarios. In one embodiment of the present invention, the horizontal motors, vertical motors and vertical motors are all stepper motors. It should be noted that the present invention does not specify the type, model, quantity and distribution of the horizontal motors, vertical motors and vertical motors. The location is not specifically limited.
在具体实现中,将待测磁性样品2放置在磁传感器1下方,通过电机单元驱动磁传感器1对待测磁性样品2进行逐行扫描,获取待测磁性样品2的二维表面磁场分布信息,并与标准样品或事先设定的数据进行对比,以判断待测磁性样品2的内部信息。In the specific implementation, the magnetic sample 2 to be measured is placed under the magnetic sensor 1, and the magnetic sensor 1 is driven by the motor unit to scan the magnetic sample 2 to be measured line by line to obtain the two-dimensional surface magnetic field distribution information of the magnetic sample 2 to be measured, and Compare it with a standard sample or preset data to determine the internal information of the magnetic sample 2 to be tested.
本发明通过探测待测磁性样品表面的磁场大小和分布情况,来判断待测磁性样品内部和表面是否存在缺陷、材质、均匀性和残余应力等;探测方式大大简化,没有任何复杂庞大的磁化、退磁、辅助耗材以及机械传动装置,不仅可以做成便携式的检测装置;非接触的测量方式可以直接安装在某些需要重点观测的地点,如地下管道、化工管道等一些容易发生事故的地方并随时传输数据,对待测目标的性能做到实时检测。The present invention determines whether there are defects, materials, uniformity, residual stress, etc. inside and on the surface of the magnetic sample to be measured by detecting the size and distribution of the magnetic field on the surface of the magnetic sample to be measured; the detection method is greatly simplified, and there is no complicated and huge magnetization, Demagnetization, auxiliary consumables and mechanical transmission devices can not only be made into portable detection devices; non-contact measurement methods can be directly installed in certain locations that require key observations, such as underground pipelines, chemical pipelines and other accident-prone places, and can be used at any time. Transmit data to detect the performance of the target under test in real time.
本发明实施例提供的基于磁传感器的无损检测系统,通过样品驱动装置驱动待测磁性样品与磁传感器的相对位置发生变化;通过磁传感器实时其所在位置的磁场强度信息;通过信息处理模块对磁传感器的磁场强度检测信号进行采集、记录、存储和处理,并将信号处理结果上传到上位机;通过上位机对信号处理结果以可视化界面显示,并与标准样品所对应的信号进行对比,从而得到待测磁性样品的检测结果;通过探测待测磁性样品表面的磁场大小和分布情况,来判断待测磁性样品内部和表面是否存在缺陷、材质、均匀性和残余应力等;针对有磁性的材料进行检测,无需对样品进行磁化,去除了复杂的磁化装置,极大地降低了成本;无需任何耦合剂或磁粉液体,操作简单、检测快速便捷;非接触式检测,可以完全实现自动化或半自动化检测,减少人力成本;可以检测任何形状不规则的待测磁性样品。The non-destructive testing system based on the magnetic sensor provided by the embodiment of the present invention uses the sample driving device to drive the relative position of the magnetic sample to be tested and the magnetic sensor to change; uses the magnetic sensor to obtain real-time magnetic field intensity information at its location; and uses the information processing module to detect the magnetic field intensity. The magnetic field strength detection signal of the sensor is collected, recorded, stored and processed, and the signal processing results are uploaded to the host computer; the signal processing results are displayed on a visual interface through the host computer and compared with the signals corresponding to the standard samples, thereby obtaining Test results of the magnetic sample to be tested; by detecting the size and distribution of the magnetic field on the surface of the magnetic sample to be tested, it is possible to determine whether there are defects, materials, uniformity, residual stress, etc. inside and on the surface of the magnetic sample to be tested; for magnetic materials The detection does not require magnetizing the sample, eliminating the complex magnetization device, which greatly reduces the cost; it does not require any coupling agent or magnetic powder liquid, the operation is simple, and the detection is fast and convenient; the non-contact detection can fully realize automatic or semi-automatic detection. Reduce labor costs; can detect any irregularly shaped magnetic samples to be tested.
至此,已经详细描述了本公开的各实施例。为了避免遮蔽本公开的构思,没有描述本领域所公知的一些细节。本领域技术人员根据上面的描述,完全可以明白如何实施这里公开的技术方案。Up to this point, various embodiments of the present disclosure have been described in detail. To avoid obscuring the concepts of the present disclosure, some details that are well known in the art have not been described. Based on the above description, those skilled in the art can completely understand how to implement the technical solution disclosed here.
虽然已经通过示例对本公开的一些特定实施例进行了详细说明,但是本领域的技术人员应该理解,以上示例仅是为了进行说明,而不是为了限制本公开的范围。本领域的技术人员应该理解,可在不脱离本公开的范围和精神的情况下,对以上实施例进行修改或者对部分技术特征进行等同替换。本公开的范围由所附权利要求来限定。Although some specific embodiments of the present disclosure have been described in detail through examples, those skilled in the art will understand that the above examples are for illustration only and are not intended to limit the scope of the disclosure. Those skilled in the art should understand that the above embodiments can be modified or some technical features can be equivalently replaced without departing from the scope and spirit of the present disclosure. The scope of the disclosure is defined by the appended claims.
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