CN118225013A - On-machine ultrasonic thickness measurement pose selection method based on rotation scanning measurement - Google Patents
On-machine ultrasonic thickness measurement pose selection method based on rotation scanning measurement Download PDFInfo
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- 238000005259 measurement Methods 0.000 title claims abstract description 128
- 238000009683 ultrasonic thickness measurement Methods 0.000 title claims abstract description 28
- 238000010187 selection method Methods 0.000 title claims abstract description 8
- 238000000034 method Methods 0.000 claims description 39
- 239000000523 sample Substances 0.000 claims description 37
- 239000002173 cutting fluid Substances 0.000 claims description 3
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B17/00—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations
- G01B17/02—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations for measuring thickness
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Abstract
The invention discloses an on-machine ultrasonic thickness measurement pose selection method based on rotary scanning measurement, which belongs to the technical field of ultrasonic measurement and comprises the following steps: operating one of the rotating shafts of the machine tool, and carrying out first scanning measurement on the position to be detected; obtaining an optimal measurement position I of the rotating shaft based on echo waveform data; operating the other rotating shaft of the machine tool, and performing second scanning measurement on the position to be measured according to the same steps to obtain an optimal measurement position II of the rotating shaft; operating two rotating shafts of the machine tool to respectively reach respective optimal measuring positions for thickness measurement; and taking the average value of the measured data of the two rotation shafts at the optimal measuring position as the accurate thickness measured value of the position to be measured. The invention can eliminate measurement inaccuracy caused by incomplete parallel lamination of the surface to be measured and the end face of the measuring head, and realize high-efficiency and high-precision thickness measurement.
Description
Technical Field
The invention relates to the technical field of ultrasonic thickness measurement, in particular to an on-machine ultrasonic thickness measurement pose selection method based on rotary scanning measurement.
Background
Parts or components comprising thin walls and sheet structures are widely used in the fields of aerospace, molds, ships and the like, and for processing and manufacturing of such parts, a plurality of or even tens of process procedures are often included, and the thickness measurement is carried out on the key thin walls and sheet structures of the parts between key procedures, so that the effective evaluation of the quality of the processing process can be realized, and the subsequent process procedures can be timely adjusted to improve the yield.
Ultrasonic measurement is a common industrial measurement means, has the advantages of low cost, high measurement speed, no harm to human bodies and the like, and is widely applied to the fields of metal flaw detection, residual stress measurement, thickness measurement and the like. For ultrasonic thickness measurement, the traditional mode is to stop and wait between working procedures, and a field operator uses a handheld ultrasonic thickness gauge to measure the thickness, and the method needs to stop for a long time and introduces manual operation, so that the automation degree and the processing efficiency of a production line are reduced, and as unmanned manufacturing and intelligent manufacturing develop, the industry is urgent to the requirements of automatic on-machine ultrasonic thickness measurement equipment and systems without manual participation. For on-machine ultrasonic thickness measurement, some inventions or products, such as RWP20.50-G-UTP series ultrasonic thickness measurement probes of Hakkan, patents Ding Jiexiong, meng Guodong, wang Jiawen and the like, are available, and a flexible-contact knife handle type on-machine ultrasonic thickness measurement device, such as CNC111843617 B.2022, ding Jiexiong, xue Erjiang, liao Chengyu and the like, is available.
However, in the actual on-machine ultrasonic thickness measurement process, because the thickness measurement object is a curved surface or a sheet structure to be measured has a machining error, an included angle may exist between the surface of the thickness measurement object and the plane of the thickness measurement probe, and the surface of the thickness measurement object and the plane of the thickness measurement probe cannot be attached in parallel, so that the thickness measurement accuracy is unstable. In order to solve the problem, patent Liu Haibo, yang Wei, lenalling, etc. the probe adaptively adjusts the thin-walled part on-machine ultrasonic thickness measuring method, CN106643591B.2018, zhao Zhengcai, li Yao, fu Yucan, etc. an on-machine thickness measuring system based on ultrasonic signals and mechanical signals is provided, the CN106649591 B.2021 'designs a ball axis mechanism which can make the probe and the surface to be measured in parallel to each other, so that the probe can rotate in any direction, but the two methods both involve complex probe rotating mechanism and/or sensor system, increase the risk of interference with machine tool parts or parts to be measured in the thickness measuring process, and the patent Zhao Zhengcai, li Yao, fu Yucan, etc. the thickness of the complex thin-walled structure parts on-machine measuring method, CN110076631B.2020' provides an on-machine thickness measuring method by using a contact probe, and then ultrasonic thickness measuring is carried out according to the normal vector, so as to realize the surface to be measured to be attached to the ultrasonic probe, but the method involves multiple measuring instruments such as an on-machine ultrasonic thickness measuring instrument, a contact probe and calculating operation, so as to realize the ultrasonic thickness measuring process is more difficult to realize the ultrasonic thickness measuring process in parallel to realize high-efficient and fast and convenient thickness measuring process.
Disclosure of Invention
Aiming at the problem that an included angle exists between the surface of a thickness measuring object and the plane of a thickness measuring probe, which possibly exists in the existing on-machine ultrasonic thickness measurement, the surface of the thickness measuring object and the plane of the thickness measuring probe cannot be attached in parallel, so that the thickness measuring precision is unstable, the invention provides an on-machine ultrasonic thickness measuring pose selection method based on rotary scanning measurement, which is used for eliminating measurement inaccuracy caused by the fact that the surface to be measured and the end face of a measuring head cannot be attached in parallel completely, and further realizing high-efficiency and high-precision thickness measurement.
In order to achieve the above object, the present invention has the following technical scheme:
An on-machine ultrasonic thickness measurement pose selection method based on rotary scanning measurement is characterized by comprising the following steps of:
s1, operating one of rotating shafts of a machine tool, and carrying out first scanning measurement on a to-be-positioned position;
s2, during measurement, the current position of the rotating shaft is taken as the center, measurement is performed once at certain unit angles, and a plurality of echo waveform data are returned after each measurement;
S3, obtaining an optimal measurement position I of the rotating shaft based on echo waveform data;
S4, operating another rotating shaft of the machine tool, and carrying out second scanning measurement on the position to be measured according to the same steps to obtain an optimal measurement position II of the rotating shaft;
S5, two rotating shafts of the machine tool are operated to reach respective optimal measuring positions respectively, and thickness measurement is carried out;
s6, taking the average value of the measurement data of the two rotating shafts at the optimal measurement position as the accurate thickness measurement value of the position to be measured.
Before operation, preparing a measuring environment, operating a machine tool to jet or spray cutting fluid at a position to be measured, ensuring that no solid sundries remain at the position to be measured, and smearing a couplant or substituting the couplant for fluid.
Before operation, determining an initial measurement gesture according to part number model or visual inspection, enabling the ultrasonic probe to be approximately vertical to the position to be measured, and then operating a machine tool to move the ultrasonic thickness measuring probe to the position to be measured, so that the end face of the probe is tightly attached to the position to be measured.
After the initial measurement gesture is determined, the current measurement point is set as a measurement base point, and the gesture of the current measuring head is a reference gesture.
When the first scanning measurement is carried out, the RTCP function of the machine tool is started, the position of the end face of the measuring head is fixed, and one rotating shaft of the machine tool is scanned and measured within the range of +/-3 degrees.
One rotation axis of the machine tool is measured at intervals of 0.3 DEG for 5s, and echo waveforms are acquired every 1 s.
For echo waveform data returned by each measurement, stability discrimination is performed, including: grasping peak-peak time t P1-P2 of the echo waveform, namely the interval time of the first echo and the second echo; if the peak-to-peak time t P1-P2 remains stable for each measurement period, then a stable measurement is determined, with the remainder being invalid measurements.
Further, for all stable measurements, the first peak time t O-P1 of the echo waveform is grabbed, and the rotation axis position corresponding to the minimum time t O-P1 is found, namely the optimal measurement position of the rotation axis.
Further, peak-to-peak time values with maximum jitter deviation magnitudes less than + -1% are considered to remain stable.
In summary, the invention has the following advantages:
1. According to the invention, through rotary scanning measurement on two rotary shafts of a five-axis machine tool, the change trend of the first peak position and the first peak-second peak difference value of echo signals is received and analyzed, the optimal measurement gesture can be judged, and the corresponding measurement data in the gesture is read as the thickness measurement result data which is finally output;
2. By adopting the method, hardware is not required to be modified or other auxiliary detection instruments are not required to be added, the parallel lamination of the surface to be detected and the end face of the ultrasonic measuring head can be ensured only by adding the links of scanning measurement and data analysis, the measurement inaccuracy caused by the fact that the surface to be detected and the end face of the measuring head are not completely parallel laminated is eliminated, and further the high-efficiency high-precision thickness measurement is realized, and the operation cost is low.
Drawings
FIG. 1 is a schematic view of the course of an ultrasonic wave during measurement;
FIG. 2 is a graph of an ultrasonic echo waveform after noise/clutter interference is removed;
FIG. 3 is a schematic diagram showing the effect of the thickening of the coupling layer on the time to capture the first peak when the probe forms an angle with the plane to be measured;
FIG. 4 is a schematic diagram of measurement errors in which the coupling layer thickens when the probe forms an included angle (< 3 DEG) with the plane to be measured;
FIG. 5 is a schematic diagram of a measurement error of an ultrasonic wave in an object to be measured with a travel distance increase when an included angle (< 3 DEG) between a probe and the plane to be measured is formed;
FIG. 6 is a schematic diagram showing various measurement error conditions when the probe forms an included angle (> 3 DEG) with the plane to be measured;
FIG. 7 is a schematic measurement of the present method;
FIG. 8 is a flow chart of an implementation of the method;
fig. 9 is a diagram showing an application example of the method.
Detailed Description
In order to more clearly illustrate the present invention, the present invention will be further described with reference to preferred embodiments and the accompanying drawings. It is to be understood by persons skilled in the art that the following detailed description is illustrative and not restrictive, and that this invention is not limited to the details given herein.
The basic principle of ultrasonic thickness measurement is that by collecting the time of incidence and reflection of ultrasonic waves in a structure to be measured (usually, the time from grabbing vibration to receiving a first echo, or the interval time between grabbing the first echo and a second echo formed after the upper surface of an object to be measured is reflected), the grabbing mode is usually selected according to the structure and thickness range of the object to be measured, or the two modes are used simultaneously), as shown in fig. 1 and fig. 2 (fig. 1 is a schematic stroke diagram of ultrasonic waves in the measuring process, fig. 2 is an ultrasonic echo waveform diagram after noise/clutter interference is eliminated), the distance of the ultrasonic waves travelling back and forth in the structure to be measured can be obtained by multiplying the sound velocity, namely, the thickness is twice, and the calculation formula of the thickness h can be expressed as follows:
Where v is the propagation speed of the ultrasonic wave in the material, t O-P1 is the time from the ultrasonic wave transmission to the reception of the first echo (abbreviated as first peak time), and t P1-P2 is the interval time between the first echo and the second echo (abbreviated as peak-to-peak time).
In an ideal measurement process, the surface to be measured and the end face of the ultrasonic measuring head are attached in parallel, but in actual measurement, an offset included angle exists between the actual position and the ideal position of the surface due to the machining error of the surface to be measured, or the structure to be measured belongs to a complex curved surface, the condition that the included angle exists between the surface to be measured and the end face of the measuring head possibly occurs in the measurement process, and the measurement is inaccurate, and can be specifically divided into the following two conditions:
(1) When the angle is small (generally considered to be less than 3 °):
an included angle exists between the plane of the measuring head and the surface of the structure to be measured, and thickness measuring errors of two different mechanisms can be introduced:
(1-1) thickening of the coupling layer between the probe and the structure under test
The coupling layer refers to a gap between a part to be measured and the probe, and is generally filled with a coupling agent, and the thickness of the coupling layer is generally ignored in the ultrasonic measurement process or the influence of the coupling layer is eliminated in links such as sound velocity measurement and calculation. When the probe forms an included angle with the plane to be measured, the inclination angle can cause the travel of the ultrasonic wave in the coupling layer to be increased, namely the coupling layer is thickened, as shown in fig. 3, and the increased thickness deltah of the coupling layer is related to the included angle and the radius of the probe, which can be expressed as:
Δh＝R*tanθ；
In the formula, theta is the included angle between the ultrasonic probe and the plane to be measured, default ultrasonic waves are emitted from the center of the probe, and R is the radius of the ultrasonic probe. It can be seen that the included angle θ increases, the thickening Δh of the coupling layer increases along with the increase, and if the probe is 5mm, the maximum thickening Δh=5 mm×tan (3 °) =0.26 mm of the coupling layer in the included angle range of 3 ° is assumed, and the accuracy of the on-machine ultrasonic thickness measurement is generally between 0.01 and 0.1mm, and the thickness measurement accuracy is greatly affected by the error caused by the increase of the coupling layer.
It should be specifically noted that, for two types of ultrasonic time grabbing manners, the first peak time t O-P1 and the peak-to-peak time t P1-P2, the influence caused by the thickening of the coupling layer is completely different, as shown in fig. 4, let the ultrasonic wave pass through the thickened coupling layer once for a time t Coupling of , pass through the object to be measured for a time t Object(s) , and the first peak time t O-P1 can be expressed as:
tO-P1＝2*t Object(s) +2*t Coupling of ；
The effect Δt O-P1 of coupling layer thickening on t O-P1 can be expressed as:
And peak-to-peak time t P1-P2 may be expressed as:
It can be seen that the times of the first and second echoes passing in the coupling side cancel each other out, and that the coupling layer thickening has no effect on t P1-P2.
(1-2) Ultrasonic wave travel distance increases in the object to be measured
The included angle between the probe and the object to be measured may cause the ultrasonic wave to be incident from a direction inclined to the normal direction of the surface of the object to be measured, resulting in an increase in the travel distance of the ultrasonic wave in the object to be measured, as shown in fig. 5, the increase Δs in the travel distance is related to the included angle and the thickness h of the object to be measured, which may be expressed as:
Δs＝h/cosθ-h；
It can be seen that the included angle θ increases, the travel distance increases, and assuming that the maximum thickness is 10mm, the coupling layer thickens by a maximum of Δs=10 mm/cos (3 °) -10 mm= 0.0137mm within the included angle range of 3 °), and the effect is almost smaller than the measurement error of the conventional ultrasonic thickness measurement of 0.01-0.1 mm.
Combining (1-1) and (1-2), the probe plane-surface included angle of the object to be measured within 3 degrees can introduce two errors: the coupling layer thickening error and the intra-object travel distance increasing error are increased along with the increase of the included angle, so that the influence on the thickness measuring precision is larger, but only the increase of the first peak time t O-P1 is caused, the acquisition of the peak-to-peak time t P1-P2 is not influenced, and the intra-object travel distance increasing error is generally existed in various time grabbing algorithms and corresponding thickness measuring algorithms, but the absolute value is smaller, and basically does not influence the time grabbing and the corresponding thickness calculation.
(2) When the included angle is large (generally considered to be greater than 3 °):
as shown in fig. 6, there may be various situations that the ultrasonic wave is diffusely reflected, the ultrasonic wave reflected wave cannot be received by the probe, the ultrasonic wave is directly reflected on the surface to be measured, that is, received, and the like, and the measured value is repeatedly jumped, so that the stable first peak time t O-P1 and the peak-to-peak time t P1-P2 cannot be grabbed.
By combining the characteristics, the optimization of the optimal thickness measuring position can be realized by taking the peak value-peak value time t P1-P2 which is not easy to influence within +/-3 degrees as a stable judgment basis and taking the first peak value time t O-P1 as an optimization basis.
Therefore, the invention provides an on-machine ultrasonic thickness measurement pose selection method based on rotary scanning measurement, the operation schematic diagram of the method is shown in fig. 7, a knife point (the end face position of a measuring head) is fixed, a rotating shaft is operated within a certain range, a certain unit degree is separated for carrying out multiple measurements, whether the peak-peak time t P1-P2 is within a smaller included angle range of +/-3 degrees is judged through the stability of the peak-peak time t P1-P2, for all the measurements within the range, the first peak time t O-P1 is acquired and compared, the minimum t O-P1 is searched, the corresponding pose is the optimal measurement pose without included angle, and the measurement at the point is the accurate ultrasonic thickness measurement result.
As shown in fig. 8, the specific operation steps of the method are as follows:
1) Firstly, preparing a thickness measuring environment, operating a machine tool to jet or spray cutting fluid at a position to be measured, ensuring that no solid sundries such as metal scraps remain at the position, and smearing a couplant or substituting the couplant for fluid;
2) Determining an initial measurement gesture according to part number model or visual inspection, so that the ultrasonic probe is approximately vertical to the position to be measured (without being exactly parallel and basically parallel), and operating a machine tool to move the ultrasonic thickness measuring probe to the position to be measured, so that the end face of the probe is tightly attached to the position to be measured;
3) Setting a current measuring point as a measuring base point, and setting the posture of a current measuring head as a reference posture;
4) First scan measurement: turning on RTCP (Rotation Tool Center Point) functions of the machine tool, setting a knife point position (a measuring head end surface position) to be fixed, operating one of rotating shafts (hereinafter referred to as a rotating shaft 1) of the five-axis machine tool, taking the current position of the rotating shaft as a center, scanning and measuring within a range of +/-3 degrees, measuring at intervals of a certain unit angle (generally set to be 0.3 degree) once, continuously measuring for 5 seconds each time, and collecting echo waveforms every 1 second so as to ensure that measurement reference data are sufficient;
5) Analyzing the data obtained by the first scanning measurement:
5.1 For each measurement, the stability determination is carried out, the peak-peak time t P1-P2 of the echo waveform is grasped, if t P1-P2 is kept stable within 5s, the stable measurement is determined, and the rest is determined as invalid measurement; in this example, a peak-to-peak time value with a maximum jitter deviation of less than + -1% is considered to be stable.
5.2 For all stable measurements, carrying out gesture optimization, grabbing the first peak time t O-P1 of the echo waveform, and searching the position of the rotating shaft 1 corresponding to the minimum time t O-P1, namely the optimal measurement position of the rotating shaft 1;
6) Second scan measurement: keeping the RTCP function of the machine tool open, keeping the position of the cutter point (the position of the end face of the measuring head) fixed, setting the rotating shaft 1 to be fixed at the optimal measuring position obtained in the step 5, and operating the other rotating shaft (hereinafter referred to as the rotating shaft 2) of the machine tool to perform scanning measurement by taking the current position as the center, wherein the specific operation is the same as that of the step 4;
7) Echo waveform analysis obtained by the second scanning measurement:
7.1 For each measurement, judging the stability, and performing the same specific operation as the step 5.1;
7.2 For all stable measurements, carrying out gesture optimization, grabbing the first peak time t O-P1 of the echo waveform, and searching the position of the rotating shaft 2 corresponding to the minimum time t O-P1, namely the optimal measurement position of the rotating shaft 2;
8) Operating the machine tool rotating shaft 1 and the rotating shaft 2 to reach the optimal positions obtained in the step 5 and the step 7, performing thickness measurement, continuously measuring for 5 seconds, collecting thickness data every 1 second, and obtaining an average value of the measured data as an accurate thickness measurement value;
9) The optimal measuring positions of the current rotating shaft 1 and the rotating shaft 2 are recorded and can be used as initial reference measuring postures of the next measurement of the parts in the same batch.
Fig. 9 is an ultrasound echo waveform actually measured when the included angles between the probe and the plane to be measured are respectively 0 °, 1.5 ° and 3 ° for the same object to be measured, wherein the ordinate is the ultrasound echo amplitude (unit: mV) and the abscissa is the time (unit: 20 ns). By using the method provided by the invention, firstly, according to the judgment of the stability of the peak-peak time t P1-P2, the thickness measurement data with the included angle of 3 degrees can be eliminated, and then according to t O-P1, the measurement gesture with the included angle of 0 degrees is selected as the optimal measurement gesture, so that the thickness can be accurately calculated.
The foregoing description is only a preferred embodiment of the present invention, and is not intended to limit the present invention in any way, and any simple modification, equivalent variation, etc. of the above embodiment according to the technical matter of the present invention fall within the scope of the present invention.
Claims (9)
1. An on-machine ultrasonic thickness measurement pose selection method based on rotary scanning measurement is characterized by comprising the following steps of:
s1, operating one of rotating shafts of a machine tool, and carrying out first scanning measurement on a to-be-positioned position;
s2, during measurement, the current position of the rotating shaft is taken as the center, measurement is performed once at certain unit angles, and a plurality of echo waveform data are returned after each measurement;
S3, obtaining an optimal measurement position I of the rotating shaft based on echo waveform data;
S4, operating another rotating shaft of the machine tool, and carrying out second scanning measurement on the position to be measured according to the same steps to obtain an optimal measurement position II of the rotating shaft;
S5, two rotating shafts of the machine tool are operated to reach respective optimal measuring positions respectively, and thickness measurement is carried out;
s6, taking the average value of the measurement data of the two rotating shafts at the optimal measurement position as the accurate thickness measurement value of the position to be measured.
2. The method for selecting the pose of the on-machine ultrasonic thickness measurement based on the rotary scanning measurement according to claim 1, wherein the method is characterized in that a measurement environment is prepared before the operation, the machine tool is operated to jet air or spray cutting fluid at a position to be measured, the position to be measured is ensured to have no solid sundries, and a couplant or a couplant substitute liquid is smeared.
3. The method for selecting the on-machine ultrasonic thickness measurement pose based on the rotary scanning measurement according to claim 1, wherein before the operation, an initial measurement pose is determined according to a part number model or visual inspection so that an ultrasonic probe is approximately vertical to a position to be measured, and then a machine tool is operated to move the ultrasonic thickness measurement probe to the position to be measured so that the end face of the probe is closely attached to the position to be measured.
4. The method for selecting the on-machine ultrasonic thickness measurement pose based on the rotational scanning measurement according to claim 3, wherein after the initial measurement pose is determined, the current measurement point is set as a measurement base point, and the pose of the current measuring head is set as a reference pose.
5. The method for selecting the pose of on-machine ultrasonic thickness measurement based on rotary scanning measurement according to claim 1, wherein the RTCP function of the machine tool is turned on during the first scanning measurement, the position of the end face of the measuring head is fixed, and one rotation shaft of the machine tool is scanned and measured within a range of +/-3 degrees.
6. The method for selecting the pose of on-machine ultrasonic thickness measurement based on rotary scanning measurement according to claim 1 or 5, wherein one rotation axis of a machine tool is measured at intervals of 0.3 ° for 5s each time, and echo waveforms are acquired every 1 s.
7. The method for selecting the pose of the on-machine ultrasonic thickness measurement based on the rotation scanning measurement according to claim 1, wherein the method for judging the stability of the echo waveform data returned by each measurement comprises the following steps: grasping peak-peak time t P1-P2 of the echo waveform, namely the interval time of the first echo and the second echo; if the peak-to-peak time t P1-P2 remains stable for each measurement period, then a stable measurement is determined, with the remainder being invalid measurements.
8. The method for selecting the pose of on-machine ultrasonic thickness measurement based on rotational scanning measurement according to claim 7, wherein for all stable measurements, the first peak time t O-P1 of echo waveform is grasped, and the position of the rotation axis corresponding to the minimum time t O-P1 is found, namely the optimal measurement position of the rotation axis.
9. The method for selecting the pose of on-machine ultrasonic thickness measurement based on rotational scanning measurement according to claim 7, wherein the maximum jitter deviation of peak-to-peak time values is less than ±1% and is considered to be stable.
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| CN118463874A (en) * | 2024-07-10 | 2024-08-09 | 成都飞机工业（集团）有限责任公司 | Ultrasonic pulse echo reflection thickness measurement method based on heterogeneous logic adaptive cross-validation |
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