CN119044320B - Real-time visualization method and device for weld defect ultrasonic detection - Google Patents
Real-time visualization method and device for weld defect ultrasonic detection Download PDFInfo
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Abstract
The invention discloses a real-time visualization method and a device for weld defect ultrasonic detection, which relate to the technical field of metal weld defect nondestructive detection and comprise the following specific steps that firstly, a device is utilized to scan a weld (such as an in-service pressure container weld) to obtain ultrasonic data of the weld and inertial sensor data of a reaction defect plane position, and defect types are judged; analyzing the ultrasonic data and the inertial sensor data, determining the space coordinates of the weld defects, and realizing the space positioning and visualization of the defects, and simulating and verifying the ultrasonic detection process of the weld with the defects. According to the method, visualization of ultrasonic propagation and visualization of weld defects in the detection process are completed through ultrasonic and inertial sensor data, a visual database is built, information traceability is achieved, the data are used for dynamic safety evaluation of equipment, safety of the equipment can be evaluated during regular detection, and data and model support are provided for dynamic monitoring and evaluation of the equipment in the service use process.
Description
Technical Field
The invention relates to the technical field of nondestructive detection of metal weld defects, in particular to a real-time visualization method and device for weld defect ultrasonic detection.
Background
The equipment is an important mark of a modern civilization society, is also an important foundation of social development, and is not equipped with human beings but returns to the ancient agriculture and animal husbandry times of manual work. Welding is the basic process of almost all equipment manufacturing processes. For equipment related to important safety, such as boilers, pressure vessels, pressure pipes, elevators, hoisting machines, amusement rides, motor vehicles, etc., equipment has been managed by national inclusion of special equipment, and welds are critical parts in determining the safety and reliability of welding equipment or structures. Therefore, special equipment safety management regulations and related national specifications not only require nondestructive inspection of welding seams after equipment manufacturing is completed, but also require periodic nondestructive inspection and evaluation of welding seams of in-service equipment or structures, so that the special equipment in petroleum and chemical industries has huge quantity, heavy periodic inspection tasks, production stopping during the fixed inspection, huge quantity of input professionals and instruments, high labor intensity and long detection period.
The ultrasonic detection technology is always a main means of nondestructive detection of welding seams by virtue of the advantages of low cost, high precision, environmental friendliness, portability and the like. However, the traditional ultrasonic detection has the problems of high requirements on quality of detection personnel, long weld evaluation reporting period, poor traceability of detection data, incapability of rechecking and the like, realizes the visualization of ultrasonic information in the weld detection process, can improve the evaluation efficiency of the detection process, reduce the requirements on the detection personnel, improve the traceability of the data and shorten the reporting period.
At present, in the literature research of ultrasonic detection of welding seams, namely analysis of a nondestructive testing method of a finished oil pipeline, relevant contrast analysis shows that ultrasonic detection has advantages compared with phased array ultrasonic detection in the aspects of detection calibration, adjustment, technical requirements and the like. The phased array equipment is complex in structure, for example, a pressure container defect detection device (CN 201720851191.1) moves circumferentially on a gear groove through a stepping motor to realize automatic detection of a girth weld, a welding seam flaw detection device for a pressure container and a using method (CN 202211174021.6) are designed, a sliding type large ultrasonic detection device based on ultrasonic waves is designed to transport the pressure container into the device, detection and marking of defective parts can be completed, a penetrating piece girth weld automatic ultrasonic detection device (CN 202211103419.0) adopts a segmented splicing structure, a laser paint removal module is contained in the device, automatic detection of the welding seam defect is completed, a girth weld ultrasonic automatic detection device (CN 202222485787.8) adopts a tramcar defect detection mode, movement track of a trolley and accuracy of related information of the defect are guaranteed, and a circular trolley ultrasonic detection device (CN 202320130479.5) is designed to complete detection of the welding seam through a cylinder and a translation structure, and can realize cleaning of the welding seam surface. However, the prior art also has the following limitations:
(1) Lack of real-time visualization in the ultrasonic propagation process has high judgment requirements on defects and evaluation reliability thereof;
(2) A visual database for ultrasonic detection of weld defects and positioning thereof cannot be formed, traceability cannot be conveniently realized, and dynamic monitoring of weld safety of production process equipment cannot be realized to provide support.
In order to solve the problems, the invention designs a real-time visualization method and device for ultrasonic detection of weld defects by combining a theoretical and experimental method with an ultrasonic detection principle, and the device has the advantages of simple overall structure and low cost, can realize visualization of ultrasonic propagation and visualization of defects, can also establish a complete weld database with defect positions, and lays a foundation for in-service dynamic monitoring and real-time analysis of related equipment.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a real-time visualization method and device for weld defect ultrasonic detection, and solves the problems in the background art.
In order to achieve the purpose, the invention is realized by the following technical scheme that the method and the device for realizing the ultrasonic detection and real-time visualization of the weld defects comprise the following specific steps:
Scanning a welding seam by using a device, acquiring ultrasonic data of the welding seam and inertial sensor data of a reaction defect plane position, and judging the type of the welding seam defect by using spectrum analysis of the ultrasonic data;
analyzing the ultrasonic data and the inertial sensor data, determining the space coordinates of the weld defects, and realizing the space positioning and visualization of the defects;
and thirdly, simulating and verifying the ultrasonic detection process of the weld joint containing the defects.
Optionally, the specific method flow for judging the weld defect type is as follows:
(1) The single chip microcomputer is provided with a voltage transformation module which converts 220V voltage into 24V voltage to supply power for the inclined ultrasonic transducer, so that the inclined ultrasonic transducer transmits a circulating pulse signal in a time interval and circularly reads an ultrasonic echo signal;
(2) The echo signals of the singlechip are collected at a high speed by using an FPGA (field programmable gate array), wherein the FPGA is formed by a plurality of logic gate arrays, and the specific collection flow is as follows:
A. selecting parameters of an inclined probe, including K value and frequency, by combining industry standards and the wall thickness of a structure at a welding seam;
B. Smearing a coupling agent on the surface near the weld to be detected, and using an inclined probe with radian, wherein the two probes are tightly attached;
C. the oblique probe emits ultrasonic waves, and receives echoes of the circulating pulse signals according to ultrasonic propagation characteristics;
D. in order to analyze the ultrasonic echo signals, noise reduction treatment is needed to be carried out on the signals, so that the signal to noise ratio is improved;
The method comprises the steps of adopting self-programming and importing data into Unity3D, and completing real-time display of waveforms in a serial port communication mode;
(3) Performing fast Fourier change on the discrete defect ultrasonic amplitude signals to obtain spectrograms of various defect signals, thereby finding out that extreme frequencies of three defects of cracks, air holes and slag inclusion are different, wherein the transformation amplitude of the cracks is maximum and the transformation amplitude of the slag inclusion is minimum;
(4) And judging the type of the defect according to the main frequency.
Optionally, the singlechip is provided with two-stage band-pass filtering.
Optionally, the specific method for positioning the defect space coordinate includes the following steps:
(1) Through binding of the inclined probe and the inertial sensor, before resolving the probe posture, the original data output by each sensor in the IMU (Inertial measurement unit, a device for measuring the three-axis posture angle and acceleration of an object, wherein the IMU comprises a gyroscope and an accelerometer) is required to be corrected;
the calibration method of the accelerometer adopts a vertical suspension method, and the forward suspension and the reverse suspension respectively last for 3min;
calibrating a gyroscope, adopting a static denoising method, obtaining a zero offset error of a triaxial after static, and removing in the follow-up process;
(2) The inertial sensor uploads gesture data to an upper computer in a Bluetooth communication mode, introduces a quaternion gesture interface of the Unity3D, translates the gesture data into a double-precision floating point number in real time to complete gesture synchronization of a virtual probe, integrates high-frequency IMU acceleration data twice through a pre-integration algorithm to obtain space displacement, and fits with a simulation animation function of the Unity3D to enable the movement position of the probe to be updated continuously along with the acceleration data;
(3) Establishing a corresponding database of the three-dimensional coordinates of the probe and the ultrasonic amplitude curve, clicking a collected coordinate point in upper computer software, and checking the amplitude curve of the point;
(4) And combining the characteristic signals of the defects, the propagation characteristics, the incidence angle and the wall thickness of the ultrasonic waves, and then, calculating the three-dimensional coordinates of the defects.
Optionally, the flow of simulation verification of the ultrasonic detection process of the weld joint with the defects is as follows:
(1) A weld model is pre-built through COMSOL software, and the following parameters are changed into variables, wherein the specific parameters comprise the height of a weld structure, the diameter of a cylinder body and the wall thickness;
(2) Inputting parameters in the form of an input frame through a software prefabricated App, namely completing the parametric modeling of the three-dimensional model of the whole pressure container;
(3) According to the line standard NBT47013.3-2015, the specification of the inclined probe is selected through the wall thickness of the pressure container, and the K value of the inclined probe and the range of the pressure container, which needs to be subjected to ultrasonic detection, are combined for dynamic rendering;
(4) And combining the piezoelectric-acoustic physical field simulation of COMSOL, combining the three-dimensional space coordinates of the probe and the defect, establishing an axial section view of the pressure vessel in a parameterized manner, performing simulation of an amplitude curve, and performing comparison verification analysis with an actual amplitude curve.
A weld defect ultrasonic detection real-time visualization device comprises a computer and a multifunctional software system, wherein the computer is provided with data acquisition, data processing, data analysis, defect visualization and ultrasonic detection process simulation.
Optionally, interconnect between computer and the FPGA sampling board, interconnect between FPGA sampling board and the singlechip, interconnect between singlechip and the detection car, be equipped with the coding motor around the bottom of detection car respectively, the outside of coding motor is equipped with rotatory hinge, one side that the coding motor was kept away from to rotatory hinge is equipped with big magnetic wheel, the both sides of detection car all are equipped with auxiliary rail draw-in groove, the inside level of auxiliary rail draw-in groove runs through there is metal film track groove, the both ends of metal film track groove all are equipped with little magnetic wheel, the top middle part of detection car is equipped with inertial sensor, inertial sensor's both sides all are equipped with couplant spray set, couplant spray set's outside both sides all are equipped with the magnetism that is connected with the detection car and press the bullet pillar.
Optionally, the singlechip is internally provided with ultrasonic excitation, and the singlechip further comprises a 220V-to-24V transformer and an ultrasonic echo signal sampling point.
Optionally, the auxiliary rail clamping grooves are symmetrically distributed about the central line of the detection vehicle.
Optionally, the magnetic pressure bullet pillar and the couplant spraying device are respectively distributed symmetrically about the center line of the inertial sensor.
The invention provides a real-time visualization method and device for weld defect ultrasonic detection, which comprises the following steps of
The beneficial effects are that:
The method and the device for visualizing the weld defects in real time solve the visualization of the ultrasonic nondestructive detection process, reduce the requirements on detection personnel, improve the reliability and the speed of defects and evaluation thereof, improve the fixed detection efficiency, including improving the detection efficiency and the efficiency of forming an evaluation report, shorten the detection period and reduce the influence period on production;
The method for detecting the traditional A-type ultrasonic pulse reflection defects is designed and improved, on the basis of retaining the characteristics of A-type ultrasonic waves (economy, portability, simple structure and accurate positioning), the method can effectively avoid the omission of detection and misjudgment of the artificial defects, and can visualize the detection range by combining the requirements of line marks NBT47013.3-2015 and the inertial data of a probe, can provide a novel online monitoring method for in-service pressure containers while improving the detection efficiency, solves the visualization of the ultrasonic nondestructive detection process, reduces the requirements on detection personnel, improves the reliability of defects and evaluation thereof, establishes a visual database of ultrasonic detection weld defects and positioning thereof, provides basic support for the traceability of weld safety evaluation and the dynamic monitoring of equipment weld safety, and is beneficial to further improving the production safety.
Drawings
FIG. 1 is a schematic flow chart of a detection principle in a first embodiment of the invention;
FIG. 2 is a flow chart of a method for determining different defect types of an in-service pressure vessel according to a first embodiment of the invention;
FIG. 3 is a schematic flow chart of a method for locating spatial coordinates of defects in an in-service pressure vessel according to a first embodiment of the invention;
FIG. 4 is a schematic diagram of simulated animation function fitting in accordance with an embodiment of the invention;
FIG. 5 is a schematic view showing an axial sectional structure of a pressure vessel according to a first embodiment of the present invention;
FIG. 6 is a flow chart of a method for verifying ultrasonic simulation of defects in accordance with a first embodiment of the present invention;
FIG. 7 is a schematic diagram of a simulation of a wave amplitude curve in accordance with an embodiment of the present invention;
FIG. 8 is a schematic diagram of a front view structure of a second embodiment of the present invention;
FIG. 9 is a schematic top view of a second embodiment of the present invention;
FIG. 10 is a graph showing ultrasonic amplitude curves of cracks in a second embodiment of the invention;
FIG. 11 is a schematic view of an ultrasonic amplitude curve of an air hole in a second embodiment of the invention;
Fig. 12 is a schematic view of an ultrasonic amplitude curve of slag inclusion in the second embodiment of the present invention.
1, A computer; 2, an FPGA sampling plate, 3, a singlechip, 301, 220V-to-24V transformers, 302, ultrasonic echo signal sampling points, 4, small magnetic wheels, 5, a metal film track groove, 6, a magnetic spring strut, 7, a couplant spraying device, 8, an inertial sensor, 9, a coding motor, 10, a rotary hinge, 11, an auxiliary rail clamping groove, 12, a large magnetic wheel, 13, a detection vehicle and 14, an oblique probe clamping groove.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments.
In the description of the present invention, unless otherwise indicated, the meaning of "plurality" is two or more, and the terms "upper", "lower", "left", "right", "inner", "outer", "front", "rear", "head", "tail", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus are not to be construed as limiting the present invention. Furthermore, the terms "first," "second," "third," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In the description of the present invention, unless explicitly stated and limited otherwise, the terms "connected" and "connected" are to be construed broadly, and for example, they may be fixedly connected, detachably connected, or integrally connected, mechanically connected, electrically connected, or indirectly connected through an intermediate medium. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
Referring to fig. 1 to 7, a method for visualizing weld defects in real time by ultrasonic detection includes the following steps:
Step one, judging different defect types of the in-service pressure vessel;
The specific method for discriminating different defect types of the in-service pressure vessel comprises the following steps:
(1) The single chip 3 is provided with a transformation module which converts 220V voltage into 24V voltage to supply power for the inclined ultrasonic transducer, so that the inclined ultrasonic transducer transmits a circulating pulse signal and circularly reads an ultrasonic echo signal in a time interval, and the single chip 3 is provided with two-stage band-pass filtering;
(2) The FPGA is utilized to collect echo signals of the singlechip 3 at high speed;
A. selecting parameters of an inclined probe, including K value and frequency, by combining a line standard and the wall thickness of the pressure vessel;
B. smearing a coupling agent on the surface of a pressure container to be detected, and using an inclined probe with radian, wherein the two probes are tightly attached;
C. the oblique probe emits ultrasonic waves, and receives echoes of the circulating pulse signals according to ultrasonic propagation characteristics;
D. in order to analyze the ultrasonic echo signals, noise reduction treatment is needed to be carried out on the signals, so that the signal to noise ratio is improved;
MATLAB programming is adopted and is imported into the Unity3D, and real-time display of waveforms is completed in a serial port communication mode;
(3) Performing fast Fourier change on the discrete defect ultrasonic amplitude signals to obtain spectrograms of various defect signals, thereby finding out that the extreme frequencies of the three defects of cracks, air holes and slag inclusion are different, wherein the transformation amplitude of the cracks is the largest and the transformation amplitude of the slag inclusion is the smallest;
(4) Judging the defect type according to the main frequency;
Step two, positioning the space coordinates of the defects of the in-service pressure vessel;
The specific method for positioning the space coordinates of the defects of the in-service pressure vessel comprises the following steps:
(1) By binding the inclined probe and the inertial sensor 8, before resolving the probe posture, the original data output by each sensor in the IMU is required to be corrected;
the calibration method of the accelerometer adopts a vertical suspension method, and the forward suspension and the reverse suspension respectively last for 3min;
calibrating a gyroscope, adopting a static denoising method, obtaining a zero offset error of a triaxial after static, and removing in the follow-up process;
(2) The inertial sensor 8 uploads the gesture data to an upper computer in a Bluetooth communication mode, introduces a quaternion gesture interface of the Unity3D, translates the gesture data into a double-precision floating point number in real time to complete gesture synchronization of a virtual probe, integrates the high-frequency IMU acceleration data twice through a pre-integration algorithm to obtain space displacement, and fits with a simulation animation function of the Unity3D to enable the moving position of the probe to be updated continuously along with the acceleration data;
(3) Establishing a corresponding database of the three-dimensional coordinates of the probe and the ultrasonic amplitude curve, clicking a collected coordinate point in upper computer software, and checking the amplitude curve of the point;
(4) Combining the characteristic signals of the defects, the propagation characteristics, the incidence angle and the wall thickness of the ultrasonic waves, namely, calculating the three-dimensional coordinates of the defects;
Step three, performing ultrasonic simulation verification on the defects;
the simulation verification process for the ultrasonic detection process of the weld joint with the defects comprises the following steps:
(1) A pressure vessel is pre-built through COMSOL software, and the following parameters are changed into variables, wherein the specific parameters comprise the height of the sealing head, the diameter of the cylinder body and the wall thickness;
(2) Inputting parameters in the form of an input frame through a software prefabricated App, namely completing the parametric modeling of the three-dimensional model of the whole pressure container;
(3) According to the line standard NBT47013.3-2015, the specification of the inclined probe is selected through the wall thickness of the pressure container, and the K value of the inclined probe and the range of the pressure container, which needs to be subjected to ultrasonic detection, are combined for dynamic rendering;
(4) And combining the piezoelectric-acoustic physical field simulation of COMSOL, combining the three-dimensional space coordinates of the probe and the defect, establishing an axial section view of the pressure vessel in a parameterized manner, performing simulation of an amplitude curve, and performing comparison verification analysis with an actual amplitude curve.
Referring to fig. 8-9, a real-time visualization device for ultrasonic detection of weld defects comprises a computer 1, wherein the computer 1 is in interactive connection with an FPGA sampling plate 2, the FPGA sampling plate 2 is in interactive connection with a singlechip 3, the singlechip 3 is in interactive connection with a detection vehicle 13, a coding motor 9 is respectively arranged at the front and back of the bottom end of the detection vehicle 13, a rotary hinge 10 is arranged at the outer side of the coding motor 9, a large magnetic wheel 12 is arranged at one side of the rotary hinge 10 far away from the coding motor 9, auxiliary rail clamping grooves 11 are respectively arranged at two sides of the detection vehicle 13, metal film track grooves 5 penetrate through the inner level of the auxiliary rail clamping grooves 11, small magnetic wheels 4 are respectively arranged at two ends of the metal film track grooves 5, an inertial sensor 8 is arranged in the middle of the top end of the detection vehicle 13, couplant spraying devices 7 are respectively arranged at two sides of the inertial sensor 8, and magnetic spring pressing struts 6 connected with the detection vehicle 13 are respectively arranged at two outer sides of the couplant spraying devices 7.
In this embodiment, the single-chip microcomputer 3 is internally provided with ultrasonic excitation, and the single-chip microcomputer 3 further comprises a 220V-to-24V transformer 301 and an ultrasonic echo signal sampling point 302.
In this embodiment, the auxiliary rail clamping grooves 11 are symmetrically distributed about the center line of the detection vehicle 13.
In this embodiment, the magnetic bomb supporting column 6 and the couplant spraying device 7 are respectively distributed symmetrically about the center line of the inertial sensor 8.
As shown in fig. 1 to 12, firstly, the accelerometer and gyroscope of the inertial sensor 8 are corrected, and the carrier coordinate system is reset; combining specific parameters (wall thickness) of a detection object, selecting proper parameters (K value and frequency) of an oblique probe, embedding the selected oblique probe into an oblique probe clamping groove 14 of a detection vehicle 13, determining the detection range of a welding line according to a row standard NBT47013.3-2015, attaching a small magnetic wheel 4 and a large magnetic wheel 12 to a pressure container to be detected, filling a couplant spraying device 7, starting the couplant spraying device 7, starting ultrasonic excitation, after the waveform signal of the point is transmitted to a computer 1, starting an encoding motor 9 to slowly move the detection vehicle 13 from the left end to the right end of a metal film track groove 5, transmitting ultrasonic excitation signals every time the detection vehicle 13 moves, using an FPGA sampling plate 2 to acquire ultrasonic waveform data at a high speed, moving the metal film track groove 5 along the circumferential direction of the pressure container when the detection vehicle 13 moves to the right end, completing the front pavement of the track under the condition of the detection vehicle 13, enabling the detection vehicle 13 to be positioned at the left end of the metal film track groove 5 again, repeating the operation until the detection of the whole circumferential direction is completed, after the point waveform signal is transmitted to the computer 1, pressing the large magnetic wheel 12 to the pressure container to be detected by the magnetic hinge 6 again, rotating the magnetic wheel 12 to be pressed up by the magnetic hinge 6 after the circumferential detection vehicle 13 is moved to the large magnetic container to complete the detection, rotating the magnetic container to complete the rotation, and the magnetic container detection by the magnetic container to be completely pressed up by the magnetic container 12, the pressure container is mainly provided with the circumferential weld and the longitudinal weld, and the metal film track groove 5 is softer, so that the detection of the longitudinal weld can be completed by paving;
then, inertial data of the probe and movement data of the coding motor 9 are acquired through the inertial sensor 8, discrete ultrasonic three-dimensional sampling points on the pressure container are in one-to-one correspondence with discrete ultrasonic amplitude curves in the computer 1, and the ultrasonic amplitude curves are shown in the following figures 10 to 12 by taking air holes, slag and cracks as examples:
The method comprises the steps of carrying out short-time Fourier transform on a discrete amplitude curve through an algorithm of a computer 1, distinguishing three main frequencies of defects, namely identifying characteristic signals and judging defects, calculating the space position of the defects through the space position of sampling points of the known defects and combining probe parameters (K values), carrying out parametric modeling on the space position of the defects through COMSOL software (narrow rectangles are adopted for cracks and circles are adopted for air hole slag inclusion) to complete two-dimensional modeling of the section of the sampling points, carrying out piezoelectric acoustic ultrasonic simulation through the COMSOL software, and carrying out discrete comparison on simulation results and the actually measured ultrasonic amplitude curve, so that whether the defects exist or not can be judged in an auxiliary mode, and the conditions of missing detection and false detection are avoided.
The foregoing is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art, who is within the scope of the present invention, should make equivalent substitutions or modifications according to the technical scheme of the present invention and the inventive concept thereof, and should be covered by the scope of the present invention.
Claims (7)
1. The ultrasonic detection real-time visualization method for the weld defects is characterized by comprising the following specific steps of:
the method comprises the steps of scanning a welding line by using a device, obtaining ultrasonic data of the welding line and inertial sensor data of a reaction defect plane position, and judging the type of the welding line defect by using spectrum analysis of the ultrasonic data, wherein the specific method comprises the following steps of:
(1) The single chip microcomputer (3) is provided with a voltage transformation module which converts 220V voltage into 24V voltage to supply power for the inclined ultrasonic transducer, so that the inclined ultrasonic transducer transmits a circulating pulse signal in a time interval and circularly reads an ultrasonic echo signal;
(2) The echo signals of the singlechip (3) are collected at high speed by using the FPGA, and the specific collection flow is as follows:
A. selecting parameters of an inclined probe, including K value and frequency, by combining industry standards and the wall thickness of a structure at a welding seam;
B. Smearing a coupling agent on the surface near the weld to be detected, and using an inclined probe with radian, wherein the two probes are tightly attached;
C. the oblique probe emits ultrasonic waves, and receives echoes of the circulating pulse signals according to ultrasonic propagation characteristics;
D. in order to analyze the ultrasonic echo signals, noise reduction treatment is needed to be carried out on the signals, so that the signal to noise ratio is improved;
The method comprises the steps of adopting self-programming and importing data into Unity3D, and completing real-time display of waveforms in a serial port communication mode;
(3) Performing fast Fourier change on the discrete defect ultrasonic amplitude signals to obtain spectrograms of various defect signals, thereby finding out that extreme frequencies of three defects of cracks, air holes and slag inclusion are different, wherein the transformation amplitude of the cracks is maximum and the transformation amplitude of the slag inclusion is minimum;
(4) Judging the type of the defect according to the main frequency;
Analyzing the ultrasonic data and the inertial sensor data, determining the spatial coordinates of the weld defects, and realizing the spatial positioning and visualization of the defects, wherein the specific method comprises the following steps:
(1) Through binding of the inclined probe and the inertial sensor (8), before resolving the posture of the probe, the original data output by each sensor in the IMU is required to be corrected;
the calibration method of the accelerometer adopts a vertical suspension method, and the forward suspension and the reverse suspension respectively last for 3min;
calibrating a gyroscope, adopting a static denoising method, obtaining a zero offset error of a triaxial after static, and removing in the follow-up process;
(2) The inertial sensor (8) uploads gesture data to an upper computer in a Bluetooth communication mode, introduces a quaternion gesture interface of the Unity3D, translates the gesture data into a double-precision floating point number in real time to complete gesture synchronization of the virtual probe, integrates high-frequency IMU acceleration data twice through a pre-integration algorithm to obtain space displacement, and fits with a simulation animation function of the Unity3D to enable the moving position of the probe to be updated continuously along with the acceleration data;
(3) Establishing a corresponding database of the three-dimensional coordinates of the probe and the ultrasonic amplitude curve, clicking a collected coordinate point in upper computer software, and checking the amplitude curve of the point;
(4) Combining the characteristic signals of the defects, the propagation characteristics, the incidence angle and the wall thickness of the ultrasonic waves, namely, calculating the three-dimensional coordinates of the defects;
Step three, simulation verification of the ultrasonic detection process of the weld joint with the defects is carried out, and the flow is as follows:
(1) A weld model is pre-built through COMSOL software, and the following parameters are changed into variables, wherein the specific parameters comprise the height of a weld structure, the diameter of a cylinder body and the wall thickness;
(2) Inputting parameters in the form of an input frame through a software prefabricated App, namely completing the parametric modeling of the three-dimensional model of the whole pressure container;
(3) According to the line standard NBT47013.3-2015, the specification of the inclined probe is selected through the wall thickness of the pressure container, and the K value of the inclined probe and the range of the pressure container, which needs to be subjected to ultrasonic detection, are combined for dynamic rendering;
(4) And combining the piezoelectric-acoustic physical field simulation of COMSOL, combining the three-dimensional space coordinates of the probe and the defect, establishing an axial section view of the pressure vessel in a parameterized manner, performing simulation of an amplitude curve, and performing comparison verification analysis with an actual amplitude curve.
2. The method for visualizing the weld defects in real time through ultrasonic detection according to claim 1, wherein the single chip microcomputer (3) is provided with two-stage band-pass filtering.
3. A real-time visualization apparatus for ultrasonic detection of weld defects according to any one of claims 1 to 2, comprising a computer (1) with a multifunctional software system for data acquisition, data processing, data analysis, defect visualization, simulation of the ultrasonic detection process.
4. The ultrasonic detection real-time visualization device for weld defects is characterized in that the computer (1) is in cross connection with the FPGA sampling plate (2), the FPGA sampling plate (2) is in cross connection with the singlechip (3), the singlechip (3) is in cross connection with the detection vehicle (13), the coding motor (9) is respectively arranged on the front side and the rear side of the bottom end of the detection vehicle (13), the rotary hinge (10) is arranged on the outer side of the coding motor (9), one side of the rotary hinge (10) far away from the coding motor (9) is provided with a large magnetic wheel (12), two sides of the detection vehicle (13) are respectively provided with an auxiliary rail clamping groove (11), the inner level of the auxiliary rail clamping groove (11) penetrates through a metal soft sheet track groove (5), two ends of the metal soft sheet track groove (5) are respectively provided with a small magnetic wheel (4), the middle part of the top end of the detection vehicle (13) is provided with an inertial sensor (8), two sides of the inertial sensor (8) are respectively provided with a coupling agent spraying device (7), two sides of the inertial sensor (8) are respectively provided with a magnetic spraying device (14), and two sides of the coupling agent spraying device (7) are respectively provided with a magnetic spraying device (13), and two sides of the magnetic probe (13) are respectively connected with the magnetic probe (13).
5. The ultrasonic detection real-time visualization device for weld defects according to claim 4, wherein the single chip microcomputer (3) is internally provided with ultrasonic excitation, and the single chip microcomputer (3) further comprises a 220V-to-24V transformer (301) and an ultrasonic echo signal sampling point (302).
6. The ultrasonic detection real-time visualization device for weld defects, as set forth in claim 4, wherein the auxiliary rail clamping grooves (11) are symmetrically distributed about the center line of the detection vehicle (13).
7. The ultrasonic detection real-time visualization device for weld defects, which is disclosed in claim 4, is characterized in that the magnetic bomb supporting column (6) and the couplant spraying device (7) are symmetrically distributed about the central line of the inertial sensor (8).
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| CN114441642A (en) * | 2020-10-30 | 2022-05-06 | 中国核工业二三建设有限公司 | Method for testing nuclear-grade ferritic steel welds in nuclear power plants using phased array ultrasonic technology |
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| CN114441642A (en) * | 2020-10-30 | 2022-05-06 | 中国核工业二三建设有限公司 | Method for testing nuclear-grade ferritic steel welds in nuclear power plants using phased array ultrasonic technology |
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