CN-122017014-A - Self-adaptive ultrasonic detection device and method for curved aluminum welding seam structure of power equipment

CN122017014ACN 122017014 ACN122017014 ACN 122017014ACN-122017014-A

Abstract

The invention discloses a self-adaptive ultrasonic detection device and method for a curved aluminum welding seam structure of power equipment. The detection device comprises a vehicle body motion control system and an ultrasonic phased array detection system, wherein the vehicle body motion control system comprises a moving device and a self-adaptive attaching mechanism, the self-adaptive attaching mechanism comprises a connecting frame, a spring shell, a spring, a lifting rod, a linkage piece and a displacement sensor, and the detection method comprises transverse wave signal excitation and acquisition, curved surface contour extraction and correction and anisotropic full-focusing imaging. The invention completes the stable coupling of the detection probe and the curved surface workpiece to be detected through the mobile device with the self-adaptive attaching mechanism, avoids signal loss, extracts the curved surface contour of the workpiece through amplitude information, can accurately calculate the sound beam transit time, and realizes the accurate positioning and the quantitative analysis of the size of the defect position by matching with the anisotropic full focusing algorithm considering the material characteristics, thereby achieving the efficient and accurate flaw detection of the aluminum weld joint.

Inventors

ZHANG JIE
YE BO
XU DONGMEI
LU KUANGDA
ZHOU ZHEN
LI XIAOYING
LIU XUEGUANG
CHEN YINZHEN
LUO HONGJIAN
ZHAO ZHOUFENG
Qiu Lvchao
ZHOU YUTONG
MEI JIAN
ZHOU ZHENG
ZOU JUNWEN
YIN WEIJIA

Assignees

杭州意能电力技术有限公司

Dates

Publication Date: 20260512
Application Date: 20260113

Claims (10)

1. The self-adaptive ultrasonic detection device for the curved aluminum welding seam structure of the power equipment is characterized by comprising a vehicle body motion control system and an ultrasonic phased array detection system; The vehicle motion control system comprises a moving device and a self-adaptive attaching mechanism, wherein the moving device comprises a movable upper vehicle plate (111), the self-adaptive attaching mechanism comprises a connecting frame (121), a spring shell (123), a spring (124), a lifting rod (126), a linkage piece (127) and a displacement sensor (125), the spring shell (123) is fixed on the upper vehicle plate (111) through the connecting frame (121), the spring (124) is arranged in the spring shell (123), the bottom of the spring (124) is abutted against the top surface of the lifting rod (126), one end of the linkage piece (127) is connected with the bottom of the lifting rod (126) in a shaft way, the other end of the linkage piece (127) is connected with the outer shell of the phased array probe in a shaft way, and the displacement sensor (125) is fixed on the upper vehicle plate (111) and is used for measuring the displacement change of the lifting rod (126) in the vertical direction in real time; The ultrasonic phased array detection system comprises a transmitting phased array probe (21), a receiving phased array probe (22), a first fixed wedge (23), a first flexible wedge (24), a second fixed wedge (27), a second flexible wedge (28), a phased array detector (25) and a signal receiving and processing unit (26), wherein the first fixed wedge (23) and the second fixed wedge (27) are respectively connected to the first flexible wedge (24) and the second flexible wedge (28), the transmitting phased array probe (21) and the receiving phased array probe (22) are respectively arranged on the first fixed wedge (23) and the second fixed wedge (27), lifting of a lifting rod (126) is realized through vertical stretching and retracting after stress of a spring (124), a linkage piece (127) and the phased array probe are driven, so that the flexible wedge and the surface of a detected curved surface work piece are in self-adaptive fit, excitation of ultrasonic signals of the transmitting phased array probe (21) and acquisition of ultrasonic signals of the receiving phased array probe (22) are realized by the phased array detector (25), displacement data from a displacement sensor (125) are processed by the signal receiving and ultrasonic signals acquired synchronously by the signal receiving and processing unit (26).
2. The adaptive ultrasonic detection device for the curved aluminum welding seam structure of the power equipment according to claim 1, wherein the moving device further comprises a pushing mechanism (114) fixed on the upper vehicle plate (111).
3. The self-adaptive ultrasonic detection device for the curved aluminum welding seam structure of the power equipment according to claim 2, wherein the pushing mechanism (114) comprises a handle (1141), a push rod (1142) and a first screw (1143), and the push rod (1142) is fixedly connected to the upper vehicle plate (111) through the first screw (1143).
4. The self-adaptive ultrasonic detection device for the curved aluminum welding seam structure of the power equipment according to claim 1, wherein the moving device further comprises a front wheel (112) and a rear wheel (113), and the front wheel (112) is fixedly connected with the upper vehicle plate (111) through a wheel frame (1121).
5. The self-adaptive ultrasonic detection device for the curved aluminum welding seam structure of the power equipment according to claim 1, wherein the connecting frame (121) is fixed on the upper vehicle plate (111) through a second screw (122).
6. The self-adaptive ultrasonic detection device for the curved aluminum welding seam structure of the power equipment, which is disclosed in claim 1, is characterized in that two groups of self-adaptive attaching mechanisms are arranged on two sides of an upper vehicle plate (111), and the transmitting phased array probe (21) and the receiving phased array probe (22) are arranged on two sides of the upper vehicle plate (111) respectively and are matched with a corresponding group of self-adaptive attaching mechanisms.
7. The self-adaptive ultrasonic detection device for the curved aluminum welding seam structure of the electric equipment is characterized in that the flexible wedge is driven to be tightly attached to the curved workpiece to be detected by motion control of the self-adaptive attaching mechanism according to different surface shapes of the curved workpiece to be detected, moves along the welding seam direction by a preset step length, scans and images at different positions in the motion process in sequence, and the signal receiving and processing unit processes the acquired ultrasonic signals by adopting a self-adaptive full-focusing algorithm which dynamically corrects a sound beam transmission path and a focusing rule based on displacement data acquired in real time so as to generate an accurate and high-resolution full-focusing image on the curved workpiece to be detected.
8. An adaptive ultrasonic detection method for a curved aluminum welding seam structure of an electric power device, which adopts the detection device as claimed in any one of claims 1 to 7, and is characterized by comprising the following steps: Step one, exciting and collecting transverse wave signals through the phased array detector: And step two, combining the anisotropism of the aluminum welding seam area material, and carrying out curved surface anisotropism full-focusing imaging on the transverse wave pulse echo signals acquired in the step one to realize transverse wave full-focusing imaging on the defects inside the inspected curved surface workpiece.
9. The method according to claim 8, wherein the specific content of the first step includes: Controlling the inclination angle of the first fixed wedge block to enable the transmitting phased array probe to transmit ultrasonic longitudinal waves at an angle larger than a first critical incident angle and smaller than a second critical incident angle, wherein the first critical incident angle is according to Snell's law And a second critical incident angle The calculation of (1) is as follows: Wherein c p1 represents the longitudinal wave sound velocity in the first fixed wedge, and c p2 and c s2 represent the refracted longitudinal wave sound velocity and refracted transverse wave sound velocity in the first flexible wedge, respectively; When the refraction transverse wave propagates to the interface between the second flexible wedge block and the inspected curved surface workpiece, the second refraction transverse wave is generated and continuously transmitted into the inspected curved surface workpiece, reflection occurs when the second refraction transverse wave encounters a defect and is received by the phased array detector through the receiving phased array probe, so that full matrix data are acquired, and then the acquired full matrix data are transmitted to the signal receiving and processing unit for processing, so that ultrasonic transverse wave detection imaging is realized.
10. The method of claim 8, wherein the specific contents of the transverse wave full focus imaging include: Step 21, equally-spaced grid division is carried out on an imaging area; step 22, calculating the distance between each scanning position point transmitting phased array probe and the point at the interface of the first fixed wedge and the first flexible wedge Calculating the propagation distance from the point at the interface of the first fixed wedge and the first flexible wedge to the target imaging point And the distance from the target imaging point to the point at the interface of the second fixed wedge and the second flexible wedge Calculating the distance from the point at the interface of the second fixed wedge and the second flexible wedge to the receiving phased array probe ; Step 23, calculating the total propagation time t h , Wherein To fix the velocity of longitudinal wave sound in the wedge, Acquiring amplitude imaging for transverse wave sound velocity in flexible wedge block In which, in the process, Representing the amplitude at grid point ab; X is the number of grid points on the axis of abscissa, and z is the number of grid points on the axis of ordinate; step 24, setting a threshold value for the amplitude, extracting the positions of sampling points of the surface contours of the flexible wedge block and the workpiece with the curved surface to be detected, fitting the contour curve by adopting a numerical interpolation method, and correcting to obtain the contour curve of the workpiece surface ; Step 25, according to the workpiece surface profile curve obtained in step 24 Calculating the distance between the point of the interface between the first fixed wedge block and the first flexible wedge block and the point of the interface between the first flexible wedge block and the inspected curved surface workpiece Propagation distance from point at interface of first flexible wedge block and detected curved surface workpiece to target imaging correction point Distance from target imaging correction point to point at interface of second flexible wedge block and detected curved surface workpiece The distance between the point of the interface between the second flexible wedge block and the inspected curved surface workpiece and the point of the interface between the second fixed wedge block and the second flexible wedge block ; Step 26, calculating a total propagation modification time t, , wherein, For ultrasonic treatment of workpiece material The velocity of the transverse wave at the angle, For ultrasonic treatment of workpiece material The velocity of the transverse wave at the angle, For the angle between the perpendicular direction of the tangent line of the incident point and the propagation direction of the sound wave in the workpiece, Obtaining corrected amplitude imaging for included angle between reflecting point and sound wave propagation direction in workpiece along tangential direction of workpiece 。

Description

Self-adaptive ultrasonic detection device and method for curved aluminum welding seam structure of power equipment Technical Field The invention belongs to the technical field of nondestructive testing of power equipment, and particularly relates to a self-adaptive ultrasonic testing device and method for a curved aluminum welding seam structure of power equipment. Background The electric power equipment (such as a transformer tank, a GIS shell, a bus pipeline and the like) usually adopts an aluminum alloy welding structure, an aluminum welding line is influenced by factors such as equipment, technology and environment in the welding and service processes, defects such as air holes, slag inclusion and cracks are easy to generate, the defects can cause the problems of stress concentration, fatigue strength reduction, bearing capacity weakening and the like, even parts failure can be possibly caused, the service life and normal operation of the equipment are seriously influenced, and therefore, the method has important significance for guaranteeing the service safety of the aluminum welding line defect detection. At present, nondestructive detection means for an aluminum welding line of power equipment mainly comprise two modes of manual detection and automatic detection. Taking a curved surface weld joint as an example, chinese patent application with the publication number of CN113933313A discloses an ultrasonic automatic detection device for the curved surface weld joint, and an automatic system for driving a probe to move along a curved surface track by a mechanical arm improves the consistency of detection, but the device has a complex structure, depends on a preset track and calibration, is difficult to deploy on site, lacks self-adaptive coupling and real-time pose sensing capability for curved surface fluctuation, and has become an important means for weld joint detection due to high imaging resolution and accurate defect quantification. The Chinese patent application with publication number of CN114993983A discloses a welding line ultrasonic detection system and a method based on a full focusing method, wherein the method can improve the imaging resolution of the welding line defect, but the dependent movement mechanism is mostly a straight line or a rotating shaft system, and the self-adaptive movement and coupling capability for a curved surface is lacking, so that the detection effect is poor when the full focusing imaging is carried out on a complex curved surface. In addition, because the aluminum welding seam shell of the power equipment is generally provided with a curved surface characteristic, the complex transmission of sound beams at the junction of different media can be caused, so that the calculation error of the ultrasonic transit time of the conventional full focusing method is caused, meanwhile, the anisotropic columnar crystal tissue formed in the welding seam region in the welding process can cause interference phenomena such as ultrasonic signal distortion, sound beam deflection and the like, and further the defect positioning accuracy and imaging resolution are obviously reduced. Disclosure of Invention In order to solve the technical problems in the prior art, the invention provides a self-adaptive ultrasonic detection device for a curved aluminum welding seam structure of an electric device, which is used for finishing stable coupling of a detection probe and a curved workpiece to be detected through a moving device with a self-adaptive attaching mechanism so as to avoid signal loss and improve the adaptability to the field environment and make the operation more flexible and simple. Therefore, the invention adopts the following technical scheme. In a first aspect, the invention provides a self-adaptive ultrasonic detection device for a curved aluminum welding seam structure of power equipment, which comprises a vehicle body motion control system and an ultrasonic phased array detection system; The vehicle body motion control system comprises a moving device and a self-adaptive attaching mechanism, wherein the moving device comprises a movable upper vehicle plate, the self-adaptive attaching mechanism comprises a connecting frame, a spring shell, a spring, a lifting rod, a linkage piece and a displacement sensor, the spring shell is fixed on the upper vehicle plate through the connecting frame, the spring is arranged in the spring shell, the bottom of the spring is abutted against the top surface of the lifting rod, one end of the linkage piece is in shaft connection with the bottom of the lifting rod, and the other end of the linkage piece is in shaft connection with the outer shell of the phased array probe; The ultrasonic phased array detection system comprises a transmitting phased array probe, a receiving phased array probe, a first fixed wedge, a first flexible wedge, a second fixed wedge, a second flexible wedge, a phased array detector and a signal receiving and process