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CN-122017043-A - Ultrasonic detection brake disc flaw detection device and method

CN122017043ACN 122017043 ACN122017043 ACN 122017043ACN-122017043-A

Abstract

The invention discloses an ultrasonic detection brake disc flaw detection device and method, comprising a rotary objective table, wherein a detection cavity is hermetically connected to the rotary objective table, high-pressure gas medium with acoustic impedance higher than that of air can be injected into the detection cavity, a magnetic suspension acoustic lens dynamic focusing array module is arranged at the top of the detection cavity, the acoustic wave radiation surface of the magnetic suspension acoustic lens dynamic focusing array module is vertically downward opposite to the rotary objective table, the physical emission aperture of the magnetic suspension acoustic lens dynamic focusing array module has dynamic reconstruction capability, the magnetic suspension acoustic lens dynamic focusing array module is electrically connected with a multichannel coherent excitation and data acquisition module, and a global optical interferometry and position feedback module is arranged on the side wall of the magnetic suspension acoustic lens dynamic focusing array module. The invention solves the problems of low detection efficiency and low precision of the traditional brake disc ultrasonic flaw detection by adopting probe mechanical point-by-point scanning.

Inventors

  • DU JIXIN
  • LIU HAIPENG
  • ZHANG JINGANG
  • LI GUANGBO
  • LIU LI

Assignees

  • 汶上海纬机车配件有限公司

Dates

Publication Date
20260512
Application Date
20260126

Claims (10)

  1. 1. The ultrasonic detection brake disc flaw detection device comprises a rotary object table (1) and is characterized in that a detection cavity (2) is hermetically connected to the rotary object table (1), high-pressure gas media with acoustic impedance higher than that of air can be injected into the detection cavity, a magnetic suspension acoustic lens dynamic focusing array module (3) is arranged at the top of the detection cavity (2), an acoustic wave radiation surface of the magnetic suspension acoustic lens dynamic focusing array module (3) is vertically and downwards opposite to the rotary object table (1), a physical emission aperture of the magnetic suspension acoustic lens dynamic focusing array module (3) has dynamic reconstruction capability, the magnetic suspension acoustic lens dynamic focusing array module (3) is electrically connected with a multichannel coherent excitation and data acquisition module, a global optical interferometry and position feedback module is arranged on the side wall of the magnetic suspension acoustic lens dynamic focusing array module (3), the magnetic suspension acoustic lens dynamic focusing array module (3) comprises a plurality of magnetic suspension focusing units (31) which are arranged in an array, and a spherical suspension body (311) is arranged in the magnetic suspension focusing unit (31), and the surface of the spherical suspension body (311) is provided with optical marks for optical tracking; The global optical interferometry and position feedback module comprises a plurality of CMOS cameras (501), and the optical axes of the plurality of CMOS cameras (501) are intersected in a detection area below the magnetic suspension acoustic lens dynamic focusing array module (3) and are used for capturing images of the optical marks; The system also comprises a central control and imaging processing system, wherein the central control and imaging processing system is electrically connected with the rotary object stage (1), the magnetic suspension acoustic lens dynamic focusing array module (3), the multichannel coherent excitation and data acquisition module and the global optical interferometry and position feedback module.
  2. 2. The ultrasonic detection brake disc flaw detection device according to claim 1, wherein the rotary objective table (1) comprises a supporting seat (101), a fixed disc (102) is fixedly connected to the top of the supporting seat (101), a motor (103) is fixedly arranged at the bottom of the fixed disc (102), an output shaft of the motor (103) vertically and upwards rotates in a sealing mode to penetrate through the top surface of the fixed disc (102), and the top of the output shaft is fixedly connected with the bottom of the rotary objective table (1).
  3. 3. The ultrasonic detection brake disc flaw detection device is characterized in that a control valve (201) communicated with the inside of the detection chamber (2) is arranged on the side wall of the detection chamber (2), an air injection pump is communicated with the control valve (201) and used for injecting high-pressure gas media with acoustic impedance higher than that of air, an air pressure sensor is fixedly and hermetically connected to the side wall of the detection chamber (2) in a penetrating mode, the monitoring end of the air pressure sensor is located in the detection chamber (2), a linear motor (202) which drives in the vertical direction is fixedly arranged on the top surface of the fixed disc (102), and the side wall of a transmission table of the linear motor (202) is fixedly connected with the outer wall of the detection chamber (2).
  4. 4. The ultrasonic detection brake disc flaw detection device according to claim 1, wherein the magnetic suspension acoustic lens dynamic focusing array module (3) comprises a shell (32) with an opening at the bottom, a fixing plate (33) is fixedly connected to the inner wall of the shell (32), and a bottom port of the shell (32) is fixedly butted with a top port of the detection chamber (2); The magnetic suspension focusing unit (31) comprises a cylinder body (313), a flexible impact film (314) is fixedly sealed at the bottom port of the cylinder body (313), two gradient coils (315) which are arranged at intervals up and down are fixedly sleeved on the outer wall of the cylinder body (313), a square shell (316) is fixedly connected to the outer wall of the two gradient coils (315) in a penetrating mode, four saddle coils (317) which are arranged in an annular array are fixedly installed in the square shell (316), the opening directions of the four saddle coils (317) face the axis of the cylinder body (313) vertically, the opening directions are opposite to each other, the two pairs of coils are arranged orthogonally, a transparent cap (318) is fixedly sealed and connected to the top of the cylinder body (313), the spherical suspension body (311) is movably arranged inside the cylinder body (313), square holes are formed in the fixing plate (33), the inner walls of the square holes are fixedly connected with the outer wall of the square shell (316), and the inside of the cylinder body (313) is in a vacuumizing mode.
  5. 5. An ultrasonic inspection brake disc inspection apparatus according to claim 1, characterized in that the spherical suspension (311) has a multi-layer spherical structure from inside to outside: The optical mark is composed of spherical samarium cobalt permanent magnet as the innermost layer, radial hexapole magnetization, tungsten carbide as the middle layer, high-density uniform coating, sequentially prepared gold reflecting film as the outermost layer, and micron-scale grating coding pattern by laser etching.
  6. 6. The ultrasonic inspection brake disc flaw detection device according to claim 4, wherein the CMOS camera (501) is fixedly embedded in the inner wall of the shell (32) in a sealing mode, the optical axis of the CMOS camera (501) is inclined, the spherical suspension bodies (311) and optical marks on the surfaces of the spherical suspension bodies are observed in an unobstructed mode through the transparent caps (318), and the global optical interferometry and position feedback module calculates and outputs three-dimensional space coordinates and vibration phases of each spherical suspension body (311) in real time through image processing.
  7. 7. The ultrasonic inspection brake disc flaw detection device according to claim 4, wherein two gradient coils (315) form an axial gradient coil pair, when reverse current is applied, magnetic field gradients in the vertical direction are generated in the axial region of the cylinder (313) for providing Z-direction levitation force and excitation force of the spherical levitation body (311), four saddle coils (317) form two orthogonal radial gradient coil pairs, and transverse magnetic field gradients can be generated by independently controlling current for providing X, Y-direction positioning force and electrostatic force of the spherical levitation body (311).
  8. 8. The ultrasonic detection brake disc flaw detection device according to claim 7, wherein the aperture dynamic reconstruction capability of the magnetic suspension acoustic lens dynamic focusing array module (3) is realized by the following steps: The central control and imaging processing system outputs a controllable static bias current to saddle coils (317); the static bias current produces a steady transverse static magnetic field gradient in its corresponding pair of saddle coils (317) to apply a continuous horizontal electrostatic force to the spherical suspension (311); Under the drive of the horizontal electrostatic force, the spherical suspension body (311) generates displacement in the horizontal plane, and is precisely moved and locked on a preset target horizontal coordinate through the real-time monitoring and closed-loop control of the global optical interferometry and position feedback module; the dynamic reconstruction of the physical aperture distribution form of the whole array is realized by independently controlling the process of each magnetic suspension focusing unit (31) in the array.
  9. 9. The ultrasonic inspection brake disc inspection device of claim 8, wherein the aperture dynamic reconfiguration is specifically configured to switch the array between two modes of operation: A large-range scanning mode, wherein the spherical suspension body (311) of the peripheral unit of the array is controlled to move outwards to enlarge the physical aperture of the array so as to obtain high spatial resolution for quick census; And in the local fine focusing mode, spherical suspension (311) of the related unit is gathered towards the center by controlling, the physical aperture of the array is reduced and the array is moved to the position above the suspicious region, so that the long depth of field and high local signal to noise ratio are obtained for fine rechecking.
  10. 10. An ultrasonic inspection method for detecting a brake disc flaw detector, characterized in that an ultrasonic inspection brake disc flaw detector according to any one of claims 1 to 9 is used, comprising the steps of: S1, loading and initializing: The brake disc is arranged on a rotary object stage (1), the detection chamber (2) is controlled to descend and butt joint, and high-pressure gas is filled into the detection chamber (2) to set air pressure Starting all magnetic suspension focusing units (31) to make each spherical suspension body (311) stably suspend in initial zero position, starting global optical interferometry and position feedback module to calibrate initial pose matrix of each spherical suspension body (311) Wherein, the method comprises the steps of, For the indexing of the magnetically levitated focusing elements, , Is the total number of units; , Respectively represent the first The initial three-dimensional spatial coordinates of the individual spherical suspensions, Respectively representing the initial rotation angle around X, Y, Z axes; s2, a dynamic phase compensation model: At any time The system acquires the first through a CMOS camera (501) Real-time pose of individual spherical suspensions (311) Calculating the offset of the model relative to the ideal sound source Wherein , 、 Similarly, the deviation of the attitude angle is Calculating the real-time dynamic phase compensation amount required by the unit The model is as follows: Wherein, the For the center frequency of the ultrasonic emission, For detecting the speed of sound in the high-pressure gaseous medium in the chamber (2) at the current temperature and pressure, Taking the X axis of an array plane coordinate system as a reference for the azimuth angle of the current electronic scanning focus direction in the horizontal plane; the acoustic coupling coefficient for horizontal displacement and axial displacement, Is a phase disturbance coefficient caused by the attitude angle deviation, Is a model of the attitude angle deviation vector; S3, an aperture reconstruction control model: When it is desired to switch the array physical aperture from mode a to mode B, for each cell to be moved , For a subset of indices of mobile units: Determining the horizontal target coordinates of the target pore size distribution ; Calculating the required horizontal electrostatic force The force is related to the target displacement vector In proportion to and incorporating a damping term, Is a unit The specific model is as follows: wherein Is a matrix of proportionality coefficients, In the form of a matrix of differential coefficients, The first derivative of displacement vector with respect to time, i.e., velocity; according to force-current conversion model The static bias current vector to be applied to the corresponding radial gradient coil pair-saddle coil 317 is solved Wherein, the method comprises the steps of, For a force constant matrix determined by the coil geometry and the magnetic moment of the levitation body, Current vectors for two orthogonal direction radial coils; iterative adjustment by feedback closed loop of CMOS camera (501) Until the spherical suspension (311) stabilizes Is not limited by the allowable error range of (2) An inner part; S4, coherent synthesis focusing and scanning: for each focus on the scan path , The coordinates of the focus in the detection coordinate system are: Calculate the first Unit to focus Is defined by the geometric sound path of (a): Thereby obtaining the theoretical propagation time ; Generating the first Total excitation phase instruction for individual cells: wherein To focus all units The minimum in theoretical propagation time of (a); The multichannel coherent excitation and data acquisition module is based on Generating synchronous excitation pulses to drive all magnetic suspension focusing units (31) to emit ultrasonic waves; Synchronous acquisition of echo signals when all units are used as receivers Wherein Index for transmitting unit ), Indexing the receiving unit ) Forming a full matrix data slice at the focal point; S5, full focus imaging and defect inversion model: Applying a full focus algorithm to the acquired complete full matrix dataset to calculate each voxel point of the imaging region Is a composite amplitude of (2) : Wherein, the method comprises the steps of, And Respectively using the S2 step to dynamically compensate The transmitting unit and the first Position data of each receiving unit, calculated from transmitting unit to voxel And then from voxels Accurate two-way propagation time to the receiving unit; data volume of three-dimensional complex image Inputting a pre-trained deep learning defect recognition network adopting an encoder-decoder structure, and an encoder Layer feature mapping The calculation is as follows: wherein 、 Is the first The weight tensor and bias vector of the layer three-dimensional convolution kernel, A batch normalization operation is shown and, A three-dimensional convolution operation is represented, For a linear rectification activation function, Input features for the previous layer; The output layer of the network produces two results in parallel, a defect probability map Wherein The function is activated for Sigmoid, 、 For output layer weights and biases, and defect attribute tensors , The method comprises the steps of classifying labels, equivalent sizes and detection confidence degrees of types of defects at each spatial position; s6, self-adaptive detection decision and report generation: The system performs imaging according to the first round of global scanning and the initial result and the defect probability map The mid-probability value exceeds the threshold value Extracting suspicious region sets , Indexing suspicious regions; For each of The system automatically decides, calls the aperture reconstruction control model of S3, and switches the array to be aimed at An optimized local fine focus mode; at the new aperture after reconstruction, pair Performing a second round of high resolution scanning, and generating a local fine image by using the imaging and inversion model of S5; and fusing the global scanning data and the local scanning data to generate a comprehensive detection report finally containing the three-dimensional positioning, quantification and classification results of the defects.

Description

Ultrasonic detection brake disc flaw detection device and method Technical Field The invention relates to the technical field of brake disc flaw detection, in particular to a brake disc flaw detection device and method based on ultrasonic detection. Background The brake disc is a core component of an automobile and rail traffic braking system, and the quality of the brake disc directly determines the running safety. The brake disc is easy to generate hidden defects such as cracks, air holes and the like in casting, processing and service, and the defects can continuously expand along with the load action to cause fracture failure, so that the brake disc needs to be comprehensively examined through nondestructive detection. Ultrasonic flaw detection is a mainstream means due to deep detection and high sensitivity, the probe is driven to move according to a preset track by a mechanical mechanism mainly depending on the probe mechanical point-by-point scanning technology at present, defect signals are captured by means of ultrasonic reflection, detection is completed by matching a coupling device with a data unit, a gap between the probe and a workpiece is filled by adopting a water immersion method generally, and ultrasonic energy loss is reduced. Although the technology is widely applied, the technology is difficult to adapt to the complex structure of the brake disc and the high-precision detection requirement, and has a plurality of bottlenecks. The method has the advantages of limited physical movement speed of the probe, limited requirement for avoiding adjustment tracks of vent holes and radiating grooves, incapability of meeting the requirement of mass production, fixed focusing parameters and aperture of the probe, easy positioning deviation of a mechanical mechanism in long-term operation, easy omission of detection of tiny defects, insufficient quantitative precision, easy corrosion of workpieces and equipment clamping stagnation caused by a water immersion method, difficulty in capturing three-dimensional characteristics of defects due to attenuation signals of air media in a dry scanning method, weak qualitative capability and high result reliability influenced by the level of operators. In summary, the existing probe mechanical point-by-point scanning technology has limitations on efficiency, precision, stability and defect identification, and cannot meet the high-efficiency and high-precision requirements of the production operation and maintenance of modern brake discs. Therefore, we propose an ultrasonic detection brake disc flaw detection device and method. Disclosure of Invention The invention aims to solve the problems of low detection efficiency and low precision of the conventional brake disc ultrasonic flaw detection by adopting probe mechanical point-by-point scanning. The ultrasonic detection brake disc flaw detection device comprises a rotary objective table, wherein a detection cavity is hermetically butted on the rotary objective table, high-pressure gas media with acoustic impedance higher than that of air can be injected into the detection cavity, a magnetic suspension acoustic lens dynamic focusing array module is arranged at the top of the detection cavity, an acoustic wave radiation surface of the magnetic suspension acoustic lens dynamic focusing array module vertically faces downwards to the rotary objective table, and a physical emission aperture of the magnetic suspension acoustic lens dynamic focusing array module has dynamic reconstruction capability; The global optical interferometry and position feedback module comprises a plurality of CMOS cameras, and the optical axes of the CMOS cameras are intersected in a detection area below the magnetic suspension acoustic lens dynamic focusing array module and are used for capturing images of optical marks; The system also comprises a central control and imaging processing system, wherein the central control and imaging processing system is electrically connected with the rotary objective table, the magnetic suspension acoustic lens dynamic focusing array module, the multichannel coherent excitation and data acquisition module and the global optical interferometry and position feedback module. Preferably, the rotary objective table comprises a supporting seat, the top of the supporting seat is fixedly connected with a fixed disc, the bottom of the fixed disc is fixedly provided with a motor, an output shaft of the motor vertically upwards rotates in a sealing way to penetrate through the top surface of the fixed disc, and the top of the output shaft is fixedly connected with the bottom of the rotary objective table. Preferably, the side wall of the detection chamber is provided with a control valve communicated with the inside of the detection chamber, the control valve is communicated with an air injection pump for injecting high-pressure gas medium with acoustic impedance higher than that of air, the side wall of the detection