CN104655718B - A kind of electromagnetic test method and system based on Hall sensor array - Google Patents
A kind of electromagnetic test method and system based on Hall sensor array Download PDFInfo
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- CN104655718B CN104655718B CN201410839730.0A CN201410839730A CN104655718B CN 104655718 B CN104655718 B CN 104655718B CN 201410839730 A CN201410839730 A CN 201410839730A CN 104655718 B CN104655718 B CN 104655718B
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Abstract
The present invention relates to a kind of electromagnetic test system, the system includes magnetic field generation device and detector for magnetic field, detector for magnetic field is by detecting that the magnetic field that magnetic field generation device is produced is detected a flaw to magnetic strength component, wherein magnetic field generation device mainly includes full-bridge inverter, main control chip, crossed yoke, power detecting module, and magnetized electromagnetic field is carried out mainly for generation of to workpiece；Detector for magnetic field includes Hall sensor array, data acquisition module, data processing module, data disaply moudle, for detecting and showing the magnetic line of force that magnetic field generation device is produced everywhere in workpiece.The present invention solves shortcoming of the magnetic powder inspection mode during Non-Destructive Testing, while improving the detection time of single charge, detection range, recall rate and detection speed again.
Description
Technical field
The present invention relates to a kind of nondestructive detection system, relate in particular to a kind of electromagnetism based on Hall sensor array and visit
Hinder method and system.
Background technology
Magnetic powder inspection is all used widely as a kind of ripe nondestructiving detecting means, at home and abroad every field, magnetic
Powder flaw detection general principle be：The permeability of nonferromagnetic material is much larger than using the permeability of ferrimagnet, according to workpiece quilt
Magnetic flux density β=μ H after magnetization are analyzed, and pass through the B root magnetic lines of force in the unit area of workpiece, and in the unit of defect area
It can not allow that the B root magnetic lines of force pass through on area, just force a part of magnetic line of force to be extruded into the material below defect, other magnetic lines of force
Have to be forced effusion workpiece surface and form leakage field with outgoing, magnetic will be attracted by so caused leakage field, and then realize
Magnetic powder inspection.
From fixed, portable to portable, from automatic, full-automatic to special equipment, from unidirectional magnetiztion to multidirectional magnetization,
The own seriation of equipment and commercialization.Although external advanced large-scale detection device Effect on Detecting is good, expensive, many times
It is not appropriate for popularization at home.And domestic relatively backward in Magnetic testing technical industry direction, the magnetic crack detector of in the market
Often can only be little to depth of defect, the single workpiece in direction is detected, to some large area, and depth of defect and direction are unknown
Workpiece sensing DeGrain.
The principle of cross-magnetizing method is that only defective orientation is vertical with magnetic line of force direction in Magnetic testing or exists
During larger angle, stray field, and then effectively absorption magnetic formation magnetic trace can be just advantageously generated.Cross-magnetizing method once may be used
To check the defect of different orientation simultaneously, ensure the reliability of detection and greatly improve detection efficiency.Domestic and international industrial flaw detection makes
Rotating excitation field magnaflux is formally based on this principle to portable crossed yoke in other words.Crossed yoke is in other words
It is that rotating excitation field is made up of two groups of coils, thus needs to supply two groups of power supplys, supply signal typically uses 36V/10A, work
Frequency fixes 50HZ AC signal.When multiple magnetic fields carry out multi-direction magnetization to workpiece simultaneously, the magnetic field acted on workpiece
It should be the superposition that the vector in each magnetic field, i.e. resultant magnetic field are each magnetic vector.
In actual flaw detection work, the Magnetic testing that especially scene is carried out, many occasions, for example：Field, height
Inside empty, container, pressure pipeline on-line checking ,~220V alternating current can not be sent to or not allowed access into for security consideration.
And due to using~220V Alternating Current Power Supply, the position of detection is often widely distributed, and each location detection is required for
~220V AC power dispatching in place, otherwise it can not detect.Quickly, still, the dispatching of power supply needs Magnetic testing speed
For a long time, inside some positions, such as high-altitude, container, power supply with returning highly difficult, leave~220V AC power, it is very little
Step is difficult to walk, and so greatly reduces operating efficiency.The personnel for being engaged in Site Detection typically have an intimate knowledge, magnetic powder inspection detection when
Between often be far below power supply distribution time.And use ~ 220V Alternating Current Power Supplies, it is also relatively dangerous.
On the other hand, current Magnetic testing is that defect is observed using magnetic as display medium.Applied during according to magnetization
Plus magnetic medium species, the detection method is divided into wet method and dry method.Magnetic is suspended in oil, water or other liquid mediums
Detected using referred to as wet method.It is in detection process, magnetic flaw detection ink to be uniformly distributed on the surface of the workpiece, the flowing of carrier fluid is utilized
The shapes and sizes of defect are shown to the attraction of magnetic with stray field.Dry method is also known as dry method can not under some special occasions
It is applied directly to when being detected using wet method and using special dry magnetic particle by program on magnetized workpiece, the fault location of workpiece
Magnetic trace is shown, dry method detection is used for heavy casting and forging blank and large-sized structural parts.Table of the both approaches to detection piece
Face smoothness requirements are higher, and the technology and skill requirement to examinations personnel are higher, and detection range is small, and speed is slow.And
Either dry method or wet method can be attracted to for the magnetic of detection due to the factor of itself remanent magnetism is detected workpiece
Surface is not easy to be eliminated, and may influence the use of workpiece, the micro- magnetic trace left for the workpiece surface formation repeatedly to detect
Also the performance of magnetic powder inspection can be influenceed.On the other hand this flaw detection mode is used every time can all consume a certain amount of magnetic and load
Liquid, which results in huge waste, and the magnetic and carrier fluid that remain can be polluted.
The content of the invention
It is an object of the invention to provide a kind of electromagnetic test method and system based on Hall sensor array, make system
While overcoming magnetic powder inspection magnetic residual and magnetic, carrier fluid to waste, also with security, detection sensitivity, detection range
In terms of advantage.
To achieve these goals, the present invention is achieved by the following technical solutions：
A kind of electromagnetic test method based on Hall sensor array, comprises the following steps：
S01：The DC inverter of input is the controllable alternating current of frequency by full-bridge inverter, and is magnetized week in each unit
Crossed yoke is supplied in phase no less than the alternating current of two different frequencies；
S02：Crossed yoke magnetizes in unit and two groups of electric currents is exported in the cycle, produces the magnetic field of different directions；
S03：Hall sensor array detects magnetic field intensity of the crossed yoke in measured workpiece Surface field；
S04：The magnetic field intensity that data collecting module collected Hall sensor array is detected, and carry out A/D conversions；
S05：Data of the data processing module analysis from data acquisition module judge whether leakage field situation, and calculate
Go out defect form；
S06：Data disaply moudle shows the analysis result from data processing module.
The Hall sensor array is made up of at least one Hall cells, and each Hall cells are included
Four Hall sensor directions in four Hall sensors, the unit be towards four of respectively plane intersect at a point it is straight
8 directions pointed by line, N in the magnetic field of crossed yoke formation or on S direction is set comprising this 8 directions
Hall cells.
The plane that 8 directions that the Hall cells are pointed to are formed is vertical with the magnetic direction of crossed yoke.
The alternating current frequency that the full-bridge inverter is provided is not more than 50HZ.
The unit different frequency that cycle and the full-bridge inverter provide that magnetizes is respectively 3 seconds and 5 frequencies：5HZ、
10HZ、20HZ、40HZ、50HZ。
A kind of electromagnetic test system based on Hall sensor array, including magnetic field generation device and detector for magnetic field,
The leakage field field intensity that detector for magnetic field detection magnetic field generation device is produced on workpiece.
Described magnetic field generation device, it includes full-bridge inverter and the crossed yoke being connected with full-bridge inverter,
Wherein, DC inverter is the controllable alternating current of frequency by full-bridge inverter, and the alternating current of different frequency is provided for crossed yoke
Stream；Crossed yoke is located at around measured workpiece, and is magnetized in unit two groups of electric currents are exported in the cycle, produces the magnetic of different directions
；
Hall sensor array provided with detection leakage field field intensity in the detector for magnetic field, Hall sensor array inspection
Survey leakage field field intensity of the crossed yoke in measured workpiece Surface field；The output of data collecting module collected Hall sensor array
Leakage field field intensity, data processing module is analyzed the leakage field field intensity collected, and analysis result is passed through into data display
Module is shown.
The magnetic field generation device also includes power detecting module, main control chip, control button, battery pack and charging
Mouthful, charging inlet is connected to battery pack and full-bridge inverter, and battery pack is connected to power detecting module and full-bridge inverter, master control
Chip is connected to full-bridge inverter, and full-bridge inverter is connected to crossed yoke, and control button is connected to main control chip.
The Hall sensor array is made up of at least one Hall cells, and each Hall cells are included
Four Hall sensor directions in four Hall sensors, the unit be towards four of respectively plane intersect at a point it is straight
8 signified directions of line, N in the magnetic field of crossed yoke formation or on S direction is set comprising this 8 directions suddenly
That sensor unit.
The plane that 8 directions that the Hall cells are pointed to are formed is vertical with the magnetic direction of crossed yoke.
The alternating current frequency that the full-bridge inverter is provided is not more than 50HZ.
The present invention compared with prior art, with advantages below：
1st, using the leakage field field intensity around Hall sensor array measuring cell, instead of using magnetic cladding element quilt
Position is detected, the reduction using the detection capability caused during magnetic in the residual of element surface formation can be avoided, can also be kept away
Exempt from waste and pollution that magnetic and carrier fluid are caused.
2nd, the present invention uses dc source, then is changed into alternating current by full-bridge inverter, overcomes in magnetic powder inspection
The danger caused in journey using high-voltage ac power, improves security.
3rd, the controllable alternating current of frequency that the present invention is changed using full-bridge inverter, unit magnetize in the time there is provided to
The continuous different frequency of flaw detection probe is magnetized, and greatly improves the recall rate of defect, expands inspection range, improves detection work
Efficiency, for example, magnetized using the alternating current of currently preferred 5 continuous different frequencies, can both detect surface and near surface
Defect, the buried defect as deep as 5mm can be detected again, overcome exchange electro-detection workpiece surface and near surface defect
When, near surface 1mm defect can only be detected；It is extremely difficult to what workpiece was once magnetized while overcoming and depending merely on a kind of frequency
The deficiency of surface and buried defect is detected in time simultaneously.
4th, the detector for magnetic field constituted using Hall sensor array replaces magnetic to show result of detection, full-bridge inverter
The electric current of generation need not be too big and the mode of rotating excitation field need not be taken just can be magnetized, and has both remained test accurate
Degree, while adding the application and detection speed of detection means, saves energy and extends battery working time again.
Brief description of the drawings
Fig. 1 is crossed yoke structural representation.
Fig. 2 is the map of current that is provided to two groups of coils of crossed yoke.
Fig. 3 is the current strength figure of two groups of coil formation of crossed yoke.
Fig. 4 is magnetic field generation device hardware block diagram.
Fig. 5 is full-bridge inverter schematic diagram.
Fig. 6 is main control chip schematic diagram.
Fig. 7 is power detecting module principle figure.
Fig. 8 is detector for magnetic field system block diagram.
Fig. 9 is a Hall cells.
Figure 10 is a Hall sensor array topological structure.
Figure 11 is the relation of working frequency and detection depth.
Figure 12 is pulse width modulated wave signal schematic representation.
Figure 13 is 8 direction of magnetizations.
Figure 14 is the output current of two groups of yokes in unit period.
Figure 15 is magnetic powder inspection depth test block.
Wherein 1,2,3,4 be Hall sensor.
Embodiment
Below in conjunction with the accompanying drawings and embodiment further illustrates the present invention.
In order that the purpose of the present invention, technical scheme, advantage are more clearly understood, with reference to drawings and Examples, to this hair
It is bright to be further elaborated.It should be appreciated that specific embodiment described in the invention is a kind of preferred mode, only
For explaining the present invention, the present invention can not be limited in any way.
The present invention provides a kind of method and system of electromagnetic test, has following steps using this method of detection：
S01：The DC inverter of input is the controllable alternating current of frequency by full-bridge inverter, and is magnetized week in each unit
Crossed yoke is supplied in phase no less than the alternating current of two different frequencies；
S02：Crossed yoke magnetizes in unit and two groups of electric currents is exported in the cycle, produces the magnetic field of different directions；
S03：Hall sensor array detects leakage field field intensity of the crossed yoke in measured workpiece Surface field；
S04：The leakage field field intensity that data collecting module collected Hall sensor array is detected, and carry out A/D conversions；
S05：Data of the data processing module analysis from data acquisition module judge whether leakage field situation, and calculate
Go out defect form.
S06：Data disaply moudle shows the analysis result from data processing module.
The electromagnetic test system that the present invention is provided includes magnetic field generation device and detector for magnetic field, magnetic field generation device energy
Enough produce magnetic field, the leakage field field intensity that detector for magnetic field detection is produced by magnetic field generation device on workpiece.
Magnetic field generation device as shown in Figure 4, including it is power detecting module, main control chip, control button, battery pack, complete
Bridge inverter, crossed yoke and charging inlet.Charging inlet is connected to battery pack and full-bridge inverter, and battery pack is connected to power supply
Detection module and full-bridge inverter, main control chip are connected to full-bridge inverter, and full-bridge inverter is connected to crossed yoke, and control is pressed
Key is connected to main control chip.
Wherein, main control chip is made up of single-chip microcomputer, and battery pack is used for powering to power detecting module and full-bridge inverter, electricity
Source detection module is mainly used to detection supply voltage and provides operating voltage to main control chip, if battery power is not enough,
When power detecting module detects the situation of under-voltage, power detecting module is supplied to the operating voltage of main control chip to send out
Changing, in order to prevent the change for the full-bridge inverter output current being connected with main control chip, main control chip can control to change complete
The power of bridge inverter, makes the electric current of output keep constant, for ensuring that full-bridge inverter generation meets the frequency of system requirements
Electric current.Meanwhile, main control chip also receives the information from outside control button.
The core of magnetic field generation device of the present invention is full-bridge inverter, for the direct current that provides battery with inversion
Mode is converted into the controllable alternating current of frequency, is output in crossed yoke as shown in Figure 1, produces crossed yoke and meets system
It is required that magnetic field.Specifically, full-bridge inverter needs to magnetize in the cycle in time of once magnetizing, i.e. unit, is crossed yoke
The alternating current of at least two different frequencies is provided, can not be while detecting near surface flaw and buried scarce to solve single-frequency
In the problem of falling into, embodiments of the present invention, full-bridge inverter needs two-way.Fig. 2 is provides to two groups of coils of crossed yoke
Map of current, Fig. 3 is the current strength figure of two groups of coil formation of crossed yoke.One group two-by-two of four magnetic poles, equivalent to 2 yokes
（That is crossed yoke）, have the sinusoidal alternating current of certain phase difference excitatory by two-phase respectively, resultant field formed on workpiece.
Rotating excitation field is formed when meeting certain condition.I.e.:
The electric current provided to two groups of coils is：
Represented with magnetic field intensity：
Work as Hm1=Hm2, and two yoke geometric angle α and two-phase exciting curent phase difference Φ is when being equal to 90 °,
Crossed yoke is centrally formed circular rotating field.
It should be noted that when the square-wave signal of use different frequency as shown in fig. 11 is detected, frequency compared with
It is high（E.g., from about 50HZ）When, the defect of near surface can only be found, with the raising of frequency, detection depth is more and more shallow, with frequency
The reduction of rate, detection depth it is more and more deeper, but frequency be more than 50HZ when, detection depth when about 50HZ compared with, not compared with
Big to change, therefore, the a-c cycle of full-bridge inverter output is controlled in no more than 50HZ scope.
Fig. 8 is the detector for magnetic field of the present invention, hall sensing of the detector for magnetic field provided with detection magnetic field magnetic field intensity
Device array, Hall sensor array includes several Hall cells, and magnetic is carried out to workpiece surface in magnetic field generation device
While change, the Hall sensor array in detector for magnetic field detects the magnetic field intensity in the specific several directions in its region,
The magnetic field strength date of data collecting module collected Hall sensor array output, data processing module is strong to the magnetic field collected
Degrees of data is analyzed, and determines that the regional magnetic force line is moved towards, and analogy it is preferable it is flawless in the case of magnetic force line strength and trend
Draw result of detection；And show analysis result by data disaply moudle.Wherein, hall sensing as of fig. 9 shown
Device unit, the quantity of Hall cells can be set according to the area of actual imaging, can be one, two, three
It is individual, four or more.Each Hall cells include four Hall sensors in four Hall sensors, the unit
8 directions of the straight line meaning that direction intersects at a point for vertical divide equally plane four.It is multiple in Hall sensor array
The placement of Hall cells can be designed as needed, in some embodiments of the invention, can be such as the institute of accompanying drawing 10
The arrangement mode shown carries out the Hall sensor direction in the design of Hall cells, i.e., all Hall cells
8 directions of identical.In the present invention, the N or S of the rotating excitation field of crossed yoke formation direction, set and comprise at least one
The Hall sensor array of individual Hall cells, for detecting the magnetic line of force by workpiece.In some implementations of the present invention
In example, it can also be respectively provided with the N and S of the rotating excitation field of crossed yoke formation direction including at least a Hall sensor
The Hall sensor array of unit, the numerical value current for detecting the magnetic line of force.In the system of the present invention, Hall sensor simultaneously
The plane that 8 directions that unit is pointed to are formed is vertical with the magnetic direction of crossed yoke, more accurate to measure.
In the embodiment tested in magnetic powder inspection depth test block shown in Figure 15, magnetic field generation device it is complete
Bridge inverter is two-way, wherein circuit theory diagrams all the way are as shown in figure 5, main control chip uses model ATMEGA48PA list
Piece movement piece, its circuit theory diagrams are as shown in fig. 6, power detecting module uses circuit theory diagrams as shown in Figure 7.Make
Unit magnetized the cycle for 3 seconds, in 3 seconds magnetize in the cycle, and the cycle is respectively as shown in fig. 13 that for full-bridge inverter generation
0.2 second, 0.1 second, 0.05 second, 0.025 second and 0.02 second, i.e. frequency are respectively 5HZ, 10HZ, 20HZ, 40HZ, 50HZ 5 frequencies
The alternating current of rate, is exported to crossed yoke.8 parts will be divided into the cycle, controlled using main control chip, make two groups of yokes in unit
Magnetize correspondence output two groups of electric currents as shown in figure 14 in the cycle, produces the magnetic field in eight directions shown in Figure 13.
Specifically, using crossed yoke as shown in Figure 1, see Figure 14 polarization current, first 1/8th weeks
The magnetic field that phase interior loop L1 and L2, L3 and L4 are produced by electric current meets No. 1 direction in Figure 14, in second 1/8th cycle
The magnetic field that coil L1 and L2 is produced by electric current meets No. 2 directions in Figure 14, the 3rd 1/8th intraperiod line circle L1 and L2,
The magnetic field that L3 and L4 is produced meets No. 3 directions in Figure 14, and producing magnetic field in the 4th 1/8th intraperiod line circle L3 and L4 expires
No. 4 directions in sufficient Figure 14, meet in the 5th 1/8th intraperiod line circle L1 and L2, L3 and the L4 magnetic field produced by electric current
No. 5 directions in Figure 14, the magnetic field that the 6th 1/8th intraperiod line circle L1 and L2 are produced by electric current meets No. 6 sides in Figure 14
To the magnetic field that the 7th 1/8th intraperiod line circle L1 and L2, L3 and L4 are produced meets No. 7 directions in Figure 14, at the 8th
/ 8th intraperiod line circle a L3 and L4 produce magnetic field and meet No. 8 directions in Figure 14, and 25% electricity can be saved in this way
Energy.
Hall sensor array needs to detect in each 1/8th cycle simultaneously, the magnetic in 8 directions as shown in fig. 13 that
Field intensity, data that data collecting module collected Hall sensor array is sent simultaneously carry out A/D conversions to data, then transfer to number
It is compared according to processing module with the magnetic force line strength under nondestructive state, judges whether slight crack, if slight crack estimation is split
The general direction of trace, is finally shown real magnetic field degree of impairment by data disaply moudle in the way of image.In this process
In, the frequency that full-bridge inverter is produced is not more than 50HZ, and power detecting module provides operating voltage for main control chip and detects electricity
Source voltage, when undervoltage condition occurs in power supply, main control chip will control the power of change full-bridge inverter, make its output current not
Become, it is ensured that the magnetic field intensity that magnetic field generation device is produced remains unchanged.
Claims (8)
1. a kind of electromagnetic test method based on Hall sensor array, it is characterised in that：This method comprises the following steps：
S01：The DC inverter of input is the controllable alternating current of frequency by full-bridge inverter, and is magnetized in each unit in the cycle
Crossed yoke is supplied to no less than the alternating current of two different frequencies；
S02：Crossed yoke magnetizes in unit and two groups of electric currents is exported in the cycle, produces the magnetic field of different directions；
S03：Hall sensor array detects magnetic field intensity of the crossed yoke in measured workpiece Surface field；
S04：The magnetic field intensity that data collecting module collected Hall sensor array is detected, and carry out A/D conversions；S05：Data
Processing module analyzes the data from data acquisition module, judges whether leakage field situation, and calculate defect form；
S06：Data disaply moudle shows the analysis result from data processing module；
The Hall sensor array is made up of at least one Hall cells, and each Hall cells include four
Four Hall sensor directions in Hall sensor, the unit are the straight line institute that is intersected at a point towards four of respectively plane
8 directions pointed to, N in the magnetic field of crossed yoke formation or on S direction sets and includes the Hall in this 8 directions
Sensor unit.
2. the electromagnetic test method according to claim 1 based on Hall sensor array, it is characterised in that：The Hall
The plane that 8 directions that sensor unit is pointed to are formed is vertical with the magnetic direction of crossed yoke.
3. the electromagnetic test method according to claim 1 based on Hall sensor array, it is characterised in that：The full-bridge
The alternating current frequency that inverter is provided is not more than 50HZ.
4. the electromagnetic test method according to claim 1 based on Hall sensor array, it is characterised in that：The unit
The different frequency that cycle and the full-bridge inverter provide that magnetizes is respectively 3 seconds and 5 frequencies：5HZ、10HZ、20HZ、40HZ、
50HZ。
5. a kind of electromagnetic test system based on Hall sensor array, it is characterised in that：Including magnetic field generation device and magnetic field
Detection means, the leakage field field intensity that detector for magnetic field detection magnetic field generation device is produced on workpiece；Described magnetic field is produced
Device, it includes full-bridge inverter and the crossed yoke that is connected with full-bridge inverter, wherein, full-bridge inverter is by direct current
Inversion is the controllable alternating current of frequency, and the alternating current of different frequency is provided for crossed yoke；Crossed yoke is located at measured workpiece
Around, and magnetized in unit two groups of electric currents are exported in the cycle, produce the magnetic field of different directions；
Hall sensor array provided with detection leakage field field intensity in the detector for magnetic field, Hall sensor array detection is handed over
Pitch leakage field field intensity of the yoke in measured workpiece Surface field；The leakage field of data collecting module collected Hall sensor array output
Field intensity, data processing module is analyzed the leakage field field intensity collected, and analysis result is passed through into data disaply moudle
Show；
The Hall sensor array is made up of at least one Hall cells, and each Hall cells include four
Four Hall sensor directions in Hall sensor, the unit are the straight line institute that is intersected at a point towards four of respectively plane
Refer to 8 directions, crossed yoke formation magnetic field in N or S direction on, set comprising this 8 directions Hall pass
Sensor cell.
6. the electromagnetic test system according to claim 5 based on Hall sensor array, it is characterised in that：The magnetic field
Generation device also includes power detecting module, main control chip, control button, battery pack and charging inlet, and charging inlet is connected to
Battery pack and full-bridge inverter, battery pack are connected to power detecting module and full-bridge inverter, and it is inverse that main control chip is connected to full-bridge
Become device, full-bridge inverter is connected to crossed yoke, and control button is connected to main control chip.
7. the electromagnetic test system according to claim 5 based on Hall sensor array, it is characterised in that：The Hall
The plane that 8 directions that sensor unit is pointed to are formed is vertical with the magnetic direction of crossed yoke.
8. the electromagnetic test system according to claim 5 based on Hall sensor array, it is characterised in that：The full-bridge
The alternating current frequency that inverter is provided is not more than 50HZ.
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