CN111999387B - Laser ultrasonic automatic detection system and method for carbon fiber composite material blade - Google Patents
Laser ultrasonic automatic detection system and method for carbon fiber composite material blade Download PDFInfo
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Abstract
The application discloses a laser ultrasonic automatic detection system and a method for a carbon fiber composite blade, the method comprises dividing the surface of blade into uniform grid units, scanning the grid units with two-dimensional laser galvanometer, generating laser ultrasonic signals on the material surface corresponding to the corresponding grid units, the multi-degree-of-freedom mechanical arm drives the pulse laser, the two-dimensional laser galvanometer, the field lens and the array type air coupling laser ultrasonic probe to synchronously move according to a preset motion track, the two-dimensional laser galvanometer can scan all grid units in sequence, laser ultrasonic signals generated by scanning are correspondingly received through the array type air coupling laser ultrasonic probe, imaging is carried out according to the laser ultrasonic signals, micron-level high-precision detection of the defects on the surface and inside of the whole blade can be realized, and the purposes of rapid and in-situ detection of the large-curvature curved surface of the carbon fiber composite blade and system miniaturization are realized.
Description
Technical Field
The application relates to the technical field of carbon fiber composite material detection, in particular to a laser ultrasonic automatic detection system and a corresponding method for a carbon fiber composite material.
Background
At present, compared with blades made of metal materials, blades made of carbon fiber composite materials have great advantages, such as low density, high specific strength and specific stiffness, the weight of the blades can be greatly reduced under the condition of ensuring the mechanical property of the blades, energy consumption can be saved, cost can be reduced, more possibility is brought to the progress of various technologies, for example, a fan blade is one of the most important parts of a modern commercial aircraft engine, according to statistics, the mass of a fan section accounts for about one third of the total mass of the engine, therefore, the development of larger and lighter carbon fiber composite material blades is a trend, and the research of more carbon fiber composite material blade detection methods is also significant.
At present, a laser ultrasonic detection system based on an optical method is large in size and cannot be suitable for scenes with large blade number, overlapped shielding, small detection space and the like.
Chinese patent publication No. CN104535648B discloses a turbine blade ultrasonic guided-wave detection method, which utilizes an ultrasonic detector and an ultrasonic guided-wave probe for exciting guided waves, after a coupling agent is coated, the ultrasonic guided-wave probe is placed on a turbine blade to be detected, the blade body of the turbine blade to be detected is comprehensively scanned, when a defect echo appears in the detection process, the equivalent comparison is performed with the echo amplitude reflected by an artificial defect groove of a reference block, and if the defect echo amplitude is greater than or equal to the artificial defect echo amplitude, the defect echo is marked as unqualified. When the surface curvature of the blade to be detected is large, the coupling coefficient of the coupling agent is not stable enough, and the detection efficiency and the resolution are low.
Chinese patent publication No. CN101435784B discloses a turbine blade CT inspection apparatus and an inspection method thereof, which are used for detecting cracks in all directions of a blade by irradiating the blade with X-rays and adjusting the inclination angle of the blade. The ray source adopted by the detection method is expensive, the detection device is large in size and cannot carry out in-situ detection, and the angle of the blade needs to be adjusted to prevent the crack perpendicular to the ray from being missed to be detected, so that the imaging speed is low and the detection efficiency is low.
Disclosure of Invention
The application provides a laser ultrasonic automatic detection system and method for a carbon fiber composite material blade, which are used for solving the technical problems that in the prior art, the carbon fiber composite material blade with large curvature is low in detection efficiency, low in resolution, high in cost and large in system volume.
In view of the above, the present application provides, in a first aspect, a laser ultrasonic automated inspection system for a carbon fiber composite blade, including:
the system comprises a pulse laser, an optical fiber, a two-dimensional laser galvanometer, a field lens, an array type air coupling laser ultrasonic probe, a multi-degree-of-freedom manipulator and a signal processing module;
the pulse laser is used for generating laser beams and then transmitting the laser beams to the two-dimensional laser galvanometer through the optical fiber;
the two-dimensional laser galvanometer is used for focusing and scanning grid units which are uniformly pre-divided on the surface of the carbon fiber composite material blade to be detected through the field lens according to a preset scanning track after receiving the laser beam so as to generate laser ultrasonic signals on the surface of the carbon fiber composite material blade to be detected corresponding to the corresponding grid units;
the optical fiber, the two-dimensional laser galvanometer, the field lens and the array type air coupling laser ultrasonic probe are all arranged at the output end of the multi-degree-of-freedom manipulator, and the multi-degree-of-freedom manipulator is used for driving the optical fiber, the two-dimensional laser galvanometer, the field lens and the array type air coupling laser ultrasonic probe to synchronously move and controlling the two-dimensional laser galvanometer to move according to a preset motion track so as to sequentially scan all the grid units uniformly divided in advance on the surface of the carbon fiber composite material blade to be detected;
the array air coupling laser ultrasonic probe is arranged corresponding to the field lens and is used for receiving the laser ultrasonic signals which are generated by the laser beams on the surface of the carbon fiber composite material blade to be detected corresponding to the grid units which are uniformly divided in advance and penetrate through the internal structure of the carbon fiber composite material blade to be detected in a preset phase control focusing mode;
the signal processing module is electrically connected with the output end of the array type air coupling laser ultrasonic probe, the signal processing module is used for preprocessing the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe, and is also used for calculating the light absorption rate of the surface structure of the carbon fiber composite material blade to be detected and the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite material blade to be detected according to the preprocessed laser ultrasonic signals, and is also used for respectively carrying out image characterization on the surface defect structure of the carbon fiber composite material blade to be detected and the internal defect structure of the carbon fiber composite material blade to be detected according to the light absorption rate of the surface structure of the carbon fiber composite material blade to be detected and the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite material blade to be detected.
Preferably, the device further comprises a dividing module, wherein the dividing module is used for carrying out grid uniform division on the carbon fiber composite material blade to be detected according to the shape and the area of the surface of the carbon fiber composite material blade to be detected so as to form a plurality of grid units.
Preferably, array air coupling laser ultrasonic probe includes upper portion open-ended casing, be equipped with in the casing and have a plurality of piezoelectric wafer and be the area array and arrange respective piezoelectric wafer array, the upper surface of piezoelectric wafer array has plated outer electrode layer, the upper surface of outer electrode layer has plated interior matching layer, the upper surface of interior matching layer has plated outer matching layer, outer matching layer is located the opening part of casing and with the carbon fiber composite blade that awaits measuring corresponds the setting, the lower surface of piezoelectric wafer array has plated the inner electrode layer, the lower surface of inner electrode layer has plated the back sheet, the casing still is equipped with the output, outer electrode layer with inner electrode layer all through the wire with the output electricity is connected.
Preferably, the outer matching layer is made of a foam material, and the outer matching layer is one fourth of the preset main frequency wavelength of the array type air coupling laser ultrasonic probe; the inner matching layer is made of a composite material which takes epoxy resin as a matrix and hollow glass beads as a filler, and the thickness of the inner matching layer is one quarter of the preset main frequency wavelength of the array type air coupling laser ultrasonic probe; the piezoelectric wafer is made of a composite material with a 1-3 type structure, a piezoelectric phase of the piezoelectric wafer is made of lead zirconate titanate, a polymer phase of the piezoelectric wafer is made of high-molecular epoxy resin, and the thickness of the piezoelectric wafer is one half of the preset main frequency wavelength of the array type air coupling laser ultrasonic probe; the backing layer is made of tungsten powder and epoxy resin in a mixing mode.
Preferably, the central frequency of the array air coupling laser ultrasonic probe is 200 KHz-2 MHz.
Preferably, the pulse width of the pulse laser is 500 ns-2.5 us.
Preferably, the signal processing module comprises a signal conditioning submodule, a data acquisition submodule and a computer;
the signal conditioning submodule is electrically connected with the output end of the array air coupling laser ultrasonic probe and is used for filtering and amplifying the laser ultrasonic signal received by the array air coupling laser ultrasonic probe;
the data acquisition sub-module is electrically connected with the signal conditioning sub-module and is used for receiving and transmitting the laser ultrasonic signal which is filtered and amplified by the signal conditioning sub-module to the computer;
the computer is electrically connected with the data acquisition submodule and is used for calculating the light absorption rate of the surface structure of the carbon fiber composite material blade to be detected and the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite material blade to be detected for the laser ultrasonic signal received by the array type air coupling laser ultrasonic probe, comparing the light absorption rate with a preset light absorption rate threshold range to obtain a light absorption rate comparison result, and comparing the laser ultrasonic signal attenuation amplitude with a preset laser ultrasonic signal attenuation threshold range to obtain a laser ultrasonic signal attenuation amplitude comparison result;
and an ultrasonic data imaging module is arranged in the computer and is used for carrying out image representation on the surface defect structure of the carbon fiber composite material blade to be detected according to the light absorption rate comparison result and carrying out image representation on the internal defect structure of the carbon fiber composite material blade to be detected according to the laser ultrasonic signal attenuation amplitude comparison result based on a prestored focusing imaging algorithm.
Preferably, the surface of one side of the carbon fiber composite material blade to be measured, which is opposite to the field lens, is superposed with the optical focal plane of the field lens.
On the other hand, the embodiment of the application also provides a laser ultrasonic automatic detection method of the carbon fiber composite material blade, and the laser ultrasonic automatic detection system based on the carbon fiber composite material blade comprises the following steps:
s101: generating laser beams by a pulse laser and transmitting the laser beams to the two-dimensional laser galvanometer through optical fibers;
s102: after the laser beam is received through the two-dimensional laser galvanometer, scanning grid units which are uniformly pre-divided on the surface of the carbon fiber composite material blade to be detected through the field lens according to a preset scanning track so as to focus on the surface of the carbon fiber composite material blade to be detected corresponding to the corresponding grid units to generate laser ultrasonic signals;
s103: the optical fiber, the two-dimensional laser galvanometer, the field lens and the array type air coupling laser ultrasonic probe are driven to synchronously move through a multi-degree-of-freedom mechanical arm, and the two-dimensional laser galvanometer is controlled to move according to a preset motion track so as to sequentially scan all the grid units uniformly divided in advance on the surface of the carbon fiber composite material blade to be detected;
s104: receiving the laser ultrasonic signals which are generated by the laser beams on the surface of the carbon fiber composite material blade to be detected corresponding to the grid units which are uniformly divided in advance and penetrate through the internal structure of the carbon fiber composite material blade to be detected in a preset phase control focusing mode through an array type air coupling laser ultrasonic probe;
s105: filtering and amplifying the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe through a signal conditioning submodule;
s106: the laser ultrasonic signal which is filtered and amplified by the signal conditioning submodule is received by the data acquisition submodule and is transmitted to the computer;
s107: calculating the light absorption rate of the surface structure of the carbon fiber composite material blade to be detected and the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite material blade to be detected by the computer according to the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe, comparing the light absorption rate with a preset light absorption rate threshold range to obtain a light absorption rate comparison result, and comparing the laser ultrasonic signal attenuation amplitude with a preset laser ultrasonic signal attenuation threshold range to obtain a laser ultrasonic signal attenuation amplitude comparison result;
s108: and performing image representation on the surface defect structure of the carbon fiber composite material blade to be detected through an ultrasonic data imaging module based on a prestored focusing imaging algorithm according to the light absorption rate comparison result, and performing image representation on the internal defect structure of the carbon fiber composite material blade to be detected according to the laser ultrasonic signal attenuation amplitude comparison result.
Preferably, before the step S102, the method further includes: and uniformly dividing the surface of the carbon fiber composite material blade to be detected into grids according to the shape and the area of the surface by a dividing module so as to form a plurality of grid units.
According to the technical scheme, the embodiment of the application has the following advantages:
the laser ultrasonic automatic detection system and the method for the carbon fiber composite material blade, which are provided by the application, form uniform grid units by carrying out grid division on the surface of the blade, scan the grid units through a two-dimensional laser galvanometer, generate laser ultrasonic signals by focusing on the material surface corresponding to the corresponding grid units, drive an optical fiber, the two-dimensional laser galvanometer, a field lens and an array type air coupling laser ultrasonic probe to synchronously move through a multi-freedom-degree manipulator according to a preset motion track, namely enable the two-dimensional laser galvanometer to sequentially scan all the grid units so as to complete the scanning of the whole blade, receive the laser ultrasonic signals generated by the scanning through the phase control and focusing of the array type air coupling laser ultrasonic probe, carry out imaging according to the laser ultrasonic signals, and carry out high signal-to-noise ratio scanning and detection of the whole blade in a large curvature range, high-precision detection and high resolution of the surface and the interior of the blade are completed, and the purpose of automatic detection of the large-curvature curved surface of the carbon fiber composite material blade in a quick and in-situ manner is achieved.
In addition, two-dimensional laser galvanometer is the small-range scanning to the grid unit in this embodiment, is favorable to the system miniaturization, and because laser ultrasonic signal has stronger penetrability for the array air coupling laser ultrasonic probe that this application embodiment set up only needs to receive laser ultrasonic signal, need not to send ultrasonic signal, the miniaturization of the array air coupling laser ultrasonic probe of being convenient for can effectively reduce the system volume, make the system volume in this embodiment less be applicable to peeping, and the acoustic cost is lower anti-interference strong.
Drawings
Fig. 1 is a schematic structural diagram of a laser ultrasonic automated inspection system for a carbon fiber composite blade according to an embodiment of the present application;
fig. 2 is a schematic structural diagram of an array type air-coupled laser ultrasonic probe of a laser ultrasonic automated detection system for a carbon fiber composite blade according to an embodiment of the present application;
FIG. 3 is a schematic structural view of the back surface of a carbon fiber composite laminated board sample with a blind hole defect in the embodiment of the application;
FIG. 4 is a representation of an image of defect detection on a carbon fiber composite laminate sample in an example of the present application;
fig. 5 is a flowchart of a laser ultrasonic automated inspection method for a carbon fiber composite blade according to an embodiment of the present application.
Detailed Description
In order to make the technical solutions of the present application better understood, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present application, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
For easy understanding, please refer to fig. 1, the present application provides a laser ultrasonic automated inspection system for a carbon fiber composite blade, comprising:
the device comprises a pulse laser 1, an optical fiber 2, a two-dimensional laser galvanometer 3, a field lens 4, an array type air coupling laser ultrasonic probe 6, a multi-degree-of-freedom manipulator 7 and a signal processing module;
the pulse laser 1 is used for generating laser beams and transmitting the laser beams to the two-dimensional laser galvanometer 3 through the optical fiber 2;
the two-dimensional laser galvanometer 3 is used for scanning grid units which are uniformly pre-divided on the surface of the carbon fiber composite material blade 5 to be detected through the field lens 4 according to a preset scanning track after receiving laser beams, so that laser ultrasonic signals are generated by focusing on the surface of the carbon fiber composite material blade 5 to be detected corresponding to the corresponding grid units;
it should be noted that, in this embodiment, in order to implement the detection of the carbon fiber composite blade with large curvature, the surface of the blade is divided into grids, where each grid is a grid unit, and the scanning track of the laser beam is adjusted by the two-dimensional laser galvanometer, so as to scan the grid unit and generate the laser ultrasonic signal on the material surface corresponding to the corresponding grid unit, and the two-dimensional laser galvanometer is preferably an MEMS galvanometer, which has a smaller volume and is convenient for the miniaturization of the system, and meanwhile, the two-dimensional laser galvanometer can change the laser propagation path to scan the grid unit of the carbon fiber composite blade, thereby greatly increasing the scanning speed of the system, improving the practicability and convenience of the system, and by focusing the field lens, the laser spot can reach the micron level, and can more accurately detect the surface characteristics and internal cracks of the carbon fiber composite blade, the detection precision of the system is improved to the micron level.
The optical fiber 2, the two-dimensional laser galvanometer 3, the field lens and the array type air coupling laser ultrasonic probe 6 are all arranged at the output end of the multi-degree-of-freedom manipulator 7, and the multi-degree-of-freedom manipulator 7 is used for driving the optical fiber 2, the two-dimensional laser galvanometer 3, the field lens and the array type air coupling laser ultrasonic probe 6 to synchronously move and controlling the two-dimensional laser galvanometer 3 to move according to a preset motion track so as to sequentially scan all grid units uniformly divided in advance on the surface of the carbon fiber composite blade 5 to be detected;
it should be noted that, in the embodiment, the two-dimensional laser galvanometer scans each grid unit, and the optical fiber, the two-dimensional laser galvanometer, the field lens and the array type air-coupled laser ultrasonic probe are driven by the multi-degree-of-freedom manipulator according to the preset motion track to perform synchronous motion, so that all grid units can be scanned in sequence, and thus, the detection of the whole blade is completed.
The array type air coupling laser ultrasonic probe 6 is arranged corresponding to the field lens, and the array type air coupling laser ultrasonic probe 6 is used for receiving laser ultrasonic signals which are generated by laser beams on the surface of the carbon fiber composite material blade 5 to be detected corresponding to the grid units which are uniformly divided in advance and penetrate through the internal structure of the carbon fiber composite material blade 5 to be detected in a preset phase control focusing mode;
it should be noted that, in this embodiment, the small range of each grid unit is scanned, and the laser ultrasonic signal generated by scanning is correspondingly received by the array type air-coupled laser ultrasonic probe, and imaging is performed according to the laser ultrasonic signal, so that the entire blade can be detected.
In addition, the laser ultrasonic signals have strong penetrability, the array type air coupling laser ultrasonic probe receives the laser ultrasonic signals in a phase control focusing mode, detection signals do not need to be transmitted, and the array type air coupling laser ultrasonic probe is convenient to miniaturize.
The signal processing module is electrically connected with the output end of the array type air coupling laser ultrasonic probe 6, and is used for preprocessing the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe 6, calculating the light absorption rate of the surface structure of the carbon fiber composite blade 5 to be detected and the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite blade 5 to be detected according to the preprocessed laser ultrasonic signals, and respectively performing image representation on the surface defect structure of the carbon fiber composite blade 5 to be detected and the internal defect structure of the carbon fiber composite blade 5 to be detected according to the light absorption rate of the surface structure of the carbon fiber composite blade 5 to be detected and the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite blade 5 to be detected.
It should be noted that the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe are preprocessed, and the preprocessing includes filtering and amplifying the laser ultrasonic signals, so that the signal-to-noise ratio of the laser ultrasonic signals is enhanced.
In addition, the absorption rates of different composite materials on the surface of the carbon fiber composite material blade to laser are different, so that the amplitudes of the ultrasonic signals excited by the different composite materials are different, the amplitudes of the excited ultrasonic signals can fluctuate periodically along with the change of a surface woven structure, the surface structure of the carbon fiber composite material blade can be obtained, when the optical absorption rate exceeds a preset optical absorption rate threshold value, the defect of the surface structure is indicated, the preset optical absorption rate threshold value can be measured by experiments according to the same carbon fiber composite material blade without the defect structure on the surface in advance, and then, the defect structure of the surface structure of the material is subjected to image representation by a phased array-based focusing imaging algorithm.
In addition, amplitude attenuation generated when the laser ultrasonic signals pass through internal defects and the difference of the propagation time of ultrasound in air and materials are utilized, whether the internal structure defects exist or not can be judged according to the attenuation degree of the amplitude and the signal receiving time delay, when the attenuation amplitude of the laser ultrasonic signals is not within a preset laser ultrasonic signal attenuation threshold value, the internal structure defects exist, the preset laser ultrasonic signal attenuation threshold value can be measured through experiments according to the same carbon fiber composite material blade which does not have the defect structure in advance, and then image representation is carried out on the internal structure defects of the materials based on a phased array focusing imaging algorithm.
Further, the device also comprises a segmentation module which is used for carrying out grid uniform segmentation on the carbon fiber composite material blade 5 to be detected according to the shape and the area of the surface of the blade so as to form a plurality of grid units.
It should be noted that the grid cells may be square, rectangular or irregular in shape, and the segmentation module may use finite element software.
Further, referring to fig. 2, the array type air-coupled laser ultrasonic probe 6 includes a housing 60 with an upper opening, a piezoelectric wafer array 62 with a plurality of piezoelectric wafers arranged in an area array is disposed in the housing 60, an outer electrode layer 63 is plated on an upper surface of the piezoelectric wafer array 62, an inner matching layer 65 is plated on an upper surface of the outer electrode layer 63, an outer matching layer 66 is plated on an upper surface of the inner matching layer 65, the outer matching layer 66 is disposed at the opening of the housing 60 and corresponds to the carbon fiber composite blade 5 to be tested, an inner electrode layer 64 is plated on a lower surface of the piezoelectric wafer array 62, a backing layer 61 is plated on a lower surface of the inner electrode layer 64, the housing 60 is further provided with an output end, and the outer electrode layer 63 and the inner electrode layer 64 are electrically connected to the output end through a lead 67.
It should be noted that, the signal phase control focusing receiving process of the array air coupling laser ultrasonic probe is as follows: according to the phased array ultrasonic receiving focusing principle, the number of the piezoelectric wafers is preset in advance according to the falling point of laser single-point scanning, the distance between each piezoelectric wafer and the ultrasonic target focus can be calculated according to the preset distance between the piezoelectric wafers, the known sound velocity in the measured medium and the central array element distance parameter of the number of the target sound focus reaching the preset number through the cosine law, so that the time of each ultrasonic wave propagating to each piezoelectric wafer can be obtained, the time delay of the received signal of each piezoelectric wafer is controlled in advance, the phased array delay and the signal summation with weight compensation are completed, and the compensation of the surface optical absorption difference and the difference of the receiving angle need to be comprehensively considered by the weight coefficient.
Further, the outer matching layer 66 is made of a foam material, and the outer matching layer 66 is a quarter of the preset main frequency wavelength of the array type air-coupled laser ultrasonic probe 6; the inner matching layer 65 is made of a composite material which takes epoxy resin as a matrix and hollow glass beads as a filler, and the thickness of the inner matching layer 65 is one quarter of the preset main frequency wavelength of the array type air coupling laser ultrasonic probe 6; the piezoelectric wafer is made of a composite material with a 1-3 type structure, the piezoelectric phase of the piezoelectric wafer is made of lead zirconate titanate, the polymer phase of the piezoelectric wafer is made of high polymer epoxy resin, and the thickness of the piezoelectric wafer is one half of the preset main frequency wavelength of the array type air coupling laser ultrasonic probe 6; the backing layer 61 is made of tungsten powder and epoxy resin.
It should be noted that the outer matching layer is one fourth of the wavelength of the preset main frequency of the array air-coupled laser ultrasonic probe, the thickness of the inner matching layer is one fourth of the wavelength of the preset main frequency of the array air-coupled laser ultrasonic probe, the thickness of the piezoelectric wafer is one half of the wavelength of the preset main frequency of the array air-coupled laser ultrasonic probe, and the piezoelectric wafer is limited according to the thickness of the structure, which is to have the best impedance matching effect, wherein the best acoustic impedance of the outer matching layer is less than 0.1MRayl, the best acoustic impedance of the inner matching layer is less than 1-3MRayl, the structure thickness determines the acoustic impedance, the main frequency wavelength of the array air-coupled laser ultrasonic probe determines the best thickness, the preset main acoustic impedance of the array air-coupled laser ultrasonic probe is the reciprocal of the center frequency, and the center frequency is set according to the laser pulse width, the pulse width is generally one-half of the reciprocal of the laser pulse width.
Further, the central frequency of the array type air coupling laser ultrasonic probe 6 is 200 KHz-2 MHz.
Further, the pulse width of the pulse laser 1 is 500ns to 2.5 us.
Furthermore, the signal processing module comprises a signal conditioning submodule, a data acquisition submodule and a computer;
the signal conditioning submodule is electrically connected with the output end of the array type air coupling laser ultrasonic probe 6 and is used for filtering and amplifying the laser ultrasonic signal received by the array type air coupling laser ultrasonic probe 6;
the data acquisition sub-module is electrically connected with the signal conditioning sub-module and is used for receiving and transmitting the laser ultrasonic signals subjected to filtering and amplification processing by the signal conditioning sub-module to the computer;
the computer is electrically connected with the data acquisition sub-module, and is used for calculating the light absorption rate of the surface structure of the carbon fiber composite material blade 5 to be detected and the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite material blade 5 to be detected according to the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe 6, comparing the light absorption rate with a preset light absorption rate threshold range to obtain a light absorption rate comparison result, and comparing the laser ultrasonic signal attenuation amplitude with the preset laser ultrasonic signal attenuation threshold range to obtain a laser ultrasonic signal attenuation amplitude comparison result;
and an ultrasonic data imaging module is arranged in the computer and is used for carrying out image representation on the surface defect structure of the carbon fiber composite material blade 5 to be detected according to the light absorption rate comparison result and carrying out image representation on the internal defect structure of the carbon fiber composite material blade 5 to be detected according to the laser ultrasonic signal attenuation amplitude comparison result based on a prestored focusing imaging algorithm.
Further, the surface of one side of the carbon fiber composite material blade 5 to be measured, which is opposite to the field lens, is superposed with the optical focal plane of the field lens.
It can be understood that the carbon fiber composite material blade to be measured is arranged on the optical focal plane of the field lens, so that the pulse laser beam can be focused on the surface of the carbon fiber composite material blade to be measured.
For convenience of understanding, the present embodiment takes the examination of a carbon fiber composite laminate sample with a thickness of 3mm as an example, and requires examination of the surface microstructure and internal defects.
Firstly, as shown in fig. 3, a blind hole defect with the diameter of 1mm and the depth of 2.6mm is processed on the back surface of a carbon fiber composite laminated board sample;
then, the system of the embodiment is adopted to detect the surface texture characteristics and the internal defects of the carbon fiber composite material laminated plate sample, and the parameter setting conditions are as follows: the laser wavelength of the pulse laser is 1064nm, the pulse width is 500ns, the diameter of a focused beam is 0.2mm during scanning, the energy of the pulse laser is 0.36mJ, and the pulse repetition frequency is 1 KHz; the central frequency of the array air coupling laser ultrasonic probe is 1MHz, and the distance from the array air coupling laser ultrasonic probe to a carbon fiber composite material laminated board sample is 5 mm; the scanning steps in the X, Y direction of the two-dimensional laser galvanometer are all 0.2mm, the step number is 50 steps, the scanning range is 10mm x 10mm, and the output end of the array type air coupling laser ultrasonic probe is sequentially connected with a 54db amplifier, a 230K high-pass filter, a 1.9M low-pass filter and an oscilloscope;
and finally, an image of the detection result is shown in fig. 4, the image in the detection result clearly shows the texture characteristics of the near surface of the carbon fiber composite laminated board, the defect that a blind hole with the diameter of 1mm exists below the surface is successfully detected, and the resolution ratio is close to the diameter of a focusing light spot and is 0.2 mm.
The above is an embodiment of a laser ultrasonic automated inspection system for a carbon fiber composite blade provided in the embodiments of the present application, and the following is an embodiment of a laser ultrasonic automated inspection method for a carbon fiber composite blade provided in the embodiments of the present application.
For convenience of understanding, please refer to fig. 5, the laser ultrasonic automated inspection method for a carbon fiber composite blade provided in this embodiment is based on the laser ultrasonic automated inspection system for a carbon fiber composite blade of the above embodiment, and includes the following steps:
s101: generating laser beams by a pulse laser and transmitting the laser beams to a two-dimensional laser galvanometer through an optical fiber;
s102: after receiving laser beams through a two-dimensional laser galvanometer, carrying out focusing scanning on grid units uniformly pre-divided on the surface of the carbon fiber composite blade to be detected through a field lens according to a preset scanning track so as to generate laser ultrasonic signals on the surface of the carbon fiber composite blade to be detected corresponding to the corresponding grid units;
s103: the optical fiber, the two-dimensional laser galvanometer, the field lens and the array type air coupling laser ultrasonic probe are driven by the multi-degree-of-freedom mechanical arm to synchronously move, and the two-dimensional laser galvanometer is controlled to move according to a preset motion track so as to sequentially scan all grid units uniformly divided in advance on the surface of the carbon fiber composite material blade to be detected;
s104: receiving laser ultrasonic signals which are generated by laser beams on the surface of the carbon fiber composite material blade to be detected corresponding to the grid units which are uniformly divided in advance and penetrate through the internal structure of the carbon fiber composite material blade to be detected in a preset phase control focusing mode through an array type air coupling laser ultrasonic probe;
s105: filtering and amplifying the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe through a signal conditioning submodule;
s106: the laser ultrasonic signal after being filtered and amplified by the signal conditioning submodule is received by the data acquisition submodule and is transmitted to the computer;
s107: calculating the light absorption rate of the surface structure of the carbon fiber composite material blade to be detected and the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite material blade to be detected by the aid of laser ultrasonic signals received by the arrayed air coupling laser ultrasonic probes through a computer, comparing the light absorption rate with a preset light absorption rate threshold range to obtain a light absorption rate comparison result, and comparing the laser ultrasonic signal attenuation amplitude with a preset laser ultrasonic signal attenuation threshold range to obtain a laser ultrasonic signal attenuation amplitude comparison result;
s108: and performing image representation on the surface defect structure of the carbon fiber composite material blade to be detected through an ultrasonic data imaging module based on a prestored focusing imaging algorithm according to the light absorption rate comparison result, and performing image representation on the internal defect structure of the carbon fiber composite material blade to be detected according to the laser ultrasonic signal attenuation amplitude comparison result.
Further, before step S102, the method further includes: and the cutting module is used for uniformly cutting the surface of the carbon fiber composite material blade to be detected according to the shape and the area of the surface so as to form a plurality of grid units.
In the several embodiments provided in the present application, it should be understood that the disclosed apparatus and method may be implemented in other ways. For example, the above-described apparatus embodiments are merely illustrative, and for example, the division of the units is only one logical division, and other divisions may be realized in practice, for example, a plurality of units or components may be combined or integrated into another system, or some features may be omitted, or not executed. In addition, the shown or discussed mutual coupling or direct coupling or communication connection may be an indirect coupling or communication connection through some interfaces, devices or units, and may be in an electrical, mechanical or other form.
The units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units, may be located in one position, or may be distributed on multiple network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of the embodiment.
In addition, functional units in the embodiments of the present application may be integrated into one processing unit, or each unit may exist alone physically, or two or more units are integrated into one unit. The integrated unit can be realized in a form of hardware, and can also be realized in a form of a software functional unit.
The integrated unit, if implemented in the form of a software functional unit and sold or used as a stand-alone product, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present application may be substantially implemented or contributed to by the prior art, or all or part of the technical solution may be embodied in a software product, which is stored in a storage medium and includes instructions for executing all or part of the steps of the method described in the embodiments of the present application through a computer device (which may be a personal computer, a server, or a network device). And the aforementioned storage medium includes: a U disk, a removable hard disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk or an optical disk, and other various media capable of storing program codes.
The above embodiments are only used for illustrating the technical solutions of the present application, and not for limiting the same; although the present application has been described in detail with reference to the foregoing embodiments, it should be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions in the embodiments of the present application.
Claims (10)
1. Laser ultrasonic automatic detection system of carbon-fibre composite blade, its characterized in that includes: the system comprises a pulse laser, an optical fiber, a two-dimensional laser galvanometer, a field lens, an array type air coupling laser ultrasonic probe, a multi-degree-of-freedom manipulator and a signal processing module;
the pulse laser is used for generating laser beams and then transmitting the laser beams to the two-dimensional laser galvanometer through the optical fiber;
the two-dimensional laser galvanometer is used for focusing and scanning grid units which are uniformly pre-divided on the surface of the carbon fiber composite material blade to be detected through the field lens according to a preset scanning track after receiving the laser beam so as to generate laser ultrasonic signals on the surface of the carbon fiber composite material blade to be detected corresponding to the corresponding grid units;
the optical fiber, the two-dimensional laser galvanometer, the field lens and the array type air coupling laser ultrasonic probe are all arranged at the output end of the multi-degree-of-freedom manipulator, and the multi-degree-of-freedom manipulator is used for driving the optical fiber, the two-dimensional laser galvanometer, the field lens and the array type air coupling laser ultrasonic probe to synchronously move and controlling the two-dimensional laser galvanometer to move according to a preset motion track so as to sequentially scan all the grid units uniformly divided in advance on the surface of the carbon fiber composite material blade to be detected;
the array air coupling laser ultrasonic probe is arranged corresponding to the field lens and is used for receiving the laser ultrasonic signals which are generated by the laser beams on the surface of the carbon fiber composite material blade to be detected corresponding to the grid units which are uniformly divided in advance and penetrate through the internal structure of the carbon fiber composite material blade to be detected in a preset phase control focusing mode;
the signal processing module is electrically connected with the output end of the array type air coupling laser ultrasonic probe, the signal processing module is used for preprocessing the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe and calculating the light absorption rate of the surface structure of the carbon fiber composite material blade to be detected according to the preprocessed laser ultrasonic signals, and calculating the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite material blade to be detected according to the preprocessed laser ultrasonic signal and the delay time of signal receiving of the preprocessed laser ultrasonic signal, and performing image representation on the surface defect structure of the carbon fiber composite material blade to be detected and the internal defect structure of the carbon fiber composite material blade to be detected respectively according to the light absorption rate of the surface structure of the carbon fiber composite material blade to be detected and the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite material blade to be detected.
2. The laser ultrasonic automatic detection system of the carbon fiber composite material blade as claimed in claim 1, further comprising a dividing module for performing grid uniform division on the surface of the carbon fiber composite material blade to be detected according to the shape and area of the surface to form a plurality of grid units.
3. The laser ultrasonic automated inspection system of a carbon fiber composite blade of claim 1, it is characterized in that the array type air coupling laser ultrasonic probe comprises a shell with an opening at the upper part, the shell is internally provided with a piezoelectric wafer array with a plurality of piezoelectric wafers which are arranged and distributed in an area array, the upper surface of the piezoelectric chip array is plated with an outer electrode layer, the upper surface of the outer electrode layer is plated with an inner matching layer, the upper surface of the inner matching layer is plated with an outer matching layer which is arranged at the opening of the shell and corresponds to the carbon fiber composite material blade to be measured, the lower surface of the piezoelectric chip array is plated with an inner electrode layer, the lower surface of the inner electrode layer is plated with a back lining layer, the shell is further provided with an output end, and the outer electrode layer and the inner electrode layer are electrically connected with the output end through wires.
4. The laser ultrasonic automatic detection system of the carbon fiber composite blade is characterized in that the outer matching layer is made of foam material, and the thickness of the outer matching layer is one quarter of the preset main frequency wavelength of the array type air coupling laser ultrasonic probe; the inner matching layer is made of a composite material which takes epoxy resin as a matrix and hollow glass beads as a filler, and the thickness of the inner matching layer is one quarter of the preset main frequency wavelength of the array type air coupling laser ultrasonic probe; the piezoelectric wafer is made of a composite material with a 1-3 type structure, a piezoelectric phase of the piezoelectric wafer is made of lead zirconate titanate, a polymer phase of the piezoelectric wafer is made of high-molecular epoxy resin, and the thickness of the piezoelectric wafer is one half of the preset main frequency wavelength of the array type air coupling laser ultrasonic probe; the backing layer is made of tungsten powder and epoxy resin in a mixing mode.
5. The laser ultrasonic automatic detection system for the carbon fiber composite blade as claimed in claim 3 or 4, wherein the central frequency of the array type air coupling laser ultrasonic probe is 200 KHz-2 MHz.
6. The laser ultrasonic automatic detection system for the carbon fiber composite material blade is characterized in that the pulse width of the pulse laser is 500 ns-2.5 us.
7. The laser ultrasonic automatic detection system of the carbon fiber composite blade as claimed in claim 1, wherein the signal processing module comprises a signal conditioning sub-module, a data acquisition sub-module and a computer;
the signal conditioning submodule is electrically connected with the output end of the array air coupling laser ultrasonic probe and is used for filtering and amplifying the laser ultrasonic signal received by the array air coupling laser ultrasonic probe;
the data acquisition sub-module is electrically connected with the signal conditioning sub-module and is used for receiving and transmitting the laser ultrasonic signal which is filtered and amplified by the signal conditioning sub-module to the computer;
the computer is electrically connected with the data acquisition submodule and is used for calculating the light absorption rate of the surface structure of the carbon fiber composite material blade to be detected according to the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe, calculating the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite material blade to be detected according to the preprocessed laser ultrasonic signals and the delay time of signal receiving of the preprocessed laser ultrasonic signals, comparing the light absorption rate with a preset light absorption rate threshold range to obtain a light absorption rate comparison result, and comparing the laser ultrasonic signal attenuation amplitude with a preset laser ultrasonic signal attenuation threshold range to obtain a laser ultrasonic signal attenuation amplitude comparison result;
and an ultrasonic data imaging module is arranged in the computer and is used for carrying out image representation on the surface defect structure of the carbon fiber composite material blade to be detected according to the light absorption rate comparison result and carrying out image representation on the internal defect structure of the carbon fiber composite material blade to be detected according to the laser ultrasonic signal attenuation amplitude comparison result based on a prestored focusing imaging algorithm.
8. The laser ultrasonic automatic detection system for the carbon fiber composite material blade as claimed in claim 1, wherein a side surface of the carbon fiber composite material blade to be detected, which is opposite to the field lens, coincides with an optical focal plane of the field lens.
9. A laser ultrasonic automatic detection method of a carbon fiber composite material blade is based on the laser ultrasonic automatic detection system of the carbon fiber composite material blade of claim 7, and is characterized by comprising the following steps:
s101: generating laser beams by a pulse laser and transmitting the laser beams to the two-dimensional laser galvanometer through optical fibers;
s102: after the laser beam is received through the two-dimensional laser galvanometer, carrying out focusing scanning on grid units uniformly pre-divided on the surface of the carbon fiber composite material blade to be detected through the field lens according to a preset scanning track so as to generate laser ultrasonic signals on the surface of the carbon fiber composite material blade to be detected corresponding to the corresponding grid units;
s103: the optical fiber, the two-dimensional laser galvanometer, the field lens and the array type air coupling laser ultrasonic probe are driven to synchronously move through a multi-degree-of-freedom mechanical arm, and the two-dimensional laser galvanometer is controlled to move according to a preset motion track so as to sequentially scan all the grid units uniformly divided in advance on the surface of the carbon fiber composite material blade to be detected;
s104: receiving the laser ultrasonic signals which are generated by the laser beams on the surface of the carbon fiber composite material blade to be detected corresponding to the grid units which are uniformly divided in advance and penetrate through the internal structure of the carbon fiber composite material blade to be detected in a preset phase control focusing mode through an array type air coupling laser ultrasonic probe;
s105: filtering and amplifying the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe through a signal conditioning submodule;
s106: the data acquisition submodule receives and transmits the laser ultrasonic signal which is filtered and amplified by the signal conditioning submodule to a computer;
s107: calculating the light absorption rate of the surface structure of the carbon fiber composite material blade to be detected according to the laser ultrasonic signals received by the array type air coupling laser ultrasonic probe through the computer, calculating the laser ultrasonic signal attenuation amplitude of the internal structure of the carbon fiber composite material blade to be detected according to the preprocessed laser ultrasonic signals and the delay time of signal receiving, comparing the light absorption rate with a preset light absorption rate threshold range to obtain a light absorption rate comparison result, and comparing the laser ultrasonic signal attenuation amplitude with a preset laser ultrasonic signal attenuation threshold range to obtain a laser ultrasonic signal attenuation amplitude comparison result;
s108: and performing image representation on the surface defect structure of the carbon fiber composite material blade to be detected through an ultrasonic data imaging module based on a prestored focusing imaging algorithm according to the light absorption rate comparison result, and performing image representation on the internal defect structure of the carbon fiber composite material blade to be detected according to the laser ultrasonic signal attenuation amplitude comparison result.
10. The laser ultrasonic automated inspection method of a carbon fiber composite blade according to claim 9, further comprising, before the step S102: and uniformly dividing the surface of the carbon fiber composite material blade to be detected into grids according to the shape and the area of the surface by a dividing module so as to form a plurality of grid units.
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| CN113703392B (en) * | 2021-10-29 | 2022-01-25 | 山东天亚达新材料科技有限公司 | Data acquisition method, device and equipment for carbon fiber product |
| CN114227008B (en) * | 2021-12-30 | 2023-07-14 | 北京卫星制造厂有限公司 | Ultrafast laser cutting method for carbon fiber composite material structure |
| CN114818799B (en) * | 2022-04-15 | 2024-03-19 | 西南交通大学 | Method for segmenting composite laminated component drilling and reaming integrated processing monitoring signals |
| CN115184462B (en) * | 2022-09-07 | 2022-12-02 | 广东工业大学 | Laser ultrasonic detection system based on combined non-contact probe |
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