CN112198227A - Ultrasonic nondestructive testing defect position backtracking method - Google Patents
Ultrasonic nondestructive testing defect position backtracking method Download PDFInfo
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/06—Visualisation of the interior, e.g. acoustic microscopy
- G01N29/0609—Display arrangements, e.g. colour displays
- G01N29/0645—Display representation or displayed parameters, e.g. A-, B- or C-Scan
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/06—Visualisation of the interior, e.g. acoustic microscopy
- G01N29/0654—Imaging
- G01N29/069—Defect imaging, localisation and sizing using, e.g. time of flight diffraction [TOFD], synthetic aperture focusing technique [SAFT], Amplituden-Laufzeit-Ortskurven [ALOK] technique
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
- G01N29/265—Arrangements for orientation or scanning by relative movement of the head and the sensor by moving the sensor relative to a stationary material
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/023—Solids
- G01N2291/0234—Metals, e.g. steel
Abstract
The invention discloses a defect position backtracking method for ultrasonic nondestructive testing, which comprises the following steps: carrying out ultrasonic scanning on the workpiece, and carrying out position coding on a scanning track path to obtain scanning signal data and coding position data; generating an image from the scanning signal data and the encoded position data; finding out and selecting the defect position on the image, and acquiring the coding position corresponding to the center of the selected image area; and backtracking to the actual corresponding defect position of the workpiece according to the coding position corresponding to the center of the selected image area. The invention can firstly carry out integral scanning on the workpiece in the process of nondestructive detection, the integral scanning consumes long time, but no professional staff participates in the whole process, and after the scanning is finished, the defect position is found out, then according to the coding position corresponding to the defect position, the defect position point of the workpiece can be reached after the scanning, and then the operations of marking, repairing or rechecking and the like are carried out, thereby being beneficial to improving the detection efficiency and reducing the cost.
Description
Technical Field
The invention relates to the technical field of ultrasonic nondestructive testing, in particular to a defect position backtracking method for ultrasonic nondestructive testing.
Background
Ultrasonic nondestructive detection is a method for detecting materials based on an ultrasonic technology, and the method is a method for detecting part defects by mainly utilizing the characteristics that ultrasonic generated by an ultrasonic probe penetrates into the deep part of an object material and enters another section from the other section and is reflected at the edge of the interface. When the ultrasonic beam passes from the surface of the part to the inside of the metal through the probe, reflected waves are generated when the ultrasonic beam meets the defect and the bottom surface of the part, the ultrasonic detector acquires the reflected waves from the ultrasonic probe to form data and pictures, and the position and the size of the defect are judged according to the data and the pictures. When ultrasonic nondestructive detection is carried out, an ultrasonic probe is often required to be carried to move and scan along the surface of a workpiece, when a position with a defect is scanned, scanning is often required to be stopped, the defect position of the workpiece is firstly marked or repaired, and the like, and then scanning is continued; scanning a workpiece often takes a lot of time, especially when the workpiece is large in size, scanning data are processed and defect positions are identified, professional staff are often required to participate in the whole process, the efficiency of ultrasonic nondestructive testing is affected to a great extent, and human resource cost is wasted.
Disclosure of Invention
The present invention is directed to solving at least one of the problems of the prior art. Therefore, the invention provides a defect position backtracking method for ultrasonic nondestructive testing, which can firstly carry out comprehensive scanning on a workpiece, and then find out the defect position and backtrack to the defect position after the scanning is completely finished, thereby improving the detection efficiency.
The method for backtracking the defect position of ultrasonic nondestructive testing comprises the following steps:
carrying out ultrasonic scanning on the workpiece, and carrying out position coding on a scanning track path to obtain scanning signal data and coding position data;
generating an image from the scanning signal data and the encoded position data;
finding out and selecting the defect position on the image, and acquiring the coding position corresponding to the center of the selected image area;
and backtracking to the actual corresponding defect position of the workpiece according to the coding position corresponding to the center of the selected image area.
The ultrasonic nondestructive detection defect position backtracking method provided by the embodiment of the invention at least has the following beneficial effects: the position coding is carried out on the scanning track path in real time in the process of scanning the workpiece, after the scanning is finished, image data generated according to scanning signal data and coding position data correspond to the coding data position, when defects are found in the images subsequently, the images of the defect positions are directly selected, the coding positions corresponding to the centers of the selected image areas can be obtained, and finally, corresponding devices are driven to the positions, actually having the defects, of the workpiece in reverse according to the coding position data to finish backtracking; through the method for tracing back the defect position of ultrasonic nondestructive testing provided by the embodiment, the workpiece can be integrally scanned firstly in the nondestructive testing process, although the integral scanning is time-consuming, no professional staff participates in the whole process, after the scanning is completed, the defect position is found out in the image, then according to the corresponding coding position, the ultrasonic probe, the marking device or the repairing device and the like can be enabled to come to the defect position point of the workpiece after the scanning, and then the operations of marking, repairing or rechecking and the like are carried out, so that the improvement of the detection efficiency and the reduction of the cost are facilitated.
According to some embodiments of the present invention, finding and selecting the defect location in the image comprises the following steps: and displaying the image on a screen, judging the image by an operator, and framing the image at the position with the defect in the image.
According to some embodiments of the present invention, finding and selecting the defect location in the image comprises the following steps: presetting a defect image area; extracting a color region distinguished from a non-defective region by color and/or threshold segmentation; and judging whether the area of the extracted color region exceeds the area of a preset defect image, if so, performing external graph fitting on the divided color region to form a picture frame, and performing frame selection.
According to some embodiments of the present invention, when the area of the extracted color region does not exceed the preset area of the defective image, the operator interprets the image from the screen, and frames the image at the position where the defect exists in the image for frame selection.
According to some embodiments of the invention, the extraction of the color region distinguished from the non-defective region by color and/or threshold segmentation comprises the following steps: converting an image into a black-and-white picture by setting hue, saturation and brightness values by using an image space; and setting a threshold value according to the converted black and white picture, and extracting the bright area in the picture.
According to some embodiments of the present invention, the method for fitting the extracted color region with a circumscribed figure to form a frame comprises the following steps: and finding X, Y maximum values and minimum values in all pixels of the bright area, and taking X, Y maximum values and minimum values as boundaries to serve as rectangular boundaries.
According to some embodiments of the present invention, the ultrasonic scanning is performed by using an ultrasonic nondestructive scanning device, and the ultrasonic nondestructive scanning device includes an ultrasonic probe and a transfer mechanism, and an end of the transfer mechanism is connected to the ultrasonic probe for driving the ultrasonic probe to move in a scanning manner.
According to some embodiments of the invention, ultrasonic scanning is carried out on a workpiece, and position coding is carried out on a scanning track path, and the method comprises the following steps of simultaneously recording position data of the tail end of the current transfer mechanism in a coordinate system of the transfer mechanism, and storing the position data in a one-to-one correspondence manner with the coded position data;
and backtracking to the actual corresponding defect position of the workpiece according to the coding position corresponding to the center of the selected image area.
According to some embodiments of the invention, the transfer mechanism is slidably disposed on the ground rail; carrying out ultrasonic scanning on the workpiece, and carrying out position coding on a scanning track path, and also comprises the following steps of simultaneously recording the current ground rail position data of the transfer mechanism, and storing the current ground rail position data in one-to-one correspondence with the coding position data;
according to some embodiments of the present invention, the step of tracing back to the defect position actually corresponding to the workpiece according to the encoding position corresponding to the center of the selected image area includes the steps of obtaining a ground rail position corresponding to the encoding position corresponding to the center of the selected image area, and controlling the transfer mechanism to move to the position.
According to some embodiments of the present invention, ultrasonically scanning a workpiece and positionally encoding a path of a scan trajectory comprises the steps of: dividing the workpiece into a plurality of areas and numbering the areas; and respectively carrying out ultrasonic scanning and scanning track path position coding on the areas with different numbers.
According to some embodiments of the present invention, ultrasonic scanning of a workpiece and position coding of a scan trajectory path further comprises the steps of:
and respectively scanning each region of the workpiece in a copying manner according to the surface profile of the workpiece, and converting each scanning position in the scanning track path into a workpiece copying plane coordinate for coding.
According to some embodiments of the present invention, after tracing back to the defect position corresponding to the actual workpiece, the method further comprises the following steps:
and carrying out spraying identification and/or repair on the defect position of the workpiece.
According to some embodiments of the invention, there is further included the steps of:
and establishing a model of the workpiece and the ultrasonic nondestructive scanning device, and planning to obtain a scanning track path of the surface of the workpiece through off-line simulation.
Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
Drawings
The above and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a schematic flow chart of the method for tracing back the position of a defect in ultrasonic nondestructive testing according to the present invention;
FIG. 2 is a schematic flow chart of a method for tracing back a defect position in an ultrasonic nondestructive testing according to an embodiment of the present invention;
FIG. 3 is a schematic flow chart of a method for tracing back the position of a defect in an ultrasonic nondestructive inspection according to another embodiment of the present invention;
FIG. 4 is a schematic flow chart of a method for tracing back a defect position in an ultrasonic nondestructive testing according to another embodiment of the present invention;
FIG. 5 is a diagram illustrating a scanning pattern within a cell according to an embodiment of the present invention;
fig. 6 is a schematic structural diagram of an ultrasonic nondestructive scanning apparatus connected to a slide table according to an embodiment of the present invention.
Reference numerals:
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.
In the description of the present invention, it should be understood that the orientation or positional relationship referred to in the description of the orientation, such as the upper, lower, left, right, front, rear, etc., is based on the orientation or positional relationship shown in the drawings, and is only for convenience of description and simplification of description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention.
In the description of the present invention, unless otherwise explicitly limited, terms such as arrangement, installation, connection and the like should be understood in a broad sense, and those skilled in the art can reasonably determine the specific meanings of the above terms in the present invention in combination with the specific contents of the technical solutions.
Referring to fig. 1, the method for tracing back the defect position of ultrasonic nondestructive testing according to the embodiment of the invention comprises the following steps:
s100, carrying out ultrasonic scanning on the workpiece, and carrying out position coding on a scanning track path to obtain scanning signal data and coding position data;
s200, generating an image according to the scanning signal data and the coding position data;
s300, finding out a defect position on the image, selecting the defect position, and acquiring a coding position corresponding to the center of the selected image area;
s400, backtracking to the actual corresponding defect position of the workpiece according to the coding position corresponding to the center of the selected image area.
The position coding is carried out on the scanning track path in real time in the process of scanning the workpiece, after the scanning is finished, image data generated according to scanning signal data and coding position data correspond to the position coding data, when defects are found in the images subsequently, the images of the defect positions are directly selected, the coding positions corresponding to the centers of the selected image areas can be obtained, and finally, according to the coding positions, corresponding devices are driven to the positions, actually having the defects, of the workpiece in reverse mode, and the backtracking can be finished.
Through the method for tracing back the defect position of ultrasonic nondestructive testing provided by the embodiment, the workpiece can be integrally scanned firstly in the nondestructive testing process, although the integral scanning is time-consuming, no professional staff participates in the whole process, after the scanning is completed, the defect position is found out in the image, then according to the coding position, the ultrasonic probe 40, the marking device or the repairing device and the like can be brought to the defect position point of the workpiece after the scanning, and then the marking, repairing or rechecking and the like are carried out, so that the detection efficiency is improved, and the cost is reduced.
Referring to fig. 2, in some embodiments of the present invention, in step S300, finding and selecting a defect position in the image includes the following manual selection step S310:
and displaying the image on a screen, judging the image by an operator, and framing the image at the position with the defect in the image.
Specifically, the image is displayed on a screen, an operator interprets the image, frames are drawn at positions where defects exist in the image, and then the encoding position is acquired according to image centers corresponding to the drawn frames. In addition, in this embodiment, in order to facilitate the operation, the frame is in a form of drawing a rectangular frame on the screen by a mouse, and the defect position is located in the rectangular frame. Certainly, according to practical situations, in other embodiments of the present invention, when the display screen is a touch screen, the frame can be directly drawn by a touch screen; in some embodiments of the present invention, the frame may be a rectangular frame, or may be other types of closed figures such as a triangular frame and a circular frame.
Referring to fig. 3, in some other embodiments of the present invention, in step 300, the defect position is found and selected in the image, and the following automatic selection step S320 is further included:
presetting a defect image area; extracting a color region distinguished from a non-defective region by color and/or threshold segmentation; and judging whether the area of the extracted color region exceeds the area of a preset defect image, if so, performing external graph fitting on the divided color region to form a picture frame, and performing frame selection.
Specifically, firstly, a value of the area of the defect image is preset, and since the small-sized defect will not affect the normal use of the workpiece, the setting of the value can eliminate the influence of the small-sized defect on the ultrasonic nondestructive testing result. Then, the image is segmented through colors and/or threshold values, so that a color area which is different from a non-defective area is extracted, and the color of the defect position in the image is obviously different from that of the non-defective area, so that the extracted color area corresponds to the defective area; and comparing the area of the extracted color region with the numerical value of the area of the preset defect image, and if the area of the extracted color region exceeds the numerical value of the area of the preset defect image, performing external graph fitting on the extracted color region to finish the selection.
Further, the image is segmented by color and/or threshold value to extract a color region different from a non-defective region, and specifically, the following method may be adopted: and converting the image into a black-and-white picture by setting hue, saturation and brightness values by using an image space, and extracting a bright area in the picture according to the converted black-and-white picture and setting a threshold value, wherein the extracted bright area is the corresponding defect area.
Optionally, the image space selection employs HSL image space. Of course, according to practical situations, in other embodiments, other types of color spaces such as HSV image space, RGB image space, and the like may be used alternatively.
In addition, in order to simplify the process of fitting the external graph and perform external graph fitting on the extracted color region, the following method may be specifically adopted: and finding X, Y maximum values and minimum values of all pixels in the selected bright area, and forming a rectangular frame by taking X, Y maximum values and minimum values as boundaries to form a rectangular frame, thereby completing the selection.
Of course, according to practical situations, besides the manner of forming the rectangular frame by the fitting, in other embodiments of the present invention, the fitted graph may be other closed graphs such as a rectangular frame, a triangular frame, or a circular frame.
Referring to fig. 4, in some other embodiments of the present invention, in step S300, the defect position is found and selected in the image, and besides the above two selection steps of manual selection and automatic selection, a method of first automatic selection and then manual supplementary selection may be selected, which includes the following steps:
specifically, a defect image area is preset; extracting a color region distinguished from a non-defective region by color and/or threshold segmentation; judging whether the area of the extracted color area exceeds the area of a preset defect image or not; if the color area exceeds the preset color area, performing external graph fitting on the divided color area to form a picture frame, and performing frame selection; and if the number of the defects in the image is not more than the preset threshold, the operator interprets the image from the screen, and frames are selected at the positions with the defects in the image.
First, in the step S320, a step of "extracting a color region different from a non-defective region by color and/or threshold segmentation with respect to a preset defective image area" is performed; subsequently, if the area of the extracted color region exceeds the preset numerical value of the area of the defect image, the step is completely the same as the step of S320; if the area of the extracted color region does not exceed the preset numerical value of the area of the defect image, the same step as the step of S310 is performed again. The automatic program selection process is relatively rigid, so that some misjudgment situations are easy to occur, the automatic and manual combined selection mode is adopted, manual work is used as supplement of the automatic selection mode, and the accuracy of searching the defect position can be further improved.
In some embodiments of the present invention, the ultrasonic scanning is performed by using an ultrasonic nondestructive scanning device, and the ultrasonic nondestructive scanning device includes an ultrasonic probe 40, a transfer mechanism, and the like, and an end of the transfer mechanism is connected to the ultrasonic probe 40 for driving the ultrasonic probe 40 to move in a scanning manner. Because the distance between the ultrasonic probe 40 and the surface of the workpiece needs to be kept constant in the process of ultrasonic nondestructive testing scanning, and higher noise pollution exists in the scanning process, the ultrasonic probe 40 is driven to move and scan by the transfer mechanism instead of manually holding the ultrasonic probe 40 for scanning, the accuracy and the efficiency of the detection process can be better ensured, and the labor intensity of workers can be favorably reduced.
In some embodiments of the present invention, step S100, performing ultrasonic scanning on the workpiece and performing position coding on the scanning track path, further comprises the following steps:
simultaneously recording position data of the tail end of the current transfer mechanism in a coordinate system of the transfer mechanism, and storing the position data in one-to-one correspondence with the coding position data;
meanwhile, in step 400, according to the coding position corresponding to the center of the selected image area, the actual corresponding defect position of the workpiece is traced back, and the method further comprises the following steps:
and acquiring the position in the coordinate system of the transfer mechanism corresponding to the coding position corresponding to the center of the selected image area, and controlling the tail end of the transfer mechanism to move to the position.
When the scanning track path is subjected to position coding, the position data of the tail end of the transfer mechanism (namely the ultrasonic probe 40) in the coordinate system of the transfer mechanism is recorded, and then the position data is stored in a one-to-one correspondence mode along with the coded position data; after finding the defect position in the image and acquiring the code position corresponding to the defect position in the image, the association can be ensured and extracted, and the ultrasonic probe 40 is positioned in the coordinate system of the transfer mechanism when scanning the defect position of the workpiece; then the moving and carrying mechanism is controlled to drive the tail end of the moving and carrying mechanism to come to the position in the backtracking process, so that backtracking can be completed, and the operation of marking or repairing the defect position of the workpiece and the like is facilitated.
Specifically, the robot 10 is selected as the transfer mechanism, the ultrasonic probe 40 is connected to the robot end through the end effector, the robot 10 can acquire the current position of the robot at any time, the current position of the robot is the coordinate position of the robot end relative to the robot coordinate system with the base of the robot 10 as the origin, and the position data of the transfer mechanism end (i.e., the ultrasonic probe 40) in the transfer mechanism coordinate system at this time is the position of the ultrasonic probe 40 in the robot coordinate system.
Of course, in some other embodiments, the transfer mechanism may be a transfer mechanism other than a robot, as long as the position of the end of the transfer mechanism in the coordinate system of the transfer mechanism itself can be obtained at any time inside the transfer mechanism.
For a workpiece with a small volume, the working space of the transfer mechanism can be enough to meet the requirement of the overall coverage scanning of the surface of the whole workpiece; however, when the size of the workpiece to be scanned is large, the size of the working space of the transfer mechanism itself is difficult to satisfy the workpiece scanning requirement.
In order to increase the size of the scanning working space, in some embodiments of the present invention, the transferring mechanism is slidably disposed on the ground rail.
Specifically, in step S100, the method for ultrasonically scanning a workpiece and position-coding a scanning trajectory path further includes:
and simultaneously recording the current ground rail position data of the transfer mechanism, and storing the data in one-to-one correspondence with the coding position data.
Specifically, in step S400, the method traces back to the defect position actually corresponding to the workpiece according to the encoding position corresponding to the center of the selected image area, and further includes the following steps:
and acquiring a ground rail position corresponding to the coding position corresponding to the center of the selected image area, and controlling the transfer mechanism to move to the position.
When the position coding is carried out on the scanning track path, the position data of the tail end of the transfer mechanism (namely the ultrasonic probe 40) in the coordinate system of the transfer mechanism and the current ground rail position data of the transfer mechanism are recorded, and then the position data are correspondingly stored one by one along with the coded position data; after finding the defect position in the image and acquiring the code position corresponding to the defect position in the image, the correlation can be ensured and extracted, and when the ultrasonic probe 40 scans the defect position of the workpiece, the ground rail position of the transfer mechanism and the position of the ultrasonic probe 40 in the coordinate system of the transfer mechanism at that time are located; and then in the backtracking process, the transfer mechanism is controlled to come to a corresponding ground rail position, and then the tail end of the transfer mechanism is controlled to come to a corresponding position in a coordinate system of the transfer mechanism, so that backtracking can be completed, and the defective position of the workpiece can be conveniently identified or repaired.
Specifically, referring to fig. 6, the robot 10 is selected as the transfer mechanism, the ultrasonic probe 40 is connected to the end of the robot through an end effector, the robot 10 is disposed on the slide table 20, the slide table 20 is slidably connected to a ground rail (not shown in the drawing), and the slide table 20 is provided with a slide table driving device 30 for driving the slide table 20 and the robot 10 to slide on the ground rail.
Of course, according to practical circumstances, besides the form of slidably connecting the transfer mechanism to the ground rail can be adopted to enlarge the working space, in some other embodiments of the present invention, a transfer mechanism with a larger working space may be adopted, for example: the ultrasonic probe 40 is carried by a large-sized beam-type traveling crane installed in a factory to perform a moving scan or the like.
In some embodiments of the present invention, because the data processing capability of the ultrasonic detector is limited, for some oversize workpieces, if the ultrasonic probe 40 is used to complete one-time scanning, the image data to be generated is huge, and thus the ultrasonic detector cannot process the data. In order to solve the above problem, step S100, performing ultrasonic scanning on a workpiece, and performing position coding on a scanning trajectory path, further includes the steps of:
dividing the workpiece into a plurality of areas and numbering the areas; and respectively carrying out ultrasonic scanning and scanning track path position coding on the areas with different numbers.
Specifically, the surface of the workpiece is divided into a plurality of small areas with proper area according to the data processing capacity of the ultrasonic detector, each area is conveniently scanned respectively during subsequent scanning, scanning signal data and coding position data of each numbered area are obtained after scanning, then the ultrasonic detector generates an image according to the scanning signal data and the coding position data of each small area, and the image required to be generated is only the image corresponding to each small area, so that the problem that the image data is huge and cannot be processed is solved.
In some embodiments of the present invention, the large workpiece to be detected may be a common planar plate, or certainly may also be a curved plate, and in order to adapt to the detection of the curved plate, step S100 is to perform ultrasonic scanning on the workpiece and perform position coding on the scanning track path, and further includes the following steps:
and respectively scanning each region of the workpiece in a copying manner according to the surface profile of the workpiece, and converting each scanning position in the scanning track path into a workpiece copying plane coordinate for coding.
Specifically, during the moving scan, the ultrasonic probe 40 is moved along the curved profile of the workpiece surface so that the gap from the workpiece surface is always kept constant, and the direction in which the ultrasonic probe 40 emits the ultrasonic wave is always kept perpendicular to the workpiece surface. The code position data generated in the position coding process is plane position data, and the plane is regarded as a workpiece copying plane, and when an image is generated, the scanning signal data generates plane image data from the code position data.
In some embodiments of the present invention, before the step S100, particularly performing the ultrasonic scanning on the workpiece, the following steps are further included:
and establishing a model of the workpiece and the ultrasonic nondestructive scanning device, and planning to obtain a scanning track path of the surface of the workpiece through off-line simulation.
When the workpiece is large, the actual scanning track path planning on the surface of the workpiece is not suitable to be directly performed through the ultrasonic nondestructive scanning device, so that the planning is performed by adopting an off-line simulation mode.
Specifically, a model of the workpiece and the ultrasonic scanning device is established through three-dimensional software, a point location track needing to be scanned by the ultrasonic probe 40 in the ultrasonic scanning device is simulated through software offline simulation, and the point location track is led out to a controller related to the ultrasonic scanning device, namely, a workpiece surface scanning track path is planned. And in the actual scanning process, a certain datum on the workpiece is referred, and then scanning is performed according to the planned point location track.
And, for each small area, a scanning trajectory path is planned which enables the ultrasonic probe 40 to cover the entire small area if the workpiece surface is divided into the small areas.
Referring to fig. 1, in some embodiments of the invention, after step S400, the following steps are further included:
and S500, carrying out spraying identification and/or repair on the defect position of the workpiece.
Specifically, the tail end of the transfer mechanism is connected with an ink-jet printer for spraying and/or repair equipment for repairing the defects, and after the tail end of the transfer mechanism is traced back to the defect position, the defect position is sprayed and marked or repaired through the ink-jet printer and/or repair equipment.
In some embodiments of the invention, the ultrasonic nondestructive testing defect position backtracking method is mainly used in the process of detecting composite materials; and specifically, the tail end of the transfer mechanism is also connected with a camera module for auxiliary detection, and the camera module is used for detecting the surface layer material of the composite material.
Of course, according to practical situations, in other embodiments of the present invention, the ultrasonic nondestructive testing defect location backtracking method of the present invention may also be applied to the testing process of other types of materials as long as the materials can be penetrated by ultrasonic waves, such as metal materials, concrete materials, etc.
Referring to fig. 1 to 6, the ultrasonic nondestructive testing defect location backtracking method according to an embodiment of the present invention is described as an embodiment. It is to be understood that the following description is illustrative only and is not intended to be in any way limiting.
Referring to fig. 6, in the present embodiment, an ultrasonic nondestructive inspection system is used for ultrasonic nondestructive inspection, and the ultrasonic nondestructive inspection system includes an ultrasonic nondestructive scanning device, a controller (not shown in the drawings), a human-machine interaction terminal (not shown in the drawings), an encoder (not shown in the drawings), an ultrasonic flaw detector (not shown in the drawings), a slide table 20, a slide table driving device 30, and a ground rail (not shown in the drawings). The ultrasonic nondestructive scanning device comprises an ultrasonic probe 40 and a transfer mechanism, wherein the transfer mechanism adopts a robot 10, the ultrasonic probe 40 is connected to the tail end of the robot, the robot 10 is arranged on a sliding table 20, the sliding table 20 is slidably arranged on a ground rail, a sliding table driving device 30 is arranged on the sliding table 20 and is used for driving the sliding table 20 to move on the ground rail, and an encoder is arranged on the sliding table 20 or the robot 10 and is used for encoding a scanning track path in the scanning process of the ultrasonic probe 40; the encoder and the ultrasonic probe 40 are electrically connected with the ultrasonic flaw detector and are respectively used for transmitting encoding position data and scanning signal data to the ultrasonic flaw detector; the human-computer interaction terminal, the ultrasonic flaw detector and the robot 10 are all electrically connected with the controller; the controller adopts a PLC, the human-computer interaction terminal adopts a PC, human-computer interaction software is installed in the PC, and the ultrasonic probe 40 is a phased array probe.
Referring to fig. 1 to 5, the method for tracing back the defect position in ultrasonic nondestructive testing of the present embodiment includes the following steps.
S100, ultrasonic scanning is carried out on the workpiece, and position coding is carried out on the scanning track path, so that scanning signal data and coding position data are obtained.
The step S100 includes the following three substeps S110, S120 and S130.
S110, dividing the workpiece into a plurality of areas and numbering the areas;
the whole surface of a large workpiece is divided into a plurality of small areas, and each small area is numbered.
Because the data processing capacity of the ultrasonic detector is limited, for a large workpiece, if the phased array probe is adopted for scanning at one time, the image data which needs to be generated is huge, so that the ultrasonic detector cannot process the data. The surface of the workpiece is divided into a plurality of small areas with proper areas according to the data processing capacity of the ultrasonic detector, and each area is convenient to scan respectively during subsequent scanning.
S120, planning a scanning track path;
when the workpiece is large, it is not suitable to directly perform actual scanning track path planning on the surface of the workpiece through the ultrasonic nondestructive scanning device, and the planning is performed in the form of off-line simulation in this embodiment.
Specifically, models of the workpiece, the ultrasonic nondestructive scanning device, the sliding table 20 and the ground rail are established through three-dimensional software, point location tracks needing to be scanned at the tail end of the robot are simulated through software offline simulation, and then the point location tracks are exported to the controller, namely, the workpiece surface scanning track path is obtained through planning. And in the actual scanning process, a certain datum on the workpiece is referred, and then scanning is performed according to the planned point location track. Then, a scanning trajectory path for covering the entire small area with the ultrasonic probe 40 is planned for each small area.
S130, ultrasonic scanning and scanning track path position coding are respectively carried out on the different numbered areas, and scanning signal data and coding position data are generated.
In the scanning process, each area of the workpiece is respectively scanned in a copying manner according to the surface profile of the workpiece, and each scanning position in a scanning track path is converted into a workpiece copying plane coordinate for encoding while scanning. In the process of the profile scanning, the gap between the ultrasonic probe 40 and the surface of the workpiece is kept constant, and the direction in which the ultrasonic probe 40 emits the ultrasonic wave is always kept perpendicular to the surface of the workpiece.
Specifically, the controller controls the sliding table driving device 30 to start, so as to drive the robot 10 to move to a designated ground rail position, and at the same ground rail position, the robot 10 carrying the ultrasonic probe 40 can scan a plurality of different numbering regions successively. In each zone, as shown in fig. 5, the robot 10 carries the ultrasonic probe 40 to perform a profiling scan on the surface of the workpiece according to a continuously bent S-shaped trajectory; in fig. 5, a horizontal arrow line in the left-right direction represents an actual scanning trajectory of the center of the ultrasonic probe 40; in fig. 5, the arrow line in the vertical direction represents the action of changing the scanning trajectory at the center of the ultrasonic probe 40.
For example, taking right as a forward direction, when scanning along a horizontal arrow line from left to right, the robot 10 sends a signal to the encoder and the ultrasonic detector through the IO signal, at this time, the IO signal indicates that the scanning state and the direction are in the "forward direction", and after receiving the signal, the ultrasonic detector controls the ultrasonic probe 40 to start working, so as to scan; when the arrow line in the vertical direction moves from top to bottom, the robot 10 sends a signal to the encoder and the ultrasonic detector through the IO signal, at this time, the IO signal indicates a "stepping" state, which means that the robot 10 at this time moves to the next scanning track with the ultrasonic probe 40 and is in a non-scanning state, and the ultrasonic detector controls the ultrasonic probe 40 to end working after receiving the signal; after the scanning track is transferred, the ultrasonic probe 40 scans along a horizontal arrow from right to left, when the scanning starts, the robot 10 sends a signal to the encoder and the ultrasonic detector through an IO signal, at this time, the IO signal indicates that the scanning state and the direction are negative, and after the ultrasonic detector receives the signal, the ultrasonic probe 40 is controlled to continue to work for scanning; then the ultrasonic probe 40 will continue to move along the arrow line in the vertical direction from top to bottom, continue to send the signal indicating the "step" state to the encoder and the ultrasonic detector, and after the ultrasonic detector receives the signal, control the ultrasonic probe 40 to end the work; then, the robot 10 carries the ultrasonic probe 40 to sequentially and circularly repeat the above processes until all the scanning paths represented by all the horizontal arrow lines of the current whole numbering region are completed, and the scanning of the current numbering region is completed; the scanning signal data is generated and transmitted to the ultrasonic flaw detector every time the ultrasonic probe 40 is operated to perform scanning. Wherein, partial overlap is allowed to exist between the scanning areas of the ultrasonic probe 40 corresponding to two adjacent scanning tracks, so as to ensure that all positions of the coding area can be scanned, and thus omission is avoided.
In the process of sending a signal indicating a scanning state to the encoder through the IO signal until sending a signal indicating a stepping state to the encoder through the IO signal, the current position of the robot is sent to the encoder in real time, the current position of the robot is the position of the tail end (the ultrasonic probe 40) of the robot in a robot coordinate system, and the encoder processes the received current position of the robot in real time and converts the current position into a workpiece surface profiling plane coordinate, namely an encoding position. In the process of circularly scanning the whole numbering area, the encoder also circularly performs the encoding process, so that the whole curved surface of the current numbering area is converted into a plane coordinate encoding position.
While the current position of the robot is converted into the encoding position of the workpiece profiling plane coordinate in real time, the encoding system also records the current position of the ground rail where the robot 10 is located, the current scanning area number, and the current position of the ultrasonic probe 40 in the robot coordinate system (i.e. the current position of the robot); and the coding position data of the workpiece copying plane coordinate corresponds to the three data one by one and is kept in a database.
When the robot 10 starts scanning with the ultrasonic probe 40 for each number region while saving data, a File name corresponding to the number of the region is generated, and after the robot 10 scans all the regions, File names corresponding to File _1, File _2, File _3, File _4, and File _5. The coding system database stores, for each region, the position of the ground track where the robot 10 is located when the region is scanned, the number of the scanned region, and the positions of the ultrasonic probes 40 in the robot coordinate system at all the scanning positions in the region.
S200, generating an image according to the scanning signal data and the coding position data;
and combining the scanning signal data and the coding position data corresponding to each numbering area to form an image corresponding to each numbering area. Specifically, the encoder sends the coded position data to the ultrasonic detector, a driving program is arranged in the ultrasonic detector, the coded position data in the coded database can be read, and the ultrasonic detector images the scanning signal data corresponding to the numbered regions on a plane coordinate according to the coded position data of each numbered region, so that plane image data is formed and displayed on display screens of a PC and the ultrasonic flaw detector. Further, specifically, the data file read by the ultrasonic probe can be switched by a button provided on the ultrasonic probe or a PC, thereby forming image displays for different numbered regions, respectively. Moreover, by means of human-computer interaction software in the PC, a plurality of data files can be acquired at one time, a special driving program for ultrasonic flaw detection is used for converting the two data into images and displaying the images on a screen of the PC, and an operator can look up the images by using a plurality of groups of data as a batch, so that the looking-up efficiency is improved.
S300, finding out a defect position on the image, selecting the defect position, and acquiring a coding position corresponding to the center of the selected image area;
in the present embodiment, the step S300 has three mode steps for selection, which are a manual selection step S310, an automatic selection step S320, and a first automatic selection and then manual supplement selection step S330. Step S310, step S320, and step S330 are described below, respectively.
S310, manually finding out a defect position in the image and selecting the defect position to obtain a coding position corresponding to the center of the selected image area;
specifically, the image is displayed on a screen, an operator interprets the image, and draws a frame at a position where a defect exists in the image, and then obtains the coding position according to the image center corresponding to the drawn frame, namely obtains the coding position of the workpiece profiling plane coordinate. And specifically, a position where the mouse has a defect in the image is used for drawing a frame, wherein the frame is a rectangular frame, and the defect position is located in the rectangular frame.
S320, automatically finding out a defect position in the image and selecting the defect position to obtain a coding position corresponding to the center of the selected image area;
automatically selecting a software program preset in the ultrasonic flaw detector; firstly, presetting a numerical value of a defect image area; then, the image is segmented through colors and/or threshold values, so that a color area which is different from a non-defective area is extracted, and the color of the defect position in the image is obviously different from the color of the non-defective area, so that the extracted color area corresponds to the defective area; comparing the area of the extracted color region with the numerical value of the area of the preset defect image, and if the area of the extracted color region exceeds the numerical value of the preset defect image, performing external graph fitting on the extracted color region to finish selection; and then acquiring a coding position according to the image center corresponding to the fitted circumscribed graph, namely acquiring the coding position of the workpiece profiling plane coordinate.
Specifically, the image is segmented by color and/or threshold value, so as to extract a color region different from a non-defective region, the following method can be adopted: and converting the image into a black-and-white picture by setting hue, saturation and brightness values by using an image space, and extracting a bright area in the picture according to the converted black-and-white picture and setting a threshold value, wherein the extracted bright area is the corresponding defect area. Wherein, the image space selection adopts HSL image space.
And, specifically, to carry out circumscribed graph fitting on the extracted color region, the following method may be adopted: and finding X, Y maximum values and minimum values of all pixels in the selected bright area, and forming a rectangular frame by taking X, Y maximum values and minimum values as boundaries to form a rectangular frame, thereby completing the selection.
S330, automatically supplementing and finding out defect positions in the image and then manually supplementing the defect positions, and acquiring a coding position corresponding to the center of the selected image area;
in this method, the step of "automatically finding and selecting the defect position in the image" in the above step S320 is performed first; if the area of the extracted color region exceeds the preset numerical value of the area of the defect image, the subsequent step of the step S320 is the same; if the area of the extracted color region does not exceed the preset numerical value of the area of the defect image, the step of S310 "manually finding and selecting the defect position in the image" is performed.
The accuracy of finding the defect position can be further improved by combining automatic and manual work and supplementing the manual work as an automatic mode.
S400, backtracking to the actual corresponding defect position of the workpiece according to the coding position of the center of the selected image area.
According to the encoding position obtained in the step S300, that is, according to the obtained encoding position of the workpiece copying plane coordinate, the ground rail position data corresponding to the robot 10 and the position data of the robot end (the ultrasonic probe 40) in the robot coordinate system when the ultrasonic probe 40 passes through the actual defect position during scanning are obtained again; and sending the two data to a controller, and controlling the robot 10 to move to the corresponding ground rail position and the tail end of the robot to move to the corresponding position in the robot coordinate system by the controller according to the two data, so as to realize the backtracking of the defect position.
S500, carrying out spraying identification and/or repair on the defect position;
specifically, the tail end of the robot is connected with an ink-jet printer for spraying and/or repair equipment for repairing the defect, and after the tail end of the robot is traced back to the defect position, the defect position is sprayed and marked and/or repaired through the ink-jet printer and/or the repair equipment.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an illustrative embodiment," "an example," "a specific example," or "some examples" or the like mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
While embodiments of the invention have been shown and described, it will be understood by those of ordinary skill in the art that: various changes, modifications, substitutions and alterations can be made to the embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.
Claims (13)
1. The method for backtracking the defect position of ultrasonic nondestructive testing is characterized by comprising the following steps:
carrying out ultrasonic scanning on the workpiece, and carrying out position coding on a scanning track path to obtain scanning signal data and coding position data;
generating an image from the scanning signal data and the encoded position data;
finding out and selecting the defect position on the image, and acquiring the coding position corresponding to the center of the selected image area;
and backtracking to the actual corresponding defect position of the workpiece according to the coding position corresponding to the center of the selected image area.
2. The ultrasonic nondestructive inspection defect position backtracking method according to claim 1, characterized in that: finding out and selecting the defect position in the image, comprising the following steps:
and displaying the image on a screen, judging the image by an operator, and framing the image at the position with the defect in the image.
3. The ultrasonic nondestructive inspection defect position backtracking method according to claim 1, characterized in that: finding out and selecting the defect position in the image, comprising the following steps:
presetting a defect image area;
extracting a color region distinguished from a non-defective region by color and/or threshold segmentation;
and judging whether the area of the extracted color region exceeds the area of a preset defect image, if so, performing external graph fitting on the divided color region to form a picture frame, and performing frame selection.
4. The ultrasonic nondestructive inspection defect position backtracking method according to claim 3, characterized in that: and when the area of the extracted color region does not exceed the preset area of the defect image, the operator interprets the image from the screen, and frames are selected at the position where the defect exists in the image.
5. The ultrasonic nondestructive inspection defect position backtracking method according to claim 3, wherein a color region distinguished from a defect-free region is extracted by color and/or threshold segmentation, comprising the steps of:
converting an image into a black-and-white picture by setting hue, saturation and brightness values by using an image space;
and setting a threshold value according to the converted black and white picture, and extracting the bright area in the picture.
6. The method of claim 5, wherein the step of performing circumscribed graph fitting on the extracted color region to form a frame comprises the steps of:
and finding X, Y maximum values and minimum values in all pixels of the bright area, and taking X, Y maximum values and minimum values as boundaries to serve as rectangular boundaries.
7. The ultrasonic nondestructive inspection defect position backtracking method according to any one of claims 1 to 6, characterized in that: the ultrasonic scanning device comprises an ultrasonic probe and a transfer mechanism, wherein the tail end of the transfer mechanism is connected with the ultrasonic probe and is used for driving the ultrasonic probe to scan and move.
8. The ultrasonic nondestructive inspection defect position backtracking method according to claim 7,
carrying out ultrasonic scanning on a workpiece and carrying out position coding on a scanning track path, wherein the method comprises the following steps of simultaneously recording position data of the tail end of a current transfer mechanism in a transfer mechanism coordinate system, and storing the position data in a one-to-one correspondence manner with the coding position data;
and backtracking to the actual corresponding defect position of the workpiece according to the coding position corresponding to the center of the selected image area.
9. The ultrasonic nondestructive testing defect position backtracking method according to claim 8, wherein the transfer mechanism is slidably disposed on the ground rail;
carrying out ultrasonic scanning on the workpiece, and carrying out position coding on a scanning track path, and also comprises the following steps of simultaneously recording the current ground rail position data of the transfer mechanism, and storing the current ground rail position data in one-to-one correspondence with the coding position data;
and backtracking to the actual corresponding defect position of the workpiece according to the coding position corresponding to the center of the selected image area.
10. The method of tracing back the defect position in ultrasonic non-destructive inspection according to any of claims 1 to 6, wherein the workpiece is ultrasonically scanned and the scanning trajectory path is position-coded, comprising the steps of:
dividing the workpiece into a plurality of areas and numbering the areas;
and respectively carrying out ultrasonic scanning and scanning track path position coding on the areas with different numbers.
11. The method of claim 10, wherein the workpiece is scanned ultrasonically and the scanning trajectory path is position-coded, further comprising the steps of:
and respectively scanning each region of the workpiece in a copying manner according to the surface profile of the workpiece, and converting each scanning position in the scanning track path into a workpiece copying plane coordinate for coding.
12. The method for tracing the defect position in the ultrasonic nondestructive testing according to any one of claims 1 to 6, wherein after tracing to the defect position corresponding to the workpiece actually, the method further comprises the following steps:
and carrying out spraying identification and/or repair on the defect position of the workpiece.
13. The ultrasonic nondestructive defect position backtracking method according to any one of claims 1 to 6, characterized by further comprising the steps of:
and establishing a model of the workpiece and the ultrasonic nondestructive scanning device, and planning to obtain a scanning track path of the surface of the workpiece through off-line simulation.
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