CN1124488C - Nondestructive inspection method and equipment for surface of axle or perforated workpieces - Google Patents
Nondestructive inspection method and equipment for surface of axle or perforated workpieces Download PDFInfo
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- CN1124488C CN1124488C CN 00135618 CN00135618A CN1124488C CN 1124488 C CN1124488 C CN 1124488C CN 00135618 CN00135618 CN 00135618 CN 00135618 A CN00135618 A CN 00135618A CN 1124488 C CN1124488 C CN 1124488C
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- eddy current
- current sensor
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- axle
- error
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Abstract
The present invention relates to a non-destructive detection method and equipment for surface defects of axle or perforated workpieces. The present invention has the method that roundness errors and main axle rotary errors of the workpieces are separated by the eddy current detection technology and the error separation principle to obtain the surface defects of the workpieces. The equipment is composed of a sensor, a probe bracket thereof, rotary equipment of the workpieces, indexing equipment, an analogue-digital converter and a computer which are assembled and connected. The present invention has the advantages of simple operation, accurate and reliable detection results, no damage to the workpieces to be measured, low cost, etc. The present invention can be widely used in non-destructive detection for surface defects of axle or perforated workpieces, such as the detection of surface defects of vehicle shafts of a railway system.
Description
The present invention relates to a kind of method and device that Surface Flaw is carried out Non-Destructive Testing.
At present, axle, hole class Surface Flaw being carried out the method that Non-Destructive Testing generally adopts is magnaflux and ultrasonic testing.There are a lot of problems in magnetic powder inspection, as: the flaw detection operation is many, complex process, and flaw detection personnel's workload is big, the labour intensity height; Because the flaw detection cycle is long, work efficiency is very low simultaneously; In addition, the energy resource consumption of magnaflux is also very big.Magnetic powder inspection not only requires highly sensitive fault indicator and good demonstration medium, and also depends on method of operating and operator's experience and sense of responsibility to a great extent.Because the influence of various subjective factors, the reliability of flaw detection are difficult to guarantee.Flaw detection personnel's the condition of work and the working environment of crack detection room are also very abominable.UT (Ultrasonic Testing) can take appropriate measures to the bigger product in container one class inner space and carry out, but then is impracticable to the little and dark product of hydraulic prop one class internal diameter.
The object of the present invention is to provide a kind of new method and device thereof that axle, hole class Surface Flaw are carried out Non-Destructive Testing.And this new method and device technique thereof simple, can lower labor strength, and can realize the detection of axle, hole surface defective accurately and fast.
The present invention utilizes eddy detection technology that axle, hole class Surface Flaw are carried out Non-Destructive Testing.Eddy detection technology is to utilize eddy current sensor that measured surface is detected, make eddy current sensor and measured workpiece surface keep certain interval, when changing, the gap utilizes the eddy current effects of metallic conductor in AC magnetic field, impedance changes, and intensity of variation is relevant with resistivity, the magnetic permeability of gap length, sheet metal, when the roller surface defectiveness, can cause the variation of above-mentioned factor as damage, cut and visible crack etc., just can pass through the eddy current sensor pickoff signals, check and analysis are come out.In addition, when the structural homogenity of magnetic conductive metal, when the distribution of carbides situation goes wrong, will cause the variation of conductivity and magnetic permeability, so also can detect by eddy current sensor signals.
The present invention utilizes the error separating theory, on the basis of having eliminated roundness error of workpiece and spindle rotation error, has realized the defective with EDDY CURRENT axle, hole class surface of the work.Its method comprises the steps:
(1) on the circumferencial direction of measured workpiece surface, installs two in order to detect the first eddy current sensor A and the second eddy current sensor C of workpiece shape error and turn error according to the method for two point method error separating by support, the first eddy current sensor A is installed earlier, and is being the installation second eddy current sensor C on counter clockwise direction 185.625 degree with the first eddy current sensor A central axis; Another is installed in order to detect the 3rd eddy current sensor S of comprehensive flaw indication on 90 degree being counterclockwise again with the first eddy current sensor A central axis, except the deviation from circular from and spindle rotation error that comprise workpiece, also comprised the information of various surface imperfection such as the crackle, the quenching (hardness, crystalline texture) that comprise workpiece surface roughness be inhomogeneous in its detection signal;
(2) workpiece is returned turn around, three sensors are sampled respectively to an integral number power five equilibrium phase point N (the present invention is 64) of 2, obtain the data in this cross section;
(3) three detected signals of sensor are by the conversion of intermediate conversion device, be converted to digital signal through A/D converter again, carry out the analysis and the processing of signal by computing machine, from the sampled data of the first eddy current sensor A and the second eddy current sensor C, isolate the shape error and the spindle rotation error of workpiece, from the detection signal of the 3rd eddy current sensor S, separate above-mentioned two kinds of error signals again, promptly obtain Surface Flaw information.Can be during measurement according to the requirement of the length and the precision of measured workpiece, the cross section number of getting measurement can be different.In general, measurement cross section number is obtained many more, and measuring accuracy is high more.
The invention provides a kind of device that the shaft-like workpiece surface imperfection is carried out Non-Destructive Testing, be characterised in that it is by base support nonmagnetic metal tubular sensor probe support, the first eddy current sensor A in three eddy current sensors, the second eddy current sensor C is installed on the sensor probe support according to two point method error separating principle, and make between its two sensor probe and the measured workpiece respectively that the transmission by a magnetic conductive metal piece contacts with measured workpiece, by probe bracket the magnetic interference signal shielding is fallen, simultaneously the 3rd eddy current sensor S is installed being on the sensor probe supports on 90 degree counterclockwise with the first eddy current sensor A central axis; Three sensors of the first eddy current sensor A, the second eddy current sensor C and the 3rd eddy current sensor S are connected with computing machine by A/D converter (A/D plate); Rotary main shaft and index plate be coaxial be installed in support by guiding trestle with measured workpiece on the horizontal guide on the same axis, link to each other with locating shaft on same horizontal line by connecting support, under the acting in conjunction of rotary main shaft and locating shaft, measured workpiece is clamped and rotation; And can be under the effect of horizontal guide, along continuous straight runs moves forward and backward.
Described index plate is a rosette, and its one week of edge, by an integral number power five equilibrium phase point of 2 uniformly-spaced behind the precision indexing, holing on drilling machine formed with dividing head.Its phase point is high more, and testing result is accurate more.When it and workpiece coaxial rotation together, the infrared ray that the photoelectric sensor transmitting terminal sends is spaced apart ground conducting and blocking-up, makes receiving end correspondingly be in conducting and cut-off state, thereby forms a string square-wave pulse.This square-wave pulse can be arrived by microcomputer monitoring, and finishes sampling work to the measured workpiece raw data in order to the control sensor.
Between rotary main shaft and measured workpiece, can adorn a rubbing cushion,, prevent workpiece slippage when rotating to increase the friction force between rotary main shaft and the measured workpiece.
The invention provides a kind of device that hole class Surface Flaw is carried out Non-Destructive Testing, it is characterized in that the shaft-like workpiece surface imperfection being carried out in the device of Non-Destructive Testing, the probe of three sensors is installed towards bore area.
Compared with prior art the present invention has following characteristics, 1, simple to operate, sense cycle is short, efficient is high.As in existing magnetic powder inspection technology, roughly need pass through rust cleaning, magnetize and take off the magnetic process the detection of measured workpiece, and need repeated multiple times, just can make, and the present invention directly can detect measured workpiece, and only need about one minute, can obtain a result; 2, the result is accurately reliable.In the magnetic powder inspection technology, be the gathering situation that adopts artificial visually examine's method to remove to observe magnetic, judge the existence of defective, so degree of accuracy is relatively low, and the present invention utilizes eddy detection technology to obtain defect information, and uses computing machine that data are handled, and the result is accurately reliable.3, do not damage test specimen, with low cost.Because the present invention need not pass through rust cleaning, magnetizes and take off processes such as magnetic, so not fragile test specimen, with low cost.
The present invention will be further described below in conjunction with accompanying drawing.
Accompanying drawing 1 is a system architecture synoptic diagram of the present invention.
Accompanying drawing 2 is method synoptic diagram that the present invention carries out Non-Destructive Testing to axle, hole class Surface Flaw.
Accompanying drawing 3 is a kind of structural representations that the shaft-like workpiece surface imperfection carried out the cannot-harm-detection device of the present invention.
Accompanying drawing 4 is A-A diagrammatic cross-sections of accompanying drawing 3.
To being described in detail as follows of method:
As shown in Figure 1 and Figure 2, establish: place the first eddy current sensor A, the 3rd eddy current sensor S of same surface level and the center line of the second eddy current sensor C to meet at desirable rotation center O point, the center of circle of measured workpiece least square circle is O ' point.Make γ
0Be the least square radius of circle.γ (θ) is to be polar coordinates with O ', the pairing workpiece radius of central angle θ.R
A, R
S, R
CIt is respectively the distance that the first eddy current sensor A, the 3rd eddy current sensor S, the second eddy current sensor C are ordered apart from O.XOY is the rectangular coordinate system by the center line of the first eddy current sensor A and some O.Rx (θ) and Ry (θ) are respectively the θ angle part diameters of axle, and in the projection of X-axis and Y direction, S (θ) is shape error (γ (θ) and the γ of place, θ angle workpiece to turn error (0-0 ' vector)
0Poor).α and β are respectively the angles between the first eddy current sensor A and the 3rd eddy current sensor S, the 3rd eddy current sensor S and the second eddy current sensor C.So just can obtain following equation:
Sa(θ)＝S(θ)+Rx(θ) ①
Ss(θ)＝S(θ+α)+Rx(θ)cosα+Ry(θ)sinα+F(θ) ②
Sc(θ)＝S(θ+α+β)+Rx(θ)cos(α+β)+Ry(θ)sin(α+β)③
Wherein Sa (θ), Ss (θ), Sc (θ) are respectively the input signal (having removed DC component, i.e. average weight) of three sensors, and F (θ) is a Surface Flaw.So just can solve the shape error of measured workpiece, the turn error of pick-up unit and the surface imperfection of measured workpiece.
Concrete testing process is as follows:
(1) workpiece returns and turns around, three sensors are sampled respectively to an integral number power five equilibrium phase point N (this research is 64) of 2, and try to achieve the DC component of its each sensor, and then sampled value is removed DC component, promptly get input signal Sa (θ), Ss (θ) and the Sc (θ) of three sensors.
(2) from the sampled data of the first eddy current sensor A and the second eddy current sensor C, isolate the shape error and the spindle rotation error of workpiece.The original equation of two-point method error separating is:
Sa(θ)＝S(θ)+Rx(θ) ①
Sc(θ)＝S(θ+α+β)+Rx(θ)cos(α+β)+Ry(θ)sin(α+β) ②
If composite signal is: C (θ)=C
1Sa (θ)+C
2Sc (θ)
C wherein
1, C
2Be by the determined coefficient of spending surely of setting angle.
1. 2. substitution following formula and simplification can get
C(θ)＝C
1S(θ)+C
2S(θ+α+β)+Rx(θ)(C
1+C
2cos(α+β))+Ry(θ)C
2sin(α+β)) ③
Eliminate 3. that the spindle rotation error component makes C (θ) only relevant with workpiece shape error S (θ) in the formula, just can try to achieve a particular solution: C
1=1, C
2=sin α/sin β
With C
1, C
2Substitution is formula 3., can only be comprised the equation of workpiece shape error:
C (θ)=S (θ)+C
2S (θ+alpha+beta) is 4. following, and we remember C (θ), S (θ) certain Along ent θ under all N five equilibriums
1=2 π i/N (i=0,1,2 ..., the sampled value of N-1) locating is C (i), S (i) and represents time domain with footnote t, and f represents frequency domain with footnote, so the 4. sampled value of formula is carried out discrete fast fourier transform and by its time delay---and phase-shift characterisitc can get:
Sf (k) [1+c
2e
J (alpha+beta) k]=C
f(k) (k=0,1,2 ..., N-1) S wherein
f(k), C
f(k) be respectively sampled value S (i), the C (i) of workpiece shape error and composite signal on the time domain amplitude through the K order harmonics on frequency domain after the fast fourier transform, and weight function
ω (k)=1+c
2e
J (alpha+beta) k(k=0,1,2 ..., N-1) if ω (k) ≠ 0, then S
f(k)=C
f(k)/ω (k) (k=0,1,2 ..., N-1) remake discrete invert fast fourier transformation and can try to achieve workpiece shape error S on the time domain
t(i), (i=0,1,2 ..., N-1). if there is integer m=N (alpha+beta)/2 π, then utilize formula 2. or 3. can obtain the component of spindle rotation error on X-axis and Y-axis:
Rx(i)＝Sa(i)-S(i)
Ry(i)＝[Sc(i)-S(i+m)-Rx(i)cos(α+β)]/sin(α+β)
(3) from the output signal Ss (θ) of the 3rd eddy current sensor (S), separate the surface imperfection information F (θ) that workpiece shape error and spindle rotation error can obtain measured workpiece:
F(θ)＝Ss(θ)-S(θ+α)-Rx(θ)cosα-Ry(θ)sinα。
F (θ) signal can be determined the size of surface imperfection quantitatively, to the frequency-domain analysis of the time-domain signal F (θ) of surface imperfection information, can further analyze the frequency spectrum of surface imperfection signal and generate reason.
To the device be described in detail as follows:
As Fig. 1, Fig. 3, shown in Figure 4, the first eddy current sensor A, the 3rd eddy current sensor S and the second eddy current sensor C are installed on the sensor probe support 4 on request, and wherein the sensor head of the first eddy current sensor A, the second eddy current sensor C respectively contacts with measured workpiece 2 by the transmission of a magnetic conductive metal piece 3; The 4th, by the sensor probe support that base 1 supports, it is made by nonmagnetic metal, and it can mask the magnetic interference signal, makes the shape error and the spindle rotation error that only comprise workpiece in the detection signal of the first eddy current sensor A, the second eddy current sensor C; The 5th, rotary main shaft, rotary main shaft 5 and index plate 6 be coaxial be installed in by guiding trestle 8 that support with measured workpiece 2 on the horizontal guide on the same axis 7, link to each other with locating shaft 10 on same horizontal line by connecting support 9, under the acting in conjunction of rotary main shaft 5 and locating shaft 10, measured workpiece 2 can be clamped and rotation, and can be under the effect of horizontal guide 7, along continuous straight runs moves forward and backward; The 6th, index plate, it be by one week of a slice rosette edge through dividing head uniformly-spaced behind 2 the branch precision indexings such as integral number power, holing on drilling machine forms, during sampling and workpiece 2 coaxial rotation together; 11 is wearing pieces, to increase the friction between rotary main shaft 5 and the workpiece 2, prevents workpiece 2 slippage when rotating; The 12nd, bearing is beneficial to the rotation of rotary main shaft 5 and locating shaft 10.
When carrying out raw data acquisition, rotate index plate 6, the infrared ray that photoelectric sensor 13 transmitting terminals are sent is spaced apart ground conducting and blocking-up, receiving end then correspondingly is in conducting and cut-off state, thereby send the pulse train signal, be used for controlling of sampling, control three current vortex sensors calibration to the sampling of measured workpiece raw data on prescribed phases.The detected signal of sensor is by the conversion of intermediate conversion device 14,15,16, be converted to digital signal through mould/number (A/D) converter 17 again, carry out the analysis and the processing of signal by computing machine 18, from the sampled data of the first eddy current sensor A and the second eddy current sensor C, isolate the shape error and the spindle rotation error of workpiece, from the detection signal of the 3rd eddy current sensor S, separate above-mentioned two kinds of error signals again, promptly obtain Surface Flaw information.
Claims (4)
1, a kind of method that axle, hole class Surface Flaw are carried out Non-Destructive Testing is characterized in that comprising the steps:
(1) on the circumferencial direction of measured workpiece surface, installs two in order to detect first eddy current sensor (A) and second eddy current sensor (C) of shape error and turn error according to two point method error separating principle by support, first eddy current sensor (A) is installed earlier, and go up second eddy current sensor (C) is installed being counterclockwise 185.625 degree with first eddy current sensor (A) central axis, go up and another is installed being counterclockwise 90 degree again in order to detect the 3rd eddy current sensor (S) of comprehensive flaw indication with first eddy current sensor (A) central axis;
(2), workpiece returned turns around, three sensors are sampled respectively to an integral number power five equilibrium phase point of 2;
(3), three detected signals of sensor by the conversion of intermediate conversion device (14,15,16), pass through A/D converter (17) again and be converted to digital signal, carry out the analysis and the processing of signal by computing machine (18), from the sampled data of first eddy current sensor (A) and second eddy current sensor (C), isolate the shape error and the spindle rotation error of workpiece, from the detected signal of the 3rd eddy current sensor (S), separate above-mentioned two kinds of error signals again, promptly obtain Surface Flaw information.
2, a kind of axle, hole class Surface Flaw are carried out the device of the method for Non-Destructive Testing according to claim 1 is described, are characterised in that:
1., the device that the shaft-like workpiece surface imperfection is detected, it is supported the probe bracket (4) of a non-magnet material by base (1), first eddy current sensor (A) in three eddy current sensors, second eddy current sensor (C) is installed on the sensor probe support (4) according to two point method error separating principle, and make first eddy current sensor (A), between second eddy current sensor (C) and the measured workpiece respectively the transmission by a magnetic conductive metal piece (3) contact with measured workpiece, by probe bracket (4) the magnetic interference signal shielding is fallen, be last the 3rd eddy current sensor (S) of installing of 90 degree counterclockwise contactlessly with first eddy current sensor (A) central axis; Rotary main shaft (5) and index plate (6) be coaxial be installed in support by guiding trestle (8) with measured workpiece (2) on the horizontal guide on the same axis (7), link to each other with locating shaft (10) on same horizontal line by connecting support (9), under the acting in conjunction of rotary main shaft (5) and locating shaft (10), measured workpiece (2) is clamped and rotation, but and along continuous straight runs move forward and backward;
2., to the device that hole class Surface Flaw detects, it is in the device that the shaft-like workpiece surface imperfection is detected, the probe of its three sensors is installed towards hole surface.
3,, it is characterized in that processing to equiphase on the circumference of described index plate (6) an integral number power aperture of 2 in order to the phase place calibration according to the described a kind of device that axle, hole class Surface Flaw are carried out Non-Destructive Testing of claim 2.
4, according to the described a kind of device that axle, hole class Surface Flaw are carried out Non-Destructive Testing of claim 2, it is characterized in that to establish a wearing piece (11) between rotary main shaft (5) and the measured workpiece (2).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 00135618 CN1124488C (en) | 2000-12-13 | 2000-12-13 | Nondestructive inspection method and equipment for surface of axle or perforated workpieces |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 00135618 CN1124488C (en) | 2000-12-13 | 2000-12-13 | Nondestructive inspection method and equipment for surface of axle or perforated workpieces |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1305107A CN1305107A (en) | 2001-07-25 |
| CN1124488C true CN1124488C (en) | 2003-10-15 |
Family
ID=4596773
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN 00135618 Expired - Fee Related CN1124488C (en) | 2000-12-13 | 2000-12-13 | Nondestructive inspection method and equipment for surface of axle or perforated workpieces |
Country Status (1)
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|---|---|
| CN (1) | CN1124488C (en) |
Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR20070072500A (en) * | 2004-10-28 | 2007-07-04 | 도요 고한 가부시키가이샤 | Device and method for inspecting scratch on cell external case |
| CN100340850C (en) * | 2004-11-15 | 2007-10-03 | 广州华工百川科技股份有限公司 | Standard defect formwork for laser tire non-destructive detector |
| CN100415446C (en) * | 2006-07-21 | 2008-09-03 | 上海大学 | Tracking method of on-line measuring roundness error and machine tool main axle error |
| CN103308021B (en) * | 2013-07-04 | 2015-12-09 | 沈阳工业大学 | A kind of method of measuring workpieces deviation from circular from |
| CN104197874B (en) * | 2014-07-04 | 2017-06-27 | 丽水学院 | A kind of high-precision rotary body bounce on-position measure method |
| CN106078508B (en) * | 2016-06-28 | 2018-11-06 | 长春工业大学 | A kind of abrasion of grinding wheel on-line monitoring method |
| CN110672005A (en) * | 2019-11-05 | 2020-01-10 | 杭州冰玉科技有限公司 | A simple and easy detection device of substrate roughness for water-soluble membrane |
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2000
- 2000-12-13 CN CN 00135618 patent/CN1124488C/en not_active Expired - Fee Related
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| Publication number | Publication date |
|---|---|
| CN1305107A (en) | 2001-07-25 |
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