CN112858483A - Phased array probe scanning track self-correcting system and method - Google Patents

Phased array probe scanning track self-correcting system and method Download PDF

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CN112858483A
CN112858483A CN202110139025.XA CN202110139025A CN112858483A CN 112858483 A CN112858483 A CN 112858483A CN 202110139025 A CN202110139025 A CN 202110139025A CN 112858483 A CN112858483 A CN 112858483A
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赵小辉
王浩
刘宇
蔡宇
徐龙哲
蒋豪
杨彬
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Jilin University
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    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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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
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Abstract

The invention relates to a phased array probe scanning track self-correcting system and a phased array probe scanning track self-correcting method, and belongs to the field of ultrasonic nondestructive inspection. The method comprises the steps that defect images in sector scanning information of phased array ultrasonic nondestructive testing correspond to actual defects one by one, the defect images in sector scanning can accurately reflect information such as depth, size and position of the actual defects, inherent incomplete penetration defects on two sides of the root of a butt welding seam with a backing plate can generate continuous inherent echoes when a phased array probe is scanned along the welding seam, continuous incomplete penetration defect detection images with relatively fixed positions appear on the sector scanning images, automatic identification and tracking of the inherent incomplete penetration defects on two sides of the root of the welding seam are achieved through an established sector scanning image defect automatic identification theory and algorithm, the transverse coordinate of the center of the welding seam is located, the transverse deviation of a scanning teaching track and a theoretical track of the phased array probe is solved, and a six-axis robot system is transmitted to eliminate the transverse deviation in real time, so that intelligent track deviation correction in the scanning process of the phased array probe is achieved.

Description

Phased array probe scanning track self-correcting system and method
Technical Field
The invention relates to the field of ultrasonic nondestructive inspection, in particular to an automatic detection system for ultrasonic internal quality of a phased array with a backing plate butt weld, and particularly relates to a self-correcting system and method for scanning tracks of a phased array probe.
Background
The phased array ultrasonic nondestructive testing technology is widely applied to internal quality detection of parent metals and welding seams in the fields of petroleum pipelines, pressure vessels, ships, aviation and the like, and in an automatic detection system for the internal quality of butt welding seams with backing plates, which is carried out based on the phased array ultrasonic technology, the following forms exist in terms of the phased array probe scanning track accurate control technology:
firstly, phased array welding seam internal quality flaw detection based on probe teaching track: due to workpiece welding deformation, workpiece installation errors to be detected and quality inspection flaw detection actuating mechanism system errors, the distance precision between the phased array probe and the center of a welding seam is not controllable in the scanning process of the phased array probe along the welding seam.
Secondly, a phased array probe scanning track deviation correcting system based on image processing visual guidance: according to the technology, heterogeneous color lines with large color value difference with base metal and welding seam metal are drawn along the welding seam direction at the welding toes, and then the scanning track of the phased array probe is corrected in real time based on a teaching track by using the heterogeneous color lines as reference lines and utilizing an image processing technology; the process of drawing heterogeneous color lines is complicated, the precision is difficult to guarantee, and the phased array probe scanning track correction on workpieces with complex structures and worn flat weld joints is not applicable.
Thirdly, a phased array probe scanning track deviation correcting system based on laser welding seam tracking: the technology scans the weld outline by using a laser line, extracts weld toe characteristic points, obtains the distance from a phased array probe to the center of a weld through coordinate conversion, calculates the scanning track deviation of the phased array probe and transmits the scanning track deviation to a robot system for deviation correction adjustment; for a weld with the height of below 1mm or a weld with ground height, the technology is difficult to apply due to the difficulty in extracting or the absence of characteristic points.
The above forms are phased array probe scanning track deviation correcting methods based on weld external characteristic information, and requirements of phased array probe scanning intelligent track deviation correction cannot be met for butt welds with backing plates, the extra height of which is lower than 1mm, the extra height of which is polished, and the tracks of which are complex.
Disclosure of Invention
The invention aims to provide a phased array probe scanning track self-correcting system and a phased array probe scanning track self-correcting method, which solve the problems in the prior art. The method is extremely suitable for the phased array nondestructive testing of the butt weld with the backing plate, the central point of the weld is intelligently identified by utilizing imaging characteristic information in the phased array testing process in the weld, the distance from the phased array probe to the center of the weld is obtained through coordinate conversion and calculation, the scanning track deviation of the phased array probe is obtained and then transmitted to a robot system for deviation rectification adjustment, and the self-correction function of the scanning track of the phased array probe is achieved.
The above object of the present invention is achieved by the following technical solutions:
a phased array probe scanning track self-correcting system comprises an industrial personal computer 1, a phased array ultrasonic nondestructive detector 2, a robot control cabinet 3, a six-axis robot 4, a quality inspection tool 5, a robot base 6, a phased array checking standard CSK-IA test block, a phased array checking standard CSK-IIA test block and a butt weld with a backing plate, wherein the six-axis robot 4 fixed on the robot base 6 clamps a phased array probe 10 to carry out ultrasonic sector scanning quality inspection on the butt weld with the backing plate, the phased array probe 10 transmits quality inspection information to the phased array ultrasonic nondestructive detector 2 in real time through a data line, the phased array ultrasonic nondestructive detector 2 transmits sector scanning information to the industrial personal computer 1, analyzes the internal state of the weld in real time, tracks and positions non-penetration defects inherent on two sides of the root of the weld in real time, and according to the centroid coordinates of the non-penetration defects inherent on the two sides on the non-penetration defect area on a sector scanning image, determining the L wave and the R wave of the phased array ultrasonic sound wave at the centroid of the inherent incomplete penetration defect area on two sides of the root of the welding seam, solving the distance S from the phased array probe 10 to the center of the welding seam under each frame of sector scanning image by constructing a solving model of the distance S from the phased array probe to the center of the welding seam, solving the transverse deviation between the scanning teaching track and the theoretical track of the phased array probe 10, feeding the transverse deviation back to the robot control cabinet 3, and eliminating the transverse deviation in real time through a control system to realize the intelligent track deviation correction in the scanning process of the phased array probe 10.
The quality inspection tool 5 comprises a CCD camera 9, a buffer spring 7, a phased array probe 10 and a connecting plate 11, the CCD camera 9 monitors the surface state of the butt welding seam of the belt backing plate visually, the CCD camera 9 and the phased array probe 10 are respectively arranged at two sides of a connecting plate 11, one end of a buffer spring 7 is connected with the connecting plate 11, the other end is connected with a flange 8, the quality inspection tool 5 is integrally fixed at the front end of the six-axis robot 4 through the flange 8 at the upper end of the connecting plate 11, when the quality inspection is carried out on the butt welding seam with the backing plate, the phased array probe 10 is tightly attached to the surface of the base metal and generates certain pressure, is positioned at one side of the welding seam and is scanned along the direction of the welding seam, the buffer spring 7 ensures that the phased array probe 10 is not damaged by rigid collision, meanwhile, the phased array probe 10 and the butt weld with the backing plate are always well coupled in the quality inspection process, and the reliability of the phased array quality inspection result is ensured.
The phased array probe 10 of the quality inspection tool 5 is composed of an inclined wedge block and a phased array ultrasonic transducer, the phased array ultrasonic transducer is installed and fixed on an inclined plane of the inclined wedge block, the inclined wedge block is fixed on a connecting plate 11, the phased array probe 10 is located at the front end of the six-axis robot 4, and quality inspection of the interior of the butt-joint weld with the backing plate is achieved through movement of each joint of the six-axis robot 4.
When the phased array probe 10 carries out quality inspection along the direction of a welding seam on the left side or the right side of a butt welding seam with a backing plate, reflection echoes always exist in inherent non-penetration defects on two sides of the root of the welding seam, the inherent non-penetration defects on two sides exist on a sector scanning image, each pixel point of the sector scanning image in an imaging area of the phased array quality inspection analysis software of the industrial personal computer 1 maps different sound beams sent by the corresponding phased array probe, the distance S from the phased array probe 10 to the center of the welding seam under each frame of sector scanning image is obtained by constructing an obtaining model of the distance S from the phased array probe to the center of the welding seam according to inherent non-penetration defect area centroid pixels on two sides of the root of the welding seam on the sector scanning image, and the transverse deviation of a teaching track and a theoretical track scanned by the phased array probe 10 is obtained, and then the data is fed back to the robot control cabinet 3, and the transverse deviation is eliminated in real time through a control system, so that the intelligent track correction in the scanning process of the phased array probe 10 is realized.
The invention also aims to provide a self-correcting method for scanning tracks of a phased array probe, which comprises the following steps:
step 1, calibrating a phased array probe, and automatically updating calibration parameters into built-in parameters;
step 2, a six-axis robot clamps a phased array probe to carry out ultrasonic sector scanning quality inspection on a butt-jointed seam with a backing plate, a phased array ultrasonic nondestructive detector transmits sector scanning information to an industrial personal computer, the industrial personal computer tracks and positions inherent non-penetration defects on two sides of the root of the seam in real time by using a sector scanning image defect automatic identification theory and algorithm, determines phased array ultrasonic sound waves L and R waves at the centroid of the inherent non-penetration defects on two sides of the root of the seam according to the centroid coordinates of the inherent non-penetration defects on the sector scanning image, and calculates the distance S from the phased array probe to the center of the seam under each frame of sector scanning image by constructing a calculation model of the distance S from the phased array probe to the center of the seam;
and 3, solving the transverse deviation between the scanning teaching track of the phased array probe and the theoretical track, and transmitting the six-axis robot system to eliminate the transverse deviation in real time, so that the purpose of self-correcting the scanning track of the phased array probe is achieved.
The phased array probe calibration in the step 1 specifically comprises the following steps:
step 1-1, scanning a phased array probe to check the cambered surface part of a standard CSK-IA test block for sound velocity calibration;
step 1-2, scanning a phased array probe to check a standard CSK-IA test block of the phased array, and measuring a transverse hole with the depth of 15mm and the diameter of phi 1.5mm to perform delay calibration;
and step 1-3, scanning a phased array checking standard CSK-IIA test block by a phased array probe, and measuring the echo of the artificial defect to carry out distance-radiation (TCG) curve calibration.
The process of solving the distance S from the phased array probe to the center of the weld joint in the step 2 is as follows:
2-1, constructing an automatic identification theory and algorithm of the defects of the incomplete penetration defect phased array sector scanning image on two sides of the root of the welding seam;
step 2-2, passing through the centroid coordinates (x) of the regions of the two sides of the root of the welding seam where the defects are not completely weldedk left,yk left) And (x)k right side,yk right side) Determining the L wave and the R wave of the phased array ultrasonic sound wave at the centroid of the inherent incomplete penetration defect area at the two sides of the root of the welding seam;
and 2-3, calculating the distance S from the phased array probe to the center of the welding seam through the L wave and the R wave of the phased array ultrasonic sound wave at the centroid of the incomplete penetration defect area on two sides of the root of the welding seam.
2-1, constructing an automatic recognition theory and algorithm for the defects of the incomplete penetration defect phased array sector scanning image on two sides of the root of the welding seam, specifically:
step 2-1-1, background difference denoising:
background difference denoising is carried out to remove noise signals of the sector scanning image, matrix operation is carried out on each frame of original image and the background to obtain a new image after background difference denoising, a background model is constructed, and difference operation is carried out on each frame of current image and the background model:
newpick(x,y,k)＝|fk(x,y,k)-fb(x,y,k)| (1)
in the formula:
newpick(x, y, k): performing background difference operation on the image matrix;
fk(x, y, k): a k frame image matrix;
fb(x, y, k): calculating a background model matrix by the background difference of the kth frame;
since the noise changes at any moment during the quality inspection, fb(x, y, k) must be updated iteratively to achieve good denoising effect:
fb(x,y,k)＝fk(x,y,k)×ρ+fb(x,y,k-1)×(1-ρ) (2)
in the formula:
fb(x, y, k-1): a background model matrix is operated by the background difference of the (k-1) th frame;
ρ: taking rho as 0.5, wherein rho is more than 0 and less than 1;
step 2-1-2, median filtering:
median filtering utilizes a sliding window of pixel gray value ordering, replacing the original gray value of the center pixel of the window with its median value:
gk(x,y,k)＝med{newpick(x-m,y-n,k),(m,n∈W)} (3)
in the formula:
gk(x, y, k): performing median filtering on the k frame image;
newpick(x, y, k): performing median filtering on the k frame image and performing background difference operation on the k frame image;
w: a two-dimensional data sequence template, typically a 3 x 3, 5 x 5 region two-dimensional data sequence, employing a 3 x 3 filter template;
step 2-1-3, dynamic threshold value image binarization:
converting the gray image into a black-and-white image based on dynamic threshold binarization according to gray values of different pixel points on the image;
step 2-1-4, morphological closed operation and edge smoothing:
the purpose of morphological image processing is to eliminate narrow and discontinuous ravines, fine holes and incomplete contour:
np＝np.ones{(5,5),np.unit8} (4)
cpick(x,y,k)＝cv2.morpho log yEx{bpick(x,y,k),cv2.MORPH_CLOSE,np} (5)
in the formula:
np: constructing a convolution kernel;
cpick(x, y, k): the image after the morphological processing of the kth frame;
bpick(x, y, k): the k frame of image after the dynamic threshold value image binaryzation;
cv2.morph _ CLOSE: represents a closed operation;
step 2-1-5, connected domain marking:
Ilabel＝bwlabel{cpick(x,y,k)} (6)
in the formula:
cpick(x, y, k): the image after the morphological processing of the kth frame;
step 2-1-6, calculating the centroid of the connected region:
(x,y)＝regionprops(Ilabel,'centroid') (7)
step 2-1-7, tracking a defect target and automatically positioning a defect centroid coordinate:
the positions of the inherent non-penetration defects on the two sides of the root of the welding seam are relatively fixed in the scanning process of the probe, the inherent non-penetration defects on the two sides of the root of the welding seam have the same mode or track in an image sequence, and other defects and noise do not have the characteristics, so the target tracking of the inherent non-penetration defects on the two sides of the root of the welding seam can be carried out by utilizing the characteristics, the inherent non-penetration defects on the two sides of the root of the welding seam are positioned by the target tracking, then the centroid calculation result of the communicating region in the step 2-1-6 is utilized to determine the centroid coordinates (x) of the non-penetration defects on the sector scanning image of thek left,yk left) And (x)k right side,yk right side)。
And 2-3, calculating the distance S from the phased array probe to the center of the welding seam, and specifically comprising the following steps:
step 2-3-1, constructing a calculation model of the distance S from the phased array probe to the center of the welding seam, wherein the model is built according to the section of the emitting wave surface of the phased array ultrasonic transducer, the phased array probe is attached to the surface of the parent metal on one side of the welding seam, coordinates O-XYZ are established by taking the central point O of the phased array ultrasonic transducer as the origin of coordinates, the direction perpendicular to the surface of the parent metal is the positive direction of a Z axis downwards, the direction from the phased array ultrasonic transducer to the center of the welding seam is the positive direction of a Y axis, the scanning direction of the phased array probe is the positive direction of an X axis, and the distance from the central point;
step 2-3-2, determining the incident angle theta L of the ultrasonic sound waves L and R of the centroid phased array ultrasonic sound waves of the region without penetration defects inherent on the two sides of the root of the welding seam1And θ R1：
Figure BDA0002928103780000061
Figure BDA0002928103780000062
In the formula:
cw: the propagation speed of ultrasonic waves in the wedge-shaped block;
cb: the propagation speed of the ultrasonic wave in the workpiece to be detected;
θL2: refraction angle of phased array ultrasonic acoustic wave L wave;
θR2: refraction angle of phased array ultrasonic sound wave R wave;
step 2-3-3: calculating the incidence point L from the central point O of the phased array ultrasonic transducer to the phased array ultrasonic sound wave L wave and R wave1And r1Distance L of1And R1：
Figure BDA0002928103780000071
Figure BDA0002928103780000072
In the formula:
h: scanning the distance from the central point O of the phased array ultrasonic transducer to the surface of the parent metal;
step 2-3-4, calculating incident points L of phased array ultrasonic sound waves L and R1And r1Distance L to centroid of region with incomplete penetration defect inherent to both sides of weld root2And R2：
Figure BDA0002928103780000073
Figure BDA0002928103780000074
Figure BDA0002928103780000075
Figure BDA0002928103780000076
Figure BDA0002928103780000077
Figure BDA0002928103780000078
Substituting equations (12), (13), (14) and (15) into equations (16) and (17) yields:
Figure BDA0002928103780000079
Figure BDA00029281037800000710
in the formula:
Figure BDA00029281037800000711
the phased array ultrasonic sound wave L wave in the inclined wedge-shaped block is from the central point O of the phased array ultrasonic transducer to the incident point L1The time of (d);
TL: the sum of the emission time of the centroid of the area with the inherent incomplete penetration defect of the left side of the root of the welding seam from the central point O of the phased array ultrasonic transducer to the L wave of the phased array ultrasonic sound wave and the receiving time of the reflected wave;
Figure BDA0002928103780000081
from incident point L of phased array ultrasonic sound wave L wave in workpiece1The time to the centroid of the inherent incomplete penetration defect area at the left side of the root of the weld;
Figure BDA0002928103780000082
the phased array ultrasonic sound wave R wave in the inclined wedge-shaped block is from the central point O of the phased array ultrasonic transducer to the incident point R1The time of (d);
TR: the sum of the emission time of the phased array ultrasonic sound wave R wave from the central point O of the phased array ultrasonic transducer to the centroid of the inherent incomplete penetration defect area on the right side of the root of the welding seam and the receiving time of the reflected wave;
Figure BDA0002928103780000083
from incident point R of phased array ultrasonic sound wave R wave in workpiece1The time to the centroid of the inherent incomplete penetration defect area on the right side of the root of the welding seam;
step 2-3-5, calculating the distance S from the phased array probe to the center of the welding seam
Calculating the centroid l of the region of the two sides of the root of the welding seam with the incomplete penetration defect2And the abscissa of r2 in the O-YZ coordinate system:
Yk left＝L2*sinθL2+L1*sinθL1 (20)
Yk right side＝R2*sinθR2+R1*sinθR1 (21)
Figure BDA0002928103780000084
Substituting equations (20) and (21) into equation (22) yields:
Figure BDA0002928103780000085
and 3, solving the transverse deviation of the scanning track of the phased array probe, which specifically comprises the following steps:
step 3-1, calculating the transverse deviation S of the phased array probe scanning teaching track and the theoretical track:
▽S＝S*-S (24) formula wherein:
S*: theoretical distance from the phased array probe to the center of the weld;
and 3-2, transmitting the actual transverse deviation S from the phase control array probe to the center of the weld joint to a robot system in real time, and eliminating the deviation.
The invention has the beneficial effects that:
1. the method achieves automatic recognition and tracking of inherent incomplete penetration defects on two sides of the root of the welding seam through a sector scanning image defect automatic recognition theory and algorithm, calculates the actual transverse coordinate of the center of the welding seam through coordinate conversion, calculates the transverse deviation between a phased array probe scanning teaching track and a theoretical track, and feeds the deviation back to a robot system in real time without an external sensor, so that the purpose of self-correcting of the phased array probe scanning track is achieved.
2. The technical defects that a phased array probe scanning track deviation correcting technology based on image processing visual guidance and a phased array probe scanning track deviation correcting technology based on laser welding seam tracking are difficult to find tracking characteristic points are overcome, and the problem of scanning track deviation correcting of the phased array probe with the backing plate butt welding seam is effectively solved.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the invention without limiting the invention.
FIG. 1 is a schematic structural diagram of a phased array probe scanning track self-correcting system of the present invention;
FIG. 2 is a schematic structural diagram of a quality inspection tool according to the present invention;
FIG. 3 is a schematic view of acoustic beam propagation for detecting incomplete penetration of butt weld of the backing plate according to the present invention;
FIG. 4 is a schematic diagram of a binarization processing process of a dynamic threshold image according to the present invention;
FIG. 5 is a schematic diagram of a defect target tracking and defect centroid coordinate autonomous location process of the present invention;
FIG. 6 is a schematic view of sector scan imaging of the present invention;
FIG. 7 is a model of the phased array probe to weld center distance S of the present invention.
In the figure: 1. an industrial personal computer; 2. a phased array ultrasonic nondestructive detector; 3. a robot control cabinet; 4. a six-axis robot; 5. a quality inspection tool; 6. a robot base; 7. a buffer spring; 8. a flange; 9. a CCD camera; 10. a phased array probe; 11. a connecting plate.
Detailed Description
The details of the present invention and its embodiments are further described below with reference to the accompanying drawings.
Referring to fig. 1 to 7, the system and method for automatically correcting the scanning track of the phased array probe of the invention are characterized in that defect images in the phased array ultrasonic nondestructive detection sector scanning information correspond to actual defects one by one, the defect images in the sector scanning can accurately reflect the information of the depth, the size, the position and the like of the actual defects, the inherent incomplete penetration defects at two sides of the butt welding seam root with a backing plate can generate continuous inherent echoes when the phased array probe scans along the welding seam, continuous incomplete penetration defect detection images with relatively fixed positions appear on the sector scanning images, the inherent incomplete penetration defects at two sides of the welding seam root can be automatically identified and tracked through the established automatic identification theory and algorithm of the sector scanning image defects, the transverse coordinate of the center of the welding seam is positioned, the transverse deviation between the scanning teaching track of the phased array probe and the theoretical track is solved, and a six-axis robot system is transmitted to eliminate in real time, therefore, intelligent track deviation correction in the scanning process of the phased array probe is realized.
Referring to fig. 1, the phased array probe scanning track self-correcting system comprises an industrial personal computer 1, a phased array ultrasonic nondestructive detector 2, a robot control cabinet 3, a six-axis robot 4, a quality inspection tool 5, a robot base 6, a phased array checking standard CSK-IA test block, a phased array checking standard CSK-IIA test block and a butt weld with a backing plate, wherein the six-axis robot 4 fixed on the robot base 6 clamps a phased array probe 10 to carry out ultrasonic sector scanning quality inspection on the butt weld with the backing plate, the phased array probe 10 transmits quality inspection information to the phased array ultrasonic nondestructive detector 2 in real time through a data line, the phased array ultrasonic nondestructive detector 2 transmits sector scanning information to the industrial personal computer 1 to analyze the internal state of the butt weld in real time, tracks and positions the inherent incomplete penetration defects at the root two sides of the butt weld in real time, and takes shape and center coordinates of the incomplete penetration defects at the two sides on a sector scanning image according to the incomplete penetration defect area, determining the L wave and the R wave of the phased array ultrasonic sound wave at the centroid of the inherent incomplete penetration defect area on two sides of the root of the welding seam, solving the distance S from the phased array probe 10 to the center of the welding seam under each frame of sector scanning image by constructing a solving model of the distance S from the phased array probe to the center of the welding seam, solving the transverse deviation between the scanning teaching track and the theoretical track of the phased array probe 10, feeding the transverse deviation back to the robot control cabinet 3, and eliminating the transverse deviation in real time through a control system to realize the intelligent track deviation correction in the scanning process of the phased array probe 10.
Referring to fig. 2, the quality inspection tool 5 includes a CCD camera 9, a buffer spring 7, a phased array probe 10 and a connecting plate 11, the CCD camera 9 monitors the surface state of the butt welding seam of the belt backing plate visually, the CCD camera 9 and the phased array probe 10 are respectively arranged at two sides of a connecting plate 11, one end of a buffer spring 7 is connected with the connecting plate 11, the other end is connected with a flange 8, the quality inspection tool 5 is integrally fixed at the front end of the six-axis robot 4 through the flange 8 at the upper end of the connecting plate 11, when the quality inspection is carried out on the butt welding seam with the backing plate, the phased array probe 10 is tightly attached to the surface of the base metal and generates certain pressure, is positioned at one side of the welding seam and is scanned along the direction of the welding seam, the buffer spring 7 ensures that the phased array probe 10 is not damaged by rigid collision, meanwhile, the phased array probe 10 and the butt weld with the backing plate are always well coupled in the quality inspection process, and the reliability of the phased array quality inspection result is ensured.
The phased array probe 10 of the quality inspection tool 5 is composed of an inclined wedge block and a phased array ultrasonic transducer, the phased array ultrasonic transducer is installed and fixed on an inclined plane of the inclined wedge block, the inclined wedge block is fixed on a connecting plate 11, the phased array probe 10 is located at the front end of the six-axis robot 4, and quality inspection of the interior of the butt-joint weld with the backing plate is achieved through movement of each joint of the six-axis robot 4.
Referring to fig. 3, a schematic diagram of sound beam propagation for detecting a lack of penetration defect of a butt weld with a backing plate is shown, a dotted line is a quality inspection phased array sound beam emitted by the phased array probe 10 in quality inspection on the left side of the weld, a solid line is a quality inspection phased array sound beam emitted by the phased array probe 10 in quality inspection on the right side of the weld, the phased array probe 10 performs quality inspection on the left side of the butt weld with the backing plate along the direction of the weld or performs quality inspection on the right side of the butt weld with the backing plate along the direction of the weld, reflection echoes always exist in the lack of penetration defect on both sides of the root of the weld within an effective distance, and the lack of penetration defect on both sides inherently exists on.
Referring to fig. 6, a schematic diagram of sector scanning imaging is shown, each pixel point of a sector scanning image maps different sound beams emitted by a corresponding phased array probe, L-wave and R-wave of phased array ultrasonic sound waves at the centroid of an unwelded defect area on both sides of the root of a weld on the sector scanning image are determined according to the centroid pixel points of the unwelded defect area on both sides of the root of the weld on the sector scanning image, a distance S from the phased array probe 10 to the center of the weld under each frame of the sector scanning image is obtained by constructing a model of the distance S from the phased array probe to the center of the weld, the lateral deviation between a teaching track and a theoretical track scanned by the phased array probe 10 is obtained and then fed back to a robot control cabinet 3, and the lateral deviation is eliminated in real time by a control system, so that the track intelligent deviation rectification in the scanning.
Referring to fig. 3 to 7, the method for automatically correcting the scanning track of the phased array probe comprises the following steps:
step 1, calibrating a phased array probe, and automatically updating calibration parameters into built-in parameters;
step 2, a six-axis robot clamps a phased array probe to carry out ultrasonic sector scanning quality inspection on a butt-jointed seam with a backing plate, a phased array ultrasonic nondestructive detector transmits sector scanning information to an industrial personal computer, the industrial personal computer tracks and positions inherent non-penetration defects on two sides of the root of the seam in real time by using a sector scanning image defect automatic identification theory and algorithm, determines phased array ultrasonic sound waves L and R waves at the centroid of the inherent non-penetration defects on two sides of the root of the seam according to the centroid coordinates of the inherent non-penetration defects on the sector scanning image, and calculates the distance S from the phased array probe to the center of the seam under each frame of sector scanning image by constructing a calculation model of the distance S from the phased array probe to the center of the seam;
and 3, solving the transverse deviation between the scanning teaching track of the phased array probe and the theoretical track, and transmitting the six-axis robot system to eliminate the transverse deviation in real time, so that the purpose of self-correcting the scanning track of the phased array probe is achieved.
The phased array probe calibration in the step 1 specifically comprises the following steps:
step 1-1, scanning a phased array probe to check the cambered surface part of a standard CSK-IA test block for sound velocity calibration;
step 1-2, scanning a phased array probe to check a standard CSK-IA test block of the phased array, and measuring a transverse hole with the depth of 15mm and the diameter of phi 1.5mm to perform delay calibration;
and step 1-3, scanning a phased array checking standard CSK-IIA test block by a phased array probe, and measuring the echo of the artificial defect to carry out distance-radiation (TCG) curve calibration.
The process of solving the distance S from the phased array probe to the center of the weld joint in the step 2 is as follows:
2-1, constructing an automatic identification theory and algorithm of the defects of the incomplete penetration defect phased array sector scanning image on two sides of the root of the welding seam;
step 2-2, passing through the centroid coordinates (x) of the regions of the two sides of the root of the welding seam where the defects are not completely weldedk left,yk left) And (x)k right side,yk right side) Determining the L wave and the R wave of the phased array ultrasonic sound wave at the centroid of the inherent incomplete penetration defect area at the two sides of the root of the welding seam;
and 2-3, calculating the distance S from the phased array probe to the center of the welding seam through the L wave and the R wave of the phased array ultrasonic sound wave at the centroid of the incomplete penetration defect area on two sides of the root of the welding seam.
2-1, constructing an automatic recognition theory and algorithm for the defects of the incomplete penetration defect phased array sector scanning image on two sides of the root of the welding seam, specifically:
step 2-1-1, background difference denoising:
background difference denoising is carried out to remove noise signals of the sector scanning image, matrix operation is carried out on each frame of original image and the background to obtain a new image after background difference denoising, a background model is constructed, and difference operation is carried out on each frame of current image and the background model:
newpick(x,y,k)＝|fk(x,y,k)-fb(x,y,k)| (1)
in the formula:
newpick(x, y, k): performing background difference operation on the image matrix;
fk(x, y, k): a k frame image matrix;
fb(x, y, k): calculating a background model matrix by the background difference of the kth frame;
since the noise changes at any moment during the quality inspection, fb(x, y, k) must be updated iteratively to achieve good denoising effect:
fb(x,y,k)＝fk(x,y,k)×ρ+fb(x,y,k-1)×(1-ρ) (2)
in the formula:
fb(x, y, k-1): a background model matrix is operated by the background difference of the (k-1) th frame;
ρ: taking rho as 0.5, wherein rho is more than 0 and less than 1;
step 2-1-2, median filtering:
median filtering utilizes a sliding window of pixel gray value ordering, replacing the original gray value of the center pixel of the window with its median value:
gk(x,y,k)＝med{newpick(x-m,y-n,k),(m,n∈W)} (3)
in the formula:
gk(x, y, k): performing median filtering on the k frame image;
newpick(x, y, k): performing median filtering on the k frame image and performing background difference operation on the k frame image;
w: a two-dimensional data sequence template, typically a 3 x 3, 5 x 5 region two-dimensional data sequence, employing a 3 x 3 filter template;
step 2-1-3, dynamic threshold value image binarization:
converting the gray image into a black-and-white image based on dynamic threshold binarization according to gray values of different pixel points on the image; the method specifically comprises the following steps: dividing each frame of image into a plurality of matrix blocks, firstly taking the mean value of the gray value of each matrix as an initial threshold value, dividing the block matrix into a part which is larger than the initial threshold value and a part which is smaller than the initial threshold value according to the initial threshold value, secondly obtaining the mean value of the gray value which is larger than the initial threshold value and the mean value of the gray value which is smaller than the initial threshold value, further taking the mean value of the gray value which is obtained by the obtained two parts of gray value as a new initial threshold value to divide the matrix block again until iteration converges, taking the threshold value which is obtained by the iteration converges as a total threshold value, giving the gray value which is larger than the total threshold value to 1 when the gray value of the block matrix is larger than the total threshold value, giving the gray value which is smaller than the;
step 2-1-4, morphological closed operation and edge smoothing:
the purpose of morphological image processing is to eliminate narrow and discontinuous ravines, fine holes and incomplete contour:
np＝np.ones{(5,5),np.unit8} (4)
cpick(x,y,k)＝cv2.morpho log yEx{bpick(x,y,k),cv2.MORPH_CLOSE,np} (5)
in the formula:
np: constructing a convolution kernel;
cpick(x, y, k): the image after the morphological processing of the kth frame;
bpick(x, y, k): the k frame of image after the dynamic threshold value image binaryzation;
cv2.morph _ CLOSE: represents a closed operation;
step 2-1-5, connected domain marking:
Ilabel＝bwlabel{cpick(x,y,k)} (6)
in the formula:
cpick(x, y, k): the image after the morphological processing of the kth frame;
step 2-1-6, calculating the centroid of the connected region:
(x,y)＝regionprops(Ilabel,'centroid') (7)
step 2-1-7, tracking a defect target and automatically positioning a defect centroid coordinate:
the positions of the inherent non-penetration defects on the two sides of the root of the welding seam are relatively fixed in the scanning process of the probe, the inherent non-penetration defects on the two sides of the root of the welding seam have the same mode or track in an image sequence, and other defects and noise do not have the characteristics, so the target tracking of the inherent non-penetration defects on the two sides of the root of the welding seam can be carried out by utilizing the characteristics, the inherent non-penetration defects on the two sides of the root of the welding seam are positioned by the target tracking, then the centroid calculation result of the communicating region in the step 2-1-6 is utilized to determine the centroid coordinates (x) of the non-penetration defects on the sector scanning image of thek left,yk left) And (x)k right side,yk right side) The method specifically comprises the following steps: determining target templates of the inherent incomplete penetration defects on the two sides of the root of each frame of welding seam according to the characteristics of the inherent incomplete penetration defects on the two sides of the root of each frame of welding seam in a sector scanning image, establishing z connected region candidate template histograms through the z connected regions obtained in the step 2-1-5, further calculating the similarity between the target template and the z connected region candidate templates by using a Bhattacharyya function to obtain the offset between the target template and the candidate templates, considering the connected region as an incomplete penetration defect region to be tracked when the offset is smaller than a set threshold, and determining the centroid coordinates (x) of the incomplete penetration defects on the two sides of the root of each frame of welding seam in the sector scanning image by using the centroid calculation result of the connected regions in the step 2-1-6k left,yk left) And (x)k right side,yk right side)。
And 2-3, calculating the distance S from the phased array probe to the center of the welding seam, and specifically comprising the following steps:
step 2-3-1, constructing a calculation model of the distance S from the phased array probe to the center of the welding seam, wherein the model is built according to the section of the emitting wave surface of the phased array ultrasonic transducer, the phased array probe is attached to the surface of the parent metal on one side of the welding seam, coordinates O-XYZ are established by taking the central point O of the phased array ultrasonic transducer as the origin of coordinates, the direction perpendicular to the surface of the parent metal is the positive direction of a Z axis downwards, the direction from the phased array ultrasonic transducer to the center of the welding seam is the positive direction of a Y axis, the scanning direction of the phased array probe is the positive direction of an X axis, and the distance from the central point;
step 2-3-2, determining the incident angle theta L of the ultrasonic sound waves L and R of the centroid phased array ultrasonic sound waves of the region without penetration defects inherent on the two sides of the root of the welding seam1And θ R1：
Figure BDA0002928103780000151
Figure BDA0002928103780000152
In the formula:
cw: the propagation speed of ultrasonic waves in the wedge-shaped block;
cb: the propagation speed of the ultrasonic wave in the workpiece to be detected;
θL2: refraction angle of phased array ultrasonic acoustic wave L wave;
θR2: refraction angle of phased array ultrasonic sound wave R wave;
step 2-3-3: calculating the incidence point L from the central point O of the phased array ultrasonic transducer to the phased array ultrasonic sound wave L wave and R wave1And r1Distance L of1And R1：
Figure BDA0002928103780000153
Figure BDA0002928103780000154
In the formula:
h: scanning the distance from the central point O of the phased array ultrasonic transducer to the surface of the parent metal;
step 2-3-4, calculating incident points L of phased array ultrasonic sound waves L and R1And r1Distance L to centroid of region with incomplete penetration defect inherent to both sides of weld root2And R2：
Figure BDA0002928103780000161
Figure BDA0002928103780000162
Figure BDA0002928103780000163
Figure BDA0002928103780000164
Figure BDA0002928103780000165
Figure BDA0002928103780000166
Substituting equations (12), (13), (14) and (15) into equations (16) and (17) yields:
Figure BDA0002928103780000167
Figure BDA0002928103780000168
in the formula:
Figure BDA0002928103780000169
the phased array ultrasonic sound wave L wave in the inclined wedge-shaped block is from the central point O of the phased array ultrasonic transducer to the incident point L1The time of (d);
TL: emitting time of phased array ultrasonic sound wave L wave from central point O of phased array ultrasonic transducer to centroid of area with incomplete penetration defect on left side of root of welding seamAnd the sum of the reflected wave reception times;
Figure BDA00029281037800001610
from incident point L of phased array ultrasonic sound wave L wave in workpiece1The time to the centroid of the inherent incomplete penetration defect area at the left side of the root of the weld;
Figure BDA00029281037800001611
the phased array ultrasonic sound wave R wave in the inclined wedge-shaped block is from the central point O of the phased array ultrasonic transducer to the incident point R1The time of (d);
TR: the sum of the emission time of the phased array ultrasonic sound wave R wave from the central point O of the phased array ultrasonic transducer to the centroid of the inherent incomplete penetration defect area on the right side of the root of the welding seam and the receiving time of the reflected wave;
Figure BDA00029281037800001612
from incident point R of phased array ultrasonic sound wave R wave in workpiece1The time to the centroid of the inherent incomplete penetration defect area on the right side of the root of the welding seam;
step 2-3-5, calculating the distance S from the phased array probe to the center of the welding seam
Calculating the centroid l of the region of the two sides of the root of the welding seam with the incomplete penetration defect2And the abscissa of r2 in the O-YZ coordinate system:
Yk left＝L2*sinθL2+L1*sinθL1 (20)
Yk right side＝R2*sinθR2+R1*sinθR1 (21)
Figure BDA0002928103780000171
Substituting equations (20) and (21) into equation (22) yields:
Figure BDA0002928103780000172
and 3, solving the transverse deviation of the scanning track of the phased array probe, which specifically comprises the following steps:
step 3-1, calculating the transverse deviation S of the phased array probe scanning teaching track and the theoretical track:
▽S＝S*-S (24) formula wherein:
S*: theoretical distance from the phased array probe to the center of the weld;
and 3-2, transmitting the actual transverse deviation S from the phase control array probe to the center of the weld joint to a robot system in real time, and eliminating the deviation.
The above description is only a preferred example of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like of the present invention shall be included in the protection scope of the present invention.

Claims (10)

1. A phased array probe scanning track self-correcting system is characterized by comprising an industrial personal computer (1), a phased array ultrasonic nondestructive detector (2), a robot control cabinet (3), a six-axis robot (4), a quality inspection tool (5), a robot base (6), a phased array checking standard CSK-IA test block, a phased array checking standard CSK-IIA test block and a butt weld with a backing plate, wherein the six-axis robot (4) fixed on the robot base (6) clamps a phased array probe (10) to carry out ultrasonic sector scanning quality inspection on the butt weld with the backing plate, the phased array probe (10) transmits quality inspection information to the phased array ultrasonic nondestructive detector (2) in real time through a data line, the phased array ultrasonic nondestructive detector (2) transmits the sector scanning information to the industrial personal computer (1), analyzes the internal state of the weld in real time, tracks and positions inherent non-penetration defects on two sides of the root of the weld in real time, according to the centroid coordinates of the unwelded defect area of the unwelded defects on the two sides of the sector scanning image, determining the L wave and the R wave of the phased array ultrasonic sound wave at the centroid of the unwelded defect area on the two sides of the root of the welding seam, solving the distance S from the phased array probe (10) to the center of the welding seam under each frame of sector scanning image by constructing a solving model of the distance S from the phased array probe to the center of the welding seam, solving the transverse deviation between the teaching track and the theoretical track scanned by the phased array probe (10), feeding back to the robot control cabinet (3), eliminating the transverse deviation in real time through a control system, and realizing intelligent deviation correction of the track in the scanning process of the phased array probe (10).
2. The phased array probe scanning track self-correction system according to claim 1, characterized in that: the quality inspection tool (5) comprises a CCD camera (9), a buffer spring (7), a phased array probe (10) and a connecting plate (11), wherein the CCD camera (9) visually monitors the surface state of the butt-joint weld joint with the backing plate, the CCD camera (9) and the phased array probe (10) are respectively arranged on two sides of the connecting plate (11), one end of the buffer spring (7) is connected with the connecting plate (11), the other end of the buffer spring is connected with a flange (8), the quality inspection tool (5) is integrally fixed at the front end of the six-axis robot (4) through the flange (8) at the upper end of the connecting plate (11), the phased array probe (10) tightly clings to the surface of a parent metal and generates certain pressure when the butt-joint weld joint with the backing plate is inspected, the phased array probe is positioned on one side of the weld joint and is scanned along the direction of the weld joint, the buffer spring (7) ensures that the phased array probe (10) is not damaged by rigid collision, and simultaneously the butt-joint, and the reliability of the phased array quality inspection result is ensured.
3. The phased array probe scanning track self-correction system according to claim 2, characterized in that: the phased array probe (10) of the quality inspection tool (5) is composed of an inclined wedge block and a phased array ultrasonic transducer, the phased array ultrasonic transducer is installed and fixed on an inclined plane of the inclined wedge block, the inclined wedge block is fixed on a connecting plate (11), the phased array probe (10) is located at the front end of a six-axis robot (4), and quality inspection of the interior of a butt-joint weld with a backing plate is achieved through movement of joints of the six-axis robot (4).
4. The phased array probe scanning track self-correction system according to claim 3, characterized in that: when the phased array probe (10) performs quality inspection along the direction of a welding seam on the left side or the right side of a butt welding seam with a backing plate, reflection echoes always exist in inherent non-penetration defects on two sides of the root of the welding seam, the inherent non-penetration defects on two sides exist on a sector scanning image, each pixel point of the sector scanning image in an imaging area of phased array quality inspection analysis software of the industrial personal computer (1) maps different sound beams sent by the corresponding phased array probe, the L wave and the R wave of the phased array ultrasonic sound wave at the centroid of the inherent non-penetration defect area on two sides of the root of the welding seam are determined according to the inherent non-penetration defect area centroid pixel points on two sides of the root of the welding seam on the sector scanning image, the distance S from the phased array probe (10) to the center of the welding seam under each frame of the sector scanning image is obtained by constructing an obtaining model of the distance S from the phased array probe to the center of the welding seam, and the transverse deviation of a teaching, and then the data is fed back to the robot control cabinet (3), and the transverse deviation is eliminated in real time through a control system, so that the intelligent track deviation correction in the scanning process of the phased array probe (10) is realized.
5. A phased array probe scanning track self-correcting method is characterized by comprising the following steps: the method comprises the following steps:
step 1, calibrating a phased array probe, and automatically updating calibration parameters into built-in parameters;
step 2, a six-axis robot clamps a phased array probe to carry out ultrasonic sector scanning quality inspection on a butt-jointed seam with a backing plate, a phased array ultrasonic nondestructive detector transmits sector scanning information to an industrial personal computer, the industrial personal computer tracks and positions inherent non-penetration defects on two sides of the root of the seam in real time by using a sector scanning image defect automatic identification theory and algorithm, determines phased array ultrasonic sound waves L and R waves at the centroid of the inherent non-penetration defects on two sides of the root of the seam according to the centroid coordinates of the inherent non-penetration defects on the sector scanning image, and calculates the distance S from the phased array probe to the center of the seam under each frame of sector scanning image by constructing a calculation model of the distance S from the phased array probe to the center of the seam;
and 3, solving the transverse deviation between the scanning teaching track of the phased array probe and the theoretical track, and transmitting the six-axis robot system to eliminate the transverse deviation in real time, so that the purpose of self-correcting the scanning track of the phased array probe is achieved.
6. The phased array probe scanning track self-correcting method according to claim 5, characterized in that: the phased array probe calibration in the step 1 specifically comprises the following steps:
step 1-1, scanning a phased array probe to check the cambered surface part of a standard CSK-IA test block for sound velocity calibration;
step 1-2, scanning a phased array probe to check a standard CSK-IA test block of the phased array, and measuring a transverse hole with the depth of 15mm and the diameter of phi 1.5mm to perform delay calibration;
and step 1-3, scanning a phased array checking standard CSK-IIA test block by a phased array probe, and measuring the echo of the artificial defect to carry out distance-radiation (TCG) curve calibration.
7. The phased array probe scanning track self-correcting method according to claim 5, characterized in that: the process of solving the distance S from the phased array probe to the center of the weld joint in the step 2 is as follows:
2-1, constructing an automatic identification theory and algorithm of the defects of the incomplete penetration defect phased array sector scanning image on two sides of the root of the welding seam;
step 2-2, passing through the centroid coordinates (x) of the regions of the two sides of the root of the welding seam where the defects are not completely weldedk left,yk left) And (x)k right side,yk right side) Determining the L wave and the R wave of the phased array ultrasonic sound wave at the centroid of the inherent incomplete penetration defect area at the two sides of the root of the welding seam;
and 2-3, calculating the distance S from the phased array probe to the center of the welding seam through the L wave and the R wave of the phased array ultrasonic sound wave at the centroid of the incomplete penetration defect area on two sides of the root of the welding seam.
8. The phased array probe scanning track self-correcting method according to claim 7, characterized in that: 2-1, constructing an automatic recognition theory and algorithm for the defects of the incomplete penetration defect phased array sector scanning image on two sides of the root of the welding seam, specifically:
step 2-1-1, background difference denoising:
background difference denoising is carried out to remove noise signals of the sector scanning image, matrix operation is carried out on each frame of original image and the background to obtain a new image after background difference denoising, a background model is constructed, and difference operation is carried out on each frame of current image and the background model:
newpick(x,y,k)＝|fk(x,y,k)-fb(x,y,k)| (1)
in the formula:
newpick(x, y, k): performing background difference operation on the image matrix;
fk(x, y, k): a k frame image matrix;
fb(x, y, k): calculating a background model matrix by the background difference of the kth frame;
since the noise changes at any moment during the quality inspection, fb(x, y, k) must be updated iteratively to achieve good denoising effect:
fb(x,y,k)＝fk(x,y,k)×ρ+fb(x,y,k-1)×(1-ρ) (2)
in the formula:
fb(x, y, k-1): a background model matrix is operated by the background difference of the (k-1) th frame;
ρ: taking rho as 0.5, wherein rho is more than 0 and less than 1;
step 2-1-2, median filtering:
median filtering utilizes a sliding window of pixel gray value ordering, replacing the original gray value of the center pixel of the window with its median value:
gk(x,y,k)＝med{newpick(x-m,y-n,k),(m,n∈W)} (3)
in the formula:
gk(x, y, k): performing median filtering on the k frame image;
newpick(x, y, k): performing median filtering on the k frame image and performing background difference operation on the k frame image;
w: a two-dimensional data sequence template, typically a 3 x 3, 5 x 5 region two-dimensional data sequence, employing a 3 x 3 filter template;
step 2-1-3, dynamic threshold value image binarization:
converting the gray image into a black-and-white image based on dynamic threshold binarization according to gray values of different pixel points on the image;
step 2-1-4, morphological closed operation and edge smoothing:
the purpose of morphological image processing is to eliminate narrow and discontinuous ravines, fine holes and incomplete contour:
np＝np.ones{(5,5),np.unit8} (4)
cpick(x,y,k)＝cv2.morphologyEx{bpick(x,y,k),cv2.MORPH_CLOSE,np} (5)
in the formula:
np: constructing a convolution kernel;
cpick(x, y, k): the image after the morphological processing of the kth frame;
bpick(x, y, k): the k frame of image after the dynamic threshold value image binaryzation;
cv2.morph _ CLOSE: represents a closed operation;
step 2-1-5, connected domain marking:
Ilabel＝bwlabel{cpick(x,y,k)} (6)
in the formula:
cpick(x, y, k): the image after the morphological processing of the kth frame;
step 2-1-6, calculating the centroid of the connected region:
(x,y)＝regionprops(Ilabel,'centroid') (7)
step 2-1-7, tracking a defect target and automatically positioning a defect centroid coordinate:
the positions of the inherent non-penetration defects on the two sides of the root of the welding seam are relatively fixed in the scanning process of the probe, the inherent non-penetration defects on the two sides of the root of the welding seam have the same mode or track in an image sequence, and other defects and noise do not have the characteristics, so the target tracking of the inherent non-penetration defects on the two sides of the root of the welding seam can be carried out by utilizing the characteristics, the inherent non-penetration defects on the two sides of the root of the welding seam are positioned by the target tracking, then the centroid calculation result of the communicating region in the step 2-1-6 is utilized to determine the centroid coordinates (x) of the non-penetration defects on the sector scanning image of thek left,yk left) And (x)k right side,yk right side)。
9. The phased array probe scanning track self-correcting method according to claim 7, characterized in that: and 2-3, calculating the distance S from the phased array probe to the center of the welding seam, and specifically comprising the following steps:
step 2-3-1, constructing a calculation model of the distance S from the phased array probe to the center of the welding seam, wherein the model is built according to the section of the emitting wave surface of the phased array ultrasonic transducer, the phased array probe is attached to the surface of the parent metal on one side of the welding seam, coordinates O-XYZ are established by taking the central point O of the phased array ultrasonic transducer as the origin of coordinates, the direction perpendicular to the surface of the parent metal is the positive direction of a Z axis downwards, the direction from the phased array ultrasonic transducer to the center of the welding seam is the positive direction of a Y axis, the scanning direction of the phased array probe is the positive direction of an X axis, and the distance from the central point;
step 2-3-2, determining the incident angle theta L of the ultrasonic sound waves L and R of the centroid phased array ultrasonic sound waves of the region without penetration defects inherent on the two sides of the root of the welding seam1And θ R1：
Figure FDA0002928103770000051
Figure FDA0002928103770000052
In the formula:
cw: the propagation speed of ultrasonic waves in the wedge-shaped block;
cb: the propagation speed of the ultrasonic wave in the workpiece to be detected;
θL2: refraction angle of phased array ultrasonic acoustic wave L wave;
θR2: refraction angle of phased array ultrasonic sound wave R wave;
step 2-3-3: calculating the incidence point L from the central point O of the phased array ultrasonic transducer to the phased array ultrasonic sound wave L wave and R wave1And r1Distance L of1And R1：
Figure FDA0002928103770000061
Figure FDA0002928103770000062
In the formula:
h: scanning the distance from the central point O of the phased array ultrasonic transducer to the surface of the parent metal;
step 2-3-4, calculating incident points L of phased array ultrasonic sound waves L and R1And r1Distance L to centroid of region with incomplete penetration defect inherent to both sides of weld root2And R2：
Figure FDA0002928103770000063
Figure FDA0002928103770000064
Figure FDA0002928103770000065
Figure FDA0002928103770000066
Figure FDA0002928103770000067
Figure FDA0002928103770000068
Substituting equations (12), (13), (14) and (15) into equations (16) and (17) yields:
Figure FDA0002928103770000069
Figure FDA00029281037700000610
in the formula:
Figure FDA0002928103770000071
the phased array ultrasonic sound wave L wave in the inclined wedge-shaped block is from the central point O of the phased array ultrasonic transducer to the incident point L1The time of (d);
TL: the sum of the emission time of the centroid of the area with the inherent incomplete penetration defect of the left side of the root of the welding seam from the central point O of the phased array ultrasonic transducer to the L wave of the phased array ultrasonic sound wave and the receiving time of the reflected wave;
Figure FDA0002928103770000072
from incident point L of phased array ultrasonic sound wave L wave in workpiece1The time to the centroid of the inherent incomplete penetration defect area at the left side of the root of the weld;
Figure FDA0002928103770000073
the phased array ultrasonic sound wave R wave in the inclined wedge-shaped block is from the central point O of the phased array ultrasonic transducer to the incident point R1The time of (d);
TR: the sum of the emission time of the phased array ultrasonic sound wave R wave from the central point O of the phased array ultrasonic transducer to the centroid of the inherent incomplete penetration defect area on the right side of the root of the welding seam and the receiving time of the reflected wave;
Figure FDA0002928103770000074
from incident point R of phased array ultrasonic sound wave R wave in workpiece1The time to the centroid of the inherent incomplete penetration defect area on the right side of the root of the welding seam;
step 2-3-5, calculating the distance S from the phased array probe to the center of the welding seam
Calculating the centroid l of the region of the two sides of the root of the welding seam with the incomplete penetration defect2And the abscissa of r2 in the O-YZ coordinate system:
Yk left＝L2*sinθL2+L1*sinθL1 (20)
Yk right side＝R2*sinθR2+R1*sinθR1 (21)
Figure FDA0002928103770000075
Substituting equations (20) and (21) into equation (22) yields:
Figure FDA0002928103770000076
10. the phased array probe scanning track self-correcting method according to claim 5, characterized in that: and 3, solving the transverse deviation of the scanning track of the phased array probe, which specifically comprises the following steps:
step 3-1, calculating the transverse deviation S of the phased array probe scanning teaching track and the theoretical track:
Figure FDA0002928103770000077
in the formula:
S*: theoretical distance from the phased array probe to the center of the weld;
step 3-2, actual transverse deviation of the phase control array probe to the center of the welding seam
Figure FDA0002928103770000081
And transmitting the data to a robot system in real time for deviation elimination.
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