CN114111658A - Knife handle type ultrasonic thickness measuring device and method based on wireless communication - Google Patents
Knife handle type ultrasonic thickness measuring device and method based on wireless communication Download PDFInfo
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- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B17/00—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations
- G01B17/02—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations for measuring thickness
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/4409—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
- G01N29/4427—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with stored values, e.g. threshold values
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- G01S15/00—Systems using the reflection or reradiation of acoustic waves, e.g. sonar systems
- G01S15/02—Systems using the reflection or reradiation of acoustic waves, e.g. sonar systems using reflection of acoustic waves
- G01S15/06—Systems determining the position data of a target
- G01S15/08—Systems for measuring distance only
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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Abstract
The invention discloses a cutter handle type ultrasonic thickness measuring device and a measuring method based on wireless communication, and belongs to the technical field of ultrasonic thickness measurement. The device organically integrates modules such as an ultrasonic sensor, a wireless communication unit, an excitation/receiving unit, a power supply and the like with a tool holder structure, and can be conveniently integrated in a conventional numerical control machine; in the ultrasonic thickness measurement process, the industrial personal computer transmits an ultrasonic excitation signal to the ultrasonic device in a wireless communication mode and finishes automatic receiving of an ultrasonic echo signal, thereby effectively avoiding interference of a signal cable on ultrasonic scanning movement in a conventional wired communication mode and providing reliable guarantee for multi-axis linkage ultrasonic on-machine thickness measurement with complex characteristics; the ultrasonic echo signals are compressed and wavelet filtered, so that the quality of the ultrasonic echo signals is effectively ensured. The ultrasonic thickness measuring device and the ultrasonic thickness measuring method overcome the defects of the ultrasonic thickness measuring device and the ultrasonic thickness measuring method based on wired communication, and improve the automatic thickness measuring capability and efficiency of ultrasonic on-machine measurement.
Description
Technical Field
The invention belongs to the technical field of ultrasonic thickness measurement, and particularly relates to a cutter handle type ultrasonic thickness measurement device and a measurement method based on wireless communication.
Background
The large thin-wall part is widely applied in the aerospace field, such as a rocket storage tank, a rocket nozzle and the like, and relates to the structure of the large thin-wall part. However, in the machining process, as the transverse size of the part is larger, the wall thickness size is smaller, the rigidity of the part is poorer, the part is easy to deform in the clamping and machining processes, and the machining precision is difficult to guarantee. Therefore, the wall thickness measuring process is introduced into a plurality of production lines, and the processing parameters are adjusted in real time in the processing process to improve the processing quality of parts, so that the accurate measurement of the wall thickness before and after processing is of great significance to the processing of large-scale thin-wall parts.
The existing wall thickness measuring mode is mostly that the thickness measuring probe is in wired connection with an industrial personal computer, then the workpiece is measured in a handheld or machine tool-mounted mode, the measuring range can be limited due to the existence of a cable, and manual disassembly and clamping are needed in the process of clamping the workpiece to the machine tool, so that the research on a wireless measuring device is very important for realizing the integration of measurement and processing.
In the patent "a contact state control method for ultrasonic on-machine thickness measurement" (application number: CN201810385105.1), a measurement system is mounted on a spindle of a machine tool, an ultrasonic probe is driven by the numerical control machine to directionally scan a measured part according to a planned path, contact force information is acquired in real time through a force sensor, a target position is rapidly and accurately adjusted, the probe is maintained to be in stable contact with the surface of the part, but contact measurement is adopted, and the pose of the sensor is adjusted through sensing of a mechanical signal, so that the part is easily scratched. In the patent of ultrasonic on-machine non-contact scanning thickness measuring equipment and method for large-scale wall plates (application number: CN201910234944.8), the non-contact scanning thickness measuring equipment and method are provided, but on-machine thickness measuring devices and methods are all based on wired data transmission, and the wired transmission is used for bringing certain limit to the measuring range due to the arrangement of cables on a machine tool during on-machine measurement and bringing troubles to the replacement and adjustment of sensors.
In the above research, no tool shank type ultrasonic thickness measuring device and method based on wireless communication are mentioned.
Disclosure of Invention
The invention mainly solves the technical problems of overcoming the defects of the prior art and inventing a cutter handle type ultrasonic thickness measuring device and a measuring method based on wireless communication aiming at the difficult problem of accurate and rapid measurement of wall thickness before and after part processing. The device organically integrates modules such as an ultrasonic sensor, a wireless communication unit, an excitation/receiving unit, a power supply and the like with a knife handle structure, and can be conveniently integrated in a conventional numerical control machine; in the ultrasonic thickness measurement process, the upper computer transmits an ultrasonic excitation signal to the ultrasonic thickness measurement device in a wireless communication mode and finishes automatic receiving of an ultrasonic echo signal, so that interference of a signal cable on ultrasonic scanning movement in a conventional wired communication mode is effectively avoided, and reliable guarantee can be provided for multi-axis linkage ultrasonic on-machine thickness measurement with complex characteristics; the ultrasonic echo signals are compressed and wavelet filtered, so that the quality of the ultrasonic echo signals is effectively ensured.
The technical scheme adopted by the invention is as follows:
the utility model provides a sword handle formula supersound thickness measuring device based on wireless communication, the device can install on 7 main shafts of digit control machine tool, and the device includes supersound cloud box 1, frock, supersound gauge head 3, power 4, router 5 and clamping device 6. The ultrasonic cloud box 1 sends a pulse electric signal to the ultrasonic probe 3; the ultrasonic probe 3 excites/receives ultrasonic waves in a tested part based on a piezoelectric/inverse piezoelectric effect; the power supply 4 supplies power to the ultrasonic cloud box 1 and the router 5; the router 5 is used for transmitting ultrasonic echo signals collected by the ultrasonic sensor 3 and compressed by the ultrasonic cloud box 1 to a wireless communication module in the industrial personal computer case 8; and finishing the man-machine interaction process of ultrasonic thickness measurement through the industrial personal computer display 9.
The tool comprises a cylindrical shell 21, a cutter handle type end cover 22, a bottom plate 23, an ultrasonic cloud box I-shaped support 24, a power supply I-shaped support 25 and a router I-shaped support 26. Wherein, the cylindrical shell 21 is a cylindrical cavity structure, two ends of which are respectively provided with a knife handle type end cover 22 and a bottom plate 23, and the fastening effect is achieved through a rubber gasket; the tool shank end cap 22 is mounted directly to the spindle of the machine tool. The lower ends of the ultrasonic cloud box I-shaped support 24, the power supply I-shaped support 25 and the router I-shaped support 26 are all connected to the bottom plate 23 through bolts, threaded holes are formed in the contact surface of the upper end of the ultrasonic cloud box I-shaped support and the handle type end cover 22, and the ultrasonic cloud box I-shaped support, the power supply I-shaped support and the router I-shaped support are connected with the handle type end cover 22 through studs.
The ultrasonic cloud box 1 is connected to the ultrasonic cloud box I-shaped bracket 24 through bolts. The power supply i-shaped bracket 25 and the router i-shaped bracket 26 are provided with through holes for mounting the clamping device 6 according to the size of the power supply 4 and the router 5, respectively, and the clamping device 6 is used for fixing the power supply 4 and the router 5 during the assembly process.
The ultrasonic measuring head 3 is connected with the bottom plate 23 through threads and consists of an ultrasonic sensor protective shell 31 and an ultrasonic sensor 32; the ultrasonic sensor protective shell 31 is provided with a coupling agent injection port c and a coupling agent outflow port d, so that smooth injection of the coupling agent is ensured, and a medium is provided for propagation of ultrasonic waves between the ultrasonic measuring head and the measured part.
The BNC interface 11 of the ultrasonic cloud box 1 is connected with the ultrasonic measuring head 3 through an ultrasonic cable; the network cable interface 14 of the ultrasonic cloud box is connected with the network cable interface 51 of the router through a network cable; and the data line interface 42 of the power supply 4 is connected with the ultrasonic cloud box power supply interface 13 and the router data line interface 52 through data lines. The ultrasonic cloud box 1 is internally provided with an ultrasonic excitation module and an acquisition module, and the acquisition module compresses the ultrasonic signals after receiving the ultrasonic signals.
An industrial personal computer transmits an excitation instruction to an excitation module in an ultrasonic cloud box 1 through a router 5 through wireless transmission a, the excitation module provides a pulse electrical signal for an ultrasonic sensor 32, the ultrasonic sensor 32 enables the surface of a measured part to generate mechanical vibration through a piezoelectric effect, the vibration is transmitted inside the part in an ultrasonic mode, the ultrasonic wave is reflected after meeting the boundary of the part and returns to an excitation point, the vibration signal is converted into an electrical signal through an inverse piezoelectric effect, the electrical signal is transmitted to an acquisition module by the ultrasonic sensor 32, the ultrasonic signal is compressed in the acquisition module and then transmitted to the industrial personal computer through a wireless transmission b for data decompression, and denoising and thickness calculation of an ultrasonic echo signal are completed in the industrial personal computer. The specific measurement steps are as follows:
Connecting the cutter handle type ultrasonic thickness measuring device with a main shaft of a numerical control machine tool 7, and connecting a couplant system; finishing the process of tool setting, adjusting the pose of the ultrasonic measuring head 3 to ensure that the normal line of the ultrasonic measuring head is vertical to the surface of the part to be measured, and adjusting the coupling distance between the ultrasonic measuring head 3 and the part to be measured; setting the density of the measuring points and the scanning speed according to the size of the measured part and the required measuring time; and executing a G code of the part processing track, and starting scanning by the ultrasonic thickness measuring device.
The industrial personal computer sends an ultrasonic excitation instruction to the cutter handle type ultrasonic thickness measuring device, and an ultrasonic signal received by the ultrasonic sensor 32 starts wireless transmission after being subjected to A/D conversion by the acquisition module of the ultrasonic cloud box 1. The wireless transmission process comprises compression, transmission and decompression of the ultrasonic echo signals. The method comprises the following specific steps:
the ultrasonic echo signal compresses data into shorter codes by using the repeatability of the data through a dictionary compression algorithm, defines the code length l to establish an index, enters a region to be coded, is empty when the coding is started, continuously fills a dictionary window along with the input of the data, and provides a queriable and coded data reference for subsequent signals; in order to ensure the compression efficiency and the length of a dictionary window to be unchanged, data in the dictionary is continuously deleted and expanded.
The compressed ultrasonic data is transmitted to an industrial personal computer in real time based on a TCP (Transmission control protocol), the handle type ultrasonic thickness measuring device serves as a server, the industrial personal computer serves as a client, and the server establishes a socket and binds ports; the client establishes a socket and is connected with the server after three times of handshake; sending the compressed ultrasonic echo signal, and closing the socket after the transmission is finished; the above process is repeated for the next data transmission. The received signal is decompressed in the industrial personal computer, and the decompression process is opposite to the compression process.
And performing wavelet denoising after time-frequency conversion on the decompressed ultrasonic echo signals. The noise signal is generally in a high frequency band, and the ultrasonic echo signal has a lower frequency than the noise. The parameters of a high-pass/low-pass filter are adjusted by defining quality factors, redundancy and decomposition levels, so that ultrasonic echo signals and noise signals are distinguished while ultrasonic signal peak information is not influenced; selecting a heuristic threshold rule, extracting an ultrasonic echo signal which can be used for calculation, and removing a noise signal; and finally, reconstructing the ultrasonic echo signal to obtain the denoised ultrasonic signal.
And (4) completing the thickness calculation of the workpiece to be measured in the industrial personal computer on the basis of the sound time difference principle. The ultrasonic wave propagates along the thickness direction of the part, is reflected and returns to the ultrasonic sensor when meeting the boundary of the part, and the thickness d of the part is calculated by the propagation speed v of the ultrasonic wave in the measured material and the time difference delta t of two echoesP。
The invention has the beneficial effects that: the ultrasonic thickness measuring device provided by the invention adopts a wireless data transmission communication mode, is free from the constraint of a cable between the ultrasonic thickness measuring device and an industrial personal computer, can be arranged in a tool magazine, completes the switching of processing-measuring functions through an automatic tool changing process, does not need manual measurement, and avoids the introduction of artificial measuring errors. The tool shank type ultrasonic thickness measuring device is miniaturized and universal, can be used for measuring different parts or different machine tools according to measurement requirements, and saves cost. The invention compresses the ultrasonic echo signal by a dictionary compression algorithm, has stable compression process, reasonably sets the compression coding length, and can reproduce the original signal without loss after data decompression. And a TCP transmission protocol is selected to complete wireless transmission of compressed signals, so that the stability of data transmission is ensured.
Drawings
Fig. 1 is a schematic diagram of an application of an ultrasonic thickness measuring device in a machining process of a machine tool.
Fig. 2 is an appearance schematic diagram of the knife handle type ultrasonic thickness measuring device.
Fig. 3 is a top view of the internal structure of the ultrasonic thickness measuring device without the end cap and its fittings.
Fig. 4 is a schematic view of internal components of the ultrasonic thickness measuring device of the blade handle type, wherein (a) shows a sectional view in the direction of an ultrasonic cloud box, (b) shows a sectional view in the direction of a router, and (c) shows a sectional view in the direction of a power supply.
Fig. 5 is a schematic structural diagram of an ultrasonic probe.
Fig. 6 is an external view of the ultrasonic cloud box.
Fig. 7 is an external view of the power supply.
Fig. 8 is an external view of a router.
Fig. 9 is a schematic view of a rack of the type of rack, in which (a) is a rack for mounting an ultrasound cloud box, (b) is a rack for mounting a power supply, and (c) is a rack for mounting a router.
Fig. 10 shows the acoustic time difference Δ t of the ultrasonic echo signal.
The system comprises an ultrasonic cloud box 1, an ultrasonic probe 3, a power supply 4, a router 5, a clamping device 6, a numerical control machine 7, an industrial control machine case 8, an industrial control machine display 9, a BNC interface 11, an ultrasonic cloud box switch 12, an ultrasonic cloud box power supply interface 13, an ultrasonic cloud box network cable interface 14, a cylindrical shell 21, a knife handle type end cover 22, a bottom plate 23, an ultrasonic cloud box I-shaped support 24, an ultrasonic power supply I-shaped support 25, an ultrasonic router I-shaped support 26, an ultrasonic sensor shell 31, an ultrasonic sensor 32, a power supply switch 41, a data cable interface 42, a router network cable interface 51, a router data cable interface 52, a coupling agent injection port c and a coupling agent outflow port d.
Detailed Description
The technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.
The workpiece to be measured is an aluminum alloy plate with the length and width of 500mm multiplied by 250mm and the thickness of about 7.5mm, the distance between measuring points is 10mm when the measurement is required, the assembly of each part of the ultrasonic thickness measuring device is completed, and the thickness measuring process based on wireless data transmission is completed by using the device, and the method comprises the following specific steps:
The ultrasonic sensor 32 with the center frequency of 10MHz is selected to be used for exciting/receiving ultrasonic waves at the tail end of the cutter handle type ultrasonic thickness measuring device, all parts of the cutter handle type ultrasonic thickness measuring device are assembled according to the structure shown in the drawing, in order to facilitate the disassembly and replacement of all parts, the ultrasonic box 1, the power supply 4 and the router 5 are respectively fixed by using the ultrasonic cloud box I-shaped bracket 24, the power supply I-shaped bracket 25 and the router I-shaped bracket 26, wherein the power supply 4 and the router 5 are clamped and fixed by the fine-adjustable clamping device 6 due to the fact that no fixing hole exists in the power supply 4 and the router 5. The whole cutter handle type ultrasonic thickness measuring device is arranged in a tool magazine of a machine tool; when in calling, the tool shank is connected with a main shaft of the machine tool through an automatic tool changing process, a couplant system is connected, and the couplant system comprises a pump, a water pipe and the like, wherein the water pipe is connected with a couplant injection port c in the graph 4; and adjusting the pose of the ultrasonic measuring head 3 to ensure that the normal line of the ultrasonic measuring head is vertical to the surface of the part to be measured, firstly enabling the ultrasonic measuring head 3 to be in contact with the workpiece, and lifting the ultrasonic measuring head 3 away by adjusting the machine tool to ensure that the coupling distance between the ultrasonic measuring head and the part to be measured is 1-3 mm.
Controlling the machine tool to drive the ultrasonic probe 3 to move to a measuring initial position, opening the ultrasonic cloud box switch 12, establishing communication among the ultrasonic cloud box 1, the ultrasonic probe 3 and the industrial personal computer, adjusting ultrasonic parameters at the initial position, calibrating an ultrasonic speed 6377m/s (obtained by calibrating a measuring standard component), and setting a sampling period to be 40 ms. And establishing a coordinate system by taking the measurement starting point as a coordinate origin for recording data in the scanning process. Changing the gate start (data acquisition start point) until two echoes appear in an observation area at the same time, and setting the signal gain to be 30 dB; and after relevant parameters are adjusted, executing a part processing track G code, scanning the ultrasonic measuring head along a workpiece processing track, and calculating the movement speed v of the measuring head by measuring point density l and a sampling period T to obtain:
Ultrasonic parameters are sent in a software interface through an industrial personal computer, the ultrasonic cloud box 1 sends pulse electric signals to the ultrasonic measuring head 3, the ultrasonic sensor 32 converts the electric signals into force signals through a piezoelectric effect, ultrasonic longitudinal waves are excited, and reflected ultrasonic echo signals are received.
4096 data are collected at a measuring point by the ultrasonic cloud box 1, the size of original data is 30KB, the data are compressed into shorter codes through a dictionary compression algorithm, the code length l is defined as 11 to establish an index, an ultrasonic echo signal enters a code area to be coded, a dictionary is empty when the coding is started, a dictionary window is continuously filled with the data input, a data reference capable of being inquired and coded is provided for subsequent signals, if a corresponding character string exists in the dictionary, the data are transmitted according to the corresponding code, if the character string does not exist, the dictionary is expanded, a new input data stream is coded, and the compressed ultrasonic echo signal is 18 KB.
The compressed ultrasonic data is transmitted to an industrial personal computer in real time based on a TCP (Transmission control protocol), the ultrasonic thickness measuring device is used as a server, the industrial personal computer is used as a client, and the server establishes a socket and binds ports; the client establishes a socket and is connected with the server after three times of handshake; sending the compressed ultrasonic echo signal, and closing the socket after the transmission is finished; the above process is repeated for the next data transmission. The received signal is decompressed in the industrial personal computer, and the decompression process is opposite to the compression process.
And performing wavelet denoising after time-frequency conversion on the decompressed ultrasonic echo signals. And separating and removing the noise signals according to the difference of the frequencies of the noise signals and the ultrasonic signals. Adopting a quality factor Q equal to 1, setting a high-pass/low-pass filter for the original signal with the redundancy r equal to 3 and the decomposition level J equal to 4 to carry out wavelet decomposition; selecting a heuristic threshold rule, extracting an ultrasonic echo signal which can be used for calculation, and separating the ultrasonic echo signal from noise; and finally, reconstructing the ultrasonic echo signal to obtain the denoised ultrasonic signal.
And the thickness of the workpiece to be measured is calculated in an industrial personal computer based on the sound time difference principle. The ultrasonic wave propagates along the thickness direction of the part, and is reflected and returned to the ultrasonic sensor when meeting the boundary of the part, and the thickness d of the part at any measuring point position is calculated by the propagation speed v of the ultrasonic wave in the measured material 6377m/s and the time difference delta t of two echoes 2.352 mu sP：
The cutter handle type ultrasonic thickness measuring device completes processing-measuring function switching through automatic cutter changing, completes data interaction with an industrial personal computer through signal compression and wireless transmission methods, and improves the measuring efficiency on the basis of guaranteeing nondestructive transmission of ultrasonic echo signals.
The above embodiments are provided to further explain the objects, technical solutions and advantages of the present invention in detail, it should be understood that the above embodiments are only examples of the present invention and are not intended to limit the present invention, and any modifications, equivalents, improvements and the like made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (2)
1. A cutter handle type ultrasonic thickness measuring device based on wireless communication is characterized by comprising an ultrasonic cloud box (1), a tool, an ultrasonic measuring head (3), a power supply (4) and a router (5);
the tool comprises a cylindrical shell (21), a knife handle type end cover (22), a bottom plate (23), an ultrasonic cloud box I-shaped support (24), a power supply I-shaped support (25) and a router I-shaped support (26); the cylindrical shell (21) is of a cylindrical cavity structure, two ends of the cylindrical shell are respectively provided with a knife handle type end cover (22) and a bottom plate (23), and the fastening effect is achieved through a rubber gasket; the lower ends of the ultrasonic cloud box I-shaped support (24), the power supply I-shaped support (25) and the router I-shaped support (26) are connected to the bottom plate (23), and the upper ends of the ultrasonic cloud box I-shaped support, the power supply I-shaped support and the router I-shaped support are connected with the cutter handle type end cover (22);
the ultrasonic cloud box (1) is connected to an ultrasonic cloud box I-shaped bracket (24); the power supply (4) and the router (5) are respectively connected to the power supply I-shaped bracket (25) and the router I-shaped bracket (26) through the clamping device (6);
the ultrasonic measuring head (3) is connected with the bottom plate (23) and consists of an ultrasonic sensor protective shell (31) and an ultrasonic sensor (32); the ultrasonic sensor protective shell (31) is provided with a coupling agent injection port (c) and a coupling agent outflow port (d), so that the coupling agent is ensured to be smoothly injected, and a medium is provided for the propagation of ultrasonic waves between the ultrasonic probe and a part to be detected;
the BNC interface (11) of the ultrasonic cloud box (1) is connected with the ultrasonic measuring head (3) through an ultrasonic cable; the network cable interface (14) of the ultrasonic cloud box is connected with the network cable interface (51) of the router through a network cable; the data line interface (42) of the power supply (4) is connected with the ultrasonic cloud box power supply interface (13) and the router data line interface (52) through data lines;
the ultrasonic cloud box (1) is internally provided with an ultrasonic excitation module and an acquisition module, and the acquisition module compresses an ultrasonic signal after receiving the ultrasonic signal; the ultrasonic cloud box (1) sends a pulse electric signal to the ultrasonic probe (3); the ultrasonic probe (3) excites/receives ultrasonic waves in a tested part based on the piezoelectric/inverse piezoelectric effect; the power supply (4) provides power for the ultrasonic cloud box (1) and the router (5); the router (5) is used for transmitting ultrasonic echo signals collected by the ultrasonic sensor (3) and compressed by the ultrasonic cloud box (1) to the wireless communication module in the industrial personal computer case (8); and the man-machine interaction process of ultrasonic thickness measurement is completed through an industrial personal computer display (9).
2. A method of ultrasonic thickness measurement using the ultrasonic thickness measuring apparatus of the shank type according to claim 1, comprising the steps of:
step 1 installation adjustment of ultrasonic thickness measuring device
Connecting the cutter handle type ultrasonic thickness measuring device with a main shaft of a numerical control machine tool, and connecting a couplant system; finishing the tool setting process, adjusting the pose of the ultrasonic measuring head (3) to ensure that the normal line of the ultrasonic measuring head is vertical to the surface of the measured part, and adjusting the coupling distance between the ultrasonic measuring head (3) and the measured part; setting the density of the measuring points and the scanning speed according to the size of the measured part and the required measuring time; executing a G code of a part processing track, and starting scanning by the ultrasonic thickness measuring device;
step 2 Wireless Transmission of ultrasound signals
The industrial personal computer sends an ultrasonic excitation instruction to the cutter handle type ultrasonic thickness measuring device, and an ultrasonic signal received by the ultrasonic sensor (32) starts wireless transmission after being subjected to A/D conversion by an acquisition module of the ultrasonic cloud box (1); the wireless transmission process comprises compression, transmission and decompression of ultrasonic echo signals, and specifically comprises the following steps:
the ultrasonic echo signal compresses data into shorter codes by using the repeatability of the data through a dictionary compression algorithm, defines the code length l to establish an index, enters a region to be coded, is empty when the coding is started, continuously fills a dictionary window along with the input of the data, and provides data reference for inquiring and coding for subsequent signals; in order to ensure the compression efficiency and the length of a dictionary window to be unchanged, data in the dictionary is continuously deleted and expanded;
the compressed ultrasonic data is transmitted to an industrial personal computer in real time based on a TCP (Transmission control protocol), the handle type ultrasonic thickness measuring device serves as a server, the industrial personal computer serves as a client, and the server establishes a socket and binds ports; the client establishes a socket and is connected with the server after three times of handshake; sending the compressed ultrasonic echo signal, and closing the socket after the transmission is finished; repeating the above process when the next data is transmitted; the received signal is decompressed in an industrial personal computer, and the decompression process is opposite to the compression process;
step 3 ultrasonic echo signal processing
Performing wavelet denoising after time-frequency conversion on the decompressed ultrasonic echo signals; adjusting parameters of a high-pass/low-pass filter through quality factors, redundancy and decomposition levels to ensure that ultrasonic echo signals and noise signals are distinguished while wave crest information of the ultrasonic signals is not influenced; selecting a heuristic threshold rule, extracting an ultrasonic echo signal for calculation, and removing a noise signal; finally, reconstructing the ultrasonic echo signal to obtain a denoised ultrasonic signal;
step 4, calculating the thickness of the measured workpiece
The ultrasonic wave propagates along the thickness direction of the part, is reflected and returns to the ultrasonic sensor when meeting the boundary of the part, and the thickness d of the part is calculated by the propagation speed v of the ultrasonic wave in the measured material and the time difference delta t of two echoesP。
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