CN218298134U - 3D detection scanning probe for water and electricity large-scale mechanical shaft system - Google Patents
3D detection scanning probe for water and electricity large-scale mechanical shaft system Download PDFInfo
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- CN218298134U CN218298134U CN202222546839.8U CN202222546839U CN218298134U CN 218298134 U CN218298134 U CN 218298134U CN 202222546839 U CN202222546839 U CN 202222546839U CN 218298134 U CN218298134 U CN 218298134U
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Abstract
The utility model discloses a 3D detection scanning probe for hydroelectric large-scale mechanical shafting, which comprises a phased array probe, wherein the phased array probe comprises a shell, a backing block, a piezoelectric element arranged on the backing block, a matching layer arranged on the piezoelectric element and an acoustic lens arranged on the matching layer, and the piezoelectric element is formed by arranging a plurality of piezoelectric wafers; the backing block, the piezoelectric element, the matching layer and the acoustic lens are packaged in the shell; the frequency of the probe is 2.5MHz; the probe type is a linear array; the array element number of the probe is 64; the array element spacing of the probe is 1.5mm; the length of the array element of the probe is 10mm.
Description
Technical Field
The utility model relates to a detect technical field, concretely relates to water and electricity large-scale mechanical shaft system 3D detects and sweeps and examines probe.
Background
The existing large-scale mechanical axis detection equipment adopts a conventional traditional A-type display ultrasonic detection method, a single-crystal low-frequency large wafer probe is used, and the waveform observation and judgment have the defects of high requirement on the experience of personnel, no record, poor repeatability, easy occurrence of conditions such as missing detection, erroneous judgment and the like.
The ultrasonic phased array is a combination of ultrasonic probe wafers, a plurality of piezoelectric wafers are distributed and arranged according to a certain rule, then each wafer is excited successively according to preset delay time, ultrasonic waves emitted by all the wafers form an integral wave front, the shape and the direction of emitted ultrasonic beams (wave front) can be effectively controlled, and beam scanning, deflection and focusing of the ultrasonic waves can be realized. It provides greater ability to determine the shape, size and direction of discontinuities than single or multiple probe systems.
The existing scanning device based on the ultrasonic phased array technology generally comprises a driving structure, wherein the driving structure is connected with a phased array probe and a wedge block, and the phased array probe is attached to the surface of an object to be detected through the wedge block. The existing probe is integrated with a wedge block and is also designed in a split mode. The driving structure drives the phased array probe to move around an object to be inspected according to a certain track, and the phased array probe feeds scanned data back to the imaging system for imaging.
However, as the motor shafting equipment of hydroelectric power generation is large, the size of the conventional phased array probe is low in emission energy, and the conventional phased array probe cannot penetrate large-scale shafting equipment, the single-chip probe is still adopted for the large-scale mechanical shafting equipment.
SUMMERY OF THE UTILITY MODEL
The utility model aims to provide a water and electricity large-scale mechanical shaft system 3D detects scanning probe, based on ultrasonic phased array technique, can pierce through large-scale shafting equipment, solves the problem among the prior art.
In order to realize the purpose, the utility model discloses the technical scheme who takes as follows:
the 3D detection scanning probe for the large-scale mechanical shafting of the water and electricity comprises a phased array probe, wherein the phased array probe comprises a shell, a backing block, a piezoelectric element arranged on the backing block, a matching layer arranged on the piezoelectric element and an acoustic lens arranged on the matching layer, and the piezoelectric element is formed by arranging a plurality of piezoelectric wafers; the backing block, the piezoelectric element, the matching layer and the acoustic lens are packaged in the shell;
the frequency of the probe is 2.5MHz; the probe type is a linear array; the array element number of the probe is 64; the array element spacing of the probe is 1.5mm; the length of the array element of the probe is 10mm.
As a preferred technical scheme, still including the scanning frame that is used for installing the phased array probe, scan frame phased array probe and can dismantle the setting in the installation frame, scan and still be equipped with encoder installation position on the frame.
As a preferred technical scheme, the matching layer is a polystyrene cross-linked resin matching layer.
As a preferred technical scheme, the acoustic impedance of the piezoelectric wafer is 34Mrayl; the mechanical coupling coefficient is more than 60%, and the mechanical quality factor is less than 30.
Compared with the prior art, the utility model, following beneficial effect has:
the utility model discloses a parameter structure to phased array probe changes for it can produce great energy, pierces through the large-scale mechanical shafting equipment of water and electricity (diameter 800mm, high 600 mm), thereby can use the phased array technique to carry out convenient 3D scanning imaging to the large-scale mechanical shafting equipment of water and electricity.
Drawings
FIG. 1 is a schematic structural view of the scanning frame;
FIG. 2 is an echo waveform of the probe;
FIG. 3 is an echo spectrum of the probe;
FIG. 4 shows a probe test project performance index 1;
FIG. 5 shows the probe test item performance index 2;
FIG. 6 is a probe test project performance index 3;
fig. 7 is a scanned image after a large mechanical shaft is used as a real object for testing.
Wherein the reference numerals are as follows: 1-scanning frame, 2-encoder installation position.
Detailed Description
The utility model aims to overcome prior art's defect, provide the large-scale mechanical shafting 3D of water and electricity and detect and sweep the probe, it is right to combine the embodiment below the utility model discloses do further detailed description.
Example 1
As shown in figure 1, the 3D detection scanning probe for the hydroelectric large-scale mechanical shafting comprises a scanning frame 1 arranged on a driving structure and a phased array probe arranged on the scanning frame 1.
In this embodiment, the phased array probe is a separate type from the longitudinal wave coupling wedge. The longitudinal wave coupling wedge block is designed to be matched with the arc surface of large-scale shafting equipment, so that the optimal sound transmission effect is achieved, and energy attenuation is reduced.
Specifically, the basic structure of the phased array probe is the same as that of the existing phased array probe, and the phased array probe comprises a backing block, a piezoelectric element arranged on the backing block, a matching layer arranged on the piezoelectric element, and an acoustic lens arranged on the matching layer. The piezoelectric element is composed of a plurality of piezoelectric wafers arranged. The backing block, piezoelectric element, matching layer, acoustic lens are encapsulated within a housing.
The difference between the present embodiment and the prior art is mainly as follows:
because the motor shaft system equipment of hydroelectric generation is great, and the size of general conventional phased array probe transmitted energy is lower, can not pierce large-scale shaft system equipment, so this embodiment is through adopting large-scale low frequency piezoelectric chip to control array element interval and with the voussoir cooperation of the anastomotic design of shaft system equipment arc surface, reach best sound transmission effect, reduce the energy decay.
First, in the development process, the core technology of a phased array probe is to use a divided array wafer.
The piezoelectric wafer functions to transmit and receive ultrasonic waves, and vibrates in a thickness resonance mode to excite longitudinal waves. The probe head is designed taking into account the size of the piezoelectric wafer, which is determined in relation to the resonance frequency. The resonance frequency is the maximum output power obtained in the resonance state, the size of the resonance frequency is determined by the thickness of the wafer, and the resonance frequency is calculated according to the frequency constant and the center frequency of the piezoelectric wafer:
frequency constant: nt = tf = C/2;
thickness of the wafer: t = C/2f;
wherein: t is the thickness of the wafer; f is the probe frequency; c is the longitudinal wave sound velocity;
the detected workpiece is steel shaft system equipment, longitudinal wave sound is about 5900mm/s, the probe frequency is 2.5MHz, the wafer thickness of the miniaturized phased array probe is calculated according to a theoretical formula and is t =1.18mm, and therefore the wafer thickness of the phased array probe can meet the requirement when being about 1.18 mm. The whole wafer cutting process is mainly divided into array wafers by using a stamping cutting method.
Secondly, determining the probe structure (frequency, array element number, array element spacing and the like) and the wafer arrangement mode according to the workpiece to be detected and the detection requirement:
phased array probe design principle: the length of the probe is greater than the length of the array elements, and the length of the array elements is greater than 6 times of the spacing of the array elements; in order to avoid grating lobes, the array element interval P is less than lambda/2, but the energy is insufficient through experiments, grating lobes cannot be avoided after balance selection, and the grating lobes are not in a detection area, so that the energy and the performance are considered, the length of the array elements is selected to be 10mm, and the array element interval is selected to be 1.5mm.
Selecting the probe frequency: the detected workpiece is steel shafting equipment, the longitudinal wave sound is about 5900mm/s, the wavelength of the detected workpiece in steel is about 2.36mm by adopting 2.5MHz frequency according to calculation, the length of a detectable defect is 1/2 =1.18mm in theory, and the detection requirement can be completely met.
Array element number selection: the thickness of the workpiece is large, so that the thickness of the workpiece is economic under the premise of meeting detection requirements, and meanwhile, the size of the probe is determined by the structure of the workpiece and can only be large, so that 64 array elements are adopted in the design of array element number.
Array element interval selection: array element interval is the important index that influences probe performance, and theoretically, array element interval is the bigger, and the directive property of acoustic beam can be better, and probe acoustic beam main lobe width can be less, but array element interval is bigger more can touch and make probe grating lamella produce, under the prerequisite of guaranteeing that detection area does not produce grating lamella, array element interval design has adopted 1.5mm.
Arrangement of probe wafers: as the detection is mainly steel shafting equipment, circumferential cracks of the inserted shaft body of the shaft can be detected, and in order to ensure that an ultrasonic main sound field and a focusing area are in the area, the wafer arrangement adopts a linear array large-space arrangement mode, so that ultrasonic waves have larger ultrasonic energy after entering the shafting equipment.
Specifically, in this embodiment, the types of the probe are: 2.5L64-1.5 × 10-C90-P-110-2.5-P2; namely the frequency of the probe is 2.5MHz; the array type is L (linear), the number of the wafers is 64, the array element interval is 1.5mm, and the probe type is C (the probe and the wedge block are separated).
Further, the piezoelectric chip is a core material of the probe, and generates and receives ultrasonic waves by the principle of piezoelectric effect (when an electric field is applied in the polarization direction of dielectrics, the dielectrics generate mechanical deformation or mechanical pressure in a certain direction, and when the applied electric field is removed, the deformation or stress disappears). The probe wafer material adopts a purchased piezoelectric composite material, and the acoustic impedance of the probe wafer material is about 34 Mrayl. The Kt value (mechanical coupling coefficient) of the material is more than 60 percent, and the Qm value (mechanical quality factor) is less than 30.
The acoustic matching layer has the functions of optimizing energy forward transfer, improving sensitivity, reducing pulse width, increasing bandwidth, and protecting the front side wafer. In order to ensure the matching effect of the acoustic impedance of the material and the piezoelectric wafer (namely, the acoustic impedance is close to the acoustic impedance of the piezoelectric wafer), and reduce the attenuation of the ultrasonic wave on the probe, a Rexolite material (polystyrene cross-linked resin) is adopted as a matching layer of the probe.
The wedge used in cooperation with the probe is required to have good sound transmission performance, and the longitudinal wave sound velocity of the wedge material is required to be lower than the longitudinal wave sound velocity of the material (5900 m/s for steel shaft system equipment), so that the wedge is made of PS material (sound velocity 2337 m/s), and AOD (Axial Outside Diameter) circular arc polishing treatment is carried out on the wedge according to the curvature of a detected workpiece, so that the coupling effect is enhanced. The wedge block is detachably connected with the shell of the probe through a bolt, so that the service life of the whole probe is prolonged.
The scanning frame 1 comprises a Contraband type installation frame, a shell of a phased array probe is placed in an opening of a Contraband type installation frame, a screw hole is formed in the top of a Contraband type installation frame, and a bolt is spirally connected in the screw hole. After being arranged in a Contraband type installation frame, the phased array probe is rotated by a bolt to abut against the shell of the phased array probe to realize clamping. Still be equipped with encoder installation position 2 on scanning frame 1 for the encoder of measuring probe orbit also installs on the installation frame.
In this embodiment, the probe manufacturing process is as follows:
the pasting process comprises the following steps:
the wafer is a dielectric, and electrodes are required to be attached to both end surfaces perpendicular to the thickness direction for applying an electric field and exciting ultrasonic vibration. The electrode layer is required to be thin and uniform, and is firmly adhered to the piezoelectric wafer, and the upper and lower stages of the electrode layer are kept parallel.
The welding process comprises the following steps:
the upper surface of the piezoelectric wafer is welded with the transmitting circuit, and the bottom surface of the wafer is welded with the bottom wire.
And (3) wafer cutting process:
and the punching and cutting mode is adopted, and the punching die and the lower die can be made into multiple rows and multiple columns according to the requirement so as to realize the batch cutting of the wafers on the material tray.
Plasma cleaning process:
the plasma cleaning machine is used for cleaning, working gas is accelerated under the action of self bias or external bias to generate kinetic energy, and then the kinetic energy bombards the surface of a wafer to be cleaned, which is placed on a negative electrode, and is generally used for removing oxides, epoxy resin or microparticle pollutants and the like, and simultaneously carrying out surface activation.
And (3) grinding process:
the front and back surfaces of the wafer are rough ground to quickly reduce the thickness of the wafer. The front and back surfaces of the wafer are then ground with an abrasive slurry to further reduce the thickness of the wafer and the front surface of the wafer is polished with a polishing slurry to reduce the thickness of the wafer to a predetermined final wafer thickness.
The bonding process comprises the following steps:
the piezoelectric chip is bonded with the protective film, the absorption damping block, the acoustic lens, etc. by using an adhesive, no air gap exists between the bonding surfaces, the bonding surface is flat and uniform, and the thinner the bonding layer is, the better.
Specifically, the structural parameters of the probe are as follows:
| frequency: | 2.5MHz | sheath of the cable: | PVC |
| the probe type: | linear array | Cable length: | 2.0±0.1m |
| array element number: | 64 | connector types: | HY |
| array element spacing: | 1.5mm | matching materials: | Rexolite |
| length of array element: | 10mm |
it is worth emphasizing that the size of the large shafting equipment for which the phased array probe is designed is as follows: 800mm in diameter and 600mm in height.
Various performance indexes of the probe are shown in fig. 2-6, fig. 7 is a 3D scanning imaging graph adopting the probe, and as can be seen from the graph, the following graph can be seen:
the sample shafting equipment has obvious results when detecting a 2mm cutting groove at the position with the diameter of 800mm and the distance of 600mm.
And (4) conclusion: the device is used for shafting equipment, and can realize detection of a 2mm cutting groove at a position with a diameter of 800mm and a distance of 600mm, and the device is successfully developed.
According to the above embodiment, alright realize the utility model discloses well. It is worth to say that, on the premise of the above structural design, in order to solve the same technical problem, even if some insubstantial changes or retouching are made in the utility model, the essence of the adopted technical scheme is still the same as the utility model, so it should be in the protection scope of the utility model.
Claims (4)
1. The 3D detection scanning probe for the large-scale mechanical shafting of the water and electricity is characterized by comprising a phased array probe, wherein the phased array probe comprises a shell, a backing block, a piezoelectric element arranged on the backing block, a matching layer arranged on the piezoelectric element and an acoustic lens arranged on the matching layer, and the piezoelectric element is formed by arranging a plurality of piezoelectric wafers; the backing block, the piezoelectric element, the matching layer and the acoustic lens are packaged in the shell;
the frequency of the probe is 2.5MHz; the probe type is a linear array; the array element number of the probe is 64; the array element spacing of the probe is 1.5mm; the length of the array element of the probe is 10mm.
2. The hydroelectric large-scale mechanical shafting 3D detection scanning probe according to claim 1, further comprising a scanning frame for mounting the phased array probe, wherein the scanning frame phased array probe is detachably arranged in the mounting frame, and an encoder mounting position is further arranged on the scanning frame.
3. The 3D detection scanning probe for the large-scale mechanical shafting of the hydroelectric power plant as claimed in claim 1, wherein the matching layer is a polystyrene cross-linked resin matching layer.
4. The probe for 3D detection and scanning of the large-scale mechanical shafting of the hydroelectric power system according to claim 1, wherein the acoustic impedance of the piezoelectric wafer is 34Mrayl; the mechanical coupling coefficient is more than 60 percent, and the mechanical quality factor is less than 30.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202222546839.8U CN218298134U (en) | 2022-09-26 | 2022-09-26 | 3D detection scanning probe for water and electricity large-scale mechanical shaft system |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202222546839.8U CN218298134U (en) | 2022-09-26 | 2022-09-26 | 3D detection scanning probe for water and electricity large-scale mechanical shaft system |
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| Publication Number | Publication Date |
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| CN218298134U true CN218298134U (en) | 2023-01-13 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202222546839.8U Active CN218298134U (en) | 2022-09-26 | 2022-09-26 | 3D detection scanning probe for water and electricity large-scale mechanical shaft system |
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