JP5325394B2 - Ultrasonic flaw detection method, ultrasonic flaw detection apparatus and ultrasonic flaw detection system for shaft member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and an apparatus for ultrasonic flaw detection of shaft members. <P>SOLUTION: Flaw-detection ultrasonic waves of vertical waves are made to be incident onto a face of a shaft member from a phased array probe mounted rotatably in the circumferential direction of the shaft member. The phased array probe is arranged eccentrically so as to tilt with respect to the face of the shaft member. The ultrasonic waves perform flaw detection in the circumferential direction of the shaft member, while a part of the shaft member at which a rotating member is press-fitted is being scanned in the axial direction of the shaft member by a sector scan method. This apparatus includes the phased array probe for transmitting flaw-detection ultrasonic waves of vertical waves; rotating disks for eccentrically fixing the phased array probe; a mechanism for holding the rotating disks at a shaft end of the shaft member for performing ultrasonic flaw detection rotation-freely; and a detector of the rotation angles of the rotating disks. <P>COPYRIGHT: (C)2009,JPO&amp;INPIT

Description

  The present invention relates to an ultrasonic flaw detection method, an ultrasonic flaw detection apparatus, and an ultrasonic flaw detection system for a roll shaft drive device of a rolling mill, a speed reducer shaft of a crane, and an axle of a train / industrial drive device.

  Since shaft members used in rolling mills and cranes are concerned about fatigue failure, an open inspection is periodically performed to disassemble the bearing portion and inspect for the presence of scratches such as fatigue cracks. However, rolling mills and crane speed reducers are large machines, and open inspections require a long construction period and large costs.

  In the case of an ultrasonic flaw detection method that detects flaws in the shaft member from the end of the shaft member, a press-fitting echo is generated at the boundary between the press-fitted portion and the non-press-fit portion when a gear or a coupling is pressed into the shaft member. If it uses a stepped shaft to fix gears such as the main speed reducer shaft of a ladle crane, it is not easy to discriminate it from cracks that occur at the same location. It is also necessary to detect flaws by distinguishing them from the back echoes of the stepped portion.

  Patent Document 1 relates to an ultrasonic flaw detection method and apparatus for a shaft member, and performs ultrasonic flaw detection from the end surface of the shaft member in order to detect a defect that occurs in the shaft member where a rotary member such as a gear is mainly press-fitted. In the probe structure, a plurality of probe segments are continuously arranged in the circumferential direction, and ultrasonic waves are sequentially incident, or one probe segment is moved along the circumferential direction, and the axis is moved. It describes that flaw detection is performed in the circumferential direction of the member.

  When a plurality of probe segments are arranged on the circumference, the defect signal received by the flaw detection data recording / analysis apparatus is analyzed by causing the changeover switch to electrically scan in the circumferential direction.

  In the method described in Patent Document 1, the ultrasonic wave used for flaw detection is a transverse wave, and the transverse wave is horizontal with respect to the traveling direction of the ultrasonic beam, thereby improving defect detection performance and suppressing the occurrence of press-in echoes. .

  However, since shear waves are used, the probe segment and the end face of the shaft member must be in close contact with each other by a thin film of highly viscous material. In order to maintain a close contact with the shaft end surface even when multiple probe segments are used for electrical scanning, the probe structure for each dimension of the shaft member I need a body.

  FIG. 6 shows an ultrasonic flaw detection method for a shaft member that the present inventors have already proposed in an unpublished prior application (Japanese Patent Application No. 2006-076239) in order to solve the above-described problems. The case of will be described.

  In the speed reducer 4, a gear 41 is press-fitted into a shaft member 43, and both ends thereof are supported by bearings 42. The shaft member 43 is a stepped shaft, and one side surface of the gear 41 is fixed by a stepped portion 45. In such a shaft member 43, scratches a such as fatigue cracks occur on the press-fitting side of the stepped portion 45.

  The ultrasonic flaw detector 1 includes a rotating disk 15 for fixing the phased array probe 11, and the rotating disk 15 itself rotates so that the ultrasonic waves generated by the phased array probe 11 are rotated around the shaft member 43. It is attached to the end surface 44 of the shaft member 43 with the jig 14 so that the direction can be inspected over the entire circumference. The flaw detection position in the circumferential direction is performed by detecting the rotation angle of the rotating disk 15 by the rotation angle detector 2 such as a rotary encoder (FIG. 7).

  The longitudinal wave ultrasonic beam transmitted from the phased array probe 11 is focused on the portion where the gear 41 is press-fitted by the shaft member 43, and in this state, the sector scan angle (angle swing method) is used for the sector scan angle b. The member 43 is swung in the radial direction, and the entire region in the axial direction of the press-fitted portion is scanned.

  When the rotating disk 15 rotates, the phased array probe 11 causes the longitudinal wave to be superposed in a state where the shaft member 43 is focused on the portion where the gear 41 is press-fitted over the entire circumference of the shaft member. A sound beam is emitted.

  If the longitudinal wave ultrasonic wave transmitted from the phased array probe 11 has a scratch a such as a fatigue crack, the end echo obtained by scattering and reflecting at the tip of the ultrasonic wave returns to the phased array probe 11 to display an image. Is sent to the flaw detection data recording / analyzing apparatus and recorded as flaw detection data.

In the ultrasonic flaw detector 1 described above, since the rotation angle detector 2 detects the rotation angle of the phased array probe 11, the flaw detection data recording analyzer 12 uses the vertical axis (Y-axis) for the obtained flaw detection data. Can be displayed as a developed image with the distance from the probe and the horizontal axis (X axis) the circumferential direction of the shaft member.
Japanese Patent Laid-Open No. 11-23540

  By the way, when the rotary member is press-fitted into the shaft member, a fitting echo is generated in the press-fitted portion as an echo from the periphery of the scratch, and when the shaft member is a stepped shaft, a back echo is generated from the stepped portion. It becomes a pseudo echo in flaw echo flaw detection such as a crack.

  FIG. 5 shows an end echo e generated from the tip of the scratch a generated when the ultrasonic wave d is incident on the scratch a generated in the press-fitting portion of the gear 41 of the shaft member 43, and generated from the start of the scratch a. A corner echo f is shown. Further, a fitting echo is generated from the press-fitting portion.

  In the flaw detection by the sector scan method using the phased array probe according to the above-mentioned unpublished prior application (Japanese Patent Application No. 2006-076239) by the applicant, the scratch echo (edge echo, corner echo) and the scratch such as a crack are detected. Pseudo echoes (fitting echoes, back echoes) from the surroundings can be compared relatively, and discrimination between them is relatively easy. However, if the shaft member has a small shaft diameter and a long shaft length, the detection accuracy can be further improved. It is desirable to improve.

  In view of this, the present invention provides a shaft member that can easily discriminate between scratch echoes (end echoes, corner echoes) such as cracks and pseudo echoes (fitting echoes, back echoes) from around the scratches even in such a case. An object of the present invention is to provide a method and apparatus for acoustic flaw detection.

The object of the present invention can be achieved by the following means.
1. Longitudinal waves from a phased array probe attached to a rotating disk attached concentrically with the shaft member on the end surface of the shaft member via a wedge provided with a chisel on a rotating disk attached to the shaft member in a circumferential direction. An ultrasonic flaw detection method for a shaft member that injects flaw detection ultrasonic waves and detects flaws such as cracks, wherein the phased array probe is arranged in the diameter direction of the rotating disk. The elements are arranged and arranged eccentrically by a certain distance from the axis of the shaft member, and the amount of eccentricity can be adjusted by moving on the rotating disk.The flaw detection ultrasonic wave is divided into sector scan angles by a sector scan method. The shaft member is swung only in the radial direction of the shaft member, and the entire region in the axial direction of the portion where the rotary member is press-fitted is scanned, and the incident angle of the flaw detection ultrasonic wave to the press-fitted portion of the shaft member becomes a predetermined angle or more. Eccentric amount, fae And adjusting at least one of the angle of incidence of from Doarei probe, the shaft member circumferential direction of the rotating member is press-fitted portion of the shaft member, characterized in that the flaw detection by rotating the rotary disk Ultrasonic flaw detection method.
2. 2. The shaft member ultrasonic flaw detection method according to claim 1, wherein the shaft member is a stepped shaft.
3. A phased array probe for transmitting longitudinal flaw detection ultrasonic waves, a rotating disk on which the phased array probe is attached via a wedge provided with a paddle, and performing ultrasonic testing on the rotating disk A shaft end of the shaft member is provided with a mechanism that is concentric with the shaft member and rotatably held in a circumferential direction of the shaft member, and a rotation angle detector of the rotating disk, and the phased array probe includes the rotating circle It lined the phased array probe each probe probe in the diameter direction of the plate, said shaft being arranged axial center eccentric by a predetermined distance member can adjust the eccentricity by moving the rotary disc upper Rukoto A shaft member ultrasonic flaw detector characterized by the above.
4). Longitudinal waves from a phased array probe attached to a rotating disk attached concentrically with the shaft member on the end surface of the shaft member via a wedge provided with a chisel on a rotating disk attached to the shaft member in a circumferential direction. An ultrasonic flaw detection system for a shaft member that injects flaw detection ultrasonic waves and detects flaws such as cracks, wherein the phased array probe is arranged in the diameter direction of the rotating disk in the direction of each of the phased array probes. lined child is decentered only axial center certain distance before Kijiku member, wherein to adjust the eccentricity by moving the rotary disc above the flaw detection ultrasound, by sector scanning method, a sector scanning angle amount corresponding swung in the radial direction of the shaft member, by scanning the entire axial range of the rotating member is press-fitted portion, the incident angle to the flaw detection ultrasonic press-fitting portion, the eccentric amount so that a predetermined angle or more Phased array And adjusting at least one of the angle of incidence of from probe, the shaft member circumferential direction of the rotating member is press-fitted portion, and testing by rotating the rotary disc, to image the resulting inspection data An ultrasonic flaw detection system for a shaft member, characterized by performing crack analysis such as cracks.

  INDUSTRIAL APPLICABILITY The present invention is applicable to a shaft member having a shaft diameter capable of arranging a phased array probe in an end face, and is highly applicable and versatile, and a rolling mill drive device and a ladle crane reducer used in the steel industry. In addition, it is possible to confirm the presence or absence of cracks such as cracks in shaft members of large important facilities such as trains and axles of industrial drive devices without performing an open inspection, which is extremely useful industrially.

  The present invention relates to a longitudinal flaw detection ultrasonic wave from a phased array probe in which scratches such as fatigue cracks occurring in a portion where a rotating member such as a gear is press-fitted in a shaft member are eccentric from the shaft center of the shaft member. It is characterized by flaw detection.

  FIG. 1 shows a situation in which ultrasonic flaw detection is performed on a shaft member of a reduction gear using an ultrasonic flaw detection apparatus according to an embodiment of the present invention, and FIG. 2 shows the ultrasonic flaw detection apparatus shown in FIG. A side view is shown. The structure of the speed reducer 4 shall be demonstrated with FIG.

  In the figure, 1 is an ultrasonic flaw detector, 2 is a rotation angle detector, 3 is a mounting jig for the rotation angle detector 2, 4 is a speed reducer, 11 is a phased array probe, 12 is a flaw detection data recording and analysis device, 13 is Wedge, 14 is a guide with magnet, 15 is a rotating disk, 16 is a jig for fixing the phased array probe 11 to the rotating disk 15, 41 is a gear, 42 is a bearing, 43 is a shaft member, 44 is a shaft member 43 , 45 is a stepped portion, a is a flaw such as a fatigue crack and is generated on the press-fitting side of the stepped portion 45 in the figure, and b is a sector scan angle.

  The ultrasonic flaw detector 1 according to the present invention includes a phased array probe 11 and a rotating disk 15 that fixes the phased array probe 11 with a jig 16, and the rotating disk 15 itself attempts to detect flaws. Rotating concentrically with the shaft member, composed of a plurality of guides 14 with magnets so that the ultrasonic waves from the phased array probe 11 can detect the circumferential direction of the shaft member 43 over the entire circumference. It is attached to the end surface 44 of the shaft member 43 by a holding mechanism.

  Further, the ultrasonic flaw detector 1 detects the rotation angle of the rotating disk 15 in order to specify the flaw detection position in the circumferential direction, for example, a rotary encoder fixed to the housing portion of the speed reducer 4 by the mounting jig 3 or the like. The rotation angle detector 2 is attached.

  The phased array probe 11 is an array probe in which a plurality of transducers are embedded, and the array probe of the simultaneous excitation group is driven with a time difference in units of nanoseconds to focus the ultrasonic beam at a certain distance. be able to.

  In the state shown in FIG. 1, the longitudinal wave ultrasonic beam transmitted from the phased array probe 11 is focused on the portion where the gear 41 is press-fitted by the shaft member 43, and in this state, the sector scan method (angle swing method) Accordingly, the entire region in the axial direction of the press-fitted portion is scanned by swinging in the radial direction of the shaft member 43 by the sector scan angle b.

  When the rotating disk 15 rotates, the phased array probe 11 causes the longitudinal wave to be superposed in a state where the shaft member 43 is focused on the portion where the gear 41 is press-fitted over the entire circumference of the shaft member. A sound beam is emitted.

  If the longitudinal wave ultrasonic wave transmitted from the phased array probe 11 has a scratch a such as a fatigue crack, the end echo obtained by scattering and reflecting at the tip of the ultrasonic wave returns to the phased array probe 11 to display an image. Is sent to the flaw detection data recording / analyzing device 12 and recorded as flaw detection data.

  In the ultrasonic flaw detector 1 according to the present invention, the phased array probe 11 is decentered by a fixed distance from the axis C of the shaft member 43 and attached to the rotating disk 15 via the wedge 13. The wedge 13 is configured to hold the phased array probe 11 against the rotating disk 15 so that the longitudinal wave ultrasonic wave from the phased array probe 11 is incident on the fitting portion of the shaft member. The shape is appropriately selected so that ultrasonic flaw detection is easy.

  The amount of eccentricity may be set by appropriately moving the phased array probe 11 on the rotating disk 15 so that pseudo echo and scratch echo can be discriminated at the time of flaw detection, and is not particularly defined in the present invention. Therefore, it is preferable that the phased array probe 11 is sandwiched by the jigs 6 on both sides of the phased array probe 11 so that the eccentric amount can be easily adjusted (FIG. 2).

  Ultrasonic flaw detection conditions are as follows: At each position where the eccentricity is changed, the incident angle of the ultrasonic wave from the phased array probe 11 is changed variously, and the eccentricity and the incident angle that allow easy discrimination of the pseudo echo and the scratch echo are changed. Select. The eccentricity is performed so that the probes of the phased array probe are arranged in the diameter direction of the rotating disk 15.

  Ultrasonic flaw detection conditions can be performed by adjusting both or one of the eccentricity and the incident angle.

  FIG. 3 is a schematic diagram for explaining a test method for examining the influence on the echo height by changing the incident angle θ of the ultrasonic wave to change the incident direction to the press-fitting portion, and is a phased array probe 11. Is moved in the axial radial direction on the end face 44 of the shaft member 43 to change the incident angle θ of the ultrasonic wave d, and the incident direction of the ultrasonic wave d to the press-fitted portion where the scratch a is generated is changed. Detected and implemented.

  FIG. 4 shows the test results. When the incident angle θ increases, the fitting echo attenuates. However, the corner echo is substantially constant. By increasing the incident angle θ, the fitting echo and the corner echo can be easily distinguished. Become.

  This test result is obtained when the ultrasonic wave is obliquely incident on the crack crack surface, and the same tendency is obtained for the end echo generated from the tip of the ridge and the back echo from the stepped portion. .

  Furthermore, since the ultrasonic waves are incident obliquely on the crack surface, the ultrasonic waves reflected from the corner of the scratch and the ultrasonic waves reflected from the tip of the scratch are easily separated in time, and the height of the scratch is increased. Detection accuracy is also improved.

  In the ultrasonic flaw detector 1 according to the present invention, the rotation angle of the phased array probe 11 is detected by the rotation angle detector 2, so that the flaw detection data recording / analysis device 12 uses the vertical axis (Y It is possible to display a developed image with the axis (axis) as the distance from the probe and the horizontal axis (X axis) as the circumferential direction of the shaft member. It is easy to detect cracks.

  When flaw detection is performed for the entire length in the axial direction, the flaw detection data obtained with the X and Y coordinate axes described above is also displayed for the total axial length (Z direction).

  In the ultrasonic flaw detection apparatus 1 according to the present invention, longitudinal ultrasonic waves are used as flaw detection ultrasonic waves, so that water having a low viscosity is used as a contact medium between the phased array probe 11 and the end face 44 (not shown in FIG. 1). It is possible to rotate the phased array probe 11 with the above-described simple device configuration without using oil or the like and needing to adhere or adhere between the two as in the case of a transverse wave and a horizontal wave.

The figure which shows the structure of the ultrasonic flaw detector based on one Example of this invention. The figure which shows the side view of the ultrasonic flaw detector shown in FIG. The schematic diagram explaining the test method which investigated the influence which changes the incident direction to a press-fit part with the incident angle (theta) of an ultrasonic wave, and has on echo height. The figure which shows the influence which the incident angle (theta) of an ultrasonic wave has on the echo height of a corner echo and a fitting echo. The schematic diagram explaining generation | occurrence | production of the echo from the crack | wound which generate | occur | produced in the press-fit part. The figure which shows the structure of the ultrasonic flaw detector which has arrange | positioned the phased array probe to the axial center of a shaft member. The side view of the ultrasonic flaw detector shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Ultrasonic flaw detector 2 Rotation angle detector 3 Mounting jig 4 Reducer 11 Phased array probe 12 Flaw detection data recording analyzer 13 Wedge 14 Guide with magnet 15 Rotating disk 16 Jig 41 Gear 42 Bearing 43 Shaft member 44 End face 45 Stepped part a Scratches such as fatigue cracks b Sector scan angle

Claims (4)

Longitudinal waves from a phased array probe attached to a rotating disk attached concentrically with the shaft member on the end surface of the shaft member via a wedge provided with a chisel on a rotating disk attached to the shaft member in a circumferential direction. An ultrasonic flaw detection method for a shaft member that injects flaw detection ultrasonic waves and detects flaws such as cracks, wherein the phased array probe is arranged in the diameter direction of the rotating disk. lined child is decentered only axial center certain distance before Kijiku member, wherein to adjust the eccentricity by moving the rotary disc above the flaw detection ultrasound, by sector scanning method, a sector scanning angle The shaft member is swung in the radial direction of the shaft member, and the entire area in the axial direction of the portion where the rotating member is press-fitted is scanned, and the incident angle of the flaw detection ultrasonic wave to the press-fitting portion of the shaft member is greater than a predetermined angle . Eccentric amount, fa And adjusting at least one of the angle of incidence of from Doarei probe, the shaft member circumferential direction of the rotating member is press-fitted portion of the shaft member, characterized in that the flaw detection by rotating the rotary disk Ultrasonic flaw detection method.   2. The method for ultrasonic inspection of a shaft member according to claim 1, wherein the shaft member is a stepped shaft. A phased array probe for transmitting longitudinal flaw detection ultrasonic waves, a rotating disk on which the phased array probe is attached via a wedge provided with a paddle, and performing ultrasonic testing on the rotating disk A shaft end of the shaft member is provided with a mechanism that is concentric with the shaft member and rotatably held in a circumferential direction of the shaft member, and a rotation angle detector of the rotating disk, and the phased array probe includes the rotating circle arrangement each probe in the diameter direction of the phased array transducer of the plate, are arranged eccentrically by axial center certain distance before Kijiku member, to adjust the eccentricity by moving the rotary disc above An ultrasonic flaw detector for a shaft member. Longitudinal waves from a phased array probe attached to a rotating disk attached concentrically with the shaft member on the end surface of the shaft member via a wedge provided with a chisel on a rotating disk attached to the shaft member in a circumferential direction. An ultrasonic flaw detection system for a shaft member that injects flaw detection ultrasonic waves and detects flaws such as cracks, wherein the phased array probe is arranged in the diameter direction of the rotating disk in the direction of each of the phased array probes. lined child is decentered only axial center certain distance before Kijiku member, wherein to adjust the eccentricity by moving the rotary disc above the flaw detection ultrasound, by sector scanning method, a sector scanning angle amount corresponding swung in the radial direction of the shaft member, by scanning the entire axial range of the rotating member is press-fitted portion, the incident angle to the flaw detection ultrasonic press-fitting portion, the eccentric amount so that a predetermined angle or more Phased array And adjusting at least one of the angle of incidence of from probe, the shaft member circumferential direction of the rotating member is press-fitted portion, and testing by rotating the rotary disc, to image the resulting inspection data An ultrasonic flaw detection system for a shaft member, characterized by performing crack analysis such as cracks.

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