KR20100076636A - Multi channel ultrasonic welding inspection system and control method - Google Patents

Abstract

PURPOSE: An ultrasonic detection device system and a control method thereof are provided to save the time to perform re-inspection by reducing the errors on detection operation and to have a very economical effect. CONSTITUTION: A control method of an ultrasonic detection device system is as follows. A probe(140) loaded on a driving machine(100) performs ultrasonic detection on a first check area. A reflective-wave signal transmitted to the probe is transferred to the scanner(124) and thus detection information is obtained. The rotation signal measured from the rotary encoder(125) loaded on the driving machine is transmitted to a motion controller(123). The detection information and location information are transmitted to a PC controller to output a coordinate value and a shape for a defect as a video signal. When the ultrasonic detection on the first check area of the driving machine is completed, the PC controller initializes a reference position point by reading a final inspection location. When the ultrasonic detection on the second check area of the driving machine is begun, the driving machine moves back from the initialized reference position point and performs the ultrasonic detection on the second check area by considering the moved-back location as a starting point.

Description

Ultrasonic Testing System and Control Method {Multi Channel Ultrasonic Welding Inspection System and Control Method}

The present invention relates to an ultrasonic flaw detection device system, and more particularly, to have a flaw detection area and an overlapping inspection section immediately before resuming the flaw detection work, thereby preventing flaw detection and flaw blanking due to mechanical operating errors at the boundary point. An ultrasonic flaw detector system and a control method thereof.

Ultrasound is a high frequency that is over the range of human audible sound (20 ~ 20000Hz). Ultrasound is a non-destructive test that detects surface and internal defects by sending high frequency sound waves into the material to be inspected.

When ultrasonic waves are delivered to the test object by using the ultrasonic waves, it proceeds inside the test body with energy loss and analyzes the amount of ultrasonic energy reflected from the discontinuity existing inside and the time of the ultrasonic wave to accurately determine the position and size of the discontinuity. There is a number.

Ultrasonic examination is a method that can check the discontinuity existing inside the test specimen. It is most widely used with radiographic examination, but it can be easily inspected even if the thickness of the test specimen is thick, and it has an excellent detection capability for flaw defects. There is this.

The information that can be obtained during the ultrasonic examination is made by reflection, refraction, diffraction and interference due to the properties of ultrasonic waves. Pulse-reflection through is mainly used.

Ultrasonic testing for industrial applications is used to detect laminations, cracks and inclusions in discontinuous parts of the base material as well as to detect pores, cracks, inclusions and fatigue cracks that may occur during processing (welding, casting, etc.) or during use. Used. In addition, it can be used in many fields such as bridges made of non-steel materials, steel structures, shipbuilding, pressure vessels, and general mechanical parts as well as steel materials.

Until now, many types of ultrasonic flaw detectors and probes have been manufactured. For example, the dual transducer has two vibrators arranged in one transducer case to transmit ultrasonic waves on one vibrator and receive reflected ultrasonic waves on the other vibrator.

In addition, the probe for the demdom injection is composed of two sets of two probes, one serves as a transmission and the other performs a receiving role like the dual probe.

In addition, the phased array transducer has a set of transducers, and as many ultrasonic probes as the number of transducers are inherent. That is, since the ultrasonic signals received by each vibrator are analyzed and synthesized by a specific software built-in computing device, the cost of the equipment is quite expensive.

On the other hand, ultrasonic inspection has a tendency to increase defect coverage because the defect detection ability and inspection time is less than other non-destructive inspection.

This is a useful ultrasonic test, but this method also has inherent problems.

First of all, ultrasonic inspection requires a highly skilled technique unlike other inspection methods. Therefore, the most suitable inspection method for the weak parts of pressure vessels and other structures is ultrasonic inspection, but it requires a highly skilled technique. There is room for thought.

Secondly, the ultrasonic flaw detection is carried out by zigzag scanning of the weld bead. However, the larger the inspection area, the longer the inspection time is, so the concentration of the inspector is lowered, which may adversely affect the judgment of the joint.

Thirdly, in order to solve the time loss caused by zigzag scanning, multi-channel multi-detector flaw detectors and techniques are currently used to solve the time loss caused by zigzag scanning.However, since special programs are installed in the ultrasonic flaw detector, dozens of general ultrasonic flaw detectors are used. As it is sold on the market at a high price of more than 200 to 300 million units, there are many problems in practicality.

As a conventional technology for solving such a problem, an ultrasonic multi-scanning flaw detector for a welding part of Korean Patent No. 10-0441757 has been proposed.

In more detail, the conventional ultrasonic multi-scanning flaw detector is arranged to space the three rectangular probes (hereinafter referred to as probes) at a predetermined distance, respectively, and to scan the ultrasonic wave as a whole in the thickness direction of the welded portion. It has a transducer combination case formed so that it can be.

In addition, the transducer cable is connected to one side of each transducer so as to transmit information related to an ultrasonic signal, and the transducer cable having an adapter on both sides and the transducer cable are integrated so that the outside of each transducer cable can be improved during inspection. Sub-cables comprising a protective cable are provided, and a transducer selection switch is formed to be connected to an adapter provided on one side of each transducer cable so as to select a desired transducer to transmit ultrasonic signals.

In addition, a main cable having an adapter at both sides and an adapter provided at one side of the main cable to be connected to one side of the transducer selection switch to transmit ultrasonic signals that do not interfere with each other, It is formed by the ultrasonic flaw detector to display the ultrasonic signals detected by the independent analysis of the ultrasonic signals that do not interfere with each other as a whole.

However, the above-described prior art is provided on one side of the welded part to inspect the defect of the welded part of the inspected object, and there is a difficulty in inspecting the defect site opposite the welded part.

In addition, the prior art has a problem that it is impossible to perform automated inspection because it is not equipped with a separate drive device, there is a limit to expand or adjust the flaw detection range, there was a problem that has a limitation in the application range.

As a result, the flaw detection apparatus of the prior art acts as a very important factor of the skill of the measurer, the deviation of the results may occur greatly depending on the inspector, there is a problem that is difficult to trust the test results because the test results are not constant.

In addition, the flaw detection apparatus of the prior art has a problem that inspection blanks are generated at the boundary point between flaw detection regions.

That is, after the inspection of the specific area and then resumed the inspection of the other area, there was a problem that the flaw detection delay and flaw blanking due to the mechanical operation error occurs. This has become a problem of lowering the reliability of the inspection results.

SUMMARY OF THE INVENTION An object of the present invention devised to solve the problems of the prior art is that when the ultrasonic flaw detection system finishes the flaw detection work for the first inspection area and then resumes the flaw detection work for the second inspection area, the second The driving gas is moved backwards by a predetermined interval so that the starting point of the inspection region starts behind the final inspection position of the first inspection region, so that duplicate inspection regions are generated. The present invention provides an ultrasonic flaw detection apparatus system and a control method thereof.

Still another object of the present invention is to minimize inspection error and increase accuracy, so that measurement can be performed without re-checking.

Ultrasonic flaw detector system for achieving the object of the present invention is to drive the traveling gas equipped with the ultrasonic probe along the welded portion of the inspected object, to automatically inspect the defect of the welded portion, and outputs the defect information as a video signal through the PC controller In the traveling ultrasonic flaw detector system for real time monitoring,

When the traveling body finishes the flaw detection work of the first inspection area of the inspected object and then starts the flaw detection work of the second inspection area, the PC control unit sets a predetermined distance using the final inspection position as the reference position point. After reversing, it is characterized in that the ultrasonic flaw detection for the second inspection region proceeds with the retracted position as a starting point.

The traveling body may include: a base frame formed in a quadrangular frame shape; A driving unit installed below the base frame; A scanning line installed in an inner transverse direction of the base frame; And a probe installed in a state in which the position of the scan line is variable.

The driving unit may include two motors each independently installed in front of the lower part of the base frame; Magnetic body shafts coupled to each of the motors to receive power; A motion controller installed at a rear end of the base frame to control driving of the motor; A scanner installed at the front end of the base frame to receive and process the scanning signal of the probe; And a rotary encoder installed near the rear end of the base frame to detect a position value of the traveling gas.

In addition, the scanning line is characterized in that the pair of transducers are installed to face each other centered on the weld.

The scan lines may be spaced apart from each other by a plurality of scan lines, and each scan line may be set to inspect different flaw detection areas to perform multi-channel flaw detection.

In this case, two to six scan lines may be installed.

According to another aspect of the present invention, there is provided a method of controlling an ultrasonic flaw detector system, the method comprising: performing ultrasonic flaw detection on a first inspection region by a probe mounted on a traveling gas; Acquiring flaw detection information by transmitting the reflected wave signal received by the probe to a scanner; Obtaining position information by transmitting a rotation signal measured by a rotary encoder mounted on the traveling body to a motion controller; Transmitting the flaw detection information and position information to a PC control unit to output coordinate values and shapes of the defect unit as image signals and to display them in real time on a monitor; At the end of the ultrasonic flaw detection for the first inspection region of the traveling body, initializing the reference position point by reading the final inspection position by the PC controller; And at the start of the ultrasonic flaw detection of the second inspection area of the traveling gas, reversing a predetermined distance from an initially set reference position point, and performing the ultrasonic flaw detection of the second inspection area using the reverse position as a starting point.

Here, the traveling gas is characterized in that a plurality of scanning lines are installed at a predetermined interval apart from each other, and each scanning line is set to inspect different flaw detection areas to perform multi-channel flaw detection.

In this case, two to six scan lines may be installed.

In addition, the test result measured in each scan line stores data for each channel, and outputs the data separately or outputs a single integrated image.

In addition, performing the ultrasonic flaw detection of the first and second inspection areas may include marking a guide line on the surface of the inspection object for guiding a predetermined flaw path of the travel gas, and sensing the guide line to detect the travel gas. The method may further include determining whether the vehicle is out of the path and resetting the driving direction of the driving body when the vehicle is out of the flaw path.

According to the present invention, when the ultrasonic flaw detector system finishes the flaw detection work for the first inspection area and then resumes the flaw detection work for the second inspection area, the starting point of the second inspection area is the final inspection of the first inspection area. By reversing the driving gas to a certain section so that the overlapping inspection section is generated to start at the rear of the position, it is possible to prevent the occurrence of flaw detection and flaw detection due to the mechanical operation error at the boundary point, and the accuracy and reliability of the flaw inspection result. Has the effect of improving.

In addition, the present invention has less error in the flaw detection work and can save time such as re-inspection work.

Hereinafter, with reference to the accompanying drawings for a preferred embodiment of the present invention will be described in detail.

1 is a schematic view showing the overall structure of the present invention, the present invention as shown in the figure is traveling along the weld 151 of the test body 150, the traveling body 100 mounted with the ultrasonic probe 140 It is a driving ultrasonic flaw detection system to automatically inspect the defect of the welding unit 151, and output the defect information as an image signal through the PC control unit 200 to monitor in real time. Ultrasonic flaw detection apparatus system of the present invention has a configuration including a traveling gas 100, a PC control unit 200 and a wired and wireless network (not shown) connecting the traveling gas 100 and the PC control unit 200. The PC control unit 200 may be physically implemented in a personal computer or a portable computer or other specially made computer or mobile device and display device. Of course, software capable of controlling the traveling body 100 may be installed or operated in the apparatus itself, and the PC controller 200 may include the software itself, thereby controlling the traveling body 100. And an apparatus unit that performs a role of performing ultrasonic flaw detection.

As described above, the ultrasonic flaw detection apparatus system performs the flaw detection work using the method as shown in FIG. 2 when the inspection area of the inspected object 150 is large, such as a large vessel, because the entire area cannot be flawed at once.

FIG. 2 is a conceptual diagram of ultrasonic inspection of the present invention. The present invention as shown in the drawing shows that after the traveling gas 100 finishes the inspection of the first inspection region 10 of the inspected object, the second inspection region ( When starting the flaw detection operation of 20), the PC control unit 200 after the traveling body 100 reverses a predetermined distance by using the final inspection position as the reference position point P1, and then moves the reverse position to the starting point P2. Ultrasonic flaw detection for the second inspection region 20 is performed. In this way, undetected areas due to errors in machine operation or errors in machine motion can be structurally eliminated.

3 is a plan view showing the traveling gas of the present invention, Figure 4 is a front view showing the traveling gas of the present invention.

The traveling body 100 as shown in the figure is a structure in which each component for constituting the flaw detector system is mounted, and provides a base frame 110.

The base frame 110 is manufactured by using a quadrangular shape, and can be manufactured using a structure that is generally known as a profile.

Such a profile forms a rail structure of various forms in the longitudinal direction, such a rail structure can be easily performed assembling work between the structures and attaching the structure by using a fastening member such as bolts, and also along the rail It has the advantage that the coupling position of the installation structure can be easily changed.

The lower part of the base frame 110 as described above is provided with a drive unit 120 for driving the flaw detection apparatus.

The driver 120 is largely comprised of a motor 121, a magnetic wheel 122, a motion control unit 123, a scanner 124, and a rotary encoder 125.

In more detail with respect to each of the components, two motors 121 to provide driving power to the drive unit 120 is installed separately before the lower portion of the base frame 110, respectively.

At this time, it is preferable that the motor 121 uses a stepping motor capable of precise control.

In addition, the magnetic wheels 122 are mounted on the rotating shafts of the motor 121, respectively. The magnetic wheels 122 are provided with a strong magnetic force so that the flaw detector of the present invention is suspended upside down on the vertical wall or the bottom of the test subject. Allows you to drive in state.

In this case, the motor 121 is driven and controlled by the motion control unit 123 installed at the rear end of the base frame 110.

In addition, the motion control unit 123 controls the driving of the motor 121 and the rotary encoder 125 installed near the rear end of the base frame 110 to detect the current position value of the traveling body 100. Will be controlled together.

Here, the rotary encoder 125 measures the number of revolutions to measure the moving distance of the flaw detection device, that is, the current position value. Such measurement data provides the position data of the defective part with respect to the inspected object 150. The motor 121 is used to control the moving distance and the speed of the flaw detector.

In addition, the scanner 124 is installed in front of the base frame 110 to receive and process the ultrasonic scanning signal of the transducer 140.

In this case, as shown in FIGS. 3 and 4, the scanning line 130 may be installed such that the pair of transducers 140 face each other with respect to the welding unit 151.

Of course, the scan line 130 may be configured to allow a plurality of pairs of transducers 140 to be mounted at the same time.

In addition, each of the transducers 140 may vary freely on the scan line 130.

In this case, a plurality of scan lines 130 may be installed by spacing the scan lines 130 at predetermined intervals, and each scan line 130 may perform multi-channel flaw detection to set different scan areas. do.

In the multi-channel flaw detection, two to six scanning lines 130 may be installed.

At this time, each of the transducers 140 may be installed in a state capable of automatic vertical height and angle adjustment. This automatic height structure can be very useful when it is necessary to change the position or the inspection angle of the probe due to the bending or generation of the test subject.

Hereinafter, a control method of the ultrasonic flaw detector system of the present invention will be described with reference to FIG. 5.

FIG. 5 is a flow chart illustrating an ultrasonic flaw detection control method of the present invention. First, the probe 140 mounted on the traveling gas 100 performs an ultrasonic flaw detection on the first inspection area.

At this time, the PC control unit 200 controls the scanner 124, generates a high voltage pulse of about 500V or more and transmits to the transducer 140 to generate ultrasonic waves.

At this time, the transducer 140 transmits ultrasonic waves to the inside of the inspected object 150 which is in contact with the contact medium, which is not shown, and when there is a defect inside the inspected object 150, the ultrasonic waves reflected from the defective position are scanners. The signal is amplified and received by the receiving unit 124, and then transmitted to the PC controller 200.

In this case, the scanner 124 is a timing signal generator for inputting the received synchronization signal output from the transducer 140 to provide a timing signal for signal processing, an analog for converting the analog flaw detection signal of the transducer 140 into a digital signal / Digital converter, a memory for temporarily storing the digital signal, and an interface for transmitting the ultrasound signal and position information to the PC.

Next, a step of obtaining position information by transmitting the rotation signal measured by the rotary encoder 125 mounted on the traveling body 100 to the motion control unit 123. (S20)

Next, the flaw detection and position information is transmitted to the PC control unit 200 to output the coordinate value and the shape of the defect unit as an image signal and display the real time on the monitor.

6 is a screen of a defective part output to a monitor using the ultrasonic flaw detector according to the present invention.

Next, at the end of the ultrasonic flaw detection of the first inspection region 10 of the traveling body 100, the PC controller 200 reads the final inspection position and initially sets the reference position point P1. S40) If the flaw detection result is no defect in the welded portion, then flaw detection for the second inspection region 20 is started. The first inspection service 10 and the second inspection area 20 are often physically continuous as one continuous welding site.

Next, when the first inspection service 10 and the second inspection area 20 are physically continuous as one continuous welding part, the ultrasonic wave of the second inspection area 20 of the traveling gas 100 is At the start of the flaw detection, a step of reversing a predetermined distance from the initially set reference position point P1 and performing the ultrasonic flaw detection with respect to the second inspection area 20 using the reverse position as the start point P2 is performed (S50).

Here, the traveling body 100 may be provided with a plurality of scanning lines 130 which are installed at a predetermined interval apart from each other, and each scanning line 130 is set to inspect different flaw detection areas to perform multi-channel flaw detection. have.

It is preferable to install two to six scanning lines 130 for the multi-channel flaw detection.

In addition, the test result measured in each scan line 130 may store data for each channel, and may output the data separately or output as one integrated image.

In addition, performing the ultrasonic flaw detection of the first and second inspection areas may include marking a guide line on the surface of the inspected object for guiding a predetermined flaw path of the traveling gas 100 and sensing the guide line to travel. The method may further include determining whether the gas 100 leaves the flaw path and causing the driving direction of the driving gas 100 to be reset when the gas 100 leaves the flaw path. The marking on the surface of the test object is more useful when the test object is severely curved, has a large curvature, or is highly variable.

The test result measured by the multi-channel flaw detector as described above may store data for each channel, and the data may be output individually or as a single integrated image to enable three-dimensional analysis. If multiple weld defects are found in the weld, such weld joints would preferably be output in one report rather than generating one report per weld defect. The information to be reported preferably includes any one or more of the welding defect related information that can be found through positional information, size information, and other flaw detection.

The PC control unit 20 is a step of finding a plurality of weld joints as a result of the ultrasonic flaw detection; Examining whether the plurality of welding defects meet predetermined reporting criteria; And reporting the welding defect through the step of outputting information about the plurality of welding defects in one unit report when the welding defects meet the preset reporting criteria. The output to the report means any one or more of printer output, monitor output, file storage, e-mail transmission, and wired and wireless transmission of welding defect information to a predetermined server or computer.

1 is a schematic diagram showing the overall structure of the present invention.

2 is a conceptual diagram of the ultrasonic flaw detection of the present invention.

3 is a plan view showing a traveling gas of the present invention.

4 is a front view showing a traveling body of the present invention.

Figure 5 is a flow chart illustrating the ultrasonic flaw detection control method of the present invention.

Figure 6 is a defect screen output to the monitor using the ultrasonic flaw detector system of the present invention.

<Description of the symbols for the main parts of the drawings>

100: driving body 110: base frame

120: drive unit 121: motor

122: magnetic body wheel 123: motion control unit

124: scanner 125: rotary encoder

130: scanning line 140: probe

150: test object 151: weld

200: PC controller

Claims (12)

The traveling ultrasonic 100 equipped with the ultrasonic probe runs along the welded portion of the inspected object, automatically inspects the welded defect, and outputs the defect information as an image signal through the PC controller 200 to monitor in real time. In the flaw detector system, When the traveling body 100 finishes the inspection work of the first inspection region 10 of the inspected object and then starts the inspection work of the second inspection region 20, the PC control unit 200 performs the traveling gas. After the 100 has retracted a predetermined distance using the final inspection position as the reference position point P1, the ultrasonic flaw detection of the second inspection region 20 proceeds using the reverse position as the starting point P2. Ultrasonic flaw detector system. The method of claim 1, The traveling body 100, A base frame 110 formed in a quadrangular shape; A driving unit 120 installed below the base frame 110; A scan line 130 installed in an inner transverse direction of the base frame 110; And A probe (140) installed on the scan line (130) in a position variable; Ultrasonic flaw detector system comprising a. 3. The method of claim 2, The drive unit 120, Two motors 121 each independently installed at the front front and rear of the lower part of the base frame 110; Magnetic body wheels 122 coupled to each of the motors 121 to receive power; A motion controller 123 installed at a rear end of the base frame 110 to control driving of the motor 121; A scanner 124 installed in front of the base frame 110 to receive and process a scan signal of the probe 140; And A rotary encoder 125 installed near the rear end of the base frame 110 to detect a position value of the traveling body 100; Ultrasonic flaw detector system comprising a. 3. The method of claim 2, The scanning line 130 is an ultrasonic flaw detector system, characterized in that a pair of transducers 140 are installed to face each other with respect to the welding unit (151). The method of claim 4, wherein Ultrasonic waves, characterized in that a plurality of scanning lines 130 are installed by spacing the scan line 130 at a predetermined interval, and each scanning line 130 is set to inspect different flaw detection areas to perform multi-channel flaw detection. Flaw detection system. The method of claim 5, Ultrasonic flaw detector system, characterized in that to install two to six scanning lines 130. Performing ultrasonic inspection on the first inspection area by the probe 140 mounted on the traveling body 100; Transmitting the reflected wave signal received by the probe 140 to the scanner 124 to obtain flaw detection information; Obtaining position information by transmitting a rotation signal measured by the rotary encoder 125 mounted on the traveling body 100 to the motion controller 123; Transmitting the flaw detection information and the position information to the PC control unit 200 and outputting the coordinate values and the shapes of the defect units as video signals and displaying them on a monitor in real time; At the end of the ultrasonic flaw detection of the first inspection region 10 of the traveling body 100, the PC controller 200 reads the final inspection position and initially sets the reference position point P1; And At the start of the ultrasonic flaw detection of the second inspection region 20 of the traveling body 100, the vehicle reverses a predetermined distance from the initially set reference position point P1 and sets the reverse position as the starting point P2. Conducting ultrasonic flaw detection for; Control method of the ultrasonic flaw detector system comprising a. The method of claim 7, wherein The traveling body 100 is provided with a plurality of scanning lines 130 are installed at a predetermined interval apart from each other, and each scanning line 130 is set to inspect different flaw detection area to perform multi-channel flaw detection Control method of ultrasonic flaw detector system. The method of claim 8, Control method of the ultrasonic flaw detector system, characterized in that to install two to six scanning lines (130). The method of claim 8, The control method of the ultrasonic flaw detector system, characterized in that for storing the test results measured in each scanning line 130 for each channel, the data is output separately or as a single integrated image. The method of claim 7, wherein Ultrasonic flaw detection of the first and second inspection areas may include marking a guide line for guiding a predetermined flaw path of the traveling gas 100 on the surface of the inspected object, and sensing the guide line to sense the traveling gas ( And determining that 100 is out of the flaw path and causing the driving direction of the traveling gas to be reset when the flaw is out of the flaw path. The method of claim 7, wherein Finding a plurality of weld joints as a result of the ultrasonic flaw detection; Examining whether the plurality of welding defects meet predetermined reporting criteria; And And outputting information about the plurality of welding defects in one unit report when the welding defects meet a predetermined reporting criterion.

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