RU2589521C1 - Method for automated ultrasonic inspection of large-size, thick-walled objects with shape of rotation bodies - Google Patents

Abstract

FIELD: control devices.

SUBSTANCE: invention can be used for ultrasonic inspection of large-size, thick-walled objects with shape of rotation bodies. Invention consists in fact thatobject of control during control maintains state of rest and is controlled on side of side and end surfaces, scanning of converters on surfaces of input and reception of acoustic oscillations in pendulum mode along circular trajectory, complete revolution, for example, clockwise, complete turn in reverse direction, wherein after each full turn one converter is shifted by pitch along side forming and other is along radius of article to its rotational axis. Results of control at side and end surfaces simultaneously by two channels are processed flaw detection computer equipment and printed in sequence in one protocol and defectogram, then in other protocol and defectogram.

EFFECT: technical result is increased efficiency of control, reduced power consumption, high reliability of monitoring.

1 cl, 4 dwg

Description

The invention relates to the field of non-destructive testing methods, in particular to input ultrasonic testing of stamped thick-walled products having the form of bodies of revolution (cylinders, cones), and can be widely used in various branches of mechanical engineering.

A known method [1] of ultrasonic testing of products having the form of bodies of revolution, including installing the controlled product on a stage table, centering it with cams, filling the immersion bath with contact liquid, installing and adjusting the ultrasonic transducer at a given point on the surface of the product in manual mode, performing ultrasonic testing in automatic mode, while the product rotates with the table and the bath, and the converter moves progressively up or down along the generatrix of the product, The result is a scanning of the ultrasonic transducer along the side surface of the product in a spiral, flaw detection equipment detects the presence and absence of defects.

The method has several disadvantages, which are:

- the impossibility of using it for ultrasonic testing of large-sized workpieces, because they require a large mass of water (several tons), which must be rotated;

- reducing the level of safety as a result of the rotation of large masses;

- increasing energy costs while increasing the size of the controlled product;

- great inertia of the rotating system;

- low reliability of control, since the sensitivity of flaw detection equipment is set in manual mode, and the product is controlled in automatic mode;

- control only cylindrical products;

- the impossibility of setting the optimal scan step.

There is also known a method [2] for ultrasonic testing of large-sized products having the form of bodies of revolution, which consists in the fact that the sensitivity of flaw detection equipment is manually adjusted, it is checked in automatic mode, a controlled product is installed on the installation table, it is centered, and the converter is brought into start control zone on the surface of the product, turn on the automatic control mode, scan the surface of the product with a converter in a spiral, fix in the process of control for with flaw detection equipment, the presence and absence of defects in it; in this case, after manual adjustment of the flaw detection equipment, it is checked in automatic mode, and input-reception of acoustic vibrations into the product during its control and also into the standards during tuning and its verification is carried out by the contact-gap method using converters with local bath.

The described method is intended for automated ultrasonic testing of large-sized products in the form of bodies of revolution, it increases the level of safety of service personnel, it is possible to control cylindrical and conical products, the inertia of the rotating system is reduced, the reliability and reliability of the automated control are increased, it is possible to set the optimal scanning step.

However, the described method [2] in the presence of a number of advantages over the method [1] has its drawbacks in that, when controlling large-sized, thick-walled blanks:

- reduced control performance due to an increase in end areas;

- increases the metal consumption of installations by increasing the mass of controlled billets;

- increased power consumption;

- the reliability of the control decreases, because with an increase in the dimensions of the faceplate, its end runout increases;

- ultimately, the initial cost of equipment and the operational cost of ultrasonic testing increase.

However, despite the existing disadvantages, the method [2] is the closest analogue of the proposed method and therefore is taken as a prototype.

The objective of the invention is to provide a method for controlling large-sized, thick-walled products having the form of bodies of revolution, eliminating the disadvantages of the analogue and prototype.

The problem is solved by the following technical solutions:

- the product in the process of ultrasonic control maintains a state of rest;

- ultrasonic transducers scan along the end and side surfaces of the product simultaneously in the pendulum mode: a full revolution in one direction, a full revolution in the other direction;

- after each full revolution, the ultrasonic transducers are displaced by one step on the side surface - along the generatrix, on the end surface - by one step along the radius;

- processing of the control results of the end and side surfaces is carried out simultaneously on their channels;

- printout of control results is carried out sequentially;

- documentation is carried out sequentially on one and the second channel;

- flaw detection equipment using encoders reads the coordinates of the position of the transducer around the circumference and along the generatrix or radius and registers them when defects are detected;

- the control results are simultaneously processed by flaw detection computerized equipment through two channels.

The essence of the proposed control method is illustrated by the graphic materials presented in figures 1-4.

In FIG. 1 is a diagram of ultrasonic inspection of a controlled product from its lateral outer surface.

In FIG. 2 is a view A of FIG. 1 (scheme of ultrasonic testing of the product 1 from the side of the surface of the upper end).

In FIG. Figure 3 shows the technological ring (a sample for checking manual tuning of flaw detection equipment in automatic mode).

In FIG. 4 shows a section BB in FIG. 3.

The ultrasonic monitoring circuitry of FIG. 1 and 2 include:

1 - controlled product; 2 - side surface of the product 1; 3 - end surface of the product 1; 4 - converter control products 1 from the side of the side surface 2; 5 - converter control products 1 from the end surface 3; 6 - the direction of movement of the Converter 4 on the side surface 2 of the product 1 clockwise; 7 - the movement of the Converter 4 counterclockwise on the side surface of the product 1; 8 - the direction of movement of the Converter 4 on the side surface 2 of the product 1 along the generatrix; 9 - the direction of movement of the Converter 5 on the end surface 3 of the product 1 clockwise; 10 - the movement of the Converter 5 on the end surface 3 of the product 1 counterclockwise; 11 - the direction of movement of the Converter 5 on the end surface 3 of the product 1 along the radius.

Technological ring 12 is a sample for checking the manual adjustment of flaw detection equipment (not shown in the drawings), is a ring 12 (Fig. 3, 4) with through side holes 13. The axis of the holes 13 are perpendicular to the axis of the ring 12 and are located at the same distance from it. In the holes 13, samples 14 of a set of standard samples of the type KSO-2 GOST 21397-81 with flat-bottomed reflectors 15 located at different depths according to GOST 21397-81 are installed. The working surfaces 16 of the samples 14 (KCO-2) are aligned with the working surface of the ring 12 using a straightedge and fixed in the holes 13 of the ring 12 with screws 17.

Ultrasonic quality control of the product is as follows.

Before starting the inspection, defectoscopic equipment (not shown in the drawings) is manually adjusted on samples 14 of type KSO-2 GOST 21397-81 by moving the transducer 4 or 5 along the working surface of each sample and obtaining the maximum amplitude of the echo signal reflected from the flat-bottomed reflector 15 of a given diameter at different depths from 5 mm to 180 mm or more.

Checking the manual sensitivity settings of flaw detection equipment in automatic mode is carried out on the process ring 12 (Fig. 3). Technological ring 12 using lifting equipment is installed on the product 1 and is aligned according to its inner or outer diameter. A scanning device is installed on specimen 12 (not shown in the drawings) and transducer 4 (5) is brought to the center of one of the KSO-2 type 14 specimens, 5-7 mm higher than the transducer relative to the center of specimen 14. Flaw detection equipment is turned on, and then the automatic operating mode of the scanning device. After 10-15 full revolutions, the automatic operation of the device is turned off. The equipment is set up correctly if all the artificial reflectors of samples 14 were recorded with at least two strokes. If at least one of them has not been recorded or recorded in one stroke, measures are taken for additional manual tuning of the flaw detection equipment and verification of other factors. Similarly, the manual adjustment of the equipment is checked with another converter 5. After checking the manual adjustment of the equipment, sample 12 is removed from the product 1.

Install the Converter 4 on the side surface of the product 1 in the zone of the beginning of control. The transducer 5 is installed on the end surface 2 of the product 1 at a diametrically opposite point, offset 180 ° from the beginning of the control zone on the side surface (Fig. 2), so that the radiation from the transducers does not affect each other. Converters 4 and 5 are connected to flaw detection equipment (not shown in the drawings). Turn on the flaw detector in the power supply, then turn on the automatic scan mode. The transducers 4 and 5, respectively, on the side surface 2 and on the end surface 3 of the product 1 are moved clockwise a full revolution around the axis of the product 1 according to the flaw detector program, they are stopped, shifted one step, respectively, the transducer 4 down (along the generatrix of the product 1), and the transducer 5 is radially to the axis of the product 1. Then, the transducers 4 and 5, respectively, on the side surface 2 and on the end surface 3 of the product 1 move counterclockwise for a full revolution, return to the starting position of the control start zone is stopped, the transducer 4 is moved down one step, respectively, along the generatrix of the product 1, and the transducer 5, along the radius of the product 1, is one step to its axis. In this case, each step of the transducer 4 is carried out along the same generatrix, and the transducer 5 along the same radius. As a result, the transducer 4 scans the entire lateral surface 2 of the product 1 with a constant circle circumference, and the transducer 5 scans the entire end surface 3 of the product 1 circumferentially, and each transducer emits ultrasonic vibrations into the body of the product 1 and receives echo signals from defects if any those in the controlled product 1.

The monitoring results of the transducers 4 and 5 are processed simultaneously on different channels of the flaw detector in accordance with the connection of the transducers to them, and defectograms with protocols are printed sequentially, first, on one channel of the transducer 4, then on the other channel of the transducer 5.

Thus, the control object, a large-sized, thick-walled product, during the control process maintains a state of rest, scanning ultrasonic transducers along the surfaces of the input-receiving ultrasonic vibrations is carried out in a pendulum mode along a circular path - a full revolution in one direction, a full revolution in the opposite direction - after each complete revolution, one converter is shifted by a step along the side generatrix, and the other converter is shifted by a step along the radius of the product to its axis of rotation.

Information sources

1. USSR author's certificate No. 1522088 "Device for ultrasonic testing of products", cl. G01N, priority dated 12/11/1986.

2. RF patent No. 23237153 "Method for ultrasonic testing of products having the form of bodies of revolution", cl. G01N, priority of 08.26.2006.

Claims (1)

A method for automated ultrasonic testing of large-sized, thick-walled products having the form of bodies of revolution, including adjusting the sensitivity of flaw detection equipment in manual mode, checking it in automatic mode, installing the controlled product on the base, bringing the transducer to the control start zone on the product surface, turning on the automated control mode, scanning by the transducer of the surface of the product, input-receiving of acoustic vibrations into the product during its control, and also standards for adjusting the sensitivity and testing it using the contact-slot method using transducers with a local bath, fixing defects during inspection of the product with flaw detection equipment, determining their magnitude, depth, coordinates, documenting the results of control, characterized in that a large-sized, thick-walled product in the process its scanning saves a state of rest and is simultaneously controlled from the side and end surfaces, scanning by transducers along The surfaces of the input-reception of acoustic vibrations are carried out in a pendulum mode along a circular path, a full revolution in one direction, a full revolution in the opposite direction, and after each full revolution one transducer is shifted a step along the side generatrix, and the other along the radius of the product to its axis rotations, control results on the lateral and end surfaces simultaneously on two channels are processed by flaw detection computerized equipment and printed sequentially in one protocol and defectogram e, then into another protocol and defectogram.

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