WO2015001625A1 - Dispositif et procédé de détection de défauts aux ultrasons, et procédé permettant d'inspecter la zone de soudure d'une structure de panneau - Google Patents

Dispositif et procédé de détection de défauts aux ultrasons, et procédé permettant d'inspecter la zone de soudure d'une structure de panneau Download PDF

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Publication number
WO2015001625A1
WO2015001625A1 PCT/JP2013/068198 JP2013068198W WO2015001625A1 WO 2015001625 A1 WO2015001625 A1 WO 2015001625A1 JP 2013068198 W JP2013068198 W JP 2013068198W WO 2015001625 A1 WO2015001625 A1 WO 2015001625A1
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WIPO (PCT)
Prior art keywords
ultrasonic
ultrasonic array
array sensor
welded portion
defect
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PCT/JP2013/068198
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English (en)
Japanese (ja)
Inventor
将裕 三木
聡 北澤
雅己 小方
紀朗 後藤
小林　善宏
晋 安西
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株式会社 日立製作所
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Priority to PCT/JP2013/068198 priority Critical patent/WO2015001625A1/fr
Publication of WO2015001625A1 publication Critical patent/WO2015001625A1/fr

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22—Details, e.g. general constructional or apparatus details
    • G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
    • G01N29/265—Arrangements for orientation or scanning by relative movement of the head and the sensor by moving the sensor relative to a stationary material
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/11—Analysing solids by measuring attenuation of acoustic waves
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22—Details, e.g. general constructional or apparatus details
    • G01N29/225—Supports, positioning or alignment in moving situation
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22—Details, e.g. general constructional or apparatus details
    • G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
    • G01N29/262—Arrangements for orientation or scanning by relative movement of the head and the sensor by electronic orientation or focusing, e.g. with phased arrays
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
    • G01N29/4409—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
    • G01N29/4427—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with stored values, e.g. threshold values
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/04—Wave modes and trajectories
    • G01N2291/044—Internal reflections (echoes), e.g. on walls or defects
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/10—Number of transducers
    • G01N2291/106—Number of transducers one or more transducer arrays
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/26—Scanned objects
    • G01N2291/267—Welds
    • G01N2291/2675—Seam, butt welding

Definitions

  • the present invention relates to an ultrasonic inspection method and inspection apparatus for flaws, cracks, and weld defects generated in a welded portion for joining plate materials.
  • Welding is indispensable for manufacturing large structures, but welding defects rarely occur at the weld due to welding. Therefore, the quality of a welded part is guaranteed by performing an appropriate nondestructive inspection on the welded part.
  • a general nondestructive inspection method for a welded portion an ultrasonic flaw detection method or a radiation inspection method can be cited.
  • the ultrasonic flaw detection method is widely used because of the simplicity of the apparatus and the absence of operations such as shielding necessary for radiation inspection.
  • Patent Document 1 discloses an ultrasonic flaw detection method for a welded portion in which plate materials are joined to each other.
  • two oblique probes are arranged on one surface of a welded portion so as not to be on the same straight line, and the ultrasonic probe is scanned back and forth in the direction orthogonal to the welded portion. Then, the defect generated in the thickness direction is detected by adjusting the incident angle of the ultrasonic wave to the weld line and the distance to the weld line.
  • Patent Document 2 discloses a method for inspecting a welded portion of a welded steel pipe formed by welding a steel pipe having a semicircular cross section. According to the invention disclosed in Patent Document 2, when a pair of ultrasonic probes is fixedly arranged along the weld line and a reflected signal is detected by both of the pair of ultrasonic probes, The reflected signal is determined as a defect.
  • Patent 3140157 Japanese Patent Laid-Open No. 2003-322643
  • the ultrasonic probe For inspection of welded parts of long members, conventionally, the ultrasonic probe was manually moved in a direction crossing the welding line and in the welding line direction to detect the welded part. Normally, convex weld surpluses are generated on the surface of the welded portion. Therefore, the surplus is ground with a grinder and the surface of the welded portion is smoothed, and then the flaw detection is performed. In this method, since it is necessary to delete surplus before inspection, a technique for performing welding inspection at high speed without pretreatment is desired.
  • a coordinate system is set for the object to be welded, and the longitudinal direction of the weld line, which is the center line of the weld, is orthogonal to the X direction and the longitudinal direction of the weld line.
  • the direction is the Y direction, and the plate thickness depth direction to be inspected is the Z direction.
  • Patent Document 2 is a method of arranging an ultrasonic probe in a fixed manner, and does not consider the movement of the ultrasonic probe in the first place.
  • the present invention is an ultrasonic that can inspect the presence or absence of a defect in a welded part only by parallel (X direction) movement along the weld line without performing forward / reverse (Y direction) scanning of the ultrasonic probe. It is an object of the present invention to provide a flaw detection apparatus, a flaw detection method, or a flaw detection method for a panel structure that is joined by welding various shapes.
  • an ultrasonic flaw detector used for ultrasonic inspection of a welded portion includes an ultrasonic array transducer that transmits and receives ultrasonic waves to the welded portion, and the welded portion
  • the first ultrasonic array sensor and the second ultrasonic array sensor disposed across the first and second ultrasonic array sensors, and the distance between the first and second ultrasonic array sensors is kept constant, the first and second An ultrasonic array sensor holder that moves the ultrasonic array sensor along the longitudinal direction of the weld, an ultrasonic controller that converts the ultrasonic wave received by the ultrasonic array transducer into an echo signal, and the echo
  • a flaw detection controller that detects a defect in the weld using a signal is provided.
  • FIG. 3 is a schematic diagram illustrating an arrangement of ultrasonic array sensors in the ultrasonic flaw detector according to the first embodiment.
  • FIG. 3 is a B-B ′ sectional view of the schematic diagram of FIG. 2 (YZ sectional view of the ultrasonic array sensor arrangement diagram of FIG. 2).
  • FIG. 3 is a C-C ′ sectional view of the schematic diagram of FIG. 2 (ZX sectional view of the ultrasonic array sensor arrangement diagram of FIG.
  • FIG. 3 is an enlarged view of a main part showing an ultrasonic propagation path in the ultrasonic flaw detector of Example 1. It is an example of the test result displayed on the display of the ultrasonic flaw detector of Example 1.
  • 3 is a flowchart for explaining processing in the ultrasonic flaw detector according to Embodiment 1; It is explanatory drawing of the to-be-inspected object of the ultrasonic flaw detector of Example 2.
  • FIG. 3 is a schematic diagram showing the positional relationship between the ultrasonic flaw detector of Example 2 and an inspection object (corresponding to the A-A ′ cross-sectional view of FIG. 1).
  • 6 is a layout diagram of ultrasonic array sensors in the ultrasonic flaw detector according to Embodiment 2.
  • FIG. 11 is a D-D ′ sectional view (ZX section) of the ultrasonic array sensor arrangement diagram shown in FIG. 10.
  • (A) It is a principal part enlarged view which shows the ultrasonic propagation path
  • FIG. (B) It is a principal part enlarged view which shows another ultrasonic propagation path in the ultrasonic flaw detector of Example 2.
  • FIG. It is an example of the test result displayed on the indicator of the ultrasonic flaw detector of Example 2.
  • FIG. 1C is a system configuration diagram of the ultrasonic flaw detector according to the present embodiment.
  • the ultrasonic flaw detection apparatus includes an ultrasonic array probe 101 that transmits and receives an ultrasonic wave in contact with an object to be inspected, and transmits the ultrasonic wave as an analog echo signal, and the ultrasonic array.
  • a phased array flaw detector 102 that controls the probe 101 and a display 14 that displays the inspection result are configured.
  • the phased array flaw detector 102 includes an analog / digital conversion board that digitizes an analog signal transmitted from the ultrasonic array probe 101, an amplifier that amplifies the AD-converted digital signal, and various types of digitalized echo signals.
  • a processor that executes processing, a memory that stores software executed by the processor, a secondary storage device, and the like are included.
  • FIG. 1A is a schematic diagram showing a state in which the ultrasonic array probe 101 is placed on a structure in which the plate materials 3a and 3b are joined by the welded portion 1.
  • FIG. 1A is a schematic diagram showing a state in which the ultrasonic array probe 101 is placed on a structure in which the plate materials 3a and 3b are joined by the welded portion 1.
  • the ultrasonic array probe 101 includes a pair of ultrasonic array sensors 4 and 5, an ultrasonic array sensor holder 6 that holds the ultrasonic array sensor, and the like.
  • the ultrasonic array sensor holder 6 includes a casing for holding the first and second ultrasonic array sensors 4 and 5 at a fixed distance from each other, and the first and second ultrasonic arrays.
  • the sensors 4 and 5 are fixed to the casing with an ultrasonic array sensor fixing screw 7.
  • the first and second ultrasonic array sensors 4 and 5 fixed to the casing are installed on the upper surface of the plate material 3a or 3b so as to straddle the welded portion 1, and ultrasonic waves are incident from the plate material and welded. Inspect part 1.
  • a contact medium such as water, oil, or glycerin paste may be applied to the array sensor installation surface.
  • an ultrasonic array sensor stored in the ultrasonic array sensor holder 6 either a single transducer type ultrasonic array sensor or a dual transducer type ultrasonic array sensor is used. Also good.
  • the ultrasonic array sensor holder 6 is self-propelled and is provided with a probe mover for moving along the longitudinal direction (so-called weld line) of the welded part of the inspection object.
  • a probe mover for moving along the longitudinal direction (so-called weld line) of the welded part of the inspection object.
  • four tires 8 and a motor 10 for driving the tires are installed, and the longitudinal direction of the welded portion 1 (X direction in FIG. 1A). Can translate. If the motor 10 is installed for at least one of the four tires 8, the ultrasonic array sensor holder 6 can be moved.
  • a movement amount measuring device 9 is connected to at least one of the four tires 8 and the distance traveled by the ultrasonic array sensor holder 6 is measured from the rotation amount of the tire.
  • the phased array flaw detector 102 includes an ultrasonic controller 11 that performs switching control of ultrasonic transmission and reception to the ultrasonic array sensor, and a probe movement controller that performs movement control and movement amount measurement of the ultrasonic array sensor holder. 12. It is comprised by the flaw detection controller 13 etc. which carry out overall control of the whole ultrasonic inspection.
  • the ultrasonic controller 11, the probe movement controller 12, and the flaw detection controller 13 described above are realized by the processor described in FIG. 1C executing various software.
  • the ultrasonic controller 11 is connected to the first and second ultrasonic array sensors 4 and 5 and controls transmission of ultrasonic waves and reflection from a defect or reception of diffraction echoes.
  • the received echo is converted into an electric signal (hereinafter referred to as an echo signal), digitized and recorded, and further converted into image information and sent to the flaw detection controller 12.
  • the probe movement controller 12 controls the movement of the ultrasonic array sensor holder 6 by calculating the movement distance of the movement amount measuring device 9 and driving control of the motor 10, and thereby controls the first and second ultrasonic array sensors. 4 and 5 are controlled.
  • the calculation result of the moving distance is transmitted to the flaw detection controller 13, and is used for the flaw detection result display and the defect occurrence range recording in the flaw detection controller 13.
  • the ultrasonic array sensor holder 6 can be self-propelled by a command from the probe movement controller 12.
  • the flaw detection controller 13 controls the ultrasonic controller 11 and the probe movement controller 12.
  • An ultrasonic wave transmission instruction is sent from the ultrasonic controller 11 to record and record information on the received wave.
  • the defect signal extraction unit extracts a defect signal based on the received wave information.
  • the defect determination unit performs defect determination on the detection signal from the defect signal extraction unit.
  • the movement control unit issues a movement instruction by the probe movement controller 12, receives movement distance information, and records position information of the first and second ultrasonic array sensors 4 and 5. Also, defect detection determination information based on the received wave information in the ultrasonic controller 11 and inspection based on the positional information of the first and second ultrasonic array sensors 4 and 5 in the probe movement controller 12. The result is sent to the display 14.
  • the display unit 14 displays the positions of the first and second ultrasonic array sensors 4 and 5, flaw detection results, and the like based on the inspection result output information from the flaw detection controller 13.
  • Example 1 The first embodiment will be described below. In the present embodiment, an example will be described in which a single-vibrator ultrasonic array sensor is used as the ultrasonic array sensor and applied to a welded portion inspection between plate members. As an inspection target, a structure in which plate members are joined together by welding is assumed, and defects are present inside the weld bead.
  • the ultrasonic array sensor used in the ultrasonic inspection a single transducer type ultrasonic array sensor is used, and is arranged on the surface of the plate material so as to face each other with the welded portion 1 interposed therebetween as shown in FIG.
  • FIG. 3 is a cross-sectional view (B-B ′ cross section in FIG. 2) of the ultrasonic array sensor holder 6 in the direction intersecting the weld line.
  • the plate members 3a and 3b are joined by a welded portion 1 which is a joining bead, and the cross section of the welded portion 1 has a shape similar to a sector shape with the surplus on the upper side (the mounting surface side of the ultrasonic array probe). ing.
  • the purpose is to detect the defect 2 described above, and for this purpose, the ultrasonic array sensor is arranged so that the ultrasonic wave is incident on the defect from an oblique direction.
  • ultrasonic array transducers 4a and 5a which are aggregates of elements that transmit and receive ultrasonic waves, are installed inside the first and second ultrasonic array sensors 4 and 5, ultrasonic array transducers 4a and 5a, which are aggregates of elements that transmit and receive ultrasonic waves, are installed.
  • the ultrasonic array transducers 4a and 5a are composed of a plurality of arranged transducers, and the ultrasonic wave transmission direction and the focal position can be adjusted by electronic scanning for adjusting the voltage time applied to the transducers.
  • a wedge-shaped member (wedge 16 shown in FIG. 3) is installed at the lower part of the vibrator to tilt the ultrasonic array vibrator. .
  • the wedge 16 is built in the ultrasonic array sensor to reduce the size.
  • Ultrasonic waves can be scanned by programming and changing the applied voltage time described above. Thereby, the inspection range can be shortened because a wide range can be inspected by minimizing the moving range of the ultrasonic array sensor.
  • the electronic scanning conditions of the ultrasonic array sensor can be optimized and the optimum scanning conditions that can inspect the defects assumed in the welded portion can be determined, so that the inspection time can be shortened.
  • points O 1 and O 2 are intersections between a perpendicular drawn from the transducer that transmits the ultrasonic wave to the surface of the inspection object and the surface of the inspection object, and are sector-shaped obtained by the sector scan method. This is the position corresponding to the key of the ultrasonic image.
  • FIG. 4 shows a C-C ′ cross section in FIG.
  • the X direction is the longitudinal direction of the weld line
  • the defect length L is the distance in the X direction
  • the defect height H is the distance in the Z direction.
  • the defect length L is obtained by measuring the moving distance of the ultrasonic array sensor in the X direction, while the defect height H is calculated from the ultrasonic reflection signal. The defect height measurement will be described later.
  • the ultrasonic flaw detection apparatus of the present embodiment has a function of executing the first flaw detection method and the second flaw detection method.
  • the first flaw detection method is flaw detection using only one of the pair of ultrasonic array sensors, that is, only the first ultrasonic array sensor 4 or the second ultrasonic array sensor 5.
  • an ultrasonic wave 15a is transmitted from the ultrasonic array transducer 4a, a reflected ultrasonic wave (reflected echo) at the defect 2 is received by the ultrasonic array transducer 4a, and the received ultrasonic wave.
  • the presence or absence of a defect is determined by analyzing the reflected echo signal obtained from the above.
  • the first flaw detection method is a defect detection method based on the ultrasonic reflection method, but the signal intensity of the reflected ultrasonic wave from the defect changes depending on the defect occurrence position and the defect direction with respect to the weld. Therefore, the reflected echo is detected by using both the first ultrasonic array sensor 4 and the second ultrasonic array sensor 5, and the accuracy of defect determination is enhanced by using both reflected echo signals for defect determination.
  • the second flaw detection method is flaw detection using both two single-element ultrasonic array sensors.
  • FIG. 5 schematically shows an ultrasonic propagation path in the second flaw detection method.
  • the ultrasonic wave transmitted from the ultrasonic array transducer 4a is diffracted by the defect 2, and reaches the ultrasonic array transducer 5a through the path indicated by 15c in FIG. 5 as an ultrasonic diffraction wave.
  • the first ultrasonic array sensor 4 may detect the ultrasonic diffraction echoes transmitted from the second ultrasonic array sensor 5 by reversing the transmission and reception. The echo received through the path 15d in FIG.
  • the height H of the defect 2 (the length of the defect with respect to the depth direction of the plate material) can be measured by measuring the distance difference in the Z direction between the two signals of the echo signal 15c and the ultrasonic diffracted wave 15d.
  • a reflection echo from the back surface of the plate material is referred to as a back surface echo.
  • the object of ultrasonic flaw detection has a relatively simple shape such as a plate or hollow shape, and the position information of the position where ultrasonic reflection due to physical dimensions such as thickness and groove or shape occurs is the start of flaw detection. I know before. Therefore, an appropriate reference position (for example, the surface of the face plate) is set on the target, and the physical position information of the position where the reflection due to the shape occurs and the reflected echo signal from the reflection position are used. The relative position information of the ultrasonic array sensor with respect to the position where the reflection occurs is acquired.
  • the relative position information of the defect with respect to the ultrasonic array sensor is acquired.
  • the distance between the position where the reflection due to the shape occurs and the defect can be found by taking the difference between the two. .
  • the position where reflection due to the shape occurs is the back surface of the plate material immediately below the defect (in the case of the double skin shape material of Example 2, the interface G between the back plate and the face plate directly below the defect). Therefore, the defect height H can be calculated by measuring the distance of the back surface echo and the distance of the diffraction echo at the upper end of the defect or the reflected echo signal from the defect.
  • FIG. 6 shows a display example of the inspection result displayed on the display 14.
  • the inspection result is displayed using four images S1 to S4.
  • the image of S1 is a sector scan image in the first flaw detection method.
  • Ultrasonic waves are transmitted from the ultrasonic array transducer 4a, and reflected ultrasonic waves from the defect 2 are received by the ultrasonic array transducer 4a.
  • the flaw detection result by the ultrasonic wave 15a is displayed.
  • flaw detection image indicated by fan-shaped it indicates the position of the ultrasonic array probe upper left vertex portion O 1 is reception
  • Y-direction represents the horizontal distance to the reflection source from the ultrasonic array sensor
  • -Z direction The vertical direction indicated by indicates the depth from the ultrasonic array sensor to the reflection source. Therefore, the sector scan image clearly shows the positional relationship between the ultrasonic array sensor and the reflection source.
  • E1 is an ultrasonic echo caused by a defect
  • E1 echo does not appear in a portion having no defect
  • E2 is an ultrasonic echo caused by the welding back wave.
  • the welding back wave is a well-shaped corrugated weld pool formed on the back side in welding performed from only one side, and becomes an ultrasonic wave reflection source.
  • the ultrasonic wave incident position should be the same in the YZ plane. E2 always appears at the same position, so the ultrasonic echo E2 is a reference for confirming whether the ultrasonic array sensor is operating normally when the ultrasonic array probe is moved along the weld line. Can be used as a signal.
  • S2 is another sector scan image obtained by the first flaw detection method, in which an ultrasonic wave is transmitted from the ultrasonic array transducer 5a and a reflected ultrasonic wave from the defect 2 is received by the ultrasonic array transducer 5a.
  • a flaw detection image by the waved ultrasonic wave 15b is displayed.
  • two echoes received by the system shown in FIG. 4 are displayed.
  • E1 and E2 are close to each other, it is difficult to distinguish between a defect echo and a back echo.
  • E1 and E2 approach is an image based on reception by the ultrasonic array sensor 4 in the S1 image, an echo from the w1 surface at the welding back wave is displayed as E2.
  • the position where the defect occurs cannot be predicted, and it is not known whether the defect exists on the left or right of the center line of the weld 1.
  • S3 is a sector scan image obtained by the second flaw detection method.
  • Ultrasonic waves are transmitted from the ultrasonic array transducer 4a, and ultrasonic diffracted waves generated at the tip of the defect 2 shown in FIG. It is a flaw detection image at the time of receiving with the array transducer
  • E1 is an ultrasonic echo detected through the path 15c shown in FIG. 5
  • E3 is an ultrasonic echo detected through the path 15d.
  • E2 is also an ultrasonic echo due to the shape, so it always occurs regardless of the presence or absence of defects.
  • a defect echo attention area having a certain width set in the vicinity of the weld groove shape line is set, and the defect in the obtained image information Defect determination is performed using only image information within the echo area of interest.
  • A1 to A3 in S1 to S3 are defect echo attention areas, which correspond to regions indicated by dotted lines in FIG. In the above area, the E1 echo is detected, and when it is detected at S1 or S2 and detected at S3, it is determined as “defective”. The determination result is displayed on the screen S4.
  • defect determination information is displayed based on the screens from S1 to S3.
  • the horizontal axis is the flaw detection position (position in the X direction in FIG. 1), and the vertical axis is pass (no defect, OK) and fail (defective, NG). indicate.
  • the generated back wave shows the same behavior as the reflected wave from the defect, which may make it difficult to determine the defect.
  • the defect determination accuracy is improved. Since the inspection pattern switching between the first flaw detection method and the second flaw detection method is performed by electrical switching of the phased array method, the inspection time does not increase. Further, since the signal intensity of the diffracted wave is weak, the detection accuracy is improved by using it in combination with the first flaw detection method as compared with the defect identification based only on the echo signal caused by the diffracted wave.
  • FIG. 7 is a flowchart showing the contents of control processing in the ultrasonic flaw detector according to the present embodiment. This control process is performed based on a program stored in advance in the internal memory of the ultrasonic controller 11, the probe movement controller 12, and the flaw detection controller 13.
  • the ultrasonic controller 11 and the probe movement control are performed with appropriate inspection conditions taking into account the state of the inspection section (for example, plate material, plate thickness, weld groove shape, etc.).
  • the state of the inspection section for example, plate material, plate thickness, weld groove shape, etc.
  • the threshold value P 0 for determining the received signal strength in step S140 or the defect height threshold value H used for determining the defect height in step S180 is determined by the operation of the program stored in the memory of the flaw detection controller 13. Set 0 .
  • the threshold value P 0 of the received signal intensity level is determined in advance by ultrasonic inspection for the defect dimension H 0 that is harmful in terms of structural strength. Find and store it in memory.
  • the movement amount for each flaw detection step of the ultrasonic array sensor is set.
  • step S110 the ultrasonic array sensor holder 6 is moved to the inspection measurement position.
  • the ultrasonic array sensor holder 6 is set to the start position of the inspection object.
  • the 1st and 2nd ultrasonic array sensors 4 and 5 are arrange
  • step S120 the ultrasonic array sensor 4 is used to irradiate and receive an ultrasonic beam.
  • a process of receiving ultrasonic waves from the ultrasonic array sensor 4 and receiving reflected ultrasonic waves from the defect 2 by the ultrasonic array sensor 4, which is a first flaw detection method, is performed.
  • step S130 the ultrasonic array sensor 5 is used to irradiate and receive an ultrasonic beam.
  • a process of transmitting an ultrasonic wave from the ultrasonic array 5 sensor and receiving a reflected ultrasonic wave from the defect 2 by the ultrasonic array sensor 5 is performed.
  • step S140 the ultrasonic array sensor 4 and the ultrasonic array sensor 5 are used to irradiate and receive an ultrasonic beam.
  • an ultrasonic wave is transmitted from the ultrasonic array sensor 4 and a reflected ultrasonic wave at the defect 2 is received by the ultrasonic array sensor 5.
  • step S150 the signals received in step S120, step S130, and step S140 are calculated and displayed. That is, the received signal is calculated by the flaw detection controller 13, and the images of S1, S2, and S3 shown in FIG.
  • step S160 defect signal detection processing is performed.
  • the defect signal extraction unit of the flaw detection controller 13 performs the process of extracting the reflected wave signal intensity of the defect 2 from the result of step S150.
  • the defect echo E1 is generated in the vicinity of the echo E2 from the welding back wave D. Therefore, the maximum value P of the received wave signal intensity in the vicinity of the echo E2 is extracted.
  • step S170 the defect determination unit of the flaw detection controller 13 performs the reflected wave signal amplitude determination.
  • the maximum value P of the received wave signal intensity in the vicinity of the echo E2 extracted in step S160 is compared with the threshold value P 0 for determining the received signal intensity.
  • the threshold value P 0 it is determined that the defect is harmful in terms of structural strength, and it is necessary to perform defect height measurement as a second flaw detection method. Therefore, if the received wave amplitude is P ⁇ P 0 in this determination, it is determined that there is no defect, and the process of step S180 is performed. If the received wave amplitude is P ⁇ P 0 , it is determined that there is a suspicion of a defect, and the process proceeds to step S210.
  • step S180 the defect determination unit of the flaw detection controller 13 determines that there is no defect, and the result is displayed on the “OK” portion of the display unit 14 as shown in the S4 screen of FIG.
  • step S190 the ultrasonic array sensor position is determined. If the ultrasonic array sensor has reached the end of the member to be inspected by the processing of the flaw detection controller 13, the inspection is terminated and the processing of step S200 is performed. However, if the ultrasonic array sensor has not reached the end of the member to be inspected, the process proceeds to step S110, and after moving by a specified amount, flaw detection at a new point is repeated.
  • step S210 If it is determined in step S170 that there is a suspicion of a defect, a defect height calculation process in step S210 is performed.
  • the defect determination unit of the flaw detection controller 13 obtains the defect height calculation process based on the S3 image of FIG. 6 by the method described in the second flaw detection method. That is, as described in the explanation of FIG. 6, the defect height H is calculated by obtaining the difference in the Z direction between the two signals on the S3 screen.
  • step S220 the defect height is determined.
  • the defect determination unit of the flaw detection controller 13 compares the defect height H obtained in step S210 with the defect size H 0 harmful to the structural strength set in step S100 as a threshold value. If H ⁇ H 0 in this comparison determination, it is determined that the defect is small and there is no structurally harmful defect, and the process of step S180 is performed. Further, if H ⁇ H 0, is determined as a defect height is large structurally detrimental defects than a threshold routine to proceed to step S230.
  • step S230 the defect determination unit of the flaw detection controller 13 processes the portion determined to be defective based on the defect height determination result as a failure, and the “NG” portion of the display unit 14 as shown in the S4 screen of FIG. To display the results. Then, the process after step S180 is performed.
  • the ultrasonic flaw detection apparatus or the flaw detection method of the present embodiment realizes an apparatus / method that can quickly measure a weld defect even if there is a surplus weld. Further, by performing defect determination using both the reflection echo and the diffraction echo, it becomes possible to detect a defect with much higher accuracy than when performing defect determination using only the reflection echo.
  • Example 2 Next, a second embodiment will be described. In the present embodiment, an example will be described in which an ultrasonic flaw detector equipped with a two-element ultrasonic array sensor is applied to a weld inspection of a panel structure in which extruded hollow members are joined by welding.
  • the ultrasonic inspection of the welded portion of the panel structure by the extruded hollow shape material can be inspected by the ultrasonic inspection apparatus according to the first embodiment, but the inspection by the ultrasonic inspection apparatus according to the second embodiment described below is more effective. Is.
  • FIG. 8 shows a schematic diagram of a railway vehicle structure as an example of a structure constituted by a panel structure.
  • Rail vehicles such as a railway vehicle structure 901 are often manufactured by standing a side structure 901, a wife structure 902, and a roof structure 903 on a frame 904 and joining them together by welding. These weld lines are as shown by a one-dot chain line in FIG.
  • the side structure 901, the end structure 902, the roof structure 903, or the base frame 904 is usually formed by joining long plate materials or hollow shapes that are extruded in the width direction.
  • a method such as welding or friction stir welding (FSW) is used for joining the plate member or the hollow member.
  • FSW friction stir welding
  • FIG. 8 the joining lines of the constituent members of the side structure 901 are indicated by 905, the joining lines of the constituent members of the roof structure 903 are indicated by 906, and the joining lines of the constituent members of the end structure 902 are indicated by 907.
  • the side structure 903 of this embodiment is configured by joining extruded hollow shapes 908 and 909 by welding, and after joining, the surface of the welded portion 1 is ground and smoothed by a grinder.
  • the structure is a bone skin structure, and when it is composed of an extruded hollow shape material, it is referred to as a double skin structure. It is necessary to inspect each joint line of a structure or a weld line between structures.
  • FIG. 9 schematically shows a state in which the ultrasonic flaw detector according to the present embodiment is arranged when the panel structure shown in the lower part of FIG. 8 is inspected.
  • the double skin structure panel to be inspected in the present embodiment is formed by fitting extruded hollow shapes 908 and 909 and welding the upper and lower groove portions thereof.
  • the extruded hollow member 908 has a structure in which a pair of face plates (one face plate is referred to as a face plate 910) is connected by a rib 912.
  • the extruded hollow shape member 909 has a structure in which a pair of face plates (one face plate is referred to as a face plate 911) is connected by a rib 913, but a plate projecting further outward from the lower portion of the end portion of the face plate 911.
  • a portion 914 is provided.
  • the plate portion 914 is fitted into a concave portion formed by the face plate 910 and the rib 912 when the extruded hollow shape member 908 and 909 are abutted for bonding, and acts as a back plate of the face plate 910 during welding. . Therefore, the extruded hollow member 908 is a female side member, and the extruded hollow member 909 is a male member. Further, since the panel structure shown in FIG. 9 is in a state before finish grinding by the grinder, the welded portion 1 still has a surplus.
  • An ultrasonic array probe is disposed on the panel structure so as to straddle the weld 1.
  • the overall configuration of the ultrasonic flaw detector is the same as the configuration described with reference to FIG. 1, and therefore description of portions having the same function / structure will not be repeated.
  • FIG. 10 is an enlarged view of the ultrasonic array sensors 4 and 5 shown in FIG. 1 as a top view as viewed from the weld line.
  • the dual transducer type ultrasonic array sensor is a sensor that uses an ultrasonic array transducer that transmits ultrasonic waves and an ultrasonic array transducer that receives ultrasonic waves separately.
  • the first ultrasonic array sensor 4 shown in FIG. 10 is the first and second ultrasonic array transducers 4a and 4b, and the second ultrasonic array sensor 5 is the first and second ultrasonic array transducers.
  • the ultrasonic array transducers 5a and 5b held by the second ultrasonic array sensor 5 are respectively connected to the third ultrasonic array transducer and the fourth ultrasonic array transducer. You may call it.
  • the transmitting ultrasonic array transducer is 4a, for example, the ultrasonic array transducer 4b is used as the receiving ultrasonic array transducer. Switching between the transmitting ultrasonic array transducer and the receiving ultrasonic array transducer is performed by setting on the transmitting side / receiving side of the ultrasonic controller 11.
  • the ultrasonic wave propagating on the sensor surface layer or the ultrasonic echo that makes multiple reflections inside the wedge is applied to the plate material.
  • the defect may not be sufficiently identified by overlapping with the reflected wave signal from the defect that has propagated back.
  • the face plate thickness of the extruded hollow shape member generally used for the railway vehicle structure is about 3 mm, and the defect identification may be insufficient in the inspection using the single transducer ultrasonic array sensor as in the first embodiment.
  • FIG. 11 is a cross-sectional view taken along D-D ′ of the ultrasonic array sensor 4 shown in FIG. 10 (corresponding to the ZX plane).
  • the inclination of the roof angle is performed by inclining the ultrasonic array transducers 4a and 4b in the central direction in the ZX cross section shown in FIG.
  • the sound axis in the ultrasonic propagation direction is designed to intersect at the sensor central portion and the assumed defect position.
  • the first wedge-shaped member 16a is provided below the first ultrasonic array transducer, and the second wedge is provided below the second ultrasonic array transducer.
  • Each of the shaped members 16b is installed and needs to be designed so that the normal direction of the ultrasonic array transducer surface intersects at the target position of the weld. For this reason, a structure in which both the ultrasonic array transducer surfaces are inclined in the facing direction is adopted. Note that the first wedge-shaped member 16a and the second wedge-shaped member 16 both have a wedge shape in the YZ section as in FIG. 3 of the first embodiment, as shown in FIG. 12 described later.
  • the first flaw detection method is flaw detection using one of the two-element ultrasonic array sensors, that is, the ultrasonic array sensor 4 or 5.
  • the ultrasonic array sensor 4 When the ultrasonic array sensor 4 is used, ultrasonic waves are transmitted from the ultrasonic array transducer 4a, and reflected ultrasonic waves from the defect 2 are received by the ultrasonic array transducer 4b.
  • the two-element ultrasonic array sensor 5 is also used for the inspection. That is, ultrasonic waves are transmitted from the ultrasonic array transducer 5a, and reflected ultrasonic waves from the defect 2 are received by the ultrasonic array transducer 5b.
  • the ultrasonic propagation paths described above are shown as ultrasonic paths 15a and 15b in FIG.
  • the second flaw detection method is flaw detection using two two-element ultrasonic array sensors 4 and 5. For example, by transmitting ultrasonic waves from the ultrasonic array transducer 4a and receiving ultrasonic diffracted waves generated at the defect 2 by the ultrasonic array transducer 5b, echoes of diffracted ultrasonic waves can be detected. .
  • the ultrasonic propagation path described above is shown as an ultrasonic path 15c in FIG. In this method, the roles of transmission and reception can be reversed, and a combination of the ultrasonic array transducers 5a and 4b is also possible.
  • the inspection pattern switching between the first flaw detection method and the second flaw detection method is performed by electrical switching of the phased array method, the inspection time does not increase, and the diffracted wave has a weak signal intensity.
  • the defect determination accuracy is improved when the method and the second flaw detection method are used in combination.
  • the height of the defect can be measured simultaneously with the presence or absence of the defect.
  • the defect determination is performed using the three pieces of image information S1 to S3 obtained by the first flaw detection method and the second flaw detection method.
  • a sector scan of the welded portion 1 by the first ultrasonic array sensor 4 and the second ultrasonic array sensor 5 is independently performed at a predetermined position in the longitudinal direction (X direction) of the welded portion 1, and S1 and S2 are performed. Obtain image information sequentially. Thereafter, the ultrasonic controller 11 switches between the transmitting-side array transducer and the receiving-side array transducer of the first ultrasonic array sensor 4 and the second ultrasonic array sensor 5, and the first ultrasonic array A sector scan of the welded portion 1 is performed by the sensor 4 and the second ultrasonic array sensor 5, and the image information of S3 is acquired.
  • an echo of reflected ultrasonic waves caused by the joint portion shape indicated by F in FIG. 12A is detected in S1.
  • the propagation path of this reflected ultrasonic wave is 15e shown in FIG.
  • This is an echo that is always observed when an extruded hollow member having the shape of the present embodiment is used, and can be used as a position reference in the YZ section.
  • the defect occurrence position can be calculated from the coordinates of the E1 echo and can be fed back to the specification of the repair position and the improvement of the welding conditions.
  • FIG. 13 shows a display example of the inspection result displayed on the display 14 in this embodiment.
  • the image of S1 is a sector scan image by the first flaw detection method described above, and an ultrasonic wave is transmitted from the first ultrasonic array transducer 4a (on the first ultrasonic array sensor side) and reflected by the defect 2 It is a flaw detection result by an ultrasonic signal received by the second ultrasonic array transducer 4b.
  • a rectangle A4 in the image of S1 is a defect echo attention area. E1 is a reflected echo caused by the defect, and E4 is a reflected echo caused by the shape of the joint portion F described above. Since the E1 echo does not appear in the portion having no defect, only one ultrasonic echo E4 is observed.
  • S2 is a sector scan image obtained when the first flaw detection method is performed by the ultrasonic array transducer 5a, and the ultrasonic scan is performed from the first ultrasonic array transducer 5a (on the second ultrasonic array sensor side).
  • This is a flaw detection result by an ultrasonic signal in which a sound wave is transmitted and a reflected ultrasonic wave at the defect 2 is received by the second ultrasonic array transducer 5b.
  • S3 is a sector scan image in the second flaw detection method, and transmits a ultrasonic wave from the first ultrasonic array transducer 4a on the first ultrasonic array sensor side, and a diffracted wave generated in the defect 2 Is a flaw detection image obtained by receiving the signal by the second ultrasonic array transducer 5b on the second ultrasonic array sensor side.
  • E1 which is a diffraction echo caused by a defect
  • E3 which is a reflection echo at the interface G.
  • the defect height H can be calculated by measuring the difference between the two signals in the Z direction.
  • defect determination information is displayed based on the screens from S1 to S3.
  • the horizontal axis is the flaw detection position (X-direction position in FIG. 1), and the vertical axis is pass (no defect, OK) and fail (defective, NG). indicate.
  • the inspection result is displayed here, as shown in FIG. 1C, when the inspection result is superimposed on the three-dimensional shape diagram of the panel structure and displayed on S4 or another screen, the defect distribution is visually grasped. This improves the usability of the device.
  • the ultrasonic flaw detection apparatus or the welding inspection method of this embodiment since a pair of two-transducer ultrasonic array sensors are used, inspection can be performed even when the plate thickness is thin. And the second flaw detection method can be used together to improve the defect determination accuracy. Further, the defect position can be calculated by utilizing the echo caused by the fitting part shape F or the interface G, and the defect occurrence position can be measured with high accuracy.

Abstract

L'invention porte sur un procédé qui permet d'effectuer une inspection aux ultrasons à grande vitesse tout en réduisant à un minimum la quantité de balayage mécanique effectuée par une sonde ultrasonore, même lors de l'inspection d'une longue ligne de soudure. Le dispositif selon l'invention comprend : un premier et un second réseau de capteurs ultrasonores situés sur des côtés opposés d'une zone de soudure, chacun desdits réseaux de capteurs ultrasonores comprenant un réseau de transducteurs ultrasonores qui envoie des ultrasons vers la zone de soudure et qui en reçoit des ultrasons; un support de réseau de capteurs ultrasonores qui maintient une distance constante entre le premier réseau de capteurs ultrasonores et le second réseau de capteurs ultrasonores et qui déplace le premier et le second réseau de capteurs ultrasonores dans le sens de la longueur de la zone de soudure; une contrôleur d'ultrasons qui convertit les ultrasons reçus par les réseaux de transducteurs ultrasonores en signaux d'écho; et un contrôleur de détection de défauts qui utilise lesdits signaux d'écho pour détecter des défauts dans la zone de soudure.
PCT/JP2013/068198 2013-07-03 2013-07-03 Dispositif et procédé de détection de défauts aux ultrasons, et procédé permettant d'inspecter la zone de soudure d'une structure de panneau WO2015001625A1 (fr)

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