WO2024113960A1 - 一种t型电子束焊缝熔宽的检测方法及装置 - Google Patents

一种t型电子束焊缝熔宽的检测方法及装置 Download PDF

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Publication number
WO2024113960A1
WO2024113960A1 PCT/CN2023/113166 CN2023113166W WO2024113960A1 WO 2024113960 A1 WO2024113960 A1 WO 2024113960A1 CN 2023113166 W CN2023113166 W CN 2023113166W WO 2024113960 A1 WO2024113960 A1 WO 2024113960A1
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Prior art keywords
weld
scanning
reflected wave
signal
ultrasonic
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English (en)
French (fr)
Inventor
王建超
王永红
潘兆义
陈少斌
张鹏
赵灿
王东方
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Xi'an Space Engine Co Ltd
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Xi'an Space Engine Co Ltd
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Priority to EP23790531.0A priority Critical patent/EP4400807A4/en
Publication of WO2024113960A1 publication Critical patent/WO2024113960A1/zh
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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
    • G01N29/04—Analysing solids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0013—Positioning or observing workpieces, e.g. with respect to the impact; Aligning, aiming or focusing electron beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0053—Seam welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups B23K1/00 - B23K28/00
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups B23K1/00 - B23K28/00 relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B17/00—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B5/00—Measuring arrangements characterised by the use of mechanical techniques
    • G01B5/0037—Measuring of dimensions of welds
    • 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
    • G01N29/30—Arrangements for calibrating or comparing, e.g. with standard objects
    • 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
    • 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
    • G01N29/4436—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with a reference signal
    • 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
    • G01N2291/26—Scanned objects
    • G01N2291/267—Welds

Definitions

  • the present application relates to the field of ultrasonic detection technology, and in particular to a method and device for detecting the weld width of a T-type electron beam weld.
  • the rotor assembly is a rotating body structure
  • the horizontal plate is a full circle of guard belts
  • the vertical plates are blades on the rotating body
  • the guard belts and blades are connected by T-shaped electron beam welds, because the rotor assembly needs to rotate at high speed during operation, the strength of the weld connection is very important
  • the main indicator for testing the strength of the weld connection is the fusion width of the weld (abbreviated as fusion width).
  • fusion width the fusion width
  • X-rays can be used to detect the fusion width of the weld, but since the rotor assembly is a rotating body structure, X-rays such as vertical weld surface perspective cannot penetrate the weld due to the thickness and structure of the rotor assembly, and parallel to the weld perspective cannot show the fusion area, so the fusion width of the rotor assembly T-type electron beam weld cannot be detected.
  • the horizontal plate thickness of the rotor assembly T-type electron beam weld is only 1mm
  • the vertical plate is the blade, and there are 53 welds on the entire product.
  • the weld width is narrow and the number is large, requiring a high-precision and fast detection method.
  • the technical problem solved by the present application is: in view of the fact that the detection of the weld width of a T-type electron beam weld in the prior art cannot meet the actual demand, the present application provides a method and device for detecting the weld width of a T-type electron beam weld.
  • the electron beam weld of the product to be tested is automatically detected by means of an ultrasonic scanning detection system, and multiple welds can be detected at one time.
  • the reflected wave signals are normalized according to the scanned image to obtain a processed scanned image, that is, the solution provided in the embodiment of the present application uses the surface reflected wave monitoring technology to monitor the changes in the surface morphology of the weld and detect the changes based on the surface reflection wave monitoring technology.
  • the incident sound wave energy is compensated according to the morphology change, so that the sound wave energy reaching the weld fusion surface is uniform, thereby eliminating the influence of surface morphology change on the detection result and realizing accurate measurement of weld fusion width.
  • an embodiment of the present application provides a method for detecting the weld width of a T-type electron beam weld, the method comprising: detecting a preset comparison test block through an ultrasonic scanning detection system to determine the weld fusion boundary, wherein the product parameters and weld parameters of the comparison test block are the same as those of the product to be tested; collecting a first scanning signal corresponding to the product to be tested through an ultrasonic scanning detection system, and generating a first scanning image of a weld surface reflection wave according to the first scanning signal, wherein the first scanning signal includes reflection wave signals of each weld surface; normalizing each reflection wave signal in the first scanning signal according to the first scanning image to obtain a second scanning signal, and generating a second scanning image according to the second scanning signal; and measuring the weld width according to the weld boundary parameters and the second scanning image.
  • the weld boundary is determined by detecting a preset comparison test block through an ultrasonic scanning detection system, including: placing an ultrasonic probe in the ultrasonic scanning detection system at the weld of the vertical comparison test block, and incident ultrasonic waves perpendicular to the weld surface of the comparison test block; adjusting ultrasonic parameters to collect the weld surface reflection wave signal of a specified groove width on the comparison test block, and generating a third scanning image based on the weld surface reflection wave signal of the specified groove width; and analyzing the third scanning image to determine the weld fusion boundary.
  • collecting a first scanning signal corresponding to the product to be tested by an ultrasonic scanning detection system includes: placing an ultrasonic probe in the ultrasonic scanning detection system at a weld perpendicular to the product to be tested, and The ultrasonic wave is incident perpendicularly to the weld surface of the product to be tested; the reflected wave signals of each weld surface of the product to be tested and the reflected wave signals of the bottom surface of the horizontal plate are collected to obtain the first scanning signal.
  • the comparison test block is provided with welds with various groove widths of 0 mm, 0.2 mm, 0.4 mm, 0.6 mm and 0.8 mm; wherein the designated weld is a weld with a groove width of 0.4 mm.
  • normalizing each reflected wave signal in the first scanning signal according to the first scanning image to obtain a second scanning signal includes: determining scanning data of the first scanning signal on the first scanning image, generating characteristic information of the reflected wave on the weld surface based on the scanning data, wherein the characteristic information includes amplitude information and position information of the reflected wave at each point on the weld surface; comparing the characteristic information of the reflected wave corresponding to each point with a specified value to calculate a relative gain value, and obtaining the second scanning signal according to the relative gain value of each point.
  • generating a second scanning image according to the second scanning signal includes: performing gain calculation on the corresponding reflected wave height according to the relative gain value of each point in the second scanning signal to obtain normalized reflected wave characteristic information; generating the second scanning image according to the normalized reflected wave characteristic information.
  • the electron beam weld of the product to be tested is automatically detected by means of an ultrasonic scanning detection system, and multiple welds can be detected at one time.
  • each reflected wave signal is normalized according to the scanned image to obtain a processed scanned image, that is, the solution provided in the embodiment of the present application uses the surface reflected wave monitoring technology to monitor the changes in the surface morphology of the weld and compensates the incident sound wave energy according to the morphology changes, so that the sound wave energy reaching the weld fusion surface is uniform, thereby eliminating the influence of the surface morphology changes on the detection results, and realizing the accurate measurement of the weld fusion width.
  • FIG1 is a schematic structural diagram of a rotor assembly provided in an embodiment of the present application.
  • FIG2 is a schematic flow chart of a method for detecting the weld width of a T-type electron beam weld provided in an embodiment of the present application;
  • FIG3 is a schematic diagram of the structure of a comparison block provided in an embodiment of the present application.
  • FIG. 4 is a schematic diagram of the structure of a product to be tested provided in an embodiment of the present application.
  • Step 201 detecting a preset comparison test block by an ultrasonic scanning detection system to determine a weld fusion boundary, wherein the comparison test block has the same product parameters and weld parameters as the product to be tested.
  • the ultrasonic scanning detection system is such as a water immersion ultrasonic C-scan detection system
  • the water immersion ultrasonic C-scan detection system is composed of an ultrasonic probe, an ultrasonic flaw detector, a scanning imaging system (such as an A/B/C scanning imaging system), a single-chip microcomputer control, and a computer system master control platform.
  • the computer first sends a control signal to the single-chip microcomputer, and transmits the signal to the scanning mechanism.
  • the scanning mechanism drags the ultrasonic probe in the water tank for scanning.
  • the ultrasonic flaw detector transmits the detection signal measured by the probe to the computer in real time.
  • the computer integrates the position of the probe and the measured detection signal to form a scan image.
  • the ultrasonic scanning detection system is used to detect the preset comparison test block to determine the weld boundary, including: placing the ultrasonic probe in the ultrasonic scanning detection system at the weld of the vertical comparison test block, and incident the ultrasonic wave perpendicular to the weld surface of the comparison test block; adjusting the ultrasonic parameters to collect the weld surface reflection wave signal of the specified groove width on the comparison test block, and generating a third scanning image according to the weld surface reflection wave signal of the specified groove width; analyzing the third scanning image to determine the weld fusion boundary.
  • the welds mentioned in the context of the embodiments of the present application are all electron beam welds.
  • the comparison block is electron beam welded with a plate having the same material and thickness as the product to be tested, and the welding parameters are the same as the product.
  • the comparison block 12 has 5 electron beam welds. After welding, a flat bottom groove is processed at the fusion surface of the weld, and the width of each weld groove is 0mm, 0.2mm, 0.4mm, 0.6mm, and 0.8mm respectively.
  • analyzing the third scanned image to determine the weld fusion boundary includes: analyzing the third scanned image to determine the height of the reflected wave; multiplying the height of the reflected wave by a specified ratio as the weld fusion boundary.
  • the comparison test block is provided with welds with multiple groove widths of 0 mm, 0.2 mm, 0.4 mm, 0.6 mm and 0.8 mm; wherein the specified weld is a weld with a groove width of 0.4 mm.
  • the test parameters are adjusted according to the test results so that the groove with a width of 0.4 mm can be detected, and the fusion surface boundary is determined on the generated scanned image so that the difference between the ultrasonically measured fusion width and the groove width is less than 0.1 mm.
  • FIG3 shows a schematic structural diagram of a comparison block provided in an embodiment of the present application.
  • the comparison block includes a guard belt, a substrate, and a weld.
  • the comparison block is 40 mm long and 9 mm wide.
  • the comparison block is tested by an ultrasonic scanning detection system to determine the weld fusion boundary.
  • the test block is tested, and the detection parameters are adjusted according to the test results so that a groove with a width of 0.4 mm can be detected, and the fusion surface boundary is determined on the generated scan image so that the difference between the ultrasonically measured fusion width and the groove width is less than 0.1 mm.
  • Step 202 collecting a first scanning signal corresponding to the product to be tested through an ultrasonic scanning detection system, and generating a first scanning image of the weld surface reflected wave according to the first scanning signal, wherein the first scanning signal includes the reflected wave signals of each weld surface.
  • a first scanning signal corresponding to the product to be tested is collected by an ultrasonic scanning detection system, including: placing an ultrasonic probe in the ultrasonic scanning detection system at a weld perpendicular to the product to be tested, and incident ultrasonic waves perpendicular to the weld surface of the product to be tested; collecting reflected wave signals on the surfaces of each weld of the product to be tested and reflected wave signals on the bottom of the cross plate to obtain a first scanning signal.
  • the product to be tested (such as a rotor assembly) is mounted on the testing fixture, and the testing fixture clamps the product to be tested to ensure that the product to be tested does not shake when rotating in the testing equipment, and the coaxiality between the axis of the product to be tested and the axis of the equipment turntable is less than 0.01 mm.
  • the ultrasonic probe in the ultrasonic scanning detection system is perpendicular to the weld surface, and the ultrasonic wave is incident perpendicular to the weld surface.
  • Two gates are set, one to collect the reflected wave signal from the weld surface, and the other to collect the reflected wave signal from the bottom of the horizontal plate, and record, for example, a full-wave A-scan signal, and generate a C-scan image based on the full-wave A-scan signal.
  • FIG. 4 shows a schematic structural diagram of a product to be tested provided in an embodiment of the present application.
  • the product to be tested includes a horizontal plate and a vertical plate arranged perpendicular to the horizontal plate, and a T-shaped electron beam weld is arranged perpendicular to the horizontal plate.
  • the purpose of the embodiment of the present application is to accurately measure the weld width of the T-shaped electron beam weld.
  • the device provided in FIG1 should also include a detection fixture for fixing a comparison block or a product to be tested. For example, when testing the product to be tested, the product to be tested is mounted on the detection fixture, and the detection fixture clamps the product to ensure that the product does not shake when rotating in the testing equipment, and the coaxiality between the product axis and the axis of the equipment turntable is less than 0.01 mm.
  • Step 203 normalize each reflected wave signal in the first scanning signal according to the first scanning image to obtain a second scanning signal, and generate a second scanning image according to the second scanning signal; and measure the weld width according to the weld boundary parameters and the second scanning image.
  • normalizing each reflected wave signal in the first scanning signal according to the first scanning image to obtain a second scanning signal includes: determining scanning data of the first scanning signal on the first scanning image, and generating characteristic information of the reflected wave on the weld surface based on the scanning data, wherein the characteristic information includes amplitude information and position of the reflected wave at each point on the weld surface Information; comparing the characteristic information of the reflected wave corresponding to each point with the specified value to calculate a relative gain value, and obtaining the second scanning signal according to the relative gain value of each point.
  • generating a second scanning image based on the second scanning signal includes: performing gain calculation on the corresponding reflected wave height according to the relative gain value of each point in the second scanning signal to obtain normalized reflected wave characteristic information; generating the second scanning image based on the normalized reflected wave characteristic information.
  • the scanning image of the weld surface reflection wave is analyzed, and the surface reflection wave energy at each position is normalized for the situation where the incident wave energy changes due to the change of the weld surface morphology, thereby affecting the change of the bottom surface reflection wave.
  • the same processing rules are used to process the bottom surface reflection wave signal of the horizontal plate, thereby eliminating the influence of the weld surface morphology.
  • the weld scanning image is generated according to the processed scanning signal. Further, the detected scanning signal output generates the surface reflection wave feature information of the weld area, and this feature information contains the reflection wave amplitude information and position information of each point. If the weld surface morphology has no uneven changes, its reflection wave height is the expected 100%. Due to the change of the surface morphology, its reflection wave height will vary. The reflection wave height at each position is compared with 100% and calculated to obtain the relative gain value.
  • the scanning signal output generates the reflected wave characteristic information of the fusion surface of the weld area, and the relative gain value obtained by surface wave normalization is used to perform corresponding gain calculation on the reflected wave height corresponding to each position in the data to obtain the reflected wave characteristic information of the fusion surface after surface wave normalization, and a processed scanned image (equivalent to the above-mentioned second scanned image) is generated based on the data.
  • the weld width is measured on the processed scanned image, and the boundary of the weld is determined according to the detection result of the comparison block. For the T-type electron beam weld, 10% of the reflected wave height is used as the weld boundary, and the length of the vertical line between the two boundaries is the weld width.
  • the ultrasonic scanning detection system 11 when used to detect the weld width on the comparison block and the product to be tested, the ultrasonic probe in the ultrasonic scanning detection system 11 is perpendicular to the weld surface, and the sound wave is incident perpendicular to the weld surface.
  • Two gates are set, one to collect the weld surface echo signal, and the other to collect the cross plate bottom echo signal, and record their scanning signals (for example, full-wave A-scan signals), and generate scanning images (for example, C-scan images) based on the scanning signals. Then, the scanning images are analyzed to determine the weld parameters (for example, weld fusion boundary, weld width).
  • the electron beam weld of the product to be tested is automatically detected by means of an ultrasonic scanning detection system, and multiple welds can be detected at one time.
  • each reflected wave signal is normalized according to the scanned image to obtain a processed scanned image, that is, the solution provided in the embodiment of the present application uses the surface reflected wave monitoring technology to monitor the changes in the surface morphology of the weld and compensates the incident sound wave energy according to the morphology changes, so that the sound wave energy reaching the weld fusion surface is uniform, thereby eliminating the influence of the surface morphology changes on the detection results, and realizing the accurate measurement of the weld fusion width.

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Abstract

一种 T型电子束焊缝熔宽的检测方法及装置，该方法包括：通过超声波扫描检测系统对预设的对比试块进行检测确定出焊缝熔合边界，其中，对比试块与待测产品的产品参数以及焊缝参数均相同(S201)；通过超声波扫描检测系统采集待测产品所对应的第一扫描信号，根据第一扫描信号生成焊缝表面反射波第一扫描图像，其中，第一扫描信号包括各个焊缝表面的反射波信号(S202)；根据第一扫描图像对第一扫描信号中各反射波信号进行归一化处理得到第二扫描信号，根据第二扫描信号生成第二扫描图像(S203)。解决了现有技术中检测 T型电子束焊缝的熔宽不能满足实际需求的技术问题。

Description

一种T型电子束焊缝熔宽的检测方法及装置 技术领域
本申请涉及超声波检测技术领域，尤其涉及一种T型电子束焊缝熔宽的检测方法及装置。
背景技术
转子组件为一回转体结构，其横板为一整圈的卫带，竖板为回转体上的叶片，卫带与叶片通过T型电子束焊缝连接，因转子组件在工作时需要高速旋转，焊缝连接强度至关重要，检测焊缝连接强度的主要指标即为焊缝的熔合宽度(简称熔宽)。具体的，转子组件的结构示意图如图1所示。
目前，可以采用例如X射线来检测焊缝的熔合宽度，但是由于转子组件为回转体结构，X射线如垂直焊缝表面透视，因为转子组件厚度和结构原因无法穿透该焊缝，而平行于焊缝透照无法显示处熔合区，因而不能检测转子组件T型电子束焊缝的熔宽。另外，转子组件T型电子束焊缝的横板厚度仅1mm的环形卫带，竖板为叶片，整个产品上有53条焊缝，焊缝宽度窄，数量多，需要高精度且快速的检测方法。
发明内容
本申请解决的技术问题是：针对现有技术中检测T型电子束焊缝的熔宽不能满足实际需求，本申请提供了一种T型电子束焊缝熔宽的检测方法及装置，本申请实施例所提供的方案中，借助超声波扫描检测系统，对待测产品的电子束焊缝进行自动检测，可一次性检测多条焊缝。另外，根据扫描图像对所各反射波信号进行归一化处理得到处理后的扫描图像，即本申请实施例所提供的方案采用表面反射波监测技术对焊缝表面形貌的变化进行监测并根 据形貌变化情况对入射声波能量进行补偿，使得到达焊缝熔合面处的声波能量均匀，进而消除表面形貌变化对检测结果的影响，实现焊缝熔宽的精确测量。
第一方面，本申请实施例提供一种T型电子束焊缝熔宽的检测方法，该方法包括：通过超声波扫描检测系统对预设的对比试块进行检测确定出焊缝熔合边界，其中，所述对比试块与待测产品的产品参数以及焊缝参数均相同；通过超声波扫描检测系统采集待测产品所对应的第一扫描信号，根据所述第一扫描信号生成焊缝表面反射波第一扫描图像，其中，所述第一扫描信号包括各个焊缝表面的反射波信号；根据所述第一扫描图像对所述第一扫描信号中各反射波信号进行归一化处理得到第二扫描信号，根据第二扫描信号生成第二扫描图像；根据所述焊缝边界参数以及所述第二扫描图像测量焊缝熔宽。
可选地，通过超声波扫描检测系统对预设的对比试块进行检测确定出焊缝边界，包括：将超声波扫描检测系统中超声探头放置于垂直对比试块的焊缝处，并垂直于对比试块的焊缝表面入射超声波；调整超声波参数以采集到所述对比试块上指定槽宽的焊缝表面反射波信号，根据所述指定槽宽的焊缝表面反射波信号生成第三扫描图像；分析所述第三扫描图像确定出焊缝熔合边界。
可选地，分析所述第三扫描图像确定出焊缝熔合边界，包括：分析所述第三扫描图像确定出反射波的高度；将所述反射波的高度乘以指定比例的结果作为所述焊缝熔合边界。
可选地，通过超声波扫描检测系统采集待测产品所对应的第一扫描信号，包括：将超声波扫描检测系统中超声探头放置于垂直待测产品的焊缝处，并 垂直于待测产品的焊缝表面入射超声波；采集待测产品各焊缝表面反射波信号以及横板底面反射波信号得到第一扫描信号。
可选地，所述对比试块设置有0mm、0.2mm、0.4mm、0.6mm以及0.8mm多种槽宽的焊缝；其中，指定焊缝为0.4mm槽宽的焊缝。
可选地，根据所述第一扫描图像对所述第一扫描信号中各反射波信号进行归一化处理得到第二扫描信号，包括：根据所述第一扫描图像上确定所述第一扫描信号的扫描数据，基于所述扫描数据生成焊缝表面反射波的特征信息，其中，所述特征信息包括焊缝表面每个点的反射波的幅值信息和位置信息；将每个点对应的反射波的特征信息与指定值进行比较计算得到相对增益值，根据所述每个点的相对增益值得到所述第二扫描信号。
可选地，根据第二扫描信号生成第二扫描图像，包括：根据所述第二扫描信号中每个点的相对增益值对其对应的反射波高度进行增益计算，得到归一化的反射波特征信息；根据所述归一化的反射波特征信息生成所述第二扫描图像。
与现有技术相比，本申请实施例所提供的方案至少具有如下有益效果：
本申请实施例所提供的方案中，借助超声波扫描检测系统，对待测产品的电子束焊缝进行自动检测，可一次性检测多条焊缝。另外，根据扫描图像对所各反射波信号进行归一化处理得到处理后的扫描图像，即本申请实施例所提供的方案采用表面反射波监测技术对焊缝表面形貌的变化进行监测并根据形貌变化情况对入射声波能量进行补偿，使得到达焊缝熔合面处的声波能量均匀，进而消除表面形貌变化对检测结果的影响，实现焊缝熔宽的精确测量。
附图说明
图1为本申请实施例所提供的一种转子组件的结构示意图；
图2为本申请实施例所提供的一种T型电子束焊缝熔宽的检测方法的流程示意图；
图3为本申请实施例所提供的一种对比块的结构示意图；
图4为本申请实施例所提供的一种待测产品的结构示意图。
具体实施方式
本申请实施例提供的方案中，所描述的实施例仅是本申请一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其它实施例，都属于本申请保护的范围。
为了更好的理解上述技术方案，下面通过附图以及具体实施例对本申请技术方案做详细的说明，应当理解本申请实施例以及实施例中的具体特征是对本申请技术方案的详细的说明，而不是对本申请技术方案的限定，在不冲突的情况下，本申请实施例以及实施例中的技术特征可以相互组合。
以下结合说明书附图对本申请实施例所提供的一种T型电子束焊缝熔宽的检测方法做进一步详细的说明，该方法具体实现方式可以包括以下步骤(方法流程如图2所示)：
步骤201，通过超声波扫描检测系统对预设的对比试块进行检测确定出焊缝熔合边界，其中，所述对比试块与待测产品的产品参数以及焊缝参数均相同。
具体的，在本申请实施例所提供的方案中，超声波扫描检测系统例如水浸超声波C扫描检测系统，水浸超声波C扫描检测系统由超声探头、超声探伤仪、扫描成像系统(例如A/B/C扫描成像系统)、单片机控制以及计算机系统总控平台等组成，。计算机首先发送控制信号给单片机，并将信号传递给扫描机构，扫描机构拖动超声波探头在水槽中进行扫描，同时超声波探伤仪将探头测得的检测信号实时传给计算机，计算机将探头所在位置和测得的检测信号综合形成扫描图像。
作为举例，通过超声波扫描检测系统对预设的对比试块进行检测确定出焊缝边界，包括：将超声波扫描检测系统中超声探头放置于垂直对比试块的焊缝处，并垂直于对比试块的焊缝表面入射超声波；调整超声波参数以采集到所述对比试块上指定槽宽的焊缝表面反射波信号，根据所述指定槽宽的焊缝表面反射波信号生成第三扫描图像；分析所述第三扫描图像确定出焊缝熔合边界。应理解，本申请实施例上下文所说的焊缝均为电子束焊缝。
对比块采用与待测产品材料、厚度等均相同的板材进行电子束焊接，焊接参数与产品相同。例如，对比块12有焊接5条电子束焊缝。焊接完成后在焊缝熔合面处加工平底槽，每条焊缝槽宽分别为0mm、0.2mm、0.4mm、0.6mm、0.8mm。
又作为举例，分析所述第三扫描图像确定出焊缝熔合边界，包括：分析所述第三扫描图像确定出反射波的高度；将所述反射波的高度乘以指定比例的结果作为所述焊缝熔合边界。例如，所述对比试块设置有0mm、0.2mm、0.4mm、0.6mm以及0.8mm多种槽宽的焊缝；其中，指定焊缝为0.4mm槽宽的焊缝。在对试块进行检测，根据检测结果调整检测参数使宽度0.4mm的槽能够检出，在生成的扫描图像上确定熔合面边界，使超声波测量熔宽与槽宽的差异小于0.1mm。
图3展示本申请实施例所提供的一种对比块的结构示意图。
作为举例，在图3中，对比块包括卫带、基板以及焊缝。例如，对比块长度为40mm，宽度为9mm。通过超声波扫描检测系统对对比试块进行检测确定出焊缝熔合边界。例如，对试块进行检测，根据检测结果调整检测参数使宽度0.4mm的槽能够检出，在生成的扫描图像上确定熔合面边界，使超声波测量熔宽与槽宽的差异小于0.1mm。
步骤202，通过超声波扫描检测系统采集待测产品所对应的第一扫描信号，根据所述第一扫描信号生成焊缝表面反射波第一扫描图像，其中，所述第一扫描信号包括各个焊缝表面的反射波信号。
作为举例，通过超声波扫描检测系统采集待测产品所对应的第一扫描信号，包括：将超声波扫描检测系统中超声探头放置于垂直待测产品的焊缝处，并垂直于待测产品的焊缝表面入射超声波；采集待测产品各焊缝表面反射波信号以及横板底面反射波信号得到第一扫描信号。
具体的，将待测产品(例如转子组件)安装在检测工装上，检测工装夹持住待测产品，确保待测产品在检测设备中转动时不发生晃动,待测产品轴线与设备转台轴线的同轴度小于0.01mm。将超声波扫描检测系统中的超声探头垂直焊缝表面，超声波垂直焊缝表面入射，设置两个闸门，一个采集焊缝表面反射波信号，一个采集横板底面反射波信号，记录例如全波A扫描信号，并根据全波A扫描信号生成C扫描图像。
图4展示本申请实施例所提供的一种待测产品的结构示意图。
作为举例，在图4中，待测产品包括横板以及与横板垂直设置的竖板，垂直于横板设置有T型电子束焊缝。本申请实施例的目的就是准确测量T型电子束焊缝的熔宽。另外，在图1所提供的装置中，还应包括检测工装，用于固定对比块或者待测产品。例如，在对待测产品进行检测时，将待测产品安装在检测工装上，检测工装夹持住产品，确保产品在检测设备中转动时不发生晃动,产品轴线与设备转台轴线的同轴度小于0.01mm。
步骤203，根据所述第一扫描图像对所述第一扫描信号中各反射波信号进行归一化处理得到第二扫描信号，根据第二扫描信号生成第二扫描图像；根据所述焊缝边界参数以及所述第二扫描图像测量焊缝熔宽。
作为举例，根据所述第一扫描图像对所述第一扫描信号中各反射波信号进行归一化处理得到第二扫描信号，包括：根据所述第一扫描图像上确定所述第一扫描信号的扫描数据，基于所述扫描数据生成焊缝表面反射波的特征信息，其中，所述特征信息包括焊缝表面每个点的反射波的幅值信息和位置 信息；将每个点对应的反射波的特征信息与指定值进行比较计算得到相对增益值，根据所述每个点的相对增益值得到所述第二扫描信号。
又作为举例，根据第二扫描信号生成第二扫描图像，包括：根据所述第二扫描信号中每个点的相对增益值对其对应的反射波高度进行增益计算，得到归一化的反射波特征信息；根据所述归一化的反射波特征信息生成所述第二扫描图像。
具体的，分析焊缝表面反射波扫描图像，对由于焊缝表面形貌变化导致的入射波能量变化从而影响底面反射波变化的情况，对各位置的表面反射波能量进行归一化处理，将同样的处理规则用于处理横板底面反射波信号，从而消除焊缝表面形貌的影响。根据处理后的扫描信号生成焊缝扫描图像。进一步，将检测的扫描信号输出生成焊缝区域表面反射波特征信息，此特征信息包含每个点的反射波幅值信息和位置信息。如焊缝表面形貌无凹凸不平的变化，其反射波高为期望的100％，因表面形貌变化，其反射波高度会有高低变化，将每个位置的反射波高度与100％进行比较计算，得出相对增益值。
再进一步，将扫描信号输出生成焊缝区域熔合面的反射波特征信息，利用表面波归一化所得的相对增益值对该数据中的每个位置对应的反射波高度进行相应的增益计算，得到表面波归一化后熔合面的反射波特征信息，根据该数据生成处理后的扫描图像(等同于上述第二扫描图像)。接着，在处理后的扫描图像上测量焊缝熔宽，焊缝的边界根据对比块检测结果确定，对于该T型电子束焊缝，以反射波高度10％作为焊缝边界，两个边界之间垂直连线的长度即为焊缝熔宽。
另外，在本申请实施例所提供的方案中，用超声波扫描检测系统11检测对比块以及待测产品上的焊缝熔宽时，需用超声波扫描检测系统11中的超声探头垂直焊缝表面，声波垂直焊缝表面入射，设置两个闸门，一个采集焊缝表面回波信号，一个采集横板底面回波信号，记录其扫描信号(例如，全波A扫描信号)，并基于扫描信号生成扫描图像(例如C扫描图像)。然后，分析扫描图像确定出焊缝参数(例如，焊缝熔合边界、焊缝熔宽)。
本申请实施例所提供的方案中，借助超声波扫描检测系统，对待测产品的电子束焊缝进行自动检测，可一次性检测多条焊缝。另外，根据扫描图像对所各反射波信号进行归一化处理得到处理后的扫描图像，即本申请实施例所提供的方案采用表面反射波监测技术对焊缝表面形貌的变化进行监测并根据形貌变化情况对入射声波能量进行补偿，使得到达焊缝熔合面处的声波能量均匀，进而消除表面形貌变化对检测结果的影响，实现焊缝熔宽的精确测量。
显然，本领域的技术人员可以对本申请进行各种改动和变型而不脱离本申请的精神和范围。这样，倘若本申请的这些修改和变型属于本申请权利要求及其等同技术的范围之内，则本申请也意图包含这些改动和变型在内。

Claims (7)

  1. 一种T型电子束焊缝熔宽的检测方法，其特征在于，包括：
    通过超声波扫描检测系统对预设的对比试块进行检测确定出焊缝熔合边界，其中，所述对比试块与待测产品的产品参数以及焊缝参数均相同；
    通过超声波扫描检测系统采集待测产品所对应的第一扫描信号，根据所述第一扫描信号生成焊缝表面反射波第一扫描图像，其中，所述第一扫描信号包括各个焊缝表面的反射波信号；
    根据所述第一扫描图像对所述第一扫描信号中各反射波信号进行归一化处理得到第二扫描信号，根据第二扫描信号生成第二扫描图像；根据所述焊缝边界参数以及所述第二扫描图像测量焊缝熔宽。
  2. 如权利要求1所述的方法，其特征在于，通过超声波扫描检测系统对预设的对比试块进行检测确定出焊缝边界，包括：
    将超声波扫描检测系统中超声探头放置于垂直对比试块的焊缝处，并垂直于对比试块的焊缝表面入射超声波；
    调整超声波参数以采集到所述对比试块上指定槽宽的焊缝表面反射波信号，根据所述指定槽宽的焊缝表面反射波信号生成第三扫描图像；
    分析所述第三扫描图像确定出焊缝熔合边界。
  3. 如权利要求2所述的方法，其特征在于，分析所述第三扫描图像确定出焊缝熔合边界，包括：
    分析所述第三扫描图像确定出反射波的高度；
    将所述反射波的高度乘以指定比例的结果作为所述焊缝熔合边界。
  4. 如权利要求3所述的方法，其特征在于，通过超声波扫描检测系统采 集待测产品所对应的第一扫描信号，包括：
    将超声波扫描检测系统中超声探头放置于垂直待测产品的焊缝处，并垂直于待测产品的焊缝表面入射超声波；
    采集待测产品各焊缝表面反射波信号以及横板底面反射波信号得到第一扫描信号。
  5. 如权利要求1～4任一项所述的方法，其特征在于，所述对比试块设置有0mm、0.2mm、0.4mm、0.6mm以及0.8mm多种槽宽的焊缝；其中，指定焊缝为0.4mm槽宽的焊缝。
  6. 如权利要求1～4任一项所述的方法，其特征在于，根据所述第一扫描图像对所述第一扫描信号中各反射波信号进行归一化处理得到第二扫描信号，包括：
    根据所述第一扫描图像上确定所述第一扫描信号的扫描数据，基于所述扫描数据生成焊缝表面反射波的特征信息，其中，所述特征信息包括焊缝表面每个点的反射波的幅值信息和位置信息；
    将每个点对应的反射波的特征信息与指定值进行比较计算得到相对增益值，根据所述每个点的相对增益值得到所述第二扫描信号。
  7. 如权利要求6所述的方法，其特征在于，根据第二扫描信号生成第二扫描图像，包括：根据所述第二扫描信号中每个点的相对增益值对其对应的反射波高度进行增益计算，得到归一化的反射波特征信息；
    根据所述归一化的反射波特征信息生成所述第二扫描图像。
PCT/CN2023/113166 2022-11-28 2023-08-15 一种t型电子束焊缝熔宽的检测方法及装置 Ceased WO2024113960A1 (zh)

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