阅读说明：本技术 一种数控机床的超声自动检测系统及其工作方法 (Ultrasonic automatic detection system of numerical control machine tool and working method thereof ) 是由 陈茂隆 于 2021-07-26 设计创作，主要内容包括：一种数控机床的超声自动检测系统及其工作方法,包括上位机、相控阵超声成像检测仪器、电气控制模块、超声检测组件；所述上位机基于PXI总线,所述上位机配备有人机交互软件,所述人机交互软件用于将操作人员的指令转化并传递给相控阵超声成像检测仪器、电气控制模块、超声检测组件,同时接收相控阵超声成像检测仪器、电气控制模块、超声检测组件的反馈数据和信息,协调电气控制模块与超声检测组件协调运作,完成相控阵超声成像检测仪器在线成像。本发明所述的数控机床的超声自动检测系统及其工作方法,结构设计合理,基于超声波相控阵技术,自动化程度高,超声波声束能覆盖全部被检区域,声束路径清晰,回波信号易于分析,提高了检测的准确度。(An ultrasonic automatic detection system of a numerical control machine tool and a working method thereof comprise an upper computer, a phased array ultrasonic imaging detection instrument, an electrical control module and an ultrasonic detection assembly; the upper computer is based on a PXI bus, is provided with human-computer interaction software, and the human-computer interaction software is used for converting and transmitting instructions of an operator to the phased array ultrasonic imaging detection instrument, the electrical control module and the ultrasonic detection assembly, receiving feedback data and information of the phased array ultrasonic imaging detection instrument, the electrical control module and the ultrasonic detection assembly, coordinating the coordinated operation of the electrical control module and the ultrasonic detection assembly, and finishing the online imaging of the phased array ultrasonic imaging detection instrument. The ultrasonic automatic detection system of the numerical control machine tool and the working method thereof have reasonable structural design, are based on the ultrasonic phased array technology, have high automation degree, can cover all detected areas by ultrasonic sound beams, have clear sound beam paths, are easy to analyze echo signals, and improve the detection accuracy.)

1. An ultrasonic automatic detection system of a numerical control machine tool is characterized by comprising an upper computer (1), a phased array ultrasonic imaging detection instrument (2), an electric control module (3) and an ultrasonic detection assembly (4); the upper computer (1) is based on a PXI bus, the upper computer (1) is provided with human-computer interaction software, the human-computer interaction software is used for converting and transmitting instructions of an operator to the phased array ultrasonic imaging detection instrument (2), the electrical control module (3) and the ultrasonic detection assembly (4), meanwhile, feedback data and information of the phased array ultrasonic imaging detection instrument (2), the electrical control module (3) and the ultrasonic detection assembly (4) are received, the electrical control module (3) and the ultrasonic detection assembly (4) are coordinated to operate in a coordinated mode, and online imaging of the phased array ultrasonic imaging detection instrument (2) is completed; the electrical control module (3) comprises a PLC motion controller (31) and a driver component (32), the PLC motion controller (31) is connected with the upper computer (1) through a serial communication interface, and the PLC motion controller (31) converts motion control instructions and parameters sent by the upper computer (1) into high-speed pulses through the driver component (32) for output; the ultrasonic detection assembly (4) comprises a supporting device (41), a clamping device (42) and an ultrasonic detection device (43), wherein the supporting device (41) is installed on the numerical control machine tool, the clamping device (42) and the ultrasonic detection device (43) are respectively fixed through the supporting device (41), a workpiece to be detected is fixed through the clamping device (42), and the ultrasonic detection device (43) is located above the clamping device (42);

the ultrasonic detection device (43) comprises a plurality of phased array probes (431), each phased array probe (431) is connected with a phased array ultrasonic imaging detection instrument (2), the phased array probes (431) are arranged on two sides above a workpiece to be detected, the distance between the phased array probes (431) on each side is distributed, the sound beam angle of each phased array probe (431) is 40-70 degrees, fan scanning of 40-70 degrees is carried out on the workpiece to be detected, and defect information is acquired.

2. The ultrasonic automatic detection system of the numerical control machine according to claim 1, wherein the supporting device (41) comprises a base (411), a first side plate (412), a second side plate (413), a first ball groove (414), a second ball groove (415) and a top plate (416), the base (411) is installed on the numerical control machine, the first side plate (412) and the second side plate (413) are respectively arranged on two sides above the base (411), the first ball groove (414) and the second ball groove (415) are grooves formed on two sides of the upper surface of the base (411), and the top plate (416) spans over the first side plate (412) and the second side plate (413).

3. The ultrasonic automatic detection system of the numerical control machine according to claim 2, wherein the clamping device (42) comprises a first L-shaped limiting plate (421), a second L-shaped limiting plate (422), a first lead screw (423), a second lead screw (424), a first motor (425), a second motor (426), a first ball (427) and a second ball (428), one end of the first lead screw (423) is connected with the first L-shaped limiting plate (421) through a first bearing and the other end passes through a first side plate (412) to be connected with the first motor (425), one end of the second lead screw (424) is connected with the second L-shaped limiting plate (422) through a second bearing and the other end passes through a second side plate (413) to be connected with the second motor (426), the first ball (427) and the second ball (428) are respectively arranged below the first L-shaped limiting plate (421) and the second L-shaped limiting plate (422) and are positioned in the first ball groove (414) and the second ball groove (415) and can be positioned in the first ball groove (428) Moving; a workpiece to be detected is placed between the first L-shaped limiting plate (421) and the second L-shaped limiting plate (422).

4. The ultrasonic automatic inspection system of the numerical control machine tool according to claim 3, characterized in that the ultrasonic detection device (43) further comprises a connection block (4311), a T-shaped rod (432), a cylinder (433), a smearing box (434); an X-axis component (417) and a Y-axis component (418) are transversely installed at the bottom of the top plate (416), a cross sliding table structure consisting of the X-axis component (417) and the Y-axis component (418) is installed at the bottom of the cross sliding table structure, a connecting block (4311) is installed at the bottom of the cross sliding table structure, the X-axis component (417) and the Y-axis component (418) drive corresponding screw-nut mechanisms of the X-axis component (417) and the Y-axis component (418) through an X-axis servo motor (419) and a Y-axis servo motor (420), and the movement of the connecting block (4311) in the X direction and the Y direction is realized; the middle of the top surface of the T-shaped rod (432) is connected with the bottom of the connecting block (4311), the left end and the right end of the T-shaped rod (432) are respectively provided with a plurality of phased array probes (431) and are positioned on two sides above a workpiece to be detected, and the phased array probes (431) on each side are distributed equidistantly along the Y-axis direction; the air cylinder (433) is arranged at the bottom of the T-shaped rod (432), the smearing box (434) is arranged below the air cylinder (433), the air cylinder (433) is connected with the air pump (435), and the air pump (435) drives the air cylinder (433) to work.

5. The ultrasonic automatic detection system of the numerical control machine tool according to claim 4, wherein the electric control module (3) further comprises a photoelectric encoder (33) and a Hall sensor (34), the driver assembly (32) comprises a first motor driver (331), a second motor driver (322), an X-axis servo motor driver (323), a Y-axis servo motor driver (324) and an air pump driver (325), the first motor driver (331), the second motor driver (322), the X-axis servo motor driver (323), the Y-axis servo motor driver (324) and the air pump driver (325) are respectively connected with a first motor (425), a second motor (426), an X-axis servo motor (419), a Y-axis servo motor (420) and an air pump (435), and the first motor (425), the second motor (426) and the air pump (435) are connected, And the X-axis servo motor (419) and the Y-axis servo motor (420) are respectively provided with a photoelectric encoder (33) and a Hall sensor (34).

6. The ultrasonic automatic inspection system of the numerical control machine tool according to claim 4, wherein the smearing box (434) comprises a smearing sponge (4341) and a feed inlet (4342), the feed inlet (4342) is arranged on one side above the smearing box (434), and the smearing sponge (4341) is arranged at the bottom of the smearing box (434).

7. The working method of the ultrasonic automatic inspection system of the numerical control machine tool according to any one of claims 1 to 6, characterized in that the working method comprises the steps of:

(1) the workpiece to be detected is fixed through a clamping device (42); wherein, a workpiece to be detected is placed between a first L-shaped limiting plate (421) and a second L-shaped limiting plate (422) of a clamping device (42), a PLC motion controller (31) converts motion control instructions and parameters issued by an upper computer (1) into high-speed pulses through a first motor driver (331) and a second motor driver (322) of a driver component (32) respectively and outputs the high-speed pulses to a first motor (425) and a second motor (426) of the clamping device (42) to drive a first lead screw (423) and a second lead screw (424) of the clamping device (42) to rotate in a first side plate (412) and a second side plate (413) of a supporting device (41), thereby driving the first L-shaped limiting plate (421) and the second L-shaped limiting plate (422) to move, clamping the workpiece to be detected, and moving the left and right positions of the workpiece to be detected through the first motor (425) and the second motor (426); the first motor (425) and the second motor (426) are both provided with a photoelectric encoder (33) and a Hall sensor (34), and position information feedback is carried out on the PLC motion controller (31) through the photoelectric encoder (33) and the Hall sensor (34);

(2) pouring a coupling agent into the smearing box (434) through a feeding hole (4342) of the smearing box (434) of the ultrasonic detection device (43) in advance to enable the coupling agent to infiltrate a smearing sponge (4341) of the smearing box (434), then driving an air pump (435) by a PLC (programmable logic controller) through an air pump driver (325) according to a motion control command and parameters issued by an upper computer (1), starting an air cylinder (433), pushing the smearing box (434) downwards by the air cylinder (433) until the smearing sponge (4341) is tightly attached to a workpiece to be detected, and smearing the detected area of the workpiece to be detected in a full-coverage manner by the coupling agent smeared on the sponge (4341); the motion trail control of the smearing sponge (4341) in the smearing process is realized by driving a motion control command and parameters issued by an upper computer (1) through an X-axis servo motor driver (323) and a Y-axis servo motor driver (324) by a PLC (programmable logic controller) driver (31) to drive an X-axis servo motor (419) and a Y-axis servo motor (420), driving an X-axis part (417) and a Y-axis part (418) by the X-axis servo motor (419) and the Y-axis servo motor (420) to drive a screw nut mechanism corresponding to the X-axis part and the Y-axis part (418), so that the motion of the connecting block (4311) in the X direction and the Y direction is realized, and the motion of the smearing sponge (4341) is driven;

(3) after the smearing is finished, the PLC motion controller (31) drives the air pump (435) through the air pump driver (325), controls the air cylinder (433) to contract, and retracts the smearing box (434); the phased array probe (431) covers sound beams of a workpiece to be detected on the left side and the right side above the workpiece to be detected, and the motion trail of the phased array probe (431) is controlled in the detection process, motion control instructions and parameters sent by an upper computer (1) are driven by a PLC (programmable logic controller) through an X-axis servo motor driver (323) and a Y-axis servo motor driver (324) to drive an X-axis servo motor (419) and a Y-axis servo motor (420), the X-axis servo motor (419) and the Y-axis servo motor (420) drive a screw-nut mechanism corresponding to an X-axis part (417) and a Y-axis part (418), so that the motion of a connecting block (4311) in the X direction and the Y direction is realized, the phased array probe (431) is driven to move, the phased array probe (431) adopts a scanning mode combining scanning and fan scanning along the line, scanning along the extension direction of the X axis or the Y axis of the workpiece to be detected, and simultaneously scanning the workpiece to be detected by 40-70 degrees in a sector mode to obtain defect information;

(4) the defect information signals acquired by the phased array probe (431) are transmitted to a phased array ultrasonic imaging detection instrument (2), the phased array ultrasonic imaging detection instrument (2) transmits signals of defect information to an upper computer (1) through a PXI bus, the signals of the defect information enter an FPGA through a transmitting and receiving unit of the phased array ultrasonic imaging detection instrument (2) in sequence, are input to a high-speed bus switching module after sound beam synthesis and filtering, waveform conversion, sampling and envelope processing processes of receiving delay control, then a DSP reads real-time data through the high-speed bus switching module, and the real-time data are calculated, written into an RAM according to an agreed packet format of man-machine interaction software, and uploaded to the upper computer (1) in a DMA (direct memory access) mode for imaging, so that ultrasonic detection of defects of a workpiece to be detected is achieved.

Technical Field

The invention belongs to the technical field of numerical control machines, and particularly relates to an ultrasonic automatic detection system of a numerical control machine and a working method thereof.

Background

In the process of processing a workpiece by a numerical control machine tool, nondestructive detection is often required to be carried out on the workpiece, in the traditional ultrasonic detection, a detector directly uses an ultrasonic probe to carry out manual ultrasonic detection on the workpiece on the machine tool, the ultrasonic wave of the ultrasonic probe can be transmitted in the workpiece in a specific direction and speed, and when the ultrasonic probe contacts different interfaces, the ultrasonic wave can have physical phenomena such as reflection, refraction and the like due to the change of a medium. Because the defects in the workpiece and the workpiece belong to different media, if the ultrasonic wave meets the defects during propagation in the workpiece, the ultrasonic wave is liable to be reflected and refracted, and an ultrasonic nondestructive testing technology is generated based on the principle.

In manual detection of detection personnel, the reliability of a detection result is greatly related to the detection experience of the detection personnel, and once the detection personnel neglect, the detection result is unreliable. In addition, if the detection environment has potential danger during manual detection, potential safety hazards can be caused to detection personnel. Therefore, it is necessary to develop an ultrasonic automatic detection system of a numerical control machine tool and a working method thereof to solve the above technical problems.

The Chinese patent application No. CN202022959630.5 discloses an ultrasonic nondestructive testing device for gradient residual stress of thick-wall metal, aiming at being used for gradient nondestructive testing of surface tangential residual stress of large-size thick-wall metal, improving the residual stress testing efficiency and not improving an ultrasonic automatic testing system of a numerical control machine tool and a working method thereof.

Disclosure of Invention

The purpose of the invention is as follows: in order to overcome the defects, the invention aims to provide an ultrasonic automatic detection system of a numerical control machine tool and a working method thereof, the structural design is reasonable, the ultrasonic phased array technology is based, the automation degree is high, the accurate movement of ultrasonic detection and couplant coating is realized, ultrasonic sound beams can cover all detected areas, the sound beam paths are clear, echo signals are easy to analyze, the detection accuracy is improved, and the application prospect is wide.

The purpose of the invention is realized by the following technical scheme:

an ultrasonic automatic detection system of a numerical control machine tool comprises an upper computer, a phased array ultrasonic imaging detection instrument, an electrical control module and an ultrasonic detection assembly; the upper computer is based on a PXI bus, is provided with human-computer interaction software, and is used for converting and transmitting instructions of an operator to the phased array ultrasonic imaging detection instrument, the electrical control module and the ultrasonic detection assembly, receiving feedback data and information of the phased array ultrasonic imaging detection instrument, the electrical control module and the ultrasonic detection assembly, coordinating the coordinated operation of the electrical control module and the ultrasonic detection assembly, and finishing the online imaging of the phased array ultrasonic imaging detection instrument; the electrical control module comprises a PLC motion controller and a driver component, the PLC motion controller is connected with an upper computer through a serial communication interface, and the PLC motion controller converts motion control instructions and parameters sent by the upper computer into high-speed pulses through the driver component for output; the ultrasonic detection assembly comprises a supporting device, a clamping device and an ultrasonic detection device, wherein the supporting device is installed on the numerical control machine tool, the clamping device and the ultrasonic detection device are fixed through the supporting device respectively, a workpiece to be detected is fixed through the clamping device, and the ultrasonic detection device is positioned above the clamping device;

the ultrasonic detection device comprises a plurality of phased array probes, each phased array probe is connected with a phased array ultrasonic imaging detection instrument, the phased array probes are arranged on two sides above a workpiece to be detected, the distance between the phased array probes on each side is distributed, the sound beam angle of each phased array probe is 40-70 degrees, the workpiece to be detected is subjected to sector scanning of 40-70 degrees, and defect information is obtained.

Further, foretell automatic ultrasonic testing system of digit control machine tool, strutting arrangement includes base, first curb plate, second curb plate, first ball groove, second ball groove and roof, the pedestal mounting is on the digit control machine tool, first curb plate, second curb plate set up respectively in base top both sides, first ball groove, second ball groove are the recess seted up for base upper surface both sides, the roof spanes in first curb plate and second curb plate top.

Furthermore, in the automatic ultrasonic detection system for the numerical control machine tool, the clamping device includes a first L-shaped limiting plate, a second L-shaped limiting plate, a first lead screw, a second lead screw, a first motor, a second motor, a first ball and a second ball, one end of the first lead screw is connected with the first L-shaped limiting plate through a first bearing, the other end of the first lead screw penetrates through the first side plate and is connected with the first motor, one end of the second lead screw is connected with the second L-shaped limiting plate through a second bearing, the other end of the second lead screw penetrates through the second side plate and is connected with the second motor, and the first ball and the second ball are respectively arranged below the first L-shaped limiting plate and the second L-shaped limiting plate, are located in the first ball groove and the second ball groove, and can move; and a workpiece to be detected is placed between the first L-shaped limiting plate and the second L-shaped limiting plate.

Further, in the ultrasonic automatic detection system of the numerical control machine tool, the ultrasonic detection device further comprises a connecting block, a T-shaped rod, a cylinder and a smearing box; an X-axis component and a Y-axis component are transversely installed at the bottom of the top plate 416, a cross sliding table structure consisting of the X-axis component and the Y-axis component is installed at the bottom of the cross sliding table structure, a connecting block is installed at the bottom of the cross sliding table structure, and the X-axis component and the Y-axis component drive corresponding lead screw nut mechanisms of the X-axis component and the Y-axis component through an X-axis servo motor and a Y-axis servo motor respectively to realize the movement of the connecting block in the X direction and the Y direction; the middle part of the top surface of the T-shaped rod is connected with the bottom of the connecting block, a plurality of phased array probes are respectively installed at the left end and the right end of the T-shaped rod and are positioned at two sides above a workpiece to be detected, and the phased array probes at each side are distributed at equal intervals along the Y-axis direction; the air cylinder is arranged at the bottom of the T-shaped rod, the smearing box is arranged below the air cylinder, the air cylinder is connected with the air pump, and the air pump drives the air cylinder to work.

The ultrasonic detection device in the prior art is easy to cause the problem that a detection area cannot be completely covered, and the incident angle of an acoustic beam is single.

The X-axis component and the Y-axis component are both common structures in the prior art, and both the X-axis component and the Y-axis component are composed of components such as a guide rail, a guide rail slider, a coupler, a lead screw nut seat, a bearing seat and a bearing plate, and are not repeated here

Further, the supersound automatic check out system of foretell digit control machine tool, electrical control module still includes photoelectric encoder and hall sensor, the driver subassembly includes first motor driver, second motor driver, X axle servo motor driver, Y axle servo motor driver, air pump driver, first motor driver, second motor driver, X axle servo motor driver, Y axle servo motor driver, air pump driver are connected with first motor, second motor, X axle servo motor, Y axle servo motor, air pump respectively, all install photoelectric encoder and hall sensor on first motor, second motor, X axle servo motor, the Y axle servo motor.

The electric control module is responsible for power supply and motion control of detection of the whole ultrasonic automatic detection system, when ultrasonic detection is carried out, when a set sampling point is reached, the photoelectric encoder and the Hall sensor can feed back the PLC motion controller, the PLC motion controller feeds back the upper computer, the upper computer sends a data acquisition command to the phased array ultrasonic imaging detection instrument and the phased array probe, and the photoelectric encoder and the Hall sensor feed back current position information simultaneously.

Further, foretell digit control machine tool's supersound automatic check out system, paint the box including paint sponge, feed inlet, the feed inlet setting is smearing box top one side, paint the sponge setting and is smearing the box bottom.

The invention also relates to a working method of the ultrasonic automatic detection system of the numerical control machine tool, which comprises the following steps: the method comprises the following steps:

(2) fixing a workpiece to be detected through a clamping device; the PLC motion controller converts motion control commands and parameters sent by an upper computer into high-speed pulses through a first motor driver and a second motor driver of a driver assembly respectively and outputs the high-speed pulses to a first motor and a second motor of the clamping device, drives a first lead screw and a second lead screw of the clamping device to rotate in a first side plate and a second side plate of a supporting device, so that the first L-shaped limiting plate and the second L-shaped limiting plate are driven to move, the workpiece to be detected is clamped, and the left and right positions of the workpiece to be detected are moved through the first motor and the second motor; the first motor and the second motor are both provided with a photoelectric encoder and a Hall sensor, and position information feedback is carried out on the PLC motion controller through the photoelectric encoder and the Hall sensor;

(2) pouring a coupling agent into the smearing box through a smearing box feeding port of the ultrasonic detection device in advance to enable the coupling agent to infiltrate the smearing sponge of the smearing box, driving an air pump by a PLC (programmable logic controller) through an air pump driver according to a motion control command and parameters sent by an upper computer 1, starting an air cylinder, and pushing the smearing box downwards by the air cylinder until the smearing sponge is tightly attached to a workpiece to be detected so that the coupling agent smeared with the sponge is smeared on the detected area of the workpiece to be detected in a full-coverage manner; the motion trail control of the smearing sponge in the smearing process is realized by driving motion control instructions and parameters sent by an upper computer through an X-axis servo motor driver and a Y-axis servo motor driver by a PLC motion controller, driving an X-axis servo motor and a Y-axis servo motor by the X-axis servo motor and the Y-axis servo motor, driving a screw nut mechanism corresponding to an X-axis part and a Y-axis part by the X-axis servo motor and the Y-axis servo motor, realizing the motion of a connecting block in the X direction and the Y direction, and driving the smearing sponge to move;

(3) after the smearing is finished, the PLC motion controller drives the air pump through the air pump driver to control the air cylinder to contract so as to withdraw the smearing box; the phased array probe covers the workpiece to be detected on the left side and the right side above the workpiece to be detected by sound beams, in the motion trail control of the phased array probe in the detection process, a motion control command and parameters sent by an upper computer are driven by a PLC motion controller through an X-axis servo motor driver and a Y-axis servo motor driver to drive an X-axis servo motor and a Y-axis servo motor, the X-axis servo motor and the Y-axis servo motor drive a screw nut mechanism corresponding to an X-axis part and a Y-axis part to realize the motion of a connecting block in the X direction and the Y direction, the phased array probe is scanned along the extension direction of the X axis or the Y axis of the workpiece to be detected in a scanning mode combining line scanning and fan scanning, and meanwhile, the workpiece to be detected is subjected to fan scanning of 40-70 degrees to obtain defect information;

(4) the method comprises the steps that a defect information signal acquired by a phased array probe is transmitted to a phased array ultrasonic imaging detection instrument, the phased array ultrasonic imaging detection instrument transmits a defect information signal to an upper computer through a PXI bus, the defect information signal enters an FPGA through a transmitting and receiving unit of the phased array ultrasonic imaging detection instrument in sequence, the defect information signal is input to a high-speed bus switching module after sound beam synthesis and filtering, waveform conversion, sampling and enveloping processes of receiving delay control, then a DSP reads real-time data through the high-speed bus switching module, the real-time data are calculated, the data are written into an RAM according to an agreed packet format of man-machine interaction software, the data are uploaded to the upper computer in a DMA mode to be used for imaging, and then ultrasonic detection of the defect of a workpiece to be detected is achieved.

Compared with the prior art, the invention has the following beneficial effects: the ultrasonic detection device has the advantages of reasonable structural design, simple working method, high automation and intelligence degree, high automation degree based on an ultrasonic phased array technology, realization of accurate movement of ultrasonic detection and smearing of a coupling agent, coverage of all detected areas by ultrasonic sound beams, clear sound beam paths, easiness in analysis of echo signals, improvement of detection accuracy and wide application prospect.

Drawings

FIG. 1 is a schematic structural diagram of an ultrasonic detection assembly of an ultrasonic automatic detection system of a numerically-controlled machine tool according to the present invention;

FIG. 2 is a frame diagram of an ultrasonic automatic detection system of a numerically controlled machine tool according to the present invention;

in the figure: the ultrasonic detection device comprises an upper computer 1, a phased array ultrasonic imaging detection instrument 2, an electrical control module 3, a PLC motion controller 31, a driver assembly 32, a first motor driver 331, a second motor driver 322, an X-axis servo motor driver 323, a Y-axis servo motor driver 324, an air pump driver 325, a photoelectric encoder 33, a Hall sensor 34, an ultrasonic detection assembly 4, a supporting device 41, a base 411, a first side plate 412, a second side plate 413, a first ball groove 414, a second ball groove 415, a top plate 416, an X-axis part 417, a Y-axis part 418, an X-axis servo motor 419, a Y-axis servo motor 420, a clamping device 42, a first L-shaped limiting plate 421, a second L-shaped limiting plate 422, a first lead screw 423, a second lead screw 424, a first motor 425, a second motor 426, a first ball 427, a second ball 428, an ultrasonic detection device 43, a phased array probe 431, a first L-shaped limiting plate 422, a second ball 423, a second lead screw 424, a second ball 427, a second ball 426, a second ball-shaped probe head, a second ball head 431, a probe head, a probe, A connecting block 4311, a T-shaped rod 432, an air cylinder 433, an applying box 434, an applying sponge 4341, a feeding hole 4342, an air pump 435, an acoustic beam coverage area a and a workpiece b to be detected.

Detailed Description

The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the following specific embodiments and accompanying fig. 1-2, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

As shown in fig. 1-2, the following embodiments provide an ultrasonic automatic detection system of a numerically-controlled machine tool, including an upper computer 1, a phased array ultrasonic imaging detection instrument 2, an electrical control module 3, and an ultrasonic detection assembly 4; the upper computer 1 is based on a PXI bus, the upper computer 1 is provided with human-computer interaction software, the human-computer interaction software is used for converting and transmitting instructions of an operator to the phased array ultrasonic imaging detection instrument 2, the electrical control module 3 and the ultrasonic detection assembly 4, meanwhile, feedback data and information of the phased array ultrasonic imaging detection instrument 2, the electrical control module 3 and the ultrasonic detection assembly 4 are received, the electrical control module 3 and the ultrasonic detection assembly 4 are coordinated to operate in a coordinated mode, and online imaging of the phased array ultrasonic imaging detection instrument 2 is completed; the electrical control module 3 comprises a PLC motion controller 31 and a driver component 32, the PLC motion controller 31 is connected with the upper computer 1 through a serial communication interface, and the PLC motion controller 31 converts motion control instructions and parameters sent by the upper computer 1 into high-speed pulses through the driver component 32 for output; the ultrasonic detection assembly 4 comprises a supporting device 41, a clamping device 42 and an ultrasonic detection device 43, wherein the supporting device 41 is installed on the numerical control machine tool, the clamping device 42 and the ultrasonic detection device 43 are respectively fixed through the supporting device 41, a workpiece to be detected is fixed through the clamping device 42, and the ultrasonic detection device 43 is located above the clamping device 42;

the ultrasonic detection device 43 comprises a plurality of phased array probes 431, each phased array probe 431 is connected with the phased array ultrasonic imaging detection instrument 2, the phased array probes 431 are arranged on two sides above a workpiece to be detected, the distance between the phased array probes 431 on each side is distributed, the sound beam angle of each phased array probe 431 is 40-70 degrees, the workpiece to be detected is scanned by a fan at 40-70 degrees, and defect information is acquired.

Further, the supporting device 41 includes a base 411, a first side plate 412, a second side plate 413, a first ball groove 414, a second ball groove 415, and a top plate 416, the base 411 is installed on the numerical control machine tool, the first side plate 412 and the second side plate 413 are respectively disposed on two sides above the base 411, the first ball groove 414 and the second ball groove 415 are grooves formed on two sides of the upper surface of the base 411, and the top plate 416 spans over the first side plate 412 and the second side plate 413.

Further, the clamping device 42 includes a first L-shaped limiting plate 421, a second L-shaped limiting plate 422, a first lead screw 423, a second lead screw 424, a first motor 425, a second motor 426, a first ball 427 and a second ball 428, wherein one end of the first lead screw 423 is connected to the first L-shaped limiting plate 421 through a first bearing, the other end of the first lead screw passes through the first side plate 412 and is connected to the first motor 425, one end of the second lead screw 424 is connected to the second L-shaped limiting plate 422 through a second bearing, the other end of the second lead screw passes through the second side plate 413 and is connected to the second motor 426, and the first ball 427 and the second ball 428 are respectively disposed below the first L-shaped limiting plate 421 and the second L-shaped limiting plate 422 and are located in the first ball groove 414 and the second ball groove 415 and are capable of moving; and a workpiece to be detected is placed between the first L-shaped limiting plate 421 and the second L-shaped limiting plate 422.

Further, the ultrasonic detection device 43 further comprises a connecting block 4311, a T-shaped rod 432, a cylinder 433, and an application box 434; an X-axis component 417 and a Y-axis component 418 are transversely installed at the bottom of the top plate 416, a cross sliding table structure consisting of the X-axis component 417 and the Y-axis component 418 is installed at the bottom of the cross sliding table structure, a connecting block 4311 is installed at the bottom of the cross sliding table structure, and the X-axis component 417 and the Y-axis component 418 drive corresponding screw-nut mechanisms of the X-axis component 417 and the Y-axis component 418 through an X-axis servo motor 419 and a Y-axis servo motor 420 respectively to realize the movement of the connecting block 4311 in the X direction and the Y direction; the middle part of the top surface of the T-shaped rod 432 is connected with the bottom of the connecting block 4311, the left end and the right end of the T-shaped rod 432 are respectively provided with a plurality of phased array probes 431 and are positioned at two sides above a workpiece to be detected, and the phased array probes 431 at each side are equidistantly distributed along the Y-axis direction; the air cylinder 433 is arranged at the bottom of the T-shaped rod 432, the smearing box 434 is arranged below the air cylinder 433, the air cylinder 433 is connected with the air pump 435, and the air pump 435 drives the air cylinder 433 to work.

Further, the electrical control module 3 further includes a photoelectric encoder 33 and a hall sensor 34, the driver assembly 32 includes a first motor driver 331, a second motor driver 322, an X-axis servo motor driver 323, a Y-axis servo motor driver 324 and an air pump driver 325, the first motor driver 331, the second motor driver 322, the X-axis servo motor driver 323, the Y-axis servo motor driver 324 and the air pump driver 325 are respectively connected with the first motor 425, the second motor 426, the X-axis servo motor 419, the Y-axis servo motor 420 and the air pump 435, and the photoelectric encoder 33 and the hall sensor 34 are respectively installed on the first motor 425, the second motor 426, the X-axis servo motor 419 and the Y-axis servo motor 420.

Further, the smearing box 434 comprises a smearing sponge 4341 and a feed inlet 4342, wherein the feed inlet 4342 is arranged on one side above the smearing box 434, and the smearing sponge 4341 is arranged at the bottom of the smearing box 434.

Examples

The working method of the ultrasonic automatic detection system of the numerical control machine tool comprises the following steps: the working method comprises the following steps:

(1) the workpiece to be detected is fixed through the clamping device 42; a workpiece to be detected is placed between a first L-shaped limiting plate 421 and a second L-shaped limiting plate 422 of the clamping device 42, the PLC motion controller 31 converts a motion control command and a parameter issued by the upper computer 1 into a high-speed pulse through a first motor driver 331 and a second motor driver 322 of the driver component 32, and outputs the high-speed pulse to a first motor 425 and a second motor 426 of the clamping device 42, respectively, so as to drive a first lead screw 423 and a second lead screw 424 of the clamping device 42 to rotate in a first side plate 412 and a second side plate 413 of the supporting device 41, so as to drive the first L-shaped limiting plate 421 and the second L-shaped limiting plate 422 to move and clamp the workpiece to be detected, and the left and right positions of the workpiece to be detected are moved through the first motor 425 and the second motor 426; the first motor 425 and the second motor 426 are both provided with a photoelectric encoder 33 and a hall sensor 34, and position information feedback is carried out on the PLC motion controller 31 through the photoelectric encoder 33 and the hall sensor 34;

(2) pouring a coupling agent into the smearing box 434 through a feeding hole 4342 of the smearing box 434 of the ultrasonic detection device 43 in advance to enable the coupling agent to infiltrate the smearing sponge 4341 of the smearing box 434, driving the air pump 435 through the air pump driver 325 by using a motion control command and parameters sent by the upper computer 1 through the PLC motion controller 31, starting the air cylinder 433, and pushing the smearing box 434 downwards by using the air cylinder 433 until the smearing sponge 4341 is attached to the workpiece to be detected, so that the coupling agent smeared on the sponge 4341 can completely cover the detected area of the workpiece to be detected; the motion trail control of the smearing sponge 4341 in the smearing process is realized by controlling motion control commands and parameters issued by the upper computer 1 through the PLC motion controller 31 through the X-axis servo motor driver 323 and the Y-axis servo motor driver 324 to drive the X-axis servo motor 419 and the Y-axis servo motor 420, driving the X-axis servo motor 419 and the Y-axis servo motor 420 to drive the screw-nut mechanisms corresponding to the X-axis part 417 and the Y-axis part 418 through the X-axis servo motor driver 419 and the Y-axis servo motor 420, realizing the motion of the connecting block 4311 in the X direction and the Y direction, and driving the smearing sponge 4341 to move;

(3) after the smearing is finished, the PLC motion controller 31 drives the air pump 435 through the air pump driver 325, controls the air cylinder 433 to contract, and retracts the smearing box 434; the phased array probe 431 covers sound beams of workpieces to be detected on the left side and the right side above the workpieces to be detected, in addition, the motion trail control of the phased array probe 431 is realized by that a motion control instruction and parameters sent by an upper computer 1 are driven by an X-axis servo motor driver 323 and a Y-axis servo motor driver 324 through a PLC motion controller 31 to drive an X-axis servo motor 419 and a Y-axis servo motor 420, the X-axis servo motor 419 and the Y-axis servo motor 420 drive an X-axis part 417 and a lead screw nut mechanism corresponding to the Y-axis part 418, the motion of a connecting block 4311 in the X direction and the Y direction is realized, so that the phased array probe 431 is driven to move, the phased array probe 431 adopts a scanning mode combining line scanning and fan scanning, the scanning is carried out along the X-axis or Y-axis extending direction of the workpieces to be detected, and the fan scanning is carried out at 40-70 degrees on the workpieces to be detected at the same time, acquiring defect information;

(4) the method comprises the steps that a defect information signal acquired by a phased array probe 431 is transmitted to a phased array ultrasonic imaging detection instrument 2, the phased array ultrasonic imaging detection instrument 2 transmits a defect information signal to an upper computer 1 through a PXI bus, the defect information signal enters an FPGA through a transmitting and receiving unit of the phased array ultrasonic imaging detection instrument 2 in sequence, the defect information signal is input to a high-speed bus switching module after sound beam synthesis and filtering, waveform conversion, sampling and enveloping processing processes of receiving delay control, then a DSP reads real-time data through the high-speed bus switching module, the real-time data are calculated, the data are written into an RAM according to an appointed packet format of man-machine interaction software, the data are uploaded to the upper computer 1 in a DMA mode and are used for imaging, and then ultrasonic detection of the defect of a workpiece to be detected is achieved.

Therefore, the ultrasonic automatic detection system of the numerical control machine tool is reasonable in structural design, based on an ultrasonic phased array technology, high in automation degree, capable of achieving accurate movement of ultrasonic detection and couplant smearing, and capable of solving the problems that an ultrasonic detection device in the prior art is prone to generating detection areas which cannot be completely covered and the incident angle of an acoustic beam is single.

The electric control module is responsible for power supply of the whole automatic ultrasonic detection system and motion control of detection, when ultrasonic detection is carried out, when a set sampling point is reached, the photoelectric encoder and the Hall sensor can feed back the PLC motion controller and the PLC motion controller to feed back the upper computer, the upper computer sends a data acquisition command to the phased array ultrasonic imaging detection instrument and the phased array probe, and the photoelectric encoder and the Hall sensor feed back current position information at the same time.

The specific working method of the invention is many, and the above description is only the preferred embodiment of the invention. It should be noted that the above examples are only for illustrating the present invention, and are not intended to limit the scope of the present invention. It will be apparent to those skilled in the art that various modifications can be made without departing from the principles of the invention and these modifications are to be considered within the scope of the invention.