阅读说明：本技术 一种基于超声相控阵全聚焦成像技术的螺栓裂纹检测系统 (Bolt crack detection system based on ultrasonic phased array full-focus imaging technology ) 是由 王东利 程庆阳 黄杰 蔡云龙 于 2021-09-06 设计创作，主要内容包括：本发明提供了一种基于超声相控阵全聚焦成像技术的螺栓裂纹检测系统,包括内部设置有阵元的超声探头、多通道超声激励接收相控阵板卡和计算机,超声探头为圆环形,超声探头的外径与螺栓大径一致,超声探头为分体式结构,由弧形组件拼接而成,弧形组件上均连接设置有安装件,通过圆盘架固定拼接并通过限位销固定在螺栓的杆端部,超声探头安装孔和限位销安装孔的上方均连接有固定螺钉；圆盘架上设置有一组以上的超声探头安装孔,超声探头对应设置有一个以上,计算机对每个弧形组件的超声信号分别独立存储处理并分开单独成像。该检测系统在完全显示螺栓表面状态的同时成像速度快,适用于多种型号螺栓的检测。(The invention provides a bolt crack detection system based on an ultrasonic phased array full-focus imaging technology, which comprises an ultrasonic probe, a multi-channel ultrasonic excitation receiving phased array board card and a computer, wherein array elements are arranged in the ultrasonic probe, the ultrasonic probe is in a ring shape, the outer diameter of the ultrasonic probe is consistent with the major diameter of a bolt, the ultrasonic probe is in a split structure and is formed by splicing arc-shaped components, the arc-shaped components are connected with installation pieces, the installation pieces are fixedly spliced through a disc frame and fixed at the end part of a rod of the bolt through a limiting pin, and fixing screws are connected above an ultrasonic probe installation hole and the limiting pin installation hole; more than one group of ultrasonic probe mounting holes are formed in the disc frame, more than one ultrasonic probe is correspondingly arranged, and the computer respectively and independently stores and processes the ultrasonic signals of each arc-shaped component and separately and independently images the ultrasonic signals. The detection system has high imaging speed while completely displaying the surface state of the bolt, and is suitable for detecting bolts of various types.)

1. The utility model provides a bolt crack detecting system based on ultrasonic phased array full focus imaging technique, includes that inside is provided with ultrasonic probe, multichannel supersound excitation receiving phased array integrated circuit board and the computer of array element, multichannel supersound excitation receiving phased array integrated circuit board is connected with array element and computer respectively to detect the state of bolt surface, its characterized in that: the ultrasonic probe is in a ring shape, array elements are distributed in the ultrasonic probe in a linear array mode along the ring direction, the outer diameter of the ultrasonic probe is consistent with the major diameter of a bolt, the ultrasonic probe is in a split structure and is formed by splicing more than two arc-shaped components, each arc-shaped component is connected with a mounting piece, the arc-shaped components are fixedly spliced through a disc frame and fixed at the end part of the bolt through a limiting pin, an ultrasonic probe mounting hole matched with the mounting piece in shape and position is formed in the disc frame, the mounting pieces are clamped in the ultrasonic probe mounting holes, the ultrasonic probe is integrally mounted under the disc frame, limiting pin mounting holes matched with the limiting pin are further distributed in the disc frame, the limiting pin is mounted in the limiting pin mounting holes and attached to the side wall of the bolt, and the ultrasonic probe mounting holes distributed in the same circle on the disc frame are in a group, the disc rack is provided with more than one group of ultrasonic probe mounting holes and more than one group of limiting pin mounting holes correspondingly, and the ultrasonic probes are correspondingly provided with more than one group of limiting pin mounting holes and used for detecting bolts of different types; the multichannel ultrasonic excitation receiving phased array board card is respectively connected with each array element of each arc-shaped component and respectively transmits ultrasonic signals of the array elements to the computer, and the computer respectively and independently stores and processes the ultrasonic signals of each arc-shaped component and separately and independently images the ultrasonic signals.

2. The bolt crack detection system based on the ultrasonic phased array full focus imaging technology according to claim 1, characterized in that: the inner diameter of the ultrasonic probe is 0.8-0.95 times of the small diameter of the bolt.

3. The bolt crack detection system based on the ultrasonic phased array full focus imaging technology according to claim 1, characterized in that: the installed part is including connecting the spacing board that is the arc on the arc subassembly and connecting the spacing head that is "7" style of calligraphy on the limiting plate.

4. The bolt crack detection system based on the ultrasonic phased array full focus imaging technology according to claim 1, characterized in that: and fixing screw mounting holes are communicated with the upper parts of the ultrasonic probe mounting hole and the limiting pin mounting hole, and fixing screws for fixing the ultrasonic probe and the limiting pin are connected to the fixing screw mounting holes.

5. The bolt crack detection system based on the ultrasonic phased array full focus imaging technology according to claim 1, characterized in that: and the computer sets excitation parameters and sampling parameters according to the shape and size of the bolt and the distribution condition of array elements in the arc-shaped assemblies, so that each arc-shaped assembly only detects the rod surface state of the corresponding arc-shaped bolt.

Technical Field

The invention relates to the technical field of bolt crack detection, in particular to a bolt crack detection system based on an ultrasonic phased array full-focus imaging technology.

Background

Bolted joints are a very widely used structural joint in various engineering techniques, where the bolts are subjected to cyclic action of tensile and compressive loads. Under the action of alternating tension and compression loads, cracks are easily generated on the surface of the thread, and the connection strength is affected. In large-scale equipment or structures such as wind power, petrochemical pipelines, bridges and the like, after cracks are generated on the surfaces of threads, if the cracks are not found in time, serious potential safety hazards can be generated, and the risks of equipment or structure damage and casualties exist.

For the detection of the state of the bolt in service, at present, whether the bolt tightening torque or the bolt tension is reduced is generally detected, but the detection method can only judge whether the bolt is loosened, and the surface crack of the bolt cannot be effectively found. At present, some companies or organizations begin to use ultrasonic phased array full-focus imaging equipment to detect surface cracks of bolts in service, but the ultrasonic phased array full-focus imaging equipment is not developed for detecting the surface cracks of the bolts, and the following problems exist:

(1) the bolt types are numerous, the difference between the area of the ultrasonic probe and the sectional area of the bolt rod is large, and if the ultrasonic probe with a small area is used, the probe needs to be moved for many times and imaging is carried out for many times, so that the surface state of the bolt can be completely displayed; if a large-area ultrasonic probe is used, because the ultrasonic phased array full-focus imaging technology needs to acquire and process a lot of data, a data collecting card and a computer with very strong computing power need to be equipped, the cost is high, and the imaging speed is slow.

(2) When the surface of the ultrasonic probe is contacted with the end face of the bolt head, the ultrasonic probe is not positioned and limited, the probe needs to be moved for many times to be accurately positioned, and the detection process consumes more time.

(3) Under the condition that the end part of the bolt rod is limited in extension or the use space is limited, a special ultrasonic probe with small volume needs to be separately developed, and the method is time-consuming and high in cost.

Disclosure of Invention

In order to solve the defects in the prior art, the invention provides a bolt crack detection system based on an ultrasonic phased array full-focus imaging technology, which has high imaging speed while completely displaying the surface state of a bolt, is suitable for detecting bolts of various types, is suitable for the condition that the extending part of the end part of a bolt rod is limited or the use space is limited, can quickly judge the position of the bolt crack, and has visual and reliable detection results.

The technical scheme adopted for realizing the above purpose of the invention is as follows:

a bolt crack detection system based on an ultrasonic phased array full-focus imaging technology comprises an ultrasonic probe, a multi-channel ultrasonic excitation receiving phased array board card and a computer, wherein an array element is arranged inside the ultrasonic probe, the multi-channel ultrasonic excitation receiving phased array board card is respectively connected with the array element and the computer so as to detect the state of the outer surface of a bolt, the ultrasonic probe is in a ring shape, the array elements are distributed in the ultrasonic probe in a linear array mode along the direction of a ring, the outer diameter of the ultrasonic probe is consistent with the major diameter of the bolt, the ultrasonic probe is in a split structure and is formed by splicing more than two arc-shaped components, each arc-shaped component is connected and provided with an installation part, the arc-shaped components are fixedly spliced through a disc frame and fixed at the end part of the bolt through a limiting pin, an ultrasonic probe installation hole matched with the shape and the position of the installation part is arranged on the disc frame, and the installation part is clamped in the ultrasonic probe installation hole, the ultrasonic probe is integrally arranged right below the disc frame, limiting pin mounting holes matched with the limiting pins are further distributed on the disc frame, the limiting pins are mounted in the limiting pin mounting holes and attached to the side walls of the bolts, the ultrasonic probe mounting holes distributed on the same circle on the disc frame are in a group, more than one group of ultrasonic probe mounting holes are formed in the disc frame and correspondingly provided with more than one group of limiting pin mounting holes, and the ultrasonic probes are correspondingly provided with more than one group of limiting pin mounting holes and used for detecting bolts of different types; the multichannel ultrasonic excitation receiving phased array board card is respectively connected with each array element of each arc-shaped component and respectively transmits ultrasonic signals of the array elements to the computer, and the computer respectively and independently stores and processes the ultrasonic signals of each arc-shaped component and separately and independently images the ultrasonic signals.

The inner diameter of the ultrasonic probe is 0.8-0.95 times of the small diameter of the bolt.

The installed part is including connecting the spacing board that is the arc on the arc subassembly and connecting the spacing head that is "7" style of calligraphy on the limiting plate.

And fixing screw mounting holes are communicated with the upper parts of the ultrasonic probe mounting hole and the limiting pin mounting hole, and fixing screws for fixing the ultrasonic probe and the limiting pin are connected to the fixing screw mounting holes.

And the computer sets excitation parameters and sampling parameters according to the shape and size of the bolt and the distribution condition of array elements in the arc-shaped assemblies, so that each arc-shaped assembly only detects the rod surface state of the corresponding arc-shaped bolt.

Compared with the prior art, the technical scheme provided by the invention has the following advantages: 1. the bolt crack detection system provided by the invention comprehensively detects the surface of the bolt based on the ultrasonic phased array full-focus imaging technology, the surface state of the bolt directly displays a picture on a display screen of a computer, and the computer respectively processes and separately images ultrasonic signals of each arc-shaped component, so that the position of the bolt crack can be quickly judged, and the detection is simple and convenient. 2. According to the invention, the ultrasonic probe is fixed and limited through the disc frame and the limiting pin, and meanwhile, the fixing screws are arranged above the ultrasonic probe mounting hole and the limiting pin mounting hole in a communicated and connected mode, so that the ultrasonic probe and the limiting pin are further fixed, the connection is simple and stable, and the later detection is convenient. 3. The inner diameter of the ultrasonic probe is 0.8-0.95 times of the small diameter of the bolt, the outer diameter of the ultrasonic probe is consistent with the large diameter of the bolt, and for the bolt with a certain large diameter, the ultrasonic probe with the corresponding outer diameter and inner diameter is adopted to detect the surface of the bolt, so that the detection range is effectively reduced while the comprehensive detection of the surface of the bolt is completed, and the rapid imaging is facilitated. 4. The ultrasonic probe is of a split structure, and only part of arc-shaped assemblies can be installed for detection under the condition that the part extending out of the rod end part of the bolt is limited or the use space is limited and all the arc-shaped assemblies cannot be installed, so that the detection is convenient and flexible. 5. The disc frame is provided with more than one group of ultrasonic probe mounting holes, each group of ultrasonic probe mounting holes are correspondingly provided with more than one group of limiting pin mounting holes, and the ultrasonic probes are correspondingly provided with more than one group of limiting pin mounting holes, are used for mounting and fixing ultrasonic probes with different outer diameters and are suitable for detecting bolts with different models. 6. According to the invention, the computer sets the excitation parameters and the sampling parameters according to the shape and size of the bolt and the distribution condition of the array elements in the arc-shaped assemblies, so that each arc-shaped assembly only detects the rod surface state of the corresponding arc-shaped bolt, and the imaging speed is high.

Drawings

Fig. 1 is a schematic mounting diagram of an ultrasonic probe in a bolt crack detection system based on an ultrasonic phased array full-focus imaging technology provided in the invention;

FIG. 2 is an exploded view of a bolt crack detection system based on the ultrasonic phased array full focus imaging technology provided in the present invention;

FIG. 3 is a schematic structural view of an arcuate assembly of an ultrasonic probe of the present invention;

wherein (a) is a three-dimensional structure diagram of the arc-shaped component, and (b) is a top view of the arc-shaped component;

FIG. 4 is a view showing the construction of a stopper pin according to the present invention;

FIG. 5 is a schematic view of the upper surface of a puck frame according to the present invention;

FIG. 6 is a schematic view of the lower surface of the disc holder of the present invention;

FIG. 7 is a cross-sectional view of a puck frame of the present invention;

wherein (a) - (d) are sectional views from the upper surface to the lower surface in sequence;

FIG. 8 is a schematic view of the positions of the limiting pin mounting hole and the ultrasonic probe mounting hole on the disc holder according to the present invention;

FIG. 9 is a schematic view of the connection of the ultrasonic probe, the disk holder, the spacer pin and the fixing screw according to the present invention;

wherein (a) and (b) are perspective views from different perspectives;

in the figure: 1-bolt, 2-ultrasonic probe, 21-arc component, 3-mounting piece, 31-limiting plate, 32-limiting head, 4-disc rack, 41-ultrasonic probe mounting hole, 42-limiting pin mounting hole, 43-fixing screw mounting hole, 5-limiting pin and 6-fixing screw.

Detailed Description

The invention is described in detail below with reference to the drawings and specific embodiments.

The bolt crack detection system based on the ultrasonic phased array full-focusing imaging technology is structurally shown in fig. 1 and fig. 2, and at least comprises an ultrasonic probe 2 with an array element arranged inside, wherein the ultrasonic probe is used for detecting the surface state of the bolt 1, the array element is used for transmitting and receiving ultrasonic signals, the array element in the ultrasonic probe is connected with a multichannel ultrasonic excitation receiving phased array board card through a signal line, the multichannel ultrasonic excitation receiving phased array board card is connected with a computer, the computer controls the multichannel ultrasonic excitation receiving phased array board card to output excitation signals, the multichannel ultrasonic excitation receiving phased array board card excites the array element to transmit the ultrasonic signals, and the multichannel ultrasonic excitation receiving phased array board card receives the ultrasonic signals of the array element and transmits the ultrasonic signals to the computer. The multi-channel ultrasonic excitation receiving phased array board card can simultaneously excite each array element on the ultrasonic probe to sequentially send out ultrasonic signals, can receive and process ultrasonic signal data returned by each array element, and transmits the ultrasonic signal data to the computer. The computer can receive data, store the data, analyze the data and carry out 3D formation of image to ultrasonic data based on ultrasonic phased array full focus imaging technique to the image that shows becomes, thereby realize the detection of bolt surface state.

The ultrasonic probe is in a ring shape, the array elements are distributed in the ultrasonic probe in a linear array mode along the ring direction, the outer diameter of the ultrasonic probe is consistent with the major diameter of the bolt, the inner diameter of the ultrasonic probe is 0.8-0.95 times of the minor diameter of the bolt, only the whole surface state of the bolt is detected, excessive data collected and processed due to the fact that the area of the ultrasonic probe is too large cannot be obtained, and incomplete display of the surface state of the bolt due to the fact that the area of the ultrasonic probe is too small cannot be achieved.

The ultrasonic probe is of a split structure and is formed by splicing more than two arc-shaped components 21. All connect on every arc subassembly and be provided with installed part 3, the installed part is including connecting the spacing head 32 that is "7" style of calligraphy on the limiting plate that is curved limiting plate 31 on the arc subassembly. In this embodiment, the ultrasonic probe is formed by splicing three arc-shaped components, and the three arc-shaped components are respectively provided with a mounting part, and the structure of the ultrasonic probe is shown in fig. 3. Under the condition that the part of the bolt extending out of the rod end is limited or the use space is limited, when all arc-shaped assemblies cannot be installed, only part of the arc-shaped assemblies can be installed for detection, and the detection is convenient and flexible. The arc-shaped component is fixedly spliced through the disc frame 4 and fixed at the end part of the bolt rod through the limiting pin 5. In this embodiment, the signal lines of the signal output receiving end of the multi-channel ultrasonic excitation receiving phased-array board card can be respectively connected with each array element of each arc-shaped component, and can simultaneously excite each array element of each arc-shaped component to sequentially send out an ultrasonic signal, and can also receive and process ultrasonic signal data returned by each array element of each arc-shaped component, and respectively transmit the ultrasonic signal data to the computer, and the computer respectively and independently stores and processes the ultrasonic signal of each arc-shaped component and separately and independently images. And the computer sets excitation parameters and sampling parameters according to the shape and size of the bolt and the distribution condition of array elements in the arc-shaped assemblies, so that each arc-shaped assembly only detects the rod surface state of the corresponding arc-shaped bolt, and the imaging speed is improved.

Specifically, the disc rack is provided with ultrasonic probe mounting holes 41 matched with the mounting parts in shape and position, the mounting parts are clamped in the ultrasonic probe mounting holes, so that the ultrasonic probes are integrally mounted under the disc rack, the disc rack is also provided with limiting pin mounting holes 42 matched with the limiting pins in a distributed manner, the limiting pins are mounted in the limiting pin mounting holes and attached to the side walls of the bolts, and the structure of the limiting pins is shown in fig. 4. And fixing screw mounting holes 43 are communicated with the upper parts of the ultrasonic probe mounting hole and the limiting pin mounting hole, and fixing screws 6 used for fixing the ultrasonic probe and the limiting pin are connected to the fixing screw mounting holes. Therefore, the ultrasonic probe is positioned and limited, the connection is simple and stable, and the detection is simple and convenient.

The mounting parts corresponding to the circular ultrasonic probes are positioned on the same circle, the corresponding ultrasonic probe mounting holes are also positioned on the same circle, and the corresponding limiting pin mounting holes are also positioned on the same circle. The ultrasonic probe mounting holes distributed on the same circle on the disc frame are a group, more than one group of ultrasonic probe mounting holes are formed in the disc frame, a group of limiting pin mounting holes are correspondingly formed in each group of ultrasonic probe mounting holes, and more than one ultrasonic probe is correspondingly formed in the ultrasonic probe mounting holes and used for detecting bolts of different types. In this embodiment, three sets of ultrasonic probe mounting holes are provided for mounting three ultrasonic probes with corresponding diameters, three sets of limiting pin mounting holes are correspondingly provided for mounting limiting pins and fixing the ultrasonic probes, and the structure of the disc rack is shown in fig. 5 to 7. Therefore, the bolt detection device can be used for detecting bolts of three types with different diameters, and corresponds to the sizes of three common bolts in practical application. The positions of the ultrasonic probe mounting hole and the spacer pin mounting hole are shown in fig. 8. Fig. 9 is a schematic connection diagram of the ultrasonic probe, the disc frame, the stop pin and the fixing screw, at this time, according to the size of the large diameter of the detection bolt, the ultrasonic probe is installed in the second group of ultrasonic probe installation holes on the disc frame, the stop pin is correspondingly installed in the second group of stop pin installation holes, and the fixing screw is installed above the second group of ultrasonic probe installation holes and the second group of stop pin installation holes.

The bolt crack detection system based on the ultrasonic phased array full-focus imaging technology provided by the invention has the following working steps:

(1) when the outer surface state of the bolt is detected, firstly, the arc-shaped component of the corresponding ultrasonic probe is installed on the ultrasonic probe installation hole of the disk rack and is fastened by the fixing screw; and then the limiting pin is arranged on the limiting pin mounting hole and is fastened by a fixing screw.

(2) And coating a couplant on the rod surface of the bolt, sleeving an ultrasonic probe on the rod end part of the bolt to enable the surface of the ultrasonic probe to be in contact with the rod end part of the bolt, and fixing and limiting through a limiting pin to finish the installation of the detection device.

(3) And the computer software controls the multichannel ultrasonic excitation receiving phased array board card to simultaneously excite the array elements on the ultrasonic probe to sequentially send out ultrasonic signals, and simultaneously all the array elements on the ultrasonic probe receive the returned ultrasonic signals and transmit the ultrasonic signals to the computer through the multichannel ultrasonic excitation receiving phased array board card.

(4) When the computer software controls the multichannel ultrasonic excitation receiving phased array board card to output excitation signals and receive ultrasonic signals, related excitation parameters and sampling parameters are set according to the shape and size of the bolt and the distribution condition of array elements on the ultrasonic probes, so that the arc-shaped component of each ultrasonic probe only detects the rod surface state of the corresponding arc-shaped part bolt, and the imaging speed is improved.

(5) The computer independently stores and processes the ultrasonic signal data received by the array elements on the same arc-shaped component, and independently performs plane imaging processing on the ultrasonic signal data transmitted by each arc-shaped component based on an ultrasonic phased array full-focusing imaging technology, and sequentially displays the ultrasonic signal data on a computer display screen, namely displays the image corresponding to the arc-shaped component.

(6) If the surface of the bolt has cracks, the positions of the cracks of the bolt can be quickly judged according to the positions of the cracks of the bolt in the picture of the corresponding arc-shaped component.