激光超声法零件缺陷在线自动检测系统研究
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1.国家市场监督管理总局重点实验室(无损检测与评价) 北京 100029; 2.北京信息科技大学自动化学院 北京 100192; 3.中国特种设备检测研究院 北京 100029; 4.上海航天精密机械研究所 上海 201600; 5.西安交通大学机械工程学院 西安 710049

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TN0;TH89

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国家市场监管重点实验室(无损检测与评价)开放基金(SYS-NDT&E-2025-002)、国家自然科学基金(51975452)项目资助


Research on on-line and automatic measurement system of part defects using laser ultrasonic technique
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1.Key Laboratory of Nondestructive Testing and Evaluation, State Administration for Market Regulation,Beijing 100029, China; 2.College of Automation, Beijing Information Science and Technology University,Beijing 100192, China; 3.China Special Equipment Inspection & Research Institute,Beijing 100029, China; 4.Shanghai Spaceflight Precision Machinery Institute,Shanghai 201600, China; 5.School of Mechanical Engineering, Xi′an Jiaotong University,Xi′an 710049, China

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    摘要:

    针对增材打印、航空发动机叶片等工业生产过程及复杂构件内部存在杂质、孔洞、裂缝、残缺等缺陷的高效、高分辨率、非接触检测需求,提出宽频带激光超声信号模态分离方法,通过阵列信号时域平均降噪法、改进的经验模式分解算法、宽频带信号多特征分析的小波降噪方法、变分模态分解算法的有效结合,实现激光超声信号的降噪、特征增强与模态分离。采用传统超声B扫、C扫成像以及合成孔径聚焦成像算法,实现缺陷的二维高精度成像。在时空动态扫描形成三维矩阵的基础上,实现缺陷的三维定量显示。研制五轴机床高精度扫查式、机械臂自由扫查式两套激光超声缺陷在线检测系统,采用基于光干涉的高精度超声阵列传感器以及电磁超声传感器两种信号检测方式,设计四种预置缺陷模拟试块包括平底孔、横通孔、表面裂纹以及内部裂纹进行前期验证。实际叶片、涡轮盘缺陷检测结果表明系统可有效检测大小为0.1 mm的缺陷,缺陷尺寸误差在10%以内,位置误差小于0.3 mm。研制的激光超声检测系统成熟度达到6级,在航天、航海、核电、轨道交通、压力容器与管道、有毒气体容器与管道等领域具有进一步推广和应用价值。

    Abstract:

    Aiming at the high-efficiency, high-resolution and non-contact measurement requirements for impurities, holes, cracks and imperfections in industrial production processes such as additive printing, aeroengine blades and complex components, a wideband laser ultrasonic signal modal separation method is proposed. Through the effective combination of array signal time-domain average denoising method, improved empirical mode decomposition algorithm, wavelet denoising method for wideband signal multi feature analysis, and variational mode decomposition algorithm, the denoising, feature enhancement and modal separation of laser ultrasonic signals are achieved. Traditional ultrasound B-scan, C-scan imaging, and synthetic aperture focusing imaging algorithms are used to achieve high-precision two-dimensional imaging of defects is achieved. Based on forming a three-dimensional matrix through spatiotemporal dynamic scanning, three-dimensional quantitative display of defects is achieved. Two sets of laser ultrasonic defect measurement systems with high precision scanning type for five-axis machine tools and free scanning type for robot arms are developed. High-precision ultrasonic array sensors based on optical interference and electromagnetic ultrasonic sensor are designed. Four preset defect simulation test blocks are designed, including flat bottom holes, transverse through holes, surface cracks, and internal cracks, for preliminary verification. The actual blade and turbine disk defect detection results show that the system can effectively detect defects with a size of 0.1 mm, with a defect size error of less than 10% and a position error of less than 0.3 mm. The maturity of the developed laser ultrasonic detection system has reached level 6, and it has further promotion and application value in fields such as aerospace, navigation, nuclear power, rail transportation, pressure vessels and pipelines, toxic gas containers and pipelines, etc.

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郭淼,赵纪元,原可义,颜江涛,王琛玮.激光超声法零件缺陷在线自动检测系统研究[J].电子测量技术,2025,48(21):67-76

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  • 在线发布日期: 2025-12-25
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