复杂型面构件超声检测中机械回程误差的修正方法

doi:10.12382/bgxb.2022.0239

摘要/Abstract

摘要：

针对复杂型面构件超声自动检测过程中,机械系统各轴回程误差对探头位姿精度、成像质量及检测灵敏度影响的问题,研究了回程误差的识别与路径修正方法,提出一种利用C扫描图像错位锯齿量分析的回程误差测量方法。通过平面试块和棒材试块边界线单轴为主运动的C扫描成像中错位锯齿量,建立与各轴回程误差值的关系;研究利用运动学逆解实现扫描点位关节变量和探头位姿的修正方法。通过某型号复杂型面构件试块进行路径修正前后的对比扫描实验,从成像质量、图元错位情况及检测灵敏度方面验证了该方法的有效性。

关键词: 超声检测, C扫描成像, 回程误差, 路径修正

Abstract:

In the process of automatic ultrasonic detection of complex surface components, the backlash error of each axis of the mechanical system has an badly impact on the probe pose accuracy, image quality and detection sensitivity. In order to solve this problem, the method of identifying and correcting the backlash error is studied in this paper, and a method of measuring the backlash error based on the analysis of the misalignment of C-scan images is proposed. When C-scan imaging of the boundary lines of planar and bar specimens using single axis motion as the main motion, the relationship between the backlash error values of each axis and the amount of misalignment sawtooth in the C-scan image is established. The method of correcting the scanning point joint variables and probe posture using inverse kinematics solutions is studied. The effectiveness of this method is verified through comparative scanning experiments before and after path correction on a certain type of complex surface component test block in terms of imaging quality, element misalignment, and detection sensitivity.

Key words: ultrasonic testing, C-scan imaging, backlash error, path correction

中图分类号:

TP274⁺.5

张荣繁, 倪培君, 郭智敏, 杨卓琳, 付康. 复杂型面构件超声检测中机械回程误差的修正方法[J]. 兵工学报, 2023, 44(8): 2432-2440.

ZHANG Rongfan, NI Peijun, GUO Zhimin, YANG Zhuolin, FU Kang. Correction Method of Mechanical Backlash Error in Ultrasonic Testing of Curved Components[J]. Acta Armamentarii, 2023, 44(8): 2432-2440.

图/表 16

图1 复杂型面构件超声自动检测系统

Fig.1 Automatic ultrasonic testing system for curved components

图2 超声检测中检测点布置示意图

Fig.2 Schematic diagram of inspection points layout in ultrasonic testing

图3 C扫描图像锯齿错位示意图

Fig.3 Schematic diagram of sawtooth dislocation in C-scan image

图4 平面试块边界扫描示意图

Fig.4 Schematic diagram of scanning of plane specimen boundary

图5 棒材试块A轴扫描示意图

Fig.5 Schematic diagram of A-axis scanning of cylinder specimen

图6 A轴扫描步距角示意图

Fig.6 Schematic diagram of scanning step angle of axis A

图7 5自由度机械系统坐标系示意图

Fig.7 Schematic diagram of coordinate system of 5-DOF manipulator

图8 平面试块边界原始扫描图像及ηj-j曲线

Fig.8 C-Scan image of plane specimen boundary and ηj-j curve

图9 偶数行右移3图元的C扫描图像

Fig.9 C-scan image after moving 3 elements to right in even rows

表1 原始C扫描图像及移动后图像的ηmax和 η ¯值

Table 1 ηmax and η ¯ values of original C-scan image and images after moving

项目	η_max	j_max	$\bar{η}$ $η ¯$
原始图像	623071	92	53125.77
右移1	343766	91	37021.39
右移2	165541	94	23861.67
右移3	58249	100	15977.09
右移4	68589	102	17376.44

表1 原始C扫描图像及移动后图像的ηmax和 η ¯值

Table 1 ηmax and η ¯ values of original C-scan image and images after moving

项目	η_max	j_max	$\bar{η}$ $η ¯$
原始图像	623071	92	53125.77
右移1	343766	91	37021.39
右移2	165541	94	23861.67
右移3	58249	100	15977.09
右移4	68589	102	17376.44

图10 棒材试块原始C扫描图像及ηj-j曲线

Fig.10 Original C-scan image of cylinder specimen and ηj-j curve

表1 原始C扫描图像及移动后图像的 ηmax和 η ¯值

Table 1 Table 2 ηmax and η ¯ value of original C-scan image and values of images after moving

项目	η_max	j_max	$\bar{η}$ $η ¯$
原始图像	10797558	98	402419.19
右移1	3110071	99	111310.44
右移2	1642065	103	48847.28
右移3	1888771	104	76095.45

表1 原始C扫描图像及移动后图像的 ηmax和 η ¯值

Table 1 Table 2 ηmax and η ¯ value of original C-scan image and values of images after moving

项目	η_max	j_max	$\bar{η}$ $η ¯$
原始图像	10797558	98	402419.19
右移1	3110071	99	111310.44
右移2	1642065	103	48847.28
右移3	1888771	104	76095.45

图11 偶数行右移2图元的C扫描图像

Fig.11 C-scan image after moving 2 elements to right in even rows

图12 某型号复杂型面构件对比试块

Fig.12 Reference specimen of a complex curved component

图13 回程误差修正前后的C扫描成像效果图

Fig.13 C-scan images before and after correction of backlash error

表3 路径修正前后人工缺陷的信号幅值

Table 3 Signal amplitude of artificial defects before and after the correction of backlash error

序号	缺陷规格	缺陷波幅/V
序号	缺陷规格	修正前	修正后
1	ϕ2.0mm、埋深5mm	2.8	3.4
2	ϕ2.0mm、埋深10mm	2.9	3.5
3	ϕ2.0mm、埋深20mm	3.2	3.8
4	ϕ0.8mm、埋深15mm	0.8	1.1
5	ϕ0.8mm、埋深20mm	1.0	1.3

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