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8轴联动复杂曲面超声C扫系统研发及应用

Development and application of 8-axis linkage ultrasonic C-scan system for complex curved surfaces

  • 摘要: 针对高端装备复杂曲面关键零部件的检测需求,为解决传统多轴C扫描(等深度扫描)设备适配性差、扫查死角多、路径规划不灵活等突出问题,本文研制了8轴联动复杂曲面机械臂超声检测系统,完成了硬件系统集成、自主化C扫软件开发及超声检测算法优化三大核心模块的研制工作,实现了复杂曲面关键零部件的精准检测。重点突破多轴联动机电协同控制、复杂曲面全区域路径规划与仿形扫查技术、自主化超声 C 扫成像与控制技术、超声信号处理算法等核心技术。测试结果表明,系统的硬件结构完整可靠,人机交互与软件界面合理易用,优化算法可靠并由数据验证可将信噪比由4.4 dB提升至18 dB。系统可对复杂盘环件9个面无死角进行全扫查,对ϕ0.4 mm和ϕ0.8 mm微小平底孔缺陷和横孔缺陷具有稳定检出能力,且定位误差均小于1%,检测结果一致性好、稳定性高。系统已实现内部检测场景的工程化应用,实现了高端装备复杂零部件超声检测装备的国产化替代和产业化应用。

     

    Abstract: Aiming at the detection requirements of key components with complex curved surfaces in high-end equipment, and to solve the problems of poor adaptability, numerous scanning blind zones and inflexible path planning of traditional multi-axis C-scan (equal-depth scanning)equipment, an 8-axis linkage robotic arm ultrasonic testing system for complex curved surfaces is developed. The development of three core modules, including hardware system integration, independent C-scan software development and ultrasonic detection algorithm optimization, has been completed, achieving accurate detection of key components with complex curved surfaces. Key breakthroughs are achieved in core technologies including electromechanical cooperative control of multi-axis linkage systems, full-region path planning and profiling scanning technology for complex curved surfaces, autonomous ultrasonic C-scan imaging and control technology, and ultrasonic signal processing algorithms The test results indicate that the system has a complete and reliable hardware structure, and its human-computer interaction and software interface are reasonable and user-friendly. The optimized algorithm is reliable and verified by experimental data to improve the signal-to-noise ratio from 4.4 dB to 18 dB. The system can perform a full scan of all 9 surfaces of complex disk and ring components without any blind zones. It has a stable detection capability for ϕ0.4 mm and ϕ0.8 mm micro flat-bottom holes and transverse holes, with positioning errors less than 1% for both. The detection results have good consistency and high stability. The system has been successfully applied in engineering for internal testing scenarios, realizing the domestic substitution and industrialization of ultrasonic testing equipment for complex components of high-end equipment.

     

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