CN101995432A - Hall element differential array based ferromagnetic construction member surface crack detector - Google Patents
Hall element differential array based ferromagnetic construction member surface crack detector Download PDFInfo
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- CN101995432A CN101995432A CN2010105310345A CN201010531034A CN101995432A CN 101995432 A CN101995432 A CN 101995432A CN 2010105310345 A CN2010105310345 A CN 2010105310345A CN 201010531034 A CN201010531034 A CN 201010531034A CN 101995432 A CN101995432 A CN 101995432A
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Abstract
The invention relates to a Hall element differential array based ferromagnetic construction member surface crack detector, comprising a differential array type flux leakage probe, a displacement detecting unit, a signal conditioning circuit and a data acquisition unit; wherein Hall sensors arranged on one surface of a probe circuit board are arranged in a regular array, the Hall sensor group of the probe is arranged at the upper and lower sides of the circuit board in a differential way, two voltage signals are respectively output to the signal conditioning circuit, so as to form a reflective flux leakage voltage signal, and the voltage signal is input into the data acquisition unit. The invention can conveniently detect the size and position of crack defect and has the advantages of large detection area, fast speed and low defect omission ratio.
Description
Technical field
The present invention relates to the Non-Destructive Testing field, be specifically related to the nondestructive examination that surface crack, pore, slag inclusion, stress to ferromagnetic component such as concentrates at defective.
Background technology
Each is variant for existing disclosed ferromagnetic component surface crack panel detector structure and method, as ultrasonic method commonly used, rays method, electromagnetic method etc.Ultrasonic method technology comparative maturity, high but its cleanliness to surface of the work require, implement also more loaded down with trivial details; Rays method is relatively poor and ray contamination is serious to detection of gradual transitions defective effect; Electromagnetic method has magnetic particle method, electric vortex method, leakage method etc. again, but magnetic particle method and electric vortex method only are fit to material surface or nearly probing surface, and automaticity is low, complex process, be unable to do without artificial the observation, very high to technician's requirement, be difficult to realize quantitative detection.Leakage method all can detect material internal, surface imperfection, and is very responsive to the defective of ferromagnetic material, need not in the detection member is cleaned, polishes, and also need not add couplant, also can detect having under the pollutional conditions such as iron rust, greasy dirt.And existing a few money is single gauge head based on the crack detector of leakage method mostly, have only three gauge heads at most, cost an arm and a leg and can only carry out line sweep component surface, disposable area of detection is little, speed slow, it is inaccurate to detect, be easy to generate omission, more can not provide the defectives such as crackle of component surface are carried out the required data support of quantitative test, seriously hinder the utilization of leakage method in the Non-Destructive Testing field.
Summary of the invention
The present invention is directed to the deficiency of existing ferromagnetic component surface crack detector, proposed a kind of ferromagnetic component surface crack detector based on the Hall element difference array.
Technical scheme of the present invention is as follows:
A kind of ferromagnetic component surface crack detector based on the Hall element difference array, comprise difference array formula leakage field probe, the displacement detecting unit, signal conditioning circuit, data acquisition unit, described difference array formula leakage field probe comprises circuit board and a plurality of Hall element group, each Hall element group is installed in described circuit board upper and lower surface by two symmetries and forms through the identical Hall element that oppositely is provided with, the Hall element that is positioned at surface, described circuit board the same side is arranged in array, all Hall element shared grounding end and current input terminals, the voltage signal of two Hall elements of each described Hall element group exports described signal conditioning circuit respectively to, described signal conditioning circuit comprises differential operational amplifier, filtering circuit etc., described signal conditioning circuit is to the voltage signal filter away high frequency noise of input, suppress common mode interference signal, described differential operational amplifier is done the two-way voltage signal of input and is subtracted computing, and amplification difference mode signal, described difference mode signal is corresponding with the crackle magnetic leakage signal, and difference mode signal is imported data acquisition unit; Fixedly connected with described difference array formula leakage field probe in the displacement detecting unit, carrying out synchronous scanning with described difference array formula leakage field probe detects, and write down the displacement signal that described difference array formula leakage field probe moved, with this displacement signal input data acquisition unit; Data acquisition unit is set up described difference mode signal and described displacement signal one-to-one relationship according to the displacement signal of described difference mode signal that collects and the output of described displacement detecting unit.
Hall element on surface, described circuit board the same side is arranged in the two-dimensional array of rule, and described Hall element is proper alignment in each row, and the Hall element dislocation of different rows is arranged.
Identical but the polarity of two sizes and magnetic is fixed on the described displacement detecting unit towards opposite permanent magnet, described permanent magnet provides stable magnetic flux for detection, to strengthen the crackle magnetic leakage signal, be arranged symmetrically in described difference array formula leakage field probe about or the both sides, front and back.
Also comprise time sharing multiplex device, described time sharing multiplex device is installed between described difference array formula leakage field probe and the signal conditioning circuit, described time sharing multiplex device is connected the described voltage output signal of each the Hall element group on the described difference array formula leakage field probe in turn according to the time interval of setting, two voltage output signals of each selecteed described Hall element group amplify by described signal conditioning circuit difference and filtering after import described data acquisition unit.
Described displacement detecting unit comprises displacement transducer, motor and steamboat, described displacement transducer is arranged on the steamboat, described motor links to each other with steamboat, described motor drives the steamboat motion, described displacement transducer recording pen motor speed and working time are also calculated its displacement, and displacement signal is imported described data acquisition unit.
Another scheme of described displacement detecting unit also can comprise counter and steamboat, and described counter is arranged on the steamboat, and all numbers of record steamboat motion also calculate its displacement, and displacement signal is imported described data acquisition unit.
Technique effect of the present invention:
Ferromagnetic component surface crack detector based on the Hall element difference array of the present invention by difference array formula leakage field probe, has reduced undesired signal, has improved the susceptibility that detects; Unique array distributes and can realize that the face battle array to crackle on the two dimensional surface detects, and increased area and speed that one-off scanning detects and the omission of having avoided defective effectively; Match precision higher displacement detecting unit and data acquisition unit, realized real-time collection to magnetic leakage signal and displacement signal, utilize software programming can realize the corresponding one by one of displacement information and leakage field information, be convenient to testing staff's analysis and assessment, can further go to realize graphical reconstruct the component surface defect situation.Ferromagnetic component surface crack detector based on the Hall element difference array of the present invention is compared existing crack detector, have advantages such as area of detection is big, speed fast, the defective loss is low, can on price, form bigger competitive edge, possess wide market application prospect.
Description of drawings
Fig. 1 is the layout that difference array formula leakage field probe is gone up the Hall element group.
Fig. 2 is the detection schematic diagram of detector under the no externally-applied magnetic field.
Fig. 2 a is the detection synoptic diagram that detector under the crackle situation is arranged.
Fig. 2 b is the detection synoptic diagram of detector under the flawless situation.
Fig. 2 c is the Hall element output characteristics that has under the crackle situation.
Fig. 2 d is the Hall element output characteristics under the flawless situation.
Fig. 3 is the detection schematic diagram that detector under the externally-applied magnetic field is arranged.
Fig. 3 a is the detection synoptic diagram that detector under the crackle situation is arranged.
Fig. 3 b is the detection synoptic diagram of detector under the flawless situation.
Fig. 3 c is the Hall element output characteristics that has under the crackle situation.
Fig. 3 d is the Hall element output characteristics under the flawless situation.
Reference numeral is as follows:
The current input terminal of 1-Hall element, the earth terminal of 2-Hall element, the voltage output end of 3-Hall element, the shared ground wire of 4-difference array, 5-difference array common source line, the voltage output line of 6-Hall element, 7-difference array formula leakage field probe, 8-surface of the work crackle, 9-Hall element group, 10-earth magnetism stray field, 11-terrestrial magnetic field, 12-displacement transducer, 13-displacement detecting unit, 14-steamboat, 15-permanent magnet, the 16-stray field, the 17-magnetic flux.
Embodiment
Below in conjunction with accompanying drawing embodiments of the invention are described further.
Based on the structure of the ferromagnetic component surface crack detector of Hall element difference array and principle of work referring to Fig. 1 and Fig. 2.Ferromagnetic component surface crack detector based on the Hall element difference array comprises difference array formula leakage field probe 7, displacement detecting unit 13, signal conditioning circuit, data acquisition unit.Described difference array formula leakage field probe 7 comprises circuit board and a plurality of Hall element group 9 compositions, each Hall element group 9 is formed by the described circuit board upper and lower surface of being installed in of two symmetries and through the identical Hall element that oppositely is provided with, and described mounting means can be a welding manner; The Hall element that is positioned at surface, described circuit board the same side is arranged in the two-dimensional array of rule, and wherein said Hall element is proper alignment in each row, and the Hall element dislocation of different rows is arranged, as shown in Figure 1.In the array gap Hall element is connected up and welding operation.With the dislocation of the Hall element on surface, circuit board the same side arrange be because this two-dimensional array can respectively walk crosswise with diagonal on all can intensive, regularly arranged Hall element, therefore can upwards remedy because the omission of defective is avoided in the detection space that the sensitizing range is limited and assemblage gap causes of device the detection side.The selected Hall element size of the present invention is 3mm * 3mm * 1mm, the Hall element of every row can have been accomplished 20 on the present described array, through calculating the complete scan of the to be detected ferromagnetic materials surface of 3 row arrays under can accomplishing substantially described difference array formula leakage field probe covered.
As seen from Figure 1, the earth terminal 2 of all Hall elements all connects the shared ground wire 4 of difference array, the current input terminal 1 of all Hall elements all connects difference array common source line 5, the voltage output end 3 of the voltage signal of two Hall elements of each Hall element group by Hall element exports described signal conditioning circuit to by the voltage output line 6 of Hall element, described signal conditioning circuit comprises differential operational amplifier, filtering circuit etc., described signal conditioning circuit is to the voltage signal filter away high frequency noise of input, suppress common mode interference signal, described differential operational amplifier is done the two-way voltage signal of input and is subtracted computing, and amplification difference mode signal, described difference mode signal is corresponding with the crackle magnetic leakage signal, and difference mode signal is imported data acquisition unit.As seen from Figure 2, when 9 scannings of Hall element group detect surface of the work crackle 8, because terrestrial magnetic field 11 is in the variation of crackle 8 place's magnetic permeabilities, outwards form earth magnetism stray field 10, its magnetic-field component perpendicular to detection plane can enter into Hall element group 9, owing to be the above-mentioned reverse both sides up and down that are symmetrically fixed on circuit board, make that the output voltage of sensor is difference output on the same group, change on the contrary, i.e. Shu Chu voltage forward increase always, another oppositely increases.The absolute value of the two variation is more or less the same theoretically, signal is delivered in the differential operational amplifier (as INA129) of signal conditioning circuit through the voltage output line 6 of Hall element, can eliminate most common-mode signal on the one hand, detection signal can double because of difference effect on the other hand, increase the susceptibility of measuring, reduced error.This differential voltage signal can reduce the undesired signal that caused by temperature effect, surrounding environment disturbing magnetic field etc.If component surface does not have stray field, differential output signal is zero, if there is stray field in component surface, the more single-ended output of the differential way of output has more obvious signal peak one peak value.Adopt wired connection between detector and the secondary instrument, be convenient to the reliable transmission of sensor power supply and signal.
Described displacement detecting unit 13 and described difference array formula leakage field are popped one's head in and 7 are fixedlyed connected, and carry out synchronous scanning with described difference array formula leakage field probe and detect, and write down the displacement signal that described difference array formula leakage field probe moved, with its input data acquisition unit; Data acquisition unit is gathered the displacement signal of described magnetic leakage signal and 13 outputs of described displacement detecting unit simultaneously, and described magnetic leakage signal and described displacement signal are set up one-to-one relationship.
Since the terrestrial magnetic field a little less than, lift from the height of component surface to be checked in order to increase measuring accuracy and probe, also can two sizes and magnetic are identical, but polarity is fixed on the displacement detecting unit 13 towards opposite permanent magnet 15, described permanent magnet 15 provides stable magnetic flux for detection, to strengthen the MFL for Crack signal, be arranged symmetrically in described difference array formula leakage field probe about or the both sides, front and back, because two magnet sizes and magnitude of field intensity are identical, polarity is towards on the contrary, their magnetic flux is level and smooth stable magnetic flux 17 in smooth flawless plane, when detection plane had crackle, described difference array formula leakage field probe 7 can easierly detect stray field 16.Permanent magnet can adopt the rubber magnetic stripe.
Because it is limited that described data acquisition unit is used to gather the port number of data of this special two-dimensional array of Hall sensor array, so data acquisition is a scan mode.If the Hall element group that comprises on the difference array formula leakage field probe 7 is many, so also need to dispose relevant time sharing multiplex device, described time sharing multiplex device is installed between described difference array formula leakage field probe and the signal conditioning circuit, described time sharing multiplex device is connected the described voltage output signal of each the Hall element group on the described difference array formula leakage field probe in turn according to the time interval of setting, so just the voltage signal to Hall element group 9 plays control action, make in the very short time interval, can only allow two voltage signal inputs of same group of Hall element group, avoid the crowded and blurring of signalling channel.Two voltage output signals of each selecteed described Hall element group are imported described data acquisition unit after by the conditioning of described signal conditioning circuit.
Described displacement detecting unit 13 comprises steamboat 14, displacement transducer 12 or counter, and a kind of scheme is: drive steamboat 14 by motor at the uniform velocity, measure travelling speed v by displacement transducer 12, write down t working time simultaneously, then displacement signal S=v * t; Another kind of scheme is: utilize counter that steamboat 14 several N that turn-take are counted to obtain displacement signal S=N * L, L is the steamboat girth.The displacement signal that obtains is outputed to data acquisition unit.
The collecting method design aspect, array has preestablished the local relative coordinate of sensor, add the whole displacement of recorded bit when scanning detects, just can with the stray field voltage signal and accurately the locus be mapped, also just can know the position at defective place, on secondary instrument, can show clearly, perhaps can further use MATLAB that two dimensions that these data are depicted as with the plane of scanning motion are respectively x axle and y axle, with the stray field voltage signal corresponding to each position on the plane of scanning motion is the three-dimensional " topomap " of z axle, in this figure, defective place must be that height rises and falls, and like this, the position of defective and stool and urine come into plain view.
Data acquisition unit adopts single-chip microcomputer to realize, it is little to have a volume, and speed is fast, characteristics such as cost is lower, the multi-channel analog input and output can be provided, and operations such as multi-path digital input and output are very suitable for designing the ferromagnetic component surface crack detector based on the Hall element difference array of hand-held.Data acquisition unit comprises NI USB-6215 data collecting card and gating circuit, the USB-6215 data collecting card is the M series multifunctional DAQ module that a bus-powered band is isolated, also can keep high precision under high sampling rate, this module provides 16 tunnel analog inputs; 250kS/s single channel sampling rate, 2 tunnel simulation outputs, 4 way word incoming lines, 4 way word output lines, every passage has 4 input ranges able to programme, and (± 0.2V-± 10V), numeral triggers, 2 counter/timers, magnetic leakage signal on the ferromagnetic component belongs to low frequency signal, and indexs such as the sampling rate of USB-6215 data collecting card, resolution also are enough to reach the requirement that we gather magnetic leakage signal.
Should be pointed out that the above embodiment can make those skilled in the art more fully understand the present invention, but do not limit the present invention in any way.Therefore; although this instructions has been described in detail the present invention with reference to drawings and Examples; but; those skilled in the art are to be understood that; still can make amendment or be equal to replacement the present invention; and all do not break away from the technical scheme and the improvement thereof of the spirit and scope of the present invention, and it all should be encompassed in the middle of the protection model state of patent of the present invention.
Claims (10)
1. ferromagnetic component surface crack detector based on the Hall element difference array, it is characterized in that, comprise difference array formula leakage field probe, the displacement detecting unit, signal conditioning circuit, data acquisition unit, described difference array formula leakage field probe comprises circuit board and a plurality of Hall element group, each Hall element group is installed in described circuit board upper and lower surface by two symmetries and forms through the identical Hall element that oppositely is provided with, the Hall element that is positioned at surface, described circuit board the same side is arranged in array, all Hall element shared grounding end and current input terminals, the voltage signal of two Hall elements of each described Hall element group exports described signal conditioning circuit respectively to, described signal conditioning circuit comprises differential operational amplifier, filtering circuit etc., described signal conditioning circuit is to the voltage signal filter away high frequency noise of input, suppress common mode interference signal, described differential operational amplifier is done the two-way voltage signal of input and is subtracted computing, and amplification difference mode signal, described difference mode signal is corresponding with the crackle magnetic leakage signal, and difference mode signal is imported data acquisition unit; Fixedly connected with described difference array formula leakage field probe in described displacement detecting unit, carrying out synchronous scanning with described difference array formula leakage field probe detects, and write down the displacement signal that described difference array formula leakage field probe moved, with this displacement signal input data acquisition unit; Data acquisition unit is set up described difference mode signal and described displacement signal one-to-one relationship according to the displacement signal of described difference mode signal that collects and the output of described displacement detecting unit.
2. the ferromagnetic component surface crack detector based on the Hall element difference array according to claim 1, it is characterized in that, Hall element on surface, described circuit board the same side is arranged in the two-dimensional array of rule, described Hall element is proper alignment in each row, and the Hall element dislocation of different rows is arranged.
3. the ferromagnetic component surface crack detector based on the Hall element difference array according to claim 1 and 2, it is characterized in that, identical but the polarity of two sizes and magnetic is fixed on the described displacement detecting unit towards opposite permanent magnet, described permanent magnet provides stable magnetic flux for detection, to strengthen the crackle magnetic leakage signal, be arranged symmetrically in the left and right sides or the both sides, front and back of described difference array formula leakage field probe.
4. according to claim 1 or 2 one of any described ferromagnetic component surface crack detectors based on the Hall element difference array, it is characterized in that, also comprise time sharing multiplex device, described time sharing multiplex device is installed between described difference array formula leakage field probe and the signal conditioning circuit, described time sharing multiplex device is connected the described voltage output signal of each the Hall element group on the described difference array formula leakage field probe in turn according to the time interval of setting, two voltage output signals of each selecteed described Hall element group amplify by described signal conditioning circuit difference and filtering after import described data acquisition unit.
5. the ferromagnetic component surface crack detector based on the Hall element difference array according to claim 3, it is characterized in that, also comprise time sharing multiplex device, described time sharing multiplex device is installed between described difference array formula leakage field probe and the signal conditioning circuit, described time sharing multiplex device is connected the described voltage output signal of each the Hall element group on the described difference array formula leakage field probe in turn according to the time interval of setting, two voltage output signals of each selecteed described Hall element group amplify by described signal conditioning circuit difference and filtering after import described data acquisition unit.
6. the ferromagnetic component surface crack detector based on the Hall element difference array according to claim 1 and 2, it is characterized in that, described displacement detecting unit comprises displacement transducer, motor and steamboat, described displacement transducer is arranged on the steamboat, and described motor links to each other with steamboat, and described motor drives the steamboat motion, described displacement transducer recording pen motor speed and working time are also calculated its displacement, and displacement signal is imported described data acquisition unit.
7. the ferromagnetic component surface crack detector based on the Hall element difference array according to claim 3, it is characterized in that, described displacement detecting unit comprises displacement transducer, motor and steamboat, described displacement transducer is arranged on the steamboat, and described motor links to each other with steamboat, and described motor drives the steamboat motion, described displacement transducer recording pen motor speed and working time are also calculated its displacement, and displacement signal is imported described data acquisition unit.
8. the ferromagnetic component surface crack detector based on the Hall element difference array according to claim 4, it is characterized in that, described displacement detecting unit comprises displacement transducer, motor and steamboat, described displacement transducer is arranged on the steamboat, and described motor links to each other with steamboat, and described motor drives the steamboat motion, described displacement transducer recording pen motor speed and working time are also calculated its displacement, and displacement signal is imported described data acquisition unit.
9. the ferromagnetic component surface crack detector based on the Hall element difference array according to claim 5, it is characterized in that, described displacement detecting unit comprises displacement transducer, motor and steamboat, described displacement transducer is arranged on the steamboat, and described motor links to each other with steamboat, and described motor drives the steamboat motion, described displacement transducer recording pen motor speed and working time are also calculated its displacement, and displacement signal is imported described data acquisition unit.
10. according to one of any described ferromagnetic component surface crack detector of claim 1 to 5 based on the Hall element difference array, it is characterized in that, described displacement detecting unit comprises counter and steamboat, described counter is arranged on the steamboat, all numbers of record steamboat motion also calculate its displacement, and displacement signal is imported described data acquisition unit.
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Application publication date: 20110330 |