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| 磁粉探伤机新型磁化装置设计及智能化控制研究 |
| Research on Design and Intelligent Control of New Magnetizer for Magnetic Particle Flaw Detector |
| 投稿时间：2018-05-31 |
| DOI：10.16018/j.cnki.cn32-1650/n.201804002 |
| 中文关键词: 大齿圈 磁化装置 磁粉探伤 |
| 英文关键词: large ring gear magnetizing device magnetic particle inspection |
| 基金项目:江苏省产学研基金资助项目(BY2016065-30)；江苏省 “六大人才高峰”高层次人才选拔培养(2014-DZXX-039) |
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| 中文摘要: |
| 针对铁路和风电行业中大量大齿圈工件尺寸较大、其周向和径向不能同时进行磁化探伤、工件探伤率受到限制和影响的状况，设计了适用于大齿圈工件磁粉探伤机的新型磁化装置。该装置基于PLC的磁粉探伤控制系统和图像自动识别系统，采用开合式闭路磁轭和开合式矩形线圈的结构，磁化检测时将开合式闭路磁轭和开合式矩形线圈围绕在大齿圈工件单边齿圈的周围，使大齿圈同时产生同向、径向、轴向等多方向的磁场；喷洒荧光磁粉悬液的工件表面在磁场的作用下，磁粉被吸附在漏磁场处形成磁痕，荧光磁粉在紫外光照射下发射出荧光；用高像素全帧CCD摄像机对荧光进行摄像，并将荧光磁粉图像转换为视频电子信号，再通过信号采集卡将视频信号转换为计算机能处理的数字图像信号，从而完成工件表面缺陷生成磁痕的自动检测。智能磁粉探伤样机的测试表明，该新型磁化装置可实现同时对大齿圈工件的周向、径向和轴向进行全方位的多向磁化，工件无磁化盲区，检测精度高。 |
| 英文摘要: |
| N view of the situation that a large number of large gear ring workpieces in railway and wind power industry can not be magnetized simultaneously in circumference and radial direction due to their large size, and the flaw detection rate of the workpiece is limited and affected, a new magnetization device suitable for large gear ring workpieces is designed. The device is based on the magnetic particle flaw detection control system and the image automatic recognition system of the PLC. The structure of open-closed loop yoke and open-closed rectangular coil is adopted in the device. During the magnetization detection, the open-closed loop yoke and the open-closed rectangular coil are wrapped around the single-side ring gear of the large ring gear workpiece, so that the large ring gear simultaneously generates multi-directional magnetic fields in the same direction, radial direction and axial direction. Under the action of magnetic field, the surface of workpiece sprayed with fluorescent magnetic powder suspension is adsorbed at the leakage magnetic field to form magnetic trace, and fluorescent magnetic powder emits fluorescence under ultraviolet light. The fluorescence is captured by high-pixel full-frame CCD camera, and the image of fluorescent magnetic powder is converted into video electronic signal. Then the video signal is converted into digital image signal which can be processed by computer through signal acquisition card, so that the automatic detection of magnetic mark generated by workpiece surface defects can be completed. The test results of the intelligent magnetic particle testing prototype show that the new magnetization device can realize omni-directional and multi-directional magnetization of the circumferential, radial and axial direction of the large gear ring workpiece at the same time, and the workpiece has no magnetic blind area and high detection accuracy. |
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