Patent Application
20110284508
This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2010-117584 filed on May 21, 2010, the entire content of which is incorporated herein by reference.
The present invention relates to a welding system and method that use a laser ultrasonic technique.
Welding is a technology indispensable for producing a structure and, with recent technological advancement, welding can be made for an object made of a material or having a shape for which it has conventionally been difficult to perform the welding. Meanwhile, when a structure produced with an advanced welding technology is once determined to be a welding defect from inspection results, rewelding thereof often cannot be easily performed. Thus, an impact on the process or cost due to the welding defect tends to be increased. Under such circumstances, importance of an inspection technology (JIS Z3060: Method for ultrasonic examination for welds of ferritic steel (Non-Patent Document 1), and “Basics of welding technology” edited by Japan Welding Society, published on Dec. 20, 1986 (Non-Patent Document 2), the entire content of which is incorporated herein by reference) for guaranteeing reliability of a welded structure has been increased more than ever before.
As described above, when the welding defect is determined to have occurred in a technically-difficult welding, such as thick plate welding, from a result of a quality inspection after the welding, cost and construction period required for rewelding significantly increased.
Thus, it is desired that the inspection is performed not after the welding operation, but during the welding operation. According to the inspection result, welding conditions can be changed or rewelding can be fed back extemporarily to the welding process. If this procedure can be realized, it is possible to significantly reduce cost for the rewelding. Further, in the case where the inspection is performed after the welding, if an object to be welded has a large size, there may be a case where more than half a day is required for cooling the object, preventing the inspection from being performed immediately after the welding. Thus, the time taken until the start of the inspection is wasted.
As a method for solving the above problems, a technique in which welding quality is inspected during the welding operation is proposed in Jpn. Pat. Appln. Laid-Open Publication No. 2001-71139 (Patent Document 1) or Jpn. Pat. Appln. Laid-Open Publication No. 2002-71649 (Patent Document 2), the entire contents of which are incorporated herein by reference. However, those systems use a probe that contacts the surface of an object to be welded for transmitting ultrasonic waves to or receiving ultrasonic waves from the object. In those methods, a contact medium, such as glycerin or water, is required so as to allow the ultrasonic probe to contact the surface of the object to be welded, complicating post-processing. Further, in the case where the object to be welded has a high temperature, a special mechanism for preventing damage of the probe is required.
Jpn. Pat. Appln. Laid-Open Publication No. 2007-90435 (Patent Document 3, the entire content of which is incorporated herein by reference) proposes a system in which an ultrasonic wave generation mechanism is attached to a welding mechanism so as to monitor welding operation. In this system, the ultrasonic probe is not made to contact the object to be welded but is set in a welding apparatus, so that the temperature of the object to be welded need not be taken into consideration. However, in this system, it is necessary to directly set the ultrasonic generation mechanism in the welding mechanism, which requires modification of an existing welding apparatus and limits an applicable welding method to spot welding or its similar method. Thus, in this system, it is difficult to perform versatile welding, such as butt/groove welding. This is because this system does not directly detect an indication such as reflection echo from an improperly welded part caused in the actual welding, but detects a change in an ultrasonic signal, so that the improperly welded part cannot be identified. Thus, this system is not suitable for repairing a specific part of the welding.
To overcome the above problems, application of a laser ultrasonic technology allowing a non-contact inspection has been attempted. For example, in Jpn. Pat. Appln. Laid-Open Publication No. 2007-57485 (Patent Document 4, the entire content of which is incorporated herein by reference), a laser ultrasonic method capable of performing measurement in a non-contact manner is employed to allow detection of the welding defect or voids in the welded part. However, the method of Patent Document 4 is based on the assumption that the inspection is performed after completion of the welding and is thus difficult to be applied to an in-process inspection. Although the in-process measurement is proposed in Jpn. Pat. Appln. Laid-Open Publication No. H 11-101632 (Patent Document 5, the entire content of which is incorporated herein by reference), this measurement is for the thickness of an object to be welded, position of phase change therein, or compositional change therein during welding, not for welding defect inspection. Further, feedback is not performed during welding, so that if the welding defect occurs, the rewelding operation needs to be performed.
Further, Patent Documents 4 and 5 do not describe anything about influence on the state of a laser light irradiated surface which arises as a problem in the laser ultrasonic method. When an object to be welded is overheated at the welding time, the object to be welded becomes oxidized, causing the laser light irradiated surface state to change irregularly. Similarly, the state of the surface of the object to be welded changes by sputter or scatters such as fume at the welding time. Further, Patent Document 4 disclose a technique that irradiates, onto a metal to be welded, the laser light for transmitting ultrasonic waves to or receiving ultrasonic waves from the object. In the welding, such as spot welding, taken as an example in Patent Document 4 in which there is substantially no welding beads formed, reduction or change in sensitivity at the time of transmission/reception of the ultrasonic waves hardly occurs; on the other hand, the welding beads are formed in the welding in which scanning or multilayer welding is performed, and a minute change in the irregularity or change in the surface state due to the formed beads causes the reduction or change in the sensitivity of the ultrasonic waves. This significantly adversely affects the detection performance in the laser ultrasonic method.
Further, Jpn. Pat. Appln. Laid-Open Publication No. 2007-17298 (Patent Document 6, the entire content of which is incorporated herein by reference) discloses a technique that uses ultrasonic waves other than a surface wave, such as bottom echo, as a reference signal in measurement using the surface wave. However, for an arrangement in which two probes are disposed astride a welded part or for an object to be inspected having whose bottom surface is not flat and smooth, the bottom echo intensity itself serves as a parameter and thus cannot play a role of the reference signal.
There is a demand for realizing a real-time inspection with stable transmission/reception sensitivity during welding even in the case where an object to be welded has a high temperature while reducing influence on a conventional welding apparatus.
The embodiments have been made in view of the above problems, and an object thereof is to provide a welding system capable of performing a real-time inspection with stable transmission/reception sensitivity during welding even in the case where an object to be welded has a high temperature.
According to an embodiment, there is provided a welding system comprising: a welding mechanism that welds an object to be welded while moving along a welding line relative to the object to be welded; a transmission laser light source that generates transmission laser light; a transmission optical mechanism that transmits, during or after welding operation, the transmission laser light generated from the transmission laser light source to surface of the object to be welded for irradiation while moving, together with the welding mechanism, relative to the object to be welded so as to generate a transmission ultrasonic wave; a reception laser light source that generates reception laser light so as to irradiate the object to be welded with the reception laser light for the purpose of detecting a reflected ultrasonic wave obtained as a result of reflection of the transmission ultrasonic wave; a reception optical mechanism that transmits, during or after welding operation, the reception laser light generated from the reception laser light source to the surface of the object to be welded for irradiation while moving, together with the welding mechanism, relative to the object to be welded and collects laser light scattered/reflected at the surface of the object to be welded; an interferometer that performs interference measurement of the scattered/reflected laser light; and a data recording/analysis mechanism that measures and analyzes an ultrasonic signal obtained by the interferometer.
According to another embodiment, there is provided a welding method that welds an object to be welded while moving a welding mechanism along a welding line relative to the object to be welded, the method comprising: a transmission ultrasonic wave generation step of irradiating, during or after welding operation, part of the surface of the object to be welded with transmission laser light generated from a transmission laser light source while moving a transmission optical mechanism, together with the welding mechanism, relative to the object to be welded so as to generate a transmission ultrasonic wave; a reflected ultrasonic wave detection step of irradiating, during or after welding operation, part of the surface of the object to be welded with reception laser light generated from a reception laser light source while moving a reception optical mechanism, together with the welding mechanism, relative to the object to be welded and collecting laser light scattered/reflected at the surface of the object to be welded so as to detect reflected ultrasonic wave obtained as a result of reflection of the transmission ultrasonic wave; and an interference measurement step of performing interference measurement of the scattered/reflected laser light.
Hereinafter, embodiments will be described with reference to the accompanying drawings. Throughout the drawings, the same reference numerals are used for similar or corresponding elements, and redundant explanation will be omitted.
A welding system 30 according to the first embodiment includes a welding mechanism 1 for welding an object (or a work) 2 to be welded and a welding control mechanism 3 for controlling the welding mechanism 1. The object 2 to be welded is constituted by, for example, two flat plates, and end portions of the two flat plates are butted together for multilayer welding. The welding mechanism 1 is designed to be capable of moving relative to the object 2 to be welded along a welding line. That is, the object 2 to be welded may be driven with the welding mechanism 1 fixed, or conversely, the object 2 to be welded may be fixed with the welding mechanism 1 driven.
The welding mechanism 1 may be any type of mechanism that performs, e.g., gas welding, shielded metal arc welding, electroslag welding, thermit welding, submerged arc welding, inert gas arc welding, MAG welding, CO2 arc welding, electron beam welding, plasma-arc welding, laser welding, or other forms of welding such as fusion welding. Further, the welding mechanism 1 may be a type of mechanism that performs joining (crimping or brazing) other than welding, such as friction-stir bonding.
The welding system 30 further includes a transmission laser light source 4 for irradiating the object 2 to be welded with transmission laser light Ii and a reception laser light source 5 for irradiating the object 2 to be welded with reception laser light Id.
The laser used as the transmission laser light source 4 and the reception laser light source 5 may be, for example, Nd: YAG laser, CO2 laser, Er: YAG laser, titanium-sapphire laser, alexandrite laser, ruby laser, dye laser, excimer laser, or the like. The laser light source can output either continuous waves or pulse waves and may be used singularly or in multiples. In the case where a plurality of laser light sources are employed, the number of other components required for measuring ultrasonic waves is increased as needed.
The welding system 30 further includes a transmission optical mechanism 9 for transmitting the transmission laser light Ii generated from the transmission laser light source 4 to a given transmission laser light irradiation point Pi on the object 2 to be welded, a transmission optical system drive mechanism 11 for moving the position of the transmission laser light irradiation point Pi, a reception optical mechanism 10 for transmitting the reception laser light Id generated from the reception laser light source 5 to a given reception laser light irradiation point Pd on the object 2 to be welded for irradiation and collecting reflected/scattered light Ir from the reception laser light irradiation point Pd of the emitted reception laser light Id, and a reception optical system drive mechanism 12 for moving the position of the reception laser light irradiation point Pd.
The transmission optical mechanism 9 and the reception optical mechanism 10 are each constituted by lenses, mirrors, and optical fibers. In particular, in the case where the transmission laser light Ii is irradiated onto the circular transmission laser light irradiation point Pi on the surface of the object 2 to be welded, it is preferable to construct an optical system in which the irradiation diameter at the reception laser light irradiation point Pd falls within a range of from about 0.1 mm to 30 mm. Alternatively, an optical mechanism in which a cylindrical lens is used so as to make the irradiation shape be linear. In this case, it is preferable that the line length falls within a range of from about 1 mm to 100 mm and that the line width falls within a range of about 0.001 mm to 30 mm. The irradiation shape is not limited to one mentioned above.
The transmission laser light irradiation point Pi and the reception laser light irradiation point Pd are located astride a welded part W at the back of a welding point Pw in terms of the welding direction, as illustrated in
The welding system 30 further includes an interferometer 6 for performing interference measurement of laser light Ir that has undergone a change from ultrasonic wave U. The interferometer 6 may be a Michelson interferometer, a homodyne interferometer, a heterodyne interferometer, a Fizeau interferometer, a Mach-Zehnder interferometer, a Fabry-Perot interferometer, a photorefractive interferometer, or other laser interferometer. As a method other than the interference measurement, a knife-edge method may be adopted. Any of the above interferometers may be used singularly or in multiples.
The welding system 30 further includes a data recording/analysis mechanism 7 for recording an ultrasonic signal that has been converted into an electrical signal through the interference measurement so as to perform data analysis. The data recording/analysis mechanism 7 has a function of recording ultrasonic wave data obtained by the interferometer 6, a function of analyzing the obtained ultrasonic wave data, a function of recording a welding position and a welding condition, a position control function for adjusting the laser light irradiation position, and a function of recording the irradiation position information. It is assumed that the data recording/analysis mechanism 7 may be one or more mechanisms and that the above-mentioned functions are sometimes implemented in a plurality of data recording/analysis mechanisms 7 in a distributed manner.
The welding system 30 further includes a display mechanism 8 capable of displaying an inspection result obtained by the data recording/analysis mechanism 7 or welding conditions. The display mechanism 8 has at least one or more functions out of displaying an inspection result, displaying an alarm when it has been determined that there is a problem in the welding quality, urgently stopping the operation through a touch panel interface, comparing a simulation result and real data, and the like.
As the simulation, an ultrasonic wave propagation simulation in which the shape of an object to be welded is simulated is performed, before, during, or after the welding in the case where it is difficult to determine (due to complexity of the shape of the object to be welded) whether an ultrasonic waveform obtained depending on the shape of the object to be welded represents an ultrasonic signal indicating a welding defect or an ultrasonic signal indicating merely the shape of the object to be welded. This can improve accuracy of defect determination in the measurement.
Operation of the first embodiment configured as above will be described. Welding operation is performed at the welding point Pw of the object 2 to be welded to form the welded part W. Simultaneously, the transmission laser light Ii emitted from the transmission laser light source 4 passes through the transmission optical mechanism 9 and is irradiated onto the transmission laser light irradiation point Pi on the surface of the object 2 to be welded. At this time, ultrasonic wave U is generated due to reactive force against heat strain or abrasion of a superficial layer. The ultrasonic wave U generated includes various modes such as a longitudinal wave, a transverse wave, and a surface wave and is hereinafter collectively referred to as ultrasonic wave U. When the generated ultrasonic wave U reaches an improperly welded part or bottom surface of the object to be welded, the propagation path changes due to reflection, scattering, and refraction of the ultrasonic wave U.
Meanwhile, the reception laser light Id emitted from the reception laser light source 5 passes through the reception optical mechanism 10 and is irradiated onto the reception laser light irradiation point Pd on the surface of the object 2 to be welded. At this time, when the ultrasonic wave U reaches the reception laser light irradiation point Pd, the reception laser light Id undergoes amplitude modulation or phase modulation, or a change in the reflection angle and reflected as the laser light Ir containing an ultrasonic signal component.
The laser light Ir having the ultrasonic signal is collected once again by the reception optical mechanism 10 and then transmitted to the interferometer 6. The optical signal having the ultrasonic component is converted into an electrical signal by interferometer 6 and then stored as the ultrasonic wave data by the data recording/analysis mechanism 7. The data recording/analysis mechanism 7 can apply averaging processing, moving average processing, filtering, FFT (Fast Fourier Transform), wavelet transformation, aperture synthesis processing, and other signal processing to the obtained ultrasonic signal. Further, the ultrasonic signal can be corrected using welding position information, irradiation position information, temperature information, and the like.
According to the present embodiment, it is possible to perform an in-process welding inspection. A procedure of a welding method using the welding system according to the present embodiment will be described using
As illustrated in
A determination of presence/absence of the welding defect in the welding inspection (step S4) may be made automatically by the data recording/analysis mechanism 7 based on the analysis result (for example, based on a threshold value on the ultrasonic signal, based on a comparison between a simulation result and real data, etc.) or made by an operator based on the display on the display mechanism 8.
In the partial maintenance and repair process (step S5), the welding position may be set back to a location before the improperly welded part once during the welding operation for rewelding, or only the improperly welded part may be subjected to the rewelding after a series of the welding processing is ended.
Further, during or after the partial maintenance and repair process (step S5), welding conditions may be altered so as not to cause the welding defect to occur.
As described above, in this process flow, the inspection is performed during the welding and, in the case where the welding defect is detected from the inspection result, only the improperly welded part is subjected to maintenance and repair followed by another welding.
In a conventional process flow, the inspection can be performed only after the completion of the welding and application of heat treatment/cooling treatment and, thus, in the case where the number of welding passes is large, the time required until the inspection starts becomes enormous. In addition, execution of the reprocessing becomes a major burden. On the other hand, according to the present embodiment, the inspection can be performed for each welding pass or after completion of a specified number of welding passes, so that if the welding defect occurs, the burden of the reprocessing for rewelding is small. Further, a configuration may be possible in which it can be determined that there is no problem in terms of structural strength although the welding defect occurs. Further, the inspection can be performed not only for a hardened state after the welding but also for a state of melting.
A determination whether the welding defect is tolerable or not is made as follows. That is, when a signal representing the welding defect based on a threshold determination is observed a predetermined number of times or more, or a predetermined time length or more in a predetermined region as a result of the analysis performed by the data recording/analysis mechanism 7, it is determined that a welding defect exceeding a tolerable range has occurred, while when the signal representing the welding defect is observed less than a predetermined number of times, or less than a predetermined time length or more, it is determined that a welding defect within a tolerable range has occurred.
Also in the welding inspection (step S4) of
As described above, in the example of the process flow of
As described above, it is possible to perform the inspection in real time during the welding without influencing a conventional welding apparatus and, further, to temporarily stop the welding depending on the inspection result and to feed back the inspection result to the current welding conditions.
The process flow of
Further, the process flows of
Although the transmission laser light irradiation point Pi and the reception laser light irradiation point Pd are located astride the welded part W in the first embodiment, the present invention is not limited to the above positional relationship.
In the example of
Although the object 2 to be welded is constituted by two flat plates in the first embodiment, the present invention is not limited to this. For example, as illustrated in a modification of
A welding system 31 according to the present embodiment is a system obtained by adding, as a surface modification mechanism, a grinding mechanism 14a, such as a grinder or wire brush, for grinding the surface. The grinding mechanism 14a is designed to modify the surface of the object 2 to be welded on the near side with respect to the transmission laser light irradiation point Pi and the reception laser light irradiation point Pd in the welding direction.
When the transmission laser light Ii is irradiated onto the transmission laser light irradiation point Pi on the surface of the object 2 to be welded, if the transmission laser light Ii has intensive energy, the surface is abraded. Therefore, as illustrated in
Further, application of the similar grinding mechanism 14a to the reception laser light irradiation point Pd prevents the surface of the object 2 to be welded from being oxidized due to preheating for the welding operation or removes attachment such as fume or sputter. As a result, reflectivity at the reception laser light irradiation point Pd is improved to increase the light amount of the laser light Ir. It follows that the sensitivity of an obtained ultrasonic signal is enhanced.
The grinding work using the grinding mechanism 14a may be performed by an examiner or a welding operator before or during the inspection.
The third embodiment is a modification of the second embodiment, in which an application mechanism is used as the surface modification mechanism in place of the grinding mechanism of the second embodiment. An application mechanism 14b applies a coating material 16, such as high temperature resistant ink or paint or thin-film metal onto the surface of the object 2 to be welded on the near side with respect to the transmission laser light irradiation point Pi and the reception laser light irradiation point Pd in the welding direction. The coating material 16 may be a material that can withstand high temperature and can be abraded by the transmission laser light Ii, or a material that can withstand high temperature and exhibits high reflectivity with respect to the wavelength of the used reception laser light Id.
The high temperature resistant coating material 16 may be applied automatically by the application mechanism 14b, as well as, applied manually by an examiner or a welding operator before or during the inspection.
In the case where the application mechanism 14b that applies the high temperature resistant ink or paint or thin-film metal is used, not the surface of the object 2 to be welded but the coating material 16 is abraded at the transmission laser light irradiation point Pi (
Further, with the above application mechanism, the reception sensitivity at the reception laser light irradiation point Pd can be enhanced or a variation in the reception sensitivity thereat can be made constant as the effect of the grinding obtained in the second embodiment. In particular, the reception laser light is strongly influenced by the surface state.
Graphs of specific measurement results representing influence arising as a result of oxidation of the surface which is caused due to temperature increase of the object to be welded are illustrated in
A result obtained in the case where the coating material 16 has been used is illustrated in
With the configuration of the present embodiment, there can be provided a system capable of preventing a reduction in the sensitivity and providing a high-sensitivity inspection result.
The present embodiment is a modification of the first embodiment, in which the positions of the transmission laser light irradiation point Pi and the reception laser light irradiation point Pd are changed by the transmission optical system drive mechanism 11 and the reception optical system drive mechanism 12, respectively.
In the inspection of the welded part W, data recording is performed while moving the transmission optical system drive mechanism 11 and the reception optical system drive mechanism 12 generally in the direction parallel to the welding direction, i.e., X-direction in
When operation of moving the transmission optical system drive mechanism 11 and the reception optical system drive mechanism 12 in the direction perpendicular to the welding direction, i.e., Y-direction in
The aperture synthesis is a technique that synthesizes data obtained by receivers at a plurality of positions so as to increase the resolution power and is used in general in an aperture synthesis radar.
A three-dimensional region 18 illustrated in
Further, as illustrated in
The inspection can be performed during the welding operation with the results obtained by the above processing displayed on the display mechanism 8 (refer to, e.g.,
A specific display example of the two-dimensional cross-section 17b projected in the direction perpendicular to the welding direction is illustrated in
As can be confirmed in
A welding system 32 according to the present embodiment is a modification of the first embodiment and is featured in that a temperature measurement mechanism 13 for measuring the temperature of the object 2 to be welded is added to the first embodiment. The temperature measurement mechanism 13 may be, e.g., a non-contact radiation thermometer, a contact resistance thermometer, a thermistor, a thermocouple, or a technique for measuring the temperature according to other principles. Further, the number of the temperature measurement mechanisms 13 provided may be one or more. The temperature measurement mechanism 13 is preferably installed on the propagation path of the ultrasonic wave U or a portion near the propagation path.
According to the fifth embodiment, the sound velocity of an obtained ultrasonic signal can be corrected with respect to the temperature. In general, the sound velocity of the ultrasonic wave depends on the temperature. Therefore, there occurs an error when the welding defect position is calculated from the detected ultrasonic signal. Similarly, there occurs an error when signal processing using ultrasonic signal transmission/reception position information, such as the aperture synthesis processing, is performed. In order to prevent this, the temperature of the object 2 to be welded at the inspection time is measured, and a previously prepared calibration formula, etc., for adjusting a change in the sound velocity due to a temperature change is used to correct the sound velocity. With this configuration, it is possible to reduce an error due to the temperature change. As described above, according to the fifth embodiment, it is possible to perform welding operation in which the ultrasonic inspection can be performed under a high temperature environment.
A welding system 33 according to the present embodiment is a modification of the first embodiment and is featured in that a distance measurement mechanism 23 for continuously measuring both or one of a distance between the transmission optical mechanism 9 and the object 2 to be welded and a distance between the reception optical mechanism 10 and the object 2 to be welded is added to the first embodiment.
When the distance between the transmission optical mechanism 9 and the object 2 to be welded or the distance between the reception optical mechanism 10 and the object 2 to be welded is changed during the welding due to scan accuracy of the welding mechanism 1, due to deformation of the object to be welded that has undergone the welding or due to the inherent shape of the object to be welded, the collection efficiency of the laser light Ir containing the ultrasonic signal may be degraded. Further, the above change in the distance may cause a change in the irradiation spot diameter of the transmission laser light Ii or the reception laser light Id or a change in the position of the transmission laser light irradiation point Pi or the reception laser light irradiation point Pd. This incurs a reduction in the excitation efficiency of the ultrasonic wave to be generated, a reduction in the reception sensitivity, or error in the correction processing using the position information which is performed at the time of the signal processing such as the aperture synthesis processing, which constitutes a factor adversely affecting the sensitivity.
According to the present embodiment, the distance change is measured by using the distance measurement mechanism 23, and the measurement results are fed back to the transmission optical system drive mechanism 11 and the reception optical system drive mechanism 12, respectively, so as to adjust the distances to optimum values, whereby a reduction in the sensitivity can be prevented. In the case where the laser light Ir containing the ultrasonic signal is collected, the distance change may reduce the sensitivity. In order to prevent this, the distance change amount is measured, and the measurement result is fed back to the optical path adjustment function so as to ensure an optimum irradiation distance. According to the present embodiment, there can be provided a system capable of preventing a reduction in the sensitivity and providing a high-sensitivity inspection result.
A welding system 34 according to the present embodiment is a modification of the first embodiment and is featured in that a pattern projection mechanism 15 is added to the first embodiment.
The pattern projection mechanism 15 projects a pattern Ip on the surface of the object 2 to be welded using one or a combination of a laser light source, an optical lens, a mirror, a slit, and a diffraction grating, or other methods. Although the pattern Ip to be projected may be a lattice shape or a pattern in which a plurality of lines are arranged in
Since the object 2 to be welded has a high temperature, it is difficult for an operator to access the object 2 to be welded, or even if he or she can access the object 2 to be welded, there may be a danger of doing so. In the case where non-visible laser light whose wavelength falls outside the visible light wave region is used so as to confirm the transmission/reception positions of the ultrasonic wave, visible light laser serving as guide light is made to enter the laser irradiation path in a coaxial manner with respect to it, in general. In any of the cases where the laser light itself is visible and where the guide light is used to make the laser light visible, the laser irradiation point can be observed on the surface of the object to be welded.
In the case where the positions of the transmission laser light irradiation point Pi and the reception laser light irradiation point Pd are measured, the distance from the groove of the object 2 to be welded and the distance between the transmission laser light irradiation point Pi and the reception laser light irradiation point Pd are measured using a ruler or the like. However, as described above, this involves danger when the object to be welded has a high temperature. Thus, by irradiating the pattern Ip serving as a guide at the time when the positions of the transmission laser light irradiation point Pi and the reception laser light irradiation point Pd are measured, the position measurement can be facilitated, and the obtained measurement results can be used for adjusting the positions of the transmission laser light irradiation point Pi and the reception laser light irradiation point Pd or can be used in data analysis. As described above, the configuration of the present embodiment allows the ultrasonic inspection to be performed under a high temperature environment.
When an infrared camera is used, the pattern Ip need not always be made visible.
The protection mechanism 19 has an aperture 40 through which the transmission laser light Ii, the reception laser light Id, and the reflected/scattered light Ir are passed.
The welding is often performed under a dusty environment since fume or sputter is generated during the welding operation. Thus, there may be a case where the dust adversely affects an optical mechanism to reduce the sensitivity or make the apparatus unstable and, in the worst-case scenario, the apparatus breaks down. Meanwhile, the high temperature of the object 2 to be welded may give damage to the optical mechanisms 9 and 10. Thus, the heat resistant protection mechanism 19 for protecting the optical mechanism from the dust is provided and, whereby, the above adverse affects can be prevented. According to the present embodiment, there can be provided a system capable of preventing a reduction in the sensitivity and providing a high-sensitivity inspection result.
The present embodiment is a modification of the first embodiment and differs from the first embodiment in that an optical mechanism 60 for reference signal and an optical system drive mechanism 61 for reference signal are newly provided. In
The optical mechanism 60 for reference signal generates laser light Iref for reference signal from a part of the transmission laser light Ii emitted from the transmission laser light source 4 and transmits the generated laser light Iref for reference signal to a laser irradiation point Pref for reference signal on the surface of the object 2 to be welded. The laser irradiation point Pref for reference signal is disposed at a different position from the transmission laser light irradiation point Pi and from the reception laser light irradiation point Pd. It is preferable that the reception laser light irradiation point Pd and the laser irradiation point Pref for reference signal are disposed on the same side with respect to the welding line and that the transmission laser light irradiation point Pi is disposed on the different side with respect to the welding line from the reception laser light irradiation point Pd and the laser irradiation point Pref for reference signal.
The optical system drive mechanism 61 for reference signal drives the optical mechanism 60 for reference signal and is designed to move, together with the welding mechanism 1 (refer to
The transmission laser light Ii emitted from the transmission laser light source 4 passes through the transmission optical mechanism 9 and is irradiated onto the transmission laser light irradiation point Pi on the surface of the object 2 to be welded. At this time, ultrasonic wave Ui is generated due to reactive force against heat strain or abrasion of a superficial layer. The ultrasonic wave Ui generated includes various modes such as a longitudinal wave, a transverse wave, and a surface wave and is hereinafter collectively referred to as ultrasonic wave Ui. When the generated ultrasonic wave Ui reaches an improperly welded part or bottom surface of the object to be welded, the propagation path changes due to reflection, scattering, and refraction of the ultrasonic wave Ui, and the ultrasonic wave Ui returns from the improperly welded part as response ultrasonic wave Ur. The response ultrasonic wave generated includes various modes such as a longitudinal wave, a transverse wave, and a surface wave and is hereinafter collectively referred to as ultrasonic wave Ur.
Further, the transmission laser light Ii emitted from the transmission laser light source 4 enters the optical mechanism 60 for reference signal. The optical mechanism 60 for reference signal generates laser light Iref for reference signal from a part of the transmission laser light Ii, and the generated laser light Iref for reference signal is irradiated onto the laser irradiation point Pref for reference signal on the surface of the object 2 to be welded. At this time, a reference signal Uref is generated due to reactive force against heat strain or abrasion of a superficial layer. The reference signal Uref generated includes various modes such as a longitudinal wave, a transverse wave, and a surface wave and is hereinafter collectively referred to as reference signal Uref.
Meanwhile, the reception laser light Id emitted from the reception laser light source 5 passes through the reception optical mechanism 10 and is irradiated onto the reception laser light irradiation point Pd on the surface of the object 2 to be welded. At this time, when the ultrasonic waves Ur and Uref reach the reception laser light irradiation point Pd, the reception laser light Id undergoes amplitude modulation or phase modulation, or a change in the reflection angle and reflected as the laser light Ir containing an ultrasonic signal component.
The laser light Ir having the ultrasonic signal is collected once again by the reception optical mechanism 10 and then transmitted to the interferometer 6. The optical signal having the ultrasonic component is converted into an electrical signal by the interferometer 6 and then stored as the ultrasonic wave data by the data recording/analysis mechanism 7.
The data recording/analysis mechanism 7 can apply averaging processing, moving average processing, filtering, FFT (Fast Fourier Transform), wavelet transformation, aperture synthesis processing, and other signal processing to the obtained ultrasonic signal. The intensity of the obtained reference signal Uref can be measured using peak detection, integration, RMS, or other detection methods. Further, the ultrasonic signal can be corrected using the signal intensity of the reference signal Uref, welding position information, irradiation position information, temperature information, and the like. Further, a detected defect can be evaluated quantitatively by normalizing the signal intensity after correction and applying the normalized signal intensity to a DAC curve, a DGS diagram, or other calibration curves created by Calibration TP. There may be a case where the reference signal Uref is superimposed in some region to be measured; however, in this case, the reference signal Uref can be canceled as a signal appearing in a known time zone.
Effects of the ninth embodiment will be described. In the abovementioned first embodiment, a separate sound source serving as a reference for quantitative evaluation of the defect is not provided. In this case, a significant fluctuation occurs in a measurement system typified by a laser interferometer, so that although defect detection can be made, the quantitative evaluation thereof is difficult, resulting in failure to make accurate evaluation of the soundness of the welded part. Although it can be considered that a reflected wave from the bottom surface is used, a uniform reflected wave cannot always be obtained due to a difference in the penetration shape, so that accuracy is degraded.
In the ninth embodiment, in addition to the irradiation of the transmission laser light Ii and the reception laser light Id, the laser light Iref for reference signal is irradiated onto the laser irradiation point Pref for reference signal near the reception laser light irradiation point Pd.
The reference signal Uref propagates along the surface of the object 2 to be welded and is received by the reception laser light Id together with the ultrasonic wave Ui. The laser ultrasonic wave is significantly influenced by a fluctuation of a measurement system, especially by fluctuation in the sensitivity of the reception side. Thus, the reception of the reference signal Uref which is excited with a constant intensity and propagates a fixed propagation path makes it possible to quantify a fluctuation on the reception side, and normalization using the intensity of the reference signal Uref allows the fluctuation to be recorrected after the measurement. With this configuration, the signal intensity can be quantitatively represented, thereby allowing quantitative evaluation of the defect to be performed based on a calibration curve such as a DAC curve or a DGS diagram.
To cope with the ghost of the reference signal Uref appearing in a known time zone, a time frame in which the Uref is canceled is set, whereby the influence of the ghost on the measurement result can be reduced.
In the above description, the laser light Iref for reference signal is separated from the transmission laser light Ii; alternatively, as a modification, the laser light Iref for reference signal may be generated from a laser light source for reference signal separately provided from the transmission laser light source 4.
The present embodiment is obtained by adding, to the welding system (refer to
In the tenth embodiment, the grinding mechanism 14a is provided as a surface modification mechanism, as in the second embodiment, and the shallow grooves on the surface of the object 4 to be welded which are formed by the transmission laser light Ii, the reception laser light Id, and the laser light Iref for reference signal are repaired by the grinding mechanism 14a. Further, as in the case of the ninth embodiment, the reception of the reference signal Uref makes it possible to perform the quantitative evaluation of the defect on the surface of the object 2 to be welded.
Although the preferred embodiments of the present invention have been described above, the embodiments are merely illustrative and do not limit the scope of the present invention. These novel embodiments can be practiced in other various forms, and various omissions, substitutions and changes may be made without departing from the scope of the invention. The embodiments and modifications thereof are included in the scope or spirit of the present invention and in the appended claims and their equivalents.
For example, the features of the embodiments may be combined. More specifically, the surface modification mechanism of the second and third embodiments may be added to the fourth to eighth embodiments.
Further, the optical mechanism 60 for reference signal and the optical system drive mechanism 61 for reference signal of the ninth and tenth embodiments may be applied to the third to eighth embodiments.
Although the terms “plan view” and “vertical cross-sectional view” are used in the above description, they are used merely for descriptive purposes, and the vertical or horizontal direction is not especially defined in the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-117584 | May 2010 | JP | national |
