CN117147695A - Defect detection method and system for plastic mold - Google Patents
Defect detection method and system for plastic mold Download PDFInfo
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- CN117147695A CN117147695A CN202311131606.4A CN202311131606A CN117147695A CN 117147695 A CN117147695 A CN 117147695A CN 202311131606 A CN202311131606 A CN 202311131606A CN 117147695 A CN117147695 A CN 117147695A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/06—Visualisation of the interior, e.g. acoustic microscopy
- G01N29/0654—Imaging
- G01N29/069—Defect imaging, localisation and sizing using, e.g. time of flight diffraction [TOFD], synthetic aperture focusing technique [SAFT], Amplituden-Laufzeit-Ortskurven [ALOK] technique
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- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
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- G01N29/04—Analysing solids
- G01N29/045—Analysing solids by imparting shocks to the workpiece and detecting the vibrations or the acoustic waves caused by the shocks
- G01N29/046—Analysing solids by imparting shocks to the workpiece and detecting the vibrations or the acoustic waves caused by the shocks using the echo of particles imparting on a surface; using acoustic emission of particles
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- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/4409—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
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- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
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- G06T7/0002—Inspection of images, e.g. flaw detection
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Abstract
The application relates to the technical field of mold defect detection, and provides a defect detection method and system for a plastic mold, wherein the method comprises the following steps: acquiring a three-dimensional model of a plastic mold, identifying the coordinate size of a vulnerable part in the plastic mold, dividing an echo region, setting a beam diameter and a beam center in the echo region, respectively transmitting to an ultrasonic array, and acquiring an ultrasonic standard echo image of the plastic mold; acquiring ultrasonic flaw detection images at preset time intervals in an ultrasonic array; comparing the ultrasonic standard echo image and the ultrasonic flaw detection image in the same beam center, if the total difference of the wave peak heights is larger than a preset threshold value, substituting the time points of the wave peaks into a defect positioning model to obtain defect depth; the images are compared to judge whether defects exist or not, and the defects are positioned, so that the defects can be rapidly and accurately identified in the use process of the plastic mold, the shutdown faults caused by the defects in the production process are avoided, and the detection efficiency is improved.
Description
Technical Field
The application relates to the technical field of mold defect detection, in particular to a defect detection method and system for a plastic mold.
Background
The plastic mould is used for compression molding, extrusion molding, injection, blow molding and low foaming molding, and the damage condition easily occurs on the mould when the plastic mould contacts with a high-temperature plastic product to work for a long time;
in the prior art, the molds are generally detected by workers with naked eyes, so that not only is the subjective error large and the efficiency of detecting complex molds low, but also the damage which can be found by naked eyes is serious damage, and the production plan can be influenced.
Disclosure of Invention
The application provides a defect detection method of a plastic mold, which is used for solving the problem that the defect detection method of the plastic mold is lacked in the prior art and the production efficiency is affected.
The first aspect of the application provides a defect detection method of a plastic mold, comprising the following steps:
acquiring a three-dimensional model of a plastic mold, and identifying the coordinate size of a vulnerable part in the plastic mold; dividing echo areas according to the coordinate size of the vulnerable part, and setting the beam diameter and the beam center of ultrasonic waves for each echo area;
respectively sending a corresponding beam center and a beam diameter to the ultrasonic array according to each echo region, and obtaining an ultrasonic standard echo image of the plastic mold;
transmitting beam center and beam diameter parameters to an ultrasonic array every preset time to acquire an ultrasonic flaw detection image; comparing the ultrasonic standard echo image and the ultrasonic flaw detection image in the same beam center, calculating the total difference of the peak heights, and judging that the plastic mold has defects if the total difference of the peak heights is larger than a preset threshold value;
when a defect exists in the plastic mold, obtaining time points corresponding to the wave crests, identifying the wave crests with increased heights, and substituting the time points of the wave crests into a defect positioning model to obtain defect depth; the defect positioning model is as follows:
wherein D is n For the n-th elevated peak defect depth, D n The thickness of the plastic mould is v is the ultrasonic speed at normal temperature, t a T is the latest peak time point of an ultrasonic flaw detection image a T is the earliest peak time point of an ultrasonic flaw detection image a T is the latest peak time point of the ultrasonic standard echo image a T is the earliest peak time point of an ultrasonic standard echo image n The nth point of time of the ultrasonic flaw detection image at which the peak is not reduced.
Optionally, the dividing echo areas according to the coordinate size of the vulnerable part, and setting the beam diameter and the beam center of the ultrasonic wave for each echo area specifically includes:
dividing echo areas according to the coordinate sizes of vulnerable parts; two points which are farthest from each other are identified in the plane top view of each echo region, the distance between the two points is taken as the ultrasonic wave beam diameter, and the midpoint of the connecting line of the two points is taken as the beam center.
Optionally, the comparing the ultrasonic standard echo image and the ultrasonic flaw detection image of the same beam center specifically includes:
calculating the time range ratio of the ultrasonic flaw detection image and the ultrasonic standard echo image in the same beam center, correcting the peak time point of the ultrasonic flaw detection image according to the time range ratio, and identifying the peak height at the same position with the ultrasonic standard echo image based on the corrected ultrasonic flaw detection image.
Optionally, after the obtaining the ultrasonic flaw detection image, the method further includes: preprocessing an ultrasonic flaw detection image, and eliminating wave peaks smaller than a preset height in the ultrasonic flaw detection image.
The second aspect of the present application provides a defect detection system for a plastic mold, comprising:
the echo region setting module is used for acquiring a three-dimensional model of the plastic mould and identifying the coordinate size of a vulnerable part in the plastic mould; dividing echo areas according to the coordinate size of the vulnerable part, and setting the beam diameter and the beam center of ultrasonic waves for each echo area;
the standard echo detection module is used for respectively sending a corresponding beam center and a beam diameter to the ultrasonic array according to each echo region to obtain an ultrasonic standard echo image of the plastic mould;
the defect identification module is used for sending beam center and beam diameter parameters to the ultrasonic array at preset time intervals to acquire an ultrasonic flaw detection image; comparing the ultrasonic standard echo image and the ultrasonic flaw detection image in the same beam center, calculating the total difference of the peak heights, and judging that the plastic mold has defects if the total difference of the peak heights is larger than a preset threshold value;
the defect positioning module is used for acquiring time points corresponding to the wave crests when the defects exist in the plastic mold, identifying the wave crests with increased heights, and substituting the time points of the wave crests into the defect positioning model to obtain defect depths; the defect positioning model is as follows:
wherein D is n For the n-th elevated peak defect depth, D n The thickness of the plastic mould is v is the ultrasonic speed at normal temperature, t a T is the latest peak time point of an ultrasonic flaw detection image a T is the earliest peak time point of an ultrasonic flaw detection image a T is the latest peak time point of the ultrasonic standard echo image a T is the earliest peak time point of an ultrasonic standard echo image n The nth point of time of the ultrasonic flaw detection image at which the peak is not reduced.
Optionally, in the echo region setting module, the echo regions are divided according to the coordinate size of the vulnerable part, and the beam diameter and the beam center of the ultrasonic wave set for each echo region are specifically as follows:
dividing echo areas according to the coordinate sizes of vulnerable parts; two points which are farthest from each other are identified in the plane top view of each echo region, the distance between the two points is taken as the ultrasonic wave beam diameter, and the midpoint of the connecting line of the two points is taken as the beam center.
Optionally, in the defect identifying module, comparing an ultrasonic standard echo image and an ultrasonic flaw detection image of the same beam center specifically includes:
calculating the time range ratio of the ultrasonic flaw detection image and the ultrasonic standard echo image in the same beam center, correcting the peak time point of the ultrasonic flaw detection image according to the time range ratio, and identifying the peak height at the same position with the ultrasonic standard echo image based on the corrected ultrasonic flaw detection image.
Optionally, in the defect identifying module, after obtaining the ultrasonic flaw detection image, the defect identifying module further includes: preprocessing an ultrasonic flaw detection image, and eliminating wave peaks smaller than a preset height in the ultrasonic flaw detection image.
A third aspect of the present application provides a defect detection method apparatus for a plastic mold, the apparatus comprising a processor and a memory:
the memory is used for storing program codes and transmitting the program codes to the processor;
the processor is configured to execute the defect detection method of the plastic mold according to any one of the first aspect of the present application according to the instructions in the program code.
A fourth aspect of the present application provides a computer readable storage medium storing program code for executing a defect detection method of a plastic mold according to any one of the first aspect of the present application.
From the above technical scheme, the application has the following advantages: identifying the coordinate size of a vulnerable part in the plastic mould by acquiring a three-dimensional model of the plastic mould; dividing echo areas according to the coordinate size of the vulnerable part, and setting the beam diameter and the beam center of ultrasonic waves for each echo area; so that the ultrasonic echo of the same echo region can reflect the accurate position; respectively sending a corresponding beam center and a beam diameter to the ultrasonic array according to each echo region, and obtaining an ultrasonic standard echo image of the plastic mold; transmitting beam center and beam diameter parameters to an ultrasonic array every preset time to acquire an ultrasonic flaw detection image; comparing the ultrasonic standard echo image and the ultrasonic flaw detection image in the same beam center, calculating the total difference of the peak heights, and judging that the plastic mold has defects if the total difference of the peak heights is larger than a preset threshold value; when a defect exists in the plastic mold, obtaining time points corresponding to the wave crests, identifying the wave crests with increased heights, and substituting the time points of the wave crests into a defect positioning model to obtain defect depth; the ultrasonic wave echo is used for detecting the plastic mould, whether the defect exists or not is judged by comparing the image of the plastic mould under the condition of injection molding and shutdown with the image of the plastic mould under the condition of standard non-destructive, and the defect is positioned, so that the defect identification can be rapidly and accurately carried out in the use process of the plastic mould, the shutdown fault caused by the defect in the production process is avoided, the detection efficiency is improved, and the implementation of the production plan can be effectively ensured.
Drawings
In order to more clearly illustrate the embodiments of the application or the technical solutions of the prior art, the drawings which are used in the description of the embodiments or the prior art will be briefly described, it being obvious that the drawings in the description below are only some embodiments of the application, and that other drawings can be obtained from these drawings without inventive faculty for a person skilled in the art.
FIG. 1 is a first flowchart of a defect detection method of a plastic mold;
FIG. 2 is a schematic diagram of an ultrasonic echo region of a defect detection method for a plastic mold;
FIG. 3 is a second flowchart of a defect detection method of a plastic mold;
FIG. 4 is a schematic diagram showing an ultrasonic setup mode of a defect detection method for a plastic mold;
FIG. 5 is a diagram showing a defect detection system of a plastic mold.
Detailed Description
In order to make the objects, features and advantages of the present application more comprehensible, the following description of the embodiments accompanied with the accompanying drawings in the embodiments of the present application will make it apparent that the embodiments described below are only some embodiments but not all embodiments of the present application. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
The application provides a defect detection method of a plastic mold, which is used for solving the problem that the defect detection method of the plastic mold is lacked in the prior art and the production efficiency is affected.
Embodiment one:
referring to fig. 1, fig. 1 is a first flowchart of a defect detecting method for a plastic mold according to an embodiment of the application.
S100, acquiring a three-dimensional model of a plastic mold, and identifying the coordinate size of a vulnerable part in the plastic mold; dividing echo areas according to the coordinate size of the vulnerable part, and setting the beam diameter and the beam center of ultrasonic waves for each echo area;
it should be noted that, in long-time working, the plastic mold is affected by high temperature and high pressure of the plastic, stress concentration conditions are easy to occur at edges, corners, thin walls and other parts, damage is easy to occur, even when the stress value of the parts exceeds the breaking strength of the mold material, cracks are generated, the straight surface can incline, the guide post can be bent during long-time working, and the plastic mold has defects to affect production;
the plastic mould is provided with a corresponding three-dimensional model before being manufactured, and the whole appearance of the plastic mould is basically rectangular no matter how the shape of the male mould and the female mould is, so that a three-dimensional coordinate system can be established in advance based on one corner of the three-dimensional model, the vulnerable part in the model is identified through the characteristics of the preset vulnerable part, and the coordinate size corresponding to the vulnerable part is obtained; for example, identifying the corner position on the die, obtaining the coordinates of the corner points and the lengths of the edges, or the expression of the surface where the fragile thin wall is located, generally dividing the position of the same step surface into the same echo region, avoiding dividing the interface which is not connected with the same depth together, and ensuring that the position of the defect can be accurately identified in the subsequent detection; after the echo area is divided, the beam diameter and the beam center of the ultrasonic wave are set according to the area and the position of the area, so that the ultrasonic wave beam can cover the whole echo area.
S200, respectively sending a corresponding beam center and a beam diameter to an ultrasonic array according to each echo region, and acquiring an ultrasonic standard echo image of the plastic mold;
it should be noted that, step S200 is generally performed under the condition that the mold is in a standard state without damage before the plastic mold is applied to the production of the injection molding machine, and each peak in the ultrasonic standard echo image corresponds to an interface on the plastic mold perpendicular to the sounding direction of the ultrasonic array; in the embodiment, the ultrasonic array is arranged at the bottom of the plastic mold, and emits ultrasonic waves along the mold closing direction of the plastic mold; controlling the positions of the ultrasonic arrays at the bottom of the plastic mold according to different beam center data, controlling the number of excitation arrays according to the beam diameter, and concentrating ultrasonic waves into narrower beams by the ultrasonic arrays to realize accurate control of the ultrasonic direction positions;
referring to fig. 2, the plastic mold is a male mold, the two areas in the broken line are echo areas, the bottom of the plastic mold is the left side of the drawing, ultrasonic waves are emitted from the left side to the right side of the drawing along the mold closing direction, three main echo peaks appear in an ultrasonic standard echo image, the three main echo peaks respectively correspond to echoes when the ultrasonic waves enter the plastic mold, the echo of the concave surface in the echo area is shown, and the echo of the convex surface is shown, and the two corresponding echoes are received and overlapped simultaneously because the depths of the two convex surfaces in the echo area are the same; further, although an echo is generated at the interface with other echo regions at the dashed line below the drawing due to the progress of the ultrasonic wave fluctuation, the echo peak generated by the small area of the reflection region is small, and can be removed as noise by filtering or a peak height threshold value.
S300, sending beam center and beam diameter parameters to an ultrasonic array every preset time to acquire an ultrasonic flaw detection image; comparing the ultrasonic standard echo image and the ultrasonic flaw detection image in the same beam center, calculating the total difference of the peak heights, and judging that the plastic mold has defects if the total difference of the peak heights is larger than a preset threshold value;
the plastic mold is subjected to ultrasonic detection during the stop operation of the injection molding machine, disassembly is not needed, and the preset time can be the limiting time of the continuous working time of the injection molding machine and is 8-12 hours; the beam center is converted into corresponding coordinates after being sent to the ultrasonic array, the ultrasonic array moves to the corresponding position according to the coordinates, and the corresponding number of arrays are activated according to the beam diameter parameters, so that the beam diameter is controlled; the current situation of the plastic mold can be reflected in the ultrasonic flaw detection image, the main damage of the plastic mold is at the position of the surface contacted with the plastic, the wave crest of the ultrasonic flaw detection image corresponds to the information near the surface of the plastic mold, the ultrasonic standard echo image and the ultrasonic flaw detection image are compared, and the wave crest difference value of each time point can reflect the shape change near the surface of the corresponding position of the plastic mold; for example, no echo wave crest exists at a certain time point in the standard echo image, and an obvious echo wave crest appears in the flaw detection image, at the moment, the fact that a crack section appears at a corresponding position is indicated, and the included angle between the section and the ultrasonic wave emission direction is an obtuse angle, namely the included angle between the reflection direction is an acute angle; and the echo wave peak in a certain time point in the standard echo image can possibly appear, the echo wave peak height at the corresponding time point in the flaw detection image is obviously reduced, the former echo wave peak is unchanged, the time between the two wave peaks is also unchanged, the situation that the two echo wave peak time points of the plastic mold correspond to each other is indicated, the ultrasonic wave reflection is consumed due to irregular cracks or surface deformation, but the reflection direction is different from the direction of the receiver and cannot be detected, so that when the total difference of the integral peak heights is larger than a preset threshold value, the current plastic mould is larger in change from the nondestructive condition, the defect possibility is larger, and the defect can be regarded as the defect or the defect which cannot be detected; the total peak height difference in this embodiment is the sum of the absolute values of the peak height differences, and the preset threshold is set according to the parameters of the ultrasonic array and the sensitivity of the receiving instrument.
S400, when a defect exists in the plastic mold, obtaining time points corresponding to the wave crests, identifying the wave crests with increased heights, and substituting the time points of the wave crests into a defect positioning model to obtain defect depth; the defect positioning model is as follows:
wherein D is n For the n-th elevated peak defect depth, D n The thickness of the plastic mould is v is the ultrasonic speed at normal temperature, t a T is the latest peak time point of an ultrasonic flaw detection image a T is the earliest peak time point of an ultrasonic flaw detection image a T is the latest peak time point of the ultrasonic standard echo image a T is the earliest peak time point of an ultrasonic standard echo image n The nth point of time of the ultrasonic flaw detection image at which the peak is not reduced.
It should be noted that, in this embodiment, the ultrasonic flaw detection image is obtained when the plastic mold is stopped after working at a high temperature, at this time, the temperature of the plastic mold may not be reduced yet, but the ultrasonic propagation speeds of different temperatures are different, and the ultrasonic propagation speed is faster when the temperature is higher; therefore, when the temperature of the plastic mould is different between the ultrasonic flaw detection image and the standard echo image, the corresponding time points of the ultrasonic reflected at the same position are different, so that the time points are required to be corrected and the sound velocity is required to be corrected; in this embodiment, the ultrasonic path is from the bottom as a starting point, and the thickness of the plastic mold is required to be subtracted to obtain the depth of the worker when the worker processes the defect from the front, and the thickness of the plastic mold is the thickness of the echo region corresponding to the ultrasonic flaw detection image;
in order to ensure that the injection molding machine can be smoothly demolded, the plastic mold is not provided with an internal concave shape, so that echo wave crests detected in the ultrasonic wave emission direction of the embodiment mainly form interface reflection of edges, when the wave crests corresponding to the interfaces of the edges rise or echo exists at non-interfaces, the situation that the corresponding positions have cracks to reflect ultrasonic waves is indicated, and the depth of the defects can be found only by calculating the positions of the rising wave crests;
in the embodiment, the coordinate size of the vulnerable part in the plastic mould is identified by acquiring a three-dimensional model of the plastic mould; dividing echo areas according to the coordinate size of the vulnerable part, and setting the beam diameter and the beam center of ultrasonic waves for each echo area; so that the ultrasonic echo of the same echo region can reflect the accurate position; respectively sending a corresponding beam center and a beam diameter to the ultrasonic array according to each echo region, and obtaining an ultrasonic standard echo image of the plastic mold; transmitting beam center and beam diameter parameters to an ultrasonic array every preset time to acquire an ultrasonic flaw detection image; comparing the ultrasonic standard echo image and the ultrasonic flaw detection image in the same beam center, calculating the total difference of the peak heights, and judging that the plastic mold has defects if the total difference of the peak heights is larger than a preset threshold value; when a defect exists in the plastic mold, obtaining time points corresponding to the wave crests, identifying the wave crests with increased heights, and substituting the time points of the wave crests into a defect positioning model to obtain defect depth; the ultrasonic wave echo is used for detecting the plastic mould, whether the defect exists or not is judged by comparing the image of the plastic mould under the condition of injection molding and shutdown with the image of the plastic mould under the condition of standard non-destructive, and the defect is positioned, so that the defect identification can be rapidly and accurately carried out in the use process of the plastic mould, the shutdown fault caused by the defect in the production process is avoided, the detection efficiency is improved, and the implementation of the production plan can be effectively ensured.
The foregoing is a detailed description of a first embodiment of a defect detecting method for a plastic mold according to the present application, and the following is a detailed description of a second embodiment of a defect detecting method for a plastic mold according to the present application.
Embodiment two:
in this embodiment, further provided is a method for detecting defects of a plastic mold, please refer to fig. 3, step S100 specifically includes:
s101, acquiring a three-dimensional model of a plastic mold, and identifying the coordinate size of a vulnerable part in the plastic mold;
s102, dividing echo areas according to the coordinate sizes of vulnerable parts; identifying two points which are farthest from each other in a plane top view of each echo region, taking the distance between the two points as the diameter of an ultrasonic wave beam, and taking the midpoint of a connecting line of the two points as the center of the beam;
it should be noted that, the division of the echo region is determined according to the actual structural characteristics of the mold, and the defect can be positioned mainly when the depth is detected and calculated later, so that the interface which is not connected with the depth is prevented from being positioned in the same echo region;
referring to fig. 4, a shadow area on the top surface of the plastic mold is a planar top view shape of the echo area in the box mold direction, two points which are farthest from each other are identified in the shadow shape according to a preset algorithm, and two points which are farthest from each other can be obtained by adopting a traversal algorithm or a rotary clamping method; the distance between two points is used as the diameter of an ultrasonic wave beam, the detection range of ultrasonic waves can be ensured to cover a complete echo region, a circle is formed by taking the connecting line of the two points as the diameter in the plane, the section of the ultrasonic wave beam is obtained, the center coordinates are the beam center, and after the center coordinates are converted into the coordinates of the surface of the ultrasonic wave array, the movement of the ultrasonic wave array can be guided, and a specific conversion formula is set and determined according to a specific coordinate system.
Further, in step S300, the comparison between the ultrasonic standard echo image and the ultrasonic flaw detection image of the same beam center specifically includes: calculating the time range ratio of the ultrasonic flaw detection image and the ultrasonic standard echo image in the same beam center, correcting the peak time point of the ultrasonic flaw detection image according to the time range ratio, and identifying the peak height at the same position with the ultrasonic standard echo image based on the corrected ultrasonic flaw detection image;
because the temperature of the plastic mold is possibly higher when the ultrasonic flaw detection image is acquired, the ultrasonic transmission speed is higher than the normal temperature, and the time point needs to be corrected in order to avoid the situation that the corresponding time points are the same due to the speed difference of the peaks at the non-same positions and the judgment errors occur; the time range of the ultrasonic image is specifically the time difference between the first wave crest and the last wave crest in the image, which corresponds to the time from the time when the ultrasonic enters the plastic mold to the time when the ultrasonic reaches the furthest interface of the echo region, the ultrasonic transmission speed ratio corresponding to the two ultrasonic images can be obtained according to the time range ratio, and the time is corrected according to the ratio.
Further, in the step S300, after the ultrasonic flaw detection image is obtained, the method further includes preprocessing the ultrasonic flaw detection image, and removing the peak smaller than the preset height in the ultrasonic flaw detection image; in order to reduce ultrasonic wave echo caused by noise or plastic mould material, the preset height can be set according to the detection precision of the ultrasonic wave receiving device, the wave peak lower than the preset height is regarded as noise to be removed, the wave peak of the echo caused by a large number of small noise points is prevented from being regarded as defect, and the detection precision and efficiency are reduced.
The foregoing is a detailed description of a defect detection method for a plastic mold according to the first aspect of the present application, and the following is a detailed description of an embodiment of a defect detection system for a plastic mold according to the second aspect of the present application.
Referring to fig. 5, fig. 5 is a schematic diagram of a defect detecting system of a plastic mold. The embodiment provides a defect detection system of a plastic mold, which comprises:
the echo region setting module 10 is used for acquiring a three-dimensional model of the plastic mold and identifying the coordinate size of a vulnerable part in the plastic mold; dividing echo areas according to the coordinate size of the vulnerable part, and setting the beam diameter and the beam center of ultrasonic waves for each echo area;
the standard echo detection module 20 is used for respectively sending a corresponding beam center and a beam diameter to the ultrasonic array according to each echo region to obtain an ultrasonic standard echo image of the plastic mold;
the defect identification module 30 is configured to send beam center and beam diameter parameters to the ultrasonic array every preset time, and acquire an ultrasonic flaw detection image; comparing the ultrasonic standard echo image and the ultrasonic flaw detection image in the same beam center, calculating the total difference of the peak heights, and judging that the plastic mold has defects if the total difference of the peak heights is larger than a preset threshold value;
the defect positioning module 40 is configured to obtain time points corresponding to each peak when a defect exists in the plastic mold, identify the peak with increased height, and substitute the time points of each peak into the defect positioning model to obtain a defect depth; the defect positioning model is as follows:
wherein D is n For the n-th elevated peak defect depth, D n The thickness of the plastic mould is v is the ultrasonic speed at normal temperature, t a T is the latest peak time point of an ultrasonic flaw detection image a T is the earliest peak time point of an ultrasonic flaw detection image a T is the latest peak time point of the ultrasonic standard echo image a T is the earliest peak time point of an ultrasonic standard echo image n The nth point of time of the ultrasonic flaw detection image at which the peak is not reduced.
Optionally, in the echo region setting module 10, the echo regions are divided according to the coordinate size of the vulnerable portion, and the beam diameter and the beam center of the ultrasonic wave set for each echo region are specifically:
dividing echo areas according to the coordinate sizes of vulnerable parts; two points which are farthest from each other are identified in the plane top view of each echo region, the distance between the two points is taken as the ultrasonic wave beam diameter, and the midpoint of the connecting line of the two points is taken as the beam center.
Optionally, in the defect identifying module 20, the comparing the ultrasonic standard echo image and the ultrasonic flaw detection image of the same beam center specifically includes:
calculating the time range ratio of the ultrasonic flaw detection image and the ultrasonic standard echo image in the same beam center, correcting the peak time point of the ultrasonic flaw detection image according to the time range ratio, and identifying the peak height at the same position with the ultrasonic standard echo image based on the corrected ultrasonic flaw detection image.
Optionally, the defect identifying module 20 further includes, after acquiring the ultrasonic flaw detection image: preprocessing an ultrasonic flaw detection image, and eliminating wave peaks smaller than a preset height in the ultrasonic flaw detection image.
The third aspect of the present application also provides a defect detection method and apparatus for a plastic mold, including a processor and a memory: wherein the memory is used for storing the program code and transmitting the program code to the processor; the processor is used for executing the defect detection method of the plastic mould according to the instructions in the program codes.
A fourth aspect of the present application provides a computer readable storage medium storing program code for executing the above-described defect detection method for a plastic mold.
It will be clearly understood by those skilled in the art that, for convenience and brevity of description, specific working procedures of the apparatus and device described above may refer to corresponding procedures in the foregoing method embodiments, which are not described herein again.
In the several embodiments provided in the present application, it should be understood that the disclosed systems, devices, and methods may be implemented in other manners. For example, the apparatus embodiments described above are merely illustrative, e.g., the division of the units is merely a logical function division, and there may be additional divisions when actually implemented, e.g., multiple units or components may be combined or integrated into another system, or some features may be omitted or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be an indirect coupling or communication connection via some interfaces, devices or units, which may be in electrical, mechanical or other form.
The units described as separate units may or may not be physically separate, and units shown as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.
In addition, each functional unit in the embodiments of the present application may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit. The integrated units may be implemented in hardware or in software functional units.
The integrated units, if implemented in the form of software functional units and sold or used as stand-alone products, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present application may be embodied essentially or in part or all of the technical solution or in part in the form of a software product stored in a storage medium, including instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the method according to the embodiments of the present application. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a random access Memory (RAM, random Access Memory), a magnetic disk, or an optical disk, or other various media capable of storing program codes.
The above embodiments are only for illustrating the technical solution of the present application, and not for limiting the same; although the application has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present application.
Claims (10)
1. The defect detection method of the plastic mold is characterized by comprising the following steps of:
acquiring a three-dimensional model of a plastic mold, and identifying the coordinate size of a vulnerable part in the plastic mold; dividing echo areas according to the coordinate size of the vulnerable part, and setting the beam diameter and the beam center of ultrasonic waves for each echo area;
respectively sending a corresponding beam center and a beam diameter to the ultrasonic array according to each echo region, and obtaining an ultrasonic standard echo image of the plastic mold;
transmitting beam center and beam diameter parameters to an ultrasonic array every preset time to acquire an ultrasonic flaw detection image; comparing the ultrasonic standard echo image and the ultrasonic flaw detection image in the same beam center, calculating the total difference of the peak heights, and judging that the plastic mold has defects if the total difference of the peak heights is larger than a preset threshold value;
when a defect exists in the plastic mold, obtaining time points corresponding to the wave crests, identifying the wave crests with increased heights, and substituting the time points of the wave crests into a defect positioning model to obtain defect depth; the defect positioning model is as follows:
wherein D is n For the n-th elevated peak defect depth, D n The thickness of the plastic mould is v is the ultrasonic speed at normal temperature, t a T is the latest peak time point of an ultrasonic flaw detection image a T is the earliest peak time point of an ultrasonic flaw detection image a T is the latest peak time point of the ultrasonic standard echo image a T is the earliest peak time point of an ultrasonic standard echo image n The nth point of time of the ultrasonic flaw detection image at which the peak is not reduced.
2. The method for detecting defects of a plastic mold according to claim 1, wherein the steps of dividing echo regions according to coordinate dimensions of vulnerable portions, and setting beam diameters and beam centers of ultrasonic waves for each echo region are specifically as follows:
dividing echo areas according to the coordinate sizes of vulnerable parts; two points which are farthest from each other are identified in the plane top view of each echo region, the distance between the two points is taken as the ultrasonic wave beam diameter, and the midpoint of the connecting line of the two points is taken as the beam center.
3. The method for detecting defects of a plastic mold according to claim 1, wherein the comparing the ultrasonic standard echo image and the ultrasonic flaw detection image of the same beam center comprises:
calculating the time range ratio of the ultrasonic flaw detection image and the ultrasonic standard echo image in the same beam center, correcting the peak time point of the ultrasonic flaw detection image according to the time range ratio, and identifying the peak height at the same position with the ultrasonic standard echo image based on the corrected ultrasonic flaw detection image.
4. The method for detecting defects in a plastic mold according to claim 1, wherein after the ultrasonic flaw detection image is obtained, further comprising:
preprocessing an ultrasonic flaw detection image, and eliminating wave peaks smaller than a preset height in the ultrasonic flaw detection image.
5. A defect detection system for a plastic mold, comprising:
the echo region setting module is used for acquiring a three-dimensional model of the plastic mould and identifying the coordinate size of a vulnerable part in the plastic mould; dividing echo areas according to the coordinate size of the vulnerable part, and setting the beam diameter and the beam center of ultrasonic waves for each echo area;
the standard echo detection module is used for respectively sending a corresponding beam center and a beam diameter to the ultrasonic array according to each echo region to obtain an ultrasonic standard echo image of the plastic mould;
the defect identification module is used for sending beam center and beam diameter parameters to the ultrasonic array at preset time intervals to acquire an ultrasonic flaw detection image; comparing the ultrasonic standard echo image and the ultrasonic flaw detection image in the same beam center, calculating the total difference of the peak heights, and judging that the plastic mold has defects if the total difference of the peak heights is larger than a preset threshold value;
the defect positioning module is used for acquiring time points corresponding to the wave crests when the defects exist in the plastic mold, identifying the wave crests with increased heights, and substituting the time points of the wave crests into the defect positioning model to obtain defect depths; the defect positioning model is as follows:
wherein D is n For the n-th elevated peak defect depth, D n The thickness of the plastic mould is v is the ultrasonic speed at normal temperature, t a T is the latest peak time point of an ultrasonic flaw detection image a T is the earliest peak time point of an ultrasonic flaw detection image a T is the latest peak time point of the ultrasonic standard echo image a T is the earliest peak time point of an ultrasonic standard echo image n The nth point of time of the ultrasonic flaw detection image at which the peak is not reduced.
6. The defect detection system of a plastic mold according to claim 5, wherein in the echo region setting module, the echo regions are divided according to the coordinate size of the vulnerable portion, and the beam diameter and the beam center of the ultrasonic wave are set for each echo region specifically as follows:
dividing echo areas according to the coordinate sizes of vulnerable parts; two points which are farthest from each other are identified in the plane top view of each echo region, the distance between the two points is taken as the ultrasonic wave beam diameter, and the midpoint of the connecting line of the two points is taken as the beam center.
7. The defect detection system of claim 5, wherein the defect recognition module compares an ultrasonic standard echo image and an ultrasonic flaw detection image of the same beam center, and specifically comprises:
calculating the time range ratio of the ultrasonic flaw detection image and the ultrasonic standard echo image in the same beam center, correcting the peak time point of the ultrasonic flaw detection image according to the time range ratio, and identifying the peak height at the same position with the ultrasonic standard echo image based on the corrected ultrasonic flaw detection image.
8. The defect inspection system of claim 5, wherein the defect recognition module, after obtaining the ultrasonic flaw detection image, further comprises:
preprocessing an ultrasonic flaw detection image, and eliminating wave peaks smaller than a preset height in the ultrasonic flaw detection image.
9. A defect detection method apparatus for a plastic mold, the apparatus comprising a processor and a memory:
the memory is used for storing program codes and transmitting the program codes to the processor;
the processor is configured to execute the defect detection method of the plastic mold according to any one of claims 1 to 4 according to the instructions in the program code.
10. A computer readable storage medium for storing program code for performing a method of defect detection of a plastic mould according to any one of claims 1-4.
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