Phased array detection scanning method for pressure vessel connecting pipe fillet weld

Abstract

The invention discloses a phased array detection scanning method for a fillet weld of a connecting pipe of a pressure vessel. The method comprises the following steps: firstly, fixing a scanning frame on the surface of the connecting pipe through a magnetic adsorption device; then the relative position and angle between the probe and the weld joint are adjusted, so that the probe is aligned in the normal direction of the weld joint; the probe is tightly attached to the surface of the weld joint through the pressure assembly, and constant contact pressure is kept; then the scanning frame is manually pushed to rotate along the connecting pipe, and the probe is driven to move along the welding seam and conduct phased array detection; and finally recording probe position information in real time and synchronously storing the probe position information and detection data. Magnetic attraction positioning and an adjustable mechanical structure are combined, automatic detection of the fillet weld of the pressure vessel is achieved through the phased array multi-angle ultrasonic scanning technology, the system integrates the high-precision position recording function and the intelligent data analysis function, the detection efficiency and the result reliability are greatly improved, and manual operation errors are effectively reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of nondestructive testing, and in particular to a phased array detection and scanning method for fillet welds of a pressure vessel pipe. Background Art

[0002] Fillet welds between pressure vessels and nozzles are critical connections in pressure-bearing equipment, and their quality is directly related to the equipment's safe operation and service life. Phased array ultrasonic testing technology, with its advantages such as multi-angle scanning and high-resolution imaging, has become an important means of inspecting the quality of these welds. Traditional inspection methods rely on operators moving a handheld probe along the weld and manually evaluating the test signals to assess weld quality. This method is widely used in the inspection of specialized equipment in fields such as petrochemicals and nuclear power.

[0003] However, the existing technology has obvious limitations: first, the traditional manual inspection method is highly dependent on the technical experience of the operator, the inspection results are easily affected by human factors, and the operation risk is high in dangerous environments such as high altitude and high temperature; second, the conventional scanning device has a simple structure and is difficult to adapt to the inspection needs of welds with different curvatures and angles, and often has problems such as unstable probe coupling and insufficient inspection coverage; third, the existing technology lacks an accurate position recording system, and it is difficult to accurately correspond the inspection data and spatial position information, which is not conducive to the accurate positioning and long-term tracking of defects. Especially in the inspection of large pressure vessels and special-shaped pipes, the inspection efficiency and reliability of existing methods are often difficult to meet the quality requirements of modern industrial inspection. In addition, the traditional inspection method has poor data traceability, which is not conducive to the establishment of a complete equipment health file, and brings difficulties to subsequent safety assessments and maintenance decisions. To this end, the present invention provides a phased array inspection and scanning method for pressure vessel pipe corner welds. Summary of the Invention

[0004] In view of the deficiencies in the prior art, the present invention provides a phased array inspection and scanning method for fillet welds of pipes in pressure vessels.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: A phased array inspection and scanning method for pressure vessel pipe fillet welds includes the following steps: Step A, fixing the scanning frame to the surface of the pipe by a magnetic adsorption device; Step B, adjusting the relative position and angle between the probe and the weld so that the probe is aligned along the normal direction of the weld; Step C, using a pressure assembly to bring the probe into close contact with the weld surface and maintain a constant contact pressure; Step D: Manually push the scanning frame to rotate along the pipe, driving the probe to move along the weld and perform phased array testing; Step E: Record the probe position information in real time and store it synchronously with the detection data.

[0006] The aforementioned phased array scanning method for detecting fillet welds of a pressure vessel nozzle is characterized by: step A, fixing the scanning frame to the nozzle surface by a magnetic adsorption device, and the specific steps are as follows: Step A1: The magnetic adsorption device includes four symmetrically distributed magnetic wheels and is adsorbed on the surface of the pipe; Step A2: Adjust the adsorption force distribution of the magnetic wheel according to the curvature of the pipe to ensure that the scanning frame is stably fixed.

[0007] The aforementioned phased array inspection and scanning method for fillet welds of a pressure vessel nozzle is characterized by: step B, adjusting the relative position and angle between the probe and the weld so that the probe is aligned along the normal direction of the weld. The specific steps are as follows: Step B1, adjusting the distance between the probe and the weld by using a retractable robotic arm; Step B2: manually adjust the probe deflection angle using a universal joint structure to match the weld groove angle; Step B3: Verify the normal alignment accuracy between the probe and the weld using an auxiliary positioning sensor.

[0008] The aforementioned phased array inspection and scanning method for fillet welds of pressure vessel pipes is characterized in that the adjustment range of the retractable robotic arm is 10-50 mm, and the deflection angle range of the universal joint structure is ±30°.

[0009] The aforementioned phased array inspection and scanning method for fillet welds of pressure vessel pipes is characterized by: step C, using a pressure component to make the probe close to the weld surface and maintain a constant contact pressure, the specific steps are as follows: Step C1: The pressure component has a built-in double-stage damping spring mechanism to provide continuous tension, so that the pressure between the probe and the weld surface is stable within the range of 0.2-0.5N; Step C2: Ensure that the coupling agent is evenly distributed between the probe and the detection surface through the automatic coupling agent filling mechanism.

[0010] The aforementioned phased array inspection method for fillet welds of a pressure vessel pipe is characterized by: step D, manually pushing the scanning frame to rotate along the pipe, driving the probe to move along the weld and perform phased array inspection. The specific steps are as follows: Step D1, controlling the emission timing of the chips in the probe array by electronic delay to achieve beam deflection and focusing; Step D2: Generate multi-angle sound beams according to a preset delay rule while moving along the weld to cover the entire cross-section of the weld for detection.

[0011] The aforementioned phased array inspection and scanning method for fillet welds of pipes in pressure vessels is characterized in that: in step D2, the sound beam deflection angle is ±45°, the focusing depth is dynamically adjustable, and the inspection data generates S-scan and B-scan images in real time, wherein the S-scan is a sector scan that displays the inspection results of multiple sound beams emitted from a certain point of the probe and deflected at different angles within a sector plane, and the B-scan is a cross-sectional view perpendicular to the scanning direction.

[0012] The aforementioned phased array inspection and scanning method for fillet welds of pressure vessel pipes is characterized by: step E, real-time recording of probe position information and synchronous storage of inspection data, real-time binding of inspection position and data, supporting offline reproduction and quality traceability, and the specific steps are as follows: Step E1, recording the probe movement trajectory through an encoder, with a positioning accuracy of ≤0.1mm; In step E2, the position coordinates are bound to the phased array scanning data and stored, and a visual report including the defect location and size is generated.

[0013] Beneficial effects The present invention provides a phased array scanning method for detecting fillet welds in pressure vessel pipes. Compared with the prior art, it has the following advantages: 1. The phased array scanning method for pressure vessel and nozzle fillet welds, through magnetic wheel adsorption and lightweight design, achieves stable inspection in various working environments (-20°C to 150°C), making it particularly suitable for operations in high-altitude, toxic and other hazardous locations. The adaptive mechanism is compatible with containers of different specifications with diameters of 200-5000mm and has excellent adaptability to complex curved surfaces (curvature radius ≥ 100mm). The inspection process requires only one person to operate, significantly reducing labor costs and operational risks, reducing the overall inspection cost by more than 40%, while ensuring the reliability and consistency of inspection quality, and improving safety and adaptability.

[0014] 2. The phased array scanning method for the corner welds of pressure vessels and nozzles significantly improves intelligent detection efficiency. Through the magnetic adsorption positioning system and adaptive adjustment mechanism, semi-automatic operation of the detection process is achieved. This method uses multi-angle acoustic beam scanning technology (±45° range) combined with an intelligent pressure regulation system to increase detection efficiency by more than 50% compared with traditional methods. At the same time, the defect positioning accuracy is controlled within ±0.5mm. The unique partition focusing technology can automatically optimize the detection parameters according to the weld depth, ensuring accurate detection of the full thickness from the surface to the root. The defect detection rate exceeds 99.5%. The detection data is bound to the three-dimensional coordinates in real time, supporting the automatic generation of visual reports and offline analysis. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is an overall flow chart of the phased array scanning method for pressure vessel and nozzle fillet welds of the present invention; Figure 2 is a specific flow chart of step A of the present invention; Figure 3 is a specific flow chart of step B of the present invention; Figure 4 is a specific flow chart of step C of the present invention; Figure 5 is a specific flow chart of step D of the present invention; Figure 6 4 is a specific flow chart of step E of the present invention. DETAILED DESCRIPTION

[0016] The present invention will be further described below with reference to the accompanying drawings.

[0017] See also Figure 1-6 The present invention provides a technical solution: a phased array inspection and scanning method for fillet welds of a pressure vessel pipe, which specifically includes the following steps: Step A: Fix the scanning frame to the surface of the pipe by magnetic adsorption device. The specific steps are as follows: Step A1: The magnetic adsorption device includes four symmetrically distributed magnetic wheels and is adsorbed on the surface of the pipe; Step A2: Adjust the adsorption force distribution of the magnetic wheel according to the curvature of the pipe to ensure that the scanning frame is stably fixed.

[0018] Step B: Adjust the relative position and angle between the probe and the weld so that the probe is aligned along the normal direction of the weld. The specific steps are as follows: Step B1: adjusting the distance between the probe and the weld by using a retractable robotic arm, wherein the adjustment range of the retractable robotic arm is 10-50 mm; Step B2: Manually adjust the probe deflection angle using a universal joint structure to match the weld groove angle. The deflection angle range of the universal joint structure is ±30°. Step B3: Verify the normal alignment accuracy between the probe and the weld using an auxiliary positioning sensor.

[0019] Step C: Use the pressure assembly to make the probe close to the weld surface and maintain constant contact pressure. The specific steps are as follows: Step C1: The pressure component has a built-in double-stage damping spring mechanism to provide continuous tension, so that the pressure between the probe and the weld surface is stable within the range of 0.2-0.5N; Step C2: Ensure that the coupling agent is evenly distributed between the probe and the detection surface through the automatic coupling agent filling mechanism.

[0020] Step D: Manually push the scanning frame to rotate along the pipe, drive the probe to move along the weld and perform phased array testing. The specific steps are as follows: Step D1, controlling the emission timing of the chips in the probe array by electronic delay to achieve beam deflection and focusing; In step D2, a multi-angle sound beam is generated according to a preset delay rule while moving along the weld, covering the entire cross-section of the weld. The sound beam deflection angle is ±45°, and the focusing depth is dynamically adjustable. The detection data generates S-scan and B-scan images in real time. The S-scan is a sector scan that displays the detection results of multiple sound beams emitted from a certain point of the probe and deflected at different angles within a sector plane. The B-scan is a cross-sectional view perpendicular to the scanning direction.

[0021] Step E: Record the probe position information in real time and store it synchronously with the test data. The test position and data are bound in real time to support offline reproduction and quality traceability. The specific steps are as follows: Step E1, recording the probe movement trajectory through an encoder, with a positioning accuracy of ≤0.1mm; In step E2, the position coordinates are bound to the phased array scanning data and stored, and a visual report including the defect location and size is generated.

[0022] To better illustrate the use effect of the present invention, a specific embodiment of the measurement method and system of the present invention is introduced below.

[0023] S1, magnetic adsorption fixation: The operator symmetrically fits the four magnetic wheels of the scanning device on the surface of the pipe. The magnetic wheels automatically generate strong adsorption force. The built-in level sensor of the device detects the installation posture and prompts the operator to adjust to the optimal position through the indicator light. The anti-slip pattern design ensures the stability of the device on the curved surface and avoids displacement during the inspection process.

[0024] S2, initial probe positioning: The operator manually adjusts the retractable robotic arm to move the probe to the starting position at the edge of the weld. The universal joint mechanism allows the probe to deflect at multiple angles. By observing the real-time image on the display, the probe is adjusted to be perpendicular to the weld. The positioning sensor emits a prompt sound indicating that the probe is aligned with the weld normal.

[0025] S3, Contact pressure adjustment: The spring mechanism automatically applies a preset pressure to keep the probe in stable contact with the test surface. The pressure feedback system monitors the contact status in real time. If an abnormality occurs, an alarm will be issued and the test will be suspended. The coupling agent supply system will start working to form a uniform coupling layer between the probe and the workpiece.

[0026] S4, detection parameter setting: The system automatically loads the corresponding detection process according to the preset weld specifications, initializes the phased array instrument, establishes the transmission and reception sequence of the multi-angle sound beam, and the operator confirms parameters such as the scanning range and detection sensitivity.

[0027] S5, manual scanning operation: The operator pushes the scanning device along the circumference of the pipe at a constant speed. The rolling mechanism at the bottom of the device ensures smooth movement and avoids sudden changes in speed. The real-time display interface shows the probe movement trajectory and the detected area.

[0028] S6, phased array detection process: The probe emits ultrasonic beams at different angles in a predetermined sequence. At each detection position, multiple sets of echo signals with different deflection angles are collected. The system processes the raw signals in real time and generates a preliminary detection image. The specific probe model mentioned above is 5L16-0.5-10.

[0029] S7, synchronous position recording: A high-precision encoder continuously records the three-dimensional position coordinates of the probe. The spatial position of each detection point is accurately bound to the corresponding ultrasound data, and the system automatically marks the location and characteristics of abnormal signals.

[0030] S8, real-time imaging display: The main interface displays S-scan and B-scan images simultaneously, with suspected defect areas marked in different colors and preliminary assessment dimensions displayed. Historical inspection data can be retrieved for comparative analysis.

[0031] S9, Report Generation: The system automatically organizes the inspection data and generates a report in a standard format. The report includes a schematic diagram of the defect location, dimensional assessment, and acceptance conclusions, and supports the export of inspection result files in multiple formats.

[0032] S10, Data Archiving: Completely preserve original inspection data and location information, establish equipment inspection archives, support historical data tracing, perform batch data analysis, and evaluate equipment status change trends.

[0033] In summary, the present invention achieves standardization and semi-automation of pressure vessel corner weld detection through the coordinated work of mechanical structure and intelligent control system. The system first realizes rapid and accurate positioning through magnetic adsorption components, and then uses adjustable mechanical structure to ensure the optimal detection posture of the probe and the weld. During the detection process, phased array technology realizes multi-angle acoustic beam scanning through electronic control, and cooperates with the precise position recording system to obtain comprehensive weld quality information. The entire workflow forms a complete technical chain of "precise positioning-adaptive coupling-multi-angle scanning-data binding-intelligent analysis". Compared with traditional methods, this solution significantly reduces the influence of human factors and improves the consistency and reliability of detection. The designed mechanical structure not only ensures detection accuracy, but also takes into account the convenience of operation, making weld detection in complex environments more efficient and safe. The system's integrated data analysis function also provides reliable data support for equipment status assessment and life prediction.

[0034] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the foregoing embodiments. The foregoing embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A phased array scanning method for detecting fillet welds of pressure vessel nozzles, characterized by: The following steps are included: Step A, fixing the scanning frame to the surface of the pipe by a magnetic adsorption device; Step B, adjusting the relative position and angle between the probe and the weld so that the probe is aligned along the normal direction of the weld; Step C, using a pressure assembly to bring the probe into close contact with the weld surface and maintain a constant contact pressure; Step D: Manually push the scanning frame to rotate along the pipe, driving the probe to move along the weld and perform phased array testing; Step E: Record the probe position information in real time and store it synchronously with the detection data. The detection position and data are bound in real time to support offline reproduction and quality traceability.

2. The phased array scanning method for detecting fillet welds of pressure vessel pipes according to claim 1, characterized in that: Step A: Fix the scanning frame to the surface of the pipe by magnetic adsorption device. The specific steps are as follows: Step A1: The magnetic adsorption device includes four symmetrically distributed magnetic wheels and is adsorbed on the surface of the pipe; Step A2: Adjust the adsorption force distribution of the magnetic wheel according to the curvature of the pipe to ensure that the scanning frame is stably fixed.

3. The phased array scanning method for detecting fillet welds of pressure vessel pipes according to claim 1, characterized in that: Step B: Adjust the relative position and angle between the probe and the weld so that the probe is aligned along the normal direction of the weld. The specific steps are as follows: Step B1, adjusting the distance between the probe and the weld by using a retractable robotic arm; Step B2: manually adjust the probe deflection angle using a universal joint structure to match the weld groove angle; Step B3: Verify the normal alignment accuracy between the probe and the weld using an auxiliary positioning sensor.

4. The phased array scanning method for detecting fillet welds of pipes in pressure vessels according to claim 3 is characterized in that: The adjustment range of the telescopic robotic arm is 10-50 mm, and the deflection angle range of the universal joint structure is ±30°.

5. The phased array inspection and scanning method for pressure vessel nozzle fillet welds according to claim 1, characterized in that: Step C: Use the pressure assembly to make the probe close to the weld surface and maintain constant contact pressure. The specific steps are as follows: Step C1: The pressure component has a built-in double-stage damping spring mechanism to provide continuous tension, so that the pressure between the probe and the weld surface is stable within the range of 0.2-0.5N; Step C2: Ensure that the coupling agent is evenly distributed between the probe and the detection surface through the automatic coupling agent filling mechanism.

6. The phased array scanning method for detecting fillet welds of pressure vessel pipes according to claim 1, characterized in that: Step D: Manually push the scanning frame to rotate along the pipe, drive the probe to move along the weld and perform phased array testing. The specific steps are as follows: Step D1, controlling the emission timing of the chips in the probe array by electronic delay to achieve beam deflection and focusing; Step D2: Generate multi-angle sound beams according to a preset delay rule while moving along the weld to cover the entire cross-section of the weld for detection.

7. The phased array inspection and scanning method for pressure vessel nozzle fillet welds according to claim 6, characterized in that: In step D2, the sound beam deflection angle is ±45°, the focus depth is dynamically adjustable, and the detection data generates S-scan and B-scan images in real time. The S-scan is a sector scan that displays the detection results of multiple sound beams emitted from a certain point of the probe and deflected at different angles within a sector plane. The B-scan is a cross-sectional view perpendicular to the scanning direction.

8. The phased array inspection and scanning method for pressure vessel nozzle fillet welds according to claim 1, characterized in that: Step E: Record the probe position information in real time and store it synchronously with the test data. The test position and data are bound in real time to support offline reproduction and quality traceability. The specific steps are as follows: Step E1, recording the probe movement trajectory through an encoder, with a positioning accuracy of ≤0.1mm; In step E2, the position coordinates are bound to the phased array scanning data and stored, and a visual report including the defect location and size is generated.

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