Pressure-bearing equipment crack detection instrument and detection method based on eddy current technology

Abstract

The invention relates to the technical field of crack detection, in particular to a pressure-bearing equipment crack detection instrument and method based on an eddy current technology, and the instrument comprises a pulsed eddy current detector main body, a frame plate, a bearing plate and a mounting seat; wherein one side of the pulsed eddy current detector main body is provided with a connecting line, and one end of the connecting line is connected with a detection probe; wherein supporting blocks are fixed to the left side and the right side of the frame plate correspondingly, and an anti-skid rubber mat is bonded to one side of each supporting block. The mounting seat, the spring, the damping rubber block, the L-shaped adjusting bracket and other structures cooperate, so that the fluctuation limit of the distance between the detection probe and the surface of pressure-bearing equipment is reduced, and compared with a traditional instrument which greatly changes the distance due to irregular surface, the instrument can effectively avoid the interference of the distance fluctuation on eddy current signal acquisition, improve the crack detection accuracy and reduce the detection cost. The problems of missing detection and false detection caused by unstable spacing of traditional equipment are solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of crack detection, in particular to a pressure equipment crack detection instrument and method based on eddy current technology. BACKGROUND

[0002] In the manufacturing and maintenance process of pressure equipment, crack detection is a crucial safety measure. Eddy current detection technology is a commonly used non-destructive testing method that detects cracks and defects by detecting eddy currents generated on the surface of the material. However, traditional eddy current detection instruments have some technical problems in the process of use.

[0003] Traditional eddy current detection instruments usually require the probe to maintain a certain distance from the surface of the pressure equipment and maintain uniform motion during detection. This requirement is difficult to achieve in actual operation, especially when the surface of the pressure equipment is uneven or has welding lines, the distance between the probe and the surface is difficult to maintain uniform, thereby affecting the accuracy of the detection. In addition, the existing eddy current detection technology also has certain limitations in identifying and quantifying cracks.

[0004] In order to improve the accuracy and efficiency of detection, a new type of eddy current detection instrument and detection method is needed in the market, which can adapt to the irregularity of the surface of the pressure equipment and maintain the distance between the probe and the surface unchanged, while realizing uniform motion. In particular, for the detection method based on eddy current technology, further technical innovation is needed to improve its applicability in complex environments.

[0005] Pulsed eddy current detectors are a more advanced detection device that excites eddy currents by sending pulse signals and analyzes the returned signals to detect defects in materials. However, even this advanced device faces the challenge of accurate detection on the surface of pressure equipment, therefore, we propose a pressure equipment crack detection instrument and method based on eddy current technology. SUMMARY

[0006] The purpose of the present application is to provide a pressure equipment crack detection instrument and method based on eddy current technology, which has the advantage of effectively dealing with complex situations such as uneven surfaces or welding lines of pressure equipment, and solves the problem of crack detection.

[0007] To achieve the above purpose, the present application provides the following technical solution: a pressure equipment crack detection instrument and method based on eddy current technology, comprising: a pulsed eddy current detector main body, a frame plate, a bearing plate and an adjustable mounting seat; Wherein, one side of the pulsed eddy current detector main body is provided with a connecting line, one end of the connecting line is connected with a detection probe; The left and right sides of the frame plate are fixed with support blocks, one side of the support block is bonded with a non-slip rubber pad, the middle end of the rear side of the frame plate is provided with a storage battery, the top and bottom of the inner side of the frame plate are provided with guide grooves, and the left and right ends of the rear side of the frame plate are provided with handles, and the top of the handle is provided with a control button. The front of the bearing plate is provided with a recess, the bottom of the inner side of the frame plate is fixed with a toothed plate, the rear side of the bearing plate is provided with a driving motor, the output end of the driving motor is provided with a driving gear, and the driving gear is engaged with the toothed plate. 1. Realize uniform and stable movement: the bearing plate is matched with the frame plate through the guide groove, combined with the meshing transmission of the driving motor, the toothed plate and the driving gear, and cooperated with the resistance reduction of the ball, the movement of the bearing plate and the detection probe is more stable and uniform, which guarantees the continuity and consistency of signal acquisition.

[0008] 2. Convenient operation and maintenance: the handle and the control button are designed for handheld operation, the storage battery provides power to get rid of the cable bondage, and the modular design of each component facilitates the disassembly, debugging and later maintenance of the detection probe, which reduces the use and operation cost.

[0009] Preferably, the mounting seat is a U-shaped structure, the two ends of the rear side of the mounting seat are fixed with guide rods, the guide rods pass through the recess and slide on the inner surface of the bearing plate, the rear end of the guide rod is fixed with a damping rubber block, one side of the damping rubber block is in contact with the inner wall of the frame plate, the outer surface of the guide rod is sleeved with a spring, and the two ends of the spring are fixed with the inner wall of the recess and the rear side of the mounting seat respectively, the top and bottom of the mounting seat are provided with L-shaped adjusting supports, the inner surface of the L-shaped adjusting support is threadedly connected with an adjusting screw, one side of the adjusting screw is movably connected with a guide joint through a bearing, and one end of the guide joint is provided with a contact ball. 1. Improve the stability of the distance: through the cooperation of the mounting seat, the spring and the damping rubber block, the vibration is effectively buffered, the distance between the detection probe and the surface of the pressure-bearing equipment is controlled in a very low range, the interference of the traditional instrument caused by the large change of the distance due to the irregular surface on the signal acquisition of the eddy current is avoided, the crack detection accuracy is significantly improved, and the problem of missed detection and false detection is solved.

[0010] 2. Self-adapt to complex surface: the non-slip rubber pad is attached to the surface of the equipment to enhance the stability, when encountering a protrusion, the mounting seat slides along the guide rod, the spring is compressed, and the contact ball rolls, which can adapt to complex conditions such as concave-convex surface and welding line, and expand the application range of the instrument on irregular surface.

[0011] Preferably, the number of operation buttons is two, and the two operation buttons are electrically connected with the input terminals of the driving motor for reversing the driving motor, the driving motor is a direct current servo motor with a rated voltage of 12-24V and a rated power of 50-100W, and is provided with an overload protection module with an overload threshold of 1.5 times of the rated power. The technical scheme has the advantages of: 1. Precise control of moving direction: two operation buttons control the driving motor to reverse, realizing the reciprocating movement of the bearing plate and meeting the requirements of different detection paths, and the operation is intuitive and convenient.

[0012] 2. Ensure the stability and safety of driving: the direct current servo motor has stable output and is suitable for battery power supply; the overload protection module can trigger protection when the power exceeds 1.5 times of the rated value, preventing the motor from being damaged due to excessive load, prolonging the service life of the equipment, and improving the safety of the detection process.

[0013] Preferably, the upper and lower ends of the bearing plate slide on the inner side of the guide groove, and the top and bottom of the bearing plate are provided with resistance-reducing balls which are in contact with the inner wall of the guide groove. The technical scheme has the advantages of: 1. Reduce sliding resistance: the resistance-reducing balls are in contact with the inner wall of the guide groove, converting sliding friction into rolling friction, greatly reducing the resistance when the bearing plate moves, and making the movement smoother.

[0014] 2. Improve the stability of movement: the guide groove restricts the sliding direction of the bearing plate, and the resistance-reducing balls reduce the resistance, ensuring the stable movement of the bearing plate along a straight line, avoiding deviation or jamming, and ensuring the consistency of the movement trajectory of the detection probe.

[0015] Preferably, the left and right sides of the bearing plate are provided with fixing frames, and one end of the fixing frame is provided with an exhaust fan. The technical scheme has the advantages of: 1. Real-time heat dissipation: the exhaust fan can run synchronously during detection to dissipate heat in the detection area (especially the area where the equipment surface contacts the probe), avoiding the influence of local high temperature caused by long-time detection on the stability of eddy current signal or the performance of the equipment.

[0016] 2. Adapt to long-time work: the continuous heat dissipation maintains the stability of the detection environment temperature, ensures the reliability of the instrument under continuous detection conditions, and improves the detection efficiency.

[0017] Preferably, one side of the guide joint is fixed with a limiting guide piece which slides on the inner surface of the L-shaped adjusting bracket, and the surface of the limiting guide piece is provided with scale lines. The technical scheme has the advantages of: 1. Ensure the stability of adjustment: the limiting guide piece restricts the movement direction of the guide joint, avoiding the deviation of the guide joint when the adjusting screw rotates, and ensuring the accuracy of the position adjustment of the contact ball.

[0018] 2. Improve the accuracy of debugging: the scale line can intuitively display the adjustment amount, which helps the operator control the parallelism of the detection probe and the pressure-bearing device detection surface, so that the adjustment error is ≤0.5mm, laying a foundation for the accuracy of subsequent signal acquisition.

[0019] Preferably, the anti-skid rubber pad is made of nitrile rubber material, has anti-skid texture on the surface, and has a thickness of 2-5mm. The technical scheme has the following advantages: 1. Enhance the stability of fitting: nitrile rubber has good elasticity and wear resistance, and the anti-skid texture can increase the friction with the surface of the equipment. Combined with the thickness design of 2-5mm, it ensures that the frame plate is tightly fitted to the surface of the pressure-bearing equipment, preventing the fluctuation of the distance caused by sliding during detection.

[0020] 2. Adapt to complex surface: the elasticity of the rubber material can adapt to the slight concave-convex of the equipment surface, improve the fitting degree of the frame plate and the surface, and indirectly ensure the stability of the detection probe.

[0021] Preferably, the exhaust fan is an axial flow fan, the air volume is 50-100m³ / h, and the lead is connected with the storage battery through a lead wire, and the lead wire is wrapped with a fireproof insulating sleeve. The technical scheme has the following advantages: 1. High efficiency of heat dissipation: the air volume of the axial flow fan (50-100m³ / h) is suitable for the heat dissipation demand of the detection area, which can quickly remove heat and avoid high temperature affecting the detection accuracy.

[0022] 2. Improve electrical safety: the fireproof insulating sleeve wraps the lead wire, which can prevent lead wear or short circuit, adapt to the complex environment (such as oil stains and dust) that may exist in the detection site, and reduce the risk of electrical failure.

[0023] Preferably, the damping rubber block is made of polyurethane elastomer material, has a Shore hardness of 60-80A, a thickness of 5-10mm, and a micro-pit structure on the surface, and the micro-pit diameter is 0.1-0.3mm. The technical scheme has the following advantages: 1. High-efficiency vibration absorption and buffering: polyurethane elastomer with a hardness of 60-80A and a thickness of 5-10mm can effectively absorb vibration energy during detection; the surface micro-pit structure further enhances the buffering performance, reducing the impact of vibration on the mounting seat and detection probe.

[0024] 2. Ensure the stability of the distance: by absorbing vibration and cooperating with the elasticity of the spring, the fluctuation of the distance between the detection probe and the equipment surface is ≤0.2mm, which improves the stability of signal acquisition.

[0025] A detection method of an instrument, comprising the following steps: S1. Device debugging: Install the detection probe on the mounting seat, adjust the position of the contact ball through the adjusting screw of the L-shaped adjusting support, make the detection probe parallel to the detection surface of the pressure-bearing device, control the adjustment accuracy by the scale line of the limiting guide, and the error is ≤0.5mm; S2. Detection preparation: Hold the handle, attach the frame plate to the surface of the pressure-bearing device through the anti-skid rubber pad, control the button to start the drive motor, drive the gear along the toothed plate to mesh transmission, the bearing plate slides along the guide groove, the resistance-reducing ball reduces the sliding resistance, the exhaust fan operates synchronously, the wind speed is ≥2m / s, and the detection area is cooled; S3. Signal acquisition: The drive motor controls the bearing plate to move back and forth, the moving speed is 0.5-2m / min, the detection probe moves with the mounting seat, the spring and the damping rubber block buffer vibration, ensure the stable distance between the detection probe and the surface of the pressure-bearing device, the distance fluctuation is ≤0.2mm, and the pulse eddy current detector main body collects the eddy current signal; S4. Data analysis: After detection, the pulse eddy current detector main body processes the signal, identifies the crack through the crack characteristic algorithm, and generates a detection report containing the crack position, depth and length; S5. Device storage: Turn off the drive motor and exhaust fan, disassemble the detection probe, reset the bearing plate to one end of the frame plate, use the remaining battery power to charge the device, the charging time is 2-4h, and the device is properly stored after charging.

[0026] Each step of the detection method has the following technical advantages: S1. Device debugging Ensure the accuracy of the initial position: adjust the position of the contact ball through the adjusting screw of the L-shaped adjusting support, control the adjustment accuracy (error ≤0.5mm) combined with the scale line of the limiting guide, ensure that the detection probe is parallel to the detection surface of the pressure-bearing device, lay the foundation for the accuracy of subsequent signal acquisition, and avoid eddy current signal distortion caused by initial inclination of the probe.

[0027] Standardized debugging process: clear adjustment method and accuracy requirement, reduce the influence of human operation difference on the initial state of the device, improve the consistency and reliability of detection.

[0028] S2. Detection preparation Ensure stable adhesion of the device: hold the handle and attach the frame plate to the surface of the pressure-bearing device through the anti-skid rubber pad, the butyl rubber material and anti-skid texture of the anti-skid rubber pad enhance the friction force, prevent the frame plate from sliding during detection, and ensure the relative stability of the overall device and the detection surface.

[0029] Smooth driving and heat dissipation: After starting the driving motor, the driving gear meshes with the gear plate, and the guiding groove and the resistance-reducing ball cooperate to make the sliding resistance of the bearing plate small and the movement smooth. The exhaust fan operates synchronously (wind speed ≥ 2 m / s) to dissipate heat in the detection area in real time, avoiding the influence of local high temperature caused by long-time detection on the stability of eddy current signals or the performance of the equipment.

[0030] Improved operational convenience: The device is started and driven by the handle and control buttons, making the operation intuitive and simple, and reducing the use threshold of the operator.

[0031] S3. Signal acquisition Ensure uniform and stable movement: The driving motor controls the reciprocating movement of the bearing plate (speed 0.5-2 m / min) in combination with the guiding groove and the resistance-reducing ball, ensuring stable movement trajectory and uniform speed of the detection probe, and avoiding inconsistent signal acquisition intervals caused by unstable movement.

[0032] Precise control of distance fluctuation: The spring and damping rubber block cooperate to buffer vibration. When the detection probe encounters a surface protrusion, the mounting seat slides along the guide rod to compress the spring, contact the ball to roll and contact the protrusion, and cooperate with the damping rubber block to absorb vibration energy, strictly controlling the distance fluctuation between the detection probe and the surface of the device ≤0.2 mm, effectively avoiding the interference of distance change on eddy current signal acquisition, greatly improving the accuracy of crack detection, and solving the problems of missed detection and false detection caused by unstable distance in traditional equipment.

[0033] Comprehensive coverage of the detection area: The reciprocating movement of the bearing plate enables the detection probe to fully scan the area to be detected, ensuring no dead angle in signal acquisition and improving the integrity of detection.

[0034] S4. Data analysis Automatic crack identification and quantification: The pulse eddy current detector processes the collected eddy current signals, automatically identifies cracks through crack feature algorithms, and generates a detection report containing crack location, depth, and length. Compared with traditional manual analysis, it is more efficient and accurate, reducing human judgment errors.

[0035] Provide reliable decision basis: Quantitative crack parameters provide scientific data support for the maintenance and safety evaluation of pressure equipment, helping technicians quickly judge the equipment status and develop reasonable repair or replacement plans.

[0036] S5. Equipment storage Protect the service life of the equipment: After turning off the equipment, remove the detection probe and reset the bearing plate to avoid long-term stress on the components; use the remaining battery capacity to charge (2-4 hours), and a standardized charging process helps to prolong the service life of the battery and ensure sufficient power for the next detection.

[0037] Facilitates equipment management and maintenance: A unified storage procedure ensures that all equipment components are stored in an orderly manner, reducing the risk of loss or damage, while also facilitating subsequent equipment debugging and maintenance, and reducing operation and maintenance costs.

[0038] Preferably, in step S3, when the detection probe encounters a protrusion on the surface of the pressure-bearing equipment, the mounting base slides along the guide rod to compress the spring, and the contact ball rolls in contact with the protrusion, ensuring that the fluctuation of the detection probe spacing is ≤0.2mm. The damping rubber block absorbs vibration energy, preventing vibration from affecting the detection data. The advantages of this technical solution are: 1. Adaptive surface protrusion: When the detection probe encounters a protrusion, the mounting base slides along the guide rod, the spring is compressed for buffering, and the contact ball rolls to reduce friction. It can adapt to surface irregularities (such as weld lines, unevenness) and avoid direct collision between the probe and the surface.

[0039] 2. Strictly control the spacing fluctuation: Through the synergistic effect of the mechanical structure, it is ensured that even in the raised area, the spacing fluctuation between the detection probe and the equipment surface is ≤0.2mm, avoiding signal interference caused by surface defects and improving the detection accuracy under complex working conditions.

[0040] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention, through the coordinated structure of mounting base, spring, damping rubber block and L-shaped adjustment bracket, reduces the fluctuation limit of the distance between the detection probe and the surface of the pressure-bearing equipment. Compared with traditional instruments, which suffer from large changes in distance due to surface irregularities, this instrument can effectively avoid the interference of distance fluctuation on eddy current signal acquisition, improve the accuracy of crack detection, and solve the problems of missed detection and false detection caused by unstable distance in traditional equipment.

[0041] 2. The present invention utilizes the guide groove and resistance-reducing ball joint between the bearing plate and the frame plate, combined with the transmission of the drive motor, toothed plate and drive gear, to make the bearing plate have low sliding resistance and move at a uniform speed.

[0042] 3. This invention uses an anti-slip rubber pad to adhere to the surface of the pressure-bearing equipment. When encountering a protrusion, the mounting base slides along the guide rod, the spring is compressed, and the contact ball rolls, which can buffer vibration and adapt to surface irregularities. Regardless of whether the equipment surface has weld lines or unevenness, the probe can work stably, expanding the application range of the instrument in complex working conditions.

[0043] 4. This invention features a handle and control buttons for easy handheld operation and motor control. Battery power eliminates the need for cables and makes charging convenient. The modular design of each component facilitates the disassembly and assembly of the detection probe, equipment debugging, and subsequent maintenance, thereby reducing usage and maintenance costs. Attached Figure Description

[0044] Figure 1 This is a schematic diagram of the structure from a first perspective of the present invention; Figure 2It is a second perspective structure schematic view of the application; Figure 3 It is a sectional structure schematic view of the frame plate of the application; Figure 4 It is a cooperation structure schematic view of the bearing plate and the driving motor of the application; Figure 5 It is another perspective structure schematic view of the application; Figure 4 Figure 6 It is an unfolded structure schematic view of the application; Figure 5 Figure 7 It is a cooperation structure schematic view of the bearing plate and the fixing frame of the application; Figure 8 It is a structure mounting seat schematic view of the application.

[0045] In the figure: 1, pulse eddy current detector main body; 101, connecting line; 102, detection probe; 2, frame plate; 201, support block; 202, anti-skid rubber pad; 203, storage battery; 204, guide groove; 3, handle; 301, control button; 4, bearing plate; 401, fixing frame; 402, resistance-reducing ball; 403, recess; 404, exhaust fan; 5, driving motor; 501, toothed plate; 502, driving gear; 6, mounting seat; 601, L-shaped adjusting support; 602, adjusting screw; 603, spring; 604, guide rod; 605, damping rubber block; 606, limiting guide; 607, contact ball; 608, guide joint. DETAILED DESCRIPTION

[0046] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the application.

[0047] The pulse eddy current detector main body 1, the connecting line 101, the detection probe 102, the frame plate 2, the support block 201, the anti-skid rubber pad 202, the storage battery 203, the guide groove 204, the handle 3, the control button 301, the bearing plate 4, the fixing frame 401, the resistance-reducing ball 402, the recess 403, the exhaust fan 404, the driving motor 5, the toothed plate 501, the driving gear 502, the mounting seat 6, the L-shaped adjusting support 601, the adjusting screw 602, the spring 603, the guide rod 604, the damping rubber block 605, the limiting guide 606, the contact ball 607 and the guide joint 608 of the application are all general standard parts or parts known to those skilled in the art, and their structures and principles can be known by the technical personnel through a technical manual or obtained through a conventional experimental method.​​ Embodiment

[0048] Please refer to Figures 1-8 As shown in the figure, the present application provides a technical solution: a pressure equipment crack detection instrument and method based on eddy current technology, comprising: Pulsed eddy current detector main body 1, frame plate 2, bearing plate 4 and adjustable mounting seat 6; Wherein, the side of the pulsed eddy current detector main body 1 is provided with a connecting line 101, one end of the connecting line 101 is connected with a detection probe 102; Wherein, the left and right sides of the frame plate 2 are fixed with support blocks 201, one side of the support block 201 is bonded with a non-slip rubber pad 202, the middle end of the back side of the frame plate 2 is installed with a storage battery 203, the top and bottom of the inner side of the frame plate 2 are provided with guide grooves 204, the left and right ends of the back side of the frame plate 2 are installed with handles 3, the top of the handle 3 is installed with control buttons 301; Wherein, the front of the bearing plate 4 is provided with a recess 403, the bottom of the inner side of the frame plate 2 is fixed with a toothed plate 501, the back side of the bearing plate 4 is installed with a drive motor 5, the output end of the drive motor 5 is installed with a drive gear 502, and the drive gear 502 is engaged with the toothed plate 501; Wherein, the mounting seat 6 is U-shaped structure, the two ends of the back side of the mounting seat 6 are fixed with guide rods 604, the guide rods 604 pass through the recess 403 and slide on the inner surface of the bearing plate 4, the rear end of the guide rod 604 is fixed with a damping rubber block 605, and one side of the damping rubber block 605 is in contact with the inner wall of the frame plate 2, the outer surface of the guide rod 604 is sleeved with a spring 603, and the two ends of the spring 603 are fixed with the inner wall of the recess 403 and the back side of the mounting seat 6 respectively, the top and bottom of the mounting seat 6 are provided with L-shaped adjusting brackets 601, the inner surface of the L-shaped adjusting bracket 601 is threadedly connected with an adjusting screw 602, one side of the adjusting screw 602 is movably connected with a guide joint 608 through a bearing, and one end of the guide joint 608 is provided with a contact ball 607. The spring 603 and the damping rubber block 605 cooperate to buffer vibration, so that the distance between the detection probe 102 and the surface of the pressure equipment fluctuates ≤0.2mm.

[0049] The number of operation buttons 301 is two, and the two operation buttons 301 are electrically connected with the access end of the forward and reverse rotation of the driving motor 5. The driving motor 5 is a direct current servo motor, with a rated voltage of 12-24V and a rated power of 50-100W. An overload protection module is provided, and the overload threshold is 1.5 times of the rated power. The upper and lower ends of the bearing plate 4 are slid on the inner side of the guide groove 204. The top and bottom of the bearing plate 4 are provided with resistance-reducing balls 402, and the resistance-reducing balls 402 are in contact with the inner wall of the guide groove 204. The anti-skid rubber pad 202 is made of nitrile rubber material, and the surface is provided with anti-skid texture. The thickness is 2-5mm. The damping rubber block 605 is made of polyurethane elastomer material, with a shore hardness of 60-80A and a thickness of 5-10mm. The surface is provided with a micro concave hole structure, and the micro hole diameter is 0.1-0.3mm.

[0050] Through experimental verification, when the instrument is used to detect a pressure-bearing pipeline with a 0.5mm deep crack, the crack recognition accuracy is 98%; while the recognition accuracy of the traditional instrument (without spring-damping cooperative structure) is only 72%, and the false detection rate is reduced by 65%.

[0051] A detection method of an instrument, comprising the following steps: S1. Device debugging: install the detection probe 102 on the mounting seat 6, adjust the position of the contact ball 607 through the adjusting screw 602 of the L-shaped adjusting support 601 to make the detection probe 102 parallel to the detection surface of the pressure-bearing equipment, control the adjustment accuracy by using the scale line of the limiting guide 606, and the error is ≤0.5mm; S2. Detection preparation: hold the handle 3, attach the frame plate 2 to the surface of the pressure-bearing equipment through the anti-skid rubber pad 202, start the driving motor 5 through the operation button 301, drive the gear 502 to mesh transmission along the tooth plate 501, make the bearing plate 4 slide along the guide groove 204, reduce the sliding resistance through the resistance-reducing ball 402, and make the exhaust fan 404 operate synchronously, with a wind speed of ≥2m / s, to dissipate heat for the detection area; S3. Signal acquisition: control the bearing plate 4 to move back and forth through the forward and reverse rotation of the driving motor 5, with a moving speed of 0.5-2m / min, make the detection probe 102 move with the mounting seat 6, buffer vibration through the spring 603 and the damping rubber block 605, ensure that the distance between the detection probe 102 and the surface of the pressure-bearing equipment is stable, with a fluctuation of ≤0.2mm, collect the eddy current signal through the eddy current detection instrument main body 1, and control the bearing plate 4 to move back and forth at a speed of 0.5-2m / min through the driving motor 5. The speed range is matched with the elastic coefficient of the spring 603 and the hardness of the damping rubber block 605, so as to ensure that the distance fluctuation is ≤0.2mm. S4. Data analysis: After the detection is completed, the pulse eddy current detector main body 1 processes the signal, identifies the crack through a crack feature algorithm, generates a detection report containing the crack position, depth, and length, and the crack feature algorithm identifies the crack based on the amplitude mutation rate of the eddy current signal ≥ 30% and the phase shift ≥ 5°, and calculates the crack depth through the signal attenuation speed and the crack length through the signal duration. S5. Device storage: turn off the driving motor 5 and the exhaust fan 404, disassemble the detection probe 102, reset the bearing plate 4 to one end of the frame plate 2, charge the device with the remaining power of the storage battery 203, the charging time is 2-4h, and after the charging is completed, it is stored properly. The storage battery 203 is a 12V / 5Ah lithium battery, and the endurance time is ≥ 4 hours when the driving motor 5 and the exhaust fan 404 work at the same time, which meets the demand of single continuous detection.

[0052] In step S3, when the detection probe 102 encounters a protrusion on the surface of the pressure-bearing equipment, the mounting seat 6 slides along the guide rod 604 to compress the spring 603, the contact ball 607 rolls in contact with the protrusion, ensures that the distance fluctuation of the detection probe 102 is ≤ 0.2mm, and the damping rubber block 605 absorbs vibration energy to avoid the influence of vibration on the detection data.

[0053] It can be understood that: from equipment debugging (precision error ≤ 0.5mm), preparation, signal acquisition to data analysis and storage, the process is clear, the debugging ensures the initial position of the probe to be accurate, the preparation link synchronously completes the heat dissipation and the equipment in place, the signal acquisition is stable at a constant speed, the data analysis automatically identifies the crack and generates a report, and the storage is convenient for equipment maintenance and next use. The whole process improves the detection work efficiency and the standardization degree, with the help of the signal processing of the pulse eddy current detector main body 1 and the crack feature algorithm, the crack can be effectively identified and quantified in terms of position, depth, and length. Compared with the traditional technology which is fuzzy in crack identification and difficult to quantify, the present method can accurately determine the crack and provide reliable data support for the maintenance and safety evaluation of the pressure-bearing equipment. The crack feature algorithm identifies the crack based on the amplitude mutation rate and the phase shift of the pulse eddy current signal: when the amplitude mutation rate of the detection signal ≥ 30% and the phase shift ≥ 5°, it is determined as a crack signal; the crack depth is calculated through the calibration curve of the signal attenuation speed and the crack depth (for example, the amplitude attenuation is 15% for every 0.5mm increase in depth measured by experiment), and the crack length is calculated through the duration and moving speed of the continuous crack signal.

[0054] It should be noted that: the pulse eddy current detection technology is an extension of the eddy current detection technology, which is based on the principle of electromagnetic induction, analyzes the eddy current and induced magnetic field changes generated under pulse signal excitation, and detects the cracks and defects of the pressure-bearing equipment.

[0055] Actual detection operation Take the detection of the cracks in the pressure pipeline (carbon steel material, with anticorrosion coating, local welding line) of a petrochemical enterprise as an example: 1. Equipment debugging (corresponding to step S1) Remove the local anticorrosion coating of the pipeline (expose the metal surface to be detected), and place the assembled instrument next to the pipeline. Install the detection probe 102 to the mounting seat 6, rotate the adjusting screw 602 on the L-shaped adjusting bracket 601, observe the scale line of the limiting guide 606, adjust the position of the contact ball 607, make the axis of the detection probe 102 parallel to the tangent of the pipeline detection surface (circular surface), measure with a feeler gauge, ensure that the initial value of the distance between the detection probe 102 and the pipeline surface is 1mm (set according to the requirements of pulsed eddy current detection), and the adjustment error is ≤0.5mm.

[0056] 2. Detection preparation (corresponding to step S2) The operator holds the handle 3 with both hands, attaches the frame plate 2 to the pipeline surface through the anti-skid rubber pad 202, ensures tight attachment, and uses the thumbs of both hands to contact the top of the handle 3 to start the drive motor 5 forward rotation through the corresponding control button 301, the drive gear 502 is meshed and transmitted along the tooth plate 501, the carrier plate 4 slides along the guide groove 204, the rolling smoothness of the resistance reduction ball 402 is observed, and at the same time the exhaust fan 404 is started, the wind speed is measured with an anemometer, and it is confirmed that the wind speed is ≥2m / s, which is used for heat dissipation of the pipeline detection area.

[0057] 3. Signal acquisition (corresponding to step S3) The drive motor 5 rotates forward at a speed of 1m / min, the carrier plate 4 drives the mounting seat 6 and the detection probe 102 to move along the axial direction of the pipeline. During the movement, when encountering a pipeline surface welding line protrusion (height 3mm), the mounting seat 6 slides along the guide rod 604 to compress the spring 603, the contact ball 607 rolls in contact with the welding line protrusion, the spring 603 buffers the vibration, and the damping rubber block 605 absorbs the remaining vibration energy, ensuring that the fluctuation of the distance between the detection probe 102 and the pipeline surface is ≤0.2mm, and the pulsed eddy current detector main body 1 synchronously collects and stores the eddy current signals.

[0058] When the carrier plate 4 moves to the limit position of one end of the pipeline, the control button 301 is pressed to switch the drive motor 5 to reverse rotation, which drives the carrier plate 4 to move in the opposite direction, and the signal acquisition process is repeated to complete the forward and backward detection of the pipeline detection area, ensuring that the signals are covered comprehensively.

[0059] 4. Data analysis (corresponding to step S4) After the inspection is completed, the main body 1 of the pulse eddy current detector is operated, and the built-in crack feature algorithm is invoked (with the amplitude mutation rate set to ≥30% and the phase offset to ≥5° as the crack judgment threshold) to process and analyze the acquired eddy current signal. The instrument automatically identifies the crack location, and calculates the crack depth and length by combining data such as signal attenuation and phase change, generating an inspection report containing specific crack parameters and distribution. The report is then exported for technicians to assess the pipeline safety status.

[0060] 5. Equipment storage (corresponding to step S5) Turn off drive motor 5 and exhaust fan 404, remove detection probe 102 and store it properly; push the support plate 4 to reset it to the initial position at one end of frame plate 2; place the instrument on the charging base and charge it using the remaining power of battery 203. After charging for 2-4 hours (you can tell it is fully charged by the charging indicator light), unplug the charging cable and store the instrument in a dry, dustproof toolbox for the next use.

[0061] Precautions and Maintenance Before testing, the surface of the pressure equipment testing area must be cleaned of oil stains and thick rust (which can be done with sandpaper or cleaning agent) to avoid debris affecting probe adhesion and signal acquisition. If the ambient humidity is >80% and the temperature is >40℃, dehumidification and cooling measures must be taken (such as equipping a portable dehumidifier or sunshade) to prevent electrical components from getting damp or overheated and damaged.

[0062] When moving the instrument, avoid violent collisions with precision parts such as the mounting base 6 and the detection probe 102; operate the control button 301 smoothly to prevent the motor from frequently reversing and impacting the transmission components.

[0063] Regularly (recommended once a month) check the wear of the drag-reducing ball 402 and contact ball 607. If there are serious scratches on the surface of the ball or the diameter wear is >0.2mm, replace it in time. Clean the dust and debris in the guide groove 204 and the recess 403. Compressed air can be used to blow it out or a soft brush can be used to clean it to ensure that the bearing plate 4 and the mounting seat 6 slide smoothly.

[0064] Perform charge and discharge maintenance on battery 203 every quarter. Deeply discharge the battery (≤20% charge) and then fully charge it to extend its service life. Inspect the insulation of the wires. If there is any damage, repair or replace the wires with fireproof insulating sleeves of the same specification to ensure electrical safety. Example

[0065] Based on Embodiment 1, the present invention is as follows: Figures 1-8 As shown, the support plate 4 has a fixed frame 401 installed on both the left and right sides. An exhaust fan 404 is installed on the inner side of one end of the fixed frame 401. The exhaust fan 404 is an axial flow fan with an air volume of 50-100 m³ / h. It is connected to the battery 203 by a wire, and the wire is wrapped with a fireproof insulating sleeve.

[0066] The technical scheme: through the setting of the exhaust fan 404, synchronous heat dissipation can be realized, the detection environment is stable, the detection efficiency is improved, the signal acquisition is continuous and reliable due to stable movement, and the long-distance and large-area detection requirements of pressure-bearing equipment are met. Embodiments

[0067] On the basis of the first embodiment, the application is shown as Figures 1-8 One side of the guide joint 608 is fixed with a limiting guide 606, and the limiting guide 606 slides on the inner surface of the L-shaped adjusting support 601, and the surface of the limiting guide 606 is provided with a scale line.

[0068] The technical scheme: through the setting of the limiting guide 606, the stability of the guide joint 608 can be ensured, and the setting of the scale line can assist the guide joint 608 in controlling the adjusting precision.

[0069] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, and are not limited to the scope of protection of the present application. Although the present application has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present application can be modified or replaced by equivalents without departing from the essence and scope of the technical solutions of the present application.

Claims

1. A crack detection instrument for pressure equipment based on eddy current technology, characterized in that, Include: Pulsed eddy current detector main body (1), frame plate (2), bearing plate (4) and adjustable mounting seat (6); Wherein, the one side of the pulsed eddy current detector main body (1) is equipped with connecting line (101), one end of the connecting line (101) is connected with detection probe (102); Wherein, the left and right sides of the frame plate (2) are both fixed with support block (201), one side of the support block (201) is bonded with antiskid rubber pad (202), the middle end of the rear side of the frame plate (2) is installed with storage battery (203), the top and bottom of the inner side of the frame plate (2) are both provided with guide groove (204), the left and right ends of the rear side of the frame plate (2) are both installed with handle (3), the top of the handle (3) is installed with control button (301); Wherein, the front of the bearing plate (4) is provided with recess (403), one end of the bottom of the inner side of the frame plate (2) is fixed with toothed plate (501), the rear side of the bearing plate (4) is installed with driving motor (5), the output end of the driving motor (5) is installed with driving gear (502), and the driving gear (502) is engaged with the toothed plate (501).

2. A pressurized equipment crack detection instrument based on eddy current technology according to claim 1, characterized in that: The mounting seat (6) is U-shaped structure, the two ends of the rear side of the mounting seat (6) are both fixed with guide rod (604), the guide rod (604) passes through recess (403) and slides on the inner surface of the bearing plate (4), the rear end of the guide rod (604) is fixed with damping rubber block (605), and one side of the damping rubber block (605) is in contact with the inner wall of the frame plate (2), the outer surface of the guide rod (604) is sleeved with spring (603), and the two ends of the spring (603) are respectively fixed with the inner wall of recess (403) and the rear side of mounting seat (6), the top and bottom of the mounting seat (6) are both provided with L-shaped adjusting support (601), the inner surface of the L-shaped adjusting support (601) is threadedly connected with adjusting screw (602), one side of the adjusting screw (602) is movably connected with guide joint (608) through bearing, one end of the guide joint (608) is provided with contact ball (607).

3. A pressurized equipment crack detection instrument based on eddy current technology according to claim 2, characterized in that: The number of control buttons (301) is two, and the two control buttons (301) are electrically connected with the input end of the forward and reverse rotation of the driving motor (5), the driving motor (5) is a direct current servo motor, the rated voltage is 12-24V, the rated power is 50-100W, it is equipped with overload protection module, and the overload threshold is 1.5 times of the rated power.

4. A pressurized equipment crack detection instrument based on eddy current technology according to claim 2, characterized in that: The upper and lower ends of the bearing plate (4) slide in the inner side of the guide groove (204), the top and bottom of the bearing plate (4) are both provided with resistance reducing ball (402), and the resistance reducing ball (402) is in contact with the inner wall of the guide groove (204).

5. The eddy current based pressurized equipment crack detection instrument of claim 2, wherein: The left and right sides of the bearing plate (4) are both installed with fixing frame (401), one end of the inner side of the fixing frame (401) is installed with exhaust fan (404).

6. A pressurized equipment crack detection instrument based on eddy current technology according to claim 2, characterized in that: One side of the guide joint (608) is fixed with a limiting guide (606), and the limiting guide (606) slides on the inner surface of the L-shaped adjusting support (601), and the surface of the limiting guide (606) is provided with scale lines.

7. A pressurized equipment crack detection instrument based on eddy current technology according to claim 2, characterized in that: The anti-skid rubber pad (202) is made of nitrile rubber material, has anti-skid texture on the surface, and has a thickness of 2-5 mm.

8. A pressurized equipment crack detection instrument based on eddy current technology according to claim 5, characterized in that: The exhaust fan (404) is a axial flow fan, and the air volume is 50-100 m³ / h. The exhaust fan (404) is connected with the storage battery (203) through a wire, and the wire is wrapped with a fireproof insulating sleeve.

9. The eddy current based pressurized equipment crack detection instrument of claim 2, wherein: The damping rubber block (605) is made of polyurethane elastomer material, has a shore hardness of 60-80A, a thickness of 5-10 mm, and a micro concave hole structure on the surface, and the micro hole diameter is 0.1-0.3 mm.

10. A method of detection based on the apparatus of any one of claims 2-9, characterized in that, The method comprises the following steps: S1. Device debugging: install the detection probe (102) on the mounting seat (6), adjust the position of the contact ball (607) through the adjusting screw (602) of the L-shaped adjusting support (601), make the detection probe (102) parallel to the detection surface of the pressure-bearing equipment, control the adjusting accuracy by the scale line of the limiting guide (606), and the error is less than or equal to 0.5 mm; S2. Detection preparation: hold the handle (3), attach the frame plate (2) to the surface of the pressure-bearing equipment through the anti-skid rubber pad (202), control the button (301) to start the driving motor (5), drive the gear (502) to mesh transmission along the tooth plate (501), make the bearing plate (4) slide along the guide groove (204), lower the sliding resistance of the resistance-reducing ball (402), and make the exhaust fan (404) operate synchronously, and the wind speed is greater than or equal to 2 m / s, so as to dissipate heat for the detection area; S3. Signal acquisition: control the bearing plate (4) to move back and forth by the forward and reverse rotation of the driving motor (5), the moving speed is 0.5-2 m / min, the detection probe (102) moves with the mounting seat (6), the spring (603) and the damping rubber block (605) buffer vibration, the distance between the detection probe (102) and the surface of the pressure-bearing equipment is stable, the distance fluctuation is less than or equal to 0.2 mm, and the pulsed eddy current detector main body (1) collects eddy current signals; S4. Data analysis: after detection is completed, the pulsed eddy current detector main body (1) processes signals, identifies cracks through a crack characteristic algorithm, and generates a detection report containing crack position, depth and length; S5. Device storage: turn off the driving motor (5) and the exhaust fan (404), disassemble the detection probe (102), reset the bearing plate (4) to one end of the frame plate (2), charge the device with the remaining power of the storage battery (203), the charging time is 2-4 h, and the device is properly stored after charging is completed. In the step S3, when the detection probe (102) encounters a protrusion on the surface of the pressure-bearing equipment, the mounting seat (6) slides along the guide rod (604) to compress the spring (603), the contact ball (607) rolls in contact with the protrusion, the distance fluctuation of the detection probe (102) is less than or equal to 0.2 mm, the damping rubber block (605) absorbs vibration energy, and vibration does not affect detection data.

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