Cable-free hole-forming and groove-forming detection device and method of integrated depth counter

Abstract

The invention provides a cable-free hole-forming and groove-forming detection device and method integrated with a depth counter. The device comprises a winch (1), an orifice frame (2), a display terminal (3), a steel wire rope (4) and a probe (5), a waterproof depth counter (52) is integrated at the top of the probe (5), real-time depth data are directly obtained through mechanical linkage of a roller and a steel wire rope (4), ultrasonic transducers (54 and 55) collect hole wall reflection signals, and a data processing module associates the depth and the signals and stores the depth and the signals in the probe; after detection is completed, the detection result is transmitted to the display terminal (3) in a wireless / wired manner for imaging. According to the invention, the problems of high cable failure rate and heavy equipment of a traditional cable device and increased system complexity and tedious detection process caused by dependence of cable-free devices and methods in some schemes on time synchronization are solved, and the method has the advantages of light equipment, high integration level, high depth measurement precision (+ / -1mm), low equipment failure rate, simple and convenient operation and the like; the device is suitable for detection of hole forming and groove forming of various projects.

Description

Technical Field

[0001] This invention relates to the field of civil engineering testing technology, particularly ultrasonic drilling and trenching quality testing technology, specifically to a wireless drilling and trenching testing device and method integrating a depth counter. This invention is applicable to the quality testing of drilled piles, diaphragm walls, and other drilled and trenched structures in railway, highway, urban rail transit, power, bridge, reservoir, and civil building projects. Background Technology

[0002] In the foundation construction of large-scale projects, the quality of hole and trench formation (such as hole diameter / groove width, verticality, and hole wall characteristics) directly affects the load-bearing capacity and safety of the foundation structure. Therefore, rigorous testing is essential to ensure that all parameters meet design requirements. Existing ultrasonic hole and trench testing devices mostly use cables for data transmission and power supply. However, due to the harsh construction conditions on site, cables are prone to tangling, aging, wear, and breakage, resulting in high equipment failure rates, high maintenance costs, and complex operation.

[0003] To address the reliance on cables, some improved solutions (publication number CN116357302A) employ wireless communication between the probe and the winch to achieve time synchronization, thereby correlating depth data with ultrasonic data. However, the following drawbacks still exist:

[0004] (1) The testing process requires a complex synchronization mechanism (such as time calibration), and the process is cumbersome: the winch control unit needs to communicate and synchronize with the probe before testing; the winch needs to keep timed during testing; and the data needs to be matched through time synchronization after testing. The system is highly complex and has a high failure rate, which prolongs the on-site testing time and increases the risk of borehole collapse.

[0005] (2) Due to the resistance of mud with different specific gravities in the borehole and the fluctuation of winch motor speed, the probe descent speed is unstable, resulting in uneven depth intervals corresponding to ultrasonic data, which affects the accuracy of subsequent data analysis.

[0006] (3) The dedicated communication module between the probe and the winding workshop increases equipment cost and energy consumption, and requires additional maintenance.

[0007] (4) The probe function is heavily dependent on the winch's time synchronization function, and the two must work together. If the winch loses power or communication fails during testing, time synchronization will fail, and the entire testing process cannot be carried out.

[0008] Therefore, there is an urgent need for a hole and groove quality inspection solution with a simpler structure, higher integration, no need for real-time communication or time synchronization, and higher reliability, in order to further reduce the system failure rate, improve inspection efficiency, and enhance operational convenience.

[0009] To address the aforementioned technical problems, this invention proposes a wireless detection device and method that integrates a depth counter into the probe. The probe depth is directly obtained in real time through the depth counter, completely eliminating the reliance on time synchronization mechanisms, while retaining the inherent advantages of wireless connection, significantly improving detection accuracy and equipment reliability. (a) Purpose of the invention

[0010] This invention aims to provide a cableless hole-forming and grooving detection device and method with an integrated depth counter, overcoming the problems of bulky equipment, complex structure, and high failure rate caused by the reliance on cables or real-time communication in existing ultrasonic hole-forming and grooving detection equipment, as well as the cumbersome detection process and limited accuracy of some cableless solutions that rely on time synchronization to bind depth and data. This invention directly acquires depth information by integrating a waterproof depth counter into the probe itself, enabling independent data acquisition, storage, and subsequent export, thereby simplifying the system structure and improving reliability and detection accuracy. (II) Technical Solution

[0011] To achieve the above objectives, this invention provides a wireless hole-forming and grooving inspection device with an integrated depth counter, comprising a winch, a hole frame, a wire rope, a control processing and display terminal, and an integrated inspection probe. Wherein: Winch: Located next to the orifice frame, it is used to raise and lower the wire rope. Its built-in drive mechanism can control the lowering and retraction speed of the wire rope. Orifice holder: Fixed to the orifice or slot, it is equipped with a guide mechanism to limit the movement trajectory of the wire rope and ensure that the detection probe moves up and down in the vertical direction; Wire rope: One end is connected to the winch, and the other end is connected to the probe after passing around the orifice frame. It is used to suspend the probe and control its raising and lowering in the hole or slot. Control, processing, and display terminal: A terminal device with data receiving, processing, and display functions, which communicates with the integrated detection probe wirelessly or via wired means to receive, store, process, and display detection data; Integrated detection probe: As the core component of the device, its outer shell is a waterproof and sealed structure; the top of the probe integrates a depth counter, and the interior is equipped with an ultrasonic transmitting transducer, an ultrasonic receiving transducer, a signal conditioning component, a data processing module, a communication component, a memory, and a power supply module.

[0012] The specific structure of the integrated detection probe includes: Outer shell: Made of high-strength waterproof material, with an overall sealing rating of not less than IP68 to adapt to underwater high pressure and mud environments; Depth counter: Installed on top of the probe, it is mechanically linked to the wire rope to detect the displacement of the wire rope and calculate the real-time depth of the probe. Its core is a pulse encoder. When the wire rope moves, it drives the roller to rotate, which in turn drives the encoder to rotate. The encoder outputs a pulse signal for each preset angle of rotation. The data processing module calculates the depth based on the cumulative number of pulses and the circumference of the roller (depth = number of pulses × roller circumference / number of pulses per revolution). Guide pulleys: Located on both sides of the depth counter at the top of the probe, they are in contact with the wire rope and are used to limit the movement trajectory and direction of the wire rope, ensuring that the detection probe does not rotate and ensuring the accurate detection of the wire rope displacement by the depth counter; Ultrasonic transmitting transducer and receiving transducer: symmetrically distributed and embedded in the side wall of the probe; the transmitting transducer is used to transmit ultrasonic signals, and the receiving transducer is used to receive the reflected signals from the hole wall or slot wall to obtain hole diameter / slot width and hole wall characteristic information. Power button: Located on the surface of the probe housing, it features a waterproof design and is used to control the probe's startup and shutdown. Data processing module: Connected to depth counter, ultrasonic transducer, memory and communication components, it is used to synchronously process depth data and ultrasonic signals, and store the two in memory after association; Communication components: including a wireless communication module that uses wireless transmission protocols such as WiFi, Bluetooth or LoRa to wirelessly transmit data in the memory to the display terminal after detection is completed; Memory: Used for temporary storage of depth data, ultrasonic signals, and equipment status information; Power module: Uses a rechargeable lithium battery to power all components of the probe, supporting continuous working time of not less than 10 hours. (III) Working Principle

[0013] The working principle of the device of the present invention is as follows: 1. Preparation before testing: Fix the orifice frame to the orifice or slot, connect the winch to the integrated testing probe via a wire rope, and ensure that the guide pulley on the probe is aligned with the guide mechanism of the orifice frame; start the probe by pressing the power button, establish a wireless connection between the control processing display terminal and the probe, and complete the equipment self-test; after the self-test is completed, set the sampling parameters and enter the testing mode.

[0014] 2. Detection Process: The winch lowers the wire rope, and the probe descends vertically along the hole or groove. The guide pulley moves with the wire rope, which simultaneously drives the depth counter's roller to rotate. The encoder rotates accordingly and outputs pulse signals. The data processing module converts the pulse signals into real-time depth values. Simultaneously, the ultrasonic transducer emits ultrasonic signals at set depth intervals, and the receiver collects reflected signals. The signal conditioning component amplifies, filters, and performs analog-to-digital conversion on the reflected signals, which are then associated with the real-time depth values ​​and stored in memory by the data processing module. When the probe touches the bottom, the wire rope slackens, the roller stops rotating, and the depth counter outputs no new pulse signals. When the depth value remains unchanged for a certain period, the system determines that the probe has touched the bottom, stops ultrasonic signal acquisition, and completes data storage.

[0015] 3. Data transmission and processing: After the detection is completed, the probe is raised to the aperture; the depth-signal data in the memory is transmitted to the control processing and display terminal through the communication component; the terminal performs imaging processing on the data and generates detection results such as aperture-depth curve and verticality curve. Innovation

[0016] The innovation of this invention compared with the prior art lies in: The depth counter is directly integrated into the probe: the depth is calculated directly in real time through a mechanical depth counter on the top of the probe, eliminating the need for a time synchronization mechanism between the probe and the winch, simplifying the system logic and on-site inspection process, and reducing the system failure rate.

[0017] Completely cable-free connection: The cable between the winch and the probe is completely eliminated, avoiding problems such as cable tangling, aging, and damage, and reducing equipment failure rate and maintenance costs.

[0018] Significantly improved detection accuracy: The depth counter directly measures the displacement of the wire rope, eliminating time synchronization errors and enabling the matching accuracy between depth data and ultrasonic signals to reach ±1mm.

[0019] Independent data storage and dual-mode export: Detection data is independently stored in the probe's memory, providing strong anti-interference capabilities; it supports both wireless and wired data export modes, offering flexible operation and strong adaptability.

[0020] The system has strong redundancy: the winch only provides traction power, and even if it fails or loses power, it can still be manually operated to complete the detection without affecting the integrity of the data acquisition. Detailed Implementation (I) Assembly and Debugging of the Device

[0021] 1. Component selection: Depth counter: An incremental rotary encoder (500 pulses / revolution) is used, with a roller of 50mm diameter, and the depth measurement accuracy is ≤±1mm; Roller: Concave structure, surface covered with high-friction materials such as rubber or silicone, connected to the encoder input shaft through deep groove ball bearing to ensure smooth rotation without shaking; Ultrasonic transducer: center frequency 80kHz±5kHz, emission angle 30°, detection range 500-6000mm; Wireless communication module: adopts WiFi 6 module, transmission rate ≥150Mbps, communication distance ≥50m; Power module: Uses a 12V / 5000mAh lithium battery, supporting continuous system operation for ≥10 hours.

[0022] 2. Assembly of integrated detection probe: The depth counter is fixed to the top of the probe housing, and its input shaft and roller shaft can be connected by a rotary seal structure or magnetic coupling. The ultrasonic transmitting / receiving transducers are symmetrically embedded in the side wall of the probe housing and sealed with waterproof sealing rings; The data processing module, memory, and wireless communication module are integrated into the internal PCB board and connected to each component via waterproof connectors. The power button is a waterproof push-button switch embedded in the casing.

[0023] 3. System debugging: Depth calibration: The probe is raised and lowered in a vertical pipe at a known depth, and the depth counter output value is compared with the actual depth. A linear fitting algorithm is used for calibration. Signal testing: Test ultrasonic signals in a simulated hole-groove environment to verify the detection accuracy and reliability of the system.

[0024] (II) Example of Testing Process Taking the testing of bored piles as an example: Site setup: Install a borehole frame at the borehole opening and fix the winch 1.5m to its side; connect the probe to the wire rope via the guide wheel of the borehole frame to ensure alignment.

[0025] Initiating Connection: Press the probe power button to start the device; the control processing and display terminal connects to the probe via WiFi to check the device status and set parameters.

[0026] Lowering detection: The winch lowers the wire rope at a speed of 0.5 m / s; the depth counter records the depth in real time, the ultrasonic transducer collects a signal every 0.1 m, and the data processing module associates and stores the depth-signal data in real time.

[0027] Recovery and transmission: The probe automatically stops collecting data after touching the bottom; the winch recovers the probe to the orifice, and the terminal reads the data from the memory via WiFi.

[0028] Data processing: The terminal performs imaging processing on the data, generates aperture-depth curves and verticality analysis results, and completes the detection.

[0029] It is worth noting that there is no data communication between the probe and the winch during the entire testing process; the winch only provides mechanical traction. Even if the winch is powered off, the wire rope can be wound and unwound manually without affecting the acquisition and storage of testing data.

[0030] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the technical solutions of the embodiments of the present invention. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the overall structure of the wireless hole-forming and trenching detection device with integrated depth counter of the present invention.

[0032] In the diagram: 1-Windlock, 2-Orifice frame, 3-Control and display terminal, 4-Wire rope, 5-Integrated detection probe.

[0033] Figure 2 This is a schematic diagram of the integrated detection probe. In the diagram: 51-Guide pulley, 52-Depth counter, 53-Power button, 54-Transmitting transducer, 55-Receiving transducer, 56-Housing casing. Beneficial effects

[0034] Compared with the prior art, the present invention has the following significant advantages: 1. The communication link between the probe and the winch has been completely eliminated, eliminating the need for complex synchronization mechanisms and dedicated communication modules, simplifying the equipment structure, and reducing costs and failure rates.

[0035] 2. The waterproof depth counter integrated into the probe directly acquires depth information, avoiding time synchronization errors and improving the correlation accuracy between depth data and ultrasonic signals to ±1mm.

[0036] 3. Data is stored independently in the probe's memory, and the detection process is not affected by electromagnetic interference on site, resulting in higher data integrity and reliability.

[0037] 4. Supports both wireless and wired data export, offering flexible operation and adaptability to various complex construction site environments.

[0038] 5. The equipment has no cable connection, which fundamentally avoids problems such as cable tangling, aging, and damage, reduces workload, and improves testing efficiency and equipment applicability.

Claims

1. A wireless hole-forming and grooving detection device with an integrated depth counter, comprising: Winches, wire ropes, orifice frames, integrated detection probes, etc.; characterized in that: The integrated detection probe integrates a waterproof depth counter, which is in close contact with the steel wire rope through a mechanical linkage mechanism to directly obtain the probe depth in real time. The integrated detection probe has a built-in memory for directly associating and storing the depth information output by the waterproof depth counter with the characteristic signals acquired by the ultrasonic waves, without relying on external devices for time synchronization.

2. The apparatus according to claim 1, characterized in that, The integrated detection probe further includes: a lithium battery, an ultrasonic transmitting transducer, an ultrasonic receiving transducer, a signal conditioning component, a data processing module, and a communication component; the lithium battery powers the entire integrated detection probe; the ultrasonic transmitting and receiving transducers acquire quality characteristic signals of the formed holes or grooves; the signal conditioning component amplifies, filters, and performs analog-to-digital conversion on the characteristic signals; the data processing module correlates the processed characteristic signals with the depth information acquired by the waterproof depth counter; the memory stores the correlated ultrasonic characteristic signals and depth information; and the communication component uploads the correlated data in the memory to the control processing and display terminal wirelessly or via wired means after detection is completed.

3. The apparatus according to claim 1 or 2, characterized in that, The waterproof depth counter includes a waterproof housing, an encoder, and a roller; the waterproof housing has a protection rating of not less than IP68; the roller is in contact with a steel wire rope, and the steel wire rope slides as the probe rises and falls, thereby driving the roller to rotate and causing the encoder to rotate, outputting an electrical signal corresponding to the depth; this electrical signal is transmitted to the data processing module after analog-to-digital conversion, and the probe depth is directly calculated through displacement changes.

4. The apparatus according to claim 3, characterized in that, The encoder is an incremental encoder that outputs pulse signals based on the rotation of the roller; the data processing module calculates the probe depth based on the number of pulses and the preset circumference of the roller.

5. The apparatus according to claim 3, characterized in that, The roller has a concave structure and its surface is provided with anti-slip texture or covered with a high friction coefficient material to ensure that there is no relative slippage between the wire rope and the roller.

6. The apparatus according to claim 2, characterized in that, The communication component includes a wireless communication module, which is one of a WiFi module, Bluetooth module, ZigBee module, or Narrowband Internet of Things (NB-IoT) module, used to realize wireless data transmission between the integrated detection probe and the display terminal after the detection is completed.

7. The apparatus according to claim 2 or 6, characterized in that, The communication component also includes a wired interface, which is one of a USB interface, a Type-C interface, or an RS485 interface, for exporting associated data from the memory via a wired method in the event of a wireless transmission failure.

8. The apparatus according to claim 2, characterized in that, The memory is a flash memory or an erasable programmable read-only memory (EEPROM) used to store the driver program and ultrasonic data and depth data stored in real time during the detection process.

9. A method for detecting the quality of cableless hole forming and trenching based on an integrated depth counter according to any one of claims 1-8, characterized in that, Includes the following steps: S1: Before testing, confirm the communication connection status between the integrated testing probe and the control processing display terminal, and set the parameters; after setting, start the integrated testing probe and its top waterproof depth counter to enter the testing mode; S2: The winch controls the raising and lowering of the wire rope, driving the integrated detection probe into the hole or groove; the waterproof depth counter collects and calculates the probe depth information in real time, while the ultrasonic transmitting / receiving transducer synchronously collects the ultrasonic characteristic signals of the hole or groove wall; the data processing module associates the characteristic signals with the real-time depth information and stores them in the memory. S3: After the detection is completed, the integrated detection probe is removed from the mud, and the associated ultrasonic feature signal and depth information in the memory are uploaded to the control processing and display terminal through the communication component; S4: The control processing and display terminal performs imaging processing on the received associated data to generate hole or groove quality detection results.

Images