Medium-and-large-diameter pipeline welding joint phased array, TOFD and magnetic powder integrated detection system and detection method

Abstract

The invention discloses a phased array, TOFD and magnetic powder integrated detection system and method for medium and large diameter pipeline welded joints, the detection system comprises a control system, a liquid storage and supply system and a scanning system, the control system is connected with the liquid storage and supply system, the control system is connected with the scanning system, and the scanning system is connected with the control system. The liquid storage and supply system is connected with the scanning system through a flexible water pipeline and a flexible magnetic suspension pipeline; the liquid storage and supply system comprises a magnetic suspension tank and a water tank which are respectively used for storing magnetic suspension and water; the scanning system is a data acquisition center, is provided with a phased array probe, a TOFD probe, an electromagnetic yoke and a video sensor in a centralized mode, operates in a sub-control mode, is driven by a magnetic attraction wheel driving mechanism to achieve automatic scanning of a welding joint, and transmits detection data information to the control system. The device is compact in structure, convenient for later maintenance and low in manufacturing cost; according to the invention, the parameter control is accurate, the detection data can be analyzed in real time, the data interpretation is convenient, the detection precision is high, the detection speed is fast, and safety and reliability are realized.

Description

TECHNICAL FIELD

[0001] The present application relates to a kind of middle large diameter pipeline welding joint phased array, TOFD, magnetic powder integrated detection system and detection method, especially suitable for G115 New heat-resistant steel large diameter thick-walled pipeline welding joint Nondestructive testing, belongs to the technical field of industrial detection equipment manufacturing. BACKGROUND

[0002] Coal power as the "ballast" and "stabilizer" of new power system, plays an important role in ensuring energy security, promoting economic and social development, etc. With the transformation of global energy structure and the improvement of environmental protection requirements, developing advanced coal-fired power generation technology, improving the efficiency and environmental performance of coal-fired power units, and reducing pollutant emissions are the only way to achieve clean development of coal power. At present, 35MPa / 615℃ / 630℃ / 630℃ parameter million ultra-supercritical coal-fired power generating units have realized the manufacturing of key high-temperature new materials, and the successful development of new G115 heat-resistant steel has helped to break through 50% of the thermal efficiency of power generation. For P92 and G115 steel pipes with the same inner diameter, if both are applied at a steam temperature of 650℃, the outer diameter of G115 steel pipe is about 78% of P92 steel, and the weight is about 47.4% of P92 steel, which means that under the same design conditions, the use of G115 steel can reduce material consumption and equipment weight, thereby improving power generation efficiency and operating economy. The successful application of this steel grade has an important leading and demonstration role in the independent innovation of thermal power technology and the efficient and clean use of coal.

[0003] In view of the application of G115 new heat-resistant steel to high-parameter and large-capacity units, and in combination with its material properties, higher and stricter detection requirements are currently proposed for the field installation of G115 new heat-resistant steel pipe welding openings. It is usually required to conduct phased array detection and TOFD detection on the welding joints of middle large diameter thick-walled pipes, and magnetic powder detection is required for surface and near-surface defects, and full-focus imaging detection is required for recordable defects. The conventional nondestructive testing method usually uses corresponding instruments to implement independently, and after one detection method is completed, the next detection task is performed, which has low detection efficiency. In addition, the conventional detection method usually uses manual detection, the probe pressure is uneven, causing the detection sensitivity to change greatly during scanning, and the detection accuracy is relatively low, and the repeatability of manual scanning detection data results is poor. SUMMARY

[0004] The technical problem to be solved by the present application is to provide a G115 material middle large diameter pipeline welding joint phased array, TOFD, magnetic powder integrated detection system, which realizes synchronous automatic detection of multiple detection methods for G115 material pipeline welding joints, and greatly improves the detection efficiency and quality.

[0005] To address this technical problem, this invention provides an integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines. The system includes a control system, a liquid storage and supply system, and a scanning system. The control system is connected to the liquid storage and supply system via a signal line, and the control system is connected to the scanning system via a control cable. The liquid storage and supply system and the scanning system are connected via flexible water pipes and flexible magnetic suspension pipes. The control system controls the start and stop of the liquid storage and supply system and collects and processes the detection data transmitted by the scanning system. The liquid storage and supply system includes a magnetic suspension tank and a water tank, used to store magnetic suspension and water respectively, and pumps these two liquids to the scanning system. The scanning system serves as a data acquisition center, centrally housing a phased array probe, a TOFD probe, an electromagnetic yoke, and a video sensor. Operating under separate control, it automatically scans the welded joints under the drive of a magnetic chuck drive mechanism and transmits the detection data to the control system.

[0006] The control system includes a cuboid housing. The front panel of the housing is equipped with a knob, a display screen, and multiple buttons. A control cable interface is located on the upper side of the housing for data transmission with the scanning system, and a signal line interface is located on the lower side for connecting signal lines to achieve connection with the liquid storage and supply system.

[0007] The liquid storage and supply system includes a magnetic suspension tank, a magnetic suspension tank cover, a water tank cover, a water tank, a magnetic suspension pump, a water pump, and conduits. The magnetic suspension tank and the water tank are combined into one unit, with the magnetic suspension tank located above the water tank and having a partition in the middle. The magnetic suspension tank has a cylindrical magnetic suspension tank cover on top. The magnetic suspension pump is located inside the magnetic suspension tank and pumps magnetic suspension to the scanning system through the conduits during startup. The water tank has a cylindrical water tank cover on top. The water pump is located inside the water tank and pumps water to the scanning system through the conduits during startup, providing coupling agent for the phased array and TOFD scanning modules.

[0008] The scanning system includes a scanning host, a drive mechanism, a probe holding mechanism, a magnetic particle detection mechanism, and a front-end mechanism. The scanning host is a rectangular frame with rectangular slide rail cavities on both sides. Four drive mechanisms are arranged horizontally in pairs inside the rectangular slide rail cavities on both sides of the scanning host. The probe holding mechanism is installed on a rectangular cavity guide rail in the middle of the scanning host and can move left and right on the rail. The number of probe holding mechanisms can be increased or decreased according to the detection needs. The magnetic particle detection mechanism is a cross-shaped electromagnetic yoke located in the middle of the rear of the scanning host. The front-end mechanism is located in the middle of the front of the scanning host and provides image recognition for the scanning host and coupling agent for the probe.

[0009] The scanning host includes a frame, a push-button switch, a touch screen, a charging port, a phased array probe interface, a TOFD probe interface, a control cable interface, a water pipe interface, and a magnetic suspension interface. The frame is mainly composed of two rectangular housings on both sides and a central rectangular guide rail. Five guide rails are located in the middle, allowing for the simultaneous installation of probe holding mechanisms. This meets the multi-probe detection requirements of phased array and TOFD technologies for thick-walled pipes. Alternatively, a probe holding mechanism can be added in the middle to install a flexible phased array probe for fully focused imaging detection of the inspected workpiece. The upper left side of the scanning host housing has a circular push-button switch, a rectangular touch screen, and a circular charging port. A toggle switch controls the start and stop of the scanning host; the touch screen controls the input of scanning host parameters and displays status data; the charging port connects to an external power adapter to power the internal lithium battery of the scanning host; the upper right side of the scanning host housing has six cuboid phased array probe interfaces and six circular TOFD probe interfaces, which are connected to the corresponding probes to collect detection data; the rear right side of the scanning host housing has three cylindrical interfaces, the upper interface is a control cable interface 2 for connecting the control cable, the lower interface is a water pipe interface for connecting the water tank of the storage and supply system, and the lower part is a magnetic suspension interface for connecting the magnetic suspension tank 21 of the storage and supply system to receive the pumped magnetic suspension.

[0010] The driving mechanism includes a magnetic wheel, a drive motor, and a hydraulic rod. The magnetic wheel is connected to the drive motor via a rotating shaft and can rotate smoothly under the drive of the drive motor. The drive motor can move horizontally along the slide rail cavity under the push of the hydraulic rod, adjusting the spacing between the drive motors on the same side, thereby adjusting the wheel spacing of the magnetic wheel to adapt to different curvature detection requirements. The magnetic wheel is equipped with a powerful magnet inside, which can firmly attach the scanning system to the outer wall of the inspected pipe to complete the non-destructive testing of the pipe weld joints.

[0011] The probe holding mechanism is a detachable, independent module. The upper part has a housing, which includes two push-button switches and two charging ports. The lower part of the housing has four rollers, arranged in pairs on both sides of the lower housing. Two spring support rods are symmetrically positioned below each roller, and a rotating rod is located above each spring support rod. The probe holding mechanism is mounted on a track on the scanning host frame via the rotating rod. The lower parts of the spring support rods are connected by a connecting rod that passes through a slide rail on the upper part of the U-shaped probe holder, connecting the probe holder to the spring support rods. The spring support rods contain built-in springs and can freely extend and retract. The spring support rod applies a clamping force to the lower probe holder via a connecting rod, achieving a stable contact between the probe and the surface of the inspected pipe. The upper part of the probe holder is machined with an arc-shaped slide, through which the connecting rod passes and can slide relative to it, allowing the probe holder to be freely adjusted in angle. This enables the lower surface of the probe to be rotated to meet the needs of phased array and TOFD inspection of pipes with different curvatures. Two screws are symmetrically arranged at the lower part of the probe holder, allowing the probe to be clamped and disassembled by screwing in and out. The probe clamping mechanism is wirelessly connected to the scanning host via a Bluetooth module for data transmission and communication.

[0012] The magnetic particle inspection mechanism is located at the rear of the scanning host and includes a support arm, a ball joint, a camera, an electromagnetic yoke, pulleys, and a magnetic suspension nozzle. The support arm suspends the electromagnetic yoke via the ball joint. The upper part of the ball joint is embedded inside the support arm and can rotate freely. The lower part of the ball joint is connected to the cross-shaped electromagnetic yoke. By adjusting the ball joint, the four legs of the electromagnetic yoke can be made to fit against the surface of the inspected pipe, thereby enabling magnetic particle inspection of welded joints of pipes with different curvatures. Four pulleys are installed at the bottom of each leg of the electromagnetic yoke. The pulleys can rotate freely along the central axis, reducing the surface friction between the electromagnetic yoke and the inspected pipe. A camera and a magnetic suspension nozzle are respectively installed on both sides of the electromagnetic yoke. The camera is used to record magnetic trace images in real time and can automatically identify defects and issue defect alarm commands to the control system. The control system issues audio and video alarms. The magnetic suspension nozzle is symmetrically arranged with the camera and sprays magnetic suspension onto the pipe surface in a timely manner according to the instructions of the control system.

[0013] The front-end mechanism includes a monitor and nozzles. The monitor is located at the lower front end of the scanning host frame, and the nozzles are symmetrically arranged on both sides of the scanning host frame. The monitor has a built-in high-definition camera and laser locator for recording the on-site inspection, weld identification, and assisting the scanning system in automatic trajectory correction. The nozzles are used for spraying coupling agent to provide stable coupling for the phased array and TOFD detection probes.

[0014] This invention also provides a detection method using the aforementioned integrated phased array, TOFD, and magnetic particle testing system for welded joints of medium and large diameter pipelines, comprising the following steps: According to the requirements of the testing process document, select phased array probe, full-focus probe, or TOFD probe. Select the corresponding number of probe holding mechanisms for the required number of probes. Place the probes one by one in the lower center position of the probe holding mechanism, tighten the screws on both sides, and combine the probes with the probe holding mechanisms to complete the assembly. Place the assembled probe holding mechanism one by one on the central track of the scanning host frame, with pairs of probes placed in the same track. Rotate the lower rotating rod of the probe holding mechanism to fix the probe holding mechanism on the central track of the scanning host frame. Insert the probe connectors one by one into the corresponding probe interfaces on the upper part of the right module of the scanning host frame: insert the phased array probes one by one into the phased array probe interfaces, and insert the TOFD probes one by one into the TOFD probe interfaces. Connect the control system and the scanning system using control cables; connect the liquid storage and supply system and the scanning system one by one using plastic hoses, with water pipes and magnetic suspension pipes connected accordingly; connect the control system and the liquid storage and supply system using signal lines. Once all systems are connected, press the control system knob to start the control system; press the first button switch on the scanning host to start the control system; press the second button switch on the upper part of the probe holding mechanism one by one to start the probe holding mechanism one by one. The probe holding mechanism connects to the scanning host via Bluetooth module. The control system and the scanning host automatically enter the self-test program, initialize the system, and each module automatically debugs and tests. Operate the control system buttons according to the requirements of the testing process document to set the testing parameters of the control system, and operate the touch screen on the top of the scanning host to set the scanning parameters of the scanning system. Place the scanning system on the surface of the welded joint of the pipeline to be inspected. The magnetic wheels adhere to the pipeline surface. Adjust the extension and retraction of the hydraulic rod and the spacing of the magnetic wheels to make the scanning host stably adhere to the pipeline surface. Click the detection start button of the control system. The storage and supply system pumps water and magnetic suspension liquid simultaneously. Water is sprayed onto the front of the probe through the nozzle, and magnetic suspension liquid is sprayed onto the weld position at the center of the cross electromagnetic yoke through the magnetic suspension liquid nozzle. The magnetic wheels start to rotate under the drive of the drive motor, and the scanning system moves stably. The scanning system moves smoothly across the surface of the welded joint of the inspected pipeline, driving the probes (phased array probe, TOFD probe, full-focus probe, and electromagnetic yoke) to move smoothly as well. The monitor tracks the weld trajectory and the detection status of the phased array, TOFD, and full-focus probes in real time. The camera monitors the working status of the electromagnetic yoke in real time, automatically recording magnetic particle inspection images and identifying defect magnetic traces. All inspection data is transmitted to the control system via control cables. Inspection data, images, and results are displayed on the screen in real time for analysis and recording. Inspectors analyze and evaluate the inspection data using software until the inspection of the welded joint is completed, at which point the inspection task ends.

[0015] Beneficial effects: The probe holding mechanism of this invention features a modular design, with each module easily assembled and disassembled. The number of modules can be flexibly adjusted according to different workpiece specifications and testing processes, resulting in high adaptability and ease of maintenance. Manufacturing and operating costs are low. The invention offers precise parameter control, real-time analysis of detection data, intuitive display, convenient data interpretation, and high detection accuracy. It automates workpiece phased array, TOFD, magnetic particle, and full-focus imaging detection without manual intervention. It can autonomously identify workpiece changes and adjust parameters automatically, resulting in high detection sensitivity and repeatability. This invention is applicable to plate and pipe butt welds, and is suitable for welded joints in various industries and large steel structures. It boasts good process applicability, strong versatility, and high economic benefits. This system features a modular design and high integration, enabling rapid and efficient simultaneous phased array, TOFD, and magnetic particle inspection of welded joints. It displays the overall quality status of the welded joints in real time, offering fast inspection speed and high accuracy, making it an intelligent inspection system. This invention can simultaneously perform phased array, TOFD, magnetic particle, and full-focus imaging inspections of pipeline welded joints, achieving high inspection efficiency and low cost. The invention has a compact structure, with each module powered by batteries, ensuring no interference between them. It is easy to carry, safe, reliable, and widely applicable, especially suitable for installation projects at high altitudes or in complex construction environments. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the overall structure of the control system of the present invention; Figure 3 This is a schematic diagram of the liquid storage and supply system of the present invention; Figure 4 This is a schematic diagram of the internal structure of the liquid storage and supply system of the present invention; Figure 5 This is a schematic diagram of the scanning system of the present invention; Figure 6 This is a schematic diagram of the scanning host of the present invention; Figure 7 This is a schematic diagram of the drive mechanism of the present invention; Figure 8 This is a schematic diagram of the probe holding mechanism of the present invention; Figure 9 This is a schematic diagram illustrating the application of the probe holding mechanism of the present invention; Figure 10 This is a schematic diagram of the magnetic particle detection mechanism of the present invention; Figure 11 This is a schematic diagram of the structure of the pre-processor of the present invention; Figure 12 This is a schematic diagram illustrating the field application of the present invention.

[0017] In the diagram: 1. Control system; 2. Liquid storage and supply system; 3. Scanning system; 11. Housing; 12. Knob; 13. Button; 14. Display screen; 15. Control cable interface 1; 16. Signal line interface; 21. Magnetic suspension tank; 22. Magnetic suspension tank cover; 23. Water tank cover; 24. Water tank; 25. Magnetic suspension pump; 26. Water pump; 27. Conduit; 31. Scanning host; 32. Drive mechanism; 33. Probe holding mechanism; 34. Magnetic particle detection mechanism; 35. Front-end mechanism; 311. Frame; 312. Push-button switch 1; 313. Touch screen; 314. Charging port 1; 315. Phased array probe interface; 316. TOFD probe interface; 317. Control cable interface 2; 318. Water pipe interface; 319. Magnetic suspension interface; 321. Magnetic wheel; 322. Drive motor; 323. Hydraulic rod; 331. Push-button switch 2; 332. Charging port 2; 333. Roller; 334. Rotating rod; 335. Spring support rod; 336. Connecting rod; 337. Probe holder; 338. Screw; 341. Support arm; 342. Ball joint; 343. Camera; 344. Electromagnetic yoke; 345. Pulley; 346. Magnetic suspension nozzle; 351. Monitor; 352. Nozzle; A. Probe; B. Pipe welding joint. Detailed Implementation

[0018] The probe A described in this application includes three types: phased array probe, TOFD probe, and full-focus probe. The phased array probe is a major category of probes, and the full-focus probe is a type of phased array probe. The full-focus probe is a high-performance phased array probe, which is made to achieve full-focus detection effect. The commonly used full-focus probe has the same appearance and interface as the phased array probe, only the internal chip performance and arrangement are different.

[0019] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0020] like Figures 1-12As shown, this invention provides an integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines. The system includes a control system 1, a liquid storage and supply system 2, and a scanning system 3. The control system 1 is connected to the liquid storage and supply system 2 via a signal line, and the control system 1 is connected to the scanning system 3 via a control cable. The liquid storage and supply system 2 and the scanning system 3 are connected via a flexible water pipe and a flexible magnetic suspension pipe. The control system 1 controls the start and stop of the liquid storage and supply system 2, collects and processes the detection data transmitted by the scanning system 3, and displays relevant detection data, images, and detection results in real time. The liquid storage and supply system 2 includes a magnetic suspension tank 21 and a water tank 24, used to store magnetic suspension and water respectively, and pumps these two liquids to the scanning system 3. The scanning system 3 is a data acquisition center, centrally equipped with a phased array probe, a TOFD probe, an electromagnetic yoke, and a video sensor. It operates under separate control and, driven by a magnetic chuck drive mechanism, automatically scans the welded joints and transmits the detection data to the control system 1.

[0021] The control system 1 includes a cuboid housing 11. The front panel of the housing 11 is equipped with a circular knob 12, a cuboid display screen 14, and multiple square control buttons 13. The knob 12 and buttons 13 are used for setting detection parameters and debugging the instrument, while the display screen 14 is used for outputting data and detection images. A control cable interface 15 is provided on the upper side of the housing 11 for connecting the control cable to realize data transmission with the scanning system 3. A signal line interface 16 is provided on the lower side for connecting the signal line to realize the connection with the storage and supply liquid system 2 and controlling the storage and supply liquid system 2 to pump water and magnetic suspension liquid to the scanning system 3.

[0022] The liquid storage and supply system 2 includes a magnetic suspension tank 21, a magnetic suspension tank cover 22, a water tank cover 23, a water tank 24, a magnetic suspension pump 25, a water pump 26, and a conduit 27. The magnetic suspension tank 21 and the water tank 24 are combined into one unit. The magnetic suspension tank 21 is located above the water tank 24 and has a partition in the middle, dividing it into upper and lower chambers. The magnetic suspension tank 21 has a cylindrical magnetic suspension tank cover 22 on its upper part, through which the magnetic suspension is added. It is kept closed during normal use to prevent the magnetic suspension from evaporating. The magnetic suspension pump 25 is installed inside the magnetic suspension tank 21, which pumps the magnetic suspension to the scanning system 3 through the conduit 27 when started. The water tank 24 has a cylindrical water tank cover 23 on its upper part, through which water is added. It is kept closed during normal use to prevent water from evaporating. The water pump 26 is installed inside the water tank 24, which pumps water to the scanning system 3 through the conduit 27 when started, providing coupling agent for the phased array and TOFD scanning modules.

[0023] The scanning system 3 includes a scanning host 31, a drive mechanism 32, a probe holding mechanism 33, a magnetic particle detection mechanism 34, and a front-mounted mechanism 35. The scanning host 31 is a rectangular frame and serves as the main body of the scanning system 3. It has rectangular slide rail cavities on both sides. Four drive mechanisms 32 are arranged in pairs, horizontally inside the rectangular slide rail cavities on both sides of the scanning host 31, providing power to the scanning system 3. The probe holding mechanism 33 is installed on a rectangular cavity guide rail in the middle of the scanning host 31 and can move left and right on the rail to hold the detection probe and complete the scanning work. The number of probe holding mechanisms 33 is determined according to the specifications of the workpiece and the detection process, and can be increased or decreased as needed, and can be installed or removed at any time. The magnetic particle detection mechanism 34 is a cross-shaped electromagnetic yoke located in the middle of the rear of the scanning host 31, used for magnetic particle detection of the surface and near-surface of the welded joint. The front-mounted mechanism 35 is located in the middle of the front of the scanning host 31, providing image recognition for the scanning host 31 and providing coupling agent for the probe.

[0024] The scanning host 31 includes a frame 311, a push-button switch 312, a touch screen 313, a charging port 314, a phased array probe interface 315, a TOFD probe interface 316 (the TOFD probe and the phased array probe have similar shapes, but the TOFD probe is smaller than the phased array probe; the biggest difference is the interface: the TOFD probe interface is circular, while the phased array probe interface is rectangular), a control cable interface 317, a water pipe interface 318, and a magnetic suspension interface 319. The frame 311 is mainly composed of two rectangular housings on both sides and a central rectangular guide rail. Five guide rails are provided in the middle, allowing for the simultaneous installation of five pairs of probe holding mechanisms 33. This meets the multi-probe detection requirements of phased array and TOFD technologies for thick-walled pipelines. A probe holding mechanism 33 can also be added in the middle to install a flexible phased array probe for full-focus imaging detection of the inspected workpiece. The upper part of the left housing of the scanning host 31 has a circular... The system includes a rectangular button switch 312, a rectangular touchscreen 313, and a circular charging port 314. The button switch 312 controls the start and stop of the scanning host; the touchscreen 313 controls the parameter input of the scanning host 31 and displays status data; the charging port 314 connects to an external power adapter to power the internal lithium battery of the scanning host 31; the upper right side of the scanning host 31 has six cuboid phased array probe interfaces 315 and six circular TOFD probe interfaces 316, which are connected to the corresponding probes to collect detection data; the rear right side of the scanning host 31 has three cylindrical interfaces: the upper interface is a control cable interface 317, used to connect the control cable to realize communication between the scanning system and the control system; the lower interface is a water pipe interface 318, which connects to the water tank 24 of the liquid storage and supply system 2 to receive pumped water; and the lower interface is a magnetic suspension interface 319, which connects to the magnetic suspension tank 21 of the liquid storage and supply system 2 to receive pumped magnetic suspension.

[0025] The driving mechanism 32 includes a magnetic wheel 321, a drive motor 322, and a hydraulic rod 323. The magnetic wheel 321 is connected to the drive motor 322 via a rotating shaft. Under the drive of the drive motor 322, the magnetic wheel 321 can rotate smoothly, driving the scanning system to move smoothly along the outer wall of the pipeline to complete the non-destructive testing of the pipeline weld joints. The drive motor 322 can move horizontally along the slide rail cavity under the push of the hydraulic rod 323. Adjusting the spacing of the drive motors 322 on the same side adjusts the wheel spacing of the magnetic wheel 321 to adapt to different curvature testing requirements. The magnetic wheel 321 is equipped with a strong magnet inside, which can firmly attract the scanning system to the outer wall of the pipeline being inspected to complete the non-destructive testing of the pipeline weld joints.

[0026] The probe holding mechanism 33 is a detachable independent module (the main body of the TOFD probe and the phased array probe are similar in shape, and the probe holding mechanism 33 holds the TOFD probe and the phased array probe in the same way). The specific number and arrangement are determined according to the specifications of the workpiece being inspected and the inspection process. The upper part of the probe holding mechanism 33 is equipped with a housing, inside which a drive motor, a lithium battery, and a Bluetooth module are installed. The upper part of the housing is equipped with a second push-button switch 331 and a second charging port 332. The lower part of the housing is equipped with four rollers 333, which are installed in pairs on both sides of the lower part of the housing. The probe holder can roll freely on the track of the scanning host frame 311. Two spring support rods 335 are symmetrically arranged at the lower part of the roller 333, and a rotating rod 334 is provided at the upper part of the spring support rod 335. The rotating rod 334 can roll along its own central axis or rotate along the central axis of the spring support rod 335. The probe holding mechanism 33 is installed on the track of the scanning host frame 311 via the rotating rod 334. When installing the probe holding mechanism 33, the two rotating rods 334 are rotated so that they pass parallel to the track. After the probe holding mechanism roller 333 makes stable contact with the track, the two rotating rods 334 are then... Rotate 90°; the lower part of the spring support rod 335 is connected by a connecting rod 336. The connecting rod 336 passes through the upper slide rail of the U-shaped probe frame 337, connecting the probe frame 337 to the spring support rod 335. The spring support rod 335 has a built-in spring and can extend and retract freely. The spring support rod 335 applies a clamping force to the lower probe frame 337 through the connecting rod 336. The probe A is subjected to stable and uniform pressure, making stable contact with the surface of the inspected pipe. The upper part of the probe frame 337 is machined with an arc-shaped slide rail, through which the connecting rod 336 passes and can slide relative to it, allowing the probe frame 337 to be freely adjusted at an angle. The probe A's lower surface can be rotated to meet the needs of phased array and TOFD inspection of pipes with different curvatures. The probe holder 337 has two screws 338 symmetrically arranged at the lower part. By screwing in and out the screws 338, the probe A can be attached and removed. The probe attachment mechanism 33 is wirelessly connected to the scanning host 31 via Bluetooth module. Data transmission and communication are performed via Bluetooth. After receiving the displacement command from the scanning host 31, the probe attachment mechanism 33 drives the rollers at the bottom of the housing to rotate through the internal drive motor, so that the probe attachment mechanism 33 moves to the target position.

[0027] The magnetic particle inspection mechanism 34 is located at the rear of the scanning host 31 and includes a support arm 341, a ball joint 342, a camera 343, an electromagnetic yoke 344, a pulley 345, and a magnetic suspension nozzle 346. The support arm 341 suspends the electromagnetic yoke 344 through the ball joint 342. The upper part of the ball joint 342 is embedded in the support arm 341 and can rotate freely. The lower part of the ball joint 342 is connected to the cross-shaped electromagnetic yoke 344. By adjusting the ball joint 342, the four legs of the electromagnetic yoke 344 can be made to fit against the surface of the inspected pipe, thereby enabling magnetic particle inspection of welded joints of pipes with different curvatures. Four magnetic suspension nozzles are installed at the bottom of each of the four legs of the electromagnetic yoke 344. A pulley 345 is provided, which can rotate freely along the central axis to reduce the surface friction between the electromagnetic yoke 344 and the inspected pipe. The electromagnetic yoke 344 can move smoothly and steadily on the surface of the inspected pipe to perform magnetic particle inspection on the pipe weld joints. A camera 343 and a magnetic suspension nozzle 346 are respectively provided on both sides of the electromagnetic yoke 344. The camera 343 is used to record magnetic trace images in real time and can automatically identify defects and issue a defect alarm command to the control system 1. The control system 1 issues an audio-visual alarm. The magnetic suspension nozzle 346 is symmetrically arranged with the camera 343 and sprays the magnetic suspension onto the pipe surface in a timely manner according to the command of the control system 1.

[0028] The front-end mechanism 35 includes a monitor 351 and a nozzle 352. The monitor 351 is located at the lower front end of the scanning host frame 311, and the nozzles 352 are symmetrically arranged on both sides of the scanning host frame 311. The monitor 351 has a built-in high-definition camera and a laser locator, which are used to record the on-site inspection, identify weld beads, and assist the scanning system 3 in automatic trajectory correction. The nozzles 352 are used for spraying coupling agent to provide stable coupling for the phased array and TOFD detection probes.

[0029] This invention also provides a detection method using the aforementioned integrated phased array, TOFD, and magnetic particle testing system for welded joints of medium and large diameter pipelines, comprising the following steps: The inspectors verified the specifications and materials of pipe weld joint B according to the inspection requirements, and prepared inspection process documents according to relevant inspection standards. According to the requirements of the testing process document, select probe A (phased array probe, full-focus probe, TOFD probe), select the corresponding number of probe holding mechanisms 33 according to the required number of probes A, place probe A one by one at the lower center position of probe holding mechanism 33, tighten the screws 338 on both sides, and complete the combination of probe A and probe holding mechanism 33. One by one, the assembled probe holding mechanism 33 is placed on the central track of the scanning host frame 311, with pairs of probes placed in the same track. The lower rotating rod 334 of the probe holding mechanism 33 is rotated to fix the probe holding mechanism 33 on the central track of the scanning host frame 311. The probe A connectors are inserted one by one into the corresponding probe A interfaces on the upper right side of the module of the scanning host frame 311: the phased array probes are inserted one by one into the phased array probe interface 315, the TOFD probes are inserted one by one into the TOFD probe interface 316, and the full-focus probes are inserted one by one into the phased array probe interface 315.

[0030] Connect control system 1 and scanning system 3 using control cables; connect liquid storage and supply system 2 and scanning system 3 one by one using plastic hoses, with water pipes and magnetic suspension pipes connected accordingly; connect control system 1 and liquid storage and supply system 2 using signal lines; Once all systems are connected, press knob 12 of control system 1 to start control system 1; press button switch 312 of scanning host to start control system 1; press button switch 331 on the upper part of probe holding mechanism 33 one by one to start probe holding mechanism 33 one by one. Probe holding mechanism 33 connects to scanning host 31 via Bluetooth module. Control system 1 and scanning host 31 automatically enter self-test program, initialize system, and each module automatically debugs and tests. According to the requirements of the testing process document, operate the control system button 13 to set the testing parameters of the control system 1, and operate the touch screen 313 on the upper part of the scanning host 31 to set the scanning parameters of the scanning system 3. The scanning system 3 is placed on the surface of the welded joint B of the pipeline to be inspected. The magnetic wheel 321 adheres to the surface of the pipeline. The extension and retraction state of the hydraulic rod 323 is adjusted, and the spacing of the magnetic wheels 321 is adjusted so that the scanning host is stably adhered to the surface of the pipeline. The detection start button of the control system 1 is clicked. The liquid supply system 2 pumps water and magnetic suspension liquid synchronously. The water is sprayed onto the front of the probe A through the nozzle 352, and the magnetic suspension liquid is sprayed onto the weld position at the center of the cross electromagnetic yoke 344 through the magnetic suspension liquid nozzle 346. The magnetic wheel 321 starts to rotate under the drive of the drive motor 322, and the scanning system 3 moves stably. The scanning system 3 moves smoothly on the surface of the welded joint B of the inspected pipeline, driving the probe A (phased array probe, TOFD probe, and full-focus probe) to move smoothly as well. The monitor 351 monitors the weld trajectory and the detection status of the phased array, TOFD, and full-focus probes in real time. The camera 343 monitors the working status of the electromagnetic yoke 344 in real time, automatically records the magnetic particle inspection images, and identifies the magnetic traces of defects. All inspection data is transmitted to the control system 1 through the control cable. The inspection data, images, and results are displayed on the display screen 14 in real time for analysis and recording. The inspection personnel analyze and evaluate the inspection data through software until the inspection of the welded joint is completed, and the inspection task ends.

[0031] The integrated commissioning and testing of all modules in this invention enables simultaneous phased array, TOFD, and magnetic particle testing of welded joints in inspected pipelines. No manual intervention is required during the testing process; the system operates automatically to complete the testing. The integrated control cable interface allows the control system to simultaneously process data from phased array, TOFD, and magnetic particle testing—three different types of technologies. Built-in dedicated software provides real-time, partitioned display of data for each testing method, providing intuitive defect display and convenient data analysis. It also features automatic defect identification and alarm functions, demonstrating a high level of intelligence. The invention employs a dual-compartment liquid supply system, with a water tank below and a magnetic suspension tank above, isolated from each other. Pumping parameters for water and magnetic suspension can be independently controlled according to testing requirements. The water tank and magnetic suspension tank are connected by conduits. When the monitor in the magnetic suspension tank detects excessively high concentrations, the lower water tank automatically pumps water into the magnetic suspension tank. When the standard concentration is reached, the pump in the lower water tank automatically stops. The phased array, TOFD, and magnetic particle testing sensors are centrally arranged, and the scanning host is shaped like a four-wheeled cart, with a central... Five tracks allow for flexible arrangement of the probe holding mechanism. A cross-shaped electromagnetic yoke is added at the rear. The components are compactly arranged, rationally designed, and the functional modules do not interfere with each other, resulting in a high degree of intelligent integration. The simple drive mechanism of this invention works with the outer slide rail cavity and hydraulic rod on both sides of the rectangular housing of the scanning host, allowing for flexible adjustment of the spacing between the drive devices on the same side, and is highly suitable for detecting pipes with different curvatures. The probe holding mechanism of this invention has built-in Bluetooth and a motor, which can wirelessly connect with the scanning host and electrically adjust the distance of the probe holding device. This enables precise adjustment of the phased array probe translation distance and the PCS parameters of the TOFD detection probe, improving detection accuracy. The fixed structure of the probe holding mechanism can be quickly assembled and disassembled by rotating the rotating rod. The phased array probe socket and TOFD probe socket of this invention are arranged in a centralized array. The scanning host has a built-in detection data preprocessing module, which enables rapid connection and data transmission between the control system and the scanning system through the control cable, reducing the amount of data processing by the controller and improving data analysis efficiency and accuracy.

[0032] The above embodiments of the present invention are merely illustrative examples and are not the only ones. All modifications within the scope of the present invention or equivalent to the scope of the present invention are encompassed by the present invention.

Claims

1. An integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines, characterized in that: The system includes a control system (1), a liquid storage and supply system (2), and a scanning system (3). The control system (1) is connected to the liquid storage and supply system (2) via a signal line, and the control system (1) is connected to the scanning system (3) via a control cable. The liquid storage and supply system (2) and the scanning system (3) are connected via a flexible water pipe and a flexible magnetic suspension pipe. The control system (1) controls the start and stop of the liquid storage and supply system (2) and collects and processes the detection data transmitted by the scanning system (3). The liquid storage and supply system (2) includes a magnetic suspension tank (21) and a water tank (24), which are used to store magnetic suspension and water, respectively, and pump the two liquids to the scanning system (3). The scanning system (3) is a data acquisition center, which centrally arranges a phased array probe, a TOFD probe, an electromagnetic yoke, and a video sensor. It operates under separate control and realizes automatic scanning of the welded joint under the drive of the magnetic suction wheel drive mechanism, and transmits the detection data information to the control system (1).

2. The integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines according to claim 1, characterized in that: The control system (1) includes a cuboid housing (11). The front panel of the housing (11) is provided with a knob (12), a display screen (14) and multiple buttons (13). A control cable interface (15) is provided on the upper side of the housing (11) for data transmission with the scanning system (3), and a signal line interface (16) is provided on the lower side for connecting signal lines to achieve connection with the liquid storage and supply system (2).

3. The integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines according to claim 1, characterized in that: The liquid storage and supply system (2) includes a magnetic suspension tank (21), a magnetic suspension tank cover (22), a water tank cover (23), a water tank (24), a magnetic suspension pump (25), a water pump (26), and a conduit (27). The magnetic suspension tank (21) and the water tank (24) are combined into one unit. The magnetic suspension tank (21) is located above the water tank (24) and has a partition in the middle. The magnetic suspension tank (21) has a cylindrical magnetic suspension tank cover (22) on its upper part. The magnetic suspension tank (21) has a magnetic suspension pump (25) inside, which pumps magnetic suspension liquid to the scanning system (3) through the conduit (27) when it starts. The water tank (24) has a cylindrical water tank cover (23) on its upper part. The water tank (24) has a water pump (26) inside, which pumps water to the scanning system (3) through the conduit (27) when it starts, providing coupling agent for the phased array and TOFD scanning modules.

4. The integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines according to claim 1, characterized in that: The scanning system (3) includes a scanning host (31), a drive mechanism (32), a probe holding mechanism (33), a magnetic particle detection mechanism (34), and a front-mounted mechanism (35). The scanning host (31) is a rectangular frame with rectangular sliding rail cavities on both sides. The four drive mechanisms (32) are arranged in pairs and horizontally inside the rectangular sliding rail cavities on both sides of the scanning host (31). The probe holding mechanism (33) is installed on the rectangular cavity guide rail in the middle of the scanning host (31) and can move left and right on the rail. The number of probe holding mechanisms (33) can be increased or decreased according to the detection needs. The magnetic particle detection mechanism (34) is a cross-shaped electromagnetic yoke and is located in the middle of the rear of the scanning host (31). The front-mounted mechanism (35) is located in the middle of the front of the scanning host (31) and provides image recognition for the scanning host (31) and coupling agent for the probe.

5. The integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines according to claim 4, characterized in that: The scanning host (31) includes a frame (311), a push-button switch (312), a touch screen (313), a charging port (314), a phased array probe interface (315), a TOFD probe interface (316), a control cable interface (317), a water pipe interface (318), and a magnetic suspension interface (319). The frame (311) is mainly composed of two rectangular shells on both sides and a rectangular guide rail in the middle. Five guide rails are provided in the middle, which can simultaneously set five pairs of probe holding mechanisms (33), which can meet the multi-probe detection requirements of phased array and TOFD detection technologies for thick-walled pipes. A probe holding mechanism (33) can also be added in the middle to install a flexible phased array probe to achieve full-focus imaging detection of the inspected workpiece. The upper part of the left shell of the scanning host (31) is provided with a circular push-button switch (312), a rectangular touch screen (313), and a circular charging port (314). 14) The button switch (312) controls the start and stop of the scanning host; the touch screen (313) controls the parameter input of the scanning host (31) and displays the status data; the charging port (314) connects to the external power adapter to power the internal lithium battery of the scanning host (31); the upper part of the right side housing of the scanning host (31) is provided with six cuboid phased array probe interfaces (315) and six circular TOFD probe interfaces (316), which are connected to the corresponding probes to collect detection data; the rear part of the right side housing of the scanning host (31) is provided with three cylindrical interfaces, the upper interface is the control cable interface (317), which is used to connect the control cable, the lower interface is the water pipe interface (318), which connects to the water tank (24) of the liquid storage and supply system (2), and the lower part is the magnetic suspension interface (319), which connects to the magnetic suspension tank (21) of the liquid storage and supply system (2) to receive the pumped magnetic suspension.

6. The integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines according to claim 4, characterized in that: The driving mechanism (32) includes a magnetic wheel (321), a driving machine (322), and a hydraulic rod (323). The magnetic wheel (321) is connected to the driving machine (322) through a rotating shaft. The magnetic wheel (321) can rotate smoothly under the drive of the driving machine (322). The driving machine (322) can move horizontally along the slide rail cavity under the push of the hydraulic rod (323). The spacing between the driving machines (322) on the same side can be adjusted, thereby adjusting the wheel spacing of the magnetic wheel (321) to adapt to different curvature detection requirements. The magnetic wheel (321) is equipped with a strong magnet inside, which can firmly attach the scanning system to the outer wall of the inspected pipe to complete the non-destructive testing of the pipe weld joint (B).

7. The integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines according to claim 4, characterized in that: The probe holding mechanism (33) is a detachable independent module with a housing on the upper part. The housing has a second button switch (331) and a second charging port (332) on the upper part. The housing (11) has four rollers (333) on the lower part. The four rollers (333) are installed in pairs on both sides of the lower part of the housing. The rollers (333) have two spring support rods (335) symmetrically arranged on the lower part. The spring support rods (335) have a rotating rod (334) on the upper part. The probe holding mechanism (33) is installed on the track of the scanning host frame (311) through the rotating rod (334). The lower part of the spring support rods (335) is connected by a connecting rod (336). The connecting rod (336) passes through the upper slide of the U-shaped probe frame (337) to connect the probe frame (337) with the spring support rods (335). (335) has a built-in spring that can extend and retract freely. The spring support rod (335) applies a clamping force to the lower probe frame (337) through the connecting rod (336) to achieve a stable contact state between the probe (A) and the surface of the inspected pipeline. The upper part of the probe frame (337) is machined with an arc-shaped slide, through which the connecting rod (336) passes and can slide relative to it, so that the probe frame (337) can be freely adjusted in angle, thereby allowing the lower surface of the probe (A) to be rotated by an angle to meet the needs of phased array and TOFD detection of pipelines with different curvatures. The lower part of the probe frame (337) is symmetrically provided with two screws (338). By screwing in and out the screws (338), the probe (A) can be clamped and disassembled. The probe clamping mechanism (33) is wirelessly connected to the scanning host (31) through a Bluetooth module, and data transmission and communication are performed through Bluetooth.

8. The integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines according to claim 4, characterized in that: The magnetic particle inspection mechanism (34) is located at the rear of the scanning host (31) and includes a support arm (341), a ball joint (342), a camera (343), an electromagnetic yoke (344), a pulley (345), and a magnetic suspension nozzle (346). The support arm (341) suspends the electromagnetic yoke (344) through the ball joint (342). The upper part of the ball joint (342) is embedded in the support arm (341) and can rotate freely. The lower part of the ball joint (342) is connected to the cross-shaped electromagnetic yoke (344). By adjusting the ball joint (342), the four feet of the electromagnetic yoke (344) can be made to fit against the surface of the pipe being inspected, thereby enabling the inspection of welded joints (B) of pipes with different curvatures. The electromagnetic yoke (344) is equipped with four pulleys (345) at the bottom of its four feet. The pulleys (345) can rotate freely along the central axis to reduce the surface friction between the electromagnetic yoke (344) and the inspected pipe. The electromagnetic yoke (344) is equipped with a camera (343) and a magnetic suspension nozzle (346) on both sides. The camera (343) is used to record magnetic trace images in real time and can automatically identify defects and issue a defect alarm command to the control system (1). The control system (1) issues an audio-visual alarm. The magnetic suspension nozzle (346) and the camera (343) are arranged symmetrically. According to the command of the control system (1), the magnetic suspension is sprayed onto the surface of the pipe in a timely manner.

9. The integrated phased array, TOFD, and magnetic particle inspection system for welded joints of medium and large diameter pipelines according to claim 4, characterized in that: The front-end mechanism (35) includes a monitor (351) and a nozzle (352). The monitor (351) is located at the lower front end of the scanning host frame (311), and the nozzle (352) is symmetrically arranged on both sides of the scanning host frame (311). The monitor (351) has a built-in high-definition camera and a laser locator, which are used to record the on-site inspection, weld identification, and assist the scanning system (3) in automatic trajectory correction. The nozzle (352) is used for spraying coupling agent to provide stable coupling for the phased array and TOFD detection probe.

10. A detection method using the integrated phased array, TOFD, and magnetic particle testing system for welded joints of medium-to-large diameter pipelines as described in any one of claims 1-9, characterized in that: Includes the following steps: Select phased array probe, full-focus probe, or TOFD probe according to the requirements of the testing process document. Select the corresponding number of probe holding mechanisms (33) according to the required number of probes. Place the probe (A) one by one at the lower center of the probe holding mechanism (33), tighten the screws (338) on both sides, and combine the probe (A) with the probe holding mechanism (33) to complete the assembly. Place the assembled probe holding mechanism (33) one by one on the central track of the scanning host frame (311), with pairs of probes placed in the same track. Rotate the lower rotating rod (334) of the probe holding mechanism (33) to fix the probe holding mechanism (33) on the central track of the scanning host frame (311). Insert the probe (A) connector one by one into the corresponding probe (A) interface on the upper part of the right module of the scanning host frame (311): insert the phased array probe one by one into the phased array probe interface (315), and insert the TOFD probe one by one into the TOFD probe interface (316). Connect the control system (1) and the scanning system (3) using control cables; connect the storage and supply system (2) and the scanning system (3) one by one using plastic hoses, with water pipes and magnetic suspension pipes connected accordingly; connect the control system (1) and the storage and supply system (2) using signal lines. After all systems are connected, press the knob (12) of the control system (1) to start the control system (1); press the first button switch (312) of the scanning host to start the control system (1); press the second button switch (331) on the upper part of the probe holding mechanism (33) one by one to start the probe holding mechanism (33) one by one. The probe holding mechanism (33) is connected to the scanning host (31) through the Bluetooth module. The control system (1) and the scanning host (31) automatically enter the self-test program, initialize the system, and each module automatically debugs and tests. According to the requirements of the testing process document, operate the control system button (13) to set the testing parameters of the control system (1), and operate the touch screen (313) on the top of the scanning host (31) to set the scanning parameters of the scanning system (3); Place the scanning system (3) on the surface of the welded joint (B) of the pipeline to be inspected. The magnetic wheel (321) adsorbs onto the surface of the pipeline. Adjust the extension and retraction state of the hydraulic rod (323) and adjust the spacing of the magnetic wheel (321) so that the scanning host is stably adsorbed onto the surface of the pipeline. Click the detection start button of the control system (1). The storage and supply system (2) pumps water and magnetic suspension liquid synchronously. Water is sprayed onto the front of the probe (A) through the nozzle (352). The magnetic suspension liquid is sprayed onto the weld position at the center of the cross electromagnetic yoke (344) through the magnetic suspension liquid nozzle (346). The magnetic wheel (321) starts to rotate under the drive of the drive machine (322). The scanning system (3) moves stably. The scanning system (3) moves smoothly on the surface of the welded joint (B) of the inspected pipeline, driving the probe (A) to move smoothly. The monitor (351) monitors the weld trajectory and the phased array, TOFD, and full-focus detection status in real time. The camera (343) monitors the working status of the electromagnetic yoke (344) in real time, automatically records the magnetic particle detection image, and identifies the magnetic traces of defects. All detection data are transmitted to the control system (1) through the control cable. The detection data information, detection images and results are displayed on the display screen (14) in real time, and are analyzed and recorded in real time. The inspection personnel analyze and evaluate the detection data through the software until the inspection of the welded joint is completed and the inspection task ends.

Images