Phased array based branch connection seat weld defect detection device design method and device

Abstract

The application discloses a kind of based on phased array's branch pipe seat weld defect detection device design method and device, method includes establishing EMAT phased array finite element model, based on EMAT phased array finite element model to transducer sound field is carried out simulation experiment, obtain multiple sound field simulation results, based on multiple sound field simulation results to phased array synthesis sound beam quality is analyzed, and the optimal structure parameter of phased array is determined, based on optimal structure parameter to weld defect detection device is optimized design.The application utilizes finite element method to transducer sound field is carried out simulation experiment analysis, and the optimal structure parameter of phased array is determined, and the detection capability of weld defect is improved using optimal structure parameter design EMAT phased array transducer.The branch pipe seat fillet weld detection fixture device designed by the application has high modularity and flexibility, and the device can adapt to the detection needs of various special-shaped geometric structure branch pipes and can be applied to the detection of branch pipe seat weld defects with different diameters and different welding processes.

Description

Technical Field

[0001] This invention belongs to the field of non-destructive testing technology for pipe support welds, and particularly relates to a design method and device for a defect detection device for pipe support welds based on a phased array. Background Technology

[0002] With the development of petrochemical enterprises, the safety management of petrochemical plants has become increasingly complex. Accidents can easily lead to widespread equipment failure and casualties, resulting in incalculable economic losses. Branch pipes are a common structural form in pressure vessels and pipelines of petrochemical plants, playing a crucial role in connection, branching, and drainage. Currently, the effectiveness of non-destructive testing (NDT) technology for branch pipes is insufficient, making it a weak link in petrochemical plants. Branch pipe supports are pipe fittings used in piping systems, typically connecting main pipes to smaller diameter branch pipes, providing support and guiding fluid flow. Branch pipe supports are characterized by their large quantity, diverse shapes, and susceptibility to hidden defects. Furthermore, the welded area of ​​branch pipes is a fillet weld, which, due to its discontinuous geometry and the highly corrosive nature of the materials transported internally, is particularly prone to corrosion, cracking, and leakage at the fillet weld. Currently, commonly used NDT techniques for fillet welds of branch pipe supports both domestically and internationally include: magnetic flux leakage testing, ultrasonic testing, eddy current testing, radiographic testing, magnetic particle testing, and penetrant testing. Ultrasonic testing is a primary detection method, and electromagnetic ultrasound (EMU) within ultrasonic testing holds immense potential for industrial applications. However, EMU still suffers from several technical limitations, such as low sensor transduction efficiency and low signal-to-noise ratio, which reduce its effectiveness in defect detection. To enhance the effectiveness of EMU in defect detection and increase the intensity of the detection signal, researchers typically employ phased array technology for dynamic focusing on defect locations. Phased array technology follows Huygens' principle, using multiple array elements to emit ultrasonic waves according to predetermined phase delay rules, achieving flexible, convenient, and effective control over the beam shape and sound pressure distribution, thereby enabling functions such as beam deflection and dynamic focusing. By combining EMU with phased array technology, while enhancing signal-to-noise ratio, sensitivity, and resolution, functions such as beam deflection and scanning, which are difficult to achieve with a single transducer, can be realized. However, EMU phased array technology is currently in its early stages, and the design of EMU array elements still needs optimization and improvement. Summary of the Invention

[0003] To address the aforementioned issues, this invention provides a design method and apparatus for a phased array-based pipe support weld defect detection device, thereby resolving the problem of insufficient effectiveness of existing electromagnetic ultrasonic phased array transducers in detecting pipe support weld structures.

[0004] A design method for a phased array-based pipe support weld defect detection device includes:

[0005] Establish the finite element model of the EMAT phased array;

[0006] The sound field of the transducer was simulated based on the EMAT phased array finite element model, and multiple sound field simulation results were obtained.

[0007] The quality of the synthesized sound beam of the phased array is analyzed based on multiple sound field simulation results, and the optimal structural parameters of the phased array are determined.

[0008] The weld defect detection device is optimized based on the optimal structural parameters.

[0009] According to a specific embodiment of the present invention, establishing the EMAT phased array finite element model includes:

[0010] The geometric model of the EMAT phased array was created using Altium Designer software, including the geometry of the transducer coils, magnets, and support bases.

[0011] The geometric model is meshed and material properties and related parameters are set to obtain the EMAT phased array finite element model.

[0012] According to a specific embodiment of the present invention, a simulation experiment of the transducer sound field was conducted based on the EMAT phased array finite element model, and several sound field simulation results were obtained, including:

[0013] Simulation experiments were conducted based on the EMAT phased array finite element model to study the influence of different element spacings on the synthesized sound beam. The simulation results of the sound field corresponding to different element spacings were obtained, and...

[0014] Simulation experiments were conducted based on the EMAT phased array finite element model to study the influence of different coil conductor widths on the synthesized sound beam. The simulation results of the sound field corresponding to different coil conductor widths were obtained, as well as...

[0015] Simulation experiments were conducted based on the EMAT phased array finite element model to study the effect of different coil layers on the synthesized sound beam, and the sound field simulation results corresponding to different coil layers were obtained.

[0016] According to a specific embodiment of the present invention, a simulation experiment was conducted based on the EMAT phased array finite element model to simulate the effect of different element spacings on the synthesized sound beam. The simulation results of the sound field corresponding to different element spacings are as follows:

[0017] The element spacing of the phased array transducer was set to 16 μm, 24 μm, 32 μm, 40 μm, 48 μm and 56 μm respectively, and the phased array synthesized sound beam corresponding to each element spacing was simulated to obtain the sound field distribution diagram corresponding to each element spacing.

[0018] According to a specific embodiment of the present invention, a simulation experiment was conducted based on the EMAT phased array finite element model to simulate the effect of different coil conductor widths on the synthesized sound beam. The simulation results of the sound field corresponding to different coil conductor widths include:

[0019] The coil widths of the phased array transducers were set to 4 μm, 6 μm, 8 μm, 10 μm, 12 μm, and 14 μm, respectively. The phased array synthesized sound beams corresponding to each coil width were simulated to obtain the sound field distribution diagrams corresponding to each coil width.

[0020] According to a specific embodiment of the present invention, a simulation experiment was conducted based on the EMAT phased array finite element model to simulate the effect of different coil layers on the synthesized sound beam. The simulation results of the sound field corresponding to different coil layers are as follows:

[0021] The number of coil layers of the phased array transducer was set to 4, 3 and 2 layers respectively, and the phased array synthesized sound beam corresponding to each number of coil layers was simulated to obtain the sound field distribution map corresponding to each number of coil layers.

[0022] According to a specific embodiment of the present invention, the quality of the synthesized sound beam of the phased array is analyzed based on multiple sound field simulation results, and the optimal structural parameters of the phased array are determined, including:

[0023] Beam directivity function graphs at different angles are generated using the beam directivity function and sound field simulation results;

[0024] The directivity performance of the phased array beam is evaluated based on the beam directivity function diagram. Based on the evaluation results, the main lobe width of the phased array is minimized, the side lobe intensity is weakened, and the pruning effect is eliminated. Combined with the design standards of the phased array transducer, the optimal structural parameters of the phased array are determined.

[0025] According to a specific embodiment of the present invention, the beam directivity function is expressed as:

[0026]

[0027] In the formula, H(θ) is the beam directivity function, p(r,θ,t) is the sound pressure at any angle θ, p(r,θ0,t) is the sound pressure at the deflection angle θ0, t is time, and r is the equivalent radius of the line light source;

[0028] in,

[0029]

[0030] In the formula, p n (r,θ,t) represents the sound pressure at the deflection angle θ of the nth array element, where n is the array element number that was excited, and N is the total number of array elements.

[0031] A phased array-based device for detecting weld defects in branch pipe supports includes: a support plate and a right-angle support member, wherein the support plate is slidably connected to the right-angle support member, and the support plate is horizontally sleeved on the longitudinal branch pipe and fixedly connected to the longitudinal branch pipe.

[0032] The right-angle support includes a longitudinal adjuster and a lateral adjuster. A column is fixedly connected to the top of the longitudinal adjuster, and a slider is fixedly connected to one side of the column. The slider is slidably connected to the support plate. A slide block is fixedly connected to the bottom of the longitudinal adjuster. The longitudinal adjuster is slidably connected to the lateral adjuster through the slide block. An adjusting rod is provided on one side of the longitudinal adjuster and is fixedly connected to the longitudinal adjuster.

[0033] One end of the lateral adjuster is fixedly connected to a positioner, which rests against the weld of the branch pipe seat. Inside the positioner is a probe holder, which is fixedly connected to the lateral adjuster and used to connect the phased array probe.

[0034] According to a specific embodiment of the present invention, a sliding track is provided on the support plate, and the slider is slidably connected to the support plate through the sliding track.

[0035] Compared with the prior art, the design method and device for detecting defects in pipe seat welds based on phased array provided by the present invention have the following advantages:

[0036] 1) This invention uses the finite element method to establish the EMAT phased array finite element model and conducts simulation experiments to analyze the sound field of the transducer, and determines the optimal structural parameters of the phased array. The EMAT phased array transducer designed with the optimal structural parameters improves the detection capability of weld defects.

[0037] 2) The branch pipe seat fillet weld inspection fixture device designed in this invention has a high degree of modularity and flexibility. The device can adapt to the inspection needs of branch pipes with various irregular geometric structures and can be used for defect inspection of branch pipe seat welds with different diameters and different welding processes. At the same time, it ensures the stability and accuracy of the inspection process. Its structure is compact, easy to operate, and highly adaptable, which greatly improves the inspection efficiency. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of this disclosure or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 This is a flowchart of a design method for a phased array-based pipe support weld defect detection device according to an embodiment of the present invention.

[0040] Figure 2 This is a flowchart of a method for establishing a finite element model of an EMAT phased array according to an embodiment of the present invention.

[0041] Figure 3 This is a flowchart of a method for simulating the sound field of a transducer according to an embodiment of the present invention.

[0042] Figure 4 This is a flowchart of a method for analyzing the quality of synthesized acoustic beams of a phased array and determining the optimal structural parameters of the phased array, according to an embodiment of the present invention.

[0043] Figure 5 This is a sound field distribution diagram showing the effect of different array element spacings on the synthesized sound beam according to an embodiment of the present invention.

[0044] Figure 6 This is a sound field distribution diagram showing the effect of different coil conductor widths on the synthesized sound beam according to an embodiment of the present invention.

[0045] Figure 7 This is a sound field distribution diagram showing the effect of different coil layer numbers on the synthesized sound beam according to an embodiment of the present invention.

[0046] Figure 8 This is a structural diagram of a phased array-based pipe support weld defect detection device according to an embodiment of the present invention.

[0047] Figure 9 This is a side view of a phased array-based pipe seat weld defect detection device according to an embodiment of the present invention.

[0048] Figure label:

[0049] 1-Support plate; 2-Slider; 3-Column; 4-Adjusting rod; 5-Longitudinal adjuster; 6-Slide seat; 7-Transverse adjuster; 8-Probe holder; 9-Positioner; 10-Transverse branch pipe; 11-Longitudinal branch pipe; 12-Sliding track. Detailed Implementation

[0050] To enable those skilled in the art to more clearly understand the concepts and ideas of the present invention, the present invention is described in detail below with reference to specific embodiments. It should be understood that the embodiments given herein are only a part of all possible embodiments of the present invention. Those skilled in the art, after reading this specification, are capable of making improvements, modifications, or substitutions to parts or the entirety of the following embodiments, and such improvements, modifications, or substitutions are also included within the scope of protection claimed by the present invention.

[0051] In this document, the terms "first," "second," and other similar words are not intended to imply any order, quantity, or importance, but are merely used to distinguish different elements. The terms "one," "a," and other similar words are not intended to indicate the existence of only one thing, but rather that the description pertains to only one of the things, which may have one or more. The terms "contains," "includes," and other similar words are intended to indicate a logical relationship, not a spatial one. For example, "A includes B" means that logically B belongs to A, not that spatially B is located inside A. Furthermore, the meanings of the terms "contains," "includes," and other similar words should be considered open-ended, not closed. For example, "A includes B" means that B belongs to A, but B does not necessarily constitute all of A; A may also include other elements such as C, D, and E.

[0052] In this document, the terms "embodiment," "this embodiment," "an embodiment," and "one embodiment" do not imply that the description applies only to one specific embodiment, but rather that such description may also be applicable to one or more other embodiments. Those skilled in the art will understand that any description made herein with respect to one embodiment can be substituted, combined, or otherwise combined with the descriptions in one or more other embodiments. New embodiments resulting from such substitutions, combinations, or other combinations are readily conceived by those skilled in the art and fall within the scope of protection of this invention.

[0053] Example 1

[0054] Additional aspects and advantages of embodiments of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of embodiments of the invention. Figures 1-4 This invention provides a design method for a phased array-based pipe support weld defect detection device, comprising:

[0055] S1: Establish the finite element model of the EMAT phased array.

[0056] S2: Simulation experiments were conducted on the sound field of the transducer based on the EMAT phased array finite element model, and multiple sound field simulation results were obtained.

[0057] S3: Based on multiple sound field simulation results, the quality of the synthesized sound beam of the phased array is analyzed, and the optimal structural parameters of the phased array are determined.

[0058] S4: Optimize the design of the weld defect detection device based on the optimal structural parameters.

[0059] Specifically, step S1, establishing the EMAT phased array finite element model, includes:

[0060] S11: The geometric model of the EMAT phased array is created using Altium Designer software, including the geometry of the transducer coils, magnets, and support bases.

[0061] S12: Mesh the geometric model and set material properties and related parameters to obtain the EMAT phased array finite element model.

[0062] Altium Designer is a comprehensive electronic design automation (EDA) software with functions such as schematic design, PCB layout, 3D routing, circuit simulation, and prototyping. This embodiment of the invention uses Altium Designer to build an EMAT phased array finite element model for subsequent simulation experiments of the transducer's acoustic field.

[0063] Specifically, step S2 involves simulating the transducer's acoustic field based on the EMAT phased array finite element model, yielding multiple acoustic field simulation results, including:

[0064] S21: Simulation experiments were conducted on the influence of different element spacings on the synthesized sound beam based on the EMAT phased array finite element model, and the sound field simulation results corresponding to different element spacings were obtained.

[0065] Studying the element spacing is crucial for optimizing the acoustic performance of transducers. To further investigate suitable element spacing, simulation experiments were conducted using the EMAT phased array finite element model established in step S1. The element spacing parameters were optimized based on the transducer's sound field distribution. For ease of subsequent design, the units for FPC coil spacing and linewidth parameters were set to mm. A frequency domain model was used to simulate the sound field of the electromagnetic ultrasonic phased array with different element spacings. The sound wavelength λ = 3.24 mm, and the element spacing d was set to 0.25λ, 0.5λ, 0.625λ, and 0.75λ. A delay parameter was set to generate a sound beam with a deflection angle of 30° using the electromagnetic ultrasonic phased array. The simulation results are shown below. Figure 5 As shown. By Figure 5 The phased array sound field distribution shows that as d increases, the central axis of the main lobe rapidly approaches the predetermined deflection direction (30°), and the width of the main lobe continuously narrows, resulting in a significant improvement in the directivity of the sound beam.

[0066] S22: Simulation experiments were conducted on the influence of different coil conductor widths on the synthesized sound beam based on the EMAT phased array finite element model, and the sound field simulation results corresponding to different coil conductor widths were obtained.

[0067] The coil, as a key parameter of the array element, also has a certain impact on the sound field of the phased array. The design parameters of the coil, such as linewidth and line gap, directly affect the generation of the sound field. The linewidth determines the effective area of ​​the coil, thus affecting the magnitude of its induced magnetic field, while the line gap affects the coupling strength between coils, thus affecting the transmission and reception efficiency of sound waves. This embodiment of the invention fixes the line gap and mainly studies the effect of linewidth on the synthesized sound beam of the phased array. Simulation experiments are conducted using the EMAT phased array finite element model established in step S1. The simulation analysis is performed using an electromagnetic ultrasonic phased array frequency domain model. An eight-channel electromagnetic ultrasonic phased array is used, with an element spacing d = 0.5λ, a beam deflection angle set to 30°, and conductor widths of 0.1mm, 0.2mm, 0.4mm, and 0.8mm, resulting in the sound field distribution of the electromagnetic ultrasonic phased array as shown below. Figure 6 As shown, observing the acoustic field distribution of the phased array with different element spacing reveals that as the conductor width increases, the directivity of the electromagnetic ultrasonic phased array acoustic field does not change significantly, but the beam intensity increases markedly.

[0068] S23: Simulation experiments were conducted on the influence of different coil layers on the synthesized sound beam based on the EMAT phased array finite element model, and the sound field simulation results corresponding to different coil layers were obtained.

[0069] After determining the optimal linewidth of a single-layer coil, the influence of multi-layer coils on the acoustic field of the phased array was further investigated to improve the detection performance of the EMAT phased array. Simulation experiments were conducted using the finite element model of the EMAT phased array established in step S1. The number of coil layers in the phased array transducer was set to 4, 3, 2, and 1 layers, respectively, with the coils connected in parallel. Delay parameters were set to allow the electromagnetic ultrasonic phased array to generate a sound beam with a deflection angle of 30°. Simulation results of the acoustic field of the synthesized sound beam of the phased array corresponding to different numbers of coil layers were obtained, such as... Figure 7 As shown. By Figure 7 It is evident that as the number of coil layers increases, the focal point width continuously narrows, and the directivity is significantly improved, proving that increasing the number of coil layers can effectively enhance the sound field directivity of the phased array.

[0070] Due to the multi-element design of the phased array, multiple coils work together, and by precisely controlling the phase and amplitude of each coil, centralized control of the direction of the sound wave is achieved.

[0071] Specifically, step S3 analyzes the quality of the synthesized sound beam of the phased array based on multiple sound field simulation results and determines the optimal structural parameters of the phased array.

[0072] In phased array systems, the diversity of array parameters results in transducers with different acoustic characteristics, which affects the quality of the synthesized sound beam and, consequently, its defect detection capability. Therefore, analyzing the quality of the synthesized sound beam can determine the optimal structural parameters of the phased array.

[0073] Specifically, the following steps are included:

[0074] S31: Generate beam directivity function graphs at different angles using beam directivity function and sound field simulation results.

[0075] Beam deflection and focusing control is a key function of electromagnetic ultrasonic phased arrays and is crucial for achieving high-performance deflection and focusing beams. Therefore, this embodiment of the invention uses the beam directivity function H(θ) as the evaluation standard for the beam quality of the electromagnetic ultrasonic phased array. The beam directivity function H(θ) is the sound pressure p at any angle θ. n The ratio of (r,θ,t) to the sound pressure p(r,θ0,t) at the deflection angle θ0, i.e.:

[0076]

[0077] In the formula, t is time and r is the equivalent radius of the line light source.

[0078] Since the wavelength is much larger than the width of the array elements, it can be approximated as a line source, thus greatly simplifying the sound field analysis of the phased array. A line source can be equivalently represented as an infinitely long cylinder with an infinitesimally small radius, emitting sound waves in the radial direction. Therefore, in cylindrical coordinates, the sound pressure p can be expressed by time t and the equivalent radius r of the line source. According to sound field theory, the sound field distribution it induces in the cylindrical coordinate system is as follows:

[0079]

[0080] If we only study divergence fluctuations, their general solution can be expressed as one or two Hankel functions, which can be expressed as:

[0081]

[0082] In the formula, k is the frequency (Hz) and ω is the angular frequency. This is a Hankel function of the second kind, where A is a constant.

[0083] As kr approaches infinity, the Hankel function can be approximated as:

[0084]

[0085] Substituting it into formula (3) yields:

[0086]

[0087] A phased array of line sources consists of multiple line sources and can be considered as a discrete line source array. The distance from the sound field point P(r,θ) to the nth line source can be obtained using the cosine theorem:

[0088]

[0089] Substituting it into formula (5) yields:

[0090]

[0091] According to Huygens' principle, the combined sound pressure level refers to the sum of the sound pressure levels caused by multiple independent linear sound sources at a given point, that is:

[0092]

[0093] In the formula, p n (r,θ,t) represents the sound pressure at the deflection angle θ of the nth array element, where n is the array element number that was excited, and N is the total number of array elements.

[0094] The embodiments of the present invention utilize the beam directivity function of the phased array and sound field simulation data to obtain beam directivity function diagrams at different angles.

[0095] S32: The directivity performance of the phased array beam is evaluated based on the beam directivity function diagram. Based on the evaluation results, the main lobe width of the phased array is minimized, the side lobe intensity is weakened, and the pruning effect is eliminated. The optimal structural parameters of the phased array are determined in combination with the design standards of the phased array transducer.

[0096] The beam directivity function diagram can be used to evaluate the directivity performance of the beam generated by a phased array transducer. The main lobe width is a key indicator of directivity performance; a smaller width indicates better directivity. Furthermore, the relative intensity of the side lobes is also an important factor affecting directivity performance. Weaker side lobes mean that acoustic energy is more concentrated in the direction of the main lobe, thereby reducing energy leakage in other directions, improving beam directivity, and reducing interference caused by side lobe reflections, thus improving the signal-to-noise ratio of the detected signal. The grating lobe effect significantly reduces the energy of the main lobe during design and generates strong secondary echoes outside the main lobe deflection angle, potentially causing artifacts and severely impacting imaging quality. Therefore, it is necessary to eliminate the influence of the grating lobe effect when designing phased array structural parameters. This invention evaluates the directivity performance of the phased array beam using the beam directivity function diagram and, based on the evaluation results, minimizes the main lobe width, weakens the side lobe intensity, and eliminates the censoring effect. The phased array structural parameters designed under these conditions are the optimal structural parameters.

[0097] Specifically, step S4 optimizes the design of the weld defect detection device based on optimal structural parameters. This embodiment of the invention utilizes the finite element method to experimentally analyze the phased array transducer structure, optimizes the internal coil structure of the phased array transducer, and then uses 3D modeling software and mechanical engineering design software to design the mechanical structure of the detection device, thereby improving the detection capability of weld defects in branch pipe seats.

[0098] Example 2

[0099] Combination Figures 8-9 This invention also provides a phased array-based device for detecting defects in pipe seat welds, comprising:

[0100] The support plate 1 and the right-angle support are slidably connected. The support plate 1 is horizontally sleeved on the longitudinal branch pipe 11 and fixedly connected to the longitudinal branch pipe 11. In this embodiment of the invention, the support plate 1 can adapt to branch pipe structures of different diameters and can be stably fixed on the branch pipe.

[0101] The right-angle support includes a longitudinal adjuster 5 and a lateral adjuster 7. A column 3 is fixedly connected to the top of the longitudinal adjuster 5, and a slider 2 is fixedly connected to one side of the column 3. The slider 2 is slidably connected to the support plate 1. A slide block 6 is fixedly connected to the bottom of the longitudinal adjuster 5, and the longitudinal adjuster 5 is slidably connected to the lateral adjuster 7 via the slide block 6. An adjusting rod 4 is provided on one side of the longitudinal adjuster 5 and is fixedly connected to the longitudinal adjuster 5. In this embodiment of the invention, the height of the phased array probe can be adjusted by adjusting and fixing the adjusting rod 4 in the position of the longitudinal adjuster 5 with bolts. The distance between the probe and the weld can be adjusted by setting the lateral adjuster 7.

[0102] One end of the lateral adjuster 7 is fixedly connected to a positioner 9, which rests against the weld of the branch pipe seat to ensure that the distance between the phased array probe and the weld remains constant during the 360-degree rotation of the device. Inside the positioner 9 is a probe holder, which is fixedly connected to the lateral adjuster 7 and is used to connect the phased array probe.

[0103] The support plate 1 is equipped with a sliding rail 12, and the slider 2 is slidably connected to the support plate 1 via the sliding rail 12. Through the cooperation between the slider 12 and the sliding rail 12, the detection device can rotate 360 ​​degrees on the support plate 1.

[0104] The right-angle support is made of 2020 standard aluminum profile, which has high strength and excellent corrosion resistance. By adjusting the contact angle and lift-off distance, the phased array transducer connected by the right-angle support can obtain more accurate detection results. In practical applications, high-quality detection data can be obtained according to the specific shape and location of the pipeline being inspected.

[0105] The branch pipe seat is formed by welding a longitudinal branch pipe 11 and a transverse branch pipe 10. The welded part forms a fillet weld. Since the fillet weld is a structure that surrounds the branch pipe seat, the present invention uses a transducer to perform multi-angle scanning detection of the fillet weld with the branch pipe as the center. Its unique structure enables the branch pipe seat weld defect detection device provided by the present invention to adapt to the detection needs of various irregular geometric branch pipes, while ensuring the stability and accuracy of the detection process. Its structure is compact, easy to operate, and highly adaptable, which greatly improves the detection efficiency.

[0106] In summary, the design method and device for detecting defects in pipe seat welds based on phased array provided by this invention have the following advantages:

[0107] 1) This invention uses the finite element method to establish the EMAT phased array finite element model and conducts simulation experiments to analyze the sound field of the transducer, and determines the optimal structural parameters of the phased array. The EMAT phased array transducer designed with the optimal structural parameters improves the detection capability of weld defects.

[0108] 2) The branch pipe seat fillet weld inspection fixture device designed in this invention has a high degree of modularity and flexibility. The device can adapt to the inspection needs of branch pipes with various irregular geometric structures and can be used for defect inspection of branch pipe seat welds with different diameters and different welding processes. At the same time, it ensures the stability and accuracy of the inspection process. Its structure is compact, easy to operate, and highly adaptable, which greatly improves the inspection efficiency.

[0109] The concepts, principles, and ideas of the present invention have been described in detail above with reference to specific embodiments (including examples and instances). Those skilled in the art should understand that the embodiments of the present invention are not limited to those given above. After reading this application, those skilled in the art can make any possible improvements, substitutions, and equivalents to the steps, methods, systems, and components in the above embodiments. These improvements, substitutions, and equivalents should be considered to fall within the scope of the present invention, and the scope of protection of the present invention is limited to the claims.

Claims

1. A design method for a phased array-based branch pipe seat weld defect detection device, characterized in that, include: Establish the finite element model of the EMAT phased array; Based on the EMAT phased array finite element model, a simulation experiment of the transducer sound field was conducted, and multiple sound field simulation results were obtained. The quality of the synthesized sound beam of the phased array is analyzed based on multiple sound field simulation results, and the optimal structural parameters of the phased array are determined. The weld defect detection device is optimized based on the optimal structural parameters.

2. The design method of the branch pipe seat weld defect detection device based on phased array according to claim 1, characterized in that, The establishment of the EMAT phased array finite element model includes: The geometric model of the EMAT phased array was created using Altium Designer software, including the geometry of the transducer coils, magnets, and support bases. The geometric model is meshed and material properties and related parameters are set to obtain the EMAT phased array finite element model.

3. The design method of the branch pipe seat weld defect detection device based on phased array according to claim 1, characterized in that, The simulation experiment of the transducer sound field based on the EMAT phased array finite element model yielded several sound field simulation results, including: Simulation experiments were conducted based on the EMAT phased array finite element model to study the influence of different element spacings on the synthesized sound beam. The simulation results of the sound field corresponding to different element spacings were obtained. Simulation experiments were conducted based on the EMAT phased array finite element model to study the influence of different coil conductor widths on the synthesized sound beam. The simulation results of the sound field corresponding to different coil conductor widths were obtained. Based on the EMAT phased array finite element model, simulation experiments were conducted on the influence of different coil layers on the synthesized sound beam, and the sound field simulation results corresponding to different coil layers were obtained.

4. The design method of the branch pipe seat weld defect detection device based on phased array according to claim 3, characterized in that, The simulation experiment based on the EMAT phased array finite element model on the influence of different element spacings on the synthesized sound beam yielded the following sound field simulation results for different element spacings: The element spacing of the phased array transducer was set to 16mil, 24mil, 32mil, 40mil, 48mil and 56mil respectively, and the phased array synthesized sound beam corresponding to each element spacing was simulated to obtain the sound field distribution map corresponding to each element spacing.

5. The design method of the branch pipe seat weld defect detection device based on phased array according to claim 3, characterized in that, The simulation experiment based on the EMAT phased array finite element model, which examines the influence of different coil conductor widths on the synthesized sound beam, yields the following sound field simulation results corresponding to different coil conductor widths: The coil widths of the phased array transducers were set to 4mil, 6mil, 8mil, 10mil, 12mil and 14mil respectively, and the phased array synthesized sound beams corresponding to each coil width were simulated to obtain the sound field distribution diagrams corresponding to each coil width.

6. The design method of the branch pipe seat weld defect detection device based on phased array according to claim 3, characterized in that, The simulation experiment based on the EMAT phased array finite element model on the influence of different coil layers on the synthesized sound beam yielded the following sound field simulation results for different coil layer numbers: The number of coil layers of the phased array transducer was set to 4, 3 and 2 layers respectively, and the phased array synthesized sound beam corresponding to each number of coil layers was simulated to obtain the sound field distribution map corresponding to each number of coil layers.

7. The design method of the branch pipe seat weld defect detection device based on phased array according to claim 1, characterized in that, The analysis of the synthesized sound beam quality of the phased array based on multiple sound field simulation results, and the determination of the optimal structural parameters of the phased array, include: The beam directivity function and the sound field simulation results are used to generate beam directivity function graphs at different angles; The directivity performance of the phased array beam is evaluated based on the beam directivity function diagram. Based on the evaluation results, the main lobe width of the phased array is minimized, the side lobe intensity is weakened, and the pruning effect is eliminated. The optimal structural parameters of the phased array are determined in combination with the design standards of the phased array transducer.

8. The design method of the branch pipe seat weld defect detection device based on phased array according to claim 7, characterized in that, The beam directivity function is expressed as follows: In the formula, H(θ) is the beam directivity function, p(r,θ,t) is the sound pressure at any angle θ, p(r,θ0,t) is the sound pressure at the deflection angle θ0, t is time, and r is the equivalent radius of the line light source; in, In the formula, p n (r,θ,t) represents the sound pressure at the deflection angle θ of the nth array element, where n is the array element number that was excited, and N is the total number of array elements.

9. A device for detecting defects in pipe seat welds based on a phased array, characterized in that, It includes: a support plate and a right-angle support member, wherein the support plate is slidably connected to the right-angle support member, and the support plate is horizontally sleeved on the longitudinal branch pipe and fixedly connected to the longitudinal branch pipe. The right-angle support includes a longitudinal adjuster and a lateral adjuster. A column is fixedly connected to the top of the longitudinal adjuster, and a slider is fixedly connected to one side of the column. The slider is slidably connected to the support plate. A slide block is fixedly connected to the bottom of the longitudinal adjuster. The longitudinal adjuster is slidably connected to the lateral adjuster through the slide block. An adjusting rod is provided on one side of the longitudinal adjuster and is fixedly connected to the longitudinal adjuster. One end of the lateral adjuster is fixedly connected to a positioner, which rests against the weld of the branch pipe seat. Inside the positioner is a probe holder, which is fixedly connected to the lateral adjuster for connecting a phased array probe.

10. The phased array-based pipe support weld defect detection device according to claim 9, characterized in that, The support plate is provided with a sliding track, and the slider is slidably connected to the support plate through the sliding track.

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