Detection device and detection method for evaluating uniform corrosion of metal materials

Abstract

The present invention discloses a detection device for evaluating uniform corrosion of metal materials, including a matrix-type acquisition device located on the surface of the metal to be detected, the matrix-type acquisition device including at least one acquisition unit, each of the acquisition units including an eddy current sensor, the detection device also including an eddy current detector connected to the eddy current sensor and a database management device connected to the matrix-type acquisition device and the eddy current detector. The detection device for evaluating uniform corrosion of metal materials of the present invention, by providing a matrix-type acquisition device for collecting data and a database management device connected to the matrix-type acquisition device, can more intelligently, timely, accurately and scientifically evaluate the time and degree of uniform corrosion of metal materials, effectively avoid further corrosion deterioration of metal materials, and can be measured without manual field observation, and is suitable for some harsh environments such as high temperature and high radiation.

Description

Technical Field

[0001] The present invention belongs to the technical field of detecting the uniform corrosion state of a metal material surface, and specifically relates to a detection device for evaluating the uniform corrosion of a metal material and a method for evaluating the uniform corrosion of a metal material based on the device. Background Art

[0002] Corrosion refers to the physical-chemical interaction between metals and the environment, which results in changes in the properties of metals and often damages the functions of metals, the environment, or the technical systems of which they are components. In industrial production, there are often problems of failure of equipment and components due to corrosion of metal materials, which poses a serious threat to production safety.

[0003] Metal corrosion is generally divided into uniform corrosion and local corrosion, among which uniform corrosion is the most common form of corrosion. The characteristic of uniform corrosion is that corrosion occurs at almost the same rate on the entire surface of the metal. In a humid atmosphere, after the metal corrodes, the surface generally loses its metallic white luster and changes color. For example, after carbon steel corrodes in an aqueous environment, the surface color changes from white to brown-red (Fe2O3) or black (Fe3O4). Timely understanding and grasping the uniform corrosion of metal materials is of great significance to preventing further corrosion and deterioration of metal materials. Therefore, corresponding equipment and methods for evaluating the corrosion of metal materials are needed.

[0004] At present, the methods for evaluating uniform corrosion of metal materials are mainly carried out through visual inspection of metal surface corrosion or by measuring metal thinning. Both methods have shortcomings. For example, visual inspection is often affected by human subjective factors, which interferes with the evaluation results. In addition, it is limited by the inspection frequency of personnel and cannot timely detect the uniform corrosion of metal materials. Although the method of measuring metal thinning is less affected by human subjective influence, it restricts the long-term stay or entry of personnel in some areas with high heat, high radiation and other areas that are not conducive to personal safety, and cannot timely and effectively evaluate the uniform corrosion of materials. Summary of the invention

[0005] In view of this, in order to overcome the defects of the prior art, the purpose of the present invention is to provide a detection device for evaluating the uniform corrosion of metal materials, which can more timely, scientifically and accurately evaluate the uniform corrosion of metal materials, and can be applied to some harsh environments such as high temperature and high radiation.

[0006] In order to achieve the above object, the present invention adopts the following technical solutions:

[0007] A detection device for evaluating uniform corrosion of metal materials, comprising a matrix-type acquisition device located on the surface of the metal to be detected, the matrix-type acquisition device comprising a plurality of acquisition units arranged in a matrix, each of the acquisition units comprising a distance sensor for monitoring the thickness of the metal surface to be detected, the detection device further comprising a detector connected to the distance sensor and used to convert the change in the thickness of the metal surface to be detected into an electrical signal, and a database management device connected to the matrix-type acquisition device and the detector. The detector periodically turns on and stimulates the distance sensor to monitor and collect eddy current detection signals of the metal to be detected. By setting up a matrix-type acquisition device for collecting data and a database management device connected to the matrix-type acquisition device, the time and degree of uniform corrosion of metal materials can be evaluated more timely, accurately and scientifically, and the measurement can be performed without manual field observation, which is suitable for some harsh environments such as high temperature and high radiation.

[0008] Preferably, the acquisition unit also includes a camera and a light source for photographing the metal surface to be detected, and the acquisition unit is fixed to the metal surface to be detected by a bracket, and adjacent acquisition units are connected by the bracket. The camera and the light source in the matrix acquisition device are directly connected to the database management device; the distance sensor in the matrix acquisition device is connected to the detector, and the detector is connected to the database management device. The camera is used to take initial photos, and the photos taken are transmitted to the database management device and stored as reference photos. Afterwards, the camera takes photos regularly at predetermined intervals, and the photos taken are transmitted to the database management device. The database management device receives the real-time photos for personnel to view at any time. The personnel can compare the real-time photos with the pre-stored reference photos to determine whether the metal material is uniformly corroded and the degree of corrosion.

[0009] More preferably, the adjacent supports are arranged in parallel or vertically, and the collecting unit is arranged at the intersection of the supports.

[0010] Further preferably, the distance sensor is arranged at a position where the brackets intersect, the light source is arranged on the left side of the distance sensor, and the camera is arranged above the distance sensor.

[0011] More preferably, the length of the bracket is consistent, and the distances between adjacent collection units are consistent. Since the length of the bracket is consistent, the spacing between adjacent collection units is equal and the distances between all collection units and the metal surface to be detected are also equal, that is, multiple collection units are arranged in a matrix on the metal surface to be detected.

[0012] In some embodiments, the brackets between adjacent collection units may also be arranged in an arc shape, so that the detection device can be applied to non-planar metal surfaces to be detected such as pipes, thereby further expanding the application range of the detection device.

[0013] Preferably, the detection device further comprises an alarm device connected to the database management device. By setting the alarm device, when the eddy current sensor in the acquisition unit detects that the thickness of the metal surface to be detected is lower than a set value, the database management device controls the alarm device to sound an alarm.

[0014] Preferably, the distance sensor is an eddy current sensor, and the detector is an eddy current detector. The eddy current sensor can measure the distance between the metal conductor to be detected and the probe surface in a non-contact, high-linear, and high-resolution manner, and is used to detect the thickness of the metal to be detected; the eddy current detector is used to regularly turn on and excite the eddy current sensor to monitor and collect the eddy current detection signal of the metal to be detected, and convert the eddy current detection signal of the metal to be detected into an electrical signal and transmit it to the database management device, which receives the electrical signal and creates an amplitude parameter time variation curve of the electrical signal. When the amplitude of the electrical signal decreases, that is, the amplitude of the eddy current detection signal decreases, it means that the thickness of the metal to be detected becomes thinner.

[0015] In a specific implementation application, the distance between the acquisition unit and the metal surface to be measured is determined based on the principle that the actual camera can clearly capture the metal surface and the eddy current sensor can accurately detect the current signal caused by the change in metal thickness; the number of acquisition units to be installed is determined according to the size of the actual metal surface to be measured.

[0016] The present invention also provides a detection method according to the detection device for evaluating uniform corrosion of metal materials as described above, comprising the following steps:

[0017] 1) installing a plurality of collection units on the metal surface to be detected, wherein the collection units are arranged in a matrix on the metal surface to be monitored;

[0018] 2) After the detection device is installed, a camera is used to take photos, and the photos taken are transmitted to the database management device and used as reference photos;

[0019] 3) The camera takes pictures at set intervals and transmits them to the database management device, the distance sensor monitors the thickness of the metal surface to be detected in real time, and transmits the thickness change of the metal surface to be detected to the detector, and the detector converts the current change caused by the thickness change of the metal surface to be detected into an electrical signal and transmits it to the database management device;

[0020] 4) When the images captured by the cameras in all acquisition units undergo consistent changes, and the surface thickness reduction of the metal to be detected in all acquisition units is consistent, uniform corrosion occurs on the surface of the metal to be detected.

[0021] Preferably, in step 3), when the database management device receives the thickness change of the metal surface to be detected and determines that the thickness of the metal surface to be detected is lower than a set value, the database management device controls the alarm device to sound an alarm.

[0022] Compared with the prior art, the advantages of the present invention are: the detection device for evaluating uniform corrosion of metal materials of the present invention has a reasonable structural design. By setting a matrix acquisition device for collecting data and a database management device connected to the matrix acquisition device, it can more intelligently, timely, accurately and scientifically evaluate the time and degree of uniform corrosion of metal materials, provide a reference for targeted prevention or control, effectively avoid further corrosion and deterioration of metal materials, and can measure without manual field observation, saving manpower investment. It is suitable for some harsh environments such as high temperature and high radiation and some non-planar metal surfaces to be detected. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0024] Figure 1 It is a schematic diagram of the flow of a detection device for evaluating uniform corrosion of metal materials in a preferred embodiment of the present invention;

[0025] Figure 2 is a schematic diagram of a collection unit in a detection device according to a preferred embodiment of the present invention;

[0026] Among them: 1- acquisition unit; 2- camera; 3- light source; 4- eddy current sensor; 5- bracket. DETAILED DESCRIPTION

[0027] In order to enable those skilled in the art to better understand the technical solution of the present invention, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0028] Example 1 A detection device for evaluating uniform corrosion of metal materials

[0029] Refer to the attached Figure 1-2 , a detection device for evaluating uniform corrosion of metal materials in this embodiment includes a matrix acquisition device located on the surface of the metal to be detected and used to monitor the thickness of the metal surface to be detected, a detector for converting changes in the thickness of the metal surface to be detected into electrical signals, a database management device connecting the matrix acquisition device and the detector, and an alarm device connected to the database management device.

[0030] The matrix collection device includes a plurality of collection units 1 arranged in a matrix, and a bracket 5 connecting adjacent collection units 1 and fixing the collection units 1 on the metal surface to be detected. The metal surface to be detected is provided with a plurality of collection units 1, and the plurality of collection units 1 are regularly arranged in a matrix on the metal surface to be detected, so that the detection result is more accurate.

[0031] Each acquisition unit 1 includes a distance sensor for monitoring the thickness of the metal surface to be detected, a camera 2 for photographing the metal surface to be detected, and a light source 3. The acquisition unit 1 is fixed to the metal surface to be detected by a bracket 5, and adjacent acquisition units 1 are connected by the bracket 5. The camera 2 takes initial photos, and the photos taken are transmitted to the database management device and stored as reference photos. After that, the camera 2 takes photos regularly at predetermined intervals, and the photos taken are transmitted to the database management device. The database management device receives the real-time photos for personnel to view at any time. The personnel can compare the real-time photos with the pre-stored reference photos to determine whether the metal material is uniformly corroded and the degree of corrosion.

[0032] In this embodiment, the distance sensor is an eddy current sensor 4, and the detector is an eddy current detector. The eddy current sensor 4 can measure the distance between the metal conductor to be detected and the probe surface in a non-contact, high-linearity, and high-resolution manner. By setting an alarm device, when the eddy current sensor 4 in the acquisition unit 1 detects that the thickness of the metal surface to be detected is lower than a set value, the database management device controls the alarm device to sound an alarm.

[0033] Adjacent brackets 5 are arranged in parallel or vertically, and the acquisition units 1 are arranged at the intersection of the brackets 5. Specifically, the eddy current sensor 4 is arranged at the intersection of the brackets 5, the light source 3 is arranged on the left side of the distance sensor, and the camera 2 is arranged above the distance sensor. In this embodiment, the length of the brackets 5 is consistent, and the distance between adjacent acquisition units 1 is consistent. Since the length of the brackets 5 is consistent, the spacing between adjacent acquisition units 1 is equal and the distance between all acquisition units 1 and the metal surface to be detected is also equal, that is, multiple acquisition units 1 are arranged in a matrix on the metal surface to be detected, such as Figure 2As shown, the dotted line part in the figure represents the collection unit 1 that can be extended, that is, the number of the collection units 1 is set according to actual needs.

[0034] The characteristic of the matrix type is that the number of acquisition units 1 is evenly arranged according to the actual size of the metal to be detected. For example, if only 9 acquisition units 1 are needed, they can be evenly divided into three rows and three columns, with 3 in each row and column. The matrix acquisition device is placed at a certain distance from the surface of the metal to be detected, and the distance is based on ensuring that the camera 2 can shoot clearly and the eddy current sensor 4 can collect valid data.

[0035] In the specific implementation application, the distance between the acquisition unit 1 and the metal surface to be measured is determined based on the principle that the actual camera 2 can clearly capture the metal surface and the eddy current sensor 4 can accurately detect the current signal caused by the change in metal thickness; the number of acquisition units 1 installed is determined according to the size of the actual metal surface to be detected.

[0036] By setting up a matrix acquisition device for collecting data and a database management device connected to the matrix acquisition device, the time and degree of uniform corrosion of metal materials can be evaluated more timely, accurately and scientifically, and the measurement can be performed without manual field observation. It is suitable for some harsh environments such as high temperature and high radiation.

[0037] The bracket 5 in this embodiment is linear. In some other embodiments, the bracket 5 between adjacent collection units 1 can also be arc-shaped, so that the detection device can be applied to non-planar metal surfaces to be detected such as pipes, thereby further expanding the application range of the detection device.

[0038] Example 2 A detection method for evaluating uniform corrosion of metal materials

[0039] This embodiment provides a detection method for evaluating uniform corrosion of metal materials based on the detection device of Embodiment 1, comprising the following steps:

[0040] 1) A plurality of collection units 1 are installed on the metal surface to be detected, and the collection units 1 are arranged in a matrix on the metal surface to be monitored.

[0041] The characteristic of the matrix type is that the number of acquisition units 1 is evenly arranged according to the actual size of the metal to be detected. For example, if only 9 acquisition units 1 are needed, they can be evenly divided into three rows and three columns, with 3 in each row and column. The matrix acquisition device is placed at a certain distance from the surface of the metal to be detected, and the distance is based on ensuring that the camera 2 can shoot clearly and the eddy current sensor 4 can collect valid data.

[0042] The distance between the acquisition unit 1 and the metal surface to be measured is determined based on the principle that the actual camera 2 can clearly capture the metal surface and the eddy current sensor 4 can accurately detect the current signal caused by the change in metal thickness; the number of acquisition units 1 to be installed is determined according to the size of the actual metal surface to be measured.

[0043] 2) After the detection device is installed, the camera 2 is used to take photos, and the photos taken are transmitted to the database management device and used as reference photos.

[0044] Specifically, the acquisition unit 1 in the matrix acquisition device and the corresponding camera 2 can simultaneously acquire the real-time status of different representative areas of the entire surface of the metal to be detected, and record them. When shooting, the original uncorroded state of the metal to be detected is first acquired as a reference comparison photo.

[0045] 3) The camera 2 takes pictures at set intervals and transmits them to the database management device. The eddy current sensor 4 monitors the thickness of the metal surface to be detected in real time, and transmits the changes in the thickness of the metal surface to be detected to the eddy current detector. The eddy current detector converts the current changes caused by the changes in the thickness of the metal surface to be detected into signals and transmits them to the database management device.

[0046] The interval time period can be manually set by the database management device. For example, it can be set to automatically and regularly take and collect photos every 1 hour, 2 hours, etc., take and collect photos of the metal surface in situ, and transmit the collected photos to the data management system for personnel to view at any time. The corresponding eddy current sensor 4 can measure the thickness of different areas of the measured metal in real time. The eddy current sensor 4 is connected to the eddy current detector to display the real-time measured metal thickness changes and transmit them to the data management system at the same time.

[0047] In step 3), a minimum setting value of the metal surface thickness to be detected is preset in the database management device. When the database management device receives the change of the metal surface thickness to be detected and determines that the metal surface thickness to be detected is lower than the minimum setting value, the database management device controls the alarm device to sound an alarm.

[0048] 4) When the images captured by the cameras 2 in all the acquisition units 1 undergo consistent changes, and the surface thickness reduction of the metal to be detected in all the acquisition units 1 is consistent, uniform corrosion occurs on the surface of the metal to be detected.

[0049] Specifically, according to the characteristics of uniform corrosion, if the colors of the newly collected photos by the cameras 2 in all the collection units 1 change to the same degree at the same time, and the metal thickness measured by the eddy current sensor 4 decreases in a similar manner, it indicates that uniform corrosion has occurred on the metal surface. Based on this, the time and degree of uniform corrosion of the metal can be clearly determined in a timely manner. When the degree of uniform corrosion exceeds the set threshold, that is, the minimum value, the alarm system is triggered and an alarm is sounded. The threshold of the degree of uniform corrosion is set by the degree of metal thinning, that is, when the eddy current sensor 4 detects that the distance between the probe of the eddy current sensor 4 and the metal surface to be detected exceeds a certain value, the alarm system is triggered and an alarm is sounded.

[0050] The above embodiments are only for illustrating the technical concept and features of the present invention, and their purpose is to enable people familiar with this technology to understand the contents of the present invention and implement them accordingly. They cannot be used to limit the protection scope of the present invention. Any equivalent changes or modifications made according to the spirit of the present invention should be included in the protection scope of the present invention.

Claims

1. A detection method for evaluating uniform corrosion of metal materials, characterized in that: The detection device comprises a matrix-type acquisition device located on the metal surface to be detected, the matrix-type acquisition device comprises a plurality of acquisition units arranged in a matrix, each of the acquisition units comprises a distance sensor for monitoring the thickness of the metal surface to be detected, the detection device further comprises a detector connected to the distance sensor and used for converting the change of the thickness of the metal surface to be detected into an electrical signal, and a database management device connected to the matrix-type acquisition device and the detector; The acquisition unit also includes a camera and a light source for photographing the metal surface to be detected. The acquisition unit is fixed to the metal surface to be detected by a bracket, and adjacent acquisition units are connected by the bracket; the adjacent brackets are arranged in parallel or vertically, and the acquisition unit is arranged at the intersection of the brackets; The camera and the light source are connected to the database management device, the distance sensor is connected to the detector, and the detector is connected to the database management device; The camera takes an initial photo, and the photo taken is transmitted to the database management device and stored as a reference photo; thereafter, the camera takes photos regularly at a predetermined interval, and the photos taken are transmitted to the database management device, and the database management device receives the real-time photos for personnel to view at any time, and the personnel can compare the real-time photos with the pre-stored reference photos to determine whether the metal material is uniformly corroded and the degree of corrosion; The detection device also includes an alarm device connected to the database management device; when the eddy current sensor in the acquisition unit detects that the thickness of the metal surface to be detected is lower than a set value, the database management device controls the alarm device to sound an alarm; The distance between the acquisition unit and the metal surface to be detected is determined based on the principle that the actual camera can clearly capture the metal surface and the eddy current sensor can accurately detect the current signal caused by the change in metal thickness; the number of acquisition units to be installed is determined according to the size of the metal surface to be actually detected; The detection method comprises the following steps: 1) Installing a plurality of acquisition units on the metal surface to be detected, wherein the acquisition units are arranged in a matrix on the metal surface to be detected; 2) After the detection device is installed, a camera is used to take photos, and the photos taken are transmitted to the database management device and used as reference photos; 3) The camera takes pictures at set intervals and transmits them to the database management device. The distance sensor monitors the thickness of the metal surface to be detected in real time and transmits the thickness change of the metal surface to be detected to the detector. The detector converts the current change caused by the thickness change of the metal surface to be detected into an electrical signal and transmits it to the database management device. 4) When the images taken by the cameras in all acquisition units undergo consistent changes, and the surface thickness of the metal to be detected in all acquisition units decreases in a consistent manner, uniform corrosion occurs on the surface of the metal to be detected; In step 3), when the database management device receives the thickness change of the metal surface to be detected and determines that the thickness of the metal surface to be detected is lower than a set value, the database management device controls the alarm device to sound an alarm.

2. The detection method according to claim 1, characterized in that: The distance sensor is arranged at the intersection of the brackets, the light source is arranged on the left side of the distance sensor, and the camera is arranged above the distance sensor.

3. The detection method according to claim 1, characterized in that: The lengths of the brackets are consistent, and the distances between adjacent collection units are consistent.

4. The detection method according to any one of claims 1 to 3, characterized in that: The distance sensor is an eddy current sensor, and the detector is an eddy current detector.

Images