An ultrasonic detection method and system for strain clamp joints, and an electronic device

Abstract

The application discloses a strain clamp joint ultrasonic detection method and system and an electronic device, wherein the method comprises the following steps: S1, collecting strain clamp wall thickness data through a phased array detector; S2, removing the pressure interval that makes the edge distance of the strain clamp after crimping unqualified; S3, arranging the wall thickness interval of the strain clamp obtained through ultrasonic detection in the qualified pressure interval; and S4, judging whether the crimping of the strain clamp is qualified according to the collected strain clamp wall thickness data and the obtained wall thickness interval. In the technical scheme, based on the above steps, if the average value of the wall thickness obtained through detection by the ultrasonic phased array equipment is greater than the wall thickness interval obtained through arrangement under the condition that the pressure is qualified, it can be determined that the strain clamp is qualified. Compared with the prior art, the technical scheme disclosed by the application has higher detection result accuracy and higher detection efficiency.

Description

Technical Field

[0001] This application relates to the field of ultrasonic testing technology, and more specifically, to an ultrasonic testing method for tension wire clamp joints. In addition, this application also relates to an ultrasonic testing system and electronic equipment for tension wire clamp joints. Background Technology

[0002] Tension clamp crimping joints are crimped power fittings used in overhead transmission lines and are widely used in power grid systems. The process involves using a crimping machine to first crimp the steel core and aluminum stranded wire together, and then crimp the steel core aluminum stranded wire and aluminum bushing together. In this process, the crimping process control of the tension clamp crimping joint ultimately determines the quality of the crimping. Accidents caused by crimping quality problems of tension clamps and splicing pipes are mostly due to crimping quality issues such as the conductor and ground wire not being properly threaded into the crimping pipe or the crimping position not conforming to relevant regulations.

[0003] Using tension clamps with quality problems on transmission lines can lead to safety hazards. Traditional inspection and analysis methods for tension clamps can only judge the crimping quality of tension clamps based on data obtained from measuring the outer diameter, which has certain limitations. The accuracy of existing tension clamp joint quality testing methods needs to be improved.

[0004] Therefore, how to provide an ultrasonic testing method for tension wire clamps that has high accuracy and efficiency has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] To address the aforementioned technical problems, this application provides an ultrasonic testing method and system for tension wire clamps, as well as an electronic device, which has high accuracy in testing results and high testing efficiency.

[0006] The technical solution provided in this application is as follows:

[0007] This application provides an ultrasonic testing method for tension clamp joints, comprising the following steps: S1 acquiring tension clamp wall thickness data using a phased array detector; S2 removing pressure ranges that cause unqualified edge distances after tension clamp crimping; S3 adjusting the wall thickness range obtained from ultrasonic testing of the tension clamp within the qualified pressure range; S4 determining whether the tension clamp crimping is qualified based on the measured tension clamp wall thickness data and the obtained wall thickness range.

[0008] Furthermore, in a preferred embodiment of the present invention, the method further includes the step of: setting a fuzzy range of 0.5 to 1 mm; if the wall thickness of the tension clamp is detected to be within the fuzzy range, then the clamping of the tension clamp is re-detected and the result is determined to be qualified.

[0009] Furthermore, in a preferred embodiment of the present invention, the step of "acquiring tension clamp wall thickness data by ultrasonic data acquisition using a phased array detector" includes: using an ultrasonic phased array device to detect and measure the wall thickness at the point where the steel core and the steel anchor are pressed together.

[0010] Furthermore, in a preferred embodiment of the present invention, the step of "acquiring tension clamp wall thickness data by ultrasonic data acquisition using a phased array detector" includes: using an ultrasonic phased array device to detect and measure the wall thickness at the location where the slot and the aluminum sleeve are pressed together.

[0011] Furthermore, in a preferred embodiment of the present invention, the step of "acquiring tension clamp wall thickness data by ultrasonic data acquisition using a phased array detector" includes: using an ultrasonic phased array device to detect the crimping position of the aluminum stranded wire and the aluminum sleeve, and measuring the wall thickness at that location.

[0012] Furthermore, in a preferred embodiment of the present invention, the L55-20L64-0.4*5 detection probe, SL55-N0L15mm wedge, and CRS scanner head are used.

[0013] Furthermore, in a preferred embodiment of the present invention, the steel core and the steel anchor are pressed together immediately after being inspected by a phased array device. The pressed section is hexagonal in shape, and data is collected on all six sides to ensure that the probe scans all pressed positions at a uniform speed.

[0014] Furthermore, in a preferred embodiment of the present invention, a phased array ultrasonic transducer is used to concentrate acoustic energy at the detection point by emitting a focused sound beam, thereby achieving high detection resolution.

[0015] Furthermore, this application also provides an ultrasonic testing system for tension wire clamp joints, used to assist in performing the ultrasonic testing method for tension wire clamp joints as described above, comprising: a monitoring instrument, a scanner, and a probe; a hardware system, a software system, and a power control network, wherein the hardware system and software system are housed within the monitoring instrument; the hardware system includes a phased array transceiver module and a conventional transceiver module, wherein the phased array transceiver module includes an FPGA and a CPU, the FPGA is externally connected to a 256MB DDR3 memory module, and the CPU is externally connected to a memory module; the software system includes an open-source Linux kernel, a GTK interface, and GCC; the power control network includes an FPG control module and a microcontroller control module; the FPG control module includes TOFD high / low voltage control and PA high / low voltage control, and the microcontroller control module controls the power switch, the core board power control, and the power supply control of peripheral devices.

[0016] In addition, this application also provides an electronic device, including at least one processor and a memory; the memory stores computer execution instructions; the at least one processor executes the computer execution instructions stored in the memory, causing the at least one processor to perform the ultrasonic testing method for tension wire clamps as described above.

[0017] This invention provides an ultrasonic testing method, system, and electronic device for tension clamp joints. The ultrasonic testing method for tension clamp joints includes the following steps: S1 acquiring tension clamp wall thickness data using a phased array detector; S2 removing pressure ranges that cause unqualified edge distances after tension clamp crimping; S3 adjusting the wall thickness range obtained from ultrasonic testing of the tension clamp within the qualified pressure range; S4 determining whether the tension clamp crimping is qualified based on the acquired tension clamp wall thickness data and the obtained wall thickness range. In this technical solution, the feasibility of using ultrasonic phased array equipment to detect the qualification of tension clamp crimping is verified by combining the conclusions of finite element analysis and the results of ultrasonic experiments on tension clamps. Relevant ultrasonic experimental data were compiled, and based on the edge distance after crimping, a method for determining the qualification of tension clamps using ultrasonic testing was proposed: The pressure range that would cause the edge distance after crimping to be unqualified is removed; the wall thickness range obtained by ultrasonic testing within the qualified pressure range is compiled; if the average wall thickness obtained by ultrasonic phased array equipment under qualified pressure conditions is greater than the compiled wall thickness range, it can be determined as qualified. Compared with existing technologies, the technical solution involved in this invention has higher accuracy and efficiency in detection results. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application 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 only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the steps of the ultrasonic testing method for tension wire clamps provided in an embodiment of the present invention;

[0020] Figure 2 This is a schematic diagram of the ultrasonic testing system for tension clamp joints according to an embodiment of the present invention. Detailed Implementation

[0021] To enable those skilled in the art to better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly set on the other component; when a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to the other component.

[0023] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "first", "second", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0024] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" or "several" means two or more, unless otherwise explicitly specified.

[0025] It should be noted that the structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which this application can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size should still fall within the scope of the technical content disclosed in this application, provided that they do not affect the effects and purposes that this application can produce.

[0026] Please Figure 1 and Figure 2As shown, this application provides an ultrasonic testing method and system for tension clamp joints, and an electronic device. The ultrasonic testing method for tension clamp joints includes the following steps: S1 acquiring tension clamp wall thickness data using a phased array detector; S2 removing pressure ranges that cause unqualified edge distances after tension clamp crimping; S3 adjusting the wall thickness range obtained from ultrasonic testing of the tension clamp within the qualified pressure range; S4 determining whether the tension clamp crimping is qualified based on the measured tension clamp wall thickness data and the obtained wall thickness range. In this technical solution, the feasibility of using ultrasonic phased array equipment to detect the qualification of tension clamp crimping is verified by combining the conclusions of finite element analysis and the results of ultrasonic experiments on tension clamps. Relevant ultrasonic experimental data were compiled, and based on the edge distance after crimping, a method for determining the qualification of tension clamps using ultrasonic testing was proposed: The pressure range that would cause the edge distance after crimping to be unqualified is removed; the wall thickness range obtained by ultrasonic testing within the qualified pressure range is compiled; if the average wall thickness obtained by ultrasonic phased array equipment under qualified pressure conditions is greater than the compiled wall thickness range, it can be determined as qualified. Compared with existing technologies, the technical solution involved in this invention has higher accuracy and efficiency in detection results.

[0027] Specifically, in the embodiments of the present invention, the method further includes the step of setting a 0.5-1mm fuzzy range. If the wall thickness of the tension clamp is detected to be within the fuzzy range, the tension clamp is re-tested and the test is performed to determine whether the clamping is qualified. Due to factors such as acoustic interference on site and material casting errors, the present invention sets a 0.5-1mm fuzzy range. If the detection is within the fuzzy range, the test is re-tested and the test is performed, which helps to improve the accuracy of the test results.

[0028] Specifically, in an embodiment of the present invention, the step of "acquiring tension clamp wall thickness data by ultrasonic data acquisition using a phased array detector" includes: using an ultrasonic phased array device to detect and measure the wall thickness at the point where the steel core and the steel anchor are pressed together.

[0029] Specifically, in an embodiment of the present invention, the step "acquiring tensile clamp wall thickness data by ultrasonic data acquisition using a phased array detector" includes: using an ultrasonic phased array device to detect and measure the wall thickness at the location where the slot and the aluminum sleeve are pressed together.

[0030] Specifically, in an embodiment of the present invention, the step of "acquiring tension clamp wall thickness data by ultrasonic data acquisition using a phased array detector" includes: using an ultrasonic phased array device to detect the crimping position of the aluminum stranded wire and the aluminum sleeve, and measuring the wall thickness at that location.

[0031] Specifically, in the embodiments of the present invention, the L55-20L64-0.4*5 detection probe, SL55-N0L15mm wedge block, and CRS scanner head are used.

[0032] Specifically, in an embodiment of the present invention, after the steel core and the steel anchor are pressed together, a phased array device is used for detection immediately. The pressed section is hexagonal in shape, and data is collected on all six sides to achieve uniform scanning of all pressed positions by the probe.

[0033] Specifically, in embodiments of the present invention, a phased array ultrasonic transducer is used to concentrate acoustic energy at the detection point by emitting a focused sound beam, thereby achieving high detection resolution.

[0034] The ultrasonic testing method for tension clamp joints disclosed in this invention will be specifically described below with reference to specific embodiments:

[0035] In this embodiment of the invention, ultrasonic data acquisition utilizes a Phascan phased array detector, an L55-20L64-0.4*5 probe, an SL55-N0L 15mm wedge, and a CRS scanner head. When ultrasonic waves propagate to the contact surface of two parts and the cavity between the stranded wires, they bounce back onto the probe, resulting in the final ultrasonic spectrum. It should be noted that in the ultrasonic spectrum, S represents the cross-sectional view of the current probe position; C represents the top view; and B represents the B-scan view, which is a side projection display of the workpiece. The horizontal axis in the image represents the distance traveled along the scan line (scanning axis), and the vertical axis represents the depth (ultrasonic axis). The ultrasonic data naming convention is: SY-240-844-1-3000.

[0036] In this embodiment of the invention, when using a phased array device to detect the position of the steel anchor and steel core, the ultrasonic signal of the phased array detection device cannot penetrate the air, so the detection needs to be performed immediately after the steel anchor and steel core are crimped. The ultrasonic spectrum shows red diagonal lines, which are the result of the multiple strands of the steel core being twisted together. The length of this red diagonal line is the area where the steel core and steel anchor are in contact, the actual crimped area. As long as the actual crimped area is equal to the theoretical crimping length of the tension clamp, it means that the steel core is properly inserted. The theoretical crimping length between the steel anchor and steel core varies for different models of tension clamps. Specifically, the crimping area between the NY-240 / 40 steel anchor and steel core is 110mm, the NY-400 / 35 steel anchor and steel core is 100mm, and the NY-630 / 45 steel anchor and steel core is 110mm.

[0037] According to the experiment, when using a standard pressure of 80MPa for crimping, the average wall thickness of NY-400 / 35 was measured to be 4.19mm. The entire testing section was divided into several equal areas, and readings were taken, recorded, and the average value was calculated as the wall thickness of the steel core. The average wall thickness of NY-240 / 40 was 4.06mm, and the average wall thickness of NY-630 / 45 was 4.13mm.

[0038] In this embodiment of the invention, the first layer of the ultrasonic testing map of the steel anchor step and aluminum sleeve crimping position represents the top of the groove, and the lower layer represents the bottom of the groove. By measuring the depth of the top and bottom of the groove, the depth and number of grooves are determined. Taking the NY-240 / 40 tension clamp as an example, when using phased array ultrasonic testing technology, if the imaging results of the bottom of the groove show unevenness, and one detected groove bottom depth is 1.8mm while another detected groove bottom depth is less than 1.8mm, comparing the actual dimensions of the groove, there is no complete contact at the right end of the groove bottom, therefore it is judged as unqualified.

[0039] Furthermore, in this embodiment of the invention, the ultrasonic phased array device was used to detect the crimping position between the steel core and the steel anchor. The phased array imaging results showed the size of the cavity and allowed for the measurement of the wall thickness at that location. The average depth of the five NY-240 / 40 tension wire clamps crimped using the standard crimping process outside the steel anchor was recorded and calculated to be 4.06 mm. The ultrasonic phased array device was also used to detect the crimping position between the slot and the aluminum sleeve. The phased array imaging clearly showed two steps. The imaging image clearly displayed the bottom of the slot, allowing for direct reading of its depth. The average thickness of the crimping position of the five NY-240 / 40 slots crimped to the aluminum sleeve outside the aluminum sleeve was recorded and the average depth was calculated to be 6.92 mm.

[0040] The crimping locations of the aluminum stranded wire and aluminum sleeve were inspected using an ultrasonic phased array device. The phased array imaging results clearly showed multiple cavities, and the wall thickness at these locations was measured. The average thickness of the five NY-240 / 40 aluminum stranded wire and aluminum sleeve crimping locations using the standard crimping process was recorded using the ultrasonic phased array device, and the average depth value was found to be 6.51 mm.

[0041] In summary, at the steel core and steel anchor crimping location, simulation data shows the cavity depth below the measured surface is 4.48 mm, while the average experimental depth is 4.06 mm. At the slot crimping location, simulation data shows the slot bottom depth is 7.56 mm, while the experimental data shows 6.92 mm. At the aluminum sleeve and aluminum stranded wire crimping location, simulation data shows the cavity depth below the measured surface is 6.65 mm, while the experimental data shows a depth of 6.51 mm. The simulation and experimental data are very close, demonstrating the reliability of this ultrasonic device in determining the thickness of the tension clamp.

[0042] Furthermore, this application also provides an ultrasonic testing system for tension wire clamp joints, used to assist in performing the ultrasonic testing method for tension wire clamp joints as described above, comprising: a monitoring instrument, a scanner, and a probe; a hardware system, a software system, and a power control network, wherein the hardware system and software system are housed within the monitoring instrument; the hardware system includes a phased array transceiver module and a conventional transceiver module, wherein the phased array transceiver module includes an FPGA and a CPU, the FPGA is externally connected to a 256MB DDR3 memory module, and the CPU is externally connected to a memory module; the software system includes an open-source Linux kernel, a GTK interface, and GCC; the power control network includes an FPG control module and a microcontroller control module; the FPG control module includes TOFD high / low voltage control and PA high / low voltage control, and the microcontroller control module controls the power switch, the core board power control, and the power supply control of peripheral devices.

[0043] In addition, this application also provides an electronic device, including at least one processor and a memory; the memory stores computer execution instructions; the at least one processor executes the computer execution instructions stored in the memory, causing the at least one processor to perform the ultrasonic testing method for tension wire clamps as described above.

[0044] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An ultrasonic testing method for tension wire clamp joints, characterized in that, Includes the following steps: S1 uses a phased array detector to collect ultrasonic data on the wall thickness of the tension cable clamp; S2 removes the pressure zone where the edge distance is unqualified after the tension clamp is crimped; S3 is within the qualified pressure range, and the wall thickness range of the tension clamp is obtained by ultrasonic testing. S4 determines whether the tension clamp crimping is qualified based on the collected tension clamp wall thickness data and the obtained wall thickness range; if the average wall thickness obtained is greater than the obtained wall thickness range under qualified pressure, it can be judged as qualified. It also includes the following steps: setting a 0.5~1mm fuzzy range; if the wall thickness of the tension clamp is detected to be within the fuzzy range, then re-inspect and determine whether the tension clamp crimping is qualified. The step "Acquiring tension cable clamp wall thickness data using ultrasonic data acquisition via phased array detector" includes: using ultrasonic phased array equipment to detect and measure the wall thickness data at the location where the steel core and steel anchor are pressed together. The step "Acquiring tension clamp wall thickness data using ultrasonic data acquisition via phased array testing instrument" includes: using ultrasonic phased array equipment to detect and measure the wall thickness data at the joint between the slot and the aluminum sleeve. The step "Acquiring tension wire clamp wall thickness data using ultrasonic data acquisition via phased array detector" includes: using ultrasonic phased array equipment to detect the crimping position of the aluminum stranded wire and aluminum sleeve, and measuring the wall thickness data at that location.

2. The ultrasonic testing method for tension clamp joints according to any one of claims 1, characterized in that, Ultrasonic data acquisition specifically employed a PHASCAN phased array detector; L55-20L64-0.4 5 detection probes, SL55-N0L 15mm wedge block, CRS scanner head.

3. The ultrasonic testing method for tension clamp joints according to claim 1, characterized in that, Immediately after the steel core and steel anchor are crimped together, phased array equipment is used for testing. The crimped section is hexagonal in shape, and data is collected from all six sides to ensure that the probe scans all crimped positions at a uniform speed.

4. The ultrasonic testing method for tension clamp joints according to claim 2, characterized in that, By using a phased array ultrasonic transducer, a focused sound beam is emitted, concentrating the sound energy at the detection point, thereby achieving high detection resolution.

5. An ultrasonic testing system for tension wire clamp joints, characterized in that, The method for assisting in the ultrasonic testing of tension clamp joints according to any one of claims 1 to 4 includes: a monitoring instrument, a scanner, and a probe; a hardware system, a software system, and a power control network, wherein the hardware system and software system are housed within the monitoring instrument; the hardware system includes a phased array transceiver module and a conventional transceiver module, wherein the phased array transceiver module includes an FPGA and a CPU, wherein the FPGA is externally connected to a 256MB DDR3 memory module, and the CPU is externally connected to a memory module; the software system includes an open-source Linux kernel, a GTK interface, and GCC; the power control network includes an FPG control module and a microcontroller control module; the FPG control module includes TOFD high and low voltage control and PA high and low voltage control, and the microcontroller control module controls the power switch, the core board power control, and the power supply control of peripheral devices.

6. An electronic device, characterized in that, It includes at least one processor and a memory; the memory stores computer execution instructions; the at least one processor executes the computer execution instructions stored in the memory, causing the at least one processor to perform the ultrasonic testing method for tension clamp joints as described in any one of claims 1 to 4.

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