Horizontal continuous casting copper pipe blank on-line ultrasonic testing device

Abstract

The application provides a horizontal continuous casting copper pipe blank online ultrasonic detection device, which comprises a feeding assembly, a supporting assembly, a water circulation assembly, a horizontal moving assembly, a detection assembly and an upper computer, one side of the supporting assembly is provided with the feeding assembly, copper pipe blanks are arranged on the feeding assembly, the top of the supporting assembly is provided with the horizontal moving assembly, the top of the horizontal moving assembly is provided with the detection assembly, the copper pipe blanks pass through the detection assembly and are subjected to ultrasonic detection, the inside of the supporting assembly is provided with the water circulation assembly, the water circulation assembly is connected with the detection assembly and is used for supplying water to the detection assembly, and the water circulation assembly, the horizontal moving assembly and the detection assembly are connected with the upper computer. The horizontal continuous casting copper pipe blank online ultrasonic detection device can realize copper pipe blank flaw detection and thickness measurement in the horizontal continuous casting stage, can judge whether the next process is carried out according to the detection result, and is convenient to use.

Description

Technical Field

[0001] This invention relates to the field of copper tube billet inspection technology, and in particular to an online ultrasonic inspection device for horizontally continuously cast copper tube billets. Background Technology

[0002] TP2 copper tubes possess excellent electrical and thermal conductivity, weldability, and corrosion resistance, making them widely used in condensers, evaporators, and refrigeration fittings in the air conditioning and other refrigeration industries. In the production process of TP2 copper tubes, horizontal continuous casting is the first and crucial step, directly determining the performance of subsequent processing. However, defects frequently occur in the casting billets during horizontal continuous casting, leading to the scrapping of finished tubes after multiple processing steps. For example, porosity defects in the copper billet, which are difficult to heal in subsequent processing stages, can cause flaring and cracking of the copper tube, resulting in finished product scrap. Since horizontal continuous casting involves numerous steps, fundamentally avoiding defects is extremely difficult. Therefore, detecting defects during the horizontal continuous casting stage and determining whether to proceed to the next process based on the nature of the defects becomes feasible. Thus, designing an online ultrasonic testing device for horizontally continuously cast copper billets is essential. Summary of the Invention

[0003] The purpose of this invention is to provide an online ultrasonic testing device for horizontally continuously cast copper tube billets, which can perform flaw detection and thickness measurement of copper tube billets during the horizontal continuous casting stage, and determine whether to proceed to the next process based on the test results, making it convenient to use.

[0004] To achieve the above objectives, the present invention provides the following solution:

[0005] An online ultrasonic testing device for horizontally continuously cast copper tube billets includes: a feeding assembly, a support assembly, a water circulation assembly, a horizontal moving assembly, a testing assembly, and a host computer. The feeding assembly is located on one side of the support assembly, and the copper tube billet is placed on the feeding assembly. The horizontal moving assembly is located on the top of the support assembly, and the testing assembly is located on the top of the horizontal moving assembly. The copper tube billet passes through the testing assembly for ultrasonic testing. The water circulation assembly is located inside the support assembly and is connected to the testing assembly for supplying water to the testing assembly. The water circulation assembly, the horizontal moving assembly, and the testing assembly are connected to the host computer.

[0006] Optionally, the detection assembly includes a first detection water tank, a first scanning probe box, a second scanning probe box, a first flaw detection probe, a second flaw detection probe, a thickness measuring probe, a photoelectric assembly, a water receiving box, and a marking device. The first detection water tank is located on the top of the horizontal moving assembly. The first detection water tank has an input end and an output end on both sides corresponding to the copper tube blank. The copper tube blank enters the first detection water tank through the input end and exits through the output end. The first scanning probe box is located inside the first detection water tank near the input end, and the second scanning probe box is fixedly located near the output end. A reciprocating rotation motor for the detection assembly is located outside the first detection water tank, driving the reciprocating rotation motor. The first scanning probe box is connected to drive its rotation. Four first flaw detection probes are evenly arranged circumferentially on the first scanning probe box for detecting volumetric defects. Eight second flaw detection probes are arranged axially and circumferentially on the first scanning probe box for detecting strip-shaped defects. Eight thickness measuring probes are evenly arranged circumferentially on the second scanning probe box. A set of through-beam photoelectric components is installed at both the input and output ends of the first detection water tank. The output end of the first detection water tank is equipped with the water receiving box and the marking device. The first flaw detection probes, second flaw detection probes, and thickness measuring probes are connected to the ultrasonic flaw detection and thickness gauge. The ultrasonic flaw detection and thickness gauge, through-beam photoelectric components, detection component reciprocating motor, and marking device are electrically connected to the host computer.

[0007] Optionally, the water circulation assembly includes a second water tank, a third water tank, a water pump, and a filter. The water receiving box is connected to the second water tank. A filter screen and a water solenoid valve are provided between the water receiving box and the second water tank. The second water tank is connected to the third water tank. The third water tank is equipped with a water pump and a filter. The water pump is connected to the first detection water tank. The water solenoid valve, water pump, and filter are electrically connected to the host computer.

[0008] Optionally, the horizontal moving component includes an electric cable changing device, a precision positioning pin, a first support plate, a lifting component, and a second support plate. The electric cable changing device is disposed on the top of the support component, and the precision positioning pin is disposed on one side of the support component corresponding to the electric cable changing device. The first support plate is disposed on the top of the electric cable changing device, the lifting component is disposed on the top of the first support plate, the second support plate is disposed on the top of the lifting component, and the first detection water tank is disposed on the top of the second support plate. The electric cable changing device and the lifting component are electrically connected to the host computer.

[0009] Optionally, the feeding assembly includes a feeding frame and a feeding roller. The feeding frame is provided on one side of the support assembly, the feeding roller is provided on the feeding frame, and a copper tube blank is provided on the feeding roller. The discharge roller is provided on the side of the support assembly away from the feeding frame.

[0010] Optionally, the input and output ends of the first detection water tank are equipped with support wheels to support the copper tube blank.

[0011] According to specific embodiments provided by the present invention, the present invention discloses the following technical effects: The online ultrasonic testing device for horizontally continuously cast copper billets provided by the present invention includes a feeding assembly, a support assembly, a water circulation assembly, a horizontal movement assembly, a testing assembly, and a host computer. It achieves flaw detection and thickness measurement of the copper billet using the water immersion method. The water circulation assembly injects water into the first testing water tank and recovers the filtered water, achieving recycling and saving water resources. The testing assembly, with the assistance of the water circulation assembly, performs ultrasonic flaw detection and thickness measurement. The horizontal movement assembly enables the horizontal movement of the testing assembly, allowing it to test different copper billets. This device can achieve online flaw detection and thickness measurement of copper billets during the horizontal continuous casting stage, and determines whether to proceed to the next process based on the test results, making it convenient to use. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1 This is a schematic diagram of the online ultrasonic testing device for horizontal continuous casting copper tube billets according to an embodiment of the present invention;

[0014] Figure 2 This is a schematic diagram of the internal structure of the first testing water tank;

[0015] Figure 3 This is a schematic diagram illustrating the principle of ultrasonic flaw detection.

[0016] Figure 4 This is a schematic diagram illustrating the principle of ultrasonic thickness measurement.

[0017] Reference numerals in the attached drawings: 1. Copper tube blank; 2. Support assembly; 3. First inspection water tank; 4. Horizontal movement assembly; 5. Precision positioning pin; 6. Second water tank; 7. Discharge roller; 8. First flaw detection probe; 9. Second flaw detection probe; 10. Thickness measuring probe. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] The purpose of this invention is to provide an online ultrasonic testing device for horizontally continuously cast copper tube billets, which can perform flaw detection and thickness measurement of copper tube billets during the horizontal continuous casting stage, and determine whether to proceed to the next process based on the test results, making it convenient to use.

[0020] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0021] like Figure 1 As shown in the figure, the online ultrasonic testing device for horizontally continuously cast copper tube billets provided in this embodiment of the invention includes: a feeding assembly, a support assembly 2, a water circulation assembly, a horizontal moving assembly 4, a testing assembly, and a host computer. The feeding assembly is arranged on one side of the support assembly 2, and a copper tube billet 1 is arranged on the feeding assembly. The horizontal moving assembly 4 is arranged on the top of the support assembly 2, and the testing assembly is arranged on the top of the horizontal moving assembly 4. The copper tube billet 1 passes through the testing assembly for ultrasonic testing. The water circulation assembly is arranged inside the support assembly 2 and is connected to the testing assembly for supplying water to the testing assembly. The water circulation assembly, the horizontal moving assembly, and the testing assembly are connected to the host computer.

[0022] like Figure 2As shown, the detection assembly includes a first detection water tank 3, a first scanning probe box, a second scanning probe box, a first flaw detection probe 8, a second flaw detection probe 9, a thickness measuring probe 10, a photoelectric assembly, a water receiving box, and a marking device. The first detection water tank 3 is mounted on the top of the horizontal moving assembly 4. The first detection water tank 3 has an input end and an output end on both sides corresponding to the copper tube blank 1. The copper tube blank 1 enters the first detection water tank 3 through the input end and exits through the output end. The first scanning probe box is located inside the first detection water tank 3 near the input end, and the second scanning probe box is fixedly located near the output end. A reciprocating rotary motor for the detection assembly is located outside the first detection water tank 3. The reciprocating rotary motor drives the first scanning probe box to rotate. Four first flaw detection probes 8 are evenly arranged circumferentially on the first scanning probe box for detecting volumetric defects. In use, the reciprocating rotary motor controls the first scanning probe box to repeatedly and rapidly rotate circumferentially. The movement distance is greater than 1 / 4 of the circumference of the copper tube, and the effective sound beam of the probe has at least 10% overlap to ensure full coverage of the scanning range. The first scanning probe box has 8 second flaw detection probes 9 arranged along the axial direction and circumference to detect strip-shaped defects. In use, the reciprocating rotary motor of the detection component controls the first scanning probe box to move repeatedly and rapidly along the circumference, with a movement distance greater than 1 / 4 of the circumference of the copper tube. The effective sound beam of the probe has at least 10% overlap to ensure full coverage of the scanning range. It can automatically distinguish between axial and circumferential defects and record the defect position. The second scanning probe box has 8 thickness measuring probes 10 evenly arranged around the circumference, with the distance between each probe being 1 / 8 of the circumference of the copper tube. A set of through-beam photoelectric components is set at the input and output ends of the first detection water tank 3. The output end of the first detection water tank 3 is equipped with the water receiving box and the spraying device. The first flaw detection probe 8, the second flaw detection probe 9 and the thickness measuring probe 10 are connected to the ultrasonic flaw detection and thickness measuring instrument. The ultrasonic flaw detection and thickness measuring instrument, the through-beam photoelectric components, the reciprocating rotary motor of the detection component and the spraying device are electrically connected to the host computer.

[0023] It should be noted that the probe is connected to the ultrasonic flaw detector thickness gauge via a probe cable, and the probe cable is multi-layered shielded to prevent electromagnetic interference.

[0024] The photoelectric component is used to detect whether the copper tube blank 1 is in place or has left, thereby controlling the water pump and water solenoid valve;

[0025] The inkjet marking is used to mark the abnormal copper tube blank 1 when abnormalities occur during flaw detection and thickness measurement.

[0026] The water circulation assembly includes a second water tank 6, a third water tank, a water pump, and a filter. The water receiving box is connected to the second water tank 6. A filter screen and a water solenoid valve are provided between the water receiving box and the second water tank 6. The second water tank 6 is connected to the third water tank. The third water tank is equipped with a water pump and a filter. The water pump is connected to the first detection water tank 3. The water solenoid valve, water pump, and filter are electrically connected to the host computer.

[0027] The water receiving box is used to receive the water flowing out of the first detection water tank 3;

[0028] The horizontal moving component 4 includes an electric wire changing device, a precision positioning pin 5, a first support plate, a lifting component, and a second support plate. The electric wire changing device is disposed on the top of the support component 2, and the precision positioning pin 5 is disposed on one side of the support component 2 corresponding to the electric wire changing device. The first support plate is disposed on the top of the electric wire changing device, the lifting component is disposed on the top of the first support plate, the second support plate is disposed on the top of the lifting component, and the first detection water tank is disposed on the top of the second support plate. The electric wire changing device and the lifting component are electrically connected to the host computer.

[0029] The lifting assembly is used for lifting operations, and can be adjusted appropriately according to the center of different products, with an adjustment range of 40mm.

[0030] The precision positioning pin 5 is used in conjunction with the electric line changing device to ensure that the center of the first testing water tank 3 is concentric with the copper tube blank. Specifically, the bottom of the first testing water tank 3 is provided with a positioning hole, and the precision positioning pin 5 is inserted into the positioning hole for positioning.

[0031] Detailed explanation of the positioning process before use: First, adjust the height of the feeding rack, feeding roller, discharging roller 7 and the first detection water tank 3 according to different copper tube blanks 1 to the appropriate position. Then, change the line through the electric line changing device and achieve positioning through the precision positioning pin 5 to ensure that the first detection water tank 3 is concentric with the copper tube blank 1 and achieve positioning adjustment. It should be noted that the electric line changing device can be a conventional ball screw line changing device.

[0032] The feeding assembly includes a feeding frame and a feeding roller. The feeding frame is provided on one side of the support assembly 2, the feeding roller is provided on the feeding frame, and the copper tube blank 1 is provided on the feeding roller. The discharge roller 7 is provided on the side of the support assembly 2 away from the feeding frame.

[0033] The first detection water tank 3 is equipped with support wheels at both its input and output ends to support the copper tube blank 1.

[0034] The specific testing process is as follows: After the position adjustment is completed, the photoelectric component detects whether a copper tube blank 1 has passed through. If not, no action is taken. If it has, the water pump is turned on to supply water to the first testing water tank 3. It should be noted that the first testing water tank 3 is equipped with a water level gauge connected to the host computer. When the water level gauge reaches the specified height, the water pump is turned off, and a signal to start testing is sent to the ultrasonic flaw detector and thickness gauge. The ultrasonic flaw detector and thickness gauge performs testing through the flaw detection probe and the thickness measurement probe. During this process, the water level gauge monitors in real time. If the height is lower than the preset threshold, the water pump is turned on to replenish water. After the testing is completed, the test results are recorded, and the water solenoid valve is turned on to discharge the water in the first testing water tank 3 to the second water tank 6, and then to the third water tank for filtration and recycling.

[0035] It should be noted that all three water tanks are equipped with top covers and dust covers, and water circulation is achieved through pipes. This is a conventional technical method, so it will not be described in detail here.

[0036] The present invention provides an embodiment in which the inspection process is placed after the sawing machine. When the tube blank is at room temperature, a straight-through method is used, the inspection speed is <600mm / min, the outer diameter of the copper tube is Φ92mm, the wall thickness is 25mm, the surface temperature is <50 degrees, and the relevant national standards are YS-T 1000-2014 Ultrasonic (Longitudinal Wave) Flaw Detection Method for Copper and Copper Alloy Tubes and YS-T 1103-2016 Ultrasonic (Transverse Wave) Inspection Method for Copper and Copper Alloy Tubes.

[0037] First, it is necessary to introduce the principle of ultrasonic flaw detection, specifically as follows: Figure 3 As shown, the pulse-echo ultrasonic flaw detector generates high-frequency electrical pulses, which are transmitted to the elastic medium (workpiece) through the electroacoustic conversion of the probe (chip) to propagate sound waves. When the sound waves encounter interfaces with different acoustic impedances (such as defects), sound wave reflection will occur.

[0038] Secondly, the principle of ultrasonic thickness measurement will be introduced, specifically as follows: Figure 4 As shown, thickness measurement is based on the principle of ultrasonic pulse reflection. When the ultrasonic pulse emitted by the probe passes through the object being measured and reaches the material interface, the pulse is reflected back to the probe. The thickness of the material being measured is determined by accurately measuring the propagation time of the ultrasonic wave within the material.

[0039] This invention employs the water immersion method. The first and second flaw detection probes use a multi-channel rotating probe and a single-crystal angle probe for direct-through rapid scanning, displaying a multi-channel B-scan bar chart or a multi-channel C-scan chart, and performing 100% automatic scanning.

[0040] The host computer needs to be described. In this embodiment, two host computers are set up, and three slave computers are also set up. The host and slave computers are composed of multiple UTR4A (pulse transmitter and receiver board), USS8A (synchronization signal drive filter board), AD100A card, EC4A (encoder driver board), etc. All flaw detection boards have undergone aging tests, vibration tests and three-proof treatment, and their performance is stable, effectively preventing oxidation and electromagnetic interference.

[0041] The ultrasonic flaw detector thickness gauge, model BSA129, meets the requirements of ASTM E317 standard. It has strong anti-interference capabilities and uses multi-channel C-scan real-time imaging and multi-channel network-type switch peak diagram during operation. It can automatically distinguish between axial and circumferential defects and automatically add them to the report. It can display thickness measurement data in real time, and the report format can be customized according to customer requirements. The data storage capacity is 30,000 data entries. The software has functions such as interface tracking, bottom wave monitoring, and TCG curve.

[0042] All 28 probes are low-frequency water immersion focusing probes specifically designed for testing coarse-grained cast copper tubes. Each probe conforms to the ASTM E1065 standard and comes with a test report (including sensitivity, resolution, signal-to-noise ratio, etc.) to ensure consistent performance. All probe cables are multi-layered shielded to prevent electromagnetic interference.

[0043] This embodiment also includes an operating console, control cabinet, testing machine, and comparison test block for ease of use. This part is not the focus of this invention, so it will be described simply. The operating console has three displays (one for multi-channel C-scan imaging, one for multi-channel B-scan switch peak graph, and one for electrical touch screen). All mechanical actions are automatically or manually controlled by the touch screen. The back panel is equipped with Siemens PLC, drivers, and other electrical control components, and is connected to the main control host computer for communication. The control cabinet houses the main instrument components, including two host computers, three slave computers, and one switch. The comparison test block is used to calibrate the relevant parameters of the instrument and probe. The material, process, and other parameters of the test block are the same as those of the actual workpiece. Flat-bottomed holes are drilled according to the selected quality acceptance level, and flat-bottomed grooves are engraved on the axial, circumferential, upper, and lower surfaces, respectively.

[0044] The present invention provides an online ultrasonic testing device for horizontally continuously cast copper billets. The device includes a feeding assembly, a support assembly, a water circulation assembly, a horizontal movement assembly, a testing assembly, and a host computer. It achieves flaw detection and thickness measurement of the copper billets using a water immersion method. The water circulation assembly injects water into the first testing water tank and recovers filtered water, enabling water recycling and saving water resources. The testing assembly, assisted by the water circulation assembly, performs ultrasonic flaw detection and thickness measurement. The horizontal movement assembly allows for horizontal movement of the testing assembly, enabling it to test different copper billets. This device enables online flaw detection and thickness measurement of copper billets during the horizontal continuous casting stage, and determines whether to proceed to the next process based on the test results, making it convenient to use.

[0045] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. An online ultrasonic testing device for horizontally continuously cast copper tube billets, characterized in that, include: The system comprises a feeding assembly, a support assembly, a water circulation assembly, a horizontal moving assembly, a detection assembly, and a host computer. The feeding assembly is located on one side of the support assembly, and a copper tube blank is placed on the feeding assembly. The horizontal moving assembly is located on the top of the support assembly, and the detection assembly is located on the top of the horizontal moving assembly. The copper tube blank passes through the detection assembly for ultrasonic testing. The water circulation assembly is located inside the support assembly and is connected to the detection assembly to supply water to the detection assembly. The water circulation assembly, the horizontal moving assembly, and the detection assembly are connected to the host computer. The detection assembly includes a first detection water tank, a first scanning probe box, a second scanning probe box, a first flaw detection probe, a second flaw detection probe, a thickness measuring probe, a photoelectric assembly, a water receiving box, and a marking device. The first detection water tank is located on the top of the horizontal moving assembly. The first detection water tank has an input end and an output end on both sides corresponding to the copper tube blank. The copper tube blank enters the first detection water tank through the input end and exits through the output end. The first scanning probe box is located inside the first detection water tank near the input end, and the second scanning probe box is fixedly located near the output end. A reciprocating rotation motor for the detection assembly is located outside the first detection water tank. The reciprocating rotation motor drives the... The first scanning probe box is connected to drive its rotation. Four first flaw detection probes are evenly arranged circumferentially on the first scanning probe box for detecting volumetric defects. Eight second flaw detection probes are arranged axially and circumferentially on the first scanning probe box for detecting strip-shaped defects. Eight thickness measuring probes are evenly arranged circumferentially on the second scanning probe box. A set of through-beam photoelectric components is installed at both the input and output ends of the first detection water tank. The output end of the first detection water tank is equipped with the water receiving box and the marking device. The first flaw detection probes, second flaw detection probes, and thickness measuring probes are connected to an ultrasonic flaw detection and thickness gauge. The ultrasonic flaw detection and thickness gauge, through-beam photoelectric components, detection component reciprocating motor, and marking device are electrically connected to the host computer.

2. The online ultrasonic testing device for horizontally continuously cast copper tube billets according to claim 1, characterized in that, The water circulation assembly includes a second water tank, a third water tank, a water pump, and a filter. The water receiving box is connected to the second water tank. A filter screen and a water solenoid valve are provided between the water receiving box and the second water tank. The second water tank is connected to the third water tank. The third water tank is equipped with a water pump and a filter. The water pump is connected to the first detection water tank. The water solenoid valve, water pump, and filter are electrically connected to the host computer.

3. The online ultrasonic testing device for horizontally continuously cast copper tube billets according to claim 1, characterized in that, The horizontal moving assembly includes an electric cable changing device, a precision positioning pin, a first support plate, a lifting assembly, and a second support plate. The electric cable changing device is located on the top of the support assembly, and the precision positioning pin is located on one side of the support assembly corresponding to the electric cable changing device. The first support plate is located on the top of the electric cable changing device, the lifting assembly is located on the top of the first support plate, the second support plate is located on the top of the lifting assembly, and the first detection water tank is located on the top of the second support plate. The electric cable changing device and the lifting assembly are electrically connected to the host computer.

4. The online ultrasonic testing device for horizontally continuously cast copper tube billets according to claim 1, characterized in that, The feeding assembly includes a feeding frame and a feeding roller. The feeding frame is provided on one side of the support assembly, the feeding roller is provided on the feeding frame, and a copper tube blank is provided on the feeding roller. The discharge roller is provided on the side of the support assembly away from the feeding frame.

5. The online ultrasonic testing device for horizontally continuously cast copper tube billets according to claim 1, characterized in that, The first detection water tank is equipped with support wheels at both the input and output ends to support the copper tube blank.

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