Defect non-destructive testing method

Abstract

The application provides a kind of defect nondestructive testing method, comprising the following steps: S1, hoist workpiece to detection device;Detection device includes the deformable frame capable of lifting and transverse motion, the diameter of deformable frame can be telescopic, deformable frame is provided with several detection components;S2, scan the surface shape of workpiece, obtain the structure of workpiece;S3, construct the structure model of workpiece, utilize structure model to adjust the shape of deformable frame, deformable frame moves along the length direction of workpiece, and carries out nondestructive testing to workpiece by detection component;S4, detection result is input into neural network model, and output detection result.The detection component of the application is installed on the deformable frame, can be changed by the shape and diameter of deformable frame, to adapt to different shapes and sizes of workpiece, cover all surfaces and internal detection of workpiece by vertical or transverse movement of deformable frame, can detect petroleum storage tank, oil pipe and its accessories simultaneously, and has strong versatility.

Description

Technical Field

[0001] This invention belongs to the field of nondestructive testing technology for defects, and specifically relates to a nondestructive testing method and system for defects. Background Technology

[0002] Crude oil extracted from the bottom of the well undergoes processes such as oil-gas separation and dehydration before being transported directly to refineries or transfer stations via pipelines. Oil pipelines (also called pipelines or conduits) consist of oil pipes and their accessories, and are equipped with corresponding oil pump units according to the needs of the process flow, forming a complete pipeline system used to complete oil unloading and transfer tasks.

[0003] To ensure the safety of oil transportation and storage, oil storage tanks, pipelines, and their accessories must undergo non-destructive testing (NDT) before use to guarantee the quality of their surfaces and internal components. Existing NDT equipment can only perform NDT on one type of product; for example, NDT equipment for oil storage tanks can only test oil storage tanks, and NDT equipment for pipelines can only test pipelines. Pipeline accessories require separate NDT equipment for testing.

[0004] For example, the rotary non-destructive testing device for oil storage tanks disclosed in CN202220427850.X and CN201711271278.2 can only test large rotating bodies like oil storage tanks. They cannot test the inner and outer surfaces of oil pipes, nor can they test irregular oil pipe fittings such as pipe joints, supports, flanges, and pipe supports. Similarly, the ultrasonic-based non-destructive testing device for oil pipelines disclosed in CN202220954547.5 can only test regular rotating bodies like oil pipes. It cannot test irregular oil pipe fittings such as pipe joints, supports, flanges, and pipe supports, nor can it test large rotating bodies like oil storage tanks. Summary of the Invention

[0005] The present invention aims to solve the technical problems existing in the prior art. The purpose of the present invention is to provide a new non-destructive testing method for defects, which can perform non-destructive testing on oil storage tanks, oil pipelines and their accessories.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a non-destructive testing method for defects, comprising the following steps:

[0007] S1. Hoist the workpiece to be inspected for defects to the inspection device; the inspection device includes a deformable frame that can be lifted and moved laterally in a plane. The deformable frame can be deformed into a ring. The diameter of the ring deformable frame can be extended or retracted. Several inspection components are provided on the deformable frame. The inspection components include an ultrasonic inspection component for detecting internal defects of the workpiece and a camera component for detecting surface defects of the workpiece.

[0008] S2. Scan the surface shape of the workpiece to obtain its structure;

[0009] S3. Construct a structural model of the workpiece, and use the structural model to adjust the shape of the deformable frame. The deformable frame moves along the length of the workpiece and performs non-destructive testing on the workpiece using ultrasonic testing components and camera components. If the workpiece is a polyhedron or flat structure, the deformable frame is moved laterally, and the testing components on the deformable frame test the upper / lower surface of the workpiece. If the workpiece is a rotating structure, the diameter of the deformable frame changes to match the workpiece, and the deformable frame is moved vertically, with the testing components on the deformable frame testing the outer or inner surface of the workpiece.

[0010] S4. The ultrasonic testing results of the ultrasonic testing component and the image testing results of the camera component are input into the neural network model, and the testing results are output.

[0011] The above technical solution scans the surface shape of the workpiece and constructs a structural model of the workpiece. Based on the structural model, the shape of the deformable frame is automatically adjusted to adapt to workpieces of different shapes. Furthermore, the diameter of the deformable frame is adjustable, enabling the inspection of workpieces of different sizes. The ultrasonic inspection component and camera component of this invention are mounted on the deformable frame. By changing the shape and diameter of the deformable frame, it can adapt to workpieces of different shapes and sizes. The vertical or horizontal movement of the deformable frame covers the entire surface and interior of the workpiece for inspection. It can simultaneously inspect oil storage tanks, oil pipes, and their accessories, demonstrating strong versatility.

[0012] In a preferred embodiment of the present invention, the deformable frame is a continuum robot.

[0013] The above technical solution enables the continuum robot to be highly flexible and easily change shape, thus meeting the application requirements.

[0014] In another preferred embodiment of the present invention, ultrasonic detection components and camera components are provided on each segment or part of the robotic arm of the continuum robot, and the detection areas of two adjacent ultrasonic detection components can partially overlap, and the detection areas of two adjacent camera components can partially overlap.

[0015] The above technical solution allows the detection areas of two adjacent detection components to partially overlap, ensuring full coverage detection along the length of the continuous robot and complete detection.

[0016] In a preferred embodiment of the present invention, the method for adjusting the diameter of the deformable frame is to adjust the robotic arm of the continuum robot:

[0017]

[0018] Among them, l iLet be the distance traveled by the i-th robotic arm, n be the total number of robotic arms, and d be the distance traveled by the i-th robotic arm. i Let d0 be the distance between the i-th robotic arm and the detection surface, and E be the standard distance between the robotic arm and the detection surface during detection. i Let ΔE(d) be the emission intensity of the ultrasonic wave on the i-th robotic arm. i -d0), ΔE is the enhancement coefficient of ultrasonic wave emission intensity as the distance increases, and E0 is the standard emission intensity of ultrasonic wave at a standard distance.

[0019] The above technical solution adjusts the diameter of the deformable frame by adjusting the number of robotic arms of the continuous robot, the movement distance parameter, the distance from the detection surface, and the emission intensity of the ultrasonic waves on the robotic arms, so that the distance between the ultrasonic detection component and the detection surface is appropriate, ensuring the accuracy of the detection results.

[0020] In a preferred embodiment of the present invention, the rotating body structure includes a circular tube structure, a tapered tube structure, or a spherical structure; when the workpiece is a circular tube structure or a tapered tube structure, the deformable frame can be arranged around the workpiece and extend into the workpiece, and perform non-destructive testing through the detection component; when the workpiece is a spherical structure, the deformable frame can be arranged around the workpiece, and perform non-destructive testing through the detection component; when the workpiece is a tapered tube structure or a spherical structure, when the deformable frame moves vertically to detect the workpiece, the deformable frame can adjust its own diameter to match the workpiece according to the outer diameter and inner diameter of the workpiece.

[0021] In the above technical solution, for rotating workpieces of different shapes, the deformable frame adjusts its own diameter to match the outer and inner diameters of the workpiece during inspection in order to detect defects on the outer surface and inside of the workpiece.

[0022] In another preferred embodiment of the present invention, a vertical column is fixed to the ground, a support frame is slidably connected to the column, a vertical drive member is connected to the support frame to drive its vertical movement on the column, a vertical pole is slidably connected to the support frame, a horizontal drive member is connected to the vertical pole to drive its horizontal movement on the support frame, and a deformable frame is installed on the vertical pole.

[0023] The above technical solution uses a vertical drive component to move the support frame vertically, and the support frame, through the column, causes the deformable frame to move vertically accordingly. A horizontal drive component moves the upright horizontally, and the deformable frame moves horizontally along with the upright. The method of driving the deformable frame to move vertically and horizontally is simple and reliable.

[0024] In another preferred embodiment of the present invention, the ultrasonic detection component and the camera component are movably connected to the top or bottom of the deformable frame, and the deformable frame is equipped with a steering drive mechanism for driving the ultrasonic detection component and the camera component to rotate to adjust their direction.

[0025] The above technical solution uses a steering mechanism to drive the ultrasonic testing component and the camera component to move, thereby changing the direction in which the ultrasonic testing component and the camera component are aligned with the workpiece, so as to meet the requirements of all-round detection of the lower and upper surfaces, as well as the outer and inner surfaces of different workpieces.

[0026] In another preferred embodiment of the present invention, the steering drive mechanism is a motor mounted on a deformable frame, the output shaft of the motor is fixedly connected to a support plate, and the ultrasonic detection component and the camera component are arranged in pairs, with a pair of ultrasonic detection components and camera components mounted on the same support plate.

[0027] In the above technical solution, the ultrasonic detection component and the camera component are arranged in pairs. The motor enables the ultrasonic detection component and the camera component to move synchronously through the support plate. One motor can drive the ultrasonic detection component and the camera component to adjust their orientation at the same time, which is simple in structure.

[0028] Additional aspects and advantages 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 the invention. Attached Figure Description

[0029] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0030] Figure 1 This is a flowchart of a defect non-destructive testing method according to an embodiment of this application.

[0031] Figure 2 This is a side view of the detection device in the embodiments of this application.

[0032] Figure 3 This is a top view of the deformable frame in the embodiments of this application.

[0033] Figure 4 This is a side view of the detection component mounted on the deformable frame in the embodiment.

[0034] The reference numerals in the accompanying drawings include: deformable frame (continuum robot) 10, robotic arm 11, detection component 20, ultrasonic detection component 21, camera component 22, steering drive mechanism (motor) 23, support plate 24, column 30, support frame 40, and pole 50. Detailed Implementation

[0035] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0036] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "vertical", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" 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 invention 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 invention.

[0037] In the description of this invention, unless otherwise specified and limited, it should be noted that the terms "installation", "connection" and "linking" should be interpreted broadly. For example, they can refer to mechanical or electrical connections, or internal connections between two components. They can be direct connections or indirect connections through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0038] This invention provides a non-destructive testing method for defects, such as... Figure 1 As shown, in a preferred embodiment, the detection method includes the following steps:

[0039] S1. Hoist the workpiece to be inspected for defects to the inspection device. Oil storage tanks, oil pipelines and their accessories are large in size and heavy, so using a crane for hoisting facilitates non-destructive testing.

[0040] like Figure 2 and Figure 3 As shown, the detection device includes a deformable frame 10 capable of lifting, lowering, and moving laterally in a plane. For example, the deformable frame 10 may be a continuum robot with several flexibly connected robotic arms 11. The deformable frame 10 can deform into a ring (e.g., a circle), and the diameter of the ring-shaped deformable frame 10 can be extended or retracted. Specifically, the diameter can be adjusted by increasing or decreasing the number of robotic arms 11 involved in forming the ring-shaped deformable frame 10. Several detection components 20 are provided on the deformable frame 10, including an ultrasonic detection component 21 for detecting internal defects in the workpiece and a camera component 22 for detecting surface defects in the workpiece.

[0041] S2. Scan the surface shape of the workpiece to obtain its structure. A 3D scanner can be used for this purpose.

[0042] S3. Construct a structural model of the workpiece (the structural model can be constructed based on the scanning results, or the control system can pre-store models of all workpieces and select the corresponding model based on the scanning results). Use the structural model to adjust the shape of the deformable frame 10 to adapt to the shape of the workpiece. The deformable frame 10 moves along the length direction of the workpiece and performs non-destructive testing on the workpiece through the ultrasonic testing component 21 and the camera component 22.

[0043] If the workpiece is a polyhedral or flat structure, it is horizontally hoisted, and the deformable frame 10 moves laterally along the length of the workpiece. The deformable frame 10 can be positioned below / above the workpiece, allowing the detection component 20 on it to perform non-destructive testing on the lower / upper surface of the workpiece. It should be noted that, for more comprehensive workpiece testing, the position and angle of the detection component 20 need to be adjusted by the continuous robot 10 to ensure that the camera component 22 can detect all surfaces of the workpiece and the ultrasonic testing component 21 can cover the entire workpiece, achieving omnidirectional testing.

[0044] If the workpiece is a rotating structure, it is vertically hoisted, and the diameter of the deformable frame 10 changes to match the workpiece. The deformable frame 10 moves vertically along the length of the workpiece, and the detection component 20 on the deformable frame 10 inspects the outer or inner surface of the workpiece. Specifically, the rotating structure includes a circular tube structure, a tapered tube structure, or a spherical structure. When the workpiece is a circular tube or a tapered tube structure, the deformable frame 10 can be positioned around the workpiece (inspecting the outer and inner surfaces) and extend into the workpiece (inspecting the inner surface and inner surface), and non-destructive testing is performed through the detection component 20. When the workpiece is a spherical structure, the deformable frame 10 can be positioned around the workpiece and non-destructive testing is performed through the detection component 20. Furthermore, when the workpiece is a tapered tube or a spherical structure, and the deformable frame 10 moves vertically to inspect the workpiece, the deformable frame 10 can adjust its own diameter to match the outer and inner diameters of the workpiece.

[0045] S4. The ultrasound detection results from the ultrasound detection component 21 and the image detection results from the camera component 22 are input into the neural network model, which then outputs the detection results. Specifically, the neural network model used to detect the ultrasound and image detection results can employ existing neural network models, such as a dual-channel neural network model. One channel verifies the ultrasound detection results, and the other channel verifies the image detection results. The results from both channels are then fused and output. The specific data training, verification, and detection processes can utilize existing technologies and will not be elaborated upon here.

[0046] The method for adjusting the diameter of the deformable frame 10 is to adjust the robotic arm 11 of the continuum robot 10:

[0047]

[0048] Among them, l i Let be the distance traveled by the i-th robotic arm, n be the total number of robotic arms, and d be the distance traveled by the i-th robotic arm. i Let d0 be the distance between the i-th robotic arm and the detection surface, and E be the standard distance between the robotic arm and the detection surface during detection. i Let ΔE(d) be the emission intensity of the ultrasonic wave on the i-th robotic arm. i -d0), ΔE is the enhancement coefficient of ultrasonic wave emission intensity as the distance increases, and E0 is the standard emission intensity of ultrasonic wave at a standard distance.

[0049] like Figure 2 As shown, in this invention, the deformable frame 10 is raised, lowered, and moves laterally in a plane in the following manner: a vertical column 30 is fixed to the ground by anchor bolts; a support frame 40 is vertically slidably connected to the column 30; the support frame 40 is connected to a vertical drive component (not shown in the figure) that drives its vertical movement on the column 30, preferably the vertical drive component is located inside the column 30; a horizontal pole 50 is slidably connected to the support frame 40; the pole 50 is connected to a horizontal drive component (not shown in the figure) that drives its horizontal movement on the support frame 40, preferably the horizontal drive component is located inside the support frame 40; the deformable frame 10 is mounted on the top of the pole 50, and a drive mechanism that drives the continuous robot 10 to change shape is mounted in the pole 50. Specifically, the vertical and horizontal drive components can use a motor + lead screw or electric motor + sprocket and chain structure to achieve linear motion, which is existing technology and will not be described in detail here.

[0050] During non-destructive testing, the vertical drive component causes the support frame 40 to move vertically, and the support frame 40 causes the deformable frame 10 to move vertically along with it via the column 30; the horizontal drive component causes the upright 50 to move horizontally, and the deformable frame 10 moves horizontally along with the upright 50.

[0051] In this invention, ultrasonic detection components 21 and camera components 22 are provided on each section or part of the robotic arm 11 of the continuous robot 10. The detection areas of two adjacent ultrasonic detection components 21 can partially overlap, and the detection areas of two adjacent camera components 22 can partially overlap, ensuring full coverage detection along the length direction of the continuous robot 10. The detection range can cover the entire width of the workpiece, or a circle of the outer surface of the workpiece, or a circle of the inner surface of the workpiece. By moving the deformable frame 10 along the length direction of the workpiece, the entire outer or inner surface of the workpiece can be detected.

[0052] like Figure 2 and Figure 4As shown, in another preferred embodiment of the present invention, the ultrasonic detection component 21 and the camera component 22 are movably connected to the top or bottom of the deformable frame 10. A directional drive mechanism 23 is mounted on the deformable frame 10 to drive the ultrasonic detection component 21 and the camera component 22 to rotate and adjust their direction. The directional drive mechanism 23 is a reversible motor mounted on the deformable frame 10. The output shaft of the motor 23 is horizontally arranged, and a support plate 24 is fixedly connected to the output shaft of the motor 23. The ultrasonic detection component 21 and the camera component 22 are arranged in pairs, and a pair of ultrasonic detection components 21 and camera components 22 are mounted on the same support plate 24.

[0053] This embodiment uses the example of the detection component 20 being installed on top of the deformable frame 10. For a polyhedral, flat workpiece, initially, the deformable frame 10 is located below the workpiece, and the detection component 20 is vertically positioned and extends upward. When the deformable frame 10 is moved laterally, the detection component 20 on top of the deformable frame 10 is aligned with the lower surface of the workpiece from bottom to top for detection. Then, the deformable frame 10 is fitted over the workpiece, and the detection component 20 is rotated inward by the motor 23 to be horizontally positioned and extended inward, aligning with the outer peripheral surface of the workpiece for detection. The deformable frame 10 is moved vertically upward to above the workpiece, and the detection component 20 is rotated inward and downward by the motor 23 to change the angle. The deformable frame 10 is moved laterally, and the detection component 20 is tilted downward to align with the upper surface of the workpiece for detection. This completes the non-destructive testing of all external and internal defects of the polyhedral, flat workpiece.

[0054] For workpieces with a rotating structure, initially, the deformable frame 10 is located below the workpiece and can be fitted over it. The motor 23 rotates the detection component 20 to set it laterally and extend it inwards, while the deformable frame 10 moves vertically upwards. The detection component 20 then aligns with the outer surface of the workpiece for inspection. When the workpiece is a tapered tube or spherical structure, the deformable frame 10 moves vertically to inspect the workpiece, and its diameter can be adjusted to match the workpiece's outer and inner diameters. For workpieces with a circular or tapered tube structure, the deformable frame 10 needs to be moved downwards to reset, and its diameter adjusted according to the workpiece's inner diameter. The motor 23 rotates the detection component 20 to set it laterally and extend it outwards. Then, the upright 50 extends the deformable frame 10 into the workpiece, and the vertically upwards movement of the deformable frame 10 allows the detection component 20 to align with the inner surface of the workpiece for inspection.

[0055] In the description of this specification, references to terms such as "preferred embodiment," "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0056] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A non-destructive testing method for defects, characterized in that, Includes the following steps: S1. Hoist the workpiece to be inspected for defects to the inspection device; The detection device includes a deformable frame that can be raised and lowered and move laterally in a plane. The deformable frame can be deformed into a ring, and the diameter of the ring deformable frame can be extended or retracted. Several detection components are provided on the deformable frame, including an ultrasonic detection component for detecting internal defects of the workpiece and a camera component for detecting surface defects of the workpiece. The deformable frame is a continuum robot; the ultrasonic detection component and the camera component are set on each segment or part of the robotic arm of the continuum robot, and the detection areas of two adjacent ultrasonic detection components can partially overlap, and the detection areas of two adjacent camera components can partially overlap. The method for adjusting the diameter of the deformable frame is the same as adjusting the robotic arm of the continuum robot: ， in, Let be the distance traveled by the i-th robotic arm, and n be the total number of robotic arms. Let be the distance of the i-th robotic arm from the detection surface. This is the standard distance between the robotic arm and the inspection surface during inspection. Let be the emission intensity of the ultrasonic wave on the i-th robotic arm, i.e. , This represents the amplification factor of the ultrasonic wave emission intensity as the distance increases. This represents the standard emission intensity of ultrasound at a standard distance. S2. Scan the surface shape of the workpiece to obtain its structure; S3. Construct a structural model of the workpiece, adjust the shape of the deformable frame using the structural model, move the deformable frame along the length of the workpiece, and perform non-destructive testing on the workpiece using ultrasonic testing components and camera components. If the workpiece is a polyhedron or a flat structure, the deformable frame is moved laterally, and the detection components on the deformable frame detect the upper / lower surface of the workpiece. If the workpiece is a rotating structure, the diameter of the deformable frame changes and matches the workpiece, the deformable frame moves vertically, and the detection component on the deformable frame detects the outer or inner surface of the workpiece. S4. The ultrasonic testing results of the ultrasonic testing component and the image testing results of the camera component are input into the neural network model, and the testing results are output.

2. The non-destructive testing method for defects according to claim 1, characterized in that, The rotating body structure includes a circular tube structure, a conical tube structure, or a spherical structure; When the workpiece is a circular tube structure or a tapered tube structure, the deformable frame can be arranged around the workpiece and extend into the workpiece, and can be subjected to non-destructive testing through the detection components; When the workpiece is a spherical structure, the deformable frame can be arranged around the workpiece and non-destructive testing can be performed through the detection components; When the workpiece is a tapered tube structure or a spherical structure, the deformable frame can adjust its own diameter to match the workpiece according to the outer and inner diameters of the workpiece when it moves vertically to detect the workpiece.

3. The non-destructive testing method for defects according to claim 1, characterized in that, A vertical column is fixed to the ground, and a support frame is slidably connected to the column. The support frame is connected to a vertical drive component that drives it to move vertically on the column. A vertical pole is slidably connected to the support frame, and a horizontal drive component that drives it to move horizontally on the support frame. The deformable frame is installed on the vertical pole.

4. The non-destructive testing method for defects according to claim 1, characterized in that, The ultrasonic testing component and the camera component are movably connected to the top or bottom of the deformable frame, and the deformable frame is equipped with a steering drive mechanism that drives the ultrasonic testing component and the camera component to rotate to adjust their direction.

5. The non-destructive testing method for defects according to claim 4, characterized in that, The steering drive mechanism is a motor mounted on a deformable frame. The output shaft of the motor is fixed to a support plate. The ultrasonic detection component and the camera component are arranged in pairs, and a pair of ultrasonic detection components and camera components are mounted on the same support plate.

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