A pipeline inspection system
By selecting sensors through a sensor construction device and an electromagnetic simulation model, and generating AC excitation signals for pipeline inspection, the problem of difficult inspection in low-volume oil pipelines is solved, and pipeline inspection with high accuracy and strong deformation capability is achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- PIPECHINA SOUTH CHINA CO
- Filing Date
- 2023-11-02
- Publication Date
- 2026-06-23
AI Technical Summary
Existing pipeline inspection technologies cannot be effectively implemented in oil pipelines operating at low throughput, especially due to difficulties in detector operation caused by pipe deformation and impurity deposition, which affects the detection results.
The system employs a sensor construction device, a signal generator, and a data acquisition instrument. Sensors are selected through an electromagnetic simulation model, and AC excitation signals are generated for detection. This process acquires pipeline inspection data and generates defect characteristic signals, while avoiding direct contact between the sensors and the pipe wall.
It improves the accuracy of detection results and the deformation capability of the equipment, enabling effective detection of inner and outer wall defects in pipelines where conventional internal detectors cannot operate.
Smart Images
Figure CN117665091B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of pipeline inspection technology, and specifically to a pipeline inspection system. Background Technology
[0002] Oil and gas pipelines operate continuously for extended periods, and the combined effects of the internal transported medium and the external environment can lead to defects such as corrosion, deformation, and even weld cracking. Non-destructive testing of the pipeline body can effectively detect these defects, enabling timely repairs and preventing further damage. This significantly contributes to maintaining the normal operation of the pipeline system and minimizing environmental pollution and economic losses.
[0003] Pipeline internal inspection is characterized by high efficiency, good detection results, and strong economy, and is widely used in the field of long-distance oil and gas pipelines. Based on technical principles, pipeline internal inspection can be divided into magnetic flux leakage (MFL) testing, ultrasonic testing, and eddy current testing. Each testing technology has its applicability and certain requirements for pipeline operating conditions. Currently, a large number of pipelines do not meet the operating conditions of traditional internal inspection devices. According to preliminary statistics, most long-distance oil and gas pipelines both domestically and internationally cannot be internally inspected. Typically, oil pipelines operating at low flow rates for extended periods have unclear pipe deformation or reduced cross-sectional space due to internal impurity deposition, which is detrimental to the operation of the detectors. MFL internal inspection devices require the probe and brush to be in close contact with the pipe wall, demanding a low level of pipeline geometric deformation, making them unsuitable for pipelines with significant deformation. Similarly, eddy current internal inspection devices require the probe to be close to or against the pipe wall, and the deformation capacity of the testing equipment is relatively low. Ultrasonic testing requires a high degree of pipeline cleanliness; impurities floating inside the pipe can affect the emission of ultrasonic waves, causing the sensor to fail to receive a valid signal, thus affecting the detection results. Therefore, traditional pipeline internal inspection technologies cannot operate in low-flow-rate oil pipelines. Summary of the Invention
[0004] The technical problem to be solved by the present invention is to provide a pipeline inspection system to address the shortcomings of the prior art.
[0005] The technical solution of this invention to solve the above-mentioned technical problems is as follows: A pipeline inspection system, comprising: a sensor construction device, a signal generator, and a data acquisition instrument.
[0006] The sensor construction device is used to import basic pipeline parameters and multiple sensor parameters, and to construct an electromagnetic simulation model;
[0007] The required sensor is selected based on the basic parameters of the pipeline, the electromagnetic simulation model, and the parameters of multiple sensors.
[0008] The sensor is deployed inside the pipe to be inspected and electrically connected to the signal generator and the data acquisition instrument, respectively.
[0009] The signal generator is used to generate AC excitation signals;
[0010] The sensor is used to detect the pipeline to be detected based on the AC excitation signal, and obtain pipeline detection data;
[0011] The data acquisition instrument is used to generate defect feature signals based on the pipeline inspection data.
[0012] The beneficial effects of this invention are: the accuracy of detection results can be improved by using a sensor construction device, a signal generator, a data acquisition instrument, and a sensor; it does not require direct contact with the pipe wall; it has relatively strong lifting ability; it does not have components such as steel brushes that affect the passage; the equipment has relatively strong deformation ability; and it has consistent sensitivity to defects on the inner and outer walls of the pipe, making it suitable for pipes where conventional internal detectors cannot operate.
[0013] Based on the above technical solution, the present invention can be further improved as follows.
[0014] Furthermore, in the sensor construction device, the process of selecting a suitable sensor based on the basic pipeline parameters, the electromagnetic simulation model, and multiple sensor parameters includes:
[0015] The electromagnetic simulation model is trained based on the basic parameters of the pipeline and the parameters of multiple sensors to obtain the trained electromagnetic simulation model.
[0016] The basic parameters of the pipeline are simulated using the trained electromagnetic simulation model to obtain the simulated sensor parameters.
[0017] The sensor to be verified is selected based on the simulated sensor parameters, and the sensor to be verified is connected to the signal generator and the data acquisition instrument respectively.
[0018] The signal generator generates a test AC excitation signal;
[0019] The sensor to be verified detects the pipeline to be tested based on the test AC excitation signal, and obtains the detection data of the pipeline to be verified.
[0020] The data acquisition instrument generates a defect feature signal to be verified based on the pipeline inspection data to be verified.
[0021] Determine whether the amplitude of the defect feature signal to be verified is greater than a preset signal amplitude threshold and whether the phase difference of the defect feature signal is within a preset signal phase difference range. If not, the sensor to be verified does not meet the requirements. Update the simulated sensor parameters to obtain updated sensor parameters and reselect the sensor to be verified based on the updated sensor parameters. If yes, the sensor to be verified meets the requirements.
[0022] The advantages of adopting the above-mentioned further scheme are: the accuracy of the detection results is improved by constructing the sensor, it does not need to be in direct contact with the pipe wall, the lifting ability is relatively strong, there are no components such as steel brushes that affect the passage in the structure, the equipment has relatively strong deformation ability, and it has consistent sensitivity to defects on the inner and outer walls of the pipe, which can be applied to pipes where conventional internal detectors cannot operate.
[0023] Furthermore, the sensor includes an excitation coil assembly, a detection coil assembly, a sensor rod, and multiple centering support wheels.
[0024] The sensor rod is horizontally positioned at the central axis of the pipe to be inspected. The excitation coil assembly, multiple centering support wheels, and the detection coil assembly are detachably connected to the sensor rod in sequence from one end to the other. A first drag ring is provided at one end of the sensor rod near the detection coil assembly, and a second drag ring is provided at the other end of the sensor rod. The excitation coil assembly is electrically connected to the signal generator through the first drag ring to receive the AC excitation signal. The detection coil assembly is electrically connected to the data acquisition instrument through the second drag ring to detect the pipe to be inspected according to the AC excitation signal, obtain pipe detection data, and send the pipe detection data to the data acquisition instrument.
[0025] The beneficial effects of adopting the above-mentioned further solution are: by using the excitation coil assembly, detection coil assembly, sensor rod and centering support wheel, the structure can be free of components that affect the passage, such as steel brushes. The equipment has strong deformation capacity and consistent sensitivity to defects on the inner and outer walls of the pipeline, and can be applied to pipelines where conventional internal detectors cannot operate.
[0026] Furthermore, the excitation coil assembly includes a first excitation baffle, a second excitation baffle, and an excitation spool.
[0027] The excitation spool has a first thread in the middle, and the excitation spool is sleeved on the sensor rod body through the first thread. The excitation spool moves back and forth along both ends of the sensor rod body. The first excitation baffle and the second excitation baffle are both circular plate structures, and both the first excitation baffle and the second excitation baffle can be detachably connected to the excitation spool.
[0028] The beneficial effects of adopting the above-mentioned further scheme are: the accuracy of the equipment detection results can be improved by using the first excitation baffle, the second excitation baffle and the excitation spool, the equipment has relatively strong deformation ability, and has consistent sensitivity to defects on the inner and outer walls of the pipeline, which can be applied to pipelines where conventional internal detectors cannot operate.
[0029] Furthermore, the detection coil assembly includes a first detection baffle, a second detection baffle, and a detection spool.
[0030] The detection spool has a second thread in the middle, and the detection spool is sleeved on the sensor rod body through the second thread. The detection spool moves back and forth along both ends of the sensor rod body. The first detection baffle and the second detection baffle are both circular plate structures, and both the first detection baffle and the second detection baffle can be detachably connected to the detection spool.
[0031] The beneficial effects of adopting the above-mentioned further scheme are: the accuracy of the equipment detection results can be improved by using the first detection baffle, the second detection baffle and the detection spool, the equipment has relatively strong deformation ability, and has consistent sensitivity to defects on the inner and outer walls of the pipeline, which can be applied to pipelines where conventional internal detectors cannot operate.
[0032] Furthermore, there are two centering support wheels, both of which are disposed between the excitation coil assembly and the detection coil assembly.
[0033] The beneficial effects of adopting the above-mentioned further solutions are: it can improve the accuracy of equipment detection results, the equipment has relatively strong deformation capacity, and it has consistent sensitivity to defects on the inner and outer walls of the pipeline, making it applicable to pipelines where conventional internal detectors cannot operate.
[0034] Furthermore, the sensor also includes a circular shielding component, which is disposed between the plurality of centering support wheels and detachably connected to the sensor rod.
[0035] The beneficial effects of adopting the above-mentioned further solutions are: further improved detection accuracy, consistent sensitivity to defects on the inner and outer walls of the pipeline, and applicability to pipelines where conventional internal detectors cannot operate.
[0036] Furthermore, the pipeline inspection system also includes a power supply, which is electrically connected to the signal generator, the sensor, and the data acquisition instrument.
[0037] The beneficial effect of adopting the above-mentioned further solution is that it provides power to the device. Attached Figure Description
[0038] Figure 1This is a block diagram of a pipeline inspection system provided in an embodiment of the present invention;
[0039] Figure 2 This is a sensor structure diagram of a pipeline inspection system provided in an embodiment of the present invention;
[0040] Figure 3 This is a block diagram of a pipeline inspection system provided in another embodiment of the present invention;
[0041] Figure 4 This is a schematic diagram of the sensor simulation model structure of a pipeline inspection system provided in an embodiment of the present invention.
[0042] The attached diagram lists the components represented by each number as follows:
[0043] 1. Sensor rod, 2. Centering support wheel, 3. First excitation baffle, 4. Second excitation baffle, 5. Excitation spool, 6. First detection baffle, 7. Second detection baffle, 8. Detection spool, 9. Shielding component. Detailed Implementation
[0044] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.
[0045] Figure 1 This is a block diagram of a pipeline inspection system provided in an embodiment of the present invention.
[0046] like Figure 1 As shown, a pipeline inspection system includes: a sensor construction device, a signal generator, and a data acquisition unit.
[0047] The sensor construction device is used to import basic pipeline parameters and multiple sensor parameters, and to construct an electromagnetic simulation model;
[0048] The required sensor is selected based on the basic parameters of the pipeline, the electromagnetic simulation model, and the parameters of multiple sensors.
[0049] The sensor is deployed inside the pipe to be inspected and electrically connected to the signal generator and the data acquisition instrument, respectively.
[0050] The signal generator is used to generate AC excitation signals;
[0051] The sensor is used to detect the pipeline to be detected based on the AC excitation signal, and obtain pipeline detection data;
[0052] The data acquisition instrument is used to generate defect feature signals based on the pipeline inspection data.
[0053] Specifically, the signal generator can generate an AC excitation signal and output it to the sensor module (i.e., the sensor). The frequency and voltage amplitude of the AC excitation signal are adjustable. The test pipe (i.e., the pipe to be tested) contains target defects and features, including metal loss defects and welds. The sensor module (i.e., the sensor) has its overall dimensions specified according to the dimensions and parameters of the target pipe. It can move along the axial direction of the test pipe. When the sensor's detection coil passes through the target defect on the test pipe, the data acquisition instrument can record the defect feature signal.
[0054] In the above embodiments, the accuracy of detection results can be improved by using a sensor construction device, a signal generator, a data acquisition instrument, and a sensor. It does not require direct contact with the pipe wall, has relatively strong lifting capability, and does not have components such as steel brushes that affect the passage. The equipment has relatively strong deformation capability and has consistent sensitivity to defects on the inner and outer walls of the pipe, making it suitable for pipes where conventional internal detectors cannot operate.
[0055] Optionally, as an embodiment of the present invention, the process of selecting a suitable sensor in the sensor construction device based on the basic pipeline parameters, the electromagnetic simulation model, and multiple sensor parameters includes:
[0056] The electromagnetic simulation model is trained based on the basic parameters of the pipeline and the parameters of multiple sensors to obtain the trained electromagnetic simulation model.
[0057] The basic parameters of the pipeline are simulated using the trained electromagnetic simulation model to obtain the simulated sensor parameters.
[0058] The sensor to be verified is selected based on the simulated sensor parameters, and the sensor to be verified is connected to the signal generator and the data acquisition instrument respectively.
[0059] The signal generator generates a test AC excitation signal;
[0060] The sensor to be verified detects the pipeline to be tested based on the test AC excitation signal, and obtains the detection data of the pipeline to be verified.
[0061] The data acquisition instrument generates a defect feature signal to be verified based on the pipeline inspection data to be verified.
[0062] Determine whether the amplitude of the defect feature signal to be verified is greater than a preset signal amplitude threshold and whether the phase difference of the defect feature signal is within a preset signal phase difference range. If not, the sensor to be verified does not meet the requirements. Update the simulated sensor parameters to obtain updated sensor parameters and reselect the sensor to be verified based on the updated sensor parameters. If yes, the sensor to be verified meets the requirements.
[0063] It should be understood that the electromagnetic simulation model is built using the Comsol tool.
[0064] It should be understood that after reselecting the sensor to be verified, it is reconnected to the signal generator and the data acquisition instrument, and the sensor parameter verification steps are performed.
[0065] It should be understood that the basic parameters of the pipeline include the outer diameter, wall thickness, relative magnetic permeability, electrical conductivity, and the type and size of the target defect. The sensor parameters include the width, height, outer diameter, and number of turns of the excitation coil and the detection coil; the distance between the excitation coil and the detection coil; the material, size, and relative position of the shielding layer; and the frequency and amplitude of the excitation signal. These sensor parameters should be determined according to the specifications of the target pipeline.
[0066] Specifically, for pipes with a diameter of less than 300mm, the recommended initial parameters are as follows: the outer diameter of the coil is 80% to 90% of the inner diameter of the pipe; the number of coil turns is 500 to 1500; the distance between the excitation coil and the detection coil is 2 to 3 times the outer diameter of the pipe; the outer diameter of the shielding layer is about 80% to 90% of the inner diameter of the pipe; the shielding layer is made of materials such as aluminum, steel, and copper, and each layer is about 5mm to 20mm thick; the initial position of the shielding layer is between the excitation coil and the detection coil; the excitation signal amplitude is 12V; and the excitation frequency is within 50Hz.
[0067] It should be understood that the basic parameters of the target pipeline (i.e., the pipeline basic parameters) are set, the basic structure and initial parameters of the far-field eddy current sensor are given, and an electromagnetic simulation model is established.
[0068] Specifically, an electromagnetic simulation model is established in Comsol software. By changing various parameters of the sensor, the optimal combination of sensor parameters under the simulation model is determined. Generally, the following principles are followed: 1) Ensure that the amplitude of the detection signal and its phase difference with the excitation signal both reach the far-field coupling stability region; 2) Ensure that the sensor structural dimensions meet the constraints of the target pipeline and satisfy the passability requirements of the internal detector.
[0069] It should be understood that the optimal sensor parameters under the simulation model are substituted into the sensor design parameter verification device, and actual tests are carried out in the pipeline.
[0070] Specifically, based on the optimal parameters obtained from simulation, the sensor coil and shielding layer are fabricated and installed on the design parameter verification device. A target pipeline defect is created using the excitation signal given by the simulation parameters. The sensor module is dragged inside the pipeline, allowing the detection coil to pass through the target defect. The amplitude and phase changes of the detection signal are observed using a data acquisition instrument. The key parameters of the sensor are continuously fine-tuned, and the dragging test is repeated to observe the changes in the detection signal. The parameter combination that results in a high detection signal amplitude and maximum phase difference change when the sensor passes through the target defect is identified as the optimal design parameters for the sensor under the pipeline test conditions.
[0071] In the above embodiments, the accuracy of the detection results is improved by constructing the sensor. It does not need to be in direct contact with the pipe wall, has a relatively strong lifting ability, and does not have components such as steel brushes that affect the passage. The device has a relatively strong deformation ability and has consistent sensitivity to defects on the inner and outer walls of the pipe. It can be applied to pipes where conventional internal detectors cannot operate.
[0072] Optionally, as an embodiment of the present invention, such as Figure 1 and 2 As shown, the sensor includes an excitation coil assembly, a detection coil assembly, a sensor rod, and multiple centering support wheels.
[0073] The sensor rod is horizontally positioned at the central axis of the pipe to be inspected. The excitation coil assembly, multiple centering support wheels, and the detection coil assembly are detachably connected to the sensor rod in sequence from one end to the other. A first drag ring is provided at one end of the sensor rod near the detection coil assembly, and a second drag ring is provided at the other end of the sensor rod. The excitation coil assembly is electrically connected to the signal generator through the first drag ring to receive the AC excitation signal. The detection coil assembly is electrically connected to the data acquisition instrument through the second drag ring to detect the pipe to be inspected according to the AC excitation signal, obtain pipe detection data, and send the pipe detection data to the data acquisition instrument.
[0074] It should be understood that the detachable connection can be a socket.
[0075] It should be understood that the centering support wheel 2 can be an adjustable centering support wheel, or the centering support wheel in the authorized patent "CN202121935474.7 - A differential special lifting tool", and the centering support wheel 2 includes a 1.5-inch one-way caster.
[0076] It should be understood that both the sensor rod 1 and the centering support wheel 2 can be made of non-magnetic materials.
[0077] It should be understood that both the excitation coil (i.e., the excitation coil assembly) and the detection coil (i.e., the detection coil assembly) have circular outlines, and their axes coincide with the axis of the pipe (i.e., the pipe to be tested) and are placed parallel to each other inside the pipe (i.e., the pipe to be tested).
[0078] Specifically, the excitation coil (i.e., the excitation coil assembly), the detection coil (i.e., the detection coil assembly), and the adjustable centering support wheel (i.e., the centering support wheel 2) are all coaxially mounted on the nylon skeleton (i.e., the sensor rod 1). The axial position of each component can be adjusted through the thread on the central shaft of the nylon skeleton (i.e., the sensor rod 1).
[0079] It should be understood that each component of the sensor module (i.e., the sensor) can be disassembled independently and its design parameters modified independently.
[0080] Specifically, the signal generator can generate an AC excitation signal and is connected to the excitation coil (i.e., the excitation coil assembly). The data acquisition instrument is connected to the detection coil (i.e., the detection coil assembly) and can acquire the detection signal to obtain voltage amplitude and phase difference data.
[0081] In the above embodiments, the excitation coil assembly, detection coil assembly, sensor rod, and centering support wheel eliminate the need for components such as steel brushes that affect the passage of the equipment. The equipment has strong deformation capabilities and consistent sensitivity to defects on both the inner and outer walls of the pipeline, making it suitable for pipelines where conventional internal detectors cannot operate.
[0082] Optionally, as an embodiment of the present invention, the excitation coil assembly includes a first excitation baffle 3, a second excitation baffle 4, and an excitation spool 5.
[0083] The excitation spool 5 has a first thread in the middle. The excitation spool 5 is sleeved on the sensor rod 1 through the first thread. The excitation spool 5 moves back and forth along both ends of the sensor rod 1. The first excitation baffle 3 and the second excitation baffle 4 are both circular plate structures. The first excitation baffle 3 and the second excitation baffle 4 can be detachably connected to the excitation spool 5.
[0084] It should be understood that the detachable connection can be a socket.
[0085] It should be understood that the excitation coil assembly, including baffles (i.e., the first excitation baffle 3 and the second excitation baffle 4) and a spool (i.e., the excitation spool 5), can be adapted to coils with different numbers of turns and sizes.
[0086] Specifically, the excitation coil assembly includes two baffles (i.e., the first excitation baffle 3 and the second excitation baffle 4) and a spool (i.e., the excitation spool 5). The two baffles (i.e., the first excitation baffle 3 and the second excitation baffle 4) are sleeved on the spool (i.e., the excitation spool 5), and the spool (i.e., the excitation spool 5) is sleeved on the nylon skeleton (i.e., the sensor rod 1). The inner surface of the spool (i.e., the excitation spool 5) is threaded, and the entire assembly can move along the nylon skeleton (i.e., the sensor rod 1).
[0087] In the above embodiments, the accuracy of the equipment detection results can be improved by using the first excitation baffle, the second excitation baffle, and the excitation spool. The equipment has relatively strong deformation capability and consistent sensitivity to defects on the inner and outer walls of the pipeline, making it suitable for pipelines where conventional internal detectors cannot operate.
[0088] Optionally, as an embodiment of the present invention, the detection coil assembly includes a first detection baffle 6, a second detection baffle 7, and a detection spool.
[0089] The detection spool 8 has a second thread in the middle. The detection spool 8 is sleeved on the sensor rod 1 through the second thread. The detection spool 8 moves back and forth along both ends of the sensor rod 1. The first detection baffle 6 and the second detection baffle 7 are both circular plate structures. The first detection baffle 6 and the second detection baffle 7 can be detachably connected to the detection spool 8.
[0090] It should be understood that the detachable connection can be a socket.
[0091] It should be understood that the detection coil assembly, including baffles (i.e., the first detection baffle 6 and the second detection baffle 7) and a spool (i.e. the detection spool 8), can be adapted to coils with different numbers of turns and sizes.
[0092] Specifically, the excitation coil assembly includes two baffles (i.e., the first detection baffle 6 and the second detection baffle 7) and a spool (i.e., the detection spool 8). The two baffles (i.e., the first detection baffle 6 and the second detection baffle 7) are sleeved on the spool (i.e., the detection spool 8), and the spool (i.e., the detection spool 8) is sleeved on the nylon skeleton (i.e., the sensor rod 1). The inner surface of the spool (i.e., the detection spool 8) is threaded, and the entire assembly can move along the nylon skeleton (i.e., the sensor rod 1).
[0093] In the above embodiments, the accuracy of the equipment's detection results can be improved by using the first detection baffle, the second detection baffle, and the detection spool. The equipment has relatively strong deformation capability and consistent sensitivity to defects on the inner and outer walls of the pipeline, making it suitable for pipelines where conventional internal detectors cannot operate.
[0094] Optionally, as an embodiment of the present invention, two centering support wheels 2 are provided, and both centering support wheels 2 are disposed between the excitation coil assembly and the detection coil assembly.
[0095] The above embodiments can improve the accuracy of equipment detection results, have relatively strong equipment deformation capability, and have consistent sensitivity to defects on the inner and outer walls of the pipeline, making them suitable for pipelines where conventional internal detectors cannot operate.
[0096] Optionally, as an embodiment of the present invention, the sensor further includes a circular shielding component 9, which is disposed between the plurality of centering support wheels 2 and is detachably connected to the sensor rod 1.
[0097] It should be understood that the detachable connection can be a socket.
[0098] It should be understood that the shielding layer (i.e., shielding component 9) is coaxially mounted on the nylon frame (i.e., sensor rod 1), and the axial position of the shielding layer (i.e., shielding component 9) can be adjusted by the thread on the central shaft of the nylon frame (i.e., sensor rod 1).
[0099] Specifically, the outer contour of the shielding layer (i.e., the shielding component 9) is circular, and its axis coincides with the axis of the pipe (i.e., the pipe to be tested), and it is placed parallel to the pipe (i.e., the pipe to be tested).
[0100] The above embodiments further improve the detection accuracy and have consistent sensitivity to defects on both the inner and outer walls of the pipeline, making them applicable to pipelines where conventional internal detectors cannot operate.
[0101] Optionally, as an embodiment of the present invention, the pipeline inspection system further includes a power supply, which is electrically connected to the signal generator, the sensor and the data acquisition instrument respectively.
[0102] It should be understood that the power supply provides power to the entire device.
[0103] In the above embodiments, power is provided to the device.
[0104] Optionally, as another embodiment of the present invention, the present invention includes an excitation coil, a receiving coil, a shielding layer, a frame, etc., and the overall composition is relatively fixed. Therefore, the core issue in sensor design is to determine a series of parameters, such as coil size, number of coil turns, signal excitation frequency, excitation voltage, etc. Only by finding suitable parameters for the sensor can the best detection effect be obtained.
[0105] Alternatively, as another embodiment of the present invention, the present invention solves the multi-parameter optimization problem in the sensor design process, improves the efficiency of design and testing, and ensures that the sensor has the best detection effect on the target pipe and the target defect. It has the technical characteristics of being highly targeted, accurate, flexible and efficient.
[0106] Optionally, as another embodiment of the present invention, the present invention also includes a sensor design method, including sensor electromagnetic simulation and design parameter optimization.
[0107] Electromagnetic simulation of the sensor includes setting the basic parameters of the target pipeline, giving the basic structure and initial parameters of the far-field eddy current sensor, and establishing an electromagnetic simulation model.
[0108] The basic parameters of the pipeline include the outer diameter, wall thickness, relative magnetic permeability, electrical conductivity, and the type and size of the target defect.
[0109] The basic structure of the sensor includes an excitation coil, a detection coil, and a shielding layer. All three components have a circular outline, their axes coincide with the axis of the pipe, and they are placed parallel to each other inside the pipe.
[0110] The initial parameters of the sensor include the width, height, outer diameter, and number of turns of the excitation coil and the detection coil; the distance between the excitation coil and the detection coil; the material, size, and relative position of the shielding layer; and the frequency and amplitude of the excitation signal. These initial parameters should be determined based on the specifications of the target pipeline. Specifically, for pipelines with a diameter of less than 300mm, the recommended initial parameters are: coil outer diameter of 80%–90% of the pipeline's inner diameter; 500–1500 coil turns; distance between the excitation coil and the detection coil of 2–3 times the pipeline's outer diameter; outer diameter of the shielding layer approximately 80%–90% of the pipeline's inner diameter; shielding layer made of materials such as aluminum, steel, or copper; thickness of each layer approximately 5mm–20mm; initial position of the shielding layer between the excitation coil and the detection coil; excitation signal amplitude of 12V; and excitation frequency within 50Hz.
[0111] Based on the parameters, an electromagnetic simulation model is established in Comsol software. By changing various sensor parameters, the optimal combination of sensor parameters under the simulation model is determined. Generally, the following principles are followed: 1) Ensure that the amplitude of the detection signal and its phase difference with the excitation signal both reach the far-field coupling stability region; 2) Ensure that the sensor structural dimensions meet the constraints of the target pipeline and satisfy the passability requirements of the internal detector.
[0112] Design parameter optimization involves substituting the optimal sensor parameters from the simulation model into a sensor design parameter verification device and conducting actual tests within the pipeline. Specifically, based on the optimal parameters obtained from the simulation, the sensor coil and shielding layer are fabricated and installed on the design parameter verification device. A target pipeline defect is created using the excitation signal provided by the simulation parameters. The sensor module is then dragged inside the pipeline, allowing the detection coil to pass through the target defect. The amplitude and phase changes of the detection signal are observed using a data acquisition instrument. The key sensor parameters are continuously fine-tuned, and the dragging test is repeated to observe changes in the detection signal. The parameter combination that results in a high detection signal amplitude and maximum phase difference change when the sensor passes through the target defect is identified as the optimal design parameters for the sensor under the pipeline test conditions.
[0113] A far-field eddy current sensor is fabricated according to the optimal design parameters of the sensor and integrated with an in-pipe detector. The excitation coil and the detection coil are placed between the front and rear rubber cups of the in-pipe detector. An integrated electronic system is used to provide power, signal excitation source, and data acquisition and storage system, and simultaneously acquires the mileage signal provided by the mileage component to realize far-field eddy current in-pipe detection based on the optimal design parameters.
[0114] Optionally, as another embodiment of the present invention, the present invention has the following advantages: The design of a far-field eddy current pipe detection sensor hinges on the accuracy of its main parameters. Therefore, the present invention provides a device and method for rapidly and accurately designing key sensor parameters. The design parameter verification device allows for convenient modification of various key design parameters during the sensor design process, effectively verifying the detection effects of different parameter combinations: the sensor module can be independently disassembled, its components replaced, and its coil and shielding layer changed, altering their relative positions to achieve rapid changes in the sensor structure; it can change the frequency and amplitude of the excitation signal to achieve rapid changes in the electromagnetic signal; and it can conduct tests within the pipe for different defects and operating speeds, enabling rapid changes in operating conditions. Combined with the sensor design method provided by the present invention, the approximate range of key sensor parameters can be determined first through electromagnetic simulation, and then the design verification device can be used to conduct tests, verifying the actual detection effects of various parameter combinations, ensuring the effectiveness of the design parameters, and improving the success rate of sensor design and fabrication.
[0115] Alternatively, as another embodiment of the present invention, such as Figure 3 As shown, this invention uses a 219mm outer diameter pipe as a reference to optimize the design of a far-field eddy current pipe detection sensor, including a sensor module, power supply, signal generator, data acquisition instrument, and test pipe.
[0116] Optionally, as another embodiment of the present invention, the present invention includes an excitation coil assembly, a detection coil assembly, a shielding layer assembly, an adjustable centering support wheel assembly, a nylon skeleton, and drag rings at both ends. The experimental carrier skeleton is made of nylon material, the support wheel assembly is made of rubber material, and the mounting bracket and mounting screws are made of stainless steel non-magnetic material. The excitation coil, detection coil, shielding layer, and adjustable centering support wheel are all coaxially mounted on the nylon skeleton, and the axial position of each component can be adjusted by the thread on the central shaft of the nylon skeleton. The excitation coil assembly and the detection coil assembly include baffles and bobbins, and can be adapted to coils with different numbers of turns and sizes.
[0117] The power supply provides power to the entire device. The signal generator generates an AC excitation signal, which is output to the sensor module and connected to the excitation coil. The frequency and voltage amplitude of the AC excitation signal are adjustable. The data acquisition instrument is connected to the detection coil and can acquire the detection signal to obtain voltage amplitude and phase difference data. The test pipeline contains target defects and features, including metal loss defects and welds.
[0118] The sensor module is sized according to the target pipe size and parameters. It can move along the pipe axis inside the test pipe. When the sensor's detection coil passes the target defect on the test pipe, the data acquisition instrument can record the defect characteristic signal.
[0119] Alternatively, as another embodiment of the present invention, such as Figure 4 As shown, this invention optimizes the design of a far-field eddy current detection sensor for a 219mm pipeline, specifically as follows:
[0120] (1) Conduct electromagnetic simulation of sensors
[0121] This includes setting the basic parameters of the target pipeline, providing the basic structure and initial parameters of the far-field eddy current sensor, and establishing an electromagnetic simulation model. Table 1 shows the basic parameters of the target pipeline.
[0122] Table 1
[0123]
[0124] The basic structure includes an excitation coil, a detection coil, and a shielding layer. All three components have circular outlines, their axes coincide with the pipe axis, and they are placed parallel to each other inside the pipe. Table 2 shows the initial parameters of the sensor in the simulation model.
[0125] Table 2
[0126]
[0127] In the simulation model, parametric scans are performed on different parameters to find the optimal parameter combination, following these steps:
[0128] 1) Determine the excitation frequency
[0129] With fixed tube wall thickness and coil distance, parametric simulation was performed on the excitation frequency. A higher excitation frequency results in a larger detection signal amplitude. Once the excitation frequency reaches 30Hz, the detection signal amplitude becomes relatively stable; therefore, this invention selects an excitation frequency of 30Hz.
[0130] 2) Determine the outer diameter of the coil
[0131] A larger coil outer diameter results in a stronger signal amplitude. However, sensors require pipe passage, so the coil outer diameter needs to be as large as possible within the acceptable range. This invention selects a sensor coil outer diameter of 180mm.
[0132] 3) Determine the number of coil turns and dimensions
[0133] As the number of turns increases, the coil's transmitting power decreases, and the detection coil voltage decreases. In this invention, the excitation coil has 1000 turns and a wire diameter of 0.7 mm.
[0134] As the number of turns in the detection coil increases, the detection signal strength increases significantly. Therefore, a higher number of coil turns is more beneficial for signal acquisition. In this invention, the number of coil turns is selected as 8000.
[0135] 4) Spacing between shielding layer and coil
[0136] When the distance is greater than 300mm, the phase difference tends to stabilize, indicating that the two coils are far-field coupled, and the detection coil is located in the far-field region of the transmitting coil. The position of the shielding layer has little impact on the detection signal in the far-field region. Therefore, the sensor design of this invention selects a coil distance of 350mm and a shielding layer position of 200mm.
[0137] At this point, all the optimal simulation parameters for the sensor have been obtained. Table 3 shows the optimal simulation parameters for the sensor.
[0138] Table 3
[0139]
[0140] (2) Design parameter optimization
[0141] Based on the optimal parameters obtained from simulation, the sensor coil and shielding layer were fabricated and installed on the design parameter verification device. Two through-hole defects, 20mm and 30mm respectively, were created on the test pipeline.
[0142] The sensor module was dragged within the test pipe, and the phase data of the detection signal at different excitation frequencies were recorded. The stability and sensitivity of the obtained detection signal varied depending on the excitation frequency applied to the sensor module, with relatively better detection performance at 30Hz. Therefore, the optimal simulation parameters only require minor structural adjustments to become the optimal design parameters. Fabricating a far-field eddy current sensor according to these optimal design parameters can effectively improve the detection performance.
[0143] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working process of the above-described apparatus and unit can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.
[0144] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative. For instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed.
[0145] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of the embodiments of the present invention, depending on actual needs.
[0146] Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.
[0147] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. This is understood to mean that the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.
[0148] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and these modifications or substitutions should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.
Claims
1. A pipeline inspection system, characterized in that, include: Sensor construction device, signal generator, and data acquisition instrument. The sensor construction device is used to import basic pipeline parameters and multiple sensor parameters, and to construct an electromagnetic simulation model; The required sensor is selected based on the basic parameters of the pipeline, the electromagnetic simulation model, and the parameters of multiple sensors. The sensor is deployed inside the pipe to be inspected and electrically connected to the signal generator and the data acquisition instrument, respectively. The signal generator is used to generate AC excitation signals; The sensor is used to detect the pipeline to be detected based on the AC excitation signal, and obtain pipeline detection data; The data acquisition instrument is used to generate defect feature signals based on the pipeline inspection data; In the sensor construction device, the process of selecting a suitable sensor based on the basic pipeline parameters, the electromagnetic simulation model, and multiple sensor parameters includes: The electromagnetic simulation model is trained based on the basic parameters of the pipeline and the parameters of multiple sensors to obtain the trained electromagnetic simulation model. The basic parameters of the pipeline are simulated using the trained electromagnetic simulation model to obtain the simulated sensor parameters. The sensor to be verified is selected based on the simulated sensor parameters, and the sensor to be verified is connected to the signal generator and the data acquisition instrument respectively. The signal generator generates a test AC excitation signal; The sensor to be verified detects the pipeline to be tested based on the test AC excitation signal, and obtains the detection data of the pipeline to be verified. The data acquisition instrument generates a defect feature signal to be verified based on the pipeline inspection data to be verified. Determine whether the amplitude of the defect feature signal to be verified is greater than a preset signal amplitude threshold and whether the phase difference of the defect feature signal is within a preset signal phase difference range. If not, the sensor to be verified does not meet the requirements. Update the simulated sensor parameters to obtain updated sensor parameters and reselect the sensor to be verified based on the updated sensor parameters. If yes, the sensor to be verified meets the requirements.
2. The pipeline inspection system according to claim 1, characterized in that, The sensor includes an excitation coil assembly, a detection coil assembly, a sensor rod (1), and multiple centering support wheels (2). The sensor rod (1) is horizontally positioned at the central axis of the pipe to be tested. The excitation coil assembly, the multiple centering support wheels (2), and the detection coil assembly are detachably connected to the sensor rod (1) in sequence from one end to the other. The sensor rod (1) has a first drag ring at one end near the detection coil assembly and a second drag ring at the other end. The excitation coil assembly is electrically connected to the signal generator through the first drag ring to receive the AC excitation signal. The detection coil assembly is electrically connected to the data acquisition instrument through the second drag ring to detect the pipe to be tested according to the AC excitation signal, obtain pipe detection data, and send the pipe detection data to the data acquisition instrument.
3. The pipeline inspection system according to claim 2, characterized in that, The excitation coil assembly includes a first excitation baffle (3), a second excitation baffle (4), and an excitation spool (5). The excitation spool (5) has a first thread in the middle. The excitation spool (5) is sleeved on the sensor rod (1) through the first thread. The excitation spool (5) moves back and forth along both ends of the sensor rod (1). The first excitation baffle (3) and the second excitation baffle (4) are both circular plate structures. The first excitation baffle (3) and the second excitation baffle (4) can be detachably connected to the excitation spool (5).
4. The pipeline inspection system according to claim 2, characterized in that, The detection coil assembly includes a first detection baffle (6), a second detection baffle (7), and a detection spool (8). The detection spool (8) has a second thread in the middle. The detection spool (8) is sleeved on the sensor rod (1) through the second thread. The detection spool (8) moves back and forth along both ends of the sensor rod (1). The first detection baffle (6) and the second detection baffle (7) are both circular plate structures. The first detection baffle (6) and the second detection baffle (7) can be detachably connected to the detection spool (8).
5. The pipeline inspection system according to claim 2, characterized in that, There are two centering support wheels (2), and both centering support wheels (2) are arranged between the excitation coil assembly and the detection coil assembly.
6. The pipeline inspection system according to claim 5, characterized in that, The sensor also includes a circular shielding component (9), which is disposed between the plurality of centering support wheels (2) and is detachably connected to the sensor rod (1).
7. The pipeline inspection system according to claim 1, characterized in that, The pipeline inspection system also includes a power supply, which is electrically connected to the signal generator, the sensor, and the data acquisition instrument.