Weld joint phased array ultrasonic detection robot and detection method

Abstract

The invention discloses a weld phased array ultrasonic detection robot which comprises a robot body, the robot body is connected with a water pump through a pipeline, the water pump is used for conveying a coupling agent to the robot body, and the robot body is connected with a controller. The controller is used for adjusting starting, stopping and the moving direction of the robot body in real time and displaying the working state and environment information of the robot body. According to the robot and the detection method, the construction risk caused by high-altitude operation can be reduced, the safety is improved, the robot and the detection method are suitable for detection of steel pipes with large diameters, a scaffold does not need to be built, and the construction cost is reduced; the laser tracking module can emit a laser beam to detect the surrounding environment and accurately recognize the specific position of the welding seam, the requirement for manual intervention is lowered, detection errors caused by human factors are reduced, and the detection efficiency, the detection accuracy and the consistency can be remarkably improved.

Description

Technical Field

[0001] The invention relates to the technical field of lithium ion battery manufacturing, and in particular to a weld phased array ultrasonic detection robot and a detection method. Background Art

[0002] "Wind, solar, thermal and energy storage" is the deployment of my country's energy strategy, especially the development of energy storage technology, which plays an important role in energy layout. Compressed air energy storage technology is less restricted by geographical environment than hydropower, solar thermal and geothermal power generation technology. Compressed air energy storage power stations are developing rapidly, but compressed air energy storage power stations are different from traditional thermal power stations and nuclear power stations. The pressure and temperature of the medium in their pipelines are relatively low. The pipelines of some key components such as low-pressure pipelines, air intake pipelines, exhaust pipelines, cooling pipelines, pressure relief pipelines, etc., have large diameters, up to more than 30 meters.

[0003] When phased array ultrasonic testing is used on these pipeline welds, due to the large diameter of the steel pipes and the high-altitude operation, scaffolding needs to be built to assist manual flaw detection. This method results in low detection efficiency and accuracy, poor safety, and high construction costs. Summary of the invention

[0004] The purpose of the present invention is to solve the problems of the above-mentioned background technology and to provide a weld phased array ultrasonic detection robot and detection method.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] A weld phased array ultrasonic detection robot comprises: a robot body, the robot body is connected to a water pump through a pipeline, the water pump is used to transport a coupling agent to the robot body, the robot body is connected to a controller, and the controller is used to adjust the start and stop of the robot body, the moving direction and display the working status and environmental information of the robot body in real time.

[0007] As a further solution of the present invention: the robot body is provided with a magnetic wheel, the robot body is connected to a lifting mechanism, and the magnetic wheel cooperates with the lifting mechanism to lift the robot body to the surface of the steel pipe for adsorption-type movement.

[0008] As a further solution of the present invention: a laser tracking module is provided at the front end of the robot body, and the laser tracking module is used to identify and track the weld.

[0009] As a further solution of the present invention: a video module is arranged behind the laser tracking module, and the video module is used to monitor the detection environment and assist the laser tracking module in error adjustment.

[0010] As a further solution of the present invention: the robot body is connected to a TOFD scanner, the TOFD scanner is provided with a probe, one end of the pipe connected to the water pump is fixed behind the probe, and the TOFD scanner is used to detect steel pipe welds and internal defects of materials.

[0011] A detection method, using the weld phased array ultrasonic detection robot for detection, comprising:

[0012] S1, the lifting mechanism lifts the robot body to the surface of the steel pipe, presets a moving route, and the controller starts the robot body to move along the moving route;

[0013] S2. When the robot body is moving, the laser tracking module emits a laser beam and measures the time it takes for the laser beam to be reflected back, obtains the distance to the weld, captures the outline and shape of the weld, and feeds the measurement data back to the controller in real time;

[0014] S3, the video module collects the imaging data of the robot body in the moving direction and the imaging data of the steel pipe weld in real time, and the controller receives the imaging data and corrects the movement of the robot body;

[0015] S4. Coat the detection surface with coupling agent through a water pump, and use the TOFD scanner to perform weld detection and collect detection data.

[0016] As a further solution of the present invention: in step S3, the correction includes the following steps:

[0017] S31. After receiving the imaging data in the moving direction of the robot body collected by the video module, the controller converts the imaging data into a picture for display, and adjusts the moving path of the robot body through the controller according to the display result.

[0018] As a further solution of the present invention: in step S3, the correction includes the following steps:

[0019] S32. After receiving the imaging data of the steel pipe weld collected by the video module, the controller converts the imaging data into a picture for display, cleans the surface of the steel pipe according to the display result, or adjusts the moving path of the robot body through the controller.

[0020] As a further solution of the present invention: in step S3, the correction includes the following steps:

[0021] S33. After receiving the imaging data of the steel pipe weld collected by the video module, the controller integrates the measurement data provided by the laser tracking module with the imaging data of the steel pipe weld collected by the video module, compares and analyzes the actual position of the weld with the expected standard position, obtains the error nature and direction, and adjusts the moving path of the robot body.

[0022] Beneficial effects of the present invention:

[0023] (1) In the present invention, the use of the robot and the detection method can reduce the construction risks brought by high-altitude operations, improve safety, and is suitable for the detection of steel pipes with larger diameters. There is no need to build scaffolding, thereby reducing construction costs.

[0024] (2) In the present invention, the laser tracking module can emit a laser beam to detect the surrounding environment and accurately identify the specific location of the weld, thereby reducing the need for manual intervention and the detection errors caused by human factors, and can significantly improve the detection efficiency, detection accuracy and consistency.

[0025] (3) In the present invention, the laser tracking module cooperates with the video module to realize automatic tracking and following of the detection trajectory, making the positioning accuracy higher.

[0026] (4) In the present invention, the robot has strong expandability, and the robot body 1 can be equipped with phased array and TOFD hardware modules to realize automatic detection, storage and analysis of monitoring data. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The present invention will be further described below in conjunction with the accompanying drawings.

[0028] Figure 1 It is a structural schematic diagram of the weld phased array ultrasonic testing robot of the present invention;

[0029] Figure 2 yes Figure 1 The schematic diagram of the robot body;

[0030] Figure 3 It is a schematic flow chart of the detection method of the present invention.

[0031] In the figure: 1. Robot body; 11. Magnetic wheel; 12. Laser tracking module; 13. Video module; 14. TOFD scanner; 15. Cable socket; 16. Handle; 2. Water pump; 3. Controller; 4. Lifting mechanism. DETAILED DESCRIPTION

[0032] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0033] See also Figure 1-Figure 2 As shown, the present invention is a weld phased array ultrasonic detection robot, comprising: a robot body 1, the robot body 1 is designed with aluminum alloy material, the robot body 1 is connected to a water pump 2 through a pipeline, the water pump 2 is used to transport coupling agent to the robot body 1, and before the robot body 1 detects the steel pipe weld, the coupling agent can be coated on the detection surface.

[0034] Couplant is a liquid or gel-like substance that can fill the tiny air gap between the probe and the detection surface to ensure that sound waves can be effectively transmitted. Because the efficiency of sound waves propagating in the air is very low, they propagate more effectively in couplant, which can improve the quality of the echo signal received by the probe, reduce the reflection loss of sound waves, and effectively improve the sensitivity and accuracy of detection.

[0035] The robot body 1 is connected to the controller 3, and the connection between the robot body 1 and the controller 3 can be a wired connection or a wireless connection. The controller 3 is provided with a display screen and operation buttons. The display screen can display the working status and environmental information of the robot body 1. The operation buttons are provided with a start button, a stop button, and azimuth buttons in different directions. The operator can operate the operation buttons according to the information on the display screen to adjust the start and stop and the moving direction of the robot body 1. In some embodiments, the controller 3 is also provided with an execution module, which can analyze the content displayed on the display screen, and convert the analysis results into execution action instructions, which are fed back to the robot body 1 to adjust the moving direction of the robot body 1.

[0036] In this embodiment, the robot body 1 is provided with a magnetic wheel 11, and the magnetic wheel 11 is electrically driven, so that the entire robot body 1 can be moved automatically without manual pushing. The robot body 1 is connected to the lifting mechanism 4, and the magnetic wheel 11 cooperates with the lifting mechanism 4 to lift the robot body 1 to the surface of the steel pipe for adsorption movement. The lifting mechanism 4 includes but is not limited to a lifting platform, a pneumatic lift, a chain lift, and a mobile lift. The magnetic wheel 11 adopts a permanent magnet magnetic wheel, and an encoder is attached to the magnetic wheel 11 to record the distance traveled by the robot body 1. At the same time, a plurality of expansion interfaces are also provided on the magnetic wheel 11 for connecting with various modules and components.

[0037] Furthermore, a laser tracking module 12 is provided at the front end of the robot body 1, a cable socket 15 is provided at the rear end, and handles 16 are provided on both sides. Among them, the laser tracking module 12 is used to identify and track welds, and the strength and connection status of the laser tracking signal can be displayed through the display screen of the controller 3. Specifically, the laser tracking module 12 can emit a laser beam to detect the surrounding environment and accurately identify the specific location of the weld. Since the welds of long steel pipes or large-diameter pipes are usually more complicated, laser detection reduces the need for manual intervention and reduces detection errors caused by human factors, which can significantly improve detection efficiency, detection accuracy and consistency. In addition, the laser tracking module 12 can adapt to steel pipes of different materials and shapes, has good adaptability to the detection environment, and is suitable for a variety of industrial environments.

[0038] A video module 13 is arranged behind the laser tracking module 12, and the video module 13 is used to monitor the detection environment and assist the laser tracking module 12 in error adjustment. The laser tracking module 12 cooperates with the video module 13 to realize automatic tracking and following of the detection trajectory, so that the positioning accuracy is higher. The video module 13 includes a high-definition camera, and the imaging data collected by the camera can be transmitted to the controller 3 in real time and displayed, so that the user can observe the obstacles around the robot body 1 to determine whether there are any obstructions in the walking direction of the robot body 1, and can also observe whether the surface of the steel pipe is polished clean.

[0039] The robot body 1 is connected to the TOFD scanner 14, and the TOFD scanner 14 is provided with a detachable probe. In this embodiment, the probe adopts a phased array probe. The probe includes but is not limited to a phased array probe and a TOFD probe, which improves the adaptability of the robot body 1, so that it can not only use phased array detection, but also carry accessories of conventional ultrasonic detection technology and TOFD detection technology. And one end of the pipe connected to the water pump 2 is fixed behind the probe, so that the coupling agent can be applied to the detection position of the probe in advance, which is convenient for the TOFD scanner 14 to more accurately detect the welds of the steel pipe and internal defects of the material.

[0040] The present application adopts modular design so that the functions of each module can be highly integrated and can be disassembled and used separately, which is convenient for on-site installation and use.

[0041] See also Figure 1-Figure 3 As shown, a detection method is used to detect the weld phased array ultrasonic detection robot, and the detection method includes:

[0042] S1. Operate the lifting mechanism 4 to lift the robot body 1 to the surface of the steel pipe so that the robot body 1 is located on the weld, adjust the relative distance between the probe and the weld, preset a moving route, and start the robot body 1 to move along the preset moving route through the controller 3.

[0043] Before the robot body 1 is lifted, the robot body 1, the controller 3 and the water pump 2 need to be connected to an external phased array ultrasonic testing host respectively.

[0044] S2. When the robot body 1 is moving, the laser tracking module 12 emits a laser beam and measures the time it takes for the laser beam to be reflected back, obtains the distance to the weld, captures the outline and shape of the weld, and feeds back the measurement data to the controller 3 in real time.

[0045] S3, the video module 13 collects imaging data in the moving direction of the robot body 1 and the imaging data of the steel pipe weld in real time, and the controller 3 receives the imaging data and corrects the movement of the robot body 1.

[0046] The correction process includes the following steps:

[0047] S31, after receiving the imaging data in the moving direction of the robot body 1 collected by the video module 13, the controller 3 converts the imaging data into a picture for display. According to the display result, the obstacles around the robot body 1 can be observed. When the robot body 1 deviates from the preset moving route, the moving path of the robot body 1 is adjusted through the orientation button in the controller 3 until the robot body 1 moves to the preset end point, and the stop button of the controller 3 is operated to complete the detection.

[0048] S32, after the controller 3 receives the imaging data of the steel pipe weld collected by the video module 13, it converts the imaging data into a picture for display. According to the display result, it can be observed whether the surface of the steel pipe is polished clean. If there are protrusions on the surface of the steel pipe, the steel pipe is polished and cleaned by the grinding disc in the robot body 1, or the moving path of the robot body 1 is adjusted by the controller 3.

[0049] It should be noted that for steel pipes with higher requirements on weld quality, they need to be ground and cleaned before further testing to ensure the integrity of the weld. Welds that have not been ground and cleaned are prone to hide weld defects, resulting in inaccurate subsequent test results.

[0050] For steel pipes with lower weld quality requirements, if the steel pipe surface is polished to a high degree, making the steel pipe surface smoother, the moving path of the robot body 1 can be adjusted to save inspection time and cost; if the steel pipe surface is less smooth, it still needs to be polished before continuing to inspect the weld.

[0051] S33, after the controller 3 receives the imaging data of the steel pipe weld collected by the video module 13, it integrates the measurement data provided by the laser tracking module 12 with the imaging data of the steel pipe weld collected by the video module 13, and uses edge detection and feature extraction technology to detect the actual position and characteristics of the weld. The actual position of the weld is compared and analyzed with the expected standard position, the error nature and direction are obtained, and the moving path of the robot body 1 is adjusted.

[0052] Before comparing and analyzing the actual position of the weld with the expected standard position, a threshold value of the error may be set in the controller 3 to determine whether adjustment is required.

[0053] In addition, the laser tracking module 12 provides real-time feedback to the controller 3, so that the TOFD scanner 14 can continuously adjust its position during the movement to ensure that it maintains a correct distance from the target.

[0054] S4, a coupling agent is applied to the detection surface by the water pump 2, and the TOFD scanner 14 performs weld detection and collects detection data. The detection data includes waveform data, defect location data, defect characteristic parameters, image data, and signal-to-noise ratio data.

[0055] The waveform data includes echo waveform data and time parameter data. The ultrasonic echo waveform data received during the detection process can be used to analyze the characteristics of internal defects in the weld; the time parameter data, that is, the time when each echo arrives, can be used to calculate the depth and position of the defect.

[0056] The defect location data includes defect position and defect depth. The defect position is based on the echo arrival time and ultrasonic propagation speed to calculate the position of the defect in the weld (lateral and longitudinal position); the defect depth is the depth information of the defect calculated through time delay to help determine the distance between the defect and the weld surface.

[0057] The defect characteristic parameters include defect type, defect size and defect shape. The defect type is the different types of defects identified by the probe on the TOFD scanner 14, such as cracks, pores, and inclusions; the defect size is the width and height of the defect estimated based on the intensity and duration of the echo; the defect shape is the geometric shape of the defect obtained by analyzing the echo waveform.

[0058] The image data includes imaging data and cross-sectional views. The TOFD scanner 14 can generate two-dimensional or three-dimensional weld images to clearly display the overall structure and internal defects of the weld. The cross-sectional views are cross-sectional views generated at different depths to help further analyze defect characteristics.

[0059] The signal-to-noise ratio can evaluate the quality of the echo signal and reflect the reliability and accuracy of the detection.

[0060] In this embodiment, the user can integrate the inspection data to produce a detailed inspection report containing information such as defect location, type, and size to facilitate subsequent analysis and decision-making.

[0061] The present invention lifts the robot body 1 to the surface of the steel pipe through the lifting mechanism 4, operates the robot body 1 through the controller 3, and moves the magnetic wheel 11 on the surface of the steel pipe. During the movement, the water pump 2 delivers the coupling agent to the robot body 1, and the robot body 1 coats the coupling agent on the surface of the steel pipe. The laser tracking module 12 identifies the tracking weld, the video module 13 monitors the detection environment and assists the laser tracking module 12 in error adjustment, and the probe on the TOFD scanner 14 detects the steel pipe weld. The expansion interface on the magnetic wheel 11 allows the robot body 1 to be equipped with a phased array and TOFD hardware module to realize the automatic detection, storage and analysis of monitoring data. The use of this robot and detection method can reduce the construction risks brought by high-altitude operations, improve safety, and is suitable for the detection of steel pipes with larger diameters. There is no need to build scaffolding, which reduces construction costs.

[0062] Working principle: The lifting mechanism 4 lifts the robot body 1 to the surface of the steel pipe, and the controller 3 operates the robot body 1 to move the magnetic wheel 11 on the surface of the steel pipe. During the movement, the water pump 2 transports the coupling agent to the robot body 1, and the robot body 1 coats the coupling agent on the surface of the steel pipe. The laser tracking module 12 identifies the tracking weld, the video module 13 monitors the detection environment and assists the laser tracking module 12 to adjust the error, and the probe on the TOFD scanner 14 detects the steel pipe weld.

[0063] The above is a detailed description of an embodiment of the present invention, but the content is only a preferred embodiment of the present invention and cannot be considered to limit the scope of implementation of the present invention. All equivalent changes and improvements made according to the scope of application of the present invention should still fall within the scope of the claims of the present invention.

Claims

1. A weld phased array ultrasonic testing robot, characterized in that: include: A robot body (1), the robot body (1) being connected to a water pump (2) via a pipeline, the water pump (2) being used to transport coupling agent to the robot body (1); The robot body (1) is connected to a controller (3), and the controller (3) is used to adjust the start and stop of the robot body (1), the moving direction, and display the working status and environmental information of the robot body (1) in real time.

2. A weld phased array ultrasonic testing robot according to claim 1, characterized in that: The robot body (1) is provided with a magnetic wheel (11), the robot body (1) is connected to a lifting mechanism (4), and the magnetic wheel (11) cooperates with the lifting mechanism (4) to lift the robot body (1) to the surface of the steel pipe for adsorption-type movement.

3. The weld phased array ultrasonic testing robot according to claim 1, characterized in that: A laser tracking module (12) is arranged at the front end of the robot body (1), and the laser tracking module (12) is used to identify tracking welds.

4. The weld phased array ultrasonic testing robot according to claim 3, characterized in that: A video module (13) is arranged behind the laser tracking module (12), and the video module (13) is used to monitor the detection environment and assist the laser tracking module (12) in error adjustment.

5. The weld phased array ultrasonic testing robot according to claim 3, characterized in that: The robot body (1) is connected to a TOFD scanner (14), the TOFD scanner (14) is provided with a probe, one end of a pipe connected to the water pump (2) is fixed behind the probe, and the TOFD scanner (14) is used to detect steel pipe welds and internal defects of materials.

6. A detection method, characterized in that: The weld phased array ultrasonic testing robot according to any one of claims 1 to 5 is used for testing, comprising: S1, the lifting mechanism (4) lifts the robot body (1) to the surface of the steel pipe, presets a moving route, and the controller (3) starts the robot body (1) to move along the moving route; S2, when the robot body (1) is moving, the laser tracking module (12) emits a laser beam and measures the time it takes for the laser beam to be reflected back, obtains the distance to the weld, captures the outline and shape of the weld, and feeds back the measurement data to the controller (3) in real time; S3, the video module (13) collects imaging data in the moving direction of the robot body (1) and imaging data of the steel pipe weld in real time, and the controller (3) receives the imaging data and corrects the movement of the robot body (1); S4. A coupling agent is applied to the detection surface by a water pump (2), and a TOFD scanner (14) performs weld detection and collects detection data.

7. The method according to claim 6, characterized in that: In step S3, the correction includes the following steps: S31, after receiving the imaging data on the moving direction of the robot body (1) collected by the video module (13), the controller (3) converts the imaging data into a picture for display, and adjusts the moving path of the robot body (1) through the controller (3) according to the display result.

8. The method according to claim 6, characterized in that: In step S3, the correction includes the following steps: S32, after receiving the imaging data of the steel pipe weld collected by the video module (13), the controller (3) converts the imaging data into a picture for display, and cleans the surface of the steel pipe according to the display result, or adjusts the moving path of the robot body (1) through the controller (3).

9. The method according to claim 6, characterized in that: In step S3, the correction includes the following steps: S33, after the controller (3) receives the imaging data of the steel pipe weld collected by the video module (13), it integrates the measurement data provided by the laser tracking module (12) with the imaging data of the steel pipe weld collected by the video module (13), compares and analyzes the actual position of the weld with the expected standard position, obtains the error nature and direction, and adjusts the moving path of the robot body (1).

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