Array ultrasonic detection system and method for composite material repair layer of high-steel-grade pipe

Abstract

The invention provides an array ultrasonic detection system and method for a high-steel-grade pipe composite material repair layer, and relates to the technical field of ultrasonic detection.The system comprises a PC upper computer, a scanning mechanism, an array ultrasonic probe, an ultrasonic board card, a converter, a driver and a position encoder, the scanning mechanism is connected with the PC upper computer through the ultrasonic board card, the converter, the driver and the position encoder, data support is provided, the PC upper computer generates related control instructions based on detection items and provided data, efficient, accurate and automatic quality detection of the high-steel-grade pipe composite material repairing layer is achieved, dependence of manual operation is reduced, and the detection efficiency is improved. And the detection speed is accelerated, so that long-term stable operation and safety of the pipeline are ensured.

Description

Technical Field

[0001] The present invention mainly relates to the technical field of ultrasonic detection, and in particular to an array ultrasonic detection system and method for a high-grade steel pipe composite material repair layer. Background Art

[0002] In the manufacturing and maintenance of high-grade steel pipes, the quality inspection of the composite repair layer is crucial. These pipes are often used in extremely demanding industrial environments, such as oil and gas transportation, chemical processing and marine engineering, so ensuring their structural integrity and safety is essential. The quality of the composite repair layer directly affects the durability and reliability of the pipeline, while traditional ultrasonic testing methods usually rely on the experience and skills of the operator, and the detection efficiency and accuracy are limited by the inconsistency and limitations of manual operations.

[0003] With the development of non-destructive testing technology, array ultrasonic testing technology has been valued for its ability to provide more accurate test results and a wider scanning range. Array ultrasonic testing uses an array of multiple ultrasonic probes to electronically control the transmission and reception of each probe to achieve a comprehensive evaluation of the material being tested. However, existing array ultrasonic testing equipment still has deficiencies in terms of automation, detection speed, and data processing capabilities, especially when dealing with large-diameter pipes and complex repair layer structures. These deficiencies are particularly evident.

[0004] Therefore, there is an urgent need for a tool that can automatically perform array ultrasonic testing processes with high precision and efficiency to meet the quality inspection requirements of high-grade steel pipe composite repair layers. Summary of the invention

[0005] The technical problem to be solved by the present invention is to provide an array ultrasonic detection system and method for a high-grade steel pipe composite material repair layer in view of the deficiencies in the prior art.

[0006] The technical solution of the present invention to solve the above technical problems is as follows: an array ultrasonic detection system for a composite material repair layer of a high-grade steel pipe, comprising a PC host computer, a scanning mechanism, an array ultrasonic probe, an ultrasonic board, a converter, a driver and a position encoder;

[0007] The array ultrasonic probe is installed on the scanning axis of the scanning mechanism, the output interface of the scanning mechanism is connected to the position encoder, the position encoder is connected to the ultrasonic board, the array ultrasonic probe is also connected to the ultrasonic board, the ultrasonic board is connected to the first network port of the PC host computer, the second network port of the PC host computer is connected to the converter, and the converter is connected to the input port of the scanning mechanism through the driver;

[0008] The PC host computer is used to obtain the posture data of the scanning mechanism through the ultrasonic board and the position encoder, and generate a grid scanning motion code based on the detection items of the composite material repair layer and the posture data; the converter is used to convert the grid scanning motion code into motion instructions and detection instructions; the driver is used to control the operation of the stepping axis and scanning axis of the scanning mechanism according to the motion instructions, and when the target position is reached, the detection instruction is sent to the array ultrasonic probe; the array ultrasonic probe is used to detect the composite material repair layer according to the detection instruction, and send the detection result to the PC host computer through the ultrasonic board.

[0009] The beneficial effects of the present invention are as follows: the scanning mechanism carries an array ultrasonic probe, and is connected to a PC host computer through an ultrasonic board, a converter, a driver and a position encoder to provide data support. The PC host computer generates relevant control instructions based on the detection items and the provided data, thereby realizing efficient, accurate and automated quality inspection of the composite material repair layer of high-grade steel pipes, reducing dependence on manual operation, and accelerating the inspection speed, thereby ensuring the long-term stable operation and safety of the pipeline.

[0010] Based on the above technical solution, the present invention can also be improved as follows.

[0011] Further, the position encoder comprises a first position encoder and a second position encoder, and the first position encoder and the second position encoder are electrically connected to the encoder interface on the ultrasonic board respectively;

[0012] The first position encoder is installed on the stepping shaft, and is used to convert the first AB phase encoder signal of the stepping shaft into the first posture data, and send it to the ultrasonic board card; the second position encoder is installed on the scanning shaft, and is used to convert the second AB phase encoder signal of the scanning shaft into the second posture data, and send it to the ultrasonic board card;

[0013] The ultrasonic board is used to send the first posture data and the second posture data to the PC host computer through the EtherCAT protocol.

[0014] The beneficial effect of adopting the above further scheme is: by installing the first position encoder and the second position encoder on the stepping axis and the scanning axis respectively, the posture data of the stepping axis, i.e. the scanning mechanism as a whole, can be obtained, and the posture data of the scanning axis, i.e. the array ultrasonic probe, can also be obtained, and the data can be sent to the PC host computer through the ultrasonic board card, thereby providing data support for the PC host computer to make further relevant control instructions.

[0015] Furthermore, the array ultrasonic detection system further comprises a transducer, the array ultrasonic probe is electrically connected to the input of the transducer, and the output of the transducer is electrically connected to the transducer interface on the ultrasonic board;

[0016] The array ultrasonic probe is used to detect the composite material repair layer according to the detection instruction, obtain an analog signal of the composite material repair layer, and send the analog signal to the transducer;

[0017] The transducer is used to convert the received ultrasonic signal from an analog signal into a digital signal, obtain detection data, and send the detection data to the PC host computer.

[0018] The beneficial effect of adopting the above further scheme is: the PC host computer also needs to obtain the detection data related to the high-grade steel pipe composite material repair layer detected by the array ultrasonic probe, and the detection data can be sent to the PC host computer after certain processing by the transducer. The PC host computer can generate and control subsequent instructions based on the relevant detection data, thereby realizing automatic detection.

[0019] Further, the scanning mechanism includes a first drive unit, a second drive unit, an ultrasonic host, a scanning axis, a scanning axis control motor, a probe loading arm, a connecting rod, a flexible connecting member and a transmission belt;

[0020] The two ends of the connecting rod are respectively connected to the first driving unit and the second driving unit, and the ultrasound host is fixed to the middle position of the connecting rod by bolts; the scanning shaft is assembled with the first driving unit and the second driving unit by first fastening bolts;

[0021] The probe loading arm is assembled on the scanning shaft through the flexible connector and the transmission belt; the scanning shaft control motor is fixed to the end of the scanning shaft through a second fastening bolt, and the scanning shaft control motor drives the probe loading arm to move on the scanning shaft by controlling the transmission belt.

[0022] The beneficial effect of adopting the above further scheme is that the two drive units drive the entire scanning mechanism to move, and the scanning axis control motor controls the probe loaded on the scanning axis to move, thereby driving the array ultrasonic probe to move together, thereby realizing the detection related to the composite material repair layer of high-grade steel pipes.

[0023] Further, the first driving unit and the second driving unit each include a driving base, a magnetic wheel, a bracket, a connecting rod seat, a countersunk bolt and a cable connection hole;

[0024] There are four magnetic wheels, and the four magnetic wheels are grouped in pairs, and are respectively installed on both sides of the bottom of the driving base through corresponding stepping shafts and stepping shaft control motors; the driving base is provided with a through hole for connecting the connecting rod, and the connecting rod seat is installed at the through hole of the driving base and assembled with the connecting rod through the countersunk bolt; the bracket is installed on the top of the driving base, and is used to place the driving base in the starting position; the cable connection hole is provided on the outer surface of the driving base, and the stepping shaft control motor and the driver are connected through a cable, and the motion command of the driver is received through the cable, and the stepping shaft control motor drives the stepping shaft to move according to the motion command.

[0025] The beneficial effect of adopting the above further solution is that the stepper shaft control motor drives the stepper shafts of the first drive unit and the second drive unit to move together through motion instructions, thereby driving the entire scanning mechanism to move.

[0026] Further, the probe loading arm includes an array ultrasound probe fixing device, a compression spring, a quick-release rod, a fixing plate, a connecting piece, a wedge fixing bolt, a fixing top seat, a cantilever, a base and a fixing rod;

[0027] The array ultrasound probe fixing device is transversely fixed to the wedge of the array ultrasound probe by the wedge fixing bolt, and is connected to one end of the cantilever by the compression spring, and the other end of the cantilever is connected to the base, the compression spring is provided with the fixing rod along the length direction, and the fixed top seat is connected to the array ultrasound probe fixing device by the fixing rod to limit the spring to expand and contract only along the length direction; the fixing plate is fixed to the quick-release rod, and the base is connected to the scanning axis by the quick-release rod and the fixing plate, one end of the connecting piece is connected to the base, and the other end is connected to the flexible connecting piece.

[0028] The beneficial effect of adopting the above further scheme is: the array ultrasonic probe fixing device is fixed on the probe loading arm, and the array ultrasonic probe fixing device can be driven to move the detection position of the probe when performing high-grade steel pipe composite material repair layer detection, and extend and retract along the length direction, thereby realizing automatic detection work in a larger range.

[0029] Furthermore, the scanning shaft includes a shaft body, a sliding base, a sliding wheel, a fixed shaft, a quick release switch, a fixing plate, and a connecting piece;

[0030] The fixed plate is installed at one end of the shaft body close to the second driving unit, the scanning axis control motor is fixed on the fixed plate, the sliding wheel is slidably connected to the shaft body, the sliding base is fixed on the sliding wheel, the sliding wheel is electrically connected to the output shaft of the scanning axis control motor, the sliding wheel is driven by the scanning axis control motor and drives the sliding base to slide on the shaft body for axial scanning; the fixed shaft is fixed to the second driving unit and is assembled with the connecting piece through a rotating joint to realize the rotation of the scanning shaft relative to the driving unit, the connecting piece is assembled with the shaft body through bolts, and the quick release switch is assembled on the rotating joint and fixes the rotating joint.

[0031] The beneficial effect of adopting the above further solution is that the array ultrasonic probe can be driven to perform axial scanning and rotation relative to the drive unit through the scanning axis, thereby expanding the detection range and achieving multi-angle detection.

[0032] Another technical solution of the present invention to solve the above technical problem is as follows: an array ultrasonic detection method for a high-grade steel pipe composite material repair layer is applied to an array ultrasonic detection system, the array ultrasonic detection system includes a PC host computer, a scanning mechanism, an array ultrasonic probe, an ultrasonic board, a converter, a driver and a position encoder; the method includes:

[0033] The PC host computer obtains the posture data of the scanning mechanism through the ultrasonic board and the position encoder, and generates a grid scanning motion code based on the detection items of the composite material repair layer and the posture data;

[0034] The converter converts the grid scanning motion code into motion instructions and detection instructions;

[0035] The driver controls the stepping axis and the scanning axis of the scanning mechanism to run according to the motion instruction, and sends the detection instruction to the array ultrasound probe when the target position is reached;

[0036] The array ultrasonic probe detects the composite material repair layer according to the detection instruction, and sends the detection result to the PC host computer through the ultrasonic board card.

[0037] Further, the position encoder includes a first position encoder and a second position encoder, the first position encoder and the second position encoder are electrically connected to the encoder interface on the ultrasonic board, the first position encoder is installed on the stepping shaft, and the second position encoder is installed on the scanning shaft; the PC host computer obtains the position data of the scanning mechanism through the ultrasonic board and the position encoder, including:

[0038] The first position encoder converts the first AB phase encoder signal of the stepping shaft into the first position data and sends it to the ultrasonic board;

[0039] The second position encoder converts the second AB phase encoder signal of the scanning axis into second posture data and sends it to the ultrasonic board;

[0040] The ultrasonic board is used to send the first posture data and the second posture data to the PC host computer through the EtherCAT protocol. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 A schematic diagram of the architecture of an array ultrasonic detection system provided by an embodiment of the present invention;

[0042] Figure 2 A schematic diagram of the structure of a scanning mechanism provided in an embodiment of the present invention;

[0043] Figure 3 A schematic diagram of the structure of a drive unit provided by an embodiment of the present invention;

[0044] Figure 4 A schematic diagram of the structure of a probe loading arm provided in an embodiment of the present invention;

[0045] Figure 5 A schematic diagram of the structure of a scanning axis provided by an embodiment of the present invention;

[0046] Figure 6 A flow chart of an array ultrasonic detection method provided by an embodiment of the present invention;

[0047] Figure 7 An automated execution flow chart provided for an embodiment of the present invention.

[0048] In the accompanying drawings, the names of the components represented by the various marks are as follows:

[0049] 1. First drive unit 1; 2. Second drive unit; 3. Ultrasonic mainframe; 4. Scanning axis; 5. Scanning axis control motor; 6. Probe loading arm; 7. Connecting rod; 8. Flexible connector; 9. Transmission belt; 10. Magnetic wheel; 11. Bracket; 12. Connecting rod seat; 13. Countersunk bolt; 14. Cable connection hole; 41. Shaft; 42. Sliding base; 43. Sliding wheel; 44. Fixed shaft; 45. Quick release switch; 46. Fixed plate; 47. Connector; 48. Rotary joint; 61. Array ultrasonic probe fixing device; 62. Compression spring; 63. Quick release rod; 64. Fixed plate; 65. Connector; 66. Wedge fixing bolt; 67. Fixed top seat; 68. Cantilever; 69. Base; 610. Fixed rod. DETAILED DESCRIPTION

[0050] The principles and features of the present invention are described below in conjunction with the accompanying drawings. The examples given are only used to explain the present invention and are not used to limit the scope of the present invention.

[0051] The technical solution in the embodiment of the present application will be described below in conjunction with the drawings in the embodiment of the present application. In the description of the present application, unless otherwise specified, " / " indicates that the objects associated before and after are in an "or" relationship, for example, A / B can represent A or B; "and / or" in the present application is only a description of the association relationship of the associated objects, indicating that there can be three relationships, for example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone, where A and B can be singular or plural.

[0052] Furthermore, in the description of this application, unless otherwise specified, "plurality" means two or more than two. "At least one of the following" or similar expressions refers to any combination of these items, including any combination of single items or plural items. For example, at least one of a, b, or c can mean: a, b, c, ab, ac, bc, or abc, where a, b, and c can be single or multiple.

[0053] Meanwhile, in the embodiments of the present application, words such as "exemplary" or "for example" are used to indicate examples, illustrations or descriptions. Any embodiment or design described as "exemplary" or "for example" in the embodiments of the present application should not be interpreted as being more preferred or more advantageous than other embodiments or designs. Specifically, the use of words such as "exemplary" or "for example" is intended to present related concepts in a concrete manner for ease of understanding.

[0054] like Figure 1 As shown, an embodiment of the present invention provides an array ultrasonic detection system for a high-grade steel pipe composite material repair layer, including a PC host computer, a scanning mechanism, an array ultrasonic probe, an ultrasonic board, a converter, a driver, and a position encoder;

[0055] The array ultrasonic probe is installed on the scanning axis of the scanning mechanism, the output interface of the scanning mechanism is connected to the position encoder, the position encoder is connected to the ultrasonic board, the array ultrasonic probe is also connected to the ultrasonic board, the ultrasonic board is connected to the first network port of the PC host computer, the second network port of the PC host computer is connected to the converter, and the converter is connected to the input port of the scanning mechanism through the driver;

[0056] The PC host computer is used to obtain the posture data of the scanning mechanism through the ultrasonic board and the position encoder, and generate a grid scanning motion code based on the detection items of the composite material repair layer and the posture data; the converter is used to convert the grid scanning motion code into motion instructions and detection instructions; the driver is used to control the operation of the stepping axis and scanning axis of the scanning mechanism according to the motion instructions, and when the target position is reached, the detection instruction is sent to the array ultrasonic probe; the array ultrasonic probe is used to detect the composite material repair layer according to the detection instruction, and send the detection result to the PC host computer through the ultrasonic board.

[0057] Attached Figure 1 In the process, the transmission signals between various components include motor control signals, network signals, encoder signals, and ultrasonic signals.

[0058] In the above embodiment, the scanning mechanism carries an array ultrasonic probe, and is connected to a PC host computer through an ultrasonic board, a converter, a driver, and a position encoder to provide data support. The PC host computer generates relevant control instructions based on the detection items and the provided data, thereby realizing efficient, accurate, and automated quality inspection of the composite material repair layer of high-grade steel pipes, reducing dependence on manual operation, and speeding up the inspection speed, thereby ensuring the long-term stable operation and safety of the pipeline.

[0059] Preferably, the position encoder comprises a first position encoder and a second position encoder, and the first position encoder and the second position encoder are electrically connected to the encoder interface on the ultrasonic board respectively;

[0060] The first position encoder is installed on the stepping shaft, and is used to convert the first AB phase encoder signal of the stepping shaft into the first posture data, and send it to the ultrasonic board card; the second position encoder is installed on the scanning shaft, and is used to convert the second AB phase encoder signal of the scanning shaft into the second posture data, and send it to the ultrasonic board card;

[0061] The ultrasonic board is used to send the first posture data and the second posture data to the PC host computer through the EtherCAT protocol.

[0062] The first position encoder can be mounted on any stepping axis.

[0063] In the above embodiment, the first position encoder and the second position encoder are installed on the stepping axis and the scanning axis respectively, so that the posture data of the stepping axis, i.e., the scanning mechanism as a whole, can be obtained, and the posture data of the scanning axis, i.e., the array ultrasonic probe can also be obtained, and the data can be sent to the PC host computer through the ultrasonic board card, thereby providing data support for the PC host computer to make further relevant control instructions.

[0064] Preferably, the array ultrasonic detection system further comprises a transducer, the array ultrasonic probe is electrically connected to the input of the transducer, and the output of the transducer is electrically connected to the transducer interface on the ultrasonic board;

[0065] The array ultrasonic probe is used to detect the composite material repair layer according to the detection instruction, obtain an analog signal of the composite material repair layer, and send the analog signal to the transducer;

[0066] The transducer is used to convert the received ultrasonic signal from an analog signal into a digital signal, obtain detection data, and send the detection data to the PC host computer.

[0067] In the above embodiment, the PC host computer also needs to obtain the detection data related to the high-grade steel pipe composite material repair layer detected by the array ultrasonic probe. The detection data can be sent to the PC host computer after certain processing by the transducer. The PC host computer can perform subsequent instruction generation and control based on the relevant detection data, thereby realizing automatic detection.

[0068] like Figure 2 As shown, preferably, the scanning mechanism includes a first driving unit 1, a second driving unit 2, an ultrasound host 3, a scanning axis 4, a scanning axis control motor 5, a probe loading arm 6, a connecting rod 7, a flexible connecting member 8 and a transmission belt 9;

[0069] The two ends of the connecting rod 7 are respectively connected to the first driving unit 1 and the second driving unit 2, and the ultrasound host 3 is fixed to the middle position of the connecting rod 7 by bolts; the scanning shaft 4 is assembled with the first driving unit 1 and the second driving unit 2 by first fastening bolts;

[0070] The probe loading arm 6 is assembled on the scanning shaft 4 through the flexible connector 8 and the transmission belt 9; the scanning shaft control motor 5 is fixed to the end of the scanning shaft 4 through a second fastening bolt, and the scanning shaft control motor 5 drives the probe loading arm 6 to move on the scanning shaft 4 by controlling the transmission belt 9.

[0071] In the above embodiment, two driving units drive the entire scanning mechanism to move, and the scanning axis control motor 5 controls the probe loaded on the scanning axis 4 to move, thereby driving the array ultrasonic probe to move together to achieve detection related to the high-grade steel pipe composite material repair layer.

[0072] like Figure 3 As shown, preferably, the first driving unit 1 and the second driving unit 2 each include a driving base, a magnetic wheel 10, a bracket 11, a connecting rod seat 12, a countersunk bolt 13 and a cable connection hole 14;

[0073] There are four magnetic wheels 10, and the four magnetic wheels 10 are grouped in pairs, and are respectively installed on both sides of the bottom of the driving base through corresponding stepping shafts and stepping shaft control motors; the driving base is provided with a through hole for connecting the connecting rod 7, and the connecting rod seat 12 is installed at the through hole of the driving base and assembled with the connecting rod 7 through the countersunk bolt 13; the bracket 11 is installed on the top of the driving base, and is used to place the driving base in the starting position; the cable connection hole 14 is provided on the outer surface of the driving base, and the stepping shaft control motor and the driver are connected through a cable, and the motion command of the driver is received through the cable, and the stepping shaft control motor drives the stepping shaft to move according to the motion command.

[0074] The first drive unit 1 and the second drive unit 2 are connected and the distance between them is controlled by a three-position connecting rod 7, and the lengths are 600 mm, 800 mm, and 1000 mm respectively; the ultrasonic host 3 is fixed to the connecting rod 7 by bolts.

[0075] In the above embodiment, the stepper shaft control motor drives the stepper shafts of the first drive unit and the second drive unit to move together through motion instructions, thereby driving the entire scanning mechanism to move.

[0076] like Figure 4 As shown, preferably, the probe loading arm 6 includes an array ultrasound probe fixing device 61, a compression spring 62, a quick release rod 63, a fixing plate 64, a connecting piece 65, a wedge fixing bolt 66, a fixing top seat 67, a cantilever 68, a base 69 and a fixing rod 610;

[0077] The array ultrasonic probe fixing device 61 is transversely fixed to the wedge of the array ultrasonic probe by the wedge fixing bolt 66, and is connected to one end of the cantilever 68 by the compression spring 62, and the other end of the cantilever 68 is connected to the base 69. The compression spring 62 is provided with the fixing rod 610 along the length direction, and the fixed top seat 67 is connected to the array ultrasonic probe fixing device 61 through the fixing rod 610 to limit the spring to expand and contract only along the length direction; the fixing plate 64 is fixed on the quick-release rod 63, and the base 69 is connected to the scanning axis 4 through the quick-release rod 63 and the fixing plate 64. The quick-release rod 63 can be easily rotated and fixed to ensure that the array ultrasonic transducer is located at a suitable angle tangent to the surface of the pipeline repair layer. One end of the connecting member 65 is connected to the base 69, and the other end is connected to the flexible connecting member 8.

[0078] In the above embodiment, the array ultrasonic probe fixing device is fixed on the probe loading arm, and can drive the array ultrasonic probe fixing device to move the detection position of the probe when detecting the composite material repair layer of high-grade steel pipes, and extend and retract along the length direction, thereby realizing automatic detection work in a larger range.

[0079] like Figure 5 As shown, preferably, the scanning shaft 4 includes a shaft body 41, a sliding base 42, a sliding wheel 43, a fixed shaft 44, a quick release switch 45, a fixing plate 46 and a connecting member 47;

[0080] The fixed plate 46 is installed at one end of the shaft body 41 close to the second drive unit 2, the scanning axis control motor 5 is fixed on the fixed plate 46, the sliding wheel 43 is slidably connected to the shaft body 41, the sliding base 42 is fixed on the sliding wheel 43, the sliding wheel 43 is electrically connected to the output shaft of the scanning axis control motor 5, the sliding wheel 43 is driven by the scanning axis control motor 5 and drives the sliding base 42 to slide on the shaft body 41 for axial scanning; the fixed shaft 44 is fixed to the second drive unit 2, and is assembled with the connecting member 47 through a rotating joint 48 to realize the rotation of the scanning shaft relative to the drive unit, the connecting member 47 is assembled with the shaft body 41 through bolts, and the quick release switch 45 is assembled on the rotating joint 48 and fixes the rotating joint 48.

[0081] In the above embodiment, the array ultrasound probe is driven to perform axial scanning and rotate relative to the driving unit by the scanning axis, thereby expanding the detection range and achieving multi-angle detection.

[0082] like Figure 6 As shown, an embodiment of the present invention also provides an array ultrasonic detection method for a high-grade steel pipe composite material repair layer, which is applied to an array ultrasonic detection system. The array ultrasonic detection system includes a PC host computer, a scanning mechanism, an array ultrasonic probe, an ultrasonic board, a converter, a driver, and a position encoder; the method includes:

[0083] The PC host computer obtains the posture data of the scanning mechanism through the ultrasonic board and the position encoder, and generates a grid scanning motion code based on the detection items of the composite material repair layer and the posture data;

[0084] The converter converts the grid scanning motion code into motion instructions and detection instructions;

[0085] The driver controls the stepping axis and the scanning axis of the scanning mechanism to run according to the motion instruction, and sends the detection instruction to the array ultrasound probe when the target position is reached;

[0086] The array ultrasonic probe detects the composite material repair layer according to the detection instruction, and sends the detection result to the PC host computer through the ultrasonic board card.

[0087] Preferably, the position encoder includes a first position encoder and a second position encoder, the first position encoder and the second position encoder are electrically connected to the encoder interface on the ultrasonic board, the first position encoder is installed on the stepping shaft, and the second position encoder is installed on the scanning shaft; the PC host computer obtains the position data of the scanning mechanism through the ultrasonic board and the position encoder, including:

[0088] The first position encoder converts the first AB phase encoder signal of the stepping shaft into the first position data and sends it to the ultrasonic board;

[0089] The second position encoder converts the second AB phase encoder signal of the scanning axis into second posture data and sends it to the ultrasonic board;

[0090] The ultrasonic board is used to send the first posture data and the second posture data to the PC host computer through the EtherCAT protocol.

[0091] Figure 7 This is a flowchart of the automated execution of the system and method, such as Figure 7 As shown in the figure, the execution process of a detection cycle is:

[0092] In the automatic operation mode, the ultrasonic detection system receives the production line signal to start the detection cycle. The automated execution process mainly includes preparation before detection, waiting for the ready state, scanning mechanism readiness, detection imaging, generation of detection results, removal of the scanning mechanism, and end of the detection cycle.

[0093] The advantages of the present invention over the prior art are mainly reflected in the following aspects:

[0094] 1. High degree of automation: The present invention realizes full automation of the detection process, reduces human intervention, and improves the consistency and repeatability of detection.

[0095] 2. High detection efficiency: Through the automated scanning process and the precisely controlled mechanical scanning system, the present invention can quickly and continuously complete the detection of the composite material repair layer of high-grade steel pipes, greatly improving the efficiency of the detection operation.

[0096] 3. Precision and accuracy: The integrated control technology solution and the mechanical scanning system work together to ensure that the ultrasonic probe can accurately perform grid scanning on the pipeline surface. Combined with the high-speed data processing capability of the ultrasonic host, the precision and accuracy of the test results are improved.

[0097] 4. Wide scope of application: The present invention is applicable to ferromagnetic pipes with a diameter of 550 to 1000 mm, and can adapt to the detection of composite material repair layers of high-grade steel pipes of different sizes and types, and has strong adaptability and versatility.

[0098] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0099] Those skilled in the art can clearly understand that, for the convenience and brevity of description, the specific working processes of the above-described devices and units can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0100] In the several embodiments provided in this application, it should be understood that the disclosed devices and methods can be implemented in other ways. For example, the device embodiments described above are only schematic, for example, the division of units is only a logical function division, and there may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed.

[0101] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the embodiments of the present invention.

[0102] In addition, each functional unit in each embodiment of the present invention may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit. The above integrated unit may be implemented in the form of hardware or in the form of software functional units.

[0103] If the integrated unit is implemented in the form of a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention is essentially 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. The computer software product is stored in a storage medium, including several instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the methods of each embodiment of the present invention. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk and other media that can store program codes.

[0104] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. An array ultrasonic detection system for high-grade steel pipe composite material repair layer, characterized in that: It includes a PC host computer, a scanning mechanism, an array ultrasound probe, an ultrasound board, a converter, a driver and a position encoder; The array ultrasonic probe is installed on the scanning axis of the scanning mechanism, the output interface of the scanning mechanism is connected to the position encoder, the position encoder is connected to the ultrasonic board, the array ultrasonic probe is also connected to the ultrasonic board, the ultrasonic board is connected to the first network port of the PC host computer, the second network port of the PC host computer is connected to the converter, and the converter is connected to the input port of the scanning mechanism through the driver; The PC host computer is used to obtain the posture data of the scanning mechanism through the ultrasonic board and the position encoder, and generate a grid scanning motion code based on the detection items of the composite material repair layer and the posture data; The converter is used to convert the grid scanning motion code into motion instructions and detection instructions; The driver is used to control the operation of the stepping axis and the scanning axis of the scanning mechanism according to the motion instruction, and when the target position is reached, the detection instruction is sent to the array ultrasonic probe; the array ultrasonic probe is used to detect the composite material repair layer according to the detection instruction, and send the detection result to the PC host computer through the ultrasonic board.

2. The array ultrasonic detection system according to claim 1, characterized in that: The position encoder comprises a first position encoder and a second position encoder, and the first position encoder and the second position encoder are electrically connected to the encoder interface on the ultrasonic board respectively; The first position encoder is installed on the stepping shaft, and is used to convert the first AB phase encoder signal of the stepping shaft into the first posture data, and send it to the ultrasonic board card; the second position encoder is installed on the scanning shaft, and is used to convert the second AB phase encoder signal of the scanning shaft into the second posture data, and send it to the ultrasonic board card; The ultrasonic board is used to send the first posture data and the second posture data to the PC host computer through the EtherCAT protocol.

3. The array ultrasonic detection system according to claim 1, characterized in that: The array ultrasonic detection system further comprises a transducer, the array ultrasonic probe is electrically connected to the input of the transducer, and the output of the transducer is electrically connected to the transducer interface on the ultrasonic board; The array ultrasonic probe is used to detect the composite material repair layer according to the detection instruction, obtain an analog signal of the composite material repair layer, and send the analog signal to the transducer; The transducer is used to convert the received ultrasonic signal from an analog signal into a digital signal, obtain detection data, and send the detection data to the PC host computer.

4. The array ultrasonic detection system according to claim 1, characterized in that: The scanning mechanism comprises a first driving unit (1), a second driving unit (2), an ultrasonic main unit (3), a scanning axis (4), a scanning axis control motor (5), a probe loading arm (6), a connecting rod (7), a flexible connecting member (8) and a transmission belt (9); The two ends of the connecting rod (7) are respectively connected to the first drive unit (1) and the second drive unit (2); the ultrasound host (3) is fixed to the middle position of the connecting rod (7) by means of bolts; the scanning shaft (4) is assembled with the first drive unit (1) and the second drive unit (2) by means of first fastening bolts; The probe loading arm (6) is assembled on the scanning shaft (4) through the flexible connector (8) and the transmission belt (9); the scanning shaft control motor (5) is fixed to the end of the scanning shaft (4) through a second fastening bolt, and the scanning shaft control motor (5) drives the probe loading arm (6) to move on the scanning shaft (4) by controlling the transmission belt (9).

5. The array ultrasonic detection system according to claim 4, characterized in that: The first drive unit (1) and the second drive unit (2) both comprise a drive base, a magnetic wheel (10), a bracket (11), a connecting rod seat (12), a countersunk bolt (13) and a cable connection hole (14); The magnetic wheels (10) are provided with four, and the four magnetic wheels (10) are grouped in pairs and are respectively installed on both sides of the bottom of the driving base through corresponding stepping shafts and stepping shaft control motors; the driving base is provided with a through hole for connecting the connecting rod (7), the connecting rod seat (12) is installed at the through hole of the driving base, and is assembled with the connecting rod (7) through the countersunk bolt (13); the bracket (11) is installed on the top of the driving base, and is used to place the driving base in a starting position; the cable connection hole (14) is provided on the outer surface of the driving base, and the stepping shaft control motor and the driver are connected through a cable, and the motion command of the driver is received through the cable, and the stepping shaft control motor drives the stepping shaft to move according to the motion command.

6. The array ultrasonic detection system according to claim 4, characterized in that: The probe loading arm (6) comprises an array ultrasound probe fixing device (61), a compression spring (62), a quick-release rod (63), a fixing plate (64), a connecting piece (65), a wedge fixing bolt (66), a fixing top seat (67), a cantilever (68), a base (69) and a fixing rod (610); The array ultrasonic probe fixing device (61) is transversely fixed to the wedge of the array ultrasonic probe through the wedge fixing bolt (66), and is connected to one end of the cantilever (68) through the compression spring (62), and the other end of the cantilever (68) is connected to the base (69). The compression spring (62) is provided with the fixing rod (610) along the length direction, and the fixed top seat (67) is connected to the array ultrasonic probe fixing device (61) through the fixing rod (610) to limit the spring to expand and contract only along the length direction; the fixing plate (64) is fixed on the quick-release rod (63), and the base (69) is connected to the scanning axis (4) through the quick-release rod (63) and the fixing plate (64); one end of the connecting member (65) is connected to the base (69), and the other end is connected to the flexible connecting member (8).

7. The array ultrasonic detection system according to claim 4, characterized in that: The scanning shaft (4) comprises a shaft body (41), a sliding base (42), a sliding wheel (43), a fixed shaft (44), a quick-release switch (45), a fixed plate (46) and a connecting piece (47); The fixing plate (46) is mounted on one end of the shaft body (41) close to the second drive unit (2); the scanning axis control motor (5) is fixed on the fixing plate (46); the sliding wheel (43) is slidably connected to the shaft body (41); the sliding base (42) is fixed on the sliding wheel (43); the sliding wheel (43) is electrically connected to the output shaft of the scanning axis control motor (5); the sliding wheel (43) is driven by the scanning axis control motor (5) and drives the sliding base (42) to slide on the shaft body (41) for axial scanning; the fixing shaft (44) is fixed to the second drive unit (2) and is assembled with the connecting member (47) through a rotating joint (48) to realize the rotation of the scanning shaft relative to the drive unit; the connecting member (47) is assembled with the shaft body (41) through bolts; the quick release switch (45) is assembled on the rotating joint (48) and fixes the rotating joint (48).

8. An array ultrasonic detection method for a composite material repair layer of a high-grade steel pipe, applied to an array ultrasonic detection system, the array ultrasonic detection system comprising a PC host computer, a scanning mechanism, an array ultrasonic probe, an ultrasonic board, a converter, a driver and a position encoder; characterized in that: The method comprises: The PC host computer obtains the posture data of the scanning mechanism through the ultrasonic board and the position encoder, and generates a grid scanning motion code based on the detection items of the composite material repair layer and the posture data; The converter converts the grid scanning motion code into motion instructions and detection instructions; The driver controls the stepping axis and the scanning axis of the scanning mechanism to run according to the motion instruction, and sends the detection instruction to the array ultrasound probe when the target position is reached; The array ultrasonic probe detects the composite material repair layer according to the detection instruction, and sends the detection result to the PC host computer through the ultrasonic board card.

9. The array ultrasonic detection method according to claim 8, characterized in that: The position encoder comprises a first position encoder and a second position encoder, the first position encoder and the second position encoder are electrically connected to the encoder interface on the ultrasonic board, the first position encoder is mounted on the stepping shaft, and the second position encoder is mounted on the scanning shaft; characterized in that the PC host computer obtains the position data of the scanning mechanism through the ultrasonic board and the position encoder, including: The first position encoder converts the first AB phase encoder signal of the stepping shaft into the first position data and sends it to the ultrasonic board; The second position encoder converts the second AB phase encoder signal of the scanning axis into second posture data and sends it to the ultrasonic board; The ultrasonic board is used to send the first posture data and the second posture data to the PC host computer through the EtherCAT protocol.

10. The array ultrasonic detection method according to claim 8, characterized in that: The array ultrasonic detection system also includes a transducer, the array ultrasonic probe is electrically connected to the input of the transducer, and the output of the transducer is electrically connected to the transducer interface on the ultrasonic board; characterized in that the array ultrasonic probe detects the composite material repair layer according to the detection instruction, and sends the detection result to the PC host computer through the ultrasonic board, including: The array ultrasonic probe detects the composite material repair layer according to the detection instruction, obtains an analog signal of the composite material repair layer, and sends the analog signal to the transducer; The transducer converts the received ultrasonic signal from an analog signal into a digital signal to obtain detection data, and sends the detection data to the PC host computer.

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