Magnetic flux leakage digital intelligent detection and early warning device for metal defect damage

Abstract

The invention belongs to the technical field of magnetic flux leakage nondestructive testing, and particularly relates to a digital intelligent magnetic flux leakage detection and early warning device for metal defect damage. In order to realize digital defect damage detection of magnetic flux leakage of a metal material, metal defect damage evaluation and positioning program design are carried out based on a magnetic flux leakage detection principle, and a master control system is combined to intelligently control electronic chips such as a magnet exciting coil, a defect detection probe, an environment identification probe, a detection path system and an obstacle avoidance system; the metal defect damage digital intelligent detection system based on the magnetic flux leakage method is designed, so that the system structure is optimized, the number of hardware is reduced, the detection efficiency is improved, and full-automatic intelligent detection can be carried out on metal equipment according to different detection environments.

Description

Technical Field

[0001] The invention belongs to the technical field of magnetic flux leakage nondestructive detection, and in particular relates to a digital intelligent magnetic flux leakage detection and early warning device for metal defect damage. Background Art

[0002] Metal materials, with their unique physical, chemical and mechanical properties, play an indispensable role in industrial production, aerospace, energy, transportation and daily life. Metal materials will form defects and damage due to environmental factors (such as corrosion, high temperature) or long-term fatigue under load. The existence of defects will seriously affect the safe use of metal materials. When the ultimate bearing capacity of the metal defect damage is lower than the normal pressure, the leakage of the medium will cause serious safety accidents and immeasurable economic losses. Therefore, the industry attaches great importance to the accurate and efficient detection of metal material defect damage. As an advanced non-destructive testing method, magnetic flux leakage detection technology can use the strong magnetization of the metal material by the excitation source without destroying the metal material to make the metal material reach the magnetic saturation state. For the defect-free part of the metal material, most of the magnetic induction lines pass parallel inside the metal material. When encountering defects, some magnetic induction lines are deformed and enter the surface of the metal material to form a magnetic leakage signal. The magnetic sensor collects the leakage magnetic field signal at the defect of the metal material, and the collected signal is processed and analyzed to achieve the purpose of defect detection of the metal material. This technology not only supports non-contact measurement, but is also suitable for dynamic online monitoring, which greatly broadens the application scenarios of detection. However, traditional magnetic flux leakage detection equipment is large in size and heavy in weight, which makes it difficult to carry and move. Especially in situations where frequent movement or operation in a small space is required, the bulkiness of the equipment becomes a major obstacle. Due to the use of analog signal analysis, traditional magnetic flux leakage detection equipment uses a large amount of hardware and has relatively high manufacturing and maintenance costs, which poses a great economic pressure for some users with limited budgets or who need to deploy detection equipment on a large scale. Traditional magnetic flux leakage detection equipment mainly relies on manual operation or requires external power to push scanning, which not only increases the complexity of operation, but may also cause instability or errors in the detection results due to human factors. Summary of the invention

[0003] In view of the above problems, the present invention designs a digital intelligent detection system for metal defect damage based on the magnetic leakage method in order to realize digital defect damage detection of metal materials by magnetic leakage detection. Based on the magnetic leakage detection principle, a metal defect damage assessment and positioning program is designed, and the main control system is combined with the intelligent control of electronic chips such as the excitation coil, defect detection probe, environmental identification probe, detection path system, and obstacle avoidance system. The system is designed to optimize the system structure, reduce the amount of hardware, improve the detection efficiency, and can perform fully automatic intelligent detection of metal equipment according to different detection environments.

[0004] To achieve the above-mentioned purpose, the present invention adopts the following technical scheme, which includes a main control system microprocessor control system, a traveling wheel, a system mounting plate, a bracket, an environmental identification probe, an excitation coil, a defect detection probe, and an electric drive system. The main control system microprocessor control system and the electric drive system are installed on the upper part of the system mounting plate, and the traveling wheels are installed on both sides of the system mounting plate. The excitation coil and the defect detection probe are installed on the side of the system mounting plate through the bracket, and the probes of the two environmental identification probes are installed to the front position of the trolley through the bracket. The bracket can be moved to provide different detection positions and lift-off values ​​for the sensor probe. The main control system microprocessor control system first uses the leakage magnetic digital intelligent detection system main program to control the environmental identification probe to collect external infrared signals, and uses the detection path system subroutine and the obstacle avoidance system subroutine to control the electric drive system and the traveling wheel to complete the fully automatic intelligent mobile scanning function. The main control system microprocessor control system further uses the leakage magnetic digital intelligent detection system main program to control the defect detection data acquisition subroutine, control the defect detection probe to collect leakage magnetic signals, and perform stress damage detection and digital early warning analysis.

[0005] The main control system microprocessor control system includes a main control system, an environment identification probe, a defect detection probe, a detection path system, an obstacle avoidance system, a wireless remote control system, a signal processing system, a data conversion system, a reset / pause system, an electric drive system, an early warning system, an external storage system, and a data monitoring system. The key points of the structure are that the detection signal output port of the defect detection probe is connected to the detection signal input port of the data conversion system through the signal processing system, and the detection signal output port of the data conversion system is connected to the detection signal input port of the main control system; the signal output port of the environment identification probe is respectively connected to the input ports of the detection path system and the obstacle avoidance system, and the output ports of the detection path system and the obstacle avoidance system are connected to the input port of the main control system through the data conversion system; the output ports of the wireless remote control system and the reset / pause system are directly connected to the input port of the main control system; the output port of the main control system is respectively connected to the input ports of the electric drive system, the early warning system, the external storage system, and the data monitoring system;

[0006] The main program of the digital intelligent magnetic flux leakage detection system first initializes the trolley. If the trolley is not manually controlled, the detection path system subroutine is entered, and the automatic scanning detection function of the system is completed using the detection path system. The obstacle avoidance system subroutine is called to perform obstacle detection operations, and the preset obstacle avoidance function is completed under the control of the obstacle avoidance system. Under the control of the single-chip microcomputer, the defect detection probe is turned on and the defect detection data acquisition subroutine is run to collect the tangential and normal magnetic flux leakage signals of the metal surface, and the collected signals are filtered and converted to analog / digital through the signal processing system and the data conversion system, and the collected digital magnetic flux leakage detection signals are stored in the tangential and normal data storage areas TANdate and NORdate to wait for calling. After collecting the detection number, the tangential data is processed first, the extreme value unit and extreme value position unit maxdate and maxadd of the detection signal are defined, and the extreme value comparison unit LINEADR and the extreme value position comparison unit LINE are defined as temporary storage units for judgment data. The data pointer p1 is defined and points to the tangential data storage area TANdate. In the for loop statement, the size relationship between the pointer pointing value and the current extreme value unit value LINEADR is judged. If the pointer pointing value is greater than the current extreme value, the extreme value and the pointer position are updated. At the end of the loop, the maximum value of the tangential signal and the number of cycles when the maximum value is taken are obtained as addresses and stored in the extreme value position comparison unit LINE. Then the normal data is processed, the initial value of the normal data zero value unit Zeroadd is defined as 0, the pointer P2 is defined and points to the normal data storage area NORdate, and data screening is performed in the for loop. It is judged whether the pointer pointing value is 0 within the maximum number of cycles 100. If it is 0, the current number of cycles i is stored as the zero value address in the zero value address unit Zeroadd. If it is not 0, the pointer pointing value is updated and the loop continues. If there is a zero value point in the normal direction and it coincides with the tangential extreme value point, that is, Zeroadd=maxadd, it means that there is a defect. If the tangential extreme value maxdate is greater than the critical value value, it means that there is a defect that exceeds the detection critical value, then the early warning system is activated, thereby realizing the digital early warning and real-time display function of metal defect damage.

[0007] The detection path system subroutine is based on the infrared signals collected by the environmental recognition probes around the car, including the left module signal Leftled and the right module signal Rightled. When the car runs the trajectory tracking program, it detects the left and right module signals in a loop, and uses the environmental recognition probe, the detection path system, the electric drive system and the traveling wheel to perform the intelligent trajectory tracking function. The system converts the detection signal of the environmental recognition probe into a digital signal through the data conversion system and stores it in the detection path system. After analyzing and processing the detection signal, it transmits the analysis data to the main control system, and then assigns values ​​to its variables Leftled and Rightled. If the environmental recognition probe detects that the modules on both sides have not deviated from the preset scanning route, the variables Lefted and Rightled are both assigned to 0. If one side deviates from the preset scanning route, the corresponding detection module signal variable is assigned to 1, and the main control system controls the electric drive system and the traveling wheel to return the system to the original scanning route. Therefore, the environmental identification probe, detection path system, and data conversion system are used to collect and process external infrared detection signals, and the trajectory tracking is digitally calculated and analyzed, so that the main control system can be used to control the electric drive system and the traveling wheels to realize the automatic identification and scanning function of the detection path.

[0008] The obstacle avoidance system subroutine first defines Leftled as the left obstacle detection unit subroutine module signal, Rightled as the right obstacle detection unit subroutine module signal, Froled as the front obstacle detection unit subroutine module signal, and Dowled as the rear obstacle detection unit subroutine module signal. The car performs calculation and analysis of the system obstacle detection unit subroutine function through the logical output of the surrounding obstacle detection unit subroutine module signals. When the environmental recognition probe detects an obstacle, it assigns the obstacle detection unit subroutine module signal in the main control system to 1 through data processing of the obstacle avoidance system and the data conversion system. Different avoidance modes are adopted under different module unit signals, and then the main control system controls the electric drive system and the traveling wheel to complete the intelligent obstacle avoidance function of the detection system, and continues to enter the trajectory tracking mode after avoiding the obstacle detection unit subroutine. Therefore, through the collection and processing of external infrared detection signals by the environmental recognition probe, the obstacle avoidance system, and the data conversion system, as well as the digital calculation and analysis of the obstacle detection unit subroutine, the main control system is used to control the electric drive system and the traveling wheel to realize the intelligent obstacle detection and avoidance function of the system.

[0009] The defect detection data acquisition subroutine first defines the relevant parameters of the leakage magnetic signal storage area, defines the leakage magnetic signal tangential storage area TANdate, the leakage magnetic signal normal storage area NORdate, and defines data pointers P1 and P2 to point to the tangential and normal data storage areas respectively for assigning values ​​to the storage areas. The tangential data is collected cyclically within a maximum number of cycles of 100, R2 and R3 are the number of cycles respectively, IN0 is started and various signal acquisition and processing functions of the defect detection probe, signal processing system, and data conversion system are turned on, and the collected and processed values ​​are placed in the area pointed to by p1 after a delay, that is, the tangential data storage area of ​​the leakage magnetic signal. After completing the collection of the tangential data, the IN1 channel is opened, and the collected and processed values ​​are placed in the area pointed to by p2 after a delay, that is, the normal data storage area of ​​the leakage magnetic signal. After R3 reaches the maximum number of cycles of 100, the tangential and normal leakage magnetic signals are collected, filtered, and analog / digital converted, and then stored in the tangential data storage area TANdate and the normal data storage area NORdate respectively for calling.

[0010] As another preferred embodiment, the defect detection probe of the present invention uses a 49E Hall sensor to collect the strategy signal of the metal material surface under the strong magnetic excitation of the collection coil, and detects the metal defect damage area by comparing the zero value point and peak point of the tangential and normal leakage magnetic signals of the collected strategy signal.

[0011] As another preferred solution, the electric drive system of the present invention uses the L298N chip as the core chip for motor driving, controls the corresponding actions of the motor through signal changes, and uses the motor as a power source to realize energy conversion and transmission to drive the system to operate. The connection protection circuit of the diode realizes rectification and freewheeling to protect the motor from damage.

[0012] As another preferred solution, the detection path system of the present invention uses an environment identification probe and adopts a TCRT5000L reflective photoelectric sensor as an environment identification probe to detect whether there are obstacles ahead. The sensitivity is adjusted by a variable resistor R4, and signal amplification and voltage comparison are achieved through a signal comparator LM393, thereby finally realizing the identification of the detection path.

[0013] As another preferred solution, the obstacle avoidance system of the present invention uses an environmental identification probe, which is a TCRT5000L reflective photoelectric sensor, to detect infrared signals, and then amplifies the signal through a comparator LM358, a potentiometer, and resistors and capacitors, thereby effectively improving the stability during use and preventing operation delays. The obstacle avoidance function of the detection path is ultimately achieved through the combination of various parts.

[0014] As another preferred solution, the wireless remote control system of the present invention uses an astable multivibrator composed of VT8050 and R1, R2, R3, and C1 to transmit infrared signals, and an infrared decoding receiver composed of amplifier LM386, C4, C5, and C6 receives and amplifies the transmitted infrared signals, and then realizes the wireless remote control function of the system through the main control system for the electric drive system.

[0015] As another preferred solution, the signal processing system of the present invention uses the LM324 quad op amp as a core component. The LM324 includes two high-gain, independent, internally frequency-compensated dual op amps. The filtering function is realized by combining the LM324, capacitors and resistors into a bandpass filter, thereby enhancing the anti-interference ability and accuracy of the signal.

[0016] As another preferred solution, the data conversion system of the present invention uses the analog-to-digital converter TCL5510 and the operational amplifier LM7171BIM together and realizes the conversion of signals from analog to digital by connecting to the main control system, and uses a combination of capacitors and diodes to form a data conversion system to realize the digital conversion of data.

[0017] As another preferred solution, the reset / pause system of the present invention uses a 1×5 button column to form a button control, and the column button is directly connected to the IO port of the main control system to realize the button control function.

[0018] As another preferred scheme, the early warning system of the present invention uses a LED and a resistor in series to connect with the pin of the main control system to realize the display and reminder of the equipment status, uses an NPN transistor to be connected to the negative pole of the buzzer, and then connects to the pin of the main control system to realize the sound and light early warning function of the system through different signals.

[0019] As another preferred solution, the external storage system of the present invention uses latch chip 74LS373 and external storage chip 2764 to connect to the main control system via a bus to realize data latching and storage, and uses an excitation coil to directly connect to the main control system to realize circuit excitation and external memory expansion function.

[0020] As another preferred solution, the data monitoring system described in the present invention uses an LCD1602 liquid crystal display as an interactive interface to establish communication through a port and a connection with the pin of a main control system, and is used to display various information of the device. The data to be displayed is transmitted to the internal register of the main control system through a data bus, thereby realizing the display of transmitted and stored data.

[0021] Beneficial effects of the present invention:

[0022] 1. The present invention combines digital computing and analysis technology, innovates the traditional magnetic flux leakage detection method, and accurately identifies and locates the metal defect damage area through deep digital processing of tangential and normal signal characteristics, significantly improving the early warning accuracy. At the same time, it simplifies the circuit structure, reduces the system cost, and demonstrates extremely high economic benefits and monitoring accuracy.

[0023] 2. In order to enhance the intelligence and automation level of the system, the present invention utilizes the main control system technology to realize the intelligent control of key components such as the detection path system, the detection path system, and the wireless remote control system, so that the detection system can autonomously cope with complex and changeable detection environments, significantly improving the system's adaptability to changing environments and detection efficiency.

[0024] 3. In order to further enhance the signal stability and early warning response speed of the system, the present invention is equipped with an independent signal processing system and an external storage system. This not only effectively improves the anti-interference ability of the system and ensures the accuracy of the detection data, but also greatly shortens the early warning response time, providing a strong guarantee for the rapid response to emergency situations. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention is further described below in conjunction with the accompanying drawings and specific implementation methods. The protection scope of the present invention is not limited to the following description.

[0026] Figure 1 System appearance structure diagram;

[0027] Figure 2 Main control system microprocessor control system structure diagram;

[0028] Figure 3 Main program flow chart of magnetic flux leakage digital intelligent detection system;

[0029] Figure 4 Detection path system subroutine flow chart;

[0030] Figure 5 Obstacle avoidance system subroutine flow chart;

[0031] Figure 6 Defect detection data collection subroutine flow chart;

[0032] Figure 7 Defect detection probe component diagram

[0033] Figure 8 Electric drive system circuit diagram

[0034] Fig. 9 Detection path system circuit diagram

[0035] Fig.10 Obstacle avoidance system circuit diagram;

[0036] Fig.11 Wireless remote control system circuit diagram

[0037] Fig.12 Circuit diagram of signal processing system;

[0038] Fig.13 Data conversion system circuit diagram

[0039] Fig.14 Reset / Suspend System Circuit Diagram

[0040] Fig.15 Early warning system circuit diagram

[0041] Fig.16 External storage system circuit diagram

[0042] Fig.17 Data monitoring system circuit diagram DETAILED DESCRIPTION

[0043] like Figure 1 As shown, the design system of the present invention includes a main control system microprocessor control system 1, a traveling wheel 2, a system mounting plate 3, a bracket 4, an environmental identification probe 5, an excitation coil 6, a defect detection probe 7, and an electric drive system 8. The main control system microprocessor control system 1 and the electric drive system 8 are installed on the upper part of the system mounting plate 3, and the traveling wheel 2 is installed on both sides of the system mounting plate 3. The excitation coil 6 and the defect detection probe 7 are installed on the side of the system mounting plate 3 through the bracket 4, and the probes of the two environmental identification probes 5 are installed to the front position of the trolley through the bracket 4. The bracket 4 can be moved to provide different detection positions and lift-off values ​​for the sensor probe. The main control system microprocessor control system 1 first uses the main program of the leakage magnetic digital intelligent detection system to control the environmental identification probe 5 to collect external infrared signals, and uses the detection path system subroutine and the obstacle avoidance system subroutine to control the electric drive system 8 and the traveling wheel 2 to complete the fully automatic intelligent mobile scanning function. The main control system microprocessor control system 1 further utilizes the main program of the leakage magnetic digital intelligent detection system to control the defect detection data acquisition subroutine, control the defect detection probe 7 to collect leakage magnetic signals, and perform stress damage detection and digital early warning analysis.

[0044] like Figure 2As shown, the main control system microprocessor control system 1 includes a main control system 9, an environment identification probe 5, a defect detection probe 7, a detection path system 10, an obstacle avoidance system 11, a wireless remote control system 12, a signal processing system 13, a data conversion system 14, a reset / pause system 15, an electric drive system 8, an early warning system 16, an external storage system 17, and a data monitoring system 18. The key points of its structure are that the detection signal output port of the defect detection probe 7 is connected to the detection signal input port of the data conversion system 14 through the signal processing system 13, and the detection signal output port of the data conversion system 14 is connected to the detection signal input port of the main control system 9; the signal output port of the environment recognition probe 5 is respectively connected to the input ports of the detection path system 10 and the obstacle avoidance system 11, and the output ports of the detection path system 10 and the obstacle avoidance system 11 are connected to the input port of the main control system 9 through the data conversion system 14; the output ports of the wireless remote control system 12 and the reset / pause system 15 are directly connected to the input port of the main control system 9; the output port of the main control system 9 is respectively connected to the input ports of the power transmission system 8, the early warning system 16, the external storage system 17, and the data monitoring system 18;

[0045] like Figure 3As shown, the main program of the digital intelligent magnetic flux leakage detection system first initializes the trolley. If the trolley is not manually controlled, the detection path system subroutine is entered, and the automatic scanning detection function of the system is completed using the detection path system 10. The obstacle avoidance system subroutine is called to perform obstacle detection operations, and the preset obstacle avoidance function is completed under the control of the obstacle avoidance system 11. Under the control of the single-chip microcomputer, the defect detection probe 7 is turned on and the defect detection data acquisition subroutine is run to collect the tangential and normal magnetic flux leakage signals of the metal surface, and the collected signals are filtered and converted to analog / digital through the signal processing system 13 and the data conversion system 14, and then the collected digital magnetic flux leakage detection signals are stored in the tangential and normal data storage areas TANdate and NORdate to wait for calling. After collecting the detection number, the tangential data is processed first, the extreme value unit and extreme value position unit maxdate and maxadd of the detection signal are defined, and the extreme value comparison unit LINEADR and the extreme value position comparison unit LINE are defined as temporary storage units for judgment data. The data pointer p1 is defined and points to the tangential data storage area TANdate. In the for loop statement, the size relationship between the pointer pointing value and the current extreme value unit value LINEADR is judged. If the pointer pointing value is greater than the current extreme value, the extreme value and the pointer position are updated. At the end of the loop, the maximum value of the tangential signal and the number of cycles when the maximum value is taken are obtained as addresses and stored in the extreme value position comparison unit LINE. Then the normal data is processed, the initial value of the normal data zero value unit Zeroadd is defined as 0, the pointer P2 is defined and points to the normal data storage area NORdate, and data screening is performed in the for loop. It is judged whether the pointer pointing value is 0 within the maximum number of cycles 100. If it is 0, the current number of cycles i is stored as the zero value address in the zero value address unit Zeroadd. If it is not 0, the pointer pointing value is updated and the loop continues. If there is a zero value point in the normal direction and it coincides with the tangential extreme value point, that is, Zeroadd=maxadd, it means that there is a defect. If the tangential extreme value maxdate is greater than the critical value value, it means that there is a defect that exceeds the detection critical value, then the early warning system 16 is activated, thereby realizing the digital early warning and real-time display function of metal defect damage.

[0046] like Figure 4As shown, the detection path system subroutine makes judgments based on the infrared signals collected by the environmental recognition probes 5 around the car, including the left module signal Leftled and the right module signal Rightled. When the car runs the trajectory tracking program, it detects the left and right module signals in a loop, and uses the environmental recognition probe 5, the detection path system 10, the electric drive system 8 and the traveling wheel 2 to perform the intelligent trajectory tracking function. The system converts the detection signal of the environmental recognition probe 5 into a digital signal through the data conversion system 14 and stores it in the detection path system 10. After analyzing and processing the detection signal, it transmits the analysis data to the main control system 9, and then assigns values ​​to its variables Leftled and Rightled. If the environmental recognition probe 5 detects that the modules on both sides of the left and right sides have not deviated from the preset scanning route, the variables Lefted and Rightled are both assigned to 0. If one side deviates from the preset scanning route, the corresponding detection module signal variable is assigned to 1, and the main control system 9 controls the electric drive system 8 and the traveling wheel 2 to return the system to the original scanning route. Therefore, through the collection and processing of external infrared detection signals by the environment identification probe 5, the detection path system 10, and the data conversion system 14, and the digital calculation and analysis of trajectory tracking, the main control system 9 is used to control the electric transmission system 8 and the traveling wheel 2 to realize the automatic identification and scanning function of the detection path.

[0047] like Figure 5 As shown, the obstacle avoidance system subroutine first defines Leftled as the left obstacle detection unit subroutine module signal, Rightled as the right obstacle detection unit subroutine module signal, Froled as the front obstacle detection unit subroutine module signal, and Dowled as the rear obstacle detection unit subroutine module signal. The car performs system obstacle detection unit subroutine function calculation and analysis through the logical output of the surrounding obstacle detection unit subroutine module signals. When the environment recognition probe 5 detects an obstacle, it assigns the obstacle detection unit subroutine module signal in the main control system 9 to 1 through data processing of the obstacle avoidance system 11 and the data conversion system 14. Different avoidance modes are adopted under different module unit signals. Then the main control system 9 controls the electric drive system 8 and the traveling wheel 2 to complete the obstacle intelligent avoidance function of the detection system. After avoiding the obstacle detection unit subroutine, it continues to enter the track tracking mode. Therefore, through the collection and processing of external infrared detection signals by the environment recognition probe 5, the obstacle avoidance system 11, and the data conversion system 14, and the digital calculation and analysis of the obstacle detection unit subroutine, the main control system 9 is used to control the electric drive system 8 and the traveling wheel 2 to realize the system's intelligent obstacle detection and avoidance function.

[0048] like Figure 6As shown, the defect detection data acquisition subroutine first defines the relevant parameters of the leakage magnetic signal storage area, defines the leakage magnetic signal tangential storage area TANdate, the leakage magnetic signal normal storage area NORdate, and defines data pointers P1 and P2 to point to the tangential and normal data storage areas respectively, and the tangential data is collected cyclically within the maximum number of cycles 100, R2 and R3 are the number of cycles respectively, IN0 is started and the various signal acquisition and processing functions of the defect detection probe 7, the signal processing system 13, and the data conversion system 14 are turned on, and the acquisition and processing are delayed after waiting. The values ​​after the acquisition are respectively placed in the p1 pointing area, that is, the tangential data storage area of ​​the leakage magnetic signal. After completing the acquisition of the tangential data, the IN1 channel is opened, and after a delay, the acquired and processed values ​​are respectively placed in the p2 pointing area, that is, the normal data storage area of ​​the leakage magnetic signal. After R3 reaches the maximum number of cycles of 100, the defect detection probe 7, the signal processing system 13, and the data conversion system 14 are used to collect, filter, and perform analog / digital conversion on the tangential and normal leakage magnetic signals, and then store them in the tangential data storage area TANdate and the normal data storage area NORdate, waiting for being called.

[0049] like Figure 7 As shown, the defect detection probe 7 uses a 49E Hall sensor to collect the strategy signal of the metal material surface under the strong magnetic field of the collection coil, and uses the collected strategy signal to compare the zero point and peak point of the tangential and normal leakage magnetic signals to detect the metal defect damage area. Its specific connection is: Pin B of the defect detection probe 7 is grounded, Pin A of the defect detection probe is connected to the power supply, and Pin C of the defect detection probe is connected to the input port Vin1 / Vin2 in the signal processing system 13 as an output port. As a defect detection probe, the 49E Hall sensor can detect weak magnetic fields, consume less power, and collect leakage magnetic signals.

[0050] like Figure 8As shown, the electric drive system 8 uses the L298N chip as the core chip for driving the motor, controls the corresponding action of the motor through signal changes, and the motor, as a power source, realizes the conversion and transmission of energy, drives the system to operate, and realizes the functions of rectification and freewheeling through the connection protection circuit of the diode to protect the motor from damage. The specific connection is: the four input ports of the electric drive system 8, namely IN1, IN2, IN3, and IN4, are respectively connected to the designated pins of the main control system 9, which are P3.4, P2.0, P2.1, and P3.6. The core of this invention, the electric drive system 8, has a built-in L298N chip, which undertakes the key task of driving the motor. The system realizes accurate judgment of the input signal through the close cooperation of the main control system 9 and other necessary modules, and assigns specific values ​​to the corresponding ports accordingly. This process ensures that the rotation state of the motor can be flexibly and accurately controlled through the transformation of the signal state. The electric drive system 8 is also provided with control enable ports ENA and ENB, which are respectively connected to the P3.5 and P3.7 pins of the main control system 9, realizing direct control of the start and stop of the motor. The system is equipped with two current feedback pins, ISEN A and ISEN B, which are used to monitor the current state of the motor in real time when it is working, providing important data support for further optimizing the control strategy or implementing the protection mechanism.

[0051] like Fig. 9 As shown, the detection path system 10 uses the environment recognition probe 5 and adopts the TCRT5000L reflective photoelectric sensor as the environment recognition probe to detect whether there is an obstacle in front. The sensitivity adjustment is achieved through the variable resistor R4, and the signal amplification and voltage comparison are achieved through the signal comparator LM393, and finally the detection path is recognized. Its specific connection is: the output terminal Vout of the detection path system 10 is connected to the input port D3 of the data conversion system 14, and after analog-to-digital conversion, it is connected to the P0.3 port of the main control system 9. The main control system 9 controls the motor to work accordingly according to the change of the signal, thereby realizing the tracking function. The TCRT5000L reflective photoelectric sensor as the environment recognition probe 5 is one of the commonly used models in tracking and obstacle avoidance applications. It adopts the reflective measurement principle and determines the existence and position of the object by measuring the intensity of the infrared reflection. It is widely used in the tracking and obstacle avoidance system of robots, smart cars and other equipment, with high sensitivity and reliable performance.

[0052] like Fig.10As shown, the obstacle avoidance system 11 uses the environment recognition probe 5 as a TCRT5000L reflective photoelectric sensor to detect infrared signals, and then amplifies the signal through the comparator LM358, potentiometer and resistor capacitor, effectively improving the stability during use, and there will be no operation delay. The avoidance function of obstacles in the detection path is finally realized through the combination of various parts. The specific connection is: the output port Vout of the obstacle avoidance system 11 is connected to the input port D4 of the data conversion system 14. The signal detected by the environment recognition probe TCRT5000L passes through the 3 pins of the comparator LM358 through two transistors, and then outputs to the infrared transmitter. The adjustable resistor R3 is used to change its transmission power. The light-emitting diode has a voltage difference, and the signal indicator light is on, indicating that there is an obstacle ahead. After the signal is converted into digital form, the digital signal is transmitted to the P0.2 port of the main control system 9, and the main control system 9 controls the electric drive system 8 to realize the obstacle avoidance function.

[0053] like Fig.11 As shown, the wireless remote control system 12 uses an astable multivibrator composed of VT8050 and R1, R2, R3, and C1 to transmit infrared signals, and an infrared decoding receiver composed of amplifier LM386, C4, C5, and C6 receives and amplifies the transmitted infrared signals, and then realizes the wireless remote control function of the system for the power transmission system 8 through the main control system 9. The specific connection is: the output port Vout of the wireless remote control system 12 is connected to the P2.2 port of the main control system 9. It includes an astable multivibrator composed of VT8050 and R1, R2, R3, and C1, which is used to realize the remote control function. After power is turned on, a series of infrared light pulse waves are emitted. The current limiting resistor R3 is used to protect the infrared light-emitting tube, and the infrared transmitting tube D1 is used to transmit infrared signals. The resistance between the two electrodes of the infrared receiving tube D2 changes corresponding to the frequency, and the optical signal is converted into an electrical signal and amplified by VT8050 and LM385. C5 and C6 are used to determine the center frequency of LM386, which are connected to pins 7 and 8 of LM386. The main control system 9 controls the power transmission system 8 through the output signal to realize the infrared remote control function.

[0054] like Fig.12As shown, the signal processing system 13 uses the LM324 type quad op amp as the core component. The LM324 includes two high-gain, independent, internal frequency-compensated dual op amps. The filtering function is realized by combining the LM324, capacitors and resistors into a bandpass filter, which can enhance the anti-interference ability and accuracy of the signal. The specific connection is: the input port Vin of the signal processing system 13 is connected to the output port pin C of the defect detection probe 7, and the output port Vout of the signal processing system 13 is connected to the input port D of the data conversion system 14. The bandpass filter uses the LM324 type quad op amp for filtering to increase the anti-interference ability of the system detection signal. The defect detection probe 7 detects the tangential and normal signals respectively. The output port Vout1 of the tangential signal after filtering is connected to the analog signal input terminal D1 of the data conversion system 14, and the output port Vout2 of the normal signal after filtering is connected to the input terminal D2 of the data conversion system 14 for analog-to-digital conversion.

[0055] like Fig.13 As shown, the data conversion system 14 uses the analog-to-digital converter TCL5510 and the operational amplifier LM7171BIM together and realizes the conversion of the signal from analog to digital by connecting to the main control system 9, and uses a capacitor and a diode combination to form a data conversion system to realize the digital conversion of data. Its specific connection is: the input ports D1-D4 of the data conversion system 14 are respectively connected to the output ports Vout1 and Vout2 of the signal processing system 13 and the output port Vout of the obstacle avoidance system 11 and the output port Vout of the detection path system 10, and the output port of the data conversion system 14 is connected to the IO port P1.0 of the main control system 9. It includes an analog-to-digital converter TCL5510 for digitizing analog signals. The operational amplifier LM7171BIM is used for signal amplification, and its input is connected to the data output port of the TCL5510 chip.

[0056] like Fig.14 As shown, the reset / pause system 15 uses a 1×5 key combination column key control, and uses the column key to directly connect to the IO port of the main control system 9, thereby realizing the key control function. The specific connection is: the column key row of the reset / pause system 15 is respectively connected to the P1.2, P1.3, P1.4, P1.5, and P1.6 ports of the main control system 9. The reset / pause system 15 of the present invention is composed of a 1×5 matrix key keyboard, and the functions of K1-K5 are: system start key, system stop key, forward key (remote control mode), left turn key (remote control mode), and right turn key (remote control mode).

[0057] like Fig.15As shown, the early warning system 16 uses a series connection of an LED and a resistor to connect to the pin of the main control system 9 to realize the display and reminder of the device status, uses an NPN transistor to connect to the negative pole of the buzzer, and then connects to the pin of the main control system 9 to realize the sound and light early warning function of the system through different signals. The specific connection is: the early warning system 16 is connected to the P1.7 port of the main control system 9, and the main control system controls the switch of the transistor through different signals, thereby realizing the precise control of the LED light. The negative end of the buzzer is connected to an NPN transistor for control to realize the amplification and switching of the audio signal. The resistor R1, R2 and the transistor combination are used to control the signal input.

[0058] like Fig.16 As shown, the external storage system 17 uses the latch chip 74LS373 and the external storage chip 2764 to connect with the main control system 9 through the bus mode to realize the latching and storage of data, and uses the excitation coil 6 to realize the circuit excitation and external memory expansion function by directly connecting with the main control system 9. The specific connection is: the input port D0-D7 of the latch chip 74LS373 is connected to the P0 port of the main control system 9, so as to realize the writing and reading operations of data, and the chip 2764 is used to specify the specific location of data storage, and its D0-D7 data input port is connected to the P0 port of the main control system 9, and its A0-A7 address end is connected to the output end Q0-Q7 of the latch 74LS373 to realize data exchange, and its A8-A12 address end is respectively connected to P2.0, P2.1, P2.2, and P2.3 of the main control system 9 to realize the data storage of the main control system 9, and the excitation coil 6 is connected to P2.5 and P2.7 of the main control system 9. The external storage system 17 combines the latch chip 74LS373 and the external storage chip 2764 to achieve efficient and stable data storage and access.

[0059] like Fig.17As shown, the data monitoring system 18 uses LCD1602 liquid crystal display as an interactive interface to establish communication through the connection of the port with the pin of the main control system 9, which is used to display various information of the device. The data to be displayed is transmitted to the internal register of the main control system 9 through the data bus to realize the display of the transmitted and stored data. Its specific connection is: its RS (register selection) port is directly connected to the P1.0 pin of the main control system 9, which is used to indicate whether the current operation is for the instruction register or the data register; the R / W (read / write) port is connected to the P1.1 pin of the main control system 9, which is responsible for controlling the direction of data transmission, that is, whether to write data to LCD1602 or read data from it; and the E (enable) port is connected to the P2.6 pin of the main control system 9, which is used to trigger the reading or writing operation of data or instructions. The DB0 to DB7 (data bus) ports of LCD1602 are connected to the P0.0-P0.7 ports of the main control system one by one, forming the main communication channel between the two. Through this connection method and control process, stable and efficient data exchange and display functions are achieved between LCD1602 and the main control system.

[0060] The overall working process of the system is as follows: the main control system 9 calls the detection path system subroutine to collect and process the external infrared detection signals through the environmental identification probe 5, the detection path system 10, and the data conversion system 14, and performs digital calculation and analysis of trajectory tracking, so as to use the main control system 9 to control the electric drive system 8 and the traveling wheel 2 to realize the automatic recognition and scanning function of the detection path. The main control system 9 calls the obstacle avoidance system subroutine to collect and process the external infrared detection signals through the environmental identification probe 5, the obstacle avoidance system 11, and the data conversion system 14, and performs digital calculation and analysis of the obstacle detection unit subroutine, so as to use the main control system 9 to control the electric drive system 8 and the traveling wheel 2 to realize the system's intelligent obstacle detection and avoidance function. The system supports controlling the scanning direction through the wireless remote control system 12 to complete the system's intelligent mobile scanning link. The main control system 9 calls the defect detection data acquisition subroutine to use the defect detection probe 7, signal processing system 13, and data conversion system 14 to collect, filter, and convert the tangential and normal leakage magnetic signals into analog / digital signals. The main control system 9 then accurately calculates and analyzes the data. The data monitoring system 18 displays the detection data in real time, and issues an early warning through the early warning system 16, thereby achieving timely early warning of metal material defect damage and completing the system's digital metal material defect damage assessment and early warning link.

[0061] It can be understood that the above specific description of the present invention is only used to illustrate the present invention and is not limited to the technical solutions described in the embodiments of the present invention. Those skilled in the art should understand that the present invention can still be modified or replaced by equivalents to achieve the same technical effects; as long as the use requirements are met, they are within the protection scope of the present invention.

Claims

1. A digital intelligent magnetic leakage detection and early warning device for metal defect damage. The design system of the present invention includes a main control system microprocessor control system, a traveling wheel, a system mounting plate, a bracket, an environmental identification probe, an excitation coil, a defect detection probe, and an electric drive system; the main control system microprocessor control system and the electric drive system are installed on the upper part of the system mounting plate, and the traveling wheels are installed on both sides of the system mounting plate; the excitation coil and the defect detection probe are installed on the side of the system mounting plate through a bracket, and the probes of the two environmental identification probes are installed to the front position of the trolley through the bracket, and the bracket can be moved to provide different detection positions and lift-off values ​​for the sensor probe; the main control system microprocessor control system first uses the main program of the magnetic leakage digital intelligent detection system to control the environmental identification probe to collect external infrared signals, and uses the detection path system subroutine and the obstacle avoidance system subroutine to control the electric drive system and the traveling wheel to complete the fully automatic intelligent mobile scanning function; the main control system microprocessor control system further uses the main program of the magnetic leakage digital intelligent detection system to control the defect detection data acquisition subroutine, control the defect detection probe to collect magnetic leakage signals, and perform stress damage detection and digital early warning analysis; The main control system microprocessor control system includes: Main control system, environment identification probe, defect detection probe, detection path system, obstacle avoidance system, wireless remote control system, signal processing system, data conversion system, reset / pause system, electric drive system, early warning system, external storage system, data monitoring system; the key points of its structure are that the detection signal output port of the defect detection probe is connected to the detection signal input port of the data conversion system through the signal processing system, and the detection signal output port of the data conversion system is connected to the detection signal input port of the main control system; the signal output port of the environment identification probe is respectively connected to the input ports of the detection path system and the obstacle avoidance system, and the output ports of the detection path system and the obstacle avoidance system are connected to the input port of the main control system through the data conversion system; the output ports of the wireless remote control system and the reset / pause system are directly connected to the input port of the main control system; the output port of the main control system is respectively connected to the input ports of the electric drive system, the early warning system, the external storage system, and the data monitoring system; The main program of the leakage magnetic digital intelligent detection system first initializes the car. If the car is not manually controlled, it enters the detection path system subroutine and uses the detection path system to complete the system automatic scanning detection function. The obstacle avoidance system subroutine is called to perform obstacle detection operations and complete the preset obstacle avoidance function under the control of the obstacle avoidance system. Under the control of the single-chip microcomputer, the defect detection probe is turned on and the defect detection data acquisition subroutine is run to collect the tangential and normal magnetic leakage signals of the metal surface. The collected signals are filtered and converted into analog / digital through the signal processing system and the data conversion system, and then the collected digital magnetic leakage detection signals are stored in the tangential and normal data storage areas TANdate and NORdate waiting for calling. After collecting the detection number, the tangential data is processed first, and the extreme value unit and extreme value position unit maxdate and maxadd of the detection signal are defined. The extreme value comparison unit LINEADR and the extreme value position comparison unit LINE are defined as temporary storage units for judgment data. The data pointer p1 is defined and points to the tangential data storage area TANdate. In the for loop statement, the relationship between the pointer pointing value and the current extreme value unit value LINEADR is judged. If the pointer pointing value is greater than the current extreme value, the extreme value is updated and the pointer is updated. The needle position is obtained when the loop ends, and the maximum value of the tangential signal and the number of cycles when the maximum value is obtained are stored as the address in the extreme value position comparison unit LINE; then the normal data is processed, the initial value of the normal data zero value unit Zeroadd is defined as 0, the pointer P2 is defined and points to the normal data storage area NORdate, and data screening is performed in the for loop. Within the maximum number of cycles 100, it is determined whether the pointer pointing value is 0. If it is 0, the current number of cycles i is stored as the zero value address in the zero value address unit Zeroadd. If it is not 0, the pointer pointing value is updated and the loop continues; if there is a zero value point in the normal direction and it coincides with the tangential extreme value point, that is, Zeroadd=maxadd, it means that there is a defect. If the tangential extreme value maxdate is greater than the critical value value, it means that there is a defect that exceeds the detection critical value, and the early warning system is started, thereby realizing the digital early warning and real-time display function of metal defect damage; The detection path system subroutine makes judgments based on infrared signals collected by the environmental recognition probes around the car, including the left module signal Leftled and the right module signal Rightled. When the car runs the trajectory tracking program, it cyclically detects the left and right module signals, and uses the environmental recognition probe, the detection path system, the electric drive system and the traveling wheel to perform intelligent trajectory tracking functions; the system converts the detection signal of the environmental recognition probe into a digital signal through the data conversion system and stores it in the detection path system 10, which analyzes and processes the detection signal and transmits the analysis data to the main control system, and then converts its variables Leftled and Rightled into digital signals. tled is assigned a value. If the environment recognition probe detects that the modules on the left and right sides have not deviated from the preset scanning route, the variables Lefed and Righled are both assigned a value of 0. If one side deviates from the preset scanning route, the corresponding detection module signal variable is assigned a value of 1, and the main control system controls the electric drive system and the traveling wheel to return the system to the original scanning route. Thus, the environment recognition probe, the detection path system, and the data conversion system collect and process the external infrared detection signals, and the trajectory tracking digital calculation and analysis are performed, so that the main control system is used to control the electric drive system and the traveling wheel to realize the automatic recognition and scanning function of the detection path. The obstacle avoidance system subroutine first defines Leftled as the left obstacle detection unit subroutine module signal, Rightled as the right obstacle detection unit subroutine module signal, Froled as the front obstacle detection unit subroutine module signal, and Dowled as the rear obstacle detection unit subroutine module signal. The car performs calculation and analysis of the system obstacle detection unit subroutine function through the logical output of the surrounding obstacle detection unit subroutine module signals; when the environmental recognition probe detects an obstacle, it assigns the obstacle detection unit subroutine module signal in the main control system to 1 through data processing of the obstacle avoidance system and the data conversion system; different avoidance modes are adopted under different module unit signals, and then the main control system controls the electric drive system and the traveling wheel to complete the obstacle intelligent avoidance function of the detection system, and continues to enter the trajectory tracking mode after avoiding the obstacle detection unit subroutine obstacle; thus, the environmental recognition probe, the obstacle avoidance system, and the data conversion system collect and process the external infrared detection signal, and the obstacle detection unit subroutine digital calculation and analysis are performed, so that the main control system is used to control the electric drive system and the traveling wheel to realize the system intelligent obstacle detection and avoidance function; The defect detection data acquisition subroutine first defines the relevant parameters of the leakage magnetic signal storage area, defines the leakage magnetic signal tangential storage area TANdate, the leakage magnetic signal normal storage area NORdate, and defines data pointers P1 and P2 to point to the tangential and normal data storage areas respectively for assigning values ​​to the storage areas. The tangential data is collected cyclically within a maximum number of cycles of 100, R2 and R3 are the number of cycles respectively, IN0 is started and various signal acquisition and processing functions of the defect detection probe, signal processing system, and data conversion system are turned on, and the collected and processed values ​​are placed in the area pointed to by p1 after a delay, that is, the tangential data storage area of ​​the leakage magnetic signal. After completing the collection of the tangential data, the IN1 channel is opened, and the collected and processed values ​​are placed in the area pointed to by p2 after a delay, that is, the normal data storage area of ​​the leakage magnetic signal. After R3 reaches the maximum number of cycles of 100, the tangential and normal leakage magnetic signals are collected, filtered, and analog / digital converted, and then stored in the tangential data storage area TANdate and the normal data storage area NORdate respectively for calling.

2. According to claim 1, the digital intelligent magnetic leakage detection and early warning device for metal defect damage is characterized in that The defect detection probe uses a 49E Hall sensor to collect the strategy signal of the metal material surface under the strong magnetic field of the collection coil, and compares the zero value point and peak point of the tangential and normal leakage magnetic signals of the collected strategy signal to detect the metal defect damage area.

3. According to claim 1, the digital intelligent magnetic leakage detection and early warning device for metal defect damage is characterized in that The electric drive system uses the L298N chip as the core chip for motor driving, controls the corresponding actions of the motor through signal changes, and uses the motor as a power source to realize energy conversion and transmission to drive the system to operate. The connection protection circuit of the diode realizes rectification and freewheeling to protect the motor from damage.

4. According to claim 1, the digital intelligent magnetic leakage detection and early warning device for metal defect damage is characterized in that The detection path system uses an environmental identification probe and a TCRT5000L reflective photoelectric sensor as an environmental identification probe to detect whether there are obstacles ahead. The sensitivity is adjusted by a variable resistor R4, and the signal amplification and voltage comparison are achieved through a signal comparator LM393, ultimately realizing the identification of the detection path.

5. According to claim 1, the digital intelligent magnetic leakage detection and early warning device for metal defect damage is characterized in that The obstacle avoidance system uses the environment recognition probe TCRT5000L reflective photoelectric sensor to detect infrared signals, and then amplifies the signal through the comparator LM358, potentiometer and resistors and capacitors, effectively improving the stability during use, and preventing operation delays. The obstacle avoidance function of the detection path obstacles is finally achieved through the combination of various parts.

6. According to claim 1, the digital intelligent magnetic leakage detection and early warning device for metal defect damage is characterized in that The wireless remote control system uses an astable multivibrator composed of VT8050 and R1, R2, R3, and C1 to transmit infrared signals, and an infrared decoding receiver composed of amplifier LM386, C4, C5, and C6 receives and amplifies the transmitted infrared signals, and then realizes the wireless remote control function of the system for the electric drive system through the main control system.

7. The digital intelligent magnetic leakage detection and early warning device for metal defect damage according to claim 1 is characterized in that The signal processing system uses the LM324 quad op amp as a core component. The LM324 includes two high-gain, independent, internally frequency-compensated dual op amps. The filtering function is achieved by combining the LM324, capacitors, and resistors into a bandpass filter, which can enhance the signal's anti-interference ability and accuracy.

8. The digital intelligent magnetic leakage detection and early warning device for metal defect damage according to claim 1 is characterized in that The data conversion system uses the analog-to-digital converter TCL5510 and the operational amplifier LM7171BIM together and realizes the conversion of signals from analog to digital by connecting with the main control system. The data conversion system is composed of a capacitor and a diode to realize the digital conversion of data.

9. The digital intelligent magnetic leakage detection and early warning device for metal defect damage according to claim 1 is characterized in that The early warning system uses a series connection of an LED and a resistor to connect to the pin of the main control system to realize the display and reminder of the equipment status, uses an NPN transistor to connect to the negative pole of the buzzer, and then connects to the pin of the main control system to realize the sound and light early warning function of the system through different signals.

10. The digital intelligent magnetic leakage detection and early warning device for metal defect damage according to claim 1 is characterized in that The external storage system uses latch chip 74LS373 and external storage chip 2764 to connect with the main control system through bus mode to realize data latching and storage, and uses excitation coil to realize circuit excitation and external storage expansion function by directly connecting with the main control system.

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