A visual electromagnetic composite defect detection probe and method

Abstract

The application discloses a visual electromagnetic composite defect detection probe and method, which comprises a probe shell (1), a magnetic detection sensor (3) and a lens (8). The probe shell (1) comprises a connecting shell (11) and a lower shell (12). The connecting shell (11) is connected with the lower shell (12). The magnetic detection sensor (3) is connected to the lower shell (12). The lens (8) is connected to the connecting shell (11). The movement direction of the detection probe during detection is a first direction. The direction perpendicular to the surface to be detected and pointing to the surface to be detected is a second direction. The magnetic detection sensor (3) and the lens (8) are located in a detection plane determined by the first direction and the second direction. The lower shell is wedge-shaped. The lower shell has a gradually decreasing cross-sectional area along the second direction. The lower shell is arranged along the first direction.

Description

Technical Field

[0001] This invention relates to the field of nondestructive testing, specifically to a visual electromagnetic composite defect detection probe and method. Background Technology

[0002] Welding is a crucial construction method in nuclear power plant construction. The quality of welded joints significantly impacts the reliability of nuclear facility construction and installation, directly affecting the safe operation of the nuclear power plant. With the increasing number of nuclear power plants under construction, the safety of nuclear power engineering is receiving increasing attention from all parties. Currently, the main non-destructive testing technologies used in nuclear power projects under construction include radiographic testing (RT), ultrasonic testing (UT), penetrant testing (PT), eddy current testing, and magnetic particle testing. Among these, radiographic testing has a relatively large application rate, primarily due to its ease of detecting volumetric defects within welds. However, in actual engineering construction, for some important welded structures, the design often specifies internal volumetric testing (RT or ultrasonic testing) of the welds, but due to weld structure and material characteristics (e.g., certain fillet joints, saddle-shaped welded joints in branch pipes, or thick stainless steel welded joints), it is often impossible to implement conventional RT or ultrasonic testing standards. In the nuclear power plant construction standard RCC-M, for non-pipeline full-penetration fillet welds, if RT and ultrasonic testing cannot be performed post-weld, the corresponding requirements during the welding process must be followed. During the welding process, only surface inspection is generally performed (penetrating penetration test or magnetic particle test every three layers). However, surface inspection can only detect open defects on the surface of the weld and cannot detect internal defects. Therefore, without other compensation measures, defects may be missed. On the other hand, electromagnetic testing alone may ignore the undulations of the surface to be inspected.

[0003] Patent document CN114113337B discloses an electromagnetic ultrasonic flexible array probe and detection method for detecting defects in curved structures. The probe consists of four parts: an electromagnetic ultrasonic bias magnetic field unit, an electromagnetic ultrasonic excitation unit, an electromagnetic ultrasonic detection unit, and a flexible substrate. The electromagnetic ultrasonic excitation unit and the electromagnetic ultrasonic detection unit are each composed of two or more coils arranged in a certain array to enhance excitation and signal reception, which can effectively improve the detection capability and efficiency for curved structures. The flexible probe can be widely used for non-destructive testing of components with complex surface shapes and workpieces with narrow inspection spaces, expanding the application range of ultrasonic non-destructive testing technology. However, it does not solve the problem that electromagnetic detection alone may ignore the undulations of the surface to be tested.

[0004] Patent document CN116429700A discloses an additive titanium alloy laser electromagnetic ultrasonic defect detection system and a laser electromagnetic ultrasonic SAFT imaging detection method. The defect detection system includes a signal excitation unit, a signal receiving unit, an optical triggering circuit, and an industrial control computer. The optical triggering circuit is connected to both the signal excitation unit and the signal receiving unit to acquire an initial signal and to feed back the acquired trigger signal to the signal receiving unit. The laser control system in the industrial control computer emits pulsed laser light. A scanning array program or a two-dimensional scanning translation stage controls the deflection of the light source to achieve laser source scanning along a predetermined path, ultrasonic signal excitation and reception. The acquired data is then transmitted to a host computer. After the scanned array data is processed by a synthetic aperture focusing imaging algorithm, the image of the internal defects of the test block is finally reconstructed. However, this method does not address the issue that electromagnetic detection alone may overlook the undulations of the surface being inspected. Summary of the Invention

[0005] Based on the above-mentioned technical problems, this invention proposes a visual electromagnetic composite defect detection probe and method to solve the problem that electromagnetic detection alone may ignore the undulations of the surface to be detected.

[0006] To achieve the above objectives, this invention proposes a visual electromagnetic composite defect detection probe.

[0007] A visual electromagnetic composite defect detection probe:

[0008] The device includes a probe housing, a magnetic detection sensor, and a lens. The probe housing comprises a connecting housing and a lower housing. The connecting housing is connected to the lower housing, the magnetic detection sensor is connected to the lower housing, and the lens is connected to the connecting housing.

[0009] The direction of movement of the detection probe during the detection process is taken as the first direction, and the direction perpendicular to and pointing towards the surface to be measured is taken as the second direction. The magnetic detection sensor and the lens are located in the detection plane determined by the first direction and the second direction. The lower housing is wedge-shaped and has a cross-sectional area that gradually decreases along the second direction. The lower housing is arranged along the first direction.

[0010] Furthermore, the connecting housing includes a signal amplifier module, which is fixed inside the connecting housing.

[0011] Furthermore, the connecting housing includes a probe cover, which is fixed to the connecting housing.

[0012] Furthermore, the connecting housing also includes an aviation plug, which is perpendicularly connected to the probe cover along the second direction.

[0013] Furthermore, the connecting housing includes a connecting housing groove, which is located in the detection plane defined by the first direction and the second direction, and is placed on the outer side of the connecting housing.

[0014] Furthermore, the connecting housing groove includes the lens, which is disposed in the connecting housing groove.

[0015] Furthermore, the connecting housing groove also includes a surface-mount LED, which is disposed in the connecting housing groove.

[0016] Furthermore, the connecting housing includes a connecting housing slot, which is located on the outer side of the connecting housing.

[0017] Furthermore, the connecting housing slot also includes a lens circuit board, which is disposed in the connecting housing slot.

[0018] Furthermore, the lower housing is connected to the connecting housing via a plane with the largest wedge-shaped cross-sectional area.

[0019] Furthermore, the lower housing includes a probe detection groove and a probe excitation groove, which are located within the connecting housing, and the probe excitation groove is located inside the lower housing relative to the probe detection groove.

[0020] Furthermore, the probe detection groove includes the magnetic detection sensor, which is disposed in the probe detection groove.

[0021] Furthermore, the probe excitation groove includes a magnetic core, which is disposed within the probe excitation groove.

[0022] To achieve the above objectives, the present invention also proposes a visual electromagnetic composite defect detection method.

[0023] A method for visual electromagnetic composite defect detection, characterized in that it includes:

[0024] S1: The test piece is continuously acquired via a lens and a magnetic detection sensor, which collect video, Bx channel signal and Bz channel signal at the weld seam.

[0025] S2: Perform noise reduction processing on the Bx channel signal and the Bz channel signal, and plot the signal curves;

[0026] S3: Determine whether the signal is a defect signal based on the signal curve and the video of the weld seam.

[0027] S4: Send out defect information.

[0028] Further, step S3 includes:

[0029] A threshold signal is set. If the Bz channel signal in the signal curve is greater than the threshold signal, the Bz channel signal is re-acquired three times to obtain a verification Bz channel signal. If the verification Bz channel signal is consistent with the Bz channel signal in the signal curve, it is determined to be the defect signal.

[0030] Furthermore, step S3 also includes:

[0031] If the Bz channel signal in the signal curve is less than the threshold signal and / or the verification Bz channel signal is inconsistent, then the Bx channel signal in the signal curve is judged. If it is greater than the threshold signal, the surface undulation of the test piece is judged by the video of the weld seam. If the surface undulation of the test piece is less than or equal to 1 mm, it is determined to be the defect signal.

[0032] If the surface undulation of the test piece is greater than 1mm, it is determined whether it is an irrelevant display. If so, it is judged as qualified. If it is not an irrelevant display, the Bx channel signal is re-acquired three times to obtain the verification Bx channel signal. If the verification Bx channel signal is consistent with the Bx channel signal in the signal curve, it is judged as the defect signal.

[0033] Furthermore, the unrelated display includes:

[0034] The non-relevant displays include checking operational errors, checking equipment noise, checking material properties, and checking surface conditions.

[0035] Further, step S4 includes:

[0036] The defect information includes the defect signal and the corresponding keyframes of the video at the weld seam.

[0037] Based on the above technical solution, the present invention has at least the following beneficial effects:

[0038] 1. This invention proposes a visual electromagnetic composite defect detection probe. The probe's structure and internal circuitry have been redesigned and optimized, enabling the probe to adapt to narrow spaces and achieve perfect fit with narrow sections of layered weld seams. This design improvement significantly enhances the applicability and flexibility of the detection probe in complex welded structures, ensuring high efficiency and accuracy in the detection process.

[0039] 2. This invention combines electromagnetic detection and visual inspection to achieve efficient and accurate detection of defects in narrow sections of layered welds. Electromagnetic detection utilizes the acquisition and processing of signals from the Bx and Bz channels, combined with signal curves and default thresholds to determine defects, while visual inspection provides an intuitive means of defect identification through video recording and image acquisition. This composite detection method not only improves the accuracy of detection but also enhances its efficiency.

[0040] 3. This invention provides a visual electromagnetic composite defect detection method, including signal acquisition, processing, defect judgment, and final acceptance procedures. By setting clear detection steps and standards, the detection process is standardized, reducing interference from human factors and improving the consistency and reliability of detection results.

[0041] 4. The technical solution of this invention achieves a comprehensive improvement in the quality of welded joints through optimized probe structure, innovative detection methods, standardized detection procedures, and integrated detection equipment. These technological improvements not only enhance the detection quality of welded joints but also indirectly improve the safety and reliability of important facilities such as nuclear power plants, demonstrating significant practical value and broad application prospects. Attached Figure Description

[0042] The accompanying drawings, which form part of this specification, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0043] Figure 1 A cross-sectional view of a visual electromagnetic composite defect detection probe according to one embodiment is shown;

[0044] Figure 2 A three-dimensional structural diagram of a visual electromagnetic composite defect detection probe according to one embodiment is shown;

[0045] Figure 3 A flowchart of a visual electromagnetic composite defect detection method according to one embodiment is shown.

[0046] The above figures include the following reference numerals:

[0047] 1. Probe housing; 2. Magnetic core; 3. Magnetic detection sensor; 4. Signal amplification module; 5. Aviation connector; 6. Probe cover; 7. Fixing screw holes; 8. Lens;

[0048] 11. Connecting housing; 12. Lower housing;

[0049] 111. Connecting shell groove; 112. Connecting shell slot; 113. Lens circuit board; 114. SMD LED;

[0050] 121. Probe detection groove; 122. Probe excitation groove. Detailed Implementation

[0051] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0052] The present invention will be further described in detail below with reference to specific embodiments. These embodiments should not be construed as limiting the scope of protection claimed by the present invention. The term "comprising" indicates the presence of a feature, but does not exclude the presence or addition of one or more other features. The terms "lateral," "upper," "lower," "front," "rear," "left," "right," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the purpose of description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0053] In this description, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances. Furthermore, in the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0054] Example

[0055] This invention proposes a visual electromagnetic composite defect detection probe, combining... Figure 1 and Figure 2 As shown, the device includes a probe housing 1, a magnetic detection sensor 3, and a lens 8. The probe housing 1 includes a connecting housing 11 and a lower housing 12. The connecting housing 11 is connected to the lower housing 12. The magnetic detection sensor 3 is connected to the lower housing 12, and the lens 8 is connected to the connecting housing 11.

[0056] The direction of movement of the detection probe during the detection process is taken as the first direction, and the direction perpendicular to and pointing towards the surface to be tested is taken as the second direction. The magnetic detection sensor 3 and the lens 8 are located in the detection plane determined by the first direction and the second direction. The lower housing is wedge-shaped and has a cross-sectional area that gradually decreases along the second direction. The lower housing is arranged along the first direction.

[0057] Furthermore, the signal amplification module 4 is fixed inside the probe housing 1 with hot melt adhesive. The probe cover 6 is fixed to the probe housing 1 with threads. The aviation plug 5 is installed inside the probe housing 1 and connected to one side of the probe cover 6 by interference fit with the cylindrical mounting hole. The connection housing 11 is connected to the lower housing 12 with screws. The connection housing groove 111 is installed along the probe movement direction. The lens 8 and the surface mount LED 114 are installed inside the connection housing groove 111. The back is the lens connection housing slot 112, and the lens circuit board 11 is placed in the connection housing slot 112.

[0058] Furthermore, such as Figure 3 As shown, when detecting defects at the weld seam, the device is connected to the signal excitation device and the signal acquisition device via the aviation connector 5. The aviation connector 5 transmits the excitation signal to the magnetic core 2, which in turn excites a uniform current in the probe detection groove 121 of the probe. The magnetic detection sensor 3 amplifies the magnetic signal of the tiny defect at the narrow part of the weld seam through the signal amplification module 4 and then transmits it to the signal acquisition device via the aviation connector 5, thereby realizing the acquisition of the defect signal at the weld seam.

[0059] Preferably, the surface-mount LED 114 is placed close to the lens 8 to enable the lens 8 to achieve high resolution, high frame rate, small size and close-range imaging requirements. The acquired video image information is transmitted to the PC via USB through the lens circuit board 113.

[0060] To achieve the above objectives, the present invention also proposes a method for visual electromagnetic composite defect detection, using the visual electromagnetic composite defect detection probe described above, comprising the following steps:

[0061] S1: The lens 8 and the magnetic detection sensor 3 continuously acquire video, Bx channel signal and Bz channel signal of the weld seam of the test piece respectively.

[0062] S2: Perform noise reduction processing on the Bx channel signal and the Bz channel signal, and plot the signal curves.

[0063] S3: Determine whether it is a defect signal based on the signal curve and the video of the weld seam.

[0064] S4: Send out defect information.

[0065] In practice, data can be collected from the surface to be inspected simultaneously using lens 8 and magnetic detection sensor 3. Alternatively, video data can be collected and saved using lens 8, and then the Bx and Bz channel signals can be collected using magnetic detection sensor 3.

[0066] Furthermore, step S3 also includes:

[0067] If the Bz channel signal in the signal curve is less than the threshold signal and / or the verification Bz channel signal is inconsistent, then the Bx channel signal in the signal curve is judged. If it is greater than the threshold signal, the surface undulation of the test piece is judged by the video of the weld seam. If the surface undulation of the test piece is less than or equal to 1 mm, it is determined to be the defect signal.

[0068] If the surface undulation of the test piece is greater than 1mm, it is determined whether it is an irrelevant display. If so, it is judged as qualified. If it is not an irrelevant display, the Bx channel signal is re-acquired three times to obtain the verification Bx channel signal. If the verification Bx channel signal is consistent with the Bx channel signal in the signal curve, it is judged as the defect signal.

[0069] Furthermore, the unrelated display includes:

[0070] The non-relevant displays include checking operational errors, checking equipment noise, checking material properties, and checking surface conditions.

[0071] Further, step S4 includes:

[0072] The defect information includes the defect signal and the key video of the corresponding weld seam.

[0073] In summary, as can be seen from the above description, the embodiments of the present invention achieve the following technical effects:

[0074] 1. This invention proposes a visual electromagnetic composite defect detection probe. The probe's structure and internal circuitry have been redesigned and optimized, enabling the probe to adapt to narrow spaces and achieve perfect fit with narrow sections of layered weld seams. This design improvement significantly enhances the applicability and flexibility of the detection probe in complex welded structures, ensuring high efficiency and accuracy in the detection process.

[0075] 2. This invention combines electromagnetic detection and visual inspection to achieve efficient and accurate detection of defects in narrow sections of layered welds. Electromagnetic detection utilizes the acquisition and processing of signals from the Bx and Bz channels, combined with signal curves and default thresholds to determine defects, while visual inspection provides an intuitive means of defect identification through video recording and image acquisition. This composite detection method not only improves the accuracy of detection but also enhances its efficiency.

[0076] 3. This invention provides a visual electromagnetic composite defect detection method, including signal acquisition, processing, defect judgment, and final acceptance procedures. By setting clear detection steps and standards, the detection process is standardized, reducing interference from human factors and improving the consistency and reliability of detection results.

[0077] 4. The technical solution of this invention achieves a comprehensive improvement in the quality of welded joints through optimized probe structure, innovative detection methods, standardized detection procedures, and integrated detection equipment. These technological improvements not only enhance the detection quality of welded joints but also indirectly improve the safety and reliability of important facilities such as nuclear power plants, demonstrating significant practical value and broad application prospects.

[0078] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0079] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes the element.

[0080] It should be noted that, in the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

Claims

1. A visual electromagnetic composite defect detection probe, characterized in that, The device includes a probe housing (1), a magnetic detection sensor (3), and a lens (8). The probe housing (1) includes a connecting housing (11) and a lower housing (12). The connecting housing (11) is connected to the lower housing (12), the magnetic detection sensor (3) is connected to the lower housing (12), and the lens (8) is connected to the connecting housing (11). The direction of movement of the detection probe during the detection process is taken as the first direction, and the direction perpendicular to the surface to be tested and pointing towards the surface to be tested is taken as the second direction. The magnetic detection sensor (3) and the lens (8) are located in the detection plane determined by the first direction and the second direction. The lower housing is wedge-shaped. The lower housing has a cross-sectional area that gradually decreases along the second direction. The lower housing is set along the first direction. The connecting housing (11) includes a connecting housing groove (111), which is located in the detection plane defined by the first direction and the second direction and is placed on the outside side of the connecting housing (11). The connecting housing groove (111) includes the lens (8), which is disposed in the connecting housing groove (111).

2. The detection probe according to claim 1, characterized in that, The connecting housing (11) includes a signal amplifier module (4). The signal amplifier module (4) is fixed inside the connecting housing (11).

3. The detection probe according to claim 2, characterized in that, The connecting housing (11) includes a probe cap (6). The probe cap (6) is fixed to the connecting housing (11).

4. The detection probe according to claim 3, characterized in that, The connecting housing (11) also includes an aviation plug (5). The aviation plug (5) is perpendicularly connected to the probe cover (6) along the second direction.

5. The detection probe according to claim 1, characterized in that, The connecting housing groove (111) also includes a surface-mount LED (114). The patch LED (114) is disposed in the groove (111) of the connecting housing.

6. The detection probe according to claim 1, characterized in that, The connecting housing (11) includes a connecting housing slot (112). The connecting housing slot (112) is located on the outside side of the connecting housing (11).

7. The detection probe according to claim 6, characterized in that, The connecting housing slot (112) also includes a lens circuit board (113). The lens circuit board (113) is disposed in the connecting housing slot (112).

8. The detection probe according to claim 1, characterized in that, The lower housing (12) is connected to the connecting housing (11) through the plane with the largest wedge-shaped cross-sectional area.

9. The detection probe according to claim 8, characterized in that, The lower housing (12) includes a probe detection groove (121) and a probe excitation groove (122). The probe detection groove (121) and the probe excitation groove (122) are located inside the connecting housing (11), and the probe excitation groove (122) is located inside the lower housing (12) relative to the probe detection groove (121).

10. The detection probe according to claim 9, characterized in that, The probe detection groove (121) includes the magnetic detection sensor (3). The magnetic detection sensor (3) is disposed in the probe detection groove (121).

11. The detection probe according to claim 9, characterized in that, The probe excitation groove (122) includes a magnetic core (2). The magnetic core (2) is disposed in the probe excitation groove (122).

12. A method for visually detecting electromagnetic composite defects, characterized in that, include: S1: The lens (8) and the magnetic detection sensor (3) are used to continuously collect video, Bx channel signal and Bz channel signal at the weld seam of the test piece respectively; S2: Perform noise reduction processing on the Bx channel signal and the Bz channel signal, and plot the signal curves; S3: Determine whether the signal is a defect signal based on the signal curve and the video of the weld seam. S4: Send out defect information.

13. The method according to claim 12, characterized in that, Step S3 includes: A threshold signal is set. If the Bz channel signal in the signal curve is greater than the threshold signal, the Bz channel signal is re-acquired three times to obtain a verification Bz channel signal. If the verification Bz channel signal is consistent with the Bz channel signal in the signal curve, it is determined to be the defect signal.

14. The method according to claim 13, characterized in that, Step S3 further includes: If the Bz channel signal in the signal curve is less than the threshold signal and / or the verification Bz channel signal is inconsistent, then the Bx channel signal in the signal curve is judged. If it is greater than the threshold signal, the surface undulation of the test piece is judged by the video of the weld seam. If the surface undulation of the test piece is less than or equal to 1mm, it is determined to be the defect signal. If the surface undulation of the test piece is greater than 1mm, it is determined whether it is an irrelevant display. If so, it is judged as qualified. If it is not an irrelevant display, the Bx channel signal is re-acquired three times to obtain the verification Bx channel signal. If the verification Bx channel signal is consistent with the Bx channel signal in the signal curve, it is judged as the defect signal.

15. The method according to claim 14, characterized in that, The unrelated display includes: The non-relevant displays include checking operational errors, checking equipment noise, checking material properties, and checking surface conditions.

16. The method according to claim 12, characterized in that, Step S4 includes: The defect information includes the defect signal and the corresponding keyframes of the video at the weld seam.

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