Air-cooled electromagnetic ultrasonic sensor, detection system and method

Abstract

The present invention discloses an air-cooled electromagnetic ultrasonic sensor, a detection system and a method, which relate to the field of industrial detection technology. The air-cooled electromagnetic ultrasonic sensor includes a sensor body and a fan. The sensor body includes a shell, a connecting block, a magnet and a coil assembly. The connecting block, the magnet and the coil assembly are sequentially arranged in the shell along a first direction. The connecting block and the coil assembly are respectively sealed to the inner wall of the shell. A first ventilation cavity, a second ventilation cavity and an air outlet duct are provided in the shell. The detection system includes a power supply, a detector and the above-mentioned air-cooled electromagnetic ultrasonic sensor. The method for improving the heat resistance of the electromagnetic ultrasonic sensor is to insulate the coil assembly through the second ventilation cavity and to dissipate heat by introducing flowing air into the second ventilation cavity. The second ventilation cavity itself can act as an air insulation layer to insulate heat, and the introduction of flowing air can also take away the heat of the coil assembly, thereby improving the heat resistance of the electromagnetic ultrasonic sensor.

Description

Technical Field

[0001] The present invention relates to the field of industrial detection technology, and in particular to an air-cooled electromagnetic ultrasonic sensor, a detection system and a detection method. Background Art

[0002] Electromagnetic ultrasonic nondestructive testing (EUT) technology is a commonly used method for pipeline nondestructive testing (NDT). It offers many unique advantages, including low surface requirements, non-contact measurement, and no coupling considerations. When using array testing, signal consistency between channels is excellent, resulting in high sensor repeatability and ease of subsequent signal processing. In-plane displacement is easily generated, allowing for good control of the excitation mode. Its principle is to excite and receive ultrasonic waves through the interaction between a magnet and an induction coil, and then identify and measure pipeline defects through data analysis. However, at high temperatures, the magnet and induction coil, the two main components of an EUT sensor, are susceptible to damage and failure. Therefore, protecting the magnet and induction coil within the sensor is crucial for high-temperature testing. Currently, the magnet commonly used in EUT sensors is a neodymium iron boron magnet, with an operating temperature range of 80-230°C. The induction coil is often made of enameled wire with a maximum operating temperature of 220°C. The coil is typically located below the magnet, close to the object being measured, making it susceptible to heat transfer to the coil, causing it to malfunction. Magnets are also susceptible to demagnetization and demagnetization at high temperatures.

[0003] There are two main measures in the existing technology to solve the difficulties in applying electromagnetic ultrasonic sensors to high-temperature detection: one is to use high-temperature resistant coils and magnets with high residual magnetic induction intensity and high Curie point. The coils are encapsulated between heat-resistant layers, and coaxial cables using ceramic as internal insulation material can withstand high temperatures; the other is to use a local active cooling method, including setting a cooling device on the upper part of the magnet to remove heat through cooling water circulation, and at the same time wrapping the coil with a ceramic layer and a polyimide film for thermal insulation; or filling the sensor cavity with circulating cooling water to wrap the magnet and induction coil to remove heat.

[0004] However, there are many problems with the existing technology. Sensors that use physical thermal insulation require high-temperature resistant magnets and coils with high Curie points. The magnetic induction intensity is low at high temperatures, and high requirements are placed on materials and manufacturing processes. Although water-cooled sensors with local active cooling can remove heat from the surrounding area, the thermal layer between the coil and the object being measured is limited by the distance the sensor is lifted, and its thickness is limited. The high-temperature protection of the coil is weak, and long-term continuous measurement may damage the coil, and high requirements are placed on the coil material. In addition, the water cooling system is complex, with high requirements on system pressure, internal sealing of the sensor, and waterproof protection of the coil. The cooling medium is inconvenient to carry, which increases the difficulty of on-site use. Summary of the Invention

[0005] The purpose of the present invention is to provide an air-cooled electromagnetic ultrasonic sensor, a detection system and a detection method to solve the problems existing in the above-mentioned prior art and improve the high temperature resistance performance of the high temperature resistant electromagnetic ultrasonic sensor.

[0006] To achieve the above object, the present invention provides the following solutions:

[0007] The present invention provides an air-cooled, high-temperature resistant electromagnetic ultrasonic sensor, comprising a sensor body and a fan, the sensor body comprising a shell, a connecting block, a magnet and a coil assembly, the connecting block, the magnet and the coil assembly being sequentially arranged in the shell along a first direction, the connecting block and the coil assembly being sealed with the inner wall of the shell respectively, a first ventilation cavity, a second ventilation cavity and an air outlet duct being arranged in the shell, the first ventilation cavity surrounding the magnet, the second ventilation cavity being located on the side of the coil assembly away from the magnet, the first ventilation cavity and the second ventilation cavity being respectively communicated with the air outlet duct, the coil assembly being filled with sealant, and the coil assembly isolating the first ventilation cavity and the second ventilation cavity; a first air inlet communicating with the first ventilation cavity, a second air inlet communicating with the second ventilation cavity and an air outlet communicating with the air outlet duct are provided on the outer wall of the shell; the first air inlet and the second air inlet are respectively communicated with the air outlet of the fan through pipelines.

[0008] Preferably, it also includes a temperature sensor arranged in the second ventilation cavity.

[0009] Preferably, a first air inlet duct is further provided in the housing, the first air inlet is connected to the first ventilation cavity through the first air inlet duct, and the first air inlet duct is isolated from the second ventilation cavity;

[0010] A second air inlet duct is further provided in the shell, the second air inlet is communicated with the second ventilation cavity through the second air inlet duct, and the second air inlet duct is isolated from the first ventilation cavity.

[0011] Preferably, a first partition is provided in the shell, a top end of the first partition is fixedly connected to the shell, and the first air inlet duct is formed between the first partition and the inner wall of the shell.

[0012] Preferably, it also includes a wire threading tube connected to the shell, a wire placement cavity is provided in the shell, the first ventilation cavity, the second ventilation cavity, the first air inlet duct, the second air inlet duct and the air outlet duct are respectively isolated from the wire placement cavity, the wire threading tube is connected to the wire placement cavity, and the wires of the coil assembly and the signal wires of the temperature sensor pass through the wire placement cavity and the wire threading tube.

[0013] Preferably, the system further comprises a wiring harness connector provided at one end of the wire threading tube away from the housing, and the wires of the coil assembly and the signal wires of the temperature sensor are electrically connected to the wiring harness connector respectively.

[0014] Preferably, it further comprises a heat-resistant and wear-resistant plate fixedly connected to the shell, and the second ventilation cavity is located between the coil assembly and the heat-resistant and wear-resistant plate.

[0015] The present invention also provides an electromagnetic ultrasonic detection system, including a power supply, a detector, a control unit and the above-mentioned air-cooled high-temperature resistant electromagnetic ultrasonic sensor, wherein the power supply is used to power the detector and the fan, and the detector can provide pulse excitation for the coil winding in the coil assembly; the temperature sensor is signal-connected to the control unit, and the control unit can adjust the power of the fan according to the detection signal of the temperature sensor.

[0016] The present invention also provides a method for improving the heat resistance of an electromagnetic ultrasonic sensor: a second ventilation cavity and an air outlet duct are arranged in the electromagnetic ultrasonic sensor, and the second ventilation cavity is located on the side of the coil assembly of the electromagnetic ultrasonic sensor close to the high-temperature test piece to be measured, and the second ventilation cavity is communicated with the air outlet duct; the coil assembly is insulated by the second ventilation cavity, and heat is dissipated by passing flowing air into the second ventilation cavity.

[0017] Preferably, a first ventilation cavity surrounding the magnet of the electromagnetic ultrasonic sensor is provided in the electromagnetic ultrasonic sensor, so that the first ventilation cavity is communicated with the air outlet duct, the magnet is insulated by the first ventilation cavity, and heat is dissipated by introducing flowing air into the first ventilation cavity.

[0018] Compared with the prior art, the present invention has achieved the following technical effects:

[0019] The air-cooled electromagnetic ultrasonic sensor, detection system and method of the present invention provide a second ventilation cavity in the electromagnetic ultrasonic sensor. The second ventilation cavity is located between the coil assembly and the high-temperature test piece to be measured. The second ventilation cavity itself can serve as an air insulation layer to improve the heat resistance of the electromagnetic ultrasonic sensor. Furthermore, by introducing flowing air into the second ventilation cavity, the heat of the coil assembly can be taken away, thereby improving the heat dissipation performance and thus improving the heat resistance of the electromagnetic ultrasonic sensor.

[0020] Furthermore, by setting up a first ventilation cavity surrounding the magnet, the first ventilation cavity itself can serve as an air insulation layer to block heat transfer between the shell and the magnet, and by introducing flowing air into the first ventilation cavity, the heat of the magnet can be taken away, thereby improving the heat dissipation performance and thus improving the heat resistance of the electromagnetic ultrasonic sensor.

[0021] Furthermore, by setting up a temperature sensor, the temperature in the second ventilation cavity can be monitored in real time, so that the output power of the fan can be adjusted according to the real-time temperature of the second ventilation cavity, thereby maintaining the temperature in the second ventilation cavity below the set value. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0023] Figure 1 The structure of the sensor body in the air-cooled high-temperature resistant electromagnetic ultrasonic sensor of the present invention is shown in FIG. Figure 1 ;

[0024] Figure 2 The structure of the sensor body in the air-cooled high-temperature resistant electromagnetic ultrasonic sensor of the present invention is shown in FIG. Figure 2 ;

[0025] Figure 3 The top view of the sensor body in the air-cooled high-temperature resistant electromagnetic ultrasonic sensor of the present invention Figure 1 ;

[0026] Figure 4 for Figure 3 AA section view;

[0027] Figure 5 The top view of the sensor body in the air-cooled high-temperature resistant electromagnetic ultrasonic sensor of the present invention Figure 2 ;

[0028] Figure 6 for Figure 5 BB cross-sectional view;

[0029] Figure 7 This is a schematic diagram of the structure of the sensor body in the air-cooled high-temperature resistant electromagnetic ultrasonic sensor of the present invention. Figure 1 ;

[0030] Figure 8 This is a schematic diagram of the structure of the sensor body in the air-cooled high-temperature resistant electromagnetic ultrasonic sensor of the present invention. Figure 2 ;

[0031] Figure 9 It is a structural schematic diagram of the electromagnetic ultrasonic detection system of the present invention;

[0032] In the figure: 100, sensor body; 1, shell; 2, connecting block; 3, magnet; 4, coil assembly; 5, first ventilation cavity; 6, second ventilation cavity; 7, heat-resistant and wear-resistant plate; 8, first air inlet; 9, second air inlet; 10, air outlet; 11, wire tube; 12, first air inlet duct; 13, first partition; 14, second air inlet duct; 15, air outlet duct; 16, wire cavity; 17, wire partition; 18, second partition; 19, power supply; 20, fan; 21, detector; 22, control unit; 23, high-temperature specimen to be measured. DETAILED DESCRIPTION

[0033] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0034] The purpose of the present invention is to provide an air-cooled electromagnetic ultrasonic sensor, a detection system and a detection method to solve the problems existing in the above-mentioned prior art and improve the high temperature resistance performance of the high temperature resistant electromagnetic ultrasonic sensor.

[0035] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific embodiments. Example 1

[0036] like Figures 1 to 9 As shown, this embodiment provides an air-cooled high-temperature resistant electromagnetic ultrasonic sensor, including a sensor body 100 and a fan 20. The sensor body 100 includes a shell 1, a connecting block 2, a magnet 3 and a coil assembly 4. The connecting block 2, the magnet 3 and the coil assembly 4 are sequentially arranged in the shell 1 along a first direction. The connecting block 2 and the coil assembly 4 are respectively sealed with the inner wall of the shell 1. A first ventilation cavity 5, a second ventilation cavity 6 and an air outlet duct 15 are provided in the shell 1. The first ventilation cavity 5 surrounds the magnet 3, and the second ventilation cavity 6 is located on the side of the coil assembly 4 away from the magnet 3, the first ventilation cavity 5 and the second ventilation cavity 6 are respectively connected to the air outlet duct 15, the coil assembly 4 is filled with sealant, and the coil assembly 4 isolates the first ventilation cavity 5 and the second ventilation cavity 6; a first air inlet 8 communicating with the first ventilation cavity 5, a second air inlet 9 communicating with the second ventilation cavity 6 and an air outlet 10 communicating with the air outlet duct 15 are provided on the outer wall of the shell 1; the first air inlet 8 and the second air inlet 9 are respectively connected to the air outlet of the fan 20 through pipelines.

[0037] The air-cooled high-temperature resistant electromagnetic ultrasonic sensor of this embodiment further includes a temperature sensor disposed in the second ventilation cavity 6. In this embodiment, the number of the first air inlet 8 and the number of the second air inlet 9 are both two.

[0038] In an optional solution of this embodiment, preferably, a first air inlet duct 12 is further provided in the housing 1, and the first air inlet 8 is connected to the first ventilation cavity 5 through the first air inlet duct 12, and the first air inlet duct 12 is isolated from the second ventilation cavity 6;

[0039] A second air inlet duct 14 is further provided in the shell 1 , and the second air inlet 9 is communicated with the second ventilation cavity 6 through the second air inlet duct 14 , and the second air inlet duct 14 is isolated from the first ventilation cavity 5 .

[0040] In an optional solution of this embodiment, it is more preferred that a first partition 13 is provided in the shell 1 , the top end of the first partition 13 is fixedly connected to the shell 1 , and the first air inlet duct 12 is formed between the first partition 13 and the inner wall of the shell 1 .

[0041] In an optional solution of this embodiment, it is more preferred to further include a wire tube 11 connected to the housing 1. A wire cavity 16 is provided in the housing 1. The first ventilation cavity 5, the second ventilation cavity 6, the first air inlet duct 12, the second air inlet duct 14, and the air outlet duct 15 are respectively isolated from the wire cavity 16. The wire tube 11 is connected to the wire cavity 16. The wires of the coil assembly 4 and the signal wires of the temperature sensor both pass through the wire cavity 16 and the wire tube 11. In this embodiment, a portion of the wire cavity 16 is disposed between the inner wall of the housing 1 and the connecting block 2, and another portion is disposed between the second partition 18 and the inner wall of the housing 1. A wire threading partition 17 is provided in the shell 1. The wires of the coil assembly 4 and the signal wires of the temperature sensor enter the wire placement cavity 16 through the wire threading channel on the wire threading partition 17. After the wires are threaded, the wire placement cavity 16 is isolated from other cavities (including the first ventilation cavity 5, the second ventilation cavity 6, the first air inlet duct 12, the second air inlet duct 14 and the air outlet duct 15) by filling the wire threading partition 17 with sealant.

[0042] In the optional scheme of this embodiment, it is more preferred to further include a wiring harness connector arranged at the end of the wire threading tube 11 away from the shell 1, and the wires of the coil assembly 4 and the signal lines of the temperature sensor are electrically connected to the wiring harness connector respectively; the wiring harness connector is used to be electrically connected to the wiring harness connectors of other instruments, and is easy to use.

[0043] In the optional scheme of this embodiment, it is more preferred to further include a heat-resistant and wear-resistant plate 7 fixedly connected to the shell 1, and the second ventilation cavity 6 is located between the coil assembly 4 and the heat-resistant and wear-resistant plate 7; the heat-resistant and wear-resistant plate 7 blocks part of the heat from entering the interior of the sensor through its own thermal insulation performance, thereby playing a role of static heat resistance.

[0044] The specific heat dissipation principle of the air-cooled high-temperature resistant electromagnetic ultrasonic sensor of this embodiment is as follows:

[0045] The flowing air generated by the operation of the fan 20 is divided into two parts, one part passes through the first air inlet 8, the first air inlet duct 12, the first ventilation cavity 5 and the air outlet duct 15 in sequence, and the other part passes through the second air inlet 9, the second air inlet duct 14, the second ventilation cavity 6 and the air outlet duct 15 in sequence; since the first ventilation cavity 5 surrounds the magnet 3, the first ventilation cavity 5 itself can serve as an air insulation layer to block the heat transfer between the shell 1 and the magnet 3, and by passing flowing air into the first ventilation cavity 5, the heat of the magnet 3 can also be taken away, thereby improving the heat dissipation performance, thereby improving the heat resistance of the electromagnetic ultrasonic sensor; the second ventilation cavity 6 is located between the coil assembly 4 and the high-temperature test piece 23 to be tested, and the second ventilation cavity 6 itself can serve as an air insulation layer to improve the heat resistance of the electromagnetic ultrasonic sensor, and by passing flowing air into the second ventilation cavity 6, the heat of the coil assembly 4 can be taken away, thereby improving the heat dissipation performance, thereby improving the heat resistance of the electromagnetic ultrasonic sensor. The heat-resistant and wear-resistant plate 7 blocks the heat of the high-temperature test piece 23 to be measured from entering the interior of the sensor through its own heat-insulating property, thus playing a role of static heat insulation.

[0046] Furthermore, by setting a temperature sensor, the temperature in the second ventilation cavity 6 can be monitored in real time, so that the output power of the fan 20 can be adjusted according to the real-time temperature of the second ventilation cavity 6, so that the temperature in the second ventilation cavity 6 can be maintained below the set value.

[0047] It is worth noting that in actual applications, technical personnel can, based on the solution recorded in this embodiment, make actual calculations on design parameters such as the thickness of the first ventilation cavity 5, the thickness of the second ventilation cavity 6, and the speed of the fan 20 based on existing technical knowledge and the required heat dissipation, so as to achieve the purpose of ensuring heat dissipation performance and heat resistance performance; in actual applications, the magnet 3 can be a permanent magnet or an electromagnet. Example 2

[0048] like Figure 9 As shown, this embodiment provides an electromagnetic ultrasonic detection system, including a power supply 19, a detector 21, a control unit 22 and the air-cooled high-temperature resistant electromagnetic ultrasonic sensor of Example 1. The power supply 19 is used to power the detector 21 and the fan 20. The detector 21 can provide pulse excitation for the coil winding in the coil assembly 4; the temperature sensor is signal-connected to the control unit 22, and the control unit 22 can adjust the power of the fan 20 according to the detection signal of the temperature sensor; the temperature sensor does not need to be powered, and temperature changes will cause the temperature sensor itself to generate voltage and current signals. The temperature sensor only needs to transmit the electrical signal (temperature signal) to the detector 21.

[0049] In this embodiment, the control unit 22 adopts a PLC programmable controller; however, in actual applications, technicians can adaptively adjust the control unit 22 as needed. For example, the detector 21 has its own control circuit and chip, and the control unit 22 can be integrated into the control circuit of the detector 21, or the control circuit and chip in the controller can be used as the control unit 22. Example 3

[0050] The present invention also provides a method for improving the heat resistance of an electromagnetic ultrasonic sensor: a second ventilation cavity 6 and an air outlet duct 15 are arranged in the electromagnetic ultrasonic sensor, and the second ventilation cavity 6 is located on the side of the coil assembly 4 of the electromagnetic ultrasonic sensor close to the high-temperature test piece 23 to be measured, and the second ventilation cavity 6 is communicated with the air outlet duct 15; the coil assembly 4 is insulated by the second ventilation cavity 6, and heat is dissipated by passing flowing air into the second ventilation cavity 6.

[0051] In the optional scheme of this embodiment, it is more preferred to set a first ventilation cavity 5 surrounding the magnet 3 of the electromagnetic ultrasonic sensor in the electromagnetic ultrasonic sensor, so that the first ventilation cavity 5 is connected to the air outlet duct 15, the magnet 3 is insulated by the first ventilation cavity 5, and heat is dissipated by passing flowing air into the first ventilation cavity 5.

[0052] The present invention uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only intended to help understand the method and core concept of the present invention. At the same time, those skilled in the art will find that the specific implementation methods and application scopes may vary based on the concept of the present invention. In summary, the contents of this specification should not be construed as limiting the present invention.

Claims

1. An air-cooled, high-temperature-resistant electromagnetic ultrasonic sensor, characterized in that: It includes a sensor body and a fan, the sensor body includes a shell, a connecting block, a magnet and a coil assembly, the connecting block, the magnet and the coil assembly are arranged in sequence in the shell along a first direction, the connecting block and the coil assembly are respectively sealed with the inner wall of the shell, a first ventilation cavity, a second ventilation cavity and an air outlet duct are provided in the shell, the first ventilation cavity surrounds the magnet, the second ventilation cavity is located on the side of the coil assembly away from the magnet, the first ventilation cavity and the second ventilation cavity are respectively connected to the air outlet duct, the coil assembly is filled with sealant, and the coil assembly isolates the first ventilation cavity and the second ventilation cavity; a first air inlet communicating with the first ventilation cavity, a second air inlet communicating with the second ventilation cavity and an air outlet communicating with the air outlet duct are provided on the outer wall of the shell; the first air inlet and the second air inlet are respectively connected to the air outlet of the fan through pipelines.

2. The air-cooled high-temperature resistant electromagnetic ultrasonic sensor according to claim 1, characterized in that: It also includes a temperature sensor arranged in the second ventilation cavity.

3. The air-cooled high-temperature resistant electromagnetic ultrasonic sensor according to claim 2, characterized in that: A first air inlet duct is further provided in the housing, the first air inlet is connected to the first ventilation cavity through the first air inlet duct, and the first air inlet duct is isolated from the second ventilation cavity; A second air inlet duct is further provided in the shell, the second air inlet is communicated with the second ventilation cavity through the second air inlet duct, and the second air inlet duct is isolated from the first ventilation cavity.

4. The air-cooled high-temperature resistant electromagnetic ultrasonic sensor according to claim 3, characterized in that: A first partition is provided in the shell, a top end of the first partition is fixedly connected to the shell, and the first air inlet duct is formed between the first partition and the inner wall of the shell.

5. The air-cooled high-temperature resistant electromagnetic ultrasonic sensor according to claim 3, characterized in that: It also includes a wire threading tube connected to the shell, a wire placement cavity is provided in the shell, the first ventilation cavity, the second ventilation cavity, the first air inlet duct, the second air inlet duct and the air outlet duct are respectively isolated from the wire placement cavity, the wire threading tube is connected to the wire placement cavity, and the wires of the coil assembly and the signal wires of the temperature sensor pass through the wire placement cavity and the wire threading tube.

6. The air-cooled high-temperature resistant electromagnetic ultrasonic sensor according to claim 5, characterized in that: It also includes a wiring harness connector arranged at one end of the wire threading tube away from the shell, and the wires of the coil assembly and the signal wires of the temperature sensor are electrically connected to the wiring harness connector respectively.

7. The air-cooled high-temperature resistant electromagnetic ultrasonic sensor according to claim 2, characterized in that: It also includes a heat-resistant and wear-resistant plate fixedly connected to the shell, and the second ventilation cavity is located between the coil assembly and the heat-resistant and wear-resistant plate.

8. An electromagnetic ultrasonic detection system, characterized in that: It includes a power supply, a detector, a control unit and the air-cooled high-temperature resistant electromagnetic ultrasonic sensor according to any one of claims 2 to 7, wherein the power supply is used to power the detector and the fan, and the detector can provide pulse excitation for the coil winding in the coil assembly; the temperature sensor is signal-connected to the control unit, and the control unit can adjust the power of the fan according to the detection signal of the temperature sensor.

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