Online monitoring system and method for erosive wear of metal 3D printing powder conveying pipeline

Abstract

The invention provides a metal 3D printing powder conveying pipeline erosive wear online monitoring system and method, the system comprises a sensor arrangement module, a sensing network node module and a data center module, a dry coupling ultrasonic sensor is adopted to solve the problem of leakage of a traditional wet coupling agent, a monitoring key area is determined through COMSOL simulation, and the monitoring key area is determined through the data center module. And low-power-consumption data acquisition and wireless transmission are realized by using an ARM + FPGA architecture. According to the method, distributed remote real-time monitoring of the wall thickness of the pipeline is achieved through dry coupling ultrasonic thickness measurement, a temperature compensation algorithm and a wireless sensor network, the problems that the high-pressure argon erosion rule is unknown, and a sensor fails in the high-temperature environment are solved, technical support is provided for full-life-cycle health monitoring of the metal 3D printing pipeline, and the method is suitable for popularization and application. The method is suitable for nondestructive testing and on-line early warning of the pressure pipeline.

Description

Technical Field

[0001] The present invention relates to the technical field of online monitoring systems, and in particular to an online monitoring system and method for erosion and wear of a metal 3D printing powder conveying pipeline. Background Art

[0002] Pipeline transportation plays a crucial role in the delivery of metal 3D printing powder in additive manufacturing. With the continuous advancement of metal 3D printing technology, the importance of ensuring the safe use of pipelines has become increasingly prominent. During the metal 3D printing process, as pipelines age and environmental changes occur, they can age, deform, or corrode, causing their wall thickness to no longer meet safety requirements. Therefore, real-time pipeline health monitoring and early warning are crucial, and real-time detection of pipeline wall thickness is a key parameter in pipeline health monitoring.

[0003] According to laws, regulations, and standards such as the "Work Safety Law," the "Special Equipment Safety Law," and the "Regulations for Periodic Inspection of Industrial Pipelines," metal 3D printing industrial pipelines require regular inspections. Pipeline safety management should shift from the current passive "emergency rescue" model to a proactive "risk-based maintenance" model to prevent accidents. Understanding the development trends of corrosion in metal 3D printing powder delivery pipelines is crucial. Therefore, developing an online monitoring system for erosion and wear of metal 3D printing powder delivery pipelines to achieve continuous online monitoring and real-time alarms for key components is an urgent task. Summary of the Invention

[0004] In response to the above-mentioned technical deficiencies, the purpose of the present invention is to provide an online monitoring system and method for erosion and wear of metal 3D printing powder conveying pipelines, so as to realize distributed remote real-time monitoring of the wall thickness of the entire pipeline, improve measurement efficiency and reduce measurement costs.

[0005] To achieve the above object, the present invention adopts the following technical solutions:

[0006] An online monitoring system for erosion and wear of metal 3D printing powder conveying pipelines, comprising:

[0007] A sensor placement module for collecting ultrasonic data on pipe wall thickness;

[0008] Sensor network node module, used to stimulate sensors, receive data and transmit wirelessly;

[0009] Data center module, used for processing, storing, displaying data and issuing early warnings;

[0010] The sensor arrangement module is connected to the sensor network node module via a short-distance wired connection, and the sensor network node module communicates with the data center module via wireless transmission.

[0011] Preferably, the sensor arrangement module adopts a dry-coupled ultrasonic sensor, which contacts the pipeline surface through a non-liquid coupling method.

[0012] Preferably, the sensor network node module includes:

[0013] Ultrasonic excitation circuit and receiving circuit, used to generate ultrasonic waves and collect echo signals;

[0014] FPGA-based high-speed ADC acquisition circuit for signal analog-to-digital conversion;

[0015] Embedded system based on ARM architecture for data processing and wireless transmission;

[0016] Low-power power supply module, used to maintain continuous operation of the node.

[0017] Preferably, the data center module includes a host computer software system for realizing data visualization, wall thickness calculation, erosion wear trend analysis and warning threshold setting.

[0018] Preferably, the dry-coupled ultrasonic sensor is packaged with a high-temperature resistant material, and a constant pressure is applied between the sensor and the pipeline through a clamping device to form a stable acoustic coupling path.

[0019] A monitoring method for an online monitoring system for erosion and wear of a metal 3D printing powder conveying pipeline comprises the following steps:

[0020] Based on COMSOL simulation, key monitoring areas for pipeline erosion and wear were determined, and dry-coupled ultrasonic sensors were deployed.

[0021] The sensor network node module stimulates the sensor to transmit ultrasonic waves, receives the echo signal and performs analog-to-digital conversion;

[0022] Wirelessly transmit data to the data center module to calculate wall thickness and analyze erosion wear status;

[0023] When the wall thickness value exceeds the warning threshold, a real-time alarm is triggered.

[0024] Preferably, the step of arranging the dry-coupled ultrasonic sensors includes: arranging the sensors densely at easily worn locations such as pipe elbows and tees, fixing the sensors by mechanical clamping and applying coupling pressure.

[0025] Preferably, the echo signal processing step includes: realizing high-speed acquisition of ultrasonic echo signals through FPGA, and performing signal filtering, feature extraction and wall thickness calculation using an ARM embedded system.

[0026] Preferably, the wall thickness calculation step takes temperature compensation into consideration, obtains the real-time temperature of the pipeline through a pre-buried temperature sensor, and corrects the ultrasonic wave propagation velocity deviation.

[0027] Preferably, the data center module constructs a wireless sensor network through ZigBee or WiFi protocol to achieve remote aggregation and distributed processing of multi-node data.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] Solve the problem of coupling agent failure: Use dry-coupling ultrasonic sensors and mechanical clamping devices to prevent the volatilization and loss of liquid coupling agent, suitable for long-term online monitoring, and improve system stability.

[0030] Accurately locate wear areas: Analyze pipeline erosion patterns through COMSOL simulation, optimize sensor placement at easily worn areas such as elbows and tees, and improve monitoring targeting and efficiency.

[0031] Adapt to high temperature working environment: The sensor is packaged with high temperature resistant materials and combined with temperature compensation algorithm to correct the sound velocity deviation, thus solving the problems of sensor failure and thickness measurement error under high temperature.

[0032] Low-power remote monitoring: Sensor network nodes based on ARM+FPGA architecture achieve low-power data collection and build wireless sensor networks through ZigBee / WiFi to meet the flexible layout requirements of metal 3D printing sites.

[0033] Improve early warning reliability: Real-time monitoring of wall thickness changes and triggering of graded early warnings significantly shortens response time compared to manual inspections and reduces the risk of pipeline failure. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a structural block diagram of the present invention. DETAILED DESCRIPTION

[0035] The present invention will be further described below with reference to the accompanying drawings.

[0036] like Figure 1 As shown, an online monitoring system for erosion and wear of metal 3D printing powder conveying pipelines includes:

[0037] 1. Simulation of key areas of erosion wear and sensor placement

[0038] COMSOL simulation analysis

[0039] Using the COMSOL Multiphysics multi-physics simulation platform, erosion wear simulation was performed on the long pipes, elbows, tees and other structures of the metal 3D printing powder conveying pipeline. The influence of pipeline structure, material and transmission medium on the erosion wear rate was analyzed, and key monitoring areas for erosion wear, such as the outer arc surface of the elbow and the connection of the tee branch pipe, were identified.

[0040] Dry-coupled ultrasonic sensor installation

[0041] Dry-coupled ultrasonic sensors are arranged at easily worn parts such as pipe elbows and tees. The sensors are encapsulated with high-temperature resistant materials and fixed to the pipe surface by mechanical clamping devices to form a non-liquid coupling path.

[0042] The sensor layout follows the erosion wear simulation results, and the points are densely distributed in the wear rate peak area to achieve key monitoring of the weak parts of the pipeline.

[0043] 2. Sensor Network Node Hardware Implementation

[0044] Ultrasonic excitation and receiving circuit

[0045] Design ultrasonic excitation circuit and receiving circuit to generate ultrasonic waves and collect echo signals, including pulse signal generation module, preamplification module and bandpass filter module to realize ultrasonic emission and preliminary processing of echo signals.

[0046] High-speed data acquisition and embedded processing

[0047] A high-speed ADC acquisition circuit based on FPGA architecture is used to realize analog-to-digital conversion and caching of ultrasonic echo signals.

[0048] An embedded system based on ARM architecture, used to control data acquisition timing, execute signal processing algorithms and manage wireless transmission modules.

[0049] Low power supply design

[0050] The low-power power supply module is used in combination with the power management chip to achieve low-power operation of the sensor network nodes, meeting the equipment endurance requirements of the metal 3D printing site.

[0051] 3. Data Center Module Construction

[0052] Host computer software system

[0053] Develop the host computer software of the remote monitoring system to realize the processing, calculation, storage, display and early warning functions of the erosion and wear data of the metal 3D printing powder conveying pipeline, including the data receiving module, wall thickness calculation module and graded early warning module.

[0054] Wireless sensor network architecture

[0055] Use ZigBee or WiFi protocols to build a wireless sensor network to achieve remote aggregation and distributed processing of multi-node data, solving the problem of difficult wiring of traditional wired transmission at the metal 3D printing site.

[0056] 4. System Integration and Test Verification

[0057] Hardware system integration

[0058] The dry-coupled ultrasonic sensor is fixed to the preset position of the pipeline through a mechanical clamping device. The sensor network node is installed near the pipeline through a waterproof box. The sensor and the node are connected by a short-distance wired method to build a complete hardware monitoring system.

[0059] Functional testing and field application

[0060] The system is tested for thickness measurement accuracy, high temperature adaptability and wireless transmission distance to ensure that each module functions normally.

[0061] A monitoring system is deployed on-site on the metal 3D printing powder conveying pipeline to conduct distributed remote real-time monitoring of the pipeline wall thickness, and to evaluate and issue early warnings on the erosion and wear status based on the wall thickness change trend.

[0062] V. Key points for implementing key technologies

[0063] Dry-coupled ultrasonic testing method

[0064] Mechanical pressure coupling or solid coupling materials are used to achieve acoustic coupling between the sensor and the pipe surface, avoiding the leakage and volatilization problems of traditional liquid coupling agents during long-term monitoring. It is suitable for high temperature and high pressure conditions of metal 3D printing.

[0065] Erosion wear simulation and point optimization

[0066] Through COMSOL simulation analysis of pipeline erosion and wear patterns, the optimal placement of sensors in areas prone to wear is guided, monitoring efficiency and pertinence are improved, and the blindness of traditional placement is resolved.

[0067] Low-power wireless sensor networks

[0068] Low-power sensor network nodes are designed based on the ARM+FPGA architecture, and combined with ZigBee / WiFi wireless transmission technology to build a distributed monitoring network suitable for metal 3D printing sites to achieve remote transmission and processing of data.

Claims

1. An online monitoring system for erosion and wear of metal 3D printing powder conveying pipelines, characterized in that: include: A sensor placement module for collecting ultrasonic data on pipe wall thickness; Sensor network node module, used to stimulate sensors, receive data and transmit wirelessly; Data center module, used for processing, storing, displaying data and issuing early warnings; The sensor arrangement module is connected to the sensor network node module via a short-distance wired connection, and the sensor network node module communicates with the data center module via wireless transmission.

2. The metal 3D printing powder conveying pipeline erosion and wear online monitoring system according to claim 1, characterized in that: The sensor arrangement module adopts a dry-coupled ultrasonic sensor and contacts the pipeline surface through a non-liquid coupling method.

3. The online monitoring system for erosion and wear of metal 3D printing powder conveying pipelines according to claim 1, characterized in that: The sensor network node module includes: Ultrasonic excitation circuit and receiving circuit, used to generate ultrasonic waves and collect echo signals; FPGA-based high-speed ADC acquisition circuit for signal analog-to-digital conversion; Embedded system based on ARM architecture for data processing and wireless transmission; Low-power power supply module, used to maintain continuous operation of the node.

4. The metal 3D printing powder conveying pipeline erosion and wear online monitoring system according to claim 1, characterized in that: The data center module includes a host computer software system for realizing data visualization, wall thickness calculation, erosion wear trend analysis and warning threshold setting.

5. The metal 3D printing powder conveying pipeline erosion and wear online monitoring system according to claim 2, characterized in that: The dry-coupled ultrasonic sensor is packaged with high-temperature resistant materials, and a constant pressure is applied between the sensor and the pipeline through a clamping device to form a stable acoustic coupling path.

6. A monitoring method based on the online monitoring system for erosion and wear of metal 3D printing powder conveying pipelines according to any one of claims 1 to 5, characterized in that: The following steps are involved: Based on COMSOL simulation, key monitoring areas for pipeline erosion and wear were determined, and dry-coupled ultrasonic sensors were deployed. The sensor network node module stimulates the sensor to transmit ultrasonic waves, receives the echo signal and performs analog-to-digital conversion; Wirelessly transmit data to the data center module to calculate wall thickness and analyze erosion wear status; When the wall thickness value exceeds the warning threshold, a real-time alarm is triggered.

7. The method for online monitoring of erosion and wear of a metal 3D printing powder delivery pipeline according to claim 6, wherein: The arrangement steps of the dry-coupled ultrasonic sensors include: arranging sensors densely at easily worn locations such as pipe elbows and tees, fixing the sensors by mechanical clamping, and applying coupling pressure.

8. The method for online monitoring of erosion and wear of a metal 3D printing powder delivery pipeline according to claim 6, wherein: The echo signal processing step includes: realizing high-speed acquisition of ultrasonic echo signals through FPGA, and performing signal filtering, feature extraction and wall thickness calculation using ARM embedded system.

9. The method for online monitoring of erosion and wear of a metal 3D printing powder delivery pipeline according to claim 6, wherein: The wall thickness calculation step takes temperature compensation into consideration, obtains the real-time temperature of the pipeline through a pre-buried temperature sensor, and corrects the ultrasonic propagation velocity deviation.

10. The method for online monitoring of erosion and wear of a metal 3D printing powder delivery pipeline according to claim 6, wherein: The data center module builds a wireless sensor network through ZigBee or WiFi protocol to achieve remote aggregation and distributed processing of multi-node data.

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