Magnetic flux leakage detection device and method

Abstract

According to the magnetic flux leakage detection device and method provided by the invention, the driving module, the detection module, the control module, the communication module and the power supply module are integrally arranged in the robot body, the detected signal is finally transmitted to the upper computer, and the upper computer processes the defect signal, so that the intelligence of pipeline defect detection is realized; the defects caused by manual inspection are avoided, and the intelligence, accuracy and personal safety of detection are improved; and through combined use of a friction wheel, a driving wheel and an elastic piece, the device can clamp ropes with different diameters in a self-adaptive mode, and the practicability and universality of the device are improved.

Description

Technical Field

[0001] The present application relates to the field of nondestructive testing technology, and more specifically to a magnetic flux leakage detection device and method. Background Art

[0002] In recent decades, my country has built a large number of oil and natural gas pipelines, which play a critical role in ensuring energy supply and maintaining the normal operation of the industrial system. However, as pipelines age, they are susceptible to structural defects such as cracks, leaks, scaling, and blockages due to factors such as welding processes, corrosion, and stress concentration. In severe cases, these defects can lead to safety accidents such as leaks and explosions. Therefore, regular internal pipeline inspection and maintenance are particularly important.

[0003] Currently, traditional pipeline inspection methods often involve excavating the pipeline, conducting manual visual inspections, or scrapping and replacing pipelines. These methods are not only time-consuming and costly, but also difficult to implement in underground or high-altitude installations, or in hazardous environments. They also suffer from low inspection efficiency, limited coverage, and significant safety risks. Summary of the Invention

[0004] In light of this, the present application provides a magnetic flux leakage detection device that applies a magnetic field to the pipeline and intelligently detects magnetic flux leakage to detect pipeline defects. This device is easy to operate, adapts to various rope diameters, and improves detection efficiency. Furthermore, the present application provides a detection method applicable to the aforementioned magnetic flux leakage detection device.

[0005] In order to achieve the above objectives, this application provides the following technical solutions: A magnetic flux leakage detection device is provided, wherein a rope is passed through the interior of a pipe and the rope is fixed at both ends of the pipe, and the magnetic flux leakage detection device comprises: a robot body, configured to move along the rope inside the pipeline; a drive module, disposed within the robot body and configured to drive the movement of the robot body, the drive module comprising at least a drive assembly and a friction assembly, the drive assembly comprising at least a drive wheel and a first elastic member, the friction assembly comprising at least a friction wheel and a second elastic member, the drive wheel being configured to move along the rope, and the friction wheel moving along the rope driven by the drive wheel; a detection module, disposed in the robot body and configured to apply a magnetic field to the pipeline, detect magnetic flux leakage in the pipeline, and output a signal; a control module, disposed in the robot body and configured to receive the signal output by the detection module, control the movement of the robot body in real time, and perform preliminary defect identification on the signal output by the detection module; a communication module, disposed in the robot body and used to transmit the signal processed by the control module; A host computer, used to receive the signal transmitted by the communication module and process the signal; a power supply module, disposed in the robot body and used to provide working power to the driving module, the detection module, the control module and the communication module; When the magnetic flux leakage detection device passes along the rope pre-placed in the pipeline, the rope contacts the friction wheel and the drive wheel and applies radial pressure to the friction wheel and the drive wheel. The friction wheel generates radial displacement through the second elastic member, and the drive wheel generates radial displacement through the first elastic member to adaptively clamp the ropes of different diameters.

[0006] Optionally, in the above-mentioned magnetic flux leakage detection device, the robot body includes: The top shell is provided with the driving module; A middle shell is provided with the detection module and is connected to the bottom of the top shell; A bottom shell is provided with the driving module and is connected to the bottom of the middle shell; Wherein, one of the top shell and the bottom shell is provided with a partition plate, the control module, the power supply module and the communication module are provided on one side of the partition plate, and the driving module is provided on the other side of the partition plate.

[0007] Optionally, in the above-mentioned magnetic flux leakage detection device, a hinge mechanism and a snap mechanism are provided on the robot body, the hinge mechanism is used to realize the pivoting opening of the robot body, and the snap mechanism is used to realize the locking closure of the robot body.

[0008] Optionally, in the above-mentioned magnetic flux leakage detection device, the driving module further includes a first guide rail for guiding the expansion and contraction of the first elastic member and a second guide rail for guiding the expansion and contraction of the second elastic member.

[0009] Optionally, in the magnetic flux leakage detection device, the driving wheels include at least two driving wheels arranged opposite to each other, and the first guide rail is sleeved around a portion of the first elastic member; The drive assembly further includes: A first limiting member is provided on the top shell and the bottom shell and is provided at an end away from the driving wheel; a first adapter, disposed on the top shell and the bottom shell and arranged opposite to the first limiting member, with one end of the first adapter connected to the driving wheel and the other end connected to the first guide rail; Wherein, the first elastic member can be extended and retracted between the first limiting member and the first adapter member under the guidance of the first guide rail.

[0010] Optionally, in the magnetic flux leakage detection device, the friction wheels include at least two oppositely disposed friction wheels, the friction wheels are provided with encoders for collecting real-time positions of the friction wheels, and the second guide rail is partially sleeved on the second elastic member; The friction assembly further comprises: A second limiting member is provided on the top shell and the bottom shell and is provided at an end away from the friction wheel; a second adapter, disposed on the top shell and the bottom shell and arranged opposite to the second limiting member, with one end of the second adapter being connected to the friction wheel and the other end being connected to the second guide rail; Wherein, the second elastic member can be extended and retracted between the second limiting member and the second adapter member under the guidance of the second guide rail.

[0011] Optionally, in the above-mentioned magnetic flux leakage detection device, the detection module includes: A magnetic element, which is arranged in a ring inside the middle shell and is used to apply a magnetic field to the pipeline; The bracket is U-shaped and is arranged in a ring inside the magnetic component, with the opening of the bracket facing the magnetic component; The magnetic sensor is arranged at the bottom of the bracket opposite to the opening of the bracket and is used to sense and collect the leakage magnetic signal of the pipeline.

[0012] Optionally, in the above-mentioned magnetic flux leakage detection device, the magnetic generating component is composed of a plurality of permanent magnets and a plurality of magnetic conductive yokes, forming a multi-yoke structure with a symmetrical magnetic circuit.

[0013] Optionally, in the above-mentioned magnetic flux leakage detection device, the magnetic sensor includes a Hall sensor, and the Hall sensors are distributed on the bracket in an array form.

[0014] A magnetic flux leakage detection method, applicable to any of the magnetic flux leakage detection devices described above, comprising: Step 1: The magnetic flux leakage detection device is passed through the rope, and the magnetic flux leakage detection device is fastened to the rope using a snap mechanism; Step 2: ensuring that the magnetic flux leakage detection device can be suspended on the rope in a stationary state, and starting the encoder to collect the real-time position of the friction wheel and the zero point value of the magnetic sensor; Step 3: Turn on the power supply module, the communication module, the control module, the detection module, and the drive module, and sequentially detect the operating status of the magnetic sensor, the motor of the drive module, and the communication module; Step 4, recording load feedback information of the motor of the driving module before starting, and determining whether the initial torque provided by the motor of the driving module meets the torque balance requirement of the magnetic flux leakage detection device in a suspended state; Step 5, controlling the driving wheel to move along the rope; Step 6: The magnetic sensor detects magnetic leakage in real time and uploads it to the control module. After being processed by the control module, it is uploaded to the host computer using the communication module; Step 7: the magnetic flux leakage detection device moves to the pipeline terminal and stops, the buckle mechanism is unlocked, and the magnetic flux leakage detection device is removed from the rope.

[0015] The present application provides a magnetic flux leakage detection device, which is integrated into a robot body through a drive module, a detection module, a control module, a communication module and a power supply module, and ultimately transmits the detection signal to a host computer. The host computer processes the defect signal, thereby realizing intelligent magnetic flux leakage detection, avoiding the disadvantages brought about by manual inspection, and improving the intelligence, accuracy and personal safety of the detection; through the combined use of friction wheels, drive wheels and elastic parts, the device can adaptively clamp ropes of different diameters, thereby improving the practicality and versatility of the device. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are merely embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without any creative work.

[0017] Figure 1 A schematic diagram of the structure of the robot body provided in this application; Figure 2 A schematic diagram of the structure of the detection module located in the middle housing provided by this application; Figure 3 for Figure 2 A structural diagram from another perspective; Figure 4 A schematic diagram of the structure of the drive module provided in this application; Figure 5 for Figure 4 A structural diagram from another perspective; Figure 6 This is a schematic diagram of the structure of the multi-yoke permanent magnet magnetization provided in this application.

[0018] exist Figures 1-6 middle: 1. Robot body; 11. Articulated mechanism; 12. Top shell; 13. Middle shell; 14. Bottom shell; 2. Driver module; 211, driving wheel; 212, first elastic member; 213, first position-limiting member; 214, first adapter; 215, first guide rail; 221, friction wheel; 222, second elastic member; 223, second position-limiting member; 224, second adapter; 225, second guide rail; 3. Detection module; 31. Magnetic component; 32. Bracket; 33. Magnetic sensor. DETAILED DESCRIPTION

[0019] This application provides a magnetic flux leakage detection device that applies a magnetic field to a pipeline and intelligently detects magnetic flux leakage to detect pipeline defects. This device is easy to operate, adapts to various rope diameters, and improves detection efficiency. Furthermore, this application provides a detection method applicable to the magnetic flux leakage detection device.

[0020] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0021] like Figures 1-6 As shown, the present application provides a magnetic flux leakage detection device, in which a rope is pre-arranged inside the pipeline and fixed at both ends of the pipeline. The device includes: a drive module 2, a detection module 3, a control module, a communication module, a power supply module and a robot body 1, and the drive module 2, the detection module 3, the control module, the communication module, and the power supply module are integrated in the robot body 1, so that the structure is compact and the device is small, which is conducive to the movement of the device in the pipeline and the suspension on the rope.

[0022] More specifically, the driving module 2 is used to drive the robot body 1 to move along the pipeline; the detection module 3 arranged in the robot body 1 applies an excitation magnetic field to the pipeline, and detects the leakage magnetic field caused by pipeline defects, generating a corresponding detection signal; the detection signal is transmitted to the control module, and the control module processes the received signal and preliminarily identifies the pipeline defect based on the signal characteristics; then, the communication module transmits the processed defect information to the host computer, and the host computer completes the precise positioning and marking of the defect position, realizing the online identification and spatial positioning of the pipeline defect; in this process, the power supply module provides working power for the driving module 2, the detection module 3, the control module, the communication module and other power-consuming units.

[0023] In this way, real-time online detection and real-time feedback of pipeline defects are achieved, significantly improving detection efficiency; the detection module 3 performs close-range detection directly inside the pipeline, with little environmental interference and a high signal-to-noise ratio; the control module performs localized preliminary identification of the detection signal, which can effectively filter out noise and interference signals, providing a high-quality data basis for the final judgment of the host computer, thereby improving the accuracy and reliability of defect identification; the preliminary identification results are transmitted to the host computer through the communication module, and the host computer, combined with the real-time displacement of the robot body, can perform high-precision spatial coordinate positioning of the defect position and perform intuitive visual marking in the software interface, facilitating subsequent maintenance, repair decisions and pipeline integrity assessment; the robot can replace manual labor to enter narrow, dangerous or inaccessible pipelines for inspection, reducing the labor intensity and safety risks of manual inspection while ensuring the objectivity and accuracy of the inspection data.

[0024] Among them, when the leakage magnetic detection device passes along the rope pre-placed in the pipeline, the rope contacts the friction wheel 221 and the driving wheel 211, and applies radial pressure to the friction wheel 221 and the driving wheel 211. The friction wheel 221 generates radial displacement through the second elastic member 222, and the driving wheel 211 generates radial displacement through the first elastic member 212 to adaptively clamp ropes of different diameters.

[0025] By doing so, firstly, adaptive clamping of ropes of different diameters is achieved, eliminating the need to replace dedicated clamping mechanisms for different ropes, thereby improving the practicality and versatility of the device; secondly, sufficient positive pressure can be maintained even when there are slight irregularities or vibrations in the rope, thereby ensuring effective and stable transmission of the driving force, preventing slippage, and ensuring that the leakage magnetic detection device can move smoothly and continuously along the rope, thus ensuring the continuity of the detection process and the integrity of the data; thirdly, the setting of the elastic member can absorb the impact and vibration from the rope, playing a buffering and vibration reduction role, which can protect the precision sensors and structures inside the detection device. It can not only protect the parts from damage, but also reduce the wear on the rope surface, and extend the service life of both; fourthly, the adaptive clamping magnetic flux leakage detection device is based on the mechanical deformation principle of the elastic part, with a simple structural design, no complicated sensing or control circuit, reliable working principle, low maintenance cost, and is particularly suitable for the confined space inside the pipeline; fifthly, the stable clamping and driving state ensures the uniformity of the running speed of the detection device on the rope, avoids the interruption or distortion of the detection signal due to slippage or jumping, thereby improving the stability and signal-to-noise ratio of the leakage magnetic detection signal, and providing a high-quality data basis for subsequent defect identification and positioning. It should be noted that the control module is a main control system based on the ESP32-WROOM chip, which integrates analog signal acquisition, motor control and data processing functions.

[0026] The power supply module includes: 24V lithium battery pack, step-down module, among which the power supply provides dual-channel stable voltage for the whole machine.

[0027] The communication module includes: a Bluetooth communication module and a Wi-Fi module.

[0028] Furthermore, the robot body 1 includes: a top shell 12, which is provided with a drive module 2; a middle shell 13, which is provided with a detection module 3 and is connected to the bottom of the top shell 12; a bottom shell 14, which is provided with a drive module 2 and is connected to the bottom of the middle shell 13; wherein, one of the top shell 12 and the bottom shell 14 is provided with a partition plate, and a control module, a power supply module and a communication module are provided on one side of the partition plate, and a drive module 2 is provided on the other side of the partition plate.

[0029] In the present application, the top shell 12 and the bottom shell 14 have the same shape, and the diameters of both are larger than the middle shell 13. This arrangement is convenient for storing the driving module 2, and can reduce the overall weight of the device, making it convenient for hanging and moving on the rope; one of the top shell 12 and the bottom shell 14 is provided with a flat plate, on which the driving module 2 is provided, and a cover is provided on the flat plate, and the other of the top shell 12 and the bottom shell 14 is provided with a partition plate, which divides the top shell 12 and the other of the bottom shell 14 in a columnar structure into two accommodating spaces, and the driving module 2 is provided on one side of the partition plate, and the control module, the power supply module and the communication module are provided on the other side of the partition plate.

[0030] In this way, not only the weight of the device is reduced, but also the compactness of the device is improved, and the utilization rate of the internal space of the device is improved.

[0031] In some optional embodiments, the robot body 1 is provided with a hinge mechanism 11 and a snap mechanism. The hinge mechanism 11 is used to pivotally open the robot body 1, and the snap mechanism is used to lock and close the robot body 1. The robot body 1 is provided with a hinge mechanism 11 and a snap mechanism. The hinge mechanism 11 is used to pivotally open the robot body 1, and the snap mechanism is used to lock and close the robot body 1. The hinge mechanism 11 can adopt a hinge, a rotating shaft, or other structures, but is not limited thereto.

[0032] Preferably, the robot body 1 is an annular columnar structure with a triangular notch defined along its circumference. This notch divides the robot body 1 into two parts, with the columnar structure's midline as the axis of symmetry. The two parts are connected by a hinge for opening and closing. This triangular notch not only makes the robot body 1 more compact and convenient, facilitating the opening and closing of the robot body 1, but also provides a convenient passage for routing external cables. When the robot is closed, its internal cavity forms an annular clamping space suitable for the cable, facilitating stable cable grip and actuation.

[0033] In an optional embodiment, the drive module 2 further includes a first guide rail 215 for guiding the extension and retraction of the first elastic member 212, and a second guide rail 225 for guiding the extension and retraction of the second elastic member 222. First, the guide rails (referring to the first guide rail 215 and the second guide rail 225) provide precise guidance and constraints for the radial compression and rebound movement of the first and second elastic members 212, 222, effectively preventing deflection, twisting, or jamming of the elastic members during force application, ensuring that the drive wheel 211 and the friction wheel 221 move smoothly along a predetermined radial path, thereby ensuring the reliability and repeatability of the clamping action. Second, the guide rails effectively limit the lateral deformation of the elastic members (referring to the first and second elastic members 212, 222), reducing additional stress and wear during operation, significantly lowering the risk of failure of the elastic members due to instability or fatigue, and thereby extending the service life and reliability of the entire drive module 2.

[0034] It should be noted that the first elastic member 212 and the second elastic member 222 are springs.

[0035] In an optional embodiment, the driving wheel 211 includes two relatively arranged first guide rails 215 that are partially sleeved on the first elastic member 212; the driving assembly also includes: a first limiting member 213, which is arranged on the top shell 12 and the bottom shell 14, and is arranged at one end away from the driving wheel 211; a first adapter 214, which is arranged on the top shell 12 and the bottom shell 14, and is arranged opposite to the first limiting member 213, and one end of the first adapter 214 is connected to the driving wheel 211, and the other end is connected to the first guide rail 215; wherein, the first elastic member 212 can be extended and retracted between the first limiting member 213 and the first adapter 214 under the guiding action of the first guide rail 215.

[0036] Driven by their corresponding first elastic members 212, the two opposing drive wheels 211 can synchronously and symmetrically produce radial displacement, thereby accommodating ropes of varying diameters and reliably clamping them. The provision of the first adapter 214 not only effectively transmits the driving force and elastic restoring force, but also adjusts the force transmission path, optimizing the spatial layout of the drive wheel 211 assembly within the robot body 1, reducing the structural footprint and improving integration.

[0037] The first guide rail 215 is configured as a hollow cylindrical structure, and the diameter of the hollow structure matches the diameter of the first elastic member 212 , so that the first elastic member 212 can smoothly extend and retract along the first guide rail 215 without bending.

[0038] In addition, the first guide rail 215 can also be a groove structure provided at the bottom of the first elastic member 212 , and the structure is connected to the first adapter 214 , that is, the first elastic member 212 is extended and retracted along the bottom of the groove structure.

[0039] In one example, the first transition member 214 is L-shaped, but the shape of the first transition member 214 is not limited to the L-shape.

[0040] In an optional embodiment, the friction wheel 221 includes two friction wheels 221 arranged opposite to each other, and the friction wheel 221 is provided with an encoder, which is used to collect the real-time position of the friction wheel 221, and the second guide rail 225 is partially sleeved on the second elastic member 222; the friction assembly also includes: a second limit member 223, which is arranged on the top shell 12 and the bottom shell 14, and is arranged at one end away from the friction wheel 221; a second adapter 224, which is arranged on the top shell 12 and the bottom shell 14, and is arranged opposite to the second limit member 223, and one end of the second adapter 224 is connected to the friction wheel 221, and the other end is connected to the second guide rail 225; wherein, the second elastic member 222 can be extended and retracted between the second limit member 223 and the second adapter 224 under the guiding action of the second guide rail 225.

[0041] Combined with the above description of the drive wheels 211, it can be understood that the rope is clamped by at least four pulleys, including two drive wheels 211 and two friction wheels 221, achieving multi-directional positioning of the rope. The friction wheels 221 are equipped with encoders that accurately record the number of revolutions of the friction wheels 221. Because the friction wheels 221 are in close contact with the rope surface and rotate with its relative motion, this rotation information can be directly converted into the real-time displacement of the robot along the rope, thereby achieving high-precision spatial positioning of pipeline defects.

[0042] The second adapter 224 has the same function and structure as the first adapter 214 and will not be further described here. Similarly, the second guide rail 225 has the same function and structure as the first guide rail 215 and will not be further described here. However, the first adapter 214 and the second adapter 224, as well as the first guide rail 215 and the second guide rail 225, are identical, which reduces the difficulty of manufacturing and maintenance of the device.

[0043] In an optional embodiment, the detection module 3 includes: a magnetic component 31, which is arranged in a ring inside the middle shell 13 and is used to apply a magnetic field to the pipeline; a bracket 32, which is U-shaped and arranged in a ring inside the magnetic component 31, and the opening of the bracket 32 ​​faces the magnetic component 31; a magnetic sensor 33, which is arranged at the bottom of the bracket 32 ​​opposite to the opening of the bracket 32, and is used to sense and collect leakage magnetic signals of the pipeline.

[0044] The magnetic component 31 is annular and is arranged in a ring inside the middle shell 13. It can apply a uniform and stable excitation magnetic field to the circumference of the pipeline to ensure that the area to be tested is fully magnetized. When there are defects in the pipeline, it can effectively generate a significant leakage magnetic field, laying the foundation for high-sensitivity detection; the U-shaped bracket 32 ​​cleverly arranges the magnetic sensor 33 in the inner space of the magnetic component 31, making full use of the central area of ​​the annular magnetized area, realizing a highly integrated and compact design of the core detection components, which is conducive to reducing the radial size of the robot body 1 and enhancing its passability in narrow pipelines; the magnetic sensor 33 is fixed by the bracket 32, and the structure is independent, which is convenient for disassembly and assembly and subsequent maintenance or replacement of sensors of different models, thereby improving the maintainability and flexibility of the detection module 3.

[0045] In addition, the magnetic component 31 can also be an excitation coil if required.

[0046] Preferably, the raw magnetic part 31 is composed of a plurality of permanent magnets and a plurality of magnetic conductive yokes, forming a multi-yoke structure with a symmetrical magnetic circuit. In this way, firstly, a uniform and stable circumferential magnetization field can be formed, avoiding local insufficient magnetization or oversaturation, and significantly improving the coverage and consistency of defect detection; secondly, the combination of multiple permanent magnets and yokes facilitates the flexible adjustment of the number of magnetic poles, the specifications of the permanent magnets, or the geometric shape of the yokes according to parameters such as the pipe material and wall thickness, thereby achieving an optimized design of the magnetic field strength and distribution, adapting to the detection requirements of different working conditions, and improving the versatility of the system; thirdly, through the collaborative work of multiple permanent magnets, a permanent magnet unit with moderate performance and low cost can be used to achieve an overall high magnetic field output, reducing the dependence on high-grade permanent magnet materials, which is conducive to controlling manufacturing costs.

[0047] In an optional embodiment, the magnetic sensor 33 includes a Hall sensor, which is distributed in an array on the bracket 32. The Hall sensor array can simultaneously perform multi-point synchronous detection at multiple locations along the circumference or axial direction of the pipeline, improving spatial resolution and significantly increasing the spatial sampling density of detection.

[0048] In addition, the present application also provides a detection method applicable to the above-mentioned magnetic flux leakage detection device, comprising: step 1, passing the magnetic flux leakage detection device through a rope, and using a snap mechanism to snap the magnetic flux leakage detection device onto the rope; Step 2: Ensure that the magnetic flux leakage detection device can be suspended on the rope in a stationary state, and start the encoder to collect the real-time position of the friction wheel 221 and the zero point value of the magnetic sensor 33; Step 3: Turn on the power supply module, communication module, control module, detection module 3 and drive module 2, and detect the operating status of the magnetic sensor 33, the motor of the drive module 2 and the communication module in sequence.

[0049] Step 4: Record the load feedback information of the motor of the driving module 2 before starting, and determine whether the initial torque provided by the motor meets the torque balance requirement of the magnetic flux leakage detection device in the suspended state; Step 5, controlling the driving wheel 211 to move along the rope; Step 6: The magnetic sensor 33 detects magnetic leakage in real time and uploads it to the control module. After being processed by the control module, it is uploaded to the host computer using the communication module; Step 7: The magnetic flux leakage detection device moves to the pipeline terminal and stops, the buckle mechanism is released, and the magnetic flux leakage detection device is removed from the rope.

[0050] In a preferred embodiment of the present invention, the through-type permanent magnetizer has the following structural dimensions: a 50 mm diameter, 25 mm thickness, and 35 mm length of the ring magnet, with an armature length of 60 mm. Simulations using Ansys Maxwell software demonstrate that the peak flux leakage at defects in this structure can reach 50 mT, meeting the 10⁻³ T defect detection sensitivity requirement.

[0051] The control program was developed based on the Arduino IDE. The main control code calls the behavior control function, selects "forward," "backward," or "stationary" according to the host computer's instructions, and controls the motor speed by adjusting the output voltage through PWM pulses. Hall effect data is read through the GPIO interface and sent to the Bluetooth or Wi-Fi module for transmission via a timed interrupt.

[0052] Step 1: Complete the assembly of the magnetic flux leakage detection device modules and inspect each component individually for secure installation, ensuring there is no looseness or interference. Run a prefabricated rope through the pipeline and secure both ends. Place the assembled magnetic flux leakage detection device inside the magnetic cast iron pipeline to be inspected, with the central drive module 2 positioned over the prefabricated rope. Using a snap mechanism and auxiliary magnets (installed on the snap mechanism to enhance magnetic engagement), secure the magnetic flux leakage detection device to the prefabricated rope attached to the inner wall of the pipeline.

[0053] Step 2: After simulation verification using Adams software, ensure that the positive pressure provided by the elastic members (referring to the first elastic member 212 and the second elastic member 222) can meet the static friction requirements, thereby enabling the magnetic flux leakage detection device to be stably suspended on the rope in a stationary state. Subsequently, the encoder is started to collect the initial wheel position of the friction wheel 221 and the zero point value of the Hall sensor, and the initial calibration of the system is completed.

[0054] Step 3: Power on the MFD device, start the ESP32 microcontroller, and enter the software control interface. Check the operating status of the Hall effect sensor, motor, and communication module in sequence. After confirming that each module is responding normally, initialize the motor and encoder, ensure the MFD device is in a controlled static state, and check for force balance under static conditions to avoid unbalanced loading and drift errors during the test.

[0055] Step 4: In the stationary state, open the Arduino IDE's serial port monitor to record the load feedback information before the motor starts. Determine whether the initial torque provided by the motor meets the torque balance requirements in the suspended state, ensuring that the magnetic flux leakage detection device can standby stably without slipping or unexpected movement.

[0056] In step 5, after completing all preparatory steps, the control module controls the magnetic flux leakage detection device to execute the inspection path planning instructions. The drive wheel 211 moves forward in the pipeline at a steady speed of 0.1 to 0.15 m / s according to the control signal. The encoder records the number of motor revolutions in real time and converts it into linear displacement, enabling real-time positioning along the inspection path. The control module associates the defect points with the displacement information to mark the spatial coordinates of the inspection area.

[0057] During step 6, the magnetic flux leakage detection device operates, with the permanent magnetizer continuously applying a stable magnetic field to the inner wall of the pipeline. If the pipeline contains defects such as corrosion, dents, or cracks, the local magnetic permeability changes, obstructing the magnetic flux path and generating leakage magnetic flux. An array of A1324 linear Hall effect sensors positioned circumferentially around the detection area senses these changes in the leakage magnetic field in real time and converts the induction intensity into an analog voltage signal ranging from 0 to 3.3V, with 1.5V being the reference voltage for an uninterrupted magnetic field. The system reads the signal into the ESP32 microcontroller's memory buffer with a sampling period of 5 ms. After internal digital filtering and preliminary identification, the processed data packets are uploaded to the host computer system in real time via Bluetooth or Wi-Fi. The system automatically marks suspected defect data points, completing online defect identification and spatial location.

[0058] In step 7, the MFL device completes the set detection path and reaches the end of the pipeline. The detection program automatically stops the motor drive. The operator removes the MFL device from the pipeline by unfastening the buckle and performs a visual and functional inspection of the device. Any worn, loose components or abnormal signals should be promptly replaced or maintained to ensure stability during the next test.

[0059] In step 8, after the inspection is complete, the uploaded defect signal is analyzed offline using the accompanying host computer system. Based on information such as the magnitude of the magnetic flux leakage signal, waveform characteristics, and amplitude gradient, the host computer system determines the defect's location, type (corrosion, wear, cracks, etc.), and severity. It then generates a structured inspection report, completing a complete closed-loop inspection process.

[0060] The basic principles of the present application have been described above in conjunction with specific embodiments. However, it should be noted that the advantages, strengths, and effects mentioned in this application are merely illustrative and not restrictive, and it should not be assumed that these advantages, strengths, and effects are required of each embodiment of this application. In addition, the specific details disclosed above are merely illustrative and facilitating understanding, and are not restrictive. The above details do not limit this application to necessarily being implemented using the above specific details.

[0061] The block diagrams of the devices, devices, equipment, and systems involved in this application are merely illustrative examples and are not intended to require or imply that they must be connected, arranged, or configured in the manner shown in the block diagrams. As will be appreciated by those skilled in the art, these devices, devices, equipment, and systems can be connected, arranged, or configured in any manner. Words such as "include," "comprise," "have," and the like are open-ended words, meaning "including but not limited to," and can be used interchangeably therewith. The words "or" and "and" used herein refer to the words "and / or" and can be used interchangeably therewith, unless the context clearly indicates otherwise. The word "such as" used herein refers to the phrase "such as but not limited to," and can be used interchangeably therewith.

[0062] It should also be noted that in the devices, equipment, and housing of the present application, each component or each step can be decomposed and / or reassembled. Such decomposition and / or reassembly should be regarded as equivalent solutions of the present application.

[0063] The above description of the disclosed aspects is provided to enable any person skilled in the art to make or use the present application. Various modifications to these aspects will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other aspects without departing from the scope of the present application. Therefore, the present application is not intended to be limited to the aspects shown herein, but rather to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0064] It should be understood that the qualifiers "first", "second", "third", "fourth", "fifth" and "sixth" used in the description of the embodiments of the present application are only used to more clearly illustrate the technical solutions and cannot be used to limit the scope of protection of the present application.

[0065] The above description has been provided for the purpose of illustration and description. Furthermore, this description is not intended to limit the embodiments of the present application to the forms disclosed herein. Although a number of example aspects and embodiments have been discussed above, those skilled in the art will recognize certain variations, modifications, alterations, additions, and sub-combinations thereof.

Claims

1. A magnetic flux leakage detection device, characterized in that: A rope is passed through the interior of the pipe and fixed at both ends of the pipe. The magnetic flux leakage detection device includes: a robot body, configured to move along the rope inside the pipeline; a drive module, disposed within the robot body and configured to drive the movement of the robot body, the drive module comprising at least a drive assembly and a friction assembly, the drive assembly comprising at least a drive wheel and a first elastic member, the friction assembly comprising at least a friction wheel and a second elastic member, the drive wheel being configured to move along the rope, and the friction wheel moving along the rope driven by the drive wheel; a detection module, disposed in the robot body, and configured to apply a magnetic field to the pipeline, detect magnetic flux leakage in the pipeline, and output a signal; a control module, disposed in the robot body and configured to receive the signal output by the detection module, control the movement of the robot body in real time, and perform preliminary defect identification on the signal output by the detection module; a communication module, disposed in the robot body and used to transmit the signal processed by the control module; A host computer, used to receive the signal transmitted by the communication module and process the signal; a power supply module, disposed in the robot body and used to provide working power to the driving module, the detection module, the control module and the communication module; When the magnetic flux leakage detection device passes along the rope pre-placed in the pipeline, the rope contacts the friction wheel and the drive wheel and applies radial pressure to the friction wheel and the drive wheel. The friction wheel generates radial displacement through the second elastic member, and the drive wheel generates radial displacement through the first elastic member to adaptively clamp the ropes of different diameters.

2. The magnetic flux leakage detection device according to claim 1, characterized in that: The robot body comprises: The top shell is provided with the driving module; A middle shell is provided with the detection module and is connected to the bottom of the top shell; A bottom shell is provided with the driving module and is connected to the bottom of the middle shell; Wherein, one of the top shell and the bottom shell is provided with a partition plate, the control module, the power supply module and the communication module are provided on one side of the partition plate, and the driving module is provided on the other side of the partition plate.

3. The magnetic flux leakage detection device according to claim 2, characterized in that: The robot body is provided with an articulation mechanism and a buckle mechanism, wherein the articulation mechanism is used to realize the pivoting opening of the robot body, and the buckle mechanism is used to realize the locking closure of the robot body.

4. The magnetic flux leakage detection device according to claim 2, characterized in that: The driving module further includes a first guide rail for guiding the first elastic member to extend and retract, and a second guide rail for guiding the second elastic member to extend and retract.

5. The magnetic flux leakage detection device according to claim 4, characterized in that: The driving wheels include at least two oppositely disposed ones, and the first guide rail is partially sleeved on the first elastic member; The drive assembly further includes: A first limiting member is provided on the top shell and the bottom shell and is provided at an end away from the driving wheel; a first adapter, disposed on the top shell and the bottom shell and arranged opposite to the first limiting member, with one end of the first adapter connected to the driving wheel and the other end connected to the first guide rail; Wherein, the first elastic member can be extended and retracted between the first limiting member and the first adapter member under the guidance of the first guide rail.

6. The magnetic flux leakage detection device according to claim 5, characterized in that: The friction wheels include at least two oppositely disposed friction wheels, each of which is provided with an encoder for collecting the real-time position of the friction wheel. The second guide rail is partially sleeved on the second elastic member. The friction assembly further comprises: A second limiting member is provided on the top shell and the bottom shell and is provided at an end away from the friction wheel; a second adapter, disposed on the top shell and the bottom shell and arranged opposite to the second limiting member, with one end of the second adapter being connected to the friction wheel and the other end being connected to the second guide rail; Wherein, the second elastic member can be extended and retracted between the second limiting member and the second adapter member under the guidance of the second guide rail.

7. The magnetic flux leakage detection device according to claim 2, characterized in that: The detection module includes: A magnetic element, which is arranged in a ring inside the middle shell and is used to apply a magnetic field to the pipeline; The bracket is U-shaped and is arranged in a ring inside the magnetic component, with the opening of the bracket facing the magnetic component; The magnetic sensor is arranged at the bottom of the bracket opposite to the opening of the bracket and is used to sense and collect the leakage magnetic signal of the pipeline.

8. The magnetic flux leakage detection device according to claim 7, characterized in that: The magnetic generating part is composed of a plurality of permanent magnets and a plurality of magnetic conductive yokes, forming a multi-yoke structure with a symmetrical magnetic circuit.

9. The magnetic flux leakage detection device according to claim 7, characterized in that: The magnetic sensors include Hall sensors, and the Hall sensors are distributed on the bracket in an array form.

10. A magnetic flux leakage detection method, characterized in that: The magnetic flux leakage detection device according to any one of claims 1 to 9 above comprises: Step 1: The magnetic flux leakage detection device is passed through the rope, and the magnetic flux leakage detection device is fastened to the rope using a snap mechanism; Step 2: ensuring that the magnetic flux leakage detection device can be suspended on the rope in a stationary state, and starting the encoder to collect the real-time position of the friction wheel and the zero point value of the magnetic sensor; Step 3: Turn on the power supply module, the communication module, the control module, the detection module, and the drive module, and sequentially detect the operating status of the magnetic sensor, the motor of the drive module, and the communication module; Step 4, recording load feedback information of the motor of the driving module before starting, and determining whether the initial torque provided by the motor of the driving module meets the torque balance requirement of the magnetic flux leakage detection device in a suspended state; Step 5, controlling the driving wheel to move along the rope; Step 6: The magnetic sensor detects magnetic leakage in real time and uploads it to the control module. After being processed by the control module, it is uploaded to the host computer using the communication module; Step 7: the magnetic flux leakage detection device moves to the pipeline terminal and stops, the buckle mechanism is unlocked, and the magnetic flux leakage detection device is removed from the rope.

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