A kind of pressure equipment crack detection instrument and detection method based on vortex technology

Abstract

The application relates to the technical field of crack detection, in particular to a pressure-bearing equipment crack detection instrument and method based on eddy current technology, which comprises a pulse eddy current detector main body, a frame plate, a bearing plate and a mounting seat. One side of the pulse eddy current detector main body is provided with a connecting line, one end of the connecting line is connected with a detection probe, the left and right sides of the frame plate are both fixed with supporting blocks, and the side of the supporting block is bonded with an antiskid rubber pad. The mounting seat, spring, damping rubber block and L-shaped adjusting support and other structures are cooperated to reduce the fluctuation limit of the distance between the detection probe and the surface of the pressure-bearing equipment, compared with the traditional instrument, the distance is greatly changed due to the irregular surface, the instrument can effectively avoid the interference of the distance fluctuation on the eddy current signal collection, improve the crack detection precision, and solve the problems of missed detection and false detection caused by the unstable distance of the traditional equipment.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of crack detection, in particular to a pressure equipment crack detection instrument and method based on eddy current technology. BACKGROUND

[0002] In the manufacturing and maintenance process of pressure equipment, crack detection is a crucial safety measure. Eddy current detection technology is a commonly used non-destructive testing method that detects cracks and defects by detecting eddy currents generated on the surface of the material. However, traditional eddy current detection instruments have some technical problems in the process of use.

[0003] Traditional eddy current detection instruments usually require the probe to maintain a certain distance from the surface of the pressure equipment and maintain uniform motion during the detection process. This requirement is difficult to achieve in actual operation, especially when the surface of the pressure equipment is uneven or has welding lines, the distance between the probe and the surface is difficult to maintain uniform, thereby affecting the accuracy of the detection. In addition, the existing eddy current detection technology also has certain limitations in identifying and quantifying cracks.

[0004] In order to improve the accuracy and efficiency of detection, a new type of eddy current detection instrument and detection method is needed in the market, which can adapt to the irregularity of the surface of the pressure equipment and maintain the distance between the probe and the surface unchanged, while realizing uniform motion. In particular, for the detection method based on eddy current technology, further technical innovation is needed to improve its applicability in complex environments.

[0005] Pulsed eddy current detectors are a more advanced detection device that excites eddy currents by sending pulse signals and analyzes the returned signals to detect defects in materials. However, even this advanced device faces the challenge of accurate detection on the surface of pressure equipment, therefore, we propose a pressure equipment crack detection instrument and method based on eddy current technology. SUMMARY

[0006] The purpose of the present application is to provide a pressure equipment crack detection instrument and method based on eddy current technology, which has the advantage of effectively dealing with complex situations such as uneven surfaces or welding lines of pressure equipment, and solves the problem of crack detection.

[0007] To achieve the above purpose, the present application provides the following technical scheme: a pressure equipment crack detection instrument and method based on eddy current technology, comprising:

[0008] Pulsed eddy current detector main body, frame plate, bearing plate and adjustable mounting seat;

[0009] Wherein, one side of the pulsed eddy current detector main body is provided with a connecting line, one end of the connecting line is connected with a detection probe;

[0010] Wherein, the left and right sides of the frame plate are fixed with support blocks, one side of the support block is bonded with a non-slip rubber pad, the middle end of the back side of the frame plate is installed with a battery, the top and bottom of the inner side of the frame plate are provided with guide grooves, the left and right ends of the back side of the frame plate are installed with handles, and the top of the handle is installed with a control button.

[0011] Wherein, the front of the bearing plate is provided with a recess, the bottom of the inner side of the frame plate is fixed with a toothed plate, the back of the bearing plate is installed with a drive motor, the output end of the drive motor is installed with a drive gear, and the drive gear is engaged with the toothed plate. The technical scheme has the following advantages:

[0012] 1. Realize uniform and stable movement: the bearing plate is matched with the frame plate through the guide groove, combined with the meshing transmission of the drive motor, toothed plate and drive gear, and cooperated with the sliding resistance reduction of the resistance reduction ball, the movement of the bearing plate and the detection probe is more stable and uniform, and the continuity and consistency of signal acquisition are ensured.

[0013] 2. Convenient operation and maintenance: the handle and control button are designed for handheld operation, the battery power supply is free from cable constraints, and the modular design of each component facilitates the disassembly, debugging and later maintenance of the detection probe, thereby reducing the use and operation cost.

[0014] Preferably, the mounting seat is a U-shaped structure, the two ends of the back side of the mounting seat are fixed with guide rods, the guide rods pass through the recess and slide on the inner surface of the bearing plate, the rear end of the guide rod is fixed with a damping rubber block, one side of the damping rubber block is in contact with the inner wall of the frame plate, the outer surface of the guide rod is sleeved with a spring, and the two ends of the spring are respectively fixed with the inner wall of the recess and the back side of the mounting seat, the top and bottom of the mounting seat are provided with L-shaped adjusting supports, the inner surface of the L-shaped adjusting support is threadedly connected with an adjusting screw, one side of the adjusting screw is movably connected with a guide joint through a bearing, and one end of the guide joint is provided with a contact ball. The technical scheme has the following advantages:

[0015] 1. Improve the stability of the distance: through the synergistic effect of the mounting seat, spring and damping rubber block, the vibration is effectively buffered, the distance between the detection probe and the surface of the pressure-bearing equipment is controlled in a very low range, the interference of the traditional instrument caused by the large change of the distance due to the irregular surface on the signal acquisition of the eddy current is avoided, the crack detection accuracy is significantly improved, and the problem of missed detection and false detection is solved.

[0016] 2. Self-adapt to complex surface: the non-slip rubber pad is attached to the surface of the equipment to enhance the stability, when encountering a protrusion, the mounting seat slides along the guide rod, the spring is compressed, and the contact ball rolls, which can adapt to complex conditions such as surface concave-convex or welding lines, and expand the application range of the instrument on irregular surfaces.

[0017] Preferably, the number of operation buttons is two, and the two operation buttons are electrically connected with the access end of the forward and reverse rotation of the driving motor. The driving motor is a direct current servo motor with a rated voltage of 12-24V and a rated power of 50-100W, and is equipped with an overload protection module with an overload threshold of 1.5 times the rated power. The technical scheme has the advantages of:

[0018] 1. Precise control of moving direction: two operation buttons control the forward and reverse rotation of the driving motor, realizing the reciprocating movement of the bearing plate and meeting the needs of different detection paths, and the operation is intuitive and convenient.

[0019] 2. Ensure driving stability and safety: The direct current servo motor has stable output and is suitable for battery power supply; the overload protection module can trigger protection when the power exceeds 1.5 times the rated value, preventing the motor from being damaged due to excessive load, prolonging the service life of the equipment, and improving the safety of the detection process.

[0020] Preferably, the upper and lower ends of the bearing plate slide on the inner side of the guide groove, and the top and bottom of the bearing plate are provided with resistance-reducing balls, and the resistance-reducing balls are in contact with the inner wall of the guide groove. The technical scheme has the advantages of:

[0021] 1. Reduce sliding resistance: The resistance-reducing balls are in contact with the inner wall of the guide groove, converting sliding friction into rolling friction, greatly reducing the resistance when the bearing plate moves, making the movement smoother.

[0022] 2. Improve the stability of movement: The guide groove restricts the sliding direction of the bearing plate, and the resistance-reducing balls reduce the resistance, ensuring the stable movement of the bearing plate along a straight line, avoiding deviation or jamming, and ensuring the consistency of the motion trail of the detection probe.

[0023] Preferably, the left and right sides of the bearing plate are provided with fixed frames, and the inner side of one end of the fixed frame is provided with an exhaust fan. The technical scheme has the advantages of:

[0024] 1. Real-time heat dissipation: The exhaust fan can run synchronously during detection to dissipate heat in the detection area (especially the area where the equipment surface contacts the probe), avoiding the influence of local high temperature caused by long-time detection on the stability of eddy current signal or the performance of the equipment.

[0025] 2. Adapt to long-time work: The detection environment temperature is maintained stable by continuous heat dissipation, ensuring the reliability of the instrument under continuous detection conditions and improving the detection efficiency.

[0026] Preferably, one side of the guide joint is fixed with a limiting guide, and the limiting guide slides on the inner surface of the L-shaped adjusting bracket, and the surface of the limiting guide is provided with scale lines. The technical scheme has the advantages of:

[0027] 1. Guarantee the adjustment stability: The limiting guide restricts the movement direction of the guide joint, avoiding the deviation of the guide joint when the adjusting screw rotates, ensuring the accuracy of the position adjustment of the contact ball.

[0028] 2. Improve the debugging accuracy: The scale line can intuitively display the adjustment amount, assisting the operator to control the parallelism between the detection probe and the pressure-bearing equipment detection surface, so that the adjustment error is ≤0.5mm, laying a foundation for the accuracy of subsequent signal acquisition.

[0029] Preferably, the anti-slip rubber pad is made of nitrile rubber material, and the surface is provided with anti-slip texture, and the thickness is 2-5mm. The technical scheme has the advantages of:

[0030] 1. Enhance the stability of fitting: Nitrile rubber has good elasticity and wear resistance, and the anti-slip texture can increase the friction with the surface of the equipment, and cooperate with the thickness design of 2-5mm, to ensure that the frame plate is tightly fitted to the surface of the pressure-bearing equipment, preventing the distance fluctuation caused by sliding during detection.

[0031] 2. Adapt to complex surface: The elasticity of the rubber material can adapt to the slight concave-convex of the equipment surface, improve the fitting degree of the frame plate and the surface, and indirectly ensure the stability of the detection probe.

[0032] Preferably, the exhaust fan is an axial flow fan, the air volume is 50-100m³ / h, and the wire is connected with the storage battery through a lead wire, and the lead wire is wrapped with a fireproof insulating sleeve. The technical scheme has the advantages of:

[0033] 1. High efficiency of heat dissipation: The air volume of the axial flow fan (50-100m³ / h) is suitable for the heat dissipation demand of the detection area, which can quickly take away the heat and avoid the influence of high temperature on the detection accuracy.

[0034] 2. Improve the electrical safety: The lead wire is wrapped with a fireproof insulating sleeve, which can prevent the lead wire from being worn or short-circuited, and adapt to the complex environment (such as oil stains and dust) that may exist in the detection site, reducing the risk of electrical failure.

[0035] Preferably, the damping rubber block is made of polyurethane elastomer material, the Shore hardness is 60-80A, the thickness is 5-10mm, and the surface is provided with a micro-recess structure, and the micro-hole diameter is 0.1-0.3mm. The technical scheme has the advantages of:

[0036] 1. High-efficiency vibration absorption and buffering: The polyurethane elastomer cooperates with the hardness of 60-80A and the thickness of 5-10mm, which can effectively absorb the vibration energy in the detection process; the surface micro-recess structure further enhances the buffering performance, reducing the influence of vibration on the mounting seat and the detection probe.

[0037] 2. Guarantee the stability of the distance: by absorbing vibration, combining the elastic effect of the spring, further control the fluctuation of the distance between the detection probe and the surface of the equipment ≤0.2mm, improve the stability of signal acquisition.

[0038] A detection method of an instrument, comprising the following steps:

[0039] S1. Equipment debugging: install the detection probe on the mounting seat, adjust the position of the contact ball through the adjusting screw of the L-shaped adjusting support, make the detection probe parallel to the detection surface of the pressure-bearing equipment, control the adjustment accuracy by the scale line of the limiting guide, the error ≤0.5mm;

[0040] S2. Detection preparation: hold the handle, attach the frame plate to the surface of the pressure-bearing equipment through the anti-skid rubber pad, control the button to start the drive motor, drive the gear along the toothed plate to mesh transmission, the carrier plate slides along the guide groove, the resistance-reducing ball reduces the sliding resistance, the exhaust fan operates synchronously, the wind speed ≥2m / s, heat dissipation for the detection area;

[0041] S3. Signal acquisition: the drive motor controls the carrier plate to move back and forth, the moving speed is 0.5-2m / min, the detection probe moves with the mounting seat, the spring and the damping rubber block buffer vibration, guarantee the stability of the distance between the detection probe and the surface of the pressure-bearing equipment, the fluctuation of the distance ≤0.2mm, the pulse eddy current detector main body collects the eddy current signal;

[0042] S4. Data analysis: after the detection is completed, the pulse eddy current detector main body processes the signal, identifies the crack through the crack characteristic algorithm, and generates a detection report containing the crack position, depth and length;

[0043] S5. Equipment storage: turn off the drive motor and the exhaust fan, disassemble the detection probe, reset the carrier plate to one end of the frame plate, use the remaining battery capacity to charge the equipment, the charging time is 2-4h, after the charging is completed, store it properly.

[0044] Each step of the detection method has the following technical advantages:

[0045] S1. Equipment debugging

[0046] Guarantee the accuracy of the initial position: adjust the position of the contact ball through the adjusting screw of the L-shaped adjusting support, control the adjustment accuracy (error ≤0.5mm) combined with the scale line of the limiting guide, ensure that the detection probe is parallel to the detection surface of the pressure-bearing equipment, lay the foundation for the accuracy of subsequent signal acquisition, avoid the distortion of eddy current signal caused by the initial inclination of the probe.

[0047] Standardized debugging process: clear adjustment method and accuracy requirement, reduce the influence of human operation difference on the initial state of the equipment, improve the consistency and reliability of detection.

[0048] S2. Detection preparation

[0049] Ensure stable fitting of equipment: The frame plate is attached to the surface of the pressure-bearing equipment by the non-slip rubber pad through the handheld handle. The butyl rubber material and non-slip texture of the non-slip rubber pad enhance the friction, preventing the frame plate from sliding during detection and ensuring the relative stability of the overall equipment and the detection surface.

[0050] Achieve smooth driving and heat dissipation: After starting the driving motor, the driving gear engages with the gear plate for transmission, and the guiding groove and the role of the resistance-reducing ball make the sliding resistance of the bearing plate small and the movement smooth. The exhaust fan operates synchronously (wind speed ≥ 2 m / s) to dissipate heat in real time in the detection area, avoiding the influence of local high temperature caused by long-time detection on the stability of eddy current signals or equipment performance.

[0051] Convenient operation: The device is started and driven by the handle and control buttons, which is intuitive and simple to operate, reducing the use threshold of the operator.

[0052] S3. Signal acquisition

[0053] Ensure uniform and stable movement: The driving motor controls the reciprocating movement of the bearing plate (speed 0.5-2 m / min) in combination with the guiding groove and the guiding and resistance-reducing effect of the resistance-reducing ball, ensuring stable movement trajectory and uniform speed of the detection probe, avoiding inconsistent signal acquisition intervals caused by unstable movement.

[0054] Precise control of distance fluctuation: The spring and damping rubber block cooperate to buffer vibration. When the detection probe encounters a surface protrusion, the mounting seat slides along the guide rod to compress the spring, contact the ball to roll and contact the protrusion, and cooperate with the damping rubber block to absorb vibration energy, strictly controlling the distance fluctuation between the detection probe and the equipment surface ≤0.2 mm, effectively avoiding the interference of distance change on eddy current signal acquisition, greatly improving the accuracy of crack detection, and solving the problems of missed detection and false detection caused by unstable distance in traditional equipment.

[0055] Comprehensive coverage of the detection area: The reciprocating movement of the bearing plate enables the detection probe to fully scan the area to be detected, ensuring no dead angle in signal acquisition and improving the integrity of detection.

[0056] S4. Data analysis

[0057] Automatic crack identification and quantification: The main body of the pulse eddy current detector processes the collected eddy current signals, automatically identifies cracks through crack feature algorithms, and generates a detection report containing crack location, depth, and length. Compared with traditional manual analysis, it is more efficient and accurate, reducing human judgment errors.

[0058] Provide reliable decision basis: Quantitative crack parameters provide scientific data support for the maintenance and safety evaluation of pressure-bearing equipment, helping technicians quickly judge the equipment status and develop reasonable repair or replacement plans.

[0059] S5. Equipment storage

[0060] Protect the service life of the equipment: disassemble the detection probe and reset the bearing plate after turning off the equipment to avoid long-term stress on the components; use the remaining battery power to charge (2-4 hours), and a standardized charging process helps to extend the service life of the battery and ensure sufficient power for the next detection.

[0061] Convenient equipment management and maintenance: uniform storage steps allow orderly storage of equipment components, reducing the risk of loss or damage, while providing convenience for subsequent equipment debugging and maintenance, reducing operation and maintenance costs.

[0062] Preferably, in step S3, when the detection probe encounters a protrusion on the surface of the pressure-bearing equipment, the mounting seat slides along the guide rod to compress the spring, the contact ball rolls in contact with the protrusion, the detection probe distance fluctuation is guaranteed to be ≤0.2mm, and the damping rubber block absorbs vibration energy to avoid vibration affecting the detection data. The technical scheme has the following advantages:

[0063] 1. Self-adapting to surface protrusions: when the detection probe encounters a protrusion, the mounting seat slides along the guide rod, the spring is compressed to buffer, and the contact ball rolls to reduce friction, which can adapt to irregular surfaces (such as weld lines and protrusions) and avoid direct collision between the probe and the surface.

[0064] 2. Strictly control the fluctuation of the distance: through the synergistic effect of the mechanical structure, it is ensured that even in the protrusion area, the fluctuation of the distance between the detection probe and the surface of the equipment is still ≤0.2mm, which avoids signal interference caused by surface defects and improves the detection accuracy in complex working conditions.

[0065] Compared with the prior art, the present application has the following advantages:

[0066] 1. The present application cooperates with the mounting seat, spring, damping rubber block, and L-shaped adjusting bracket to reduce the fluctuation limit of the distance between the detection probe and the surface of the pressure-bearing equipment. Compared with traditional instruments, which have a large fluctuation in distance due to irregular surfaces, the present instrument can effectively avoid the interference of distance fluctuation on eddy current signal collection, improve crack detection accuracy, and solve the problems of missed detection and false detection caused by unstable distance in traditional equipment.

[0067] 2. The present application cooperates with the guide groove between the bearing plate and the frame plate, the driving motor, the gear plate, and the driving gear to make the sliding resistance of the bearing plate small and move at a uniform speed.

[0068] 3. The present application cooperates with the mounting seat, spring, and contact ball to buffer vibration and adapt to irregular surfaces when encountering protrusions. Whether the surface of the equipment has weld lines or protrusions, the probe can work stably, expanding the application range of the instrument in complex working conditions.

[0069] 4. The application is convenient to hold and operate by designing handle and control button, and is convenient to charge by battery power supply, and is convenient to detect and maintain by modular design of each component. BRIEF DESCRIPTION OF DRAWINGS

[0070] Figure 1 is a first perspective structural schematic view of the application;

[0071] Figure 2 is a second perspective structural schematic view of the application;

[0072] Figure 3 is a sectional structural schematic view of the frame plate of the application;

[0073] Figure 4 is a cooperation structural schematic view of the bearing plate and the driving motor of the application;

[0074] Figure 5 is another perspective structural schematic view of the application; Figure 4

[0075] Figure 6 is an unfolded structural schematic view of the application; Figure 5

[0076] Figure 7 is a cooperation structural schematic view of the bearing plate and the fixing frame of the application;

[0077] Figure 8 is a structural mounting seat schematic view of the application.

[0078] In the figure: 1, pulse eddy current detector main body; 101, connecting line; 102, detection probe; 2, frame plate; 201, support block; 202, anti-skid rubber pad; 203, battery; 204, guide groove; 3, handle; 301, control button; 4, bearing plate; 401, fixing frame; 402, resistance-reducing ball; 403, recess; 404, exhaust fan; 5, driving motor; 501, toothed plate; 502, driving gear; 6, mounting seat; 601, L-shaped adjusting support; 602, adjusting screw; 603, spring; 604, guide rod; 605, damping rubber block; 606, limiting guide; 607, contact ball; 608, guide joint. DETAILED DESCRIPTION

[0079] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the application.​​

[0080] The pulse eddy current detector main body 1, the connecting line 101, the detection probe 102, the frame plate 2, the support block 201, the anti-skid rubber pad 202, the storage battery 203, the guide groove 204, the handle 3, the control button 301, the bearing plate 4, the fixing frame 401, the resistance-reducing ball 402, the recess 403, the exhaust fan 404, the driving motor 5, the toothed plate 501, the driving gear 502, the mounting seat 6, the L-shaped adjusting support 601, the adjusting screw 602, the spring 603, the guide rod 604, the damping rubber block 605, the limiting guide 606, the contact ball 607 and the guide joint 608 parts of the present application are all general standard parts or parts known to those skilled in the art, and their structure and principle can be known by technical personnel through technical manual or through conventional experimental method. EMBODIMENT

[0081] Please refer to Figures 1-8 The present application provides a technical solution: a pressure-bearing equipment crack detection instrument and method based on eddy current technology, comprising:

[0082] The pulse eddy current detector main body 1, the frame plate 2, the bearing plate 4 and the adjustable mounting seat 6;

[0083] One side of the pulse eddy current detector main body 1 is provided with a connecting line 101, and one end of the connecting line 101 is connected with a detection probe 102;

[0084] The left and right sides of the frame plate 2 are both fixed with support blocks 201, one side of the support block 201 is bonded with an anti-skid rubber pad 202, the middle end of the rear side of the frame plate 2 is installed with a storage battery 203, the top and bottom of the inner side of the frame plate 2 are both provided with guide grooves 204, and the left and right ends of the rear side of the frame plate 2 are both installed with handles 3, and the top of the handle 3 is installed with control buttons 301;

[0085] The front of the bearing plate 4 is provided with recesses 403, one end of the bottom of the inner side of the frame plate 2 is fixed with a toothed plate 501, the rear side of the bearing plate 4 is installed with a driving motor 5, the output end of the driving motor 5 is installed with a driving gear 502, and the driving gear 502 is engaged with the toothed plate 501;

[0086] The mounting seat 6 is a U-shaped structure, both ends of the rear side of the mounting seat 6 are fixed with guide rods 604, the guide rods 604 pass through the recessed holes 403 and slide on the inner surface of the bearing plate 4, the rear end of the guide rod 604 is fixed with a damping rubber block 605, and one side of the damping rubber block 605 is in contact with the inner wall of the frame plate 2, the outer surface of the guide rod 604 is sleeved with a spring 603, and both ends of the spring 603 are fixed with the inner wall of the recessed hole 403 and the rear side of the mounting seat 6 respectively, the top and the bottom of the mounting seat 6 are provided with L-shaped adjusting supports 601, the inner surface of the L-shaped adjusting support 601 is threadedly connected with an adjusting screw 602, one side of the adjusting screw 602 is movably connected with a guide joint 608 through a bearing, and one end of the guide joint 608 is provided with a contact ball 607. The spring 603 and the damping rubber block 605 cooperate to buffer vibration, so that the distance between the detection probe 102 and the surface of the pressure-bearing equipment is ≤0.2mm.

[0087] The number of control buttons 301 is two, and the two control buttons 301 are electrically connected with the access end of the forward and reverse rotation of the driving motor 5. The driving motor 5 is a direct current servo motor, the rated voltage is 12-24V, the rated power is 50-100W, and an overload protection module is provided, and the overload threshold is 1.5 times of the rated power. The upper and lower ends of the bearing plate 4 slide on the inner side of the guide groove 204, the top and bottom of the bearing plate 4 are provided with resistance reduction balls 402, and the resistance reduction balls 402 are in contact with the inner wall of the guide groove 204. The anti-skid rubber pad 202 is made of nitrile rubber material, the surface is provided with anti-skid texture, the thickness is 2-5mm, the damping rubber block 605 is made of polyurethane elastomer material, the Shore hardness is 60-80A, the thickness is 5-10mm, and the surface is provided with a micro concave hole structure, and the micro hole diameter is 0.1-0.3mm.

[0088] It is verified through experiments that when the instrument is used to detect a pressure-bearing pipeline with a 0.5mm deep crack, the crack recognition accuracy is 98%, and the recognition accuracy of a traditional instrument (without spring-damping cooperative structure) is only 72%, and the false detection rate is reduced by 65%.

[0089] A detection method of an instrument, comprising the following steps:

[0090] S1. Device debugging: install the detection probe 102 on the mounting seat 6, adjust the position of the contact ball 607 through the adjusting screw 602 of the L-shaped adjusting support 601, so that the detection probe 102 is parallel to the detection surface of the pressure-bearing equipment, and the adjusting accuracy is controlled by using the scale line of the limiting guide 606, and the error is ≤0.5mm;

[0091] S2. Detection preparation: hold the handle 3, attach the frame plate 2 to the surface of the pressure-bearing equipment through the anti-skid rubber pad 202, start the drive motor 5 by operating the button 301, drive the gear 502 to mesh with the gear plate 501, slide the bearing plate 4 along the guide groove 204, lower the sliding resistance of the resistance-reducing ball 402, and synchronize the operation of the exhaust fan 404, with a wind speed of ≥2m / s, to dissipate heat in the detection area.

[0092] S3. Signal acquisition: control the bearing plate 4 to move back and forth by the forward and reverse rotation of the drive motor 5, with a moving speed of 0.5-2m / min, move the detection probe 102 with the mounting seat 6, buffer the vibration with the spring 603 and the damping rubber block 605 to ensure the stable distance between the detection probe 102 and the surface of the pressure-bearing equipment, with a distance fluctuation of ≤0.2mm, collect the eddy current signals by the pulsed eddy current detector main body 1, and control the bearing plate 4 to move back and forth at a speed of 0.5-2m / min by the drive motor 5, which is matched with the elastic coefficient of the spring 603 and the hardness of the damping rubber block 605 to ensure that the distance fluctuation is ≤0.2mm.

[0093] S4. Data analysis: after the detection is completed, process the signals by the pulsed eddy current detector main body 1, identify the cracks through the crack feature algorithm, generate a detection report containing the crack position, depth, and length, the crack feature algorithm identifies the cracks based on the amplitude mutation rate of the eddy current signals ≥30% and the phase shift ≥5°, and calculates the crack depth through the signal attenuation speed and the crack length through the signal duration.

[0094] S5. Equipment storage: turn off the drive motor 5 and the exhaust fan 404, disassemble the detection probe 102, reset the bearing plate 4 to one end of the frame plate 2, charge the equipment with the remaining power of the storage battery 203, with a charging time of 2-4h, and properly store the equipment after the charging is completed. The storage battery 203 is a 12V / 5Ah lithium battery, with a continuous running time of ≥4 hours when the drive motor 5 and the exhaust fan 404 work simultaneously, which meets the demand of single continuous detection.

[0095] In step S3, when the detection probe 102 encounters a protrusion on the surface of the pressure-bearing equipment, the mounting seat 6 slides along the guide rod 604 to compress the spring 603, the contact ball 607 rolls with the protrusion to ensure that the distance fluctuation of the detection probe 102 is ≤0.2mm, and the damping rubber block 605 absorbs the vibration energy to avoid the influence of vibration on the detection data.

[0096] It can be understood that: from equipment debugging (precision error ≤0.5mm), preparation, signal acquisition to data analysis, storage, the process is clear, the debugging ensures the initial position of the probe is accurate, the preparation link synchronously completes the heat dissipation and the equipment in place, the signal acquisition is uniform and stable, the data analysis automatically identifies the crack and generates the report, the storage is convenient for equipment maintenance and next use, the whole process improves the detection work efficiency and the standardization degree, with the help of the pulse eddy current detector main body 1 signal processing and crack characteristic algorithm, the crack can be effectively identified and quantified. Compared with the traditional technology, the crack identification is fuzzy and difficult to quantify, and the method can accurately determine the crack and provide reliable data support for the maintenance and safety evaluation of pressure equipment. The crack characteristic algorithm identifies the crack based on the amplitude mutation rate and phase shift of the pulse eddy current signal: when the amplitude mutation rate of the detection signal is ≥30% and the phase shift is ≥5°, it is determined as a crack signal; the crack depth is calculated through the calibration curve of signal attenuation speed and crack depth (such as the amplitude attenuation of 15% for every 0.5mm increase in depth measured by experiment), and the crack length is converted through the duration and moving speed of the continuous crack signal.

[0097] It should be noted that: the pulse eddy current detection technology is an extension of eddy current detection technology, which is based on electromagnetic induction principle, analyzes the eddy current and induced magnetic field changes generated under pulse signal excitation, and detects the cracks and defects of pressure equipment.

[0098] Actual detection operation

[0099] Taking the detection of cracks in the pressure pipeline (carbon steel material, with anticorrosion coating on the surface and local welding line) of a petrochemical enterprise as an example:

[0100] 1. Equipment debugging (corresponding to step S1)

[0101] Remove the local anticorrosion coating of the pipeline (expose the metal surface to be detected), and place the assembled instrument beside the pipeline. Install the detection probe 102 to the mounting seat 6, rotate the adjusting screw 602 on the L-shaped adjusting bracket 601, observe the scale line of the limiting guide 606, adjust the position of the contact ball 607, make the axis of the detection probe 102 parallel to the tangent of the pipeline detection surface (circular arc surface), measure with a feeler gauge, ensure that the initial value of the distance between the detection probe 102 and the pipeline surface is 1mm (set according to the pulse eddy current detection requirements), and the adjustment error is ≤0.5mm.

[0102] 2. Detection preparation (corresponding to step S2)

[0103] The operator holds the handle 3 with both hands, and sticks the frame plate 2 to the surface of the pipeline through the anti-skid rubber pad 202 to ensure close adhesion, and uses the thumbs of both hands to contact the control button 301 at the top of the handle 3 to start the driving motor 5 in forward rotation, the driving gear 502 is driven to mesh transmission along the tooth plate 501, the bearing plate 4 slides along the guide groove 204, the rolling smoothness of the resistance reduction ball 402 is observed, and at the same time, the exhaust fan 404 is started, and the wind speed is measured by using the anemometer to confirm that the wind speed is greater than or equal to 2 m / s, so as to dissipate heat for the pipeline detection area.

[0104] 3. Signal acquisition (corresponding to step S3)

[0105] The driving motor 5 rotates in forward rotation at a speed of 1 m / min, the bearing plate 4 drives the mounting seat 6 and the detection probe 102 to move along the axial direction of the pipeline, in the moving process, when a pipeline surface welding line protrusion (height 3 mm) is encountered, the mounting seat 6 slides along the guide rod 604 to compress the spring 603, the contact ball 607 rolls in contact with the welding line protrusion, the spring 603 buffers the vibration, and the damping rubber block 605 absorbs the remaining vibration energy, so as to ensure that the fluctuation of the distance between the detection probe 102 and the pipeline surface is less than or equal to 0.2 mm, and the pulse eddy current detector main body 1 synchronously collects and stores the eddy current signals.

[0106] When the bearing plate 4 moves to the limit position at one end of the pipeline, the control button 301 is pressed to switch the driving motor 5 to reverse rotation, which drives the bearing plate 4 to move reversely, the signal acquisition process is repeated, and the pipeline detection area is detected back and forth to ensure that the signals are covered comprehensively.

[0107] 4. Data analysis (corresponding to step S4)

[0108] After the detection is completed, the pulse eddy current detector main body 1 is operated, the built-in crack feature algorithm (the amplitude mutation rate greater than or equal to 30% and the phase shift greater than or equal to 5° are set as the crack determination threshold) is called, and the collected eddy current signals are processed and analyzed. The instrument automatically identifies the crack position, combines the signal attenuation, phase change and other data, calculates the crack depth and length, generates a detection report containing the specific parameters and distribution of the crack, and exports the report for technicians to evaluate the safety state of the pipeline.

[0109] 5. Equipment storage (corresponding to step S5)

[0110] The driving motor 5 and the exhaust fan 404 are turned off, the detection probe 102 is disassembled and properly stored, the bearing plate 4 is pushed to reset to the initial position at one end of the frame plate 2, the instrument is placed on the charging base, and the remaining power of the storage battery 203 is charged. After charging for 2-4 hours (the full charging can be judged through the charging indicator light), the charging wire is pulled out, the instrument is stored in a dry and dustproof tool box, and is ready for next use.

[0111] Notes and maintenance

[0112] Before detection, the surface of the detection area of the pressure-bearing equipment needs to be cleaned of oil stains and thick rust layers (which can be treated with sandpaper and cleaning agents) to avoid affecting the probe adhesion and signal acquisition; if the detection environment humidity > 80%, temperature > 40℃, dehumidification and cooling measures (such as portable dehumidifiers and sunshades) need to be taken to prevent electrical components from being damaged by moisture and overheating.

[0113] When moving the instrument, avoid colliding with the precision parts such as the mounting seat 6 and the detection probe 102; operate the control button 301 smoothly to prevent the motor from frequently reversing and damaging the transmission components.

[0114] Periodically (recommended once a month) check the wear of the resistance-reducing balls 402 and the contact balls 607, and replace them in time if there are serious scratches on the surface of the balls and the diameter wear is > 0.2mm; clean the dust and debris in the guide groove 204 and the recess 403, and use compressed air blowing and soft brush cleaning to ensure smooth sliding of the bearing plate 4 and the mounting seat 6.

[0115] Every quarter, the battery 203 is subjected to charge and discharge maintenance, and after deep discharge (power ≤20%), it is fully charged again to prolong the service life of the battery; check the insulation layer of the wire, and if it is damaged, repair or replace the wire with the same specification fireproof insulation sleeve to ensure electrical safety. Embodiment

[0116] Based on the embodiment one, the present application is as shown in Figures 1-8 The left and right sides of the bearing plate 4 are provided with fixed frames 401, one end of each fixed frame 401 is provided with an exhaust fan 404, the exhaust fan 404 is an axial flow fan, the air volume is 50-100m³ / h, and the battery 203 is connected through a wire, and the wire is wrapped with a fireproof insulation sleeve.

[0117] The technical solution: through the setting of the exhaust fan 404, synchronous heat dissipation can be realized, the detection environment is stable, the detection efficiency is improved, the signal acquisition is continuous and reliable due to stable movement, and the long-distance and large-area detection requirements of the pressure-bearing equipment are met. Embodiment

[0118] Based on the embodiment one, the present application is as shown in Figures 1-8 The side of the guide joint 608 is fixed with a limiting guide 606, the limiting guide 606 slides on the inner surface of the L-shaped adjusting support 601, and the surface of the limiting guide 606 is provided with scale lines.

[0119] The technical solution: through the setting of the limiting guide 606, the stability of the guide joint 608 can be guaranteed, and the setting of the scale lines can assist the guide joint 608 in controlling the adjustment accuracy.

[0120] It should be pointed out finally that the above embodiments are only used to illustrate the technical solutions of the present application, and are not intended to limit the protection scope of the present application. Although the present application has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present application can be modified or equivalently replaced without departing from the essence and scope of the technical solutions of the present application.

Claims

1. A crack detection instrument for pressure equipment based on eddy current technology, characterized in that, include: The pulse eddy current detector consists of a main body (1), a frame plate (2), a support plate (4), and an adjustable mounting base (6). The pulse eddy current detector body (1) is provided with a connecting line (101) on one side, and a detection probe (102) is connected to one end of the connecting line (101). Among them, support blocks (201) are fixed on both the left and right sides of the frame plate (2), and anti-slip pads (202) are glued to one side of the support blocks (201). A storage battery (203) is installed in the middle of the rear side of the frame plate (2). Guide grooves (204) are opened at the top and bottom of the inner side of the frame plate (2). Handles (3) are installed at both the left and right ends of the rear side of the frame plate (2), and control buttons (301) are installed on the top of the handles (3). The front of the bearing plate (4) is provided with a recessed hole (403), a toothed plate (501) is fixed at one bottom end of the inner side of the frame plate (2), a drive motor (5) is installed on the rear side of the bearing plate (4), a drive gear (502) is installed at the output end of the drive motor (5), and the drive gear (502) meshes with the toothed plate (501). The mounting base (6) has a U-shaped structure. Guide rods (604) are fixed at both ends of the rear side of the mounting base (6). The guide rods (604) pass through the concave hole (403) and slide on the inner surface of the bearing plate (4). A damping block (605) is fixed at the rear end of the guide rod (604), and one side of the damping block (605) contacts the inner wall of the frame plate (2). A spring (603) is sleeved on the outer surface of the guide rod (604), and the two ends of the spring (603) are fixed to the inner wall of the concave hole (403) and the rear side of the mounting base (6) respectively. An L-shaped adjusting bracket (601) is provided at the top and bottom of the mounting base (6). An adjusting screw (602) is threaded on the inner surface of the L-shaped adjusting bracket (601). A guide joint (608) is movably connected to one side of the adjusting screw (602) through a bearing. A contact ball (607) is provided at one end of the guide joint (608). The upper and lower ends of the bearing plate (4) slide on the inner side of the guide groove (204). The top and bottom of the bearing plate (4) are provided with drag-reducing balls (402), and the drag-reducing balls (402) are in contact with the inner wall of the guide groove (204). One side of the guide joint (608) is fixed with a limiting guide (606), and the limiting guide (606) slides on the inner surface of the L-shaped adjusting bracket (601). Meanwhile, the surface of the limiting guide (606) is provided with scale lines.

2. The pressure equipment crack detection instrument based on eddy current technology according to claim 1, characterized in that: There are two control buttons (301), and the two control buttons (301) are electrically connected to the forward and reverse input terminals of the drive motor (5). The drive motor (5) is a DC servo motor with a rated voltage of 12-24V and a rated power of 50-100W. It is equipped with an overload protection module, and the overload threshold is 1.5 times the rated power.

3. The pressure equipment crack detection instrument based on eddy current technology according to claim 1, characterized in that: The support plate (4) is equipped with a fixing frame (401) on both the left and right sides, and an exhaust fan (404) is installed on the inner side of one end of the fixing frame (401).

4. The pressure equipment crack detection instrument based on eddy current technology according to claim 1, characterized in that: The anti-slip pad (202) is made of nitrile rubber with anti-slip texture on the surface and a thickness of 2-5mm.

5. The pressure equipment crack detection instrument based on eddy current technology according to claim 3, characterized in that: The exhaust fan (404) is an axial flow fan with an air volume of 50-100 m³ / h. It is connected to the battery (203) via a wire, and the wire is wrapped with a fireproof insulating sleeve.

6. The pressure equipment crack detection instrument based on eddy current technology according to claim 1, characterized in that: The damping rubber block (605) is made of polyurethane elastomer material with a Shore hardness of 60-80A, a thickness of 5-10mm, and a micro-pore structure on the surface with a micropore diameter of 0.1-0.3mm.

7. A detection method based on the instrument according to any one of claims 1-6, characterized in that, Includes the following steps: S1. Equipment debugging: Install the detection probe (102) on the mounting base (6), adjust the position of the contact ball (607) by adjusting the screw (602) of the L-shaped adjusting bracket (601) so that the detection probe (102) is parallel to the detection surface of the pressure equipment, and use the scale line of the limit guide (606) to control the adjustment accuracy with an error ≤0.5mm; S2. Inspection preparation: Hold the handle (3), attach the frame plate (2) to the surface of the pressure equipment through the anti-slip rubber pad (202), start the drive motor (5) with the control button (301), the drive gear (502) meshes and drives along the tooth plate (501), the bearing plate (4) slides along the guide groove (204), the resistance-reducing ball (402) reduces the sliding resistance, the exhaust fan (404) runs synchronously, the wind speed is ≥2m / s, to dissipate heat in the inspection area; S3. Signal acquisition: The drive motor (5) controls the reciprocating movement of the bearing plate (4) in both forward and reverse directions at a speed of 0.5-2m / min. The detection probe (102) moves with the mounting base (6). The spring (603) and the damping rubber block (605) buffer the vibration, ensuring that the distance between the detection probe (102) and the surface of the pressure equipment is stable and the distance fluctuation is ≤0.2mm. The main body (1) of the pulse eddy current detector acquires the eddy current signal. S4. Data Analysis: After the detection is completed, the main body (1) of the pulse eddy current detector processes the signal, identifies the crack through the crack feature algorithm, and generates a detection report containing the crack location, depth and length; S5. Equipment storage: Turn off the drive motor (5) and exhaust fan (404), remove the detection probe (102), reset the support plate (4) to one end of the frame plate (2), use the remaining power of the battery (203) to charge the equipment, the charging time is 2-4 hours, and store it properly after charging is completed; In step S3, when the detection probe (102) encounters a protrusion on the surface of the pressure equipment, the mounting base (6) slides along the guide rod (604) to compress the spring (603), and the contact ball (607) rolls in contact with the protrusion to ensure that the spacing fluctuation of the detection probe (102) is ≤0.2mm. The damping rubber block (605) absorbs the vibration energy to avoid vibration affecting the detection data.

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