Device for testing hardness of circumferential weld zone of pipeline

Abstract

The hardness testing device comprises an indentation collecting and testing part, a fixed ruler (11) and an upper computer, the indentation collecting and testing part is arranged on a base, a ruler adjusting rod is arranged on the base, one end of the fixed ruler is fixed to the ruler adjusting rod, and the other end of the fixed ruler clamps and positions a weld joint sample to be tested; a to-be-tested weld seam sample is pressed through the indentation collecting and testing component, image information is obtained and uploaded to the upper computer, the diagonal length and area of an indentation are extracted through the upper computer, a hardness value is obtained through calculation, after operation is repeated, a broken line graph is drawn, and partition of the sample is achieved according to regional characteristics. According to the invention, the test data can truly reflect the weld hardness, and the accuracy of quality judgment is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of circumferential weld indentation detection and hardness testing technology, and in particular to a device for testing the hardness of the circumferential weld zone of a pipeline. Background Technology

[0002] In the petrochemical and natural gas transportation fields, pipelines serve as the core transportation carriers, and the quality of their circumferential welds directly determines the operational safety and service life of the pipeline system. As a critical part of pipeline connections, circumferential welds are prone to uneven hardness distribution and localized hardening due to factors such as differences in cooling rates during welding. Hardness, as a core parameter for evaluating the mechanical properties of welds, is a crucial basis for determining whether circumferential welds meet engineering design requirements. However, traditional hardness testing procedures require manual reading of test data and calculation of hardness values ​​using formulas. Indentation images also require observation using an additional microscope. This process is not only cumbersome and time-consuming but also susceptible to data reliability issues due to human reading errors.

[0003] Therefore, current testing devices still suffer from technical shortcomings such as inaccurate positioning and poor adaptability, failing to meet industry requirements for testing accuracy and experimental conditions. Thus, developing a hardness testing device that can accurately locate pipe circumferential welds, adapt to multiple pipe diameters, and is easy to operate has become a pressing technical problem to be solved in the field of pipeline inspection. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a pipe circumferential weld zone hardness testing device, which can effectively acquire clear hardness photos of the circumferential weld zone, thereby directly measuring the indentation in the circumferential weld zone and obtaining the data processing results of the hardness of the circumferential weld zone, with accurate and reliable results.

[0005] This invention is achieved using the following technical solution: a pipe circumferential weld zone hardness testing device, comprising an indentation acquisition and testing component, a fixed scale, and a host computer. The indentation acquisition and testing component is mounted on a base, and a scale adjustment rod is mounted on the base. One end of the fixed scale is fixed to the scale adjustment rod, and the other end clamps and positions the weld sample to be tested. The indentation acquisition and testing component presses on the weld sample to be tested and acquires image information, which is then uploaded to the host computer. The host computer extracts the diagonal length and area of ​​the indentation and calculates the hardness value. After repeating the operation, a line graph is plotted, and the sample is divided into zones according to the regional characteristics.

[0006] Furthermore, the indentation acquisition and testing component includes a crossbar, which is mounted on a base via a support frame. The support frame is equipped with a brightness adjustment knob and a support height adjustment knob.

[0007] Furthermore, the support frame is mounted on the base via a support rod, and the support rod is connected to the base via pulleys.

[0008] Furthermore, the base has a groove on its back, and a pulley at the bottom of the support rod extends into the groove. The support rod is connected to the base through the pulley, and the support rod can be moved horizontally by the rolling of the pulley.

[0009] Furthermore, an illumination assembly is provided below the crossbar, and below the illumination assembly are a switchable objective lens and a hardness testing probe. The crossbar is also equipped with a focusing knob and a magnification knob for adjusting the objective lens.

[0010] Furthermore, the lighting assembly includes a lighting panel and a plurality of LED lights, which are evenly distributed around the lighting panel.

[0011] Furthermore, the indentation acquisition test component also includes a converter, one side of which is attached to the outside of the illumination assembly. The converter can be rotated to replace the required objective lens and hardness test needle.

[0012] Furthermore, the host computer includes an indentation processing module, which processes the indentation information collected by the indentation acquisition and testing component and extracts the diagonal length and area of ​​the indentation.

[0013] Furthermore, the host computer also includes a hardness processing module, which calculates the hardness based on the data from the indentation processing module using the algorithm HV = 0.1891 × F / d²; where: HV is the Vickers hardness symbol; F is the test force; and d is the arithmetic mean of the two diagonals d1 and d2 of the indentation.

[0014] Furthermore, the host computer also includes a hardness analysis module, which is used to summarize the measured hardness and plot it as a line graph, and divide the sample into zones according to the regional characteristics; the hardness analysis module divides the sample into zones according to the hardness of the heat-affected zone, the weld zone, and the base material zone.

[0015] The beneficial effects of this invention are as follows: This invention can improve positioning accuracy and test point accuracy: the device is equipped with a positioning mechanism specifically designed for the circumferential distribution characteristics of pipe circumferential welds, which can effectively prevent the pressure head from deviating to the wrong area of ​​the base material or heat-affected zone, ensuring that the test data truly reflects the weld hardness and greatly improving the accuracy of quality judgment.

[0016] This invention enables efficient data processing and intelligent analysis: the device integrates an automated data acquisition and processing module, and data such as indentation size and applied force can be automatically acquired through high-precision sensors, achieving ultra-high pressure indentation measurement accuracy. This significantly shortens data processing time and improves decision-making efficiency in pipeline construction or operation and maintenance.

[0017] This invention reduces operational complexity and minimizes human error: the device's user interface features an intelligent design with operation guidance and automatic parameter setting functions. This reduces reliance on operator skill levels and minimizes instances where tests fail to meet standards due to human error. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a structural diagram showing the connection between the support rod and the base of the present invention; Figure 3 This is a structural diagram of the fixed scale of the present invention; Figure 4 This is a schematic diagram of the specific structure of the converter of the present invention; Figure 5 This is a schematic diagram of the specific structure of the lighting component of the present invention; Figure 6 This is a flowchart of the present invention; In the diagram: 1. Crossbar; 2. Focusing knob; 3. Illumination assembly; 4. Magnification knob; 5. Brightness adjustment knob; 6. Stand height adjustment knob; 7. Support frame; 8. Support rod; 9. Base; 10. Scale adjustment rod; 11. Fixed scale; 12. Data cable; 13. Weld sample to be tested; 14-1. Hardness treatment module; 14-2. Indentation treatment module; 14-3. Hardness analysis module; 15. Objective lens; 16. Hardness testing needle; 17. Pulley; 18. Converter; 19. LED light; 20. Illumination panel. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0021] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0022] The following detailed description of some embodiments of the present invention is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0023] See Figures 1 to 5 A pipe circumferential weld zone hardness testing device includes an indentation acquisition and testing component, a support frame 7, a support rod 8, a base 9, an illumination component 3, and a host computer. The base 9 has a groove on its back, and a pulley 17 at the lower part of the support rod 8 extends into the groove. The support rod 8 and the base 9 are connected by the pulley 17. The rotation of the pulley 17 allows the support rod 8 to move to the next position of the sample for hardness testing.

[0024] In some embodiments, the pulley 17 can be controlled to automatically control the support rod 8, thereby driving the support frame 7 to automatically find the next position of the sample for hardness testing, and completing automatic data acquisition and processing.

[0025] The indentation acquisition and testing component includes a crossbar 1, with an illumination assembly 3 located below the crossbar 1. Below the illumination assembly 3 are a hardness testing probe 16 and an objective lens 15. Using a focusing knob 2 and a magnification knob 4 on the crossbar 1, the indentation image can be quickly observed, ensuring the acquisition of a clear image of the indentation. Furthermore, a brightness adjustment knob 5 is located on the support frame 7, which can be used to adjust the light intensity of the illumination assembly 3. The illumination assembly 3 contains 40-60 LEDs 19 and an illumination panel 20; rotating the brightness adjustment knob 5 changes the light intensity. A converter 18 is located on the outside of the illumination assembly 3; rotating the converter 18 allows switching between the hardness testing probe 16 and the objective lens 15, fulfilling the different functions of indentation and observation. A camera is also installed on the crossbar 1 to acquire image information of the weld sample 13 to be tested. After the hardness test needle 16 presses the polished sample for 10-15 seconds to produce an indentation, the camera acquires the image information of the weld sample 13 to be tested and uploads it to the host computer for data processing.

[0026] In this embodiment, the support frame 7 is also equipped with a support height adjustment knob 6, which can adjust the height of the support frame 7, thereby driving the horizontal bar 1 to move up and down to achieve magnification and reduction of the observed image.

[0027] A scale adjustment rod 10 is provided on the side of the base 9. The scale adjustment rod 10 is connected to the fixed scale 11. The fixed scale 11 is used to fix the weld sample 13 to be tested, help the support rod 8 to move at equal distances, and ensure that the indentation is evenly distributed. The scale adjustment rod 10 can adjust its own height to help the scale fix the sample 13. The fixed scale 11 can also rotate around one end of the scale adjustment rod 10 as needed.

[0028] In this embodiment, the host computer includes a hardness processing module 14-1, an indentation processing module 14-2, and a hardness analysis module 14-3. The indentation processing module 14-2 is connected to the camera via a data cable 12. After receiving an image from the camera, the indentation processing module 14-2 measures and extracts the data, obtaining the diagonal length and area of ​​the indentation. This information is then transmitted to the hardness processing module, which uses the algorithm HV = 0.1891 × F / d² to determine the hardness of the sample at that location. This process is repeated until the indentations are evenly distributed across the sample. The hardness analysis module 14-3 then analyzes the overall hardness, plotting it as a line graph. Based on the characteristic that the hardness is highest in the affected area, slightly lower in the weld area, and lowest in the base material area, the sample is divided into zones.

[0029] See Figure 6 The method of using the pipe circumferential weld zone hardness testing device includes the following steps: For sample preparation, the weld sample 13 to be tested is ground to make its surface smooth enough to reduce the roughness of the sample surface. Alternatively, a tooling clamp can be used to fix the sample in a suitable position and orientation to ensure that the indenter and the sample can make uniform contact. Then, the sample is placed on the base 9, a suitable position is found, the scale adjustment rod 10 is adjusted, and the sample is fixed using the fixed scale 11.

[0030] Adjust and press the device, turn on the lighting component 3, turn the brightness adjustment knob 5 to brighten the field of vision, adjust the magnification knob 4 and the bracket height adjustment knob 6 to make the target in the center of the field of vision, turn the focus knob 2 to make the target clear, turn the converter 18 to turn the hardness test needle 16, and start pressing for 10-15 seconds.

[0031] After calculating the hardness and pressing, the converter 18 is turned to the objective lens 15. The hardness processing module 14-1 and the indentation processing module 14-2 are used to calculate and record the data. Then, the pulley 17 is used to start equidistant translation and repeat the above operation to the next suitable position.

[0032] The results are summarized and the sample is divided into regions. Once the indentation is sufficient to determine the regional properties, the hardness analysis module 14-3 plots the recorded data into a line graph and performs analysis. The sample is divided into regions according to the different properties of each region.

[0033] It should be noted that the terms "connection" and "setting" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "connection" or "setting" may explicitly or implicitly include one or more of that feature. Furthermore, the terms "connection" and "setting," etc., are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Moreover, for the foregoing embodiments, for the sake of simplicity, they are all described as a series of actions; however, those skilled in the art should understand that this application is not limited to the described order of actions, as some steps may be performed in other orders or simultaneously according to this application. Secondly, those skilled in the art should also understand that the embodiments described in the specification are preferred embodiments, and the actions involved are not necessarily essential to this application.

[0034] The above embodiments describe the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Modifications and variations made by those skilled in the art without departing from the spirit and scope of the invention should be within the protection scope of the appended claims.

Claims

1. A device for testing the hardness of a pipe circumferential weld zone, characterized in that, The system includes an indentation acquisition and testing component, a fixed scale (11), and a host computer. The indentation acquisition and testing component is mounted on a base (9). A scale adjustment rod (10) is mounted on the base (9). One end of the fixed scale (11) is fixed on the scale adjustment rod (10), and the other end clamps and positions the weld sample (13) to be tested. The indentation acquisition and testing component presses the weld sample (13) to be tested and acquires image information, which is then uploaded to the host computer. The host computer extracts the diagonal length and area of ​​the indentation and calculates the hardness value. After repeating the operation, a line graph is drawn, and the sample is partitioned according to the regional characteristics.

2. The pipe circumferential weld zone hardness testing device as described in claim 1, characterized in that, The indentation collection and testing component includes a crossbar (1), which is mounted on a base (9) via a support frame (7). The support frame (7) is equipped with a brightness adjustment knob (5) and a support height adjustment knob (6).

3. The pipe circumferential weld zone hardness testing device as described in claim 2, characterized in that, The support frame (7) is mounted on the base (9) via a support rod (8), and the support rod (8) is connected to the base (9) via a pulley (17).

4. The pipe circumferential weld zone hardness testing device as described in claim 3, characterized in that, The base (9) has a groove on its back. The pulley (17) at the bottom of the support rod (8) extends into the groove. The support rod (8) and the base (9) are connected by the pulley (17). The support rod (8) can be translated by the rolling of the pulley (17).

5. The pipe circumferential weld zone hardness testing device as described in claim 2, characterized in that, An illumination assembly (3) is provided below the crossbar (1), and a convertible objective lens (15) and a hardness test needle (16) are provided below the illumination assembly (3). A focusing knob (2) and a magnification knob (4) for adjusting the objective lens (15) are also provided on the crossbar (1).

6. The pipe circumferential weld zone hardness testing device as described in claim 5, characterized in that, The lighting component (3) includes a lighting panel (20) and a number of LED lights (19), which are evenly distributed around the lighting panel (20).

7. The pipe circumferential weld zone hardness testing device as described in claim 5, characterized in that, The indentation acquisition test component also includes a converter (18), one side of which is attached to the outside of the illumination assembly (3). The converter (18) can be rotated to replace the required objective lens (15) and hardness test needle (16).

8. The pipe circumferential weld zone hardness testing device as described in claim 1, characterized in that, The host computer includes an indentation processing module (14-2), which processes the indentation information collected by the indentation acquisition and testing component and extracts the diagonal length and area of ​​the indentation.

9. The pipe circumferential weld zone hardness testing device as described in claim 8, characterized in that, The host computer also includes a hardness processing module (14-1), which calculates the hardness based on the data from the indentation processing module (14-2) using the algorithm HV = 0.1891 × F / d²; where: HV is the Vickers hardness symbol; F is the test force; and d is the arithmetic mean of the two diagonals d1 and d2 of the indentation.

10. The pipe circumferential weld zone hardness testing device as described in claim 8, characterized in that, The host computer also includes a hardness analysis module (14-3), which is used to summarize the measured hardness and plot it as a line graph, and divide the sample into regions according to the regional characteristics. The hardness analysis module (14-3) divides the sample into regions with the highest hardness in the heat-affected zone, the second highest hardness in the weld zone, and the lowest hardness in the base material zone.

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