Online ultrasonic phased array detection equipment and detection method for spiral welded pipe

Abstract

The invention discloses a spiral welded pipe online ultrasonic phased array detection device which comprises a driving assembly (1) arranged on a manipulator or an XYZ three-axis truss, and a flaw detection function assembly matched with a spiral welded pipe (2) is arranged at the end of the driving assembly (1); the flaw detection functional assembly comprises a detection wheel angle adjusting mechanism (3), a detection wheel floating mechanism (4), a phased array flaw detection mechanism (5), an auxiliary wheel mechanism (6) and an encoder counting mechanism (7) which are matched with one another; a water drum detection wheel (51) of the phased array flaw detection mechanism (5) and an encoding wheel (71) of the encoder counting mechanism (7) are attached to the inner and outer side surfaces of the spiral welded pipe (2); and the flaw detection functional assembly further comprises a laser (9) and a visual camera (8) which are matched with each other. The automatic ultrasonic flaw detection device has the advantages that rapid and continuous automatic ultrasonic flaw detection of various spiral welds is realized, the occupied area is small, the flexibility is high, and the reliability and the accuracy of automatic ultrasonic flaw detection of the spiral welds are improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of phased array flaw detection, and particularly relates to a spiral welded pipe online ultrasonic phased array detection equipment and a detection method. BACKGROUND

[0002] Generally, the end detection of the spiral pipe basically relies on manual detection, and special personnel need to use a hand detector to perform manual detection on the pipe end of the spiral steel pipe at both ends of the steel pipe, which undoubtedly increases the detection time, affects the production progress and production efficiency, cannot be continuous, and cannot achieve efficient ultrasonic detection. At the same time, due to the fatigue work of the detection personnel, the phenomenon of missed detection often occurs, which affects the reliability and accuracy of the steel pipe detection. In order to improve the efficiency, some manufacturers begin to use ultrasonic automatic detection, but in this automatic detection process, the weld detection area and the base material detection area need to be set, which is relatively cumbersome. SUMMARY

[0003] The present application aims to solve the problems of low detection efficiency, low automation level, poor detection reliability and accuracy of the existing spiral welded pipe detection, and provides a spiral welded pipe online ultrasonic phased array detection equipment, which can realize rapid and continuous automatic ultrasonic detection of various spiral welds, has small floor area, high flexibility, improves the reliability and accuracy of the automatic ultrasonic detection of the spiral weld, and is more efficient and intelligent.

[0004] In order to achieve the above-mentioned purpose, the present application adopts the following technical scheme: A spiral welded pipe online ultrasonic phased array detection equipment, comprising a driving assembly arranged on a manipulator or an XYZ three-axis gantry, and a detection function assembly arranged at the end of the driving assembly and matched with the spiral welded pipe, wherein the spiral welded pipe is arranged on a roller mechanism for rotating the steel pipe. The detection function assembly comprises a probe wheel angle adjusting mechanism, a probe wheel floating mechanism, a phased array detection mechanism, an auxiliary wheel mechanism and an encoder counting mechanism.

[0005] The probe wheel angle adjusting mechanism is connected to the probe wheel floating mechanism below, the probe wheel floating mechanism is connected to the phased array detection mechanism below, the auxiliary wheel mechanism is arranged on the left and right sides of the phased array detection mechanism, the encoder counting mechanism is arranged on one side of the phased array detection mechanism, and the water bag probe wheel of the phased array detection mechanism and the encoder wheel of the encoder counting mechanism are both matched with the inner and outer surfaces of the spiral welded pipe.

[0006] The detection function assembly further comprises a laser and a vision camera matched with each other, and the laser and the vision camera are arranged on the front and rear sides of the phased array detection mechanism respectively, so as to find the pipe end through the laser and find the spiral weld through the camera.

[0007] Furthermore, the drive assembly is a six-axis robot, and its drive end is connected to the flaw detection function assembly through a connecting frame. The probe wheel angle adjustment mechanism is located on the upper surface of the connecting frame, and the adjustment shaft of the probe wheel angle adjustment mechanism extends downward perpendicularly to the connecting frame and is connected to the probe wheel floating mechanism.

[0008] Furthermore, the floating probe mechanism includes a mounting plate parallel to the connecting frame, an inverted U-shaped mounting bracket below the mounting plate, and a set of floating springs connected between the mounting bracket and the mounting plate to buffer and press the probe.

[0009] Furthermore, the lower end of the mounting frame is connected to both sides of the rotating shaft of the water-filled probe, and the auxiliary wheel mechanism is connected to the lower part of the mounting frame on the corresponding side. The auxiliary wheel mechanism is provided with an auxiliary wheel, the diameter of which is smaller than that of the water-filled probe, and the contact points between the auxiliary wheels on both sides and the water-filled probe and the spiral welded pipe are on the same tangent.

[0010] Furthermore, the encoder counting mechanism includes an encoder floating mechanism that cooperates with the encoder wheel, which includes, from top to bottom, a lifting cylinder, a buffer spring, a guide rod and a fixed lug. The encoder wheel is connected to the fixed lug, and an encoder is connected to one side of the encoder wheel axle.

[0011] Furthermore, one side of the mounting plate is connected to an inverted L-shaped connecting plate, and a vision camera is fixed at the lower end of the connecting plate. The vision camera is positioned facing the bottom end of the water jacket probe and the spiral weld seam of the spiral welded pipe. A laser is connected to the other side of the mounting plate.

[0012] To further achieve the objectives of this invention, this invention also provides an online ultrasonic phased array testing method for spiral welded pipes, using the aforementioned online ultrasonic phased array testing equipment, with the following specific steps: (1) Use the probe wheel angle adjustment mechanism to adjust the phased array flaw detection mechanism to the centering position that matches the spiral weld angle of the current product, rotate to position and lock it; (2) The spiral welded pipe is placed on the idler roller mechanism. As the idler roller mechanism rotates, the probe water tank rotates passively. (3) When the laser and vision camera above capture the starting position of the pipe opening and the position of the weld, the robot will automatically track and correct the position of the weld according to the product weld trajectory after software calculation, and at the same time record the starting position of the steel pipe rotation. At this time, the spiral pipe rotates slowly. (4) While the spiral tube is rotating, the water system on the phased array probe wheel mechanism will automatically start circulating water to spray water on the tube wall, wet the inner or outer wall of the tube, and use water as a coupling agent for ultrasonic testing. (5) Ultrasonic testing will inspect the weld seam and body of the steel pipe to detect defects. At the same time, the robot arm of the drive assembly will move axially towards the steel pipe, and together with the vision system, it will continuously detect the position of the spiral weld seam. (6) During this process, the encoder counting mechanism records the number of rotations of the pipe fitting, ensuring that the pipe fitting rotates completely once, and then repeats a cycle to complete the inspection of the spiral weld. When only the spiral weld is inspected, it is only necessary to rotate a distance near the weld.

[0013] (7) When the ultrasonic testing reaches the required pipe depth, the phased array testing mechanism is detached from the inner or outer wall of the pipe by the robot arm, and the phased array testing mechanism is driven out of the steel pipe. The workpiece can then flow into the next station. When the new workpiece arrives at this testing position, the sequential testing begins.

[0014] Furthermore, in step (1), the probe angle adjustment mechanism is operated by manual rotation or automatic rotation.

[0015] Furthermore, in step (6), the computer collects and processes data during the detection process, builds a three-dimensional model on the monitor, and displays the coordinates of the defect location on the model. The picture is more intuitive and convenient for manual search and confirmation.

[0016] Compared with the prior art, the advantages of the technical solution of the present invention are as follows: (1) The equipment of the present invention is flexible to use, simple to operate, miniaturized, and can be mass-produced. Moreover, no personnel are required to operate it on the production site, which ensures the health of the operators and improves the safety of operation. (2) The coupling agent of the present invention only requires circulating water and does not require expensive coupling agents, which is very economical and reduces the cost of flaw detection; (3) The probe wheel of the present invention can independently inspect the weld and also inspect the base material of the steel pipe, thus improving the comprehensiveness of the inspection; (4) The coding wheel of the present invention adopts the up and down floating function to ensure that the probe wheel is always pressed against the pipe wall. At the same time, it collects data and performs synchronous data processing to build a three-dimensional model on the display. The coordinates of the defect location are displayed on the model, making the picture more intuitive and easier for manual search and confirmation, saving time and effort. (5) This invention utilizes robotic arms and vision technology, combined with a wheeled water-filled phased array probe, to perform automated ultrasonic testing on various spiral welded pipes. It has a small footprint, high flexibility, and achieves continuous, rapid, and accurate automatic ultrasonic testing of spiral welds. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the online ultrasonic phased array testing equipment of the present invention combined with a spiral welded pipe; Figure 2 This is a structural diagram of the online ultrasonic phased array testing equipment for spiral welded pipes according to the present invention; Figure 3 This is a schematic diagram of the water-filled probe used for flaw detection inside a steel pipe according to the present invention; Figure 4 This is a schematic diagram of the water-filled probe used for flaw detection on the outside of a steel pipe according to the present invention; Figure 5 This is a schematic diagram of the laser distribution in this invention; Figure 6 This is a schematic diagram showing the online ultrasonic phased array testing equipment of the present invention in conjunction with the outer side of the steel pipe. Detailed Implementation Example

[0018] To make the present invention clearer, the following description, in conjunction with the accompanying drawings, further illustrates an online ultrasonic phased array testing device and method for spiral welded pipes. The specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention.

[0019] This invention primarily aims to automate non-destructive testing of weld seams in spiral pipes. Its main components include: a drive assembly such as a robotic arm, an XYZ three-axis truss, an ultrasonic testing mechanism such as a wheeled water-cooled phased array, a precision probe wheel angle adjustment mechanism, a floating mechanism for the ultrasonic testing mechanism, a vision camera, auxiliary driven wheels, and an encoder counting mechanism. See also... Figures 1-3 This embodiment provides an online ultrasonic phased array testing device for spiral welded pipes, characterized in that: It includes a drive assembly 1 mounted on an XYZ three-axis truss. The drive assembly 1 is a six-axis robot, and its drive end is connected to the flaw detection function assembly via a connecting frame 10. The flaw detection functional components include a probe wheel angle adjustment mechanism 3, a probe wheel floating mechanism 4, a phased array flaw detection mechanism 5, an auxiliary wheel mechanism 6, and an encoder counting mechanism 7 that work together. The probe angle adjustment mechanism 3 is located on the upper surface of the connecting frame 10. The adjustment shaft of the probe angle adjustment mechanism 3 extends downward perpendicularly to the connecting frame 10 and is connected to the probe floating mechanism 4. The floating mechanism 4 of the probe wheel includes a mounting plate 41 parallel to the connecting frame 10. An inverted U-shaped mounting frame 42 is provided below the mounting plate 41. A set of floating springs 43 is connected between the mounting frame 42 and the mounting plate 41. The lower end of the mounting bracket 42 is connected to both sides of the rotating shaft of the water-filled probe wheel 51. The auxiliary wheel mechanism 6 is connected to the lower part of the mounting bracket 42 on the corresponding side. The auxiliary wheel mechanism 6 is provided with an auxiliary wheel 61. The diameter of the auxiliary wheel 61 is smaller than the diameter of the water-filled probe wheel 51, and the contact points of the auxiliary wheel 61 and the water-filled probe wheel 51 on both sides with the spiral welded pipe 2 are on the same tangent line. The encoder counting mechanism 7 includes an encoder floating mechanism 72 that cooperates with the encoder wheel 71. From top to bottom, it includes a lifting cylinder 721, a buffer spring 722, a guide rod 723 and a fixing ear 724. The encoder wheel 71 is connected to the fixing ear 724, and an encoder 73 is connected to one side of the axle of the encoder wheel 71.

[0020] See Figure 2 , Figure 3 and Figure 5 The flaw detection function components also include a laser 9 and a vision camera 8 that work together. The laser 9 and the vision camera 8 are respectively located on the front and rear sides of the phased array flaw detection mechanism 5. One side of the mounting plate 41 is connected to an inverted L-shaped connecting plate 11. The lower end of the connecting plate 11 is fixed with the vision camera 8. The vision camera 8 is positioned facing the bottom end of the water jacket probe 51 and the spiral weld seam 2a of the spiral welded pipe 2. The other side of the mounting plate 41 is connected to the laser 9, which is used to locate the pipe end by means of the laser and to locate the spiral weld seam by means of the camera.

[0021] See Figure 1 , Figure 2 , Figure 5 and Figure 6 The encoder counting mechanism 7 is located on one side of the phased array flaw detection mechanism 5, and the water-filled probe wheel 51 of the phased array flaw detection mechanism 5 and the encoder wheel 71 of the encoder counting mechanism 7 are both in contact with the inner and outer surfaces of the spiral welded pipe 2.

[0022] See Figure 1 , Figure 3 , Figure 4 and Figure 6 The diagrams show the phased array flaw detection equipment of the present invention and its fit with the inner and outer surfaces of the steel pipe. First, the phased array flaw detection mechanism 5 is adjusted to a centering position that matches the angle of the spiral weld 2a of the current product using the probe wheel angle adjustment mechanism 3. This angle rotation mechanism can be manually or automatically rotated and then locked. Second, the spiral pipe is placed on the power roller. As the on-site roller mechanism rotates, the probe wheel water tank 51 rotates passively. When the laser 9 and vision camera 8 above capture the starting position of the pipe opening and the weld position, the robot will automatically track and correct the weld position according to the product weld trajectory after software calculation, and at the same time record the starting position of the steel pipe rotation. At this time, the spiral pipe rotates slowly.

[0023] As the spiral tube rotates, the water system on the phased array probe wheel mechanism 5 automatically activates, circulating water to spray onto the pipe wall, wetting the inner or outer wall. Water is used as a coupling agent for ultrasonic testing. Ultrasonic testing will inspect the weld seams and the base material of the steel pipe, detecting defects such as cracks, slag inclusions, porosity, incomplete welding, and lack of fusion. Simultaneously, the robotic arm moves axially along the steel pipe, working in conjunction with the vision system to continuously monitor the position of the spiral weld seam. This probe wheel can independently inspect the weld seam and also inspect the base material of the steel pipe.

[0024] In this embodiment, the encoder wheel 71 adopts a floating up-and-down function to ensure that the probe wheel is always pressed against the pipe wall, recording the number of rotations of the spiral tube, ensuring that the spiral tube completes one full rotation, and then repeating this cycle several times to complete the inspection of the spiral weld. Simultaneously, the computer collects and processes the data, building a 3D model on the monitor and displaying the coordinates of the defect location on the model, making the display more intuitive and facilitating manual identification and confirmation.

[0025] Once the ultrasonic testing reaches the required depth in the pipe, the phased array flaw detection mechanism 5 is detached from the inner or outer wall of the pipe by the robotic arm, causing the flaw detection mechanism to exit the steel pipe. This workpiece can then flow into the next station, and sequential testing begins when a new workpiece arrives at this testing position.

[0026] The testing equipment of this invention utilizes robotic arms and vision technology, combined with a wheeled water-filled phased array probe, to perform automated ultrasonic testing on various spiral welded pipes. It has a small footprint, high flexibility, and achieves the function of rapid and accurate automatic ultrasonic testing of spiral welded pipes.

[0027] In addition to the embodiments described above, the present invention may have other implementations. All technical solutions formed by equivalent substitution or equivalent transformation fall within the protection scope claimed by the present invention.

Claims

1. An online ultrasonic phased array testing device for spiral welded pipes, characterized in that: It includes a drive assembly (1) mounted on a robotic arm or an XYZ three-axis truss. The end of the drive assembly (1) is provided with a flaw detection function assembly that cooperates with the spiral welded pipe (2). The spiral welded pipe (2) is mounted on the roller mechanism. The flaw detection functional components include a probe wheel angle adjustment mechanism (3), a probe wheel floating mechanism (4), a phased array flaw detection mechanism (5), an auxiliary wheel mechanism (6), and an encoder counting mechanism (7). The lower part of the probe angle adjustment mechanism (3) is connected to the probe floating mechanism (4), the lower part of the probe floating mechanism (4) is connected to the phased array flaw detection mechanism (5), the auxiliary wheel mechanism (6) is set on the left and right sides of the phased array flaw detection mechanism (5), the encoder counting mechanism (7) is set on one side of the phased array flaw detection mechanism (5), and the water-filled probe wheel (51) of the phased array flaw detection mechanism (5) and the encoder wheel (71) of the encoder counting mechanism (7) are both in contact with the inner and outer surfaces of the spiral welded pipe (2); The flaw detection function components also include a laser (9) and a vision camera (8) that work together, with the laser (9) and vision camera (8) located on the front and rear sides of the phased array flaw detection mechanism (5), respectively.

2. The online ultrasonic phased array testing equipment for spiral welded pipes according to claim 1, characterized in that: The drive assembly (1) is a six-axis robot. Its drive end is connected to the flaw detection function assembly through the connecting frame (10). The probe wheel angle adjustment mechanism (3) is located on the upper surface of the connecting frame (10). The adjustment shaft of the probe wheel angle adjustment mechanism (3) extends downward perpendicularly to the connecting frame (10) and is connected to the probe wheel floating mechanism (4).

3. The online ultrasonic phased array testing equipment for spiral welded pipes according to claim 2, characterized in that: The floating mechanism (4) of the probe wheel includes a mounting plate (41) parallel to the connecting frame (10), and an inverted U-shaped mounting frame (42) is provided below the mounting plate (41). A set of floating springs (43) is connected between the mounting frame (42) and the mounting plate (41).

4. The online ultrasonic phased array testing equipment for spiral welded pipes according to claim 3, characterized in that: The lower end of the mounting bracket (42) is connected to both sides of the rotating shaft of the water tank probe (51). The auxiliary wheel mechanism (6) is connected to the lower side of the mounting bracket (42) on the corresponding side. The auxiliary wheel mechanism (6) is provided with an auxiliary wheel (61). The diameter of the auxiliary wheel (61) is smaller than the diameter of the water tank probe (51), and the contact points of the auxiliary wheel (61) and the water tank probe (51) on both sides with the spiral welded pipe (2) are on the same tangent.

5. The online ultrasonic phased array testing equipment for spiral welded pipes according to any one of claims 1 to 4, characterized in that: The encoder counting mechanism (7) includes an encoder floating mechanism (72) that cooperates with the encoder wheel (71). From top to bottom, it includes a lifting cylinder (721), a buffer spring (722), a guide rod (723), and a fixed ear (724). The encoder wheel (71) is connected to the fixed ear (724), and an encoder (73) is connected to one side of the axle of the encoder wheel (71).

6. The online ultrasonic phased array testing equipment for spiral welded pipes according to claim 3, characterized in that: One side of the mounting plate (41) is connected to an inverted L-shaped connecting plate (11), and a vision camera (8) is fixed at the lower end of the connecting plate (11). The vision camera (8) is positioned facing the bottom end of the water tank probe (51) and the spiral weld seam (2a) of the spiral welded pipe (2). A laser (9) is connected to the other side of the mounting plate (41).

7. A testing method for the online ultrasonic phased array testing equipment for spiral welded pipes as described in claim 1, characterized in that: Step 1: Use the probe angle adjustment mechanism (3) to adjust the phased array flaw detection mechanism (5) to the centering position that matches the angle of the spiral weld (2a) of the current product, rotate to position and lock. Step 2: The spiral welded pipe (2) is placed on the roller mechanism. As the roller mechanism rotates, the probe water tank (51) rotates passively. Step 3: When the laser (9) and vision camera (8) above capture the starting position of the pipe opening and the position of the weld, the robot will automatically track and correct the position of the weld according to the product weld trajectory after software calculation, and at the same time record the starting position of the steel pipe rotation. At this time, the spiral pipe rotates slowly. Step 4: While the spiral tube is rotating, the water system on the phased array probe wheel mechanism (5) will automatically start circulating water to spray water onto the pipe wall, wetting the inner or outer wall of the pipe, and using water as a coupling agent for ultrasonic testing. Step 5: Ultrasonic testing will inspect the weld seam and body of the steel pipe to detect defects. At the same time, the robotic arm of the drive assembly will move axially along the steel pipe, working together with the vision system to continuously inspect the position of the spiral weld seam. Step 6: During this process, the encoder counting mechanism (7) records the number of rotations of the pipe fitting, ensuring that the pipe fitting rotates completely once, and then repeats a cycle to complete the inspection of the spiral weld. Step 7: When the ultrasonic testing reaches the required pipe depth, the phased array testing mechanism (5) is detached from the inner wall or outside of the pipe by the robot arm, and the phased array testing mechanism is driven out of the pipe. The workpiece can then flow into the next station. When the new workpiece arrives at this testing position, the sequential testing will begin.

8. The detection method of the online ultrasonic phased array testing equipment for spiral welded pipes according to claim 7, characterized in that: In step one, the probe angle adjustment mechanism (3) is operated by manual rotation or automatic rotation.

9. The detection method of the online ultrasonic phased array testing equipment for spiral welded pipes according to claim 7, characterized in that: In step six, the computer simultaneously collects and processes data during the inspection, builds a three-dimensional model on the monitor, and displays the coordinates of the defect location on the model.

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