A special-shaped metal tube pressure resistance detection device and method

Abstract

This invention provides a pressure resistance testing device and method for irregularly shaped metal pipes, relating to the field of metal pipe pressure resistance testing technology. It includes a frame, a clamping system, a sealing system, a pressurizing system, a testing system, and a control system. The frame is configured as two symmetrical sets of box-shaped structures, each providing support to both ends of the metal pipe to be tested. Through holes are provided on both sides of the frame. The clamping system is located inside the frame and includes a C-shaped bracket, an upper annular clamp, and a lower annular clamp disposed inside the C-shaped bracket. The lower annular clamp is fixedly connected to the inside of the C-shaped bracket by two support rods, and the upper annular clamp is slidably connected to the inside of the C-shaped bracket by two sliding rods. A first threaded sleeve is fixedly disposed at the top of the C-shaped bracket, and a first screw is threadedly connected to the internal thread of the first threaded sleeve. This invention has advantages such as excellent sealing, non-destructive testing, and high efficiency and automation.

Description

Technical Field

[0001] This invention relates to the field of pressure resistance testing technology for metal pipes, and particularly to a pressure resistance testing device and method for irregularly shaped metal pipes. Background Technology

[0002] Metal pipe fittings are widely used in the high-voltage cable industry, and their pressure resistance is a key quality indicator. For circular cross-section metal pipes, mature pressure testing equipment and standard methods (such as hydrostatic testing and pneumatic testing) already exist. However, for irregularly shaped metal pipes such as rectangular, elliptical, and irregularly curved sections, traditional testing methods face the following technical challenges: 1. Sealing difficulties: General-purpose flat or V-shaped clamps cannot fit well with the end face of irregularly shaped pipes, which can easily lead to leakage of the medium during pressurization and make it impossible to establish stable pressure.

[0003] 2. Easily damages the tube body: In order to achieve a sealing effect, a large clamping force is often required, which can easily cause deformation of the port of irregular tubes (especially thin-walled tubes) or surface damage.

[0004] 3. Low level of automation: It relies heavily on manual operation and visual inspection, which is inefficient and highly subjective in judging minor leaks or deformations, making it easy to misjudge or miss them.

[0005] Therefore, there is an urgent need for a dedicated device and method that can adapt to the characteristics of irregularly shaped tubes and achieve efficient, reliable, and automated pressure resistance testing. Summary of the Invention

[0006] To address the technical problems of existing testing devices, such as difficulty in sealing, easy damage to the pipe body, and low degree of automation, this invention provides a pressure resistance testing device and method for irregularly shaped metal pipes.

[0007] The technical solutions provided by the embodiments of the present invention are as follows: The present invention provides a pressure resistance testing device for irregularly shaped metal tubes, comprising: a frame, a clamping system, a sealing system, a pressurizing system, a testing system, and a control system; The frame is configured as two symmetrical sets with a box-shaped structure, which are used to provide support for both ends of the metal tube to be tested, and through holes are provided on both sides of the frame. The clamping system is located inside the frame and includes a C-shaped bracket, an upper annular clamp and a lower annular clamp located inside the C-shaped bracket. The lower annular clamp is fixedly connected to the inside of the C-shaped bracket by two support rods, and the upper annular clamp is slidably connected to the inside of the C-shaped bracket by two sliding rods. A first threaded sleeve is fixedly provided at the top of the C-shaped bracket, and a first screw is threadedly connected to the inside of the first threaded sleeve. The bottom end of the first screw is rotatably connected to the upper annular clamp, and the top end of the first screw extends out of the top of the frame and is connected to a rotating handle. The sealing system is located inside the frame and includes a conformal sealing plug disposed between the C-shaped bracket and the side wall of the frame and matching the profile of the end section of the irregular metal tube; four sets of second screws rotatably connected between the C-shaped bracket and the side wall of the frame and passing through the conformal sealing plug; second threaded sleeves disposed on the conformal sealing plug and threadedly connected to the four sets of second screws respectively; and a rubber sealing gasket embedded in the inner side of the conformal sealing plug. Synchronous drive components for driving the four sets of second screws to rotate synchronously are also provided on both sides of the frame. The synchronous drive assembly includes a servo motor, a first gear, a second gear, and four sets of third gears. The servo motor is fixedly mounted on the side wall of the frame. The first gear is sleeved on the output shaft of the servo motor. The second gear is rotatably connected to the side wall of the frame and meshes with the first gear. The four sets of third gears are respectively connected to the ends of four sets of second screws and mesh with the second gears. The pressurization system is located inside one of the frames and connected to the conformal sealing plug. It includes an air inlet pipe connected to the side wall of the frame, a solenoid valve installed on the air inlet pipe, a first airflow channel located inside the conformal sealing plug, and a first air guide pipe connected between the air inlet pipe and the first airflow channel. The detection system is located inside another frame and includes a detection tube on the side wall of the frame, a pressure sensor installed at the end of the detection tube, a second airflow channel inside the conformal sealing plug, and a second air guide tube connecting the detection tube and the second airflow channel. It also includes a set of image acquisition units, which are separately located on the outside of the two frames. The control system is independently installed on the outside of the two sets of frames and is electrically connected to the pressurization system and the detection system. It is a PLC or industrial computer with an integrated human-machine interface for controlling the pressurization process, recording pressure data during the pressure holding period, analyzing image data, and outputting detection results.

[0008] This invention provides a method for testing the pressure resistance of irregularly shaped metal tubes, comprising: S1: Clamping and positioning: The two ends of the irregular metal tube to be tested are clamped and fixed in the frame by the clamping system, and the ends of the metal tube are sealed by the sealing system to form a sealed cavity; S2: Automatic pressurization: The control system starts the pressurization system to fill the sealed cavity with gas medium, and the pressure rises at a constant rate to the preset 0.4MPa; S3: Pressure holding test: After reaching 0.4MPa, the pressure holding stage begins, with a holding time of T. During this period, the pressure sensor continuously monitors the pressure value P, and the image acquisition unit continuously captures images of the pipe body. S4: Data Analysis and Judgment: The control system records pressure data in real time. If the pressure drop ΔP does not exceed the threshold ΔP_max within the pressure holding time T, and the image analysis does not find any signs of pipe expansion, cracks, or leakage, the product is deemed qualified; otherwise, it is deemed unqualified. S5: Pressure Relief and Unloading: After the pressure holding period ends, the control system controls the pressurization system to relieve pressure, and then drives the sealing system to loosen, allowing the tested pipe fitting to be removed.

[0009] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following: (1) Excellent sealing: The contour sealing plug design fundamentally solves the sealing problem of irregular pipe ends, ensuring the reliability of the seal under 0.4MPa pressure.

[0010] (2) Non-destructive testing: The axial locking force is controllable, avoiding over-positioning and over-clamping, and protecting the surface quality and dimensional accuracy of the pipe fittings.

[0011] (3) High efficiency and automation: The whole process is controlled by PLC or industrial computer program, one-click operation, automatic completion of pressurization, pressure holding, judgment and depressurization, which greatly improves the detection efficiency and consistency. Combined with pressure data and machine vision analysis, the judgment standard is quantified, avoiding human subjective error, and the detection results are more reliable. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0014] Figure 2 For the present invention Figure 1 Enlarged view of point A in the middle.

[0015] Figure 3 This is a schematic diagram of the pressurization system in this invention.

[0016] Figure 4 This is a schematic diagram of the clamping system and sealing system in this invention.

[0017] Reference numerals: 1. Frame; 11. Through hole; 12. LED light; 13. Transparent door; 14. Baffle; Clamping system; 21. C-type bracket; 22. Upper annular clamp; 23. Lower annular clamp; 24. Support rod; 25. Slide rod; 26. First threaded sleeve; 27. First screw; 28. Rotary handle; Sealing system; 31. Contouring sealing plug; 32. Second screw; 33. Second screw sleeve; 34. Rubber sealing gasket; 35. Synchronous drive assembly; 35A. Servo motor; 35B. First gear; 35C. Second gear; 35D. Third gear; Pressurization system; 41. Inlet pipe; 42. Solenoid valve; 43. First airflow channel; 44. First air guide pipe; 5. Detection system; 51. Detection tube; 52. Air pressure sensor; 53. Second airflow channel; 54. Second air guide tube; 55. Image acquisition unit; 5501. Electric chassis; 6. Control system; 61. Human-machine interface; 62. Alarm; 63. Indicator light.

[0018] As shown in the figure, specific structures and devices are marked in the figure to clearly illustrate the structure of the embodiments of the present invention. However, this is only for illustrative purposes and is not intended to limit the present invention to this specific structure, device and environment. Those skilled in the art can adjust or modify these devices and environments according to specific needs. Detailed Implementation

[0019] The technical solutions of the present invention will now be described with reference to the accompanying drawings. It should be noted that, to make the embodiments more detailed, the following embodiments are the best and preferred embodiments, and those skilled in the art can use other alternative methods to implement some well-known technologies. Furthermore, the accompanying drawings are only for more specific description of the embodiments and are not intended to specifically limit the present invention.

[0020] like Figures 1 to 4 As shown, an embodiment of the present invention provides a pressure resistance testing device for irregularly shaped metal tubes, including: a frame 1, a clamping system 2, a sealing system 3, a pressurizing system 4, a testing system 5, and a control system 6.

[0021] The frame 1 is configured as two symmetrical sets with a box-shaped structure, which are used to provide support for both ends of the metal tube to be tested. The frame 1 has through holes 11 on both sides, and the end of the metal tube to be tested can be inserted into the interior of the frame 1 through the through holes 11.

[0022] The clamping system 2 is located inside the frame 1 and includes a C-shaped bracket 21, an upper annular clamp 22 and a lower annular clamp 23 located inside the C-shaped bracket 21. The lower annular clamp 23 is fixedly connected to the inside of the C-shaped bracket 21 by two support rods 24. The upper annular clamp 22 is slidably connected to the inside of the C-shaped bracket 21 by two sliding rods 25. A first threaded sleeve 26 is fixedly provided at the top of the C-shaped bracket 21. A first screw 27 is threadedly connected to the inside of the first threaded sleeve 26. The bottom end of the first screw 27 is rotatably connected to the upper annular clamp 23. The top end of the first screw extends out of the frame 1 and is connected to a rotating handle 28.

[0023] It should be noted that the clamping system 2 can clamp the metal tube to be tested. Specifically, when the two ends of the metal tube are respectively located between the two sets of C-shaped brackets 21, the lower annular clamp 23 can support the metal tube. At this time, the first screw 27 can be rotated by the handle 28, which can make it move downward under the driving action of the first screw sleeve 26, and the upper annular clamp 22 can be moved downward. During this process, the metal tube is clamped by the upper annular clamp 22 and the lower annular clamp 23, thereby fixing the end of the metal tube.

[0024] The sealing system 3 is located inside the frame 1 and includes a contoured sealing plug 31 that is located between the C-shaped bracket 21 and the side wall of the frame 1 and matches the profile of the end section of the irregular metal tube; four sets of second screws 32 that are rotatably connected between the C-shaped bracket 21 and the side wall of the frame 1 and pass through the contoured sealing plug 31; second threaded sleeves 33 that are located on the contoured sealing plug 31 and threadedly connected to the four sets of second screws 32 respectively; and a rubber sealing gasket 34 that is embedded in the inner side of the contoured sealing plug 31. The frame 1 is also provided with synchronous drive components 35 for driving the four sets of second screws to rotate synchronously.

[0025] It should be noted that the sealing system 3 can seal the end of the metal tube. When the metal tube is clamped and fixed by the clamping system 2, the synchronous drive assembly can drive the four sets of second screws 32 to rotate synchronously. At this time, the four sets of second screws 32 can drive the contour sealing plug 33 to move towards the C-shaped bracket 21 through the second screw sleeve 33. During the movement of the contour sealing plug, the rubber sealing gasket 34 on it will abut against the end of the metal tube, thereby sealing the end of the metal tube and achieving an effective sealing effect.

[0026] The pressurization system 4 is located inside one of the frames 1 and connected to the contour sealing plug 31. It includes an air inlet pipe 41 connected to the side wall of the frame 1, a solenoid valve 42 installed on the air inlet pipe 41, a first airflow channel 43 located inside the contour sealing plug 31, and a first air guide pipe 44 connected between the air inlet pipe 41 and the first airflow channel 43.

[0027] It should be noted that gas can be injected into the metal tube through the pressurization component. Specifically, one end of the air inlet pipe is connected to an external air source. When the solenoid valve 42 is opened, the gas will flow into the second airflow channel 43 through the air inlet pipe 41 and the second air guide pipe 44. The second airflow channel will then extend into and connect to the inside of the metal tube, thereby filling the metal tube with gas.

[0028] The detection system 5 is located inside another rack 1 and includes a detection tube 51 installed on the side wall of the rack 1, a pressure sensor 52 installed at the end of the detection tube, a second airflow channel 53 installed inside the conformal sealing plug 31, a second air guide tube 54 connecting the detection tube 51 and the second airflow channel 53, and also includes a set of image acquisition units 55, which are separately located on the outside of the two racks 1.

[0029] It should be noted that the pressure inside the tube can be detected in real time through the detection component 5, and the deformation of the tube can be monitored. When gas is filled into the metal tube from one end, the second airflow channel 53 will extend into the other end of the metal tube. At this time, since the second airflow 53 is connected to the detection tube 51 through the second air guide tube 54, the pressure sensor installed on the detection tube 51 can detect the pressure inside the metal tube in real time.

[0030] The control system 6 is independently set on the outside of the two sets of frames 1 and is electrically connected to the pressurization system 4 and the detection system 5. It is a PLC or industrial computer with a human-machine interface 61 integrated on it, which is used to control the pressurization process, record the pressure data during the pressure holding period, analyze the image data and output the detection results.

[0031] Furthermore, the synchronous drive assembly 35 includes a servo motor 35A, a first gear 35B, a second gear 35C, and four sets of third gears 35D. The servo motor is fixedly mounted on the side wall of the frame 1. The first gear 35B is sleeved on the output shaft of the servo motor 35A. The second gear 35C is rotatably connected to the side wall of the frame 1 and meshes with the first gear 35B. The four sets of third gears 35D are respectively connected to the ends of the four sets of second screws 32 and mesh with the second gears 35C.

[0032] It should be noted that the output shaft of the servo motor 35A can drive the second gear 35C to rotate through the first gear 35B. At this time, the second gear 35C will simultaneously drive the four sets of third gears 35D that mesh with it to rotate, thereby driving the four sets of second screws 32 to rotate synchronously.

[0033] Furthermore, both the first air guide tube 44 and the second air guide tube 54 are telescopic bellows, which can flexibly extend and bend to adapt to the movement of the contour sealing plug 31.

[0034] In one possible implementation, both the upper annular clamp 22 and the lower annular clamp 23 are provided with rubber pads on their surfaces. The rubber pads are provided with anti-slip textures. The rubber pads can prevent clamping marks from being generated on the surface of the pipe and further improve the stability of clamping.

[0035] In one possible implementation, the frame 1 is made of aluminum alloy and has an LED light 12 mounted on its top.

[0036] It should be noted that the aluminum alloy frame 1 has the advantages of being lightweight, sturdy and reliable. During the inspection process, the operator can see the inside of the frame 1 through the light generated by the LED lighting 12, which provides convenience for the inspection work.

[0037] In one possible implementation, the image acquisition unit 55 is a high-speed camera or an industrial camera. An electric chassis 5501 is mounted on the bottom of the image acquisition unit 55. The electric chassis 5501 can drive the image acquisition unit 55 to move along the axial direction of the metal tube, thereby performing panoramic scanning or fixed-point monitoring of the tube and improving the monitoring effect.

[0038] In one possible implementation, the control system 6 is equipped with an alarm 62 and an indicator light 63. During the testing process, the indicator light 63 illuminates to remind the surrounding staff to control and observe at any time. When a non-conforming metal pipe is found, the control system 6 will control the alarm 62 to issue an alarm signal, thereby reminding the surrounding staff to record the non-conforming metal pipe in a timely manner.

[0039] In one possible implementation, a transparent door 13 is hinged to the front of the frame 1, and a baffle 14 is hinged to the side wall of the frame 1 above the through hole 11. The transparent door and baffle can enclose the frame 1, preventing external dust from entering and contaminating the internal screws and sleeves, thus ensuring transmission stability.

[0040] This invention also provides a method for testing the pressure resistance of irregularly shaped metal tubes, comprising: S1: Clamping and positioning: The two ends of the irregular metal tube to be tested are clamped and fixed in the frame by the clamping system 2, and the ends of the metal tube are sealed by the sealing system 3 to form a sealed cavity; S2: Automatic pressurization: Control system 6 starts pressurization system 4 to fill the sealed cavity with gas medium, and the pressure rises at a constant rate to the preset 0.4MPa; S3: Pressure holding test: After reaching 0.4MPa, the pressure holding stage begins, and the pressure holding time T is 2 hours. During this period, the pressure sensor 52 continuously monitors the pressure value P, and the image acquisition unit 55 continuously captures images of the pipe body. S4: Data Analysis and Judgment: The control system 6 records pressure data in real time. If the pressure drop ΔP does not exceed the threshold ΔP_max (0.2Mpa) within the pressure holding time T, and the image analysis does not find any signs of pipe expansion, cracks or leakage, the product is deemed qualified; otherwise, it is deemed unqualified. S5: Pressure Relief and Unloading: After the pressure holding period ends, the control system 6 controls the pressurization system 4 to relieve the pressure, and then drives the sealing system 3 to loosen and remove the tested pipe fitting.

[0041] This invention encompasses any substitutions, modifications, equivalent methods, and solutions made within the spirit and scope of this invention. To provide the public with a thorough understanding of this invention, specific details are described in detail in the preferred embodiments, while those skilled in the art will fully understand the invention even without these details. Furthermore, to avoid unnecessary misunderstanding of the essence of this invention, well-known methods, processes, procedures, components, and circuits are not described in detail.

[0042] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A pressure resistance testing device for irregularly shaped metal pipes, characterized in that, include: Frame, clamping system, sealing system, pressurizing system, detection system, and control system; The frame is configured as two symmetrical sets with a box-shaped structure, which are used to provide support for both ends of the metal tube to be tested, and through holes are provided on both sides of the frame. The clamping system is located inside the frame and includes a C-shaped bracket, an upper annular clamp and a lower annular clamp located inside the C-shaped bracket. The lower annular clamp is fixedly connected to the inside of the C-shaped bracket by two support rods, and the upper annular clamp is slidably connected to the inside of the C-shaped bracket by two sliding rods. A first threaded sleeve is fixedly provided at the top of the C-shaped bracket, and a first screw is threadedly connected to the inside of the first threaded sleeve. The bottom end of the first screw is rotatably connected to the upper annular clamp, and the top end of the first screw extends out of the top of the frame and is connected to a rotating handle. The sealing system is located inside the frame and includes a conformal sealing plug disposed between the C-shaped bracket and the side wall of the frame and matching the profile of the end section of the irregular metal tube; four sets of second screws rotatably connected between the C-shaped bracket and the side wall of the frame and passing through the conformal sealing plug; second threaded sleeves disposed on the conformal sealing plug and threadedly connected to the four sets of second screws respectively; and a rubber sealing gasket embedded in the inner side of the conformal sealing plug. Synchronous drive components for driving the four sets of second screws to rotate synchronously are also provided on both sides of the frame. The synchronous drive assembly includes a servo motor, a first gear, a second gear, and four sets of third gears. The servo motor is fixedly mounted on the side wall of the frame. The first gear is sleeved on the output shaft of the servo motor. The second gear is rotatably connected to the side wall of the frame and meshes with the first gear. The four sets of third gears are respectively connected to the ends of four sets of second screws and mesh with the second gears. The pressurization system is located inside one of the frames and connected to the conformal sealing plug. It includes an air inlet pipe connected to the side wall of the frame, a solenoid valve installed on the air inlet pipe, a first airflow channel located inside the conformal sealing plug, and a first air guide pipe connected between the air inlet pipe and the first airflow channel. The detection system is located inside another frame and includes a detection tube on the side wall of the frame, a pressure sensor installed at the end of the detection tube, a second airflow channel inside the conformal sealing plug, and a second air guide tube connecting the detection tube and the second airflow channel. It also includes a set of image acquisition units, which are separately located on the outside of the two frames. The control system is independently installed on the outside of the two sets of frames and is electrically connected to the pressurization system and the detection system. It is a PLC or industrial computer with an integrated human-machine interface for controlling the pressurization process, recording pressure data during the pressure holding period, analyzing image data, and outputting detection results.

2. The pressure resistance testing device for irregularly shaped metal tubes according to claim 1, characterized in that, Both the first air guide tube and the second air guide tube are telescopic corrugated tubes.

3. The pressure resistance testing device for irregularly shaped metal tubes according to claim 1, characterized in that, Both the upper and lower annular clamps are provided with rubber pads on their surfaces, and the surfaces of the rubber pads are provided with anti-slip textures.

4. The pressure resistance testing device for irregularly shaped metal tubes according to claim 1, characterized in that, The frame is made of aluminum alloy and is equipped with LED lighting on top.

5. The pressure resistance testing device for irregularly shaped metal tubes according to claim 1, characterized in that, The image acquisition unit is a high-speed camera or an industrial camera, and an electric chassis is installed at the bottom of the image acquisition unit.

6. The pressure resistance testing device for irregularly shaped metal tubes according to claim 1, characterized in that, The control system is equipped with alarms and indicator lights.

7. The pressure resistance testing device for irregularly shaped metal tubes according to claim 1, characterized in that, A transparent door is rotatably connected to the front side of the frame, and a baffle is rotatably connected to the side wall of the frame above the through hole.

8. A method for testing the pressure resistance of irregularly shaped metal tubes using the pressure resistance testing device of claim 1, characterized in that, include: S1: Clamping and positioning: The two ends of the irregular metal tube to be tested are clamped and fixed in the frame by the clamping system, and the ends of the metal tube are sealed by the sealing system to form a sealed cavity; S2: Automatic pressurization: The control system starts the pressurization system to fill the sealed cavity with gas medium, and the pressure rises at a constant rate to the preset 0.4MPa; S3: Pressure holding test: After reaching 0.4MPa, the pressure holding stage begins, with a holding time of T. During this period, the pressure sensor continuously monitors the pressure value P, and the image acquisition unit continuously captures images of the pipe body. S4: Data Analysis and Judgment: The control system records pressure data in real time. If the pressure drop ΔP does not exceed the threshold ΔP_max within the pressure holding time T, and the image analysis does not find any signs of pipe expansion, cracks, or leakage, the product is deemed qualified; otherwise, it is deemed unqualified. S5: Pressure Relief and Unloading: After the pressure holding period ends, the control system controls the pressurization system to relieve pressure, and then drives the sealing system to loosen, allowing the tested pipe fitting to be removed.

9. The pressure resistance testing method for irregularly shaped metal tubes according to claim 8, characterized in that, The pressure holding time T is 2 hours, and the pressure drop threshold ΔP_max is 0.2 MPa.

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