Acoustic emission sensor transmission device and method for detecting pipelines with different pipe diameters

Abstract

The invention provides an acoustic emission sensor transmission device and method for detecting pipelines with different pipe diameters, and belongs to the field of welding nondestructive testing. The problem of poor welding quality caused by the fact that a traditional acoustic emission sensor mounting structure cannot adapt to complex morphology is solved. An acoustic emission sensor transmission device for detecting pipelines with different pipe diameters comprises a rotating part used for rotating around the axis of a welded pipeline; the rotation driving assembly is connected with the rotating part and used for driving the rotating part to rotate; the fixed end of the linear driving assembly is connected with the rotating part, and the movable end is used for acting in the radial direction of the welded pipeline. The sound signal sensor is connected with the movable end of the linear driving assembly; the controller is used for controlling the rotation driving assembly to rotate to drive the acoustic signal sensor to track the heat source and controlling the acoustic signal sensor to detect the surface of the welded pipeline at a fixed distance through the linear driving assembly. The device is mainly used for pipeline welding detection.

Description

Technical Field

[0001] This invention belongs to the field of nondestructive testing of welding, and in particular relates to a transmission device and method for acoustic emission sensors for detecting pipes of different diameters. Background Technology

[0002] Acoustic emission (AE) detection technology is widely used in pipeline welding quality monitoring because it can capture transient elastic waves from dynamic defects such as cracks and lack of fusion during welding in real time. However, in engineering implementation, this technology first faces the drawback of "signal distortion due to lack of dynamic tracking": the welding arc or laser heat source moves along the weld at a constant speed, while the acoustic emission sensor is usually fixed to the outer wall of the pipe by a clamp or magnetic base, and the relative distance between it and the heat source changes continuously with the welding process. The propagation attenuation of the acoustic signal in the metal is exponentially related to the distance, and the distance fluctuation directly causes uncertainty in the received amplitude; at the same time, fixed sensors cannot compensate for the differences in propagation path caused by changes in the position of the heat source in real time, resulting in difficulties in amplitude calibration and a decrease in the signal-to-noise ratio, thus significantly reducing the accuracy of defect identification.

[0003] Secondly, the existing sensor installation methods suffer from poor pipe diameter adaptability. Currently used fixing methods such as clamps, magnetic attachments, or adhesives are only designed for specific pipe diameters. When projects require testing pipe diameters ranging from DN100 to DN1200 or even larger, operators must frequently change clamps or gaskets, resulting in long adjustment cycles and high labor intensity. More importantly, these rigid or semi-rigid connection methods struggle to maintain a uniform and constant preload on pipe walls with continuously varying curvature, leading to uneven coupling agent layer thickness. This, in turn, causes interface reflection and energy dissipation, resulting in signal amplitude drift and phase distortion.

[0004] Furthermore, the insufficient adaptability of traditional installation structures to complex surface morphologies also limits the reliability of detection. Local bulges or depressions appear at pipe weld reinforcement, misalignment, elbows, and flange connections. Fixed or single-degree-of-freedom sliding rail sensors cannot adapt to these three-dimensional morphological changes in real time, often resulting in momentary detachment or a sudden drop in coupling pressure, leading to signal attenuation or even complete loss, creating detection blind spots. To date, no integrated device has been publicly reported that simultaneously achieves the three functions of "dynamic heat source tracking—constant distance maintenance," "pipe diameter self-adaptation," and "conformal fit to complex surfaces." Therefore, a novel transmission mechanism is urgently needed to overcome these technical bottlenecks. Summary of the Invention

[0005] In view of this, the present invention aims to propose a transmission device and method for acoustic emission sensors to detect pipes of different diameters, so as to solve the problem that the traditional acoustic emission sensor installation structure cannot adapt to complex morphologies, resulting in poor welding quality.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: According to a first aspect of the present invention, a transmission device for an acoustic emission sensor for detecting pipes of different diameters is provided, comprising:

[0007] A rotating part, used to rotate about the axis of the pipe being welded;

[0008] A rotation drive assembly, connected to the rotating part, is used to drive the rotating part to rotate;

[0009] A linear drive assembly, with a fixed end connected to a rotating part and a movable end used to move radially along the pipe being welded;

[0010] An acoustic signal sensor is connected to the movable end of the linear drive assembly;

[0011] The controller, connected to the rotary drive assembly and the linear drive assembly, is used to control the rotation of the rotary drive assembly to drive the acoustic signal sensor to track the heat source, and to control the acoustic signal sensor through the linear drive assembly to detect the surface of the welded pipe at a fixed distance.

[0012] Furthermore, the rotating part is a semi-circular arc-shaped rack.

[0013] Furthermore, the rotation drive component is a gear that meshes with the semi-circular rack, and the gear is connected to the rotating end of the servo motor.

[0014] Furthermore, the linear drive assembly and the rotating part are detachably connected via a locking element.

[0015] Furthermore, the controller includes a distance sensor coupled to the movable end of the linear drive assembly for detecting the distance between the acoustic signal sensor and the surface of the pipe being welded.

[0016] Furthermore, the controller also includes a heat source tracking system for detecting the location of the heat source and controlling an acoustic signal sensor to track the movement of the welding heat source via a rotation drive assembly.

[0017] Furthermore, the waveguide rod of the acoustic signal sensor is in contact with the surface of the pipe being welded.

[0018] Furthermore, the linear drive assembly is an electric cylinder or a hydraulic cylinder.

[0019] Furthermore, the linear drive assembly includes a motor, a transmission unit, a threaded rod, a hollow rotating shaft, and a support unit. The support unit is connected to the rotating unit, and the motor is mounted on the support unit. The rotating end of the motor is connected to the hollow rotating shaft through the transmission unit. The hollow rotating shaft is rotatably connected to the support unit. One end of the threaded rod is threadedly connected to the hollow rotating shaft, and the other end is connected to an acoustic signal sensor. The threaded rod is slidably connected to the support unit.

[0020] According to a second aspect of the present invention, a method is provided for using an acoustic emission sensor transmission device for detecting pipes of different diameters as described above, comprising the following steps:

[0021] Fix the acoustic signal sensor to the movable end of the linear drive assembly at a predetermined distance from the pipe to be welded, and press the front end of the waveguide rod of the acoustic signal sensor against the surface of the pipe to be welded.

[0022] Welding begins; during the welding process, the controller controls the rotation drive component to drive the acoustic signal sensor to track the displacement of the heat source.

[0023] If an irregular surface is encountered on the pipe to be welded, the controller controls the movement of the moving end of the linear drive component to make the acoustic signal sensor move a predetermined distance away from the pipe to be welded, adapting to the special shape of the pipe to be welded.

[0024] Compared with the prior art, the beneficial effects of the present invention are:

[0025] 1. This transmission device is controlled by a controller, which enables the acoustic signal sensor at the moving end of the linear drive component on the rotating part to synchronize the welding displacement speed in real time and maintain a constant distance from the heat source under the driving action of the rotation drive component. This significantly eliminates the acoustic signal attenuation and distortion caused by distance fluctuations, and greatly improves the detection accuracy and stability.

[0026] 2. The linear drive assembly allows the waveguide rod's moving radius to be continuously adjusted axially, enabling stepless adaptation from thin to thick pipes, meeting the general needs of multi-diameter working conditions, and reducing the frequency of fixture replacement and on-site debugging workload.

[0027] 3. The rotation of the rotating part driven by the rotary drive assembly and the extension and retraction of the moving end of the linear drive assembly work together to enable the sensor to actively conform to and adapt to complex surface morphologies such as weld reinforcement, elbows and flanges, effectively avoiding local coupling failure, ensuring complete reception of acoustic emission signals throughout the entire path, and completely eliminating detection blind spots. Attached Figure Description

[0028] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0029] Figure 1 This is a schematic diagram of the transmission device for an acoustic emission sensor that detects pipes of different diameters according to the present invention.

[0030] Figure 2 This is a schematic diagram of the linear drive assembly described in this invention.

[0031] Linear drive assembly 1; motor 101; transmission part 102; threaded rod 103; waveguide rod 104; hollow rotating shaft 105; support part 106; rotating part 2; welded pipe 3; acoustic signal sensor 4; rotation drive assembly 5. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present invention can be combined with each other, and the described embodiments are only some embodiments of the present invention, not all embodiments.

[0033] It should be noted that the descriptions of "left," "right," "left side," "right side," "upper part," "lower part," "top," and "bottom" in this invention are defined based on the orientation or positional relationships shown in the accompanying drawings. They are merely for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the described structure must be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0034] In the description of this invention, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Specific implementation method one:

[0036] Referring to the accompanying drawings, this embodiment, according to a first aspect of the present invention, provides a transmission device for an acoustic emission sensor that detects pipes of different diameters, comprising:

[0037] The rotating part 2 is used to rotate around the axis of the pipe 3 to be welded. Specifically, the rotating part 2 is a semi-circular arc-shaped rack. The semi-circular arc-shaped rack only needs to be able to rotate around the axis of the pipe 3 to be welded. The specific rotational connection relationship can be reasonably set according to the actual situation, for example, it can be mounted on a bearing seat through a bearing. The pipe 3 to be welded is fixed by a clamp, mainly to ensure that the axis of the fixing clamp is coincident with the axis of the pipe 3 to be welded.

[0038] The rotation drive assembly 5, connected to the rotating part 2, is used to drive the rotating part 2 to rotate. The purpose of the rotation drive assembly 5 is mainly to drive the rotating part 2 to rotate around the axis of the pipe 3 being welded. The assembly is rationally configured according to the specific form of the rotating part 2. In this application, a semi-circular arc-shaped rack is selected for the rotating part 2. Correspondingly, the rotation drive assembly 5 is equipped with gears that mesh with the semi-circular arc-shaped rack. The gears are connected to the rotating end of the servo motor via a reducer. The rotational position of the gears, and the arrangement of the reducer and servo motor, can be rationally configured according to the site layout and the welding equipment required for actual operation.

[0039] The linear drive assembly 1 has a fixed end connected to the rotating part 2, and a movable end for radial movement along the welded pipe 3. The linear drive assembly 1 is primarily designed to adjust the position of the acoustic signal sensor 4 at different stages, allowing the sensor to track and detect the heat source at a certain distance. This enables the sensor to actively conform to and adapt to complex surface morphologies such as weld reinforcement, elbows, and flanges, effectively preventing local coupling failures and ensuring complete reception of the acoustic emission signal throughout the entire path, thus completely eliminating detection blind spots. Simultaneously, it reduces the workload of adjustment and improves work efficiency. The linear drive assembly 1 and the rotating part 2 are detachably connected via a locking mechanism. The locking mechanism can be either a snap-fit ​​structure or fixed with bolts, depending on actual needs. After fixing, it must meet structural strength requirements to prevent deformation of the rotating part 2 and ensure reliable operation.

[0040] The acoustic signal sensor 4 is connected to the movable end of the linear drive assembly 1. The fixing method of the acoustic signal sensor 4 and the movable end of the linear drive assembly 1 can be selected according to the type of the linear drive assembly 1. Generally, screw fixing or adhesive bonding can be selected.

[0041] The controller, connected to the rotation drive assembly 5 and the linear drive assembly 1, is used to control the rotation of the rotation drive assembly 5 to drive the acoustic signal sensor 4 to track the heat source and to control the acoustic signal sensor 4 to detect the surface of the welded pipe 3 at a fixed distance through the linear drive assembly 1.

[0042] In this embodiment, the controller includes a distance sensor coupled to the movable end of the linear drive assembly 1, which is used to detect the distance between the acoustic signal sensor 4 and the surface of the welded pipe 3.

[0043] In this embodiment, the controller further includes a heat source tracking system for detecting the position of the heat source and controlling the acoustic signal sensor 4 to track the movement of the welding heat source via the rotation drive component 5. The heat source tracking system can utilize existing technology; any system capable of tracking the heat source, transmitting a control signal to the controller, and then controlling the rotation drive component 5 to move the linear drive component 1, so that the acoustic signal sensor 4 moves synchronously with the heat source, can be used in this application. Specifically, the heat source tracking system can employ an infrared thermal imager, an infrared thermometer, an infrared array sensor, etc., selected appropriately according to actual needs. The corresponding connection method and control logic with the controller utilize existing technology.

[0044] In this embodiment, the waveguide rod 104 of the acoustic signal sensor 4 is in contact with the surface of the pipe 3 being welded. The front end of the waveguide rod 104 is coated with high-temperature silicone grease and then adheres to the surface of the pipe 3 being welded, ensuring effective acoustic signal coupling.

[0045] In this embodiment, the linear drive assembly 1 includes a motor 101, a transmission part 102, a threaded rod 103, a hollow rotating shaft 105, and a support part 106. The support part 106 is connected to the rotating part 2. The motor 101 is mounted on the support part 106. The rotating end of the motor 101 is connected to the hollow rotating shaft 105 through the transmission part 102. The hollow rotating shaft 105 is rotatably connected to the support part 106. One end of the threaded rod 103 is threadedly connected to the hollow rotating shaft 105, and the other end is connected to the acoustic signal sensor 4. The threaded rod 103 is slidably connected to the support part 106. The transmission unit 102 can use a synchronous belt. The rotating end of the motor 101 causes the hollow shaft 105 to rotate synchronously via the synchronous belt. The hollow inner wall of the hollow shaft 105 is provided with an internal thread that mates with the threaded rod 103. The threaded rod 103 is inserted into the hollow shaft 105 and mates with the thread on the hollow inner wall. At the same time, the threaded rod 103 is slidably mounted radially on the support unit 106. This structure allows the hollow shaft 105 to drive the threaded rod 103 to move linearly via the thread when rotating. This enables the acoustic signal sensor 4 at the end to move linearly.

[0046] According to a second aspect of the present invention, a method is provided for using an acoustic emission sensor transmission device for detecting pipes of different diameters as described above, comprising the following steps:

[0047] The acoustic signal sensor 4 is fixed to the movable end of the linear drive assembly 1 by a clamp at a predetermined distance from the pipe 3 to be welded. The waveguide rod of the acoustic signal sensor 4 is coated with high-temperature silicone grease and then pressed onto the surface of the pipe 3 to be welded. The welding heat source is dynamically tracked, the PC control system is started, and the displacement speed and position information of the welding heat source are obtained in real time.

[0048] Welding begins. During the welding process, the controller controls the rotation drive assembly 5, which drives the acoustic signal sensor 4 to track the displacement of the heat source through the rotating part 2 and the linear drive assembly 1.

[0049] If an irregular surface is encountered on the pipe 3 to be welded, the controller controls the movement of the moving end of the linear drive component 1 to make the acoustic signal sensor 4 a predetermined distance away from the pipe 3 to be welded, so as to adapt to the special shape of the pipe 3 to avoid coupling failure affecting the detection effect and welding quality.

[0050] The PC control system synchronizes the displacement velocity of the welding heat source in real time and dynamically adjusts the sensor position to ensure a constant distance between the sensor and the heat source, thereby eliminating acoustic signal amplitude errors caused by distance variations. This achieves dynamic tracking and acquisition of acoustic emission signals during welding, significantly improving the stability and accuracy of signal acquisition. Its design makes it widely applicable, effectively suitable for welding inspection of pipes of different diameters, and adaptable to special morphological areas on pipelines. Specific Implementation Method Two:

[0052] In this embodiment, the only difference from Specific Embodiment 1 is that the linear drive assembly 1 is an electric cylinder or a hydraulic cylinder. The fixing method of the corresponding acoustic signal sensor 4 and the fixing method of the linear drive assembly 1 and the rotating part 2 are reasonably set according to the actual situation.

[0053] The sensors, controllers, and control programs mentioned above are all existing technologies and will not be elaborated upon.

[0054] The embodiments of the present invention disclosed above are merely illustrative of the invention. These embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Many modifications and variations can be made based on the content of this specification. These embodiments are selected and specifically described in this specification to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention.

Claims

1. A transmission device for an acoustic emission sensor for detecting pipes of different diameters, characterized in that: include: Rotating part (2) is used to rotate around the axis of the pipe (3) being welded; Rotation drive assembly (5) is connected to the rotating part (2) and is used to drive the rotating part (2) to rotate; The linear drive assembly (1) has a fixed end connected to the rotating part (2) and a movable end used for radial movement along the welded pipe (3); The acoustic signal sensor (4) is connected to the movable end of the linear drive assembly (1); The controller, connected to the rotation drive assembly (5) and the linear drive assembly (1), is used to control the rotation of the rotation drive assembly (5) to drive the acoustic signal sensor (4) to track the heat source and to control the acoustic signal sensor (4) to detect the surface of the welded pipe (3) at a fixed distance through the linear drive assembly (1).

2. The acoustic emission sensor transmission device for detecting pipes of different diameters according to claim 1, characterized in that: The rotating part (2) is a semi-circular arc-shaped rack.

3. The acoustic emission sensor transmission device for detecting pipes of different diameters according to claim 2, characterized in that: The rotation drive assembly (5) is a gear that meshes with the semi-circular rack, and the gear is connected to the rotating end of the servo motor.

4. The acoustic emission sensor transmission device for detecting pipes of different diameters according to claim 1, characterized in that: The linear drive assembly (1) and the rotating part (2) are detachably connected by a locking member.

5. The acoustic emission sensor transmission device for detecting pipes of different diameters according to claim 4, characterized in that: The controller includes a distance sensor coupled to the movable end of the linear drive assembly (1) for detecting the distance between the acoustic signal sensor (4) and the surface of the welded pipe (3).

6. The acoustic emission sensor transmission device for detecting pipes of different diameters according to claim 1, characterized in that: The controller also includes a heat source tracking system for detecting the location of the heat source and controlling the acoustic signal sensor (4) to track the movement of the welding heat source by rotating drive assembly (5).

7. The acoustic emission sensor transmission device for detecting pipes of different diameters according to claim 1, characterized in that: The waveguide rod (104) of the acoustic signal sensor (4) is in contact with the surface of the welded pipe (3).

8. A transmission device for an acoustic emission sensor for detecting pipes of different diameters according to any one of claims 1-7, characterized in that: The linear drive assembly (1) is an electric cylinder or a hydraulic cylinder.

9. A transmission device for an acoustic emission sensor for detecting pipes of different diameters according to any one of claims 1-7, characterized in that: The linear drive assembly (1) includes a motor (101), a transmission part (102), a threaded rod (103), a hollow rotating shaft (105), and a support part (106). The support part (106) is connected to the rotating part (2). The motor (101) is mounted on the support part (106). The rotating end of the motor (101) is connected to the hollow rotating shaft (105) through the transmission part (102). The hollow rotating shaft (105) is rotatably connected to the support part (106). One end of the threaded rod (103) is threadedly connected to the hollow rotating shaft (105), and the other end is connected to the acoustic signal sensor (4). The threaded rod (103) is slidably connected to the support part (106).

10. A method for using an acoustic emission sensor transmission device as described in claims 1-7 for detecting pipes of different diameters, characterized in that, Includes the following steps: The acoustic signal sensor (4) is fixed to the movable end of the linear drive assembly (1) at a predetermined distance from the pipe to be welded (3), and the front end of the waveguide rod of the acoustic signal sensor (4) is pressed against the surface of the pipe to be welded (3). Welding begins. During the welding process, the controller controls the rotation drive assembly (5) to drive the acoustic signal sensor (4) to track the displacement of the heat source. If an irregular surface is encountered on the pipe to be welded (3), the controller controls the movement of the moving end of the linear drive component (1) to make the acoustic signal sensor (4) move at a predetermined distance from the pipe to be welded (3) to adapt to the special shape of the pipe to be welded (3).

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