Portable cable defect ultrasonic detection device

Abstract

A portable cable defect ultrasonic detection device comprises a bearing module, a cleaning module, a water supply assembly and a wiping assembly. The transmission module comprises at least two transmission rollers which are oppositely arranged in the accommodating cavity, the two transmission rollers are arranged at intervals, and a cable penetrates through the middle of the transmission rollers; the detection module comprises arc-shaped supports which are oppositely arranged, a plurality of ultrasonic probes are arranged in the circumferential direction of the arc-shaped supports, and coupling agent spray heads are arranged at the positions, corresponding to the ultrasonic probes, of the arc-shaped supports. According to the device, an efficient detection system is constructed through cleaning-coupling-detection integrated design, wiping clamping plates drive wiping cotton to be tightly attached to the surface of a cable, dirt, oxide and other pollutants on the surface of the cable can be removed, and multi-directional detection is achieved through circumferential distribution of ultrasonic probes.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cable detection, in particular to a portable cable defect ultrasonic detection device. BACKGROUND

[0002] As the core infrastructure in the fields of power transmission and communication connection, the operation state of the cable directly affects the stability and safety of the system. During the long-term use, the cable is prone to defects such as internal insulation layer damage, conductor oxidation and partial discharge due to the influence of laying environment, mechanical stress and aging. If not detected and processed in time, it may cause short circuit, electric leakage and even fire accidents, so regular and accurate defect detection of the cable is a key link to ensure the safe operation of the infrastructure. At present, the ultrasonic detection technology has become one of the mainstream technologies for internal defect detection of the cable due to its strong penetration, fast response and non-destructive detection. Through the emission of ultrasonic waves and the analysis of reflected wave characteristics, the internal structure abnormalities of the cable can be accurately identified to provide data support for defect positioning and evaluation.

[0003] The existing cable defect detection technology and device have many shortcomings and cannot meet the efficient detection requirements in complex scenes. On the one hand, the fixed detection device needs to disassemble and transport the cable to be detected to a special detection table, which is not only cumbersome, time-consuming and laborious, but also cannot be applied to space-limited scenes such as underground pipes and tunnels. Moreover, the device structure is fixed and cannot be quickly adjusted according to the diameter and material differences of the cable, so the adaptability to different specifications of the cable is poor. On the other hand, although the existing portable detection device has the ability to move, it still has obvious shortcomings: it lacks an effective treatment mechanism for the pollutants such as soil and oxides on the surface of the cable, which leads to poor coupling between the ultrasonic probe and the surface of the cable, serious attenuation of ultrasonic energy and a significant decrease in detection accuracy. At the same time, most of the devices lack a stable speed control system, which easily causes speed fluctuations when moving on the surface of the cable, resulting in uneven data collection and affecting the accuracy of defect positioning. In addition, the coupling agent spraying system of some devices has the problems of uneven spraying and serious waste, which cannot form a uniform and stable coupling layer on the surface of the cable, further restricting the detection effect. SUMMARY

[0004] In order to solve the problems of inconvenient movement of the detection equipment and limited application scenes in the prior art, the present application provides a portable cable defect ultrasonic detection device.

[0005] The technical scheme of the present application is as follows: A portable cable defect ultrasonic detection device, a bearing module, including a bearing frame, a containing cavity is arranged in the bearing frame, and at least one set of opposite through channels exist in the containing cavity for the passage of the cable to be detected; The cleaning module comprises a water supply assembly and a wiping assembly, the wiping assembly is located in the accommodating cavity, comprises two wiping clamping plates arranged oppositely, and the opposite end faces of the two wiping clamping plates are provided with arc-shaped channels for the cable to pass through, and wiping cotton is arranged in the arc-shaped channels; the water supply assembly comprises a water storage tank located at the bottom of the bearing frame, the water storage tank is communicated with a water supply pipe group through a water pump, a plurality of cleaning nozzles are communicated, and the cleaning nozzles are located outside the arc-shaped channels and are arranged in a circumferential direction and close to the edges of the arc-shaped channels. The transmission module comprises at least two transmission rollers arranged oppositely in the accommodating cavity, and the two transmission rollers are arranged at intervals, and the middle part is used for the cable to pass through; the bearing frame is provided with a driving assembly connected with the transmission rollers and capable of driving the transmission rollers to rotate. The detection module comprises two arc-shaped supports arranged oppositely, and a plurality of ultrasonic probes are arranged in a circumferential direction of the arc-shaped supports; the arc-shaped supports are provided with coupling agent nozzles corresponding to the positions of the ultrasonic probes, and flow-through grooves are formed in the arc-shaped supports between the coupling agent nozzles and the ultrasonic probes; the accommodating cavity is further provided with a coupling agent storage tank connected with a liquid delivery pump and communicated with the coupling agent nozzles through a plurality of delivery pipes. The control module is arranged above the bearing frame and is electrically connected with the water pump, the driving assembly, the liquid delivery pump and the coupling agent nozzles, so as to control the opening and closing of the above components; the control module is electrically connected with a touch screen for instruction interaction and data visualization, and is also electrically connected with an ultrasonic signal processing module for driving the ultrasonic probes and receiving signals emitted by the ultrasonic probes.

[0006] The bearing frame comprises a top plate and a bottom plate arranged oppositely, and an accommodating cavity is formed in the middle part; the top plate and the bottom plate are connected through support columns at four corners, and a through channel is formed between two support columns in the width direction.

[0007] The wiping clamping plate is arranged oppositely in a vertical direction, and comprises a main body portion provided with an arc-shaped channel; ear plate portions are arranged on both sides of the main body portion, and the two wiping clamping plates are respectively mounted on the top plate and the bottom plate through the ear plate portions.

[0008] In order to facilitate the extrusion of water in the wiping cotton, two groups of electric push rods are arranged on the bottom plate, the electric push rods are electrically connected with the control module, the output ends of the electric push rods penetrate the ear plate portions of the lower wiping clamping plate and are fixed thereto, a slide rod is connected to the upper end of the output end, the slide rod penetrates the top plate and is arranged in a sliding mode, a compression spring is arranged on the slide rod, and the bottom end of the compression spring is connected with the ear plate portion of the upper wiping clamping plate.

[0009] In order to collect the water extruded from the wiping cotton, the water storage tank is located below the wiping clamping plate, the projection of the main body portion of the wiping clamping plate in the vertical direction is located in the water storage tank, and a water passing groove is formed in the bottom plate corresponding to the position of the water storage tank.

[0010] The specific design of the cleaning nozzle is that 3-5 cleaning nozzles are arranged on the outer side of each wiping clamp plate, and are uniformly arrayed along the arc-shaped channel, and the interval angle between adjacent cleaning nozzles is 15-30°.

[0011] The specific design of the water supply pipe group is that the water supply pipe group comprises a first water supply pipe communicated with the water pump, the first water supply pipe is communicated with a second water supply pipe and a third water supply pipe through a three-way pipe, and the second water supply pipe and the third water supply pipe are both communicated with a plurality of branch pipes respectively communicated with the cleaning nozzles on the outer sides of the two arc-shaped clamp plates. The end face of the main body part of the upper wiping clamp plate is provided with a water pipe clamp for the second water supply pipe to pass through.

[0012] In order to facilitate the installation of the arc-shaped supports, the end faces opposite to each other of the top plate and the bottom plate are both provided with clamping rods, and the two clamping rods are respectively connected with the two arc-shaped supports.

[0013] The specific design of the driving assembly is that the driving assembly comprises a driving motor located on the bearing frame, and a driving gear is mounted on the output end of the driving motor and connected with the rotating shaft of any transmission roller, a driven gear is engaged with the driving gear, a driving pulley is mounted on the driven gear, a driven pulley is connected with the driving pulley through a belt, and the driven pulley is connected with the rotating shaft of the other transmission roller.

[0014] A portable cable defect ultrasonic detection method, the application of a kind of portable cable defect ultrasonic detection device, comprising the following steps: S1: the assembly of detection device and the cable to be detected, slowly pass through the transmission roller, arc-shaped support and two wiping cotton between one end of the cable to be detected; S2: start the defect detection of cable, start water pump, driving motor, drive the whole detection device along the cable and clean the surface of cable, at the same time, start infusion pump and ultrasonic probe, spray coupling agent on the cleaned cable surface through coupling agent nozzle to form coupling layer, ultrasonic probe emits signal and receives echo, sends the signal to ultrasonic signal processing module, and displays defect data on touch display screen through control module; S3: recover clean water, after a preset time t, close water pump, driving motor, infusion pump and ultrasonic probe, start electric push rod, drive arc-shaped clamp to squeeze wiping cotton, the squeezed clean water flows back to water storage tank through water tank, and the electric push rod drives the arc-shaped clamp to reset; S4: repeat steps S2-S3 until the detection of the whole cable is completed, close water pump, driving motor, infusion pump and ultrasonic probe, slowly pull out the detection device at the other end of the cable, and complete the detection work.

[0015] The beneficial effects of this invention are as follows: This invention is a portable ultrasonic testing device for cable defects. Compared with traditional fixed devices that require cable disassembly and portable devices that suffer from reduced detection accuracy due to poor coupling, this device constructs an efficient detection system through an integrated design of cleaning-coupling-detection. In the cleaning module, the cleaning nozzle evenly sprays clean water along the circumference of the arc-shaped channel, and the wiping clamp moves the wiping cotton to adhere tightly to the cable surface, which can remove contaminants such as dirt and oxides from the cable surface, eliminating interference for ultrasonic detection. On the arc-shaped support of the detection module, the ultrasonic probe is circumferentially distributed to achieve multi-directional detection. The coupling agent nozzle precisely sprays coupling agent through the flow channel, forming a uniform and stable coupling on the cable surface. The layer significantly reduces ultrasonic energy attenuation, solving the problem of poor coupling in traditional devices. This results in clearer ultrasonic signal reflection and significantly improves the accuracy of internal defect identification. It provides reliable data support for the location and assessment of defects such as insulation layer damage and conductor oxidation. The control module integrates a touch screen and an ultrasonic signal processing module, enabling integrated operation of parameter setting, data display, and analysis. No complex wiring or external equipment is required. The device has a compact and highly portable structure, allowing for direct testing in space-constrained environments such as underground pipelines and tunnels without disassembling the entire cable. This solves the problems of cumbersome operation and poor adaptability of fixed devices, providing an efficient, accurate, and flexible testing solution for cable maintenance. Attached Figure Description

[0016] The solutions and advantages of this application will become clear to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of the invention.

[0017] In the attached diagram: Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a partial structural diagram of the present invention; Figure 3 This is a schematic diagram of the structure without the top slab installed. Figure 4 This is a schematic diagram of the transmission module structure; Figure 5 This is a schematic diagram of the detection module; The components represented by the various reference numerals in the diagram are: 1. Load-bearing module; 11. Top plate; 12. Bottom plate; 13. Support column; 14. Receiving cavity; 15. Water trough; 2. Cleaning module; 20. Water storage tank; 21. Water pump; 22. Water supply pipe assembly; 221. First water supply pipe; 222. T-joint pipe; 223. Second water supply pipe; 224. Third water supply pipe; 225. Branch pipe; 226. Water pipe clamp; 23. Cleaning nozzle; 24. Wiping clamp; 241. Main body; 242. Ear plate; 25. Arc-shaped channel; 26. Wiping... 27. Wiping cotton; 28. Electric push rod; 29. ​​Slide rod; 3. Compression spring; 3. Transmission module; 31. Transmission roller; 32. Drive motor; 33. Drive gear; 34. Driven gear; 35. Drive pulley; 36. Belt; 37. Driven pulley; 4. Detection module; 41. Arc-shaped bracket; 42. Clamping rod; 43. Ultrasonic probe; 44. Coupling agent nozzle; 45. Flow channel; 46. Coupling agent storage box; 47. Delivery pipe; 5. Control module; 6. Touch screen; 7. Cable. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the exemplary embodiments of this application clearer, the technical solutions in the exemplary embodiments of this application are described clearly and completely below. Obviously, the described exemplary embodiments are only some embodiments of this application, and not all embodiments.

[0019] Based on the exemplary embodiments shown in this application, all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of this application. Furthermore, although the disclosures in this application are presented by way of one or more exemplary examples, it should be understood that each aspect of these disclosures can constitute a complete technical solution on its own.

[0020] Furthermore, the terms “comprising” and “having”, and any variations thereof, are intended to cover but not exclusively include, for example, a product or device that includes a series of components is not necessarily limited to those that are explicitly listed, but may include other components that are not explicitly listed or that are inherent to such product or device.

[0021] As used in this application, the term "module" means any known or subsequently developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and / or software code capable of performing the functions associated with that element.

[0022] Example 1 This embodiment discloses a portable ultrasonic cable defect detection device, aiming to systematically solve the problems of traditional ultrasonic cable detection devices in complex scenarios, such as cumbersome disassembly, poor adaptability, poor coupling, uneven data acquisition, and water waste. By integrating four core modules—cleaning, transmission, detection, and control—and combining an adjustable structure with intelligent control technology, it achieves efficient, accurate, and non-destructive testing of cables. It is particularly suitable for complex operating scenarios such as underground pipelines, tunnels, outdoor overhead lines, and confined spaces, providing reliable technical support for the operation and maintenance of power and communication cables. Its specific structure, core component details, adaptation logic, and complete usage process are as follows (see attached diagram). Figure 1 The system includes a support module 1, which serves as the supporting carrier for the entire device. It must simultaneously meet the dual requirements of lightweight design for easy handling and high strength to ensure operational stability. The support frame is made of aluminum alloy profiles, a material with low density and high tensile strength, reducing weight by 40% compared to traditional steel, allowing for easy handling by a single person. The frame includes a rectangular top plate 11 and a bottom plate 12 arranged opposite each other, forming a cuboid cavity 14 in the middle, providing ample installation space for each functional module. The four corners of the top plate 11 and bottom plate 12 are connected by support columns 13. The support columns 13 have external threads at both ends and are fixed to the pre-embedded nuts on the top plate 11 and bottom plate 12 using hexagonal nuts, enabling them to withstand the reaction force of the transmission roller 31 during the testing process without deformation.

[0023] In this embodiment, a through channel is formed between the two support columns 13 in the width direction of the frame, allowing the cable 7 to be tested to pass horizontally through. The control box of the control module 5 is fixedly installed above the top plate 11. Optionally, four foldable casters can be installed under the bottom plate 12. When unfolded, they are fixed by a locking mechanism, which facilitates the smooth movement of the device on the ground. When folded, they can completely fit against the bottom plate 12, without affecting the operation of the device in narrow spaces such as underground pipelines.

[0024] Based on the above structure, a rectangular water passage trough 15 is provided in the middle of the base plate 12. The edges of the water passage trough 15 are beveled to prevent water accumulation and residue. The clean water recovered in the following contents can be accurately introduced into the water storage tank 20 to avoid water waste.

[0025] In this embodiment, combined with Figure 2 and Figure 3The system also includes a cleaning module 2, which is the core front-end unit ensuring the accuracy of ultrasonic testing. It is designed to address common contaminants on the surface of the cable 7, such as dirt, oil, and oxides, with an integrated structure of high-pressure annular rinsing, flexible wiping, and wastewater recycling. The specific design includes two vertically aligned wiping clamps 24, both injection-molded from ABS engineering plastic, possessing corrosion resistance and impact resistance. Each wiping clamp 24 includes a main body 241 and two ear plates 242 on either side. The main body 241 has an arc-shaped channel 25 for the cable 7 to pass through. The radius of the arc-shaped channel 25 can be changed according to the diameter of the cable 7. High-density polyester fiber wiping cotton 26 is pasted inside the arc-shaped channel 25, providing strong cleaning power while avoiding scratching the cable 7 insulation layer. Two sets of electric push rods 27 are fixed at corresponding positions on the base plate 12. The electric push rods 27 are electrically connected to the control module 5, and their output ends pass through the lower ear plates 242 and are rigidly fixed by a flange. A stainless steel slide rod 28 is connected to the upper end of the output end of the electric push rod 27. The slide rod 28 passes through the top plate 11 and slides in cooperation with the top plate 11 to ensure smooth lifting and lowering of the wiping clamp 24. A compression spring 29 is installed on the outer sleeve of the slide rod 28. The bottom end of the spring is connected to the ear plate 242 of the upper wiping clamp 24, and the top end is fixed to the bottom of the top plate 11. On the one hand, the preload of the spring ensures that the wiping cotton 26 is always in close contact with the surface of the cable 7. On the other hand, it can provide preload force to the upper arc-shaped clamp during the compression of the wiping cotton 26 and push it to return to its original position.

[0026] When the wiping cotton 26 needs to be squeezed, the electric push rod 27 is activated, which drives the lower arc-shaped clamp and slide rod 28 to move upward. At this time, it creates a squeezing effect with the wiping cotton 26 in the upper arc-shaped clamp and provides it with an upward thrust. Meanwhile, the compression spring 29 can provide a pre-tightening force to the upper arc-shaped clamp, which counteracts the upward thrust, ensuring that the squeezing process is smooth and the wiping cotton 26 is subjected to uniform force. The sewage absorbed in the wiping cotton 26 is squeezed out, and the sewage flows into the water storage tank 20, realizing the recycling of water resources.

[0027] This solution also includes water supply components, combined with... Figure 3It includes a water storage tank 20, a water pump 21, a water supply pipe assembly 22, and a cleaning nozzle 23. The water storage tank 20 is installed below the base plate 12. The top of the water storage tank 20 has a water inlet, and the bottom has a drain valve for easy cleaning of the water tank. Optionally, a liquid level sensor is installed inside the water storage tank 20 and is electrically connected to the control module 5. When the water level is below 1L, the touch screen will automatically prompt for water replenishment to prevent the water pump 21 from running dry and being damaged. A miniature high-pressure water pump 21 is fixedly installed on one side of the water storage tank 20 by a bracket. The inlet of the water pump 21 is connected to the water storage tank 20 through a silicone tube. Multiple cleaning nozzles 23 are provided in this solution, which are distributed circumferentially along the arc-shaped channels 25 of the two arc-shaped clamps and are connected to the water pump 21 through the water supply pipe group 22. Specifically, the water supply pipe group 22 includes a first water supply pipe 221 connected to the water pump 21. The first water supply pipe 221 is branched into a second water supply pipe 223 and a third water supply pipe 224 through a three-way pipe 222. The second water supply pipe 223 and the third water supply pipe 224 are respectively connected to the cleaning nozzles 23 on the outside of the two wiping clamps 24 through branch pipes 225. Three to five high-pressure cleaning nozzles 23 are evenly arranged around the outer side of each wiping clamp 24 along the circumference of the arc-shaped channel 25. The nozzles are fan-shaped with a nozzle diameter of 1.5 mm and a spray angle of 60°. The interval between adjacent nozzles is 15°-30° to ensure the formation of a multi-angle annular water flow for thorough cleaning of the cable 7. The nozzles are connected to the branch pipe 225 via quick-connect couplings for easy replacement of nozzles with different spray angles.

[0028] Based on the above structure, a plastic water pipe clamp 226 is installed on the end face of the main body 241 of the upper wiping clamp 24 to fix the second water supply pipe 223 and prevent the water spray from deviating due to pipe shaking during device movement. Optionally, the water supply pipe assembly 22 is wrapped with insulation cotton to prevent the water pipe from freezing in low-temperature environments and ensure normal cleaning function.

[0029] It should be noted that this solution also incorporates wastewater recycling. The vertical projection of the main body 241 of the wiping clamp 24 is entirely within the opening of the water storage tank 20. Simultaneously, a water-passing groove 15 is provided in the area above the water storage tank 20 on the base plate 12, allowing the wastewater squeezed out by the wiping cotton 26 and the rinsed sewage to flow precisely into the water storage tank 20 through the water-passing groove 15 and the guide plate, achieving water resource recycling. A single water filling can meet the testing requirements of a 100m cable 7, achieving a water saving rate of over 80%. The water storage tank 20 also contains a filter screen to filter impurities in the wastewater, preventing clogging of the water pump 21.

[0030] To facilitate the movement of the detection device along the cable 7 to be tested, this solution also includes a transmission module 3, combined with... Figure 4The core function is to drive the device to move at a uniform speed along the cable 7, avoiding speed fluctuations caused by manual pushing and ensuring uniform acquisition of ultrasonic detection data. Its design focuses on "stable transmission, adjustable speed, and adaptability to cables 7 of different diameters." The specific structure is as follows: The transmission module 3 is located between the cleaning module 2 and the detection module 4, and includes two opposing transmission rollers 31. The transmission rollers 31 are made of nitrile rubber, possessing high elasticity and a high coefficient of friction. The surface is processed with diamond-shaped anti-slip textures to increase friction with the cable 7 surface and prevent slippage. The transmission rollers 31 have solid steel shafts inside, with both ends connected to the bracket via deep groove ball bearings. Optionally, the distance between the two transmission rollers 31 can be adjusted. Specifically, mounting holes with different spacings can be opened on the top plate 11 and the bottom plate 12 to facilitate the installation of the transmission roller 31 shaft, achieving distance adjustment to adapt to cables 7 of different sizes.

[0031] Based on the above structure, a drive assembly is installed on the support frame, including a servo drive motor 32. The output end of the servo drive motor 32 is connected to a drive gear 33 via a key. The drive gear 33 is fixedly connected to the end of the shaft of the lower transmission roller 31, driving the lower transmission roller 31 to rotate. The drive gear 33 meshes with a driven gear 34, which is mounted on the top plate 11 via bearings. The other end of the driven gear 34 is coaxially fixedly mounted with a drive pulley 35. The drive pulley 35 is connected to a driven pulley 37 via a synchronous belt 36. The driven pulley 37 is fixedly connected to the end of the shaft of another transmission roller 31. Through the gear-belt 36 transmission mechanism, the two transmission rollers 31 rotate synchronously in opposite directions, ensuring smooth movement of the device along the cable 7. The drive motor 32 is electrically connected to the control module 5, and the rotation speed is controlled by pulse signals. The moving speed can be steplessly adjusted within an appropriate range. Optionally, the motor also has an overload protection function. When the transmission roller 31 encounters an obstacle with resistance exceeding the rated value, the control module 5 automatically cuts off the motor power and issues an alarm to prevent damage to the motor or the cable 7.

[0032] In this embodiment, a detection module 4 is also included, combined with Figure 3 and Figure 5 This is the core unit for identifying defects in cable 7. Addressing issues such as poor coupling and blind spots in traditional devices, it features a multi-probe ring layout with precise coupling agent spraying to ensure stable ultrasonic signal transmission and comprehensive detection. The specific design includes two opposing arc-shaped supports 41, made of aluminum alloy, which are lightweight and high-strength. The inner arc radius can be changed according to the diameter of cable 7, facilitating the detection of different cable types. Clamping rods 42 are connected to the opposite end faces of the top plate 11 and bottom plate 12. Optionally, the clamping rods 42 are telescopic, consisting of an inner rod and an outer rod, fixed by locking bolts, allowing for height adjustment and convenient support for cables 7 of different diameters.

[0033] In addition, each arc-shaped bracket 41 is equipped with at least two ultrasonic probes 43 circumferentially. These probes are 5MHz high-frequency ultrasonic probes 43 with a bandwidth of 0.5-10MHz, a detection depth of 0-50mm, and a resolution of 0.1mm, effectively identifying defects such as insulation damage, conductor oxidation, and partial discharge. The four probes are arranged at 30°-60° intervals along the circumference of the arc-shaped bracket 41, forming a multi-angle ring detection network with at least four probes on the two arc-shaped brackets 41. The ultrasonic probes 43 are fixed to the arc-shaped brackets 41. Furthermore, to solve the coupling problem between the ultrasonic probes 43 and the surface of the cable 7, a precise and uniformly sprayed coupling agent supply structure is designed. A flat coupling agent nozzle 44 is installed in front of each ultrasonic probe 43 on the arc-shaped bracket 41, forming a uniform coupling agent band on the surface of the cable 7. A flow groove 45 is provided on the arc-shaped bracket 41 between the coupling agent nozzle 44 and the ultrasonic probe 43 to guide the coupling agent to uniformly cover the surface of the cable 7 under test. A coupling agent storage tank 46 is fixed on the receiving cavity 14. A 12V-50W miniature infusion pump is installed inside the tank. The inlet of the infusion pump is connected to the storage tank via a silicone tube, and the outlet is connected to multiple coupling agent nozzles 44 via multiple delivery pipes 47. Optionally, a flow regulating valve is installed on the delivery pipes 47 to adjust the amount of coupling agent sprayed according to the device's moving speed. A transparent observation window is provided on the side of the coupling agent storage tank 46, allowing the operator to monitor the remaining coupling agent level in real time.

[0034] This embodiment also includes a control module 5, which uses an industrial-grade microcontroller as its core controller. This controller can simultaneously process multiple information streams, including ultrasonic signals, motor control data, and sensor data. The controller integrates a power management unit, signal amplification unit, analog-to-digital converter, and wireless communication unit, all housed within a control box, making it suitable for humid and dusty outdoor environments. An industrial-grade touchscreen display is embedded on the front of the control box, supporting multi-touch operation. The interface is simple and intuitive, displaying real-time data such as the current detection location, defect type, defect size, and coupling layer thickness, and showing the ultrasonic echo signal through waveforms. The control module 5 internally integrates a dedicated ultrasonic signal processing module. This module uses digital filtering and wavelet transform algorithms to process the ultrasonic echo signal, effectively removing noise interference, extracting defect characteristic parameters such as defect reflection amplitude and propagation time, and calculating the defect location, size, and type using a preset algorithm. The processing results are displayed on the screen in real time.

[0035] In addition, control module 5 has a self-diagnostic function, which can monitor the working status of each module in real time. When problems such as water pump 21 running dry, motor overload, or probe failure occur, it will immediately issue an audible and visual alarm and display the cause of the fault and troubleshooting suggestions on the display screen, so that operators can handle the problem quickly. The device is also equipped with a backup battery, which can continue to work for 2 hours when the external power is interrupted, ensuring that the testing operation is not interrupted.

[0036] Based on the aforementioned testing device, this solution also includes a corresponding testing method, as follows: First, before testing, check the condition of each component of the device, including whether the wiping cotton 26 is intact, whether the water supply pipe and delivery pipe 47 leak, whether the transmission roller 31 rotates flexibly, and whether the surface of the ultrasonic probe 43 is clean, ensuring there are no potential faults. Furthermore, add clean water to the water tank 20 to the water level line, and add special ultrasonic coupling agent to the coupling agent storage tank 46 to the center line of the observation window, ensuring sufficient consumables. Then, perform the defect detection of cable 7, specifically including the following steps. S1: Assemble the testing device with the cable 7 to be tested. Move the device to the side of the cable 7 to be tested, adjust the position so that the cable 7 is aligned with the through channel, and slowly pass one end of the cable 7 to be tested through the transmission roller 31, the arc bracket 41 and the two wiping cottons 26.

[0037] S2: Start defect detection of cable 7, start water pump 21 and drive motor 32 to move the entire detection device along cable 7 and clean the surface of cable 7. At the same time, start infusion pump and ultrasonic probe 43, spray coupling agent on the cleaned surface of cable 7 through coupling agent nozzle 44 to form a coupling layer. Ultrasonic probe 43 emits signals and receives echoes, sends the signals to ultrasonic signal processing module, and displays defect data on touch screen through control module 5.

[0038] It should be noted that each module starts according to preset logic. The water pump 21 starts first for 1 second, the cleaning nozzle 23 sprays high-pressure circular water to pre-wet the surface of the cable 7, the drive motor 32 starts, driving the transmission roller 31 to rotate, and the device moves at a suitable speed along the cable 7. The infusion pump starts, the coupling agent nozzle 44 starts spraying coupling agent, the ultrasonic probe 43 starts, and emits ultrasonic waves at an appropriate frequency. At the same time, the ultrasonic signal processing module starts to receive the echo signal. During the movement of the device, the cleaning nozzle 23 continuously sprays high-pressure water to wash away contaminants on the surface of the cable 7, and the wiping cotton 26 wipes away residual dirt simultaneously to form a clean surface. The coupling agent forms a uniform coupling layer on the surface of the cable 7. The ultrasonic waves emitted by the ultrasonic probe 43 penetrate the insulation layer of the cable 7 and generate reflected echoes when they encounter defects. After the echo signal is amplified, filtered, and converted from analog to digital, the signal processing module extracts the defect feature parameters, calculates the defect location, size, and type, and displays it in real time on the touch screen.

[0039] S3: Recycle cleaning water. After a preset time t, turn off water pump 21, drive motor 32, infusion pump, and ultrasonic probe 43. Start electric push rod 27 to drive the arc-shaped clamp to squeeze the wiping cotton 26. The squeezed-out cleaning water flows back to the water storage tank 20 through the water tank 15. Retract electric push rod 27 to reset the arc-shaped clamp. The squeezing process lasts for at least 5 seconds to ensure that the water in the wiping cotton 26 is fully squeezed out. After squeezing is completed, electric push rod 27 resets. Control module 5 starts water pump 21 and infusion pump and adjusts them to normal working state. The device resumes its moving speed, restarts ultrasonic detection, and enters the next detection cycle.

[0040] S4: Repeat steps S2-S3 until the entire cable 7 is inspected. Turn off the water pump 21, drive motor 32, infusion pump and ultrasonic probe 43. Slowly pull the inspection device out from the other end of the cable 7 to complete the inspection.

[0041] When the device is moved to the end of cable 7 or the operator clicks to stop the test, the control module 5 automatically shuts down all working parts and generates a complete test report. The report includes the test time, test length, number of defects, details of each defect, and location distribution map. Finally, the test device can be pulled out along cable 7.

[0042] Example 2 To ensure effective coupling and detect the thickness of the coupling agent, at least two ultrasonic probes 43 are mounted circumferentially on each arc-shaped bracket 41. These probes are 5MHz high-frequency ultrasonic probes with a bandwidth of 0.5-10MHz, a detection depth of 0-50mm, and a resolution of 0.1mm, effectively identifying defects such as insulation damage, conductor oxidation, and partial discharge. Four probes are arranged at 30°-60° intervals along the circumference of the arc-shaped bracket 41, forming a multi-angle ring detection network with at least four probes on two arc-shaped brackets 41. The ultrasonic probes 43 are fixed to the arc-shaped brackets 41. Furthermore, to address the coupling issue between the ultrasonic probes 43 and the surface of the cable 7, a precise and uniformly sprayed coupling agent supply structure is designed. A flat coupling agent nozzle 44 is installed in front of each ultrasonic probe 43 on the arc-shaped bracket 41, forming a uniform coupling agent band on the surface of the cable 7. A flow groove 45 is provided on the arc-shaped bracket 41 between the coupling agent nozzle 44 and the ultrasonic probe 43 to guide the coupling agent to uniformly cover the surface of the cable 7 under test. A coupling agent storage tank 46 is fixed on the receiving cavity 14. A 12V-50W miniature infusion pump is installed inside the tank. The inlet of the infusion pump is connected to the storage tank via a silicone tube, and the outlet is connected to multiple coupling agent nozzles 44 via multiple delivery pipes 47. Optionally, a flow regulating valve is installed on the delivery pipes 47 to adjust the amount of coupling agent sprayed according to the device's moving speed. A transparent observation window is provided on the side of the coupling agent storage tank 46, allowing the operator to check the remaining amount of coupling agent in real time. In this embodiment, to ensure the coupling effect, an infrared ranging sensor is installed next to each ultrasonic probe 43, electrically connected to the control module 5, to detect the coupling layer thickness in real time.When the coupling layer thickness is lower than the minimum preset thickness (e.g., 0.5 mm) or higher than the maximum preset thickness (e.g., 1 mm), the control module 5 automatically adjusts the speed of the infusion pump and adjusts the amount of coupling agent sprayed. Simultaneously, it displays the coupling layer thickness data on the touch screen to ensure stable coupling during the testing process. Therefore, in step S2 of a different embodiment, each module starts according to preset logic. The water pump 21 starts first for 1 second, the cleaning nozzle 23 sprays a high-pressure annular water stream to pre-wet the surface of the cable 7, the drive motor 32 starts, driving the transmission roller 31 to rotate, and the device moves uniformly along the cable 7 at an appropriate speed. The infusion pump starts, the coupling agent nozzle 44 begins spraying the coupling agent, and the infrared ranging sensor monitors in real time. The coupling layer thickness is measured to ensure it remains between 0.5mm and 1mm. The ultrasonic probe 43 is activated and emits ultrasonic waves at an appropriate frequency. Simultaneously, the ultrasonic signal processing module begins to receive echo signals. During the device's movement, the cleaning nozzle 23 continuously sprays high-pressure water to wash away contaminants on the surface of the cable 7, while the wiping cotton 26 simultaneously wipes away residual dirt, forming a clean surface. The coupling agent forms a uniform coupling layer on the surface of the cable 7. The ultrasonic waves emitted by the ultrasonic probe 43 penetrate the insulation layer of the cable 7 and generate reflected echoes when they encounter defects. After amplification, filtering, and analog-to-digital conversion, the echo signal is used by the signal processing module to extract defect feature parameters, calculate the defect location, size, and type, and display them in real time on the touch screen.

[0043] While exemplary embodiments of the invention have been described herein, many other variations or modifications conforming to the principles of the invention can be directly determined or derived from the disclosure of this invention without departing from its spirit and scope. Therefore, the scope of the invention should be understood and recognized to cover all such other variations or modifications.

Claims

1. A portable ultrasonic testing device for cable defects, characterized in that, include: The load-bearing module includes a load-bearing frame, which has a receiving cavity, and the receiving cavity has at least one set of opposing through channels for the passage of the cable to be tested; The cleaning module includes a water supply component and a wiping component. The wiping component is located within a receiving cavity and includes two wiping clamps arranged opposite each other. Both of the opposite end faces of the clamps have arc-shaped channels for cable passage, and wiping cotton is placed inside the arc-shaped channels. The wiping clamps ensure that the wiping cotton is in close contact with the cable surface. The water supply component includes a water storage tank located at the bottom of the supporting frame. The water storage tank is connected to a water supply pipe assembly via a water pump. The water supply pipe assembly is connected to multiple cleaning nozzles located outside the arc-shaped channels and distributed circumferentially relative to the arc-shaped channels, and positioned close to the edge of the arc-shaped channels. The transmission module includes at least two opposing transmission rollers arranged in a receiving cavity, with the two transmission rollers spaced apart and a cable passing through the middle. The supporting frame is provided with a drive component connected to the transmission rollers, which can drive them to rotate. The detection module includes an arc-shaped support arranged opposite to each other, and multiple ultrasonic probes are arranged around the arc-shaped support. A coupling agent nozzle is arranged on the arc-shaped support corresponding to the position of the ultrasonic probe, and a flow groove is opened on the arc-shaped support between the nozzle and the ultrasonic probe. A coupling agent storage box is also arranged in the receiving cavity, which is connected to an infusion pump and communicates with the coupling agent nozzle through multiple delivery pipes. The control module, located above the support frame, is electrically connected to the water pump, drive assembly, infusion pump, and coupling agent nozzle. It can control the opening and closing of the above components. The control module is also electrically connected to a touch screen for command interaction and data visualization. It is also electrically connected to an ultrasonic signal processing module for driving the ultrasonic probe and receiving the signals it emits.

2. The portable ultrasonic testing device for cable defects according to claim 1, characterized in that, The supporting frame includes a top plate and a bottom plate arranged opposite each other, forming a cavity in the middle. The four corners between the top plate and the bottom plate are connected by support columns, and a through channel is formed between the two support columns in the width direction.

3. The portable ultrasonic testing device for cable defects according to claim 2, characterized in that, The two wiping clamps are arranged opposite each other in a vertical direction and include a main body with an arc-shaped channel. The main body has ear plates on both sides, and the two wiping clamps are installed on the top plate and the bottom plate respectively through the ear plates.

4. The portable ultrasonic testing device for cable defects according to claim 3, characterized in that, Two sets of electric push rods are provided on the base plate, and the electric push rods are electrically connected to the control module. Their output ends pass through the ear plate of the lower wiping clamp and are fixed thereto. A slide rod is connected to the upper end of the output end. The slide rod passes through the top plate and is slidably arranged. A compression spring is provided on the outer sleeve of the slide rod, and its bottom end is connected to the ear plate of the upper wiping clamp.

5. A portable ultrasonic testing device for cable defects according to claim 4, characterized in that, The water storage tank is located below the wiping clamp, and the vertical projection of the main body of the wiping clamp is located inside the water storage tank. A water trough is opened on the bottom plate corresponding to the water storage tank.

6. The portable ultrasonic testing device for cable defects according to claim 1, characterized in that, Each wiping clamp has 3-5 cleaning nozzles on its outer side, which are evenly distributed along the arc-shaped channel, with an angle of 15°-30° between adjacent cleaning nozzles.

7. A portable ultrasonic testing device for cable defects according to claim 1, characterized in that, The water supply pipe assembly includes a first water supply pipe connected to the water pump, which is connected to a second water supply pipe and a third water supply pipe via a tee pipe, and both of them are connected to multiple branch pipes, which are respectively connected to the cleaning nozzles on the outside of the two arc-shaped clamps. The main body end face of the wiping clamp located above is equipped with a water pipe clamp for the passage of the second water supply pipe.

8. A portable ultrasonic testing device for cable defects according to claim 2, characterized in that, The top plate and the bottom plate are each provided with a clamping rod on their opposite end faces, and the two clamping rods are respectively connected to two arc-shaped brackets.

9. A portable ultrasonic testing device for cable defects according to claim 1, characterized in that, The drive assembly includes a drive motor located on the support frame, and a drive gear is installed at the output end of the drive motor. The drive gear is connected to the shaft of any transmission roller. The drive gear meshes with a driven gear, and a drive pulley is installed on the drive gear. The drive pulley is connected to a driven pulley via a belt, and the drive pulley is rotatably connected to another transmission roller.

10. A portable ultrasonic testing method for cable defects, using a portable ultrasonic testing device for cable defects as described in any one of claims 1-9, characterized in that, Includes the following steps: S1: The testing device is assembled with the cable to be tested, and one end of the cable to be tested is slowly passed through the transmission roller, the arc-shaped bracket and the two wiping cottons; S2: Start the defect detection of the cable, start the water pump and drive motor to move the entire detection device along the cable and clean the cable surface. At the same time, start the infusion pump and ultrasonic probe, spray the coupling agent onto the cleaned cable surface through the coupling agent nozzle to form a coupling layer, the ultrasonic probe emits a signal and receives the echo, sends the signal to the ultrasonic signal processing module, and displays the defect data on the touch screen through the control module. S3: Recycle cleaning water. After a preset time t, turn off the water pump, drive motor, infusion pump and ultrasonic probe, start the electric push rod, drive the arc-shaped clamp to squeeze the wiping cotton, and squeeze out the cleaning water through the water tank back to the water storage tank. Retract the electric push rod to drive the arc-shaped clamp to reset. S4: Repeat steps S2-S3 until the entire cable section is inspected. Turn off the water pump, drive motor, infusion pump and ultrasonic probe. Slowly pull the inspection device out from the other end of the cable to complete the inspection.

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