A boiler water-cooled wall tube sidewall inspection device

Abstract

This invention relates to the technical field of magnetic testing and analysis of boiler water-cooled tube sidewalls, specifically providing a boiler water-cooled tube sidewall inspection device. The device includes a housing assembly, a magnetic module, an image acquisition module, a magnetic powder circulation mechanism, and a drive mechanism. The magnetic powder circulation mechanism includes an upper pulley, a lower pulley, and a rear guide pulley, each mounted on a wire-threading tube. An annular magnetic tape is mounted on the outer side, and the tape circulates. An internal upper powder-removing mechanism is located inside, and a lower front powder-applying mechanism is located at the bottom. The bottom of the powder-removing mechanism and the top of the powder-applying mechanism are connected by a powder-guiding tube. The upper part of the annular magnetic tape passes through the powder-removing mechanism for powder removal, and the front part of the tape adheres to the front of the powder-applying mechanism for powder application. The image acquisition module faces the inner surface of the annular magnetic tape. This invention can adaptively adjust the machine's movement speed, quickly inspecting non-critical areas and repeatedly testing at low speeds in critical areas, improving work efficiency and inspection accuracy.

Description

Technical Field

[0001] This invention belongs to the field of magnetic testing and analysis technology for boiler water-cooled tube sidewalls, specifically relating to a testing device for boiler water-cooled tube sidewalls. Background Technology

[0002] Boiler water-cooled wall tube sidewall inspection refers to the regular inspection of the sidewalls of boiler water-cooled wall tubes to detect potential defects such as corrosion, cracks, and wear, ensuring the safe operation of the boiler. Water-cooled wall tubes are a crucial component of the boiler, primarily absorbing heat from the furnace and protecting the furnace walls. Due to prolonged exposure to high temperatures, high pressures, and corrosive environments, water-cooled wall tubes are prone to various types of damage, making their inspection essential. Currently, boiler water-cooled wall tube sidewall inspection mainly employs manual visual inspection and instrumental inspection. Manual visual inspection involves visually examining the appearance of the water-cooled wall tubes to identify obvious defects. This method is simple and direct, but its accuracy is low, failing to detect minute internal defects. Common inspection instruments include magnetic particle detectors and ultrasonic detectors. Magnetic particle detectors magnetize the inspected workpiece, causing magnetic particles to accumulate at the defect location, thus revealing the defect. Ultrasonic detectors detect internal defects by utilizing the propagation characteristics of ultrasonic waves within the workpiece.

[0003] While these instruments can improve testing accuracy, they have significant shortcomings in terms of testing efficiency, precision, flexibility, and resource utilization when testing large-area water-cooled wall tubes. For example, ordinary testing instruments require point-by-point testing of large-area water-cooled wall tubes, which is time-consuming and labor-intensive, making it difficult to meet the needs of rapid testing. Existing automated testing equipment typically moves at a fixed speed, unable to flexibly adjust the testing speed according to the importance of the testing area, and cannot perform focused and repeated testing on important areas. Furthermore, the magnetic powder used in some testing methods is difficult to effectively recycle, leading to increased costs and resource waste.

[0004] To improve detection efficiency, reduce workload, and ensure the accuracy and reliability of detection results, it is necessary to develop a new type of detection device that can quickly screen large areas, flexibly adjust detection accuracy, and efficiently recycle magnetic powder. Summary of the Invention

[0005] In view of the defects and problems of existing technologies, the present invention aims to provide a device that can quickly and accurately detect the sidewalls of boiler water-cooled wall tubes. For large-area boiler water-cooled walls, it can quickly troubleshoot and also conduct detailed and repeated inspections of key local areas, thereby improving detection efficiency and accuracy and ensuring the safe operation of the boiler.

[0006] The solution to the technical problem of this invention is as follows: a boiler water-cooled wall tube sidewall inspection device, comprising a housing assembly, a magnetic module, and an image acquisition module. The upper and lower magnets of the magnetic module are respectively fixed to the upper front and lower front sides of the housing assembly. The image acquisition module is installed inside the housing assembly. The device also includes a magnetic powder circulation mechanism and a drive mechanism. The magnetic powder circulation mechanism includes an upper pulley, a lower pulley, and a rear guide wheel. The upper pulley, lower pulley, and rear guide wheel are respectively fitted onto wire-threading tubes at corresponding positions inside the housing assembly, and an annular ring is fitted on the outer side of each wheel. The magnetic tape, the drive mechanism is used to drive the circular magnetic tape to rotate; a de-dusting mechanism is provided on the upper side inside the outer shell assembly, and a de-dusting mechanism is provided on the front side of the lower part of the inner cavity of the outer shell assembly. The bottom of the de-dusting mechanism and the top of the de-dusting mechanism are connected through a de-dusting tube. The upper part of the circular magnetic tape passes through the de-dusting mechanism for de-dusting, and the front part of the circular magnetic tape is attached to the front side of the de-dusting mechanism for de-dusting; the image acquisition module faces the inner surface of the circular magnetic tape. The acquisition data line of the image acquisition module is led out from the back of the outer shell assembly and connected to the data input terminal of the external detection device.

[0007] Preferably, the magnetic assembly module further includes a front guard plate, an upper magnet slot is provided on the upper front side of the outer shell assembly for fixing the upper magnet, a lower magnet slot is provided on the lower front side of the outer shell assembly for fixing the lower magnet, and the front guard plate is fixed at the front end of the outer shell assembly and located between the upper and lower magnet slots.

[0008] Preferably, the front guard plate includes a central web plate and upper and lower end wing plates. Guard plate fixing seats are fixed at the upper and lower ends of the web plate, and the guard plate fixing seats are fixed to the upper and lower edges of the outer shell assembly by screws. The end wing plates located at the upper and lower ends of the front guard plate respectively wrap around the upper magnet and the lower magnet, and the upper and lower end wing plates are respectively inserted into the slots provided on the inner side wall of the upper magnet slot, so that the edges of the upper and lower end wing plates are completely fixed to the edges of the upper magnet slot and the lower magnet slot.

[0009] Preferably, the drive mechanism includes a parallel drive shaft and a driven shaft. Two pairs of shaft holes are respectively provided at the lower rear end of the two side walls of the housing assembly. The two ends of the drive shaft and the driven shaft are respectively installed in the corresponding shaft holes through bearings. A drive roller and a driven roller are respectively fitted on the drive shaft and the driven shaft. The annular magnetic tape is located between the drive roller and the driven roller and is clamped. A synchronous gearbox is fixed on the outer side of the front side wall of the housing assembly, and a drive motor is fixed on the outer side of the rear side wall. Two gears of the same type and meshing with each other are installed in parallel in the synchronous gearbox. The front ends of the drive shaft and the driven shaft are respectively fixedly installed on the shaft center of the two gears. The rear end of the drive shaft is connected to the rotating shaft of the drive motor.

[0010] Preferably, the powder removal mechanism includes a magnetic powder box, an isolation plate, and a powder scraper. The magnetic powder box is a closed box made of non-magnetic conductive and magnetically shielding material. Horizontal strip-shaped holes are respectively provided on the front and rear side walls of the magnetic powder box, and the annular magnetic tape passes through the two holes. An isolation plate is fixed horizontally inside the magnetic powder box and below the annular magnetic tape. Multiple upwardly inclined powder scrapers are distributed horizontally on the isolation plate, and the height of the multiple horizontal powder scrapers increases sequentially from front to back. A scraper armpit groove is provided at the acute angle position below the front side of each powder scraper.

[0011] Preferably, the powder feeding mechanism includes a powder collecting hopper and a thickness limiting plate. The powder collecting hopper is fixed to the front side of the lower part of the housing assembly, and the front side of the powder collecting hopper is open. The thickness limiting plate is fixedly installed or movably installed on the upper side of the open side of the powder collecting hopper. The thickness limiting plate is parallel to the inner surface of the annular magnetic tape and the two maintain an appropriate distance.

[0012] Preferably, the outer shell assembly includes a main shell and a secondary shell, with multiple pairs of wire-threading tubes distributed on the inner side of the main shell and the secondary shell respectively for connecting the two shells. A fixing screw is installed through each pair of wire-threading tubes. A counterweight groove is provided at the rear side of the outer shell assembly of the main shell and the secondary shell, and a counterweight block is installed in the counterweight groove.

[0013] Preferably, the outer casing assembly has an upper chamber and a lower chamber, and each chamber has an opening at its front end. The image acquisition module is installed in the lower chamber, and a magnetoresistive sensor is fixed in the upper chamber. The acquisition data line of the image acquisition module and the sensor data line of the magnetoresistive sensor are respectively led out from the back of the outer casing assembly and connected to the data input terminal of the external detection device.

[0014] The beneficial effects of this invention are as follows:

[0015] 1. Significantly improved detection efficiency: By adaptively adjusting the machine's movement speed, it can quickly screen non-critical areas and stop or repeatedly test at low speed in critical areas, greatly shortening the detection cycle and improving work efficiency compared to traditional instruments.

[0016] 2. Effective guarantee of detection accuracy: The internal ring magnetic tape continuously rotates to update the magnetic powder, and the thickness of the magnetic powder is controlled by the thickness limiting plate, so that the magnetic field change is captured more accurately; the image acquisition module is combined with magnetoresistive sensors, ultrasonic sensors and other means to verify the detection results from multiple dimensions and accurately judge the damage.

[0017] 3. High efficiency in magnetic powder recycling: The powder removal mechanism and the powder loading mechanism work together to allow the magnetic powder to be recycled, reducing testing costs and avoiding waste and environmental pollution.

[0018] 4. Convenient and flexible operation: The machine body is usually moved by pushing the outer shell, which is easy to operate. The detection area and accuracy can be flexibly adjusted according to the detection needs, making it highly applicable and meeting the detection requirements of different scenarios. Attached Figure Description

[0019] Figure 1 This is one of the three-dimensional structural schematic diagrams of the detection device of the present invention;

[0020] Figure 2 This is the second three-dimensional structural schematic diagram of the detection device of the present invention;

[0021] Figure 3 This is a schematic diagram showing the main and auxiliary shells in disassembled state;

[0022] Figure 4 This is a schematic diagram of the internal structure of the main shell;

[0023] Figure 5 This is a front view of the internal structure of the main shell;

[0024] Figure 6 This is a schematic diagram of the rear structure of the detection device of the present invention;

[0025] Figure 7 yes Figure 4 Enlarged structural diagram of section A in the middle;

[0026] Figure 8 yes Figure 5 Enlarged structural diagram of section B.

[0027] Figure labels: 1. Outer shell assembly; 2. Magnetic powder circulation mechanism; 3. Magnetic module; 4. Drive mechanism; 5. Image acquisition module; 6. Magnetoresistive sensor; 11. Main shell; 12. Sub-shell; 13. Handle; 14. Upper magnet slot; 15. Lower magnet slot; 16. Counterweight slot; 17. Wire threading tube; 18. Inner support; 21. Upper pulley; 22. Lower pulley; 23. Rear guide wheel; 24. Circular magnetic tape; 25. Powder removal mechanism; 26. Powder loading mechanism; 27. Powder guide tube; 31. Upper magnet; 32. Lower magnet; 33. Front guard plate; 34. Guard plate fixing seat. ; Driven shaft 41; Driven shaft 42; Driven roller 43; Driven roller 44; Synchronous gearbox 45; Drive motor 46; Motor control line 47; Data acquisition line 51; Sensor data line 61; Magnetic powder box 251; Perforated plate 252; Isolation plate 253; Powder scraper 254; Scraper armpit groove 255; Magnetic shielding layer 256; Powder discharge port 257; Powder addition port 258; Powder collection hopper 261; Track 262; Sliding box 263; Support 264; Fine adjustment wire 265; Box wing plate 266; Thickness limiting plate 267. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0029] Example 1: A boiler water-cooled wall tube sidewall inspection device, such as Figures 1-6As shown, the device mainly includes a housing assembly 1, a magnetic powder circulation mechanism 2, a magnetic assembly module 3, a drive mechanism 4, and an image acquisition module 5. Due to the large area of ​​the boiler water-cooled wall, ordinary testing instruments are time-consuming and labor-intensive. The testing device provided by this invention can achieve rapid preliminary inspection and repeated local inspection. Since the body and the internal annular magnetic tape circulation are independent, the body's movement speed can be adaptively adjusted as needed (usually by manually pushing the housing). For non-critical inspection areas, the body's movement speed is increased for preliminary inspection. When the body's movement speed is reduced or the body is stopped at a certain inspection point, the inspection accuracy at that point is enhanced. For example, when the testing device is stopped at a critical inspection point, the internal annular magnetic tape continues to rotate, constantly updating the magnetic powder in the inspection area, which is equivalent to repeated magnetic powder inspection, thus strengthening the verification of surface defects of the boiler water-cooled wall tubes at the corresponding inspection point.

[0030] like Figure 1 and Figure 2 As shown, the outer casing assembly 1 includes a main casing 11, a secondary casing 12, a handle 13, an upper magnet slot 14, a lower magnet slot 15, a counterweight slot 16, and wire-threading tubes 17, as well as fixing screws. Multiple pairs of wire-threading tubes 17 are distributed on the inner sides of the main casing 11 and the secondary casing 12 to connect the two casings. A fixing screw is installed through each pair of wire-threading tubes 17, thereby fixing the main casing 11 and the secondary casing 12 as a whole. An upper magnet slot 14 is located on the upper front side of the combined main casing 11 and the secondary casing 12, for fixing the upper magnet 31. A lower magnet slot 15 is located on the lower front side of the combined main casing 11 and the secondary casing 12, for fixing the lower magnet 32. Alternatively, a counterweight groove 16 can be provided at the lower rear side of the combined housing of the main shell 11 and the secondary shell 12, and a counterweight block can be optionally installed in the counterweight groove 16.

[0031] like Figure 4 and Figure 5As shown, the magnetic powder circulation mechanism 2 includes an upper pulley 21, a lower pulley 22, a rear guide wheel 23, an annular magnetic tape 24, a powder removal mechanism 25, and a powder loading mechanism 26. The upper pulley 21 and lower pulley 22 are located above and below the front side of the housing assembly 1, respectively, while the rear guide wheel 23 is located above the rear side of the housing assembly 1. Furthermore, the upper pulley 21, lower pulley 22, and rear guide wheel 23 are respectively mounted on the threading tubes 17 at corresponding positions. An annular magnetic tape 24 is mounted on the outer side of the upper pulley 21, lower pulley 22, and rear guide wheel 23. The annular magnetic tape 24 can be made of any of the following flexible magnetic materials: Flexmag flexible magnets, Ferrosheet magnetic printing film, or Tengye flexible magnets, or other composite coated soft magnetic materials. Flexmag flexible magnets are flexible composite sheets, strips, and extruded magnets manufactured by Industries, possessing magnetic properties and good flexibility, allowing for bending and twisting. UltraMag extruded magnets are made by combining high-quality thermoplastic elastomer (rubber) resin with magnetic powder and extruding them. The thickness can be customized, and magnetization and magnetization modes can be selected according to specific applications. They can be used in many fields such as industry, medical, aerospace, automotive, and signage. Ferrosheet magnetic printing film is a magnetic printing film material that can be used with Arnold's printable magnetic media for designing customizable signs, banners, and other promotional materials. It has a certain degree of flexibility and magnetism and can attract magnetic powder. Tengye flexible magnets are made of rubber and magnetic powder or plastic and magnetic powder. They come in various forms such as sheets and strips, and can be customized in size. They have good flexibility and machinability and can be processed using traditional tools such as cutting and punching. They can be made into flexible strips of different shapes and sizes as needed.

[0032] A powder removal mechanism 25 is provided on the upper side inside the housing assembly 1, and a powder application mechanism 26 is provided on the front side of the lower part of the inner cavity of the housing assembly 1. The bottom of the powder removal mechanism 25 and the top of the powder application mechanism 26 are connected by a powder guide tube 27. The upper part of the annular magnetic tape 24 passes through the powder removal mechanism 25, and the front part of the annular magnetic tape 24 is in contact with the front side of the powder application mechanism 26, and the front part of the annular magnetic tape 24 is parallel to the surface to be tested.

[0033] Specifically, such as Figure 5 and Figure 8As shown, the powder removal mechanism 25 includes a magnetic powder box 251, a perforated section 252, an isolation plate 253, a powder scraper 254, a scraper groove 255, a magnetic shielding layer 256, a powder discharge port 257, and a powder filling port 258. The magnetic powder box 251 is a closed box made of non-magnetic conductive and magnetic shielding material, fixed to the top inner side of the outer shell assembly 1. It is preferably made of epoxy resin, which encapsulates the magnetic powder to form a good magnetic shielding effect, preventing oxidation, moisture absorption, and other problems caused by external environmental influences. Alternatively, plastic materials such as polyethylene, polypropylene, and polytetrafluoroethylene can also be used, as they are all non-magnetic materials with characteristics such as light weight, corrosion resistance, and good insulation. Boxes of various shapes can be made as needed to fill magnetic powder and provide magnetic shielding. Horizontal perforations 252 are respectively provided on the front and rear side walls of the magnetic powder box 251, through which the annular magnetic tape 24 passes. Inside the magnetic powder box 251 and below the annular magnetic tape 24, a partition plate 253 is fixed laterally. Multiple upwardly inclined scraper plates 254 are distributed laterally on the partition plate 253, with the height of the scraper plates 254 increasing sequentially from front to back. A scraper groove 255 is provided at the acute angle below the front side of each scraper plate 254. When the annular magnetic tape 24 passes through the front and rear holes 252, the magnetic powder on the lower surface of the annular magnetic tape 24 is scraped off by the scraper plates 254 and discharged downwards from the scraper grooves 255 to the bottom of the magnetic powder box 251. The powder then enters the powder guide tube 27 through the discharge port 257. The powder guide tube 27 is connected to the top rear side of the powder collection hopper 261, and finally, the magnetic powder is discharged into the inner cavity of the powder collection hopper 261. The powder guide tube 27 and the powder collection hopper 261 are made of the same non-magnetic insulating material as the magnetic powder box 251. Meanwhile, at least one layer of alumina ceramic or zirconia ceramic material magnetic shielding layer 256 is fitted inside the top of the magnetic powder box 251, and the annular magnetic tape 24 is located below the magnetic shielding layer 256. A powder filling port 258 is provided on the back of the magnetic powder box 251 and a cover is installed thereon. At the same time, a clearance hole is provided on the back of the outer shell assembly 1, and the cover is located in the clearance hole.

[0034] like Figure 4 and Figure 7As shown, the powder feeding mechanism 26 includes a powder collecting hopper 261, tracks 262, a sliding box 263, a support 264, a fine-tuning wire 265, a box wing plate 266, and a thickness limiting plate 267. The powder collecting hopper 261 is fixed to the front side of the lower part of the outer shell assembly 1, and the front side of the powder collecting hopper 261 is open, including left and right side walls and upper and lower side walls. The left and right side walls are attached to the left and right side walls of the annular magnetic tape 24, the lower side wall is attached to the inner surface of the annular magnetic tape 24, and the upper side wall is provided with a powder return port. A pair of tracks 262 are arranged longitudinally on the upper surface behind the powder return port. A sliding box 263 is fitted on the upper side of the pair of tracks 262. The front and lower sides of the sliding box 263 are open, and the bottom of the sliding box 263 is assembled with the tracks 262, allowing it to slide along the tracks 262. A support 264 is fixed to the upper center of the powder collection hopper 261. A fine-tuning wire 265 is installed on the support 264, and the front end of the fine-tuning wire 265 is connected to the sliding box 263. When the fine-tuning wire 265 is turned, it can drive the sliding box 263 to move forward or backward. Box wing plates 266 are respectively provided on the left and right sides of the sliding box 263, and the box wing plates 266 are respectively attached to the left and right sides of the annular magnetic tape 24. A thickness limiting plate 267 is provided between the left and right box wing plates 266. The thickness limiting plate 267 is parallel to the inner surface of the annular magnetic tape 24 and maintains an appropriate distance between them. When the annular magnetic tape 24 passes through the open position at the front of the powder collection hopper 261, the annular magnetic tape 24 will attract the magnetic powder in the powder collection hopper 261 and carry it to the inner surface of the annular magnetic tape 24. However, under the restriction of the thickness limiting plate 267, excess magnetic powder on the surface of the annular magnetic tape 24 will be scraped out and re-enter the powder collection hopper 261 to maintain the surface of the annular magnetic tape 24 with magnetic powder of appropriate uniform thickness.

[0035] like Figure 3 and Figure 5As shown, the magnetic assembly module 3 includes an upper magnet 31, a lower magnet 32, a front guard plate 33, and a guard plate fixing seat 34. The upper magnet 31 is fixed in the upper magnet slot 14, and the lower magnet 32 ​​is fixed in the lower magnet slot 15. A front guard plate 33 is fixed at the front end of the outer shell assembly 1. The front guard plate 33 is parallel to the side wall of the water-cooled pipe being tested, thereby ensuring that the annular magnetic tape 24 is parallel to the surface being tested. The front guard plate 33 is a groove-shaped thin plate, preferably a stainless steel thin plate or an aluminum alloy thin plate (304 stainless steel, 306 stainless steel, austenitic stainless steel, etc. are non-magnetic stainless steels, and aluminum alloy is a non-magnetic material that is easy to process and form, and has high strength and good corrosion resistance). It can also be a polymer material plate, such as an ultra-high molecular weight polyethylene plate or a polytetrafluoroethylene plate. The front guard plate 33 includes a central web and upper and lower end wing plates. Guard plate fixing seats 34 are fixed to the upper and lower ends of the web, respectively, and are fixed to the upper and lower edges of the outer shell assembly 1 by screws. The end wing plates located at the upper and lower ends of the front guard plate 33 respectively wrap around the upper magnet 31 and the lower magnet 32, and the upper and lower end wing plates are respectively inserted into the slots provided on the inner sidewall of the upper magnet mounting slot 14, so that the edges of the upper and lower end wing plates are completely fixed to the edges of the upper magnet mounting slot 14 and the lower magnet mounting slot 15.

[0036] The upper magnet 31 and the lower magnet 32 ​​are either strong permanent magnets or electromagnets, forming a magnetic field in front of the upper magnet 31 and the lower magnet 32. When the device approaches the side wall surface of the water-cooled wall tube, the magnetic field will pass through the side wall surface and interior of the water-cooled wall tube. When the device moves upward, the magnetic field will move between the side wall surface and interior of the water-cooled wall tube.

[0037] like Figure 4 and Figure 5 As shown, an inner support 18 is fixed inside the outer casing assembly 1. The inner support 18 includes at least one chamber, or both an upper chamber and a lower chamber, and each chamber has an opening at its front end. An image acquisition module 5 is installed in the lower chamber, facing the inner surface of the annular magnetic tape 24. A magnetoresistive sensor 6 is fixed in the upper chamber, with its probe facing the inner surface of the annular magnetic tape 24. The acquisition data line 51 of the image acquisition module 5 and the sensor data line 61 of the magnetoresistive sensor 6 are led out from the back of the outer casing assembly 1 and connected to the data input terminal of an external detection device.

[0038] like Figure 3 , Figure 4 and Figure 6As shown, the drive mechanism 4 includes a drive shaft 41, a driven shaft 42, a drive roller 43, a driven roller 44, a synchronous gearbox 45, a drive motor 46, and a motor control line 47. Shaft holes are respectively provided at the lower rear end of the left and right sidewalls of the housing assembly 1. A drive shaft 41 and a driven shaft 42 are mounted side-by-side in each shaft hole via bearings. Drive rollers 43 and 44 are respectively fitted onto drive shafts 41 and 42. A synchronous gearbox 45 is fixed to the outer side of the front sidewall of the housing assembly 1. Two identical gears that mesh with each other are mounted side-by-side in the synchronous gearbox 45. The front ends of the drive shaft 41 and the driven shaft 42 are led out from the shaft holes on the front sidewall of the housing assembly 1, and their ends are fixedly mounted to the shafts of the two gears. A drive motor 46 is fixed to the back of the housing assembly 1. The rear end of the drive shaft 41 is led out from the rear sidewall of the housing assembly 1 and is connected to the shaft of the drive motor 46. The annular magnetic tape 24 is also located between the driving roller 43 and the driven roller 44, and is held by the driving roller 43 and the driven roller 44. When the driving roller 43 and the driven roller 44 rotate, the annular magnetic tape 24 can be driven to rotate counterclockwise.

[0039] When the above-mentioned device is in operation, the drive motor 46 is controlled by the controller to rotate and drive the active roller 43 to rotate, which in turn drives the driven roller 44 to rotate synchronously, thereby driving the annular magnetic tape 24 to rotate counterclockwise. At this time, located at the front end of the outer shell assembly 1, the outer surface of the annular magnetic tape 24 will adhere to the inner surface of the front guard plate 33 and move from bottom to top. The magnetic powder output from the bottom of the magnetic powder box 251 flows into the powder collection hopper 261 through the powder guide tube 27, and is then attracted from the front end of the powder collection hopper 261 to the inner surface of the annular magnetic tape 24 to complete the powder coating. Under the constraint of the thickness limiting plate 267, the magnetic powder on the inner surface of the annular magnetic tape 24 maintains a uniform thickness distribution and is transported upwards. The image acquisition module 5 acquires image information of the changes in magnetic powder on the surface of the annular magnetic tape 24. If damage occurs inside the sidewall of the water-cooled wall tube, the magnetic field distribution inside the sidewall of the water-cooled wall tube will change significantly compared to the previous magnetic field distribution. This change will cause a change in the distribution on the inner surface of the annular magnetic tape 24. At this time, based on the image capture and data transmission of the image acquisition module 5, the detection device can obtain data information of the changes in the magnetic field on the surface of the annular magnetic tape 24. Then, after analyzing the current image information through the image analysis module, the corresponding magnetic field change is output, thereby judging the damage to the sidewall of the water-cooled wall tube. At the same time, the detection device displays the image information of the changes in the magnetic field on the surface of the annular magnetic tape 24 in real time on the display screen for observation. When the annular magnetic tape 24 carrying magnetic powder is transferred to the powder removal mechanism 25, it is scraped and cleaned by the powder scraper 254 inside the powder removal mechanism 25, so that the magnetic powder is separated from the inner surface of the annular magnetic tape 24 and enters the bottom of the inner side of the magnetic powder box 251. When a magnetoresistive sensor 6 is also installed in the device, the magnetic field change signal can be acquired in real time through the magnetoresistive sensor 6 to assist in verifying the analysis results based on the image acquisition module 5. In addition, the device is not limited to installing an ultrasonic sensor in the housing assembly 1 at the same time. For example, an Olympus 38DLPlus can be used. The ultrasonic sensor sends ultrasonic waves into the side wall of the water-cooled wall tube and receives ultrasonic waves to detect the damage inside the side wall of the water-cooled wall tube.

[0040] The specific application process of this detection device is as follows:

[0041] 1. Installation Preparation: First, install the powder removal mechanism 25 and the powder application mechanism 26 in their respective positions within the housing assembly 1, and connect them via the powder guide tube 27. Then, mount the annular magnetic tape 24 onto the upper pulley 21, lower pulley 22, and rear guide pulley 23, ensuring that the upper part of the annular magnetic tape 24 passes through the powder removal mechanism 25 and the front part fits against the powder application mechanism 26. Next, install the drive shaft 41 and driven shaft 42 of the drive mechanism 4 into the shaft holes on the left and right side walls of the housing assembly 1 via bearings, install the drive roller 43 and driven roller 44, and fix the synchronous gearbox 45 and drive motor 46 in their respective positions, so that the annular magnetic tape 24 is positioned between and clamped between the drive roller 43 and driven roller 44. Finally, fix the main housing 11 and the secondary housing 12 together using the thread-passing tube 17 and fixing screws to form the housing assembly 1. Finally, install the upper magnet 31 and the lower magnet 32 ​​in the upper magnet slot 14 and the lower magnet slot 15 respectively. Then, fix the front guard plate 33 of the magnetic assembly module 3 to the front end of the outer shell assembly 1, so that the upper and lower end wing plates wrap around the magnet 31 and the lower magnet 32 ​​and insert them into the corresponding slots. If necessary, a counterweight can be installed in the counterweight slot 16 to maintain the balance of the device.

[0042] 2. Start-up and Initial Setup: Connect the power supply, start the drive motor 46 and image acquisition module 5, and set the initial speed and other parameters through the controller to make the drive roller 43 start rotating, driving the driven roller 44 and the annular magnetic tape 24 to rotate counterclockwise. Check whether the annular magnetic tape 24 is operating normally, whether the magnetic powder is circulating smoothly between the powder removal mechanism 25 and the powder application mechanism 26, and whether the magnetic field is stably formed.

[0043] 3. Troubleshooting Inspection: Hold handle 13 and push the outer casing assembly 1 to move the device along the side wall of the boiler water-cooled wall tubes. Since the movement speed is adaptively adjustable, it can be accelerated in non-critical inspection areas to quickly inspect large areas. At this time, the outer surface of the annular magnetic tape 24 moves upwards, adhering to the inner surface of the front protective plate 33. The powder application mechanism 26 adsorbs magnetic powder onto the inner surface of the annular magnetic tape 24, maintaining a uniform thickness. The image acquisition module 5 acquires image information of changes in the magnetic powder on the surface of the annular magnetic tape 24. If there is damage inside the side wall of the water-cooled wall tubes, changes in the magnetic field distribution will lead to changes in the magnetic powder distribution. By analyzing the image information through the image analysis module, a preliminary judgment can be made as to whether there are any abnormal areas.

[0044] 4. Localized Key Inspection: When a suspected abnormal area is detected or a pre-determined key inspection point is reached, the machine's movement speed is reduced or even stopped. At this time, the internal annular magnetic tape 24 continues to rotate, constantly updating the magnetic powder at the inspection site, effectively performing multiple repeated magnetic powder inspections to enhance the inspection accuracy at that point. Simultaneously, auxiliary detection equipment such as the magnetoresistive sensor 6 or ultrasonic sensor can be activated to acquire magnetic field change signals or ultrasonic detection data, which is then cross-verified with the data from the image acquisition module 5 to more accurately determine the internal damage condition of the water-cooled wall tube sidewall.

[0045] 5. Data Processing and Display: The data collected by the image acquisition module 5 and the magnetoresistive sensor 6 are transmitted to the external detection device through the data cable. The image analysis module analyzes and processes the image information, extracts key information such as magnetic field change characteristics, determines the location and extent of damage inside the sidewall of the water-cooled wall tube, and displays the results in a visual way (such as image marking, data report, etc.) in real time on the display screen for easy observation and recording by operators.

[0046] 6. Cleaning and Maintenance: After testing, turn off the drive motor 46 to stop the rotation of the ring magnetic tape 24. Clean the surface and interior of the device to remove any magnetic powder residue. Check all parts for wear or damage, and replace or repair them as needed. Check and replenish the magnetic powder in the magnetic powder box 251 to ensure sufficient quantity and good quality of magnetic powder for the next use. Finally, store the device properly for future use.

[0047] The specific embodiments described above are merely illustrative examples to explain the principles of the invention and do not constitute a limitation thereof. Therefore, any modifications, equivalent substitutions, or improvements made without departing from the spirit and scope of the invention should be included within the protection scope of the invention. For example, two pairs of wheels may be installed at the upper and lower ends of the combined housing, with the wheels moving within the grooves on the heat exchanger sidewall tubes, or a motor may be installed on the wheels to achieve controllable movement.

Claims

1. A boiler water-cooled wall tube sidewall inspection device, comprising a housing assembly (1), a magnetic module (3), and an image acquisition module (5), wherein the upper magnet (31) and lower magnet (32) of the magnetic module (3) are respectively fixed to the upper front side and lower front side of the housing assembly (1), and the image acquisition module (5) is installed inside the housing assembly (1), characterized in that, It also includes a magnetic powder circulation mechanism (2) and a drive mechanism (4). The magnetic powder circulation mechanism (2) includes an upper pulley (21), a lower pulley (22), and a rear guide pulley (23). The upper pulley (21), lower pulley (22), and rear guide pulley (23) are respectively fitted onto the wire threading tubes (17) at corresponding positions inside the housing assembly (1), and a ring magnetic tape (24) is fitted on the outside of each pulley. The drive mechanism (4) is used to drive the ring magnetic tape (24) to circulate. A powder removal mechanism (25) is provided on the upper side inside the housing assembly (1), and a powder removal mechanism (25) is provided on the lower side inside the housing assembly (1). A powder application mechanism (26) is provided on the front side of the part. The bottom of the powder removal mechanism (25) is connected to the top of the powder application mechanism (26) through a powder guide tube (27). The upper part of the annular magnetic tape (24) passes through the powder removal mechanism (25) for powder removal. The front part of the annular magnetic tape (24) is attached to the front of the powder application mechanism (26) for powder application. The image acquisition module (5) faces the inner surface of the annular magnetic tape (24). The acquisition data line (51) of the image acquisition module (5) is led out from the back of the outer shell assembly (1) and connected to the data input terminal of the external detection device. The outer shell assembly (1) is provided with an upper chamber and a lower chamber, and each chamber has an opening at the front end. The image acquisition module (5) is installed in the lower chamber, and the magnetoresistive sensor (6) is fixed in the upper chamber. The acquisition data line (51) of the image acquisition module (5) and the sensor data line (61) of the magnetoresistive sensor (6) are respectively led out from the back of the outer shell assembly (1) and connected to the data input terminal of the external detection device. The drive mechanism (4) includes a drive shaft (41) and a driven shaft (42) in parallel. Two pairs of shaft holes are provided at the lower rear end of the two side walls of the housing assembly (1). The two ends of the drive shaft (41) and the driven shaft (42) are respectively installed in the corresponding shaft holes through bearings. The drive shaft (41) and the driven shaft (42) are respectively fitted with a drive roller (43) and a driven roller (44). The annular magnetic tape (24) is located between the drive roller (43) and the driven roller (44) and is clamped. A synchronous gearbox (45) is fixed on the outer side of the front side wall of the housing assembly (1), and a drive motor (46) is fixed on the outer side of the rear side wall. Two gears of the same type and meshing with each other are installed in parallel in the synchronous gearbox (45). The front ends of the drive shaft (41) and the driven shaft (42) are respectively fixedly installed on the shaft center of the two gears. The rear end of the drive shaft (41) is connected to the shaft of the drive motor (46) for transmission. The outer shell assembly (1) includes a main shell (11) and a secondary shell (12). Multiple pairs of wire-threading tubes (17) for connecting the two shells are distributed on the inner side of the main shell (11) and the secondary shell (12). A fixing screw is installed through each pair of wire-threading tubes (17). A counterweight groove (16) is provided at the rear side of the outer shell assembly (1) of the main shell (11) and the secondary shell (12). A counterweight block is installed in the counterweight groove (16).

2. The boiler water-cooled wall tube sidewall inspection device according to claim 1, characterized in that, The magnetic module (3) also includes a front guard plate (33). An upper magnet slot (14) is provided on the upper front side of the outer shell assembly (1). The upper magnet slot (14) is used to fix the upper magnet (31). A lower magnet slot (15) is provided on the lower front side of the outer shell assembly (1). The lower magnet slot (15) is used to fix the lower magnet (32). The front guard plate (33) is fixed at the front end of the outer shell assembly (1) and between the upper magnet slot (14) and the lower magnet slot (15).

3. The boiler water-cooled wall tube sidewall inspection device according to claim 2, characterized in that, The front guard plate (33) includes a central web plate and upper and lower end wing plates. Guard plate fixing seats (34) are fixed at the upper and lower ends of the web plate respectively. The guard plate fixing seats (34) are fixed together with the upper and lower edges of the outer shell assembly (1) by screws. The end wing plates located at the upper and lower ends of the front guard plate (33) respectively wrap the upper magnet (31) and the lower magnet (32). Moreover, the upper and lower end wing plates are respectively inserted into the slots provided on the inner side wall of the upper magnet slot (14), so that the edges of the upper and lower end wing plates are completely fixed with the edges of the upper magnet slot (14) and the lower magnet slot (15).

4. The boiler water-cooled wall tube sidewall inspection device according to claim 1, characterized in that, The powder removal mechanism (25) includes a magnetic powder box (251), an isolation plate (253), and a powder scraper (254). The magnetic powder box (251) is a closed box made of non-magnetic conductive and magnetically shielding material. Horizontal strip-shaped holes (252) are respectively provided on the front and rear side walls of the magnetic powder box (251). The annular magnetic tape (24) passes through the two holes (252). An isolation plate (253) is fixed horizontally in the inner cavity of the magnetic powder box (251) and below the annular magnetic tape (24). Multiple inclined upward powder scrapers (254) are distributed horizontally on the isolation plate (253). The height of the multiple horizontal powder scrapers (254) increases sequentially from front to back. A scraper armpit groove (255) is provided at the acute angle position below the front side of each powder scraper (254).

5. The boiler water-cooled wall tube sidewall inspection device according to claim 1, characterized in that, The powder feeding mechanism (26) includes a powder collection hopper (261) and a thickness limiting plate (267). The powder collection hopper (261) is fixed to the front side of the lower part of the outer shell assembly (1), and the front side of the powder collection hopper (261) is open. The thickness limiting plate (267) is fixedly installed or movably installed on the upper side of the open side of the powder collection hopper (261). The thickness limiting plate (267) is parallel to the inner surface of the annular magnetic tape (24) and the two maintain an appropriate distance.

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