Phased array ultrasonic scanning device and system for detecting transverse defects of welded joints of medium and large-diameter pipelines and using method of phased array ultrasonic scanning device and system for detecting transverse defects of welded joints of medium and large-diameter pipelines
By designing an automated phased array ultrasonic scanning device, the problems of low efficiency and low accuracy of manual scanning in the detection of transverse defects in welded joints of medium and large diameter pipelines have been solved, achieving efficient and accurate automated detection, which is applicable to a variety of scanning methods.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-26
- Publication Date
- 2026-03-31
AI Technical Summary
In the existing technology, the detection of transverse defects in welded joints of medium and large diameter pipes suffers from low efficiency and low accuracy due to manual scanning. Furthermore, it is difficult to ensure uniform coupling and stable pressure with handheld probes, resulting in the detection data not corresponding to the actual situation and poor repeatability of the detection results.
A phased array ultrasonic scanning device for detecting transverse defects in welded joints of medium and large diameter pipes was designed. It includes a cuboid trolley with a handle, equipped with magnetic wheels and a servo motor, which can automatically tilt and scan. The probe is rotated and stably clamped by a probe clamping module. Combined with a phased array detector, it can achieve automated detection.
It enables automated detection of transverse defects in welded joints of medium and large diameter pipes, improving detection accuracy and efficiency, ensuring the accuracy and repeatability of detection data, and is applicable to pipes with different curvatures, meeting the standard requirements of various scanning methods.
Smart Images
Figure CN121762684A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a phased array ultrasonic scanning device, system, and method for detecting transverse defects in welded joints of medium and large diameter pipelines, particularly to phased array ultrasonic testing of welded joints of large diameter pipelines, belonging to the field of industrial testing equipment manufacturing technology. Background Technology
[0002] Phased array ultrasonic testing is an advanced and cutting-edge ultrasonic imaging technology. Recently applied in the West-East Gas Pipeline project in China, and after years of engineering promotion and technological upgrades, it has become a mainstream testing technology, widely used in the power, petrochemical, and pipeline industries. Relevant regulations and standards explicitly require that phased array ultrasonic testing technology be used for quality inspection of pipeline welded joints. Therefore, the demand for phased array ultrasonic testing of pipeline welded joints is huge and shows an increasing trend year by year. Relevant phased array testing technical standards stipulate that transverse defect detection should be performed for Class I welded joints at Class B inspection. Because pipeline welded joints have curved structures, they have certain unique characteristics compared to flat welded joints. While the process for longitudinal defect detection is not significantly different, the scanning surface becomes curved when detecting transverse defects in pipeline welded joints, making the inspection process more complex. Currently, manual scanning is commonly used for inspecting transverse defects in pipe welded joints, as there is no mature and feasible mechanical scanning device. When recording scanning data, the phased array detector is usually activated in time-based scanning mode, making encoder mode unusable. This results in poor correspondence between the inspection data and the actual internal condition of the inspected workpiece, leading to data distortion. Furthermore, manual scanning is less efficient than mechanical scanning; handheld probes cannot guarantee uniform probe pressure and coupling, causing significant variations in detection sensitivity and low accuracy during the scanning process; manual scanning cannot guarantee a constant probe tilt angle and translation distance, making accurate execution of the inspection process impossible, resulting in discrepancies between the inspection results and the actual defects, and poor repeatability of the inspection results. Summary of the Invention
[0003] The technical problem to be solved by the present invention is to provide a phased array ultrasonic scanning device, system and method for detecting transverse defects in welded joints of medium and large diameter pipes, which addresses the shortcomings of the existing technology. It realizes automatic tilt scanning of transverse defects in welded joints of medium and large diameter pipes, solves the problems of mismatch between manual detection data and the quality condition of the inspected workpiece and data distortion, and also solves the problems of difficulty in implementing manual scanning, low detection efficiency and low detection accuracy.
[0004] To address this technical problem, this invention provides a phased array ultrasonic scanning device for detecting transverse defects in welded joints of medium-to-large diameter pipelines. The device is a rectangular trolley with a handle, comprising a handle, a main scanning unit, a probe clamping module, magnetic wheels, and a control cable interface. The main scanning unit is the core of the device, with a U-shaped handle at the top. The probe clamping module is located at the center of the main scanning unit, clamping the phased array probe and rotating it. Four magnetic wheels with built-in powerful permanent magnets are located at the bottom of the main scanning unit, connected to a servo motor inside the main scanning unit. A cylindrical multi-core control cable interface is located at the center of the upper rear side of the main scanning unit. The control cable interface is compatible with the control cable; one end of the control cable is inserted into the control cable interface, and the other end is inserted into the interface of the phased array detector. The phased array probe cable connector is inserted into the corresponding probe interface of the phased array detector, enabling communication between the scanning device and the phased array detector.
[0005] The probe clamping module includes a pointer knob, a support frame, spring supports, support pins, a probe holder, and screws. The pointer knob is located at the top of the module and has a triangular longitudinal section. The pointer knob is connected to the lower support frame via a rotating shaft. A cylindrical spring support is located on each side of the lower part of the support frame, and the lower parts of the spring support are connected by support pins. An arc-shaped slide is machined on the upper part of the probe holder, and the support pin passes through the arc-shaped slide to connect the probe holder to the spring supports. Two screws are symmetrically located on the lower part of the probe holder to clamp the phased array probe. The support pins slide relative to each other on the arc-shaped slide, allowing the probe holder to be freely adjusted in angle, thus enabling the lower surface of the phased array probe to rotate at an angle, meeting the requirements for phased array detection of pipelines with different curvatures.
[0006] The spring support rod has a double-layer structure with an inner and outer layer. The central part has a built-in spring that can extend and retract freely. The spring support rod applies a clamping force to the lower probe frame through the support arm pin, so as to achieve a stable contact state between the phased array probe and the surface of the inspected pipeline.
[0007] The servo motor has a built-in Hall sensor that can acquire the rotational state parameters of the magnetic wheel in real time, convert them into data on the direction and distance of the magnetic wheel's movement, and transmit them to the phased array detector via a control cable.
[0008] A cylindrical connecting rod hole is machined at the center of the upper front part of the main unit of the scanning device. The connecting rod hole is a blind hole, the size of which matches the size of the connecting rod, and the connecting rod can be inserted into it. A cylindrical knob is provided at the top of the connecting rod hole. By rotating the knob, the connecting rod can be tightened or loosened, realizing the combination of two sets of scanning devices.
[0009] The scanning device has semi-circular grooves of the same size machined on both sides of the main body. A spring pin is set in the center of the groove, and the pin can automatically reset under the action of the internal spring. Z-shaped support arms are set inside the semi-circular grooves on both sides. Cylindrical through holes are machined at both ends of the Z-shaped support arms. The spring pin is inserted into the through holes of the Z-shaped support arms to combine the Z-shaped support arms with the scanning device main body. The Z-shaped support arms can rotate along the spring pin.
[0010] The present invention also provides a phased array ultrasonic scanning system for detecting transverse defects in welded joints of medium and large diameter pipes. The phased array ultrasonic scanning system includes multiple phased array ultrasonic scanning devices, which are connected by a connecting device.
[0011] The phased array ultrasonic scanning system includes three combination methods: Combination 1: Two scanning devices are inserted into the connecting rod holes of the main scanning device on the left and right sides respectively through cylindrical connecting rods. Tighten the knobs in sequence to fix the main scanning device at both ends of the connecting rod to the connecting rod, thus completing Combination 1 of the scanning devices; Combination 2: Two scanning devices are connected by a Z-shaped support arm and fixed by a spring pin, completing the second combination of scanning devices; Combination 3: The four scanning devices are divided into two groups. First, they are combined according to Combination 1, and then they are combined according to Combination 2. Finally, the four scanning device modules are combined together to form Combination 3.
[0012] The present invention also provides a method for using the phased array ultrasonic scanning device and system for detecting transverse defects in welded joints of medium and large diameter pipes as described above, comprising the following steps: 1) Based on the specifications and parameters of the welded joints of the inspected pipeline, prepare the testing process procedures and operation instructions in accordance with the requirements of the phased array ultrasonic testing standard; 2) Select the appropriate model of phased array probe. The phased array probe is fixed to the lower part of the probe frame with screws. Combine the phased array probe with the probe clamping module. 3) Rotate the pointer knob to rotate the phased array probe to a certain angle, which is equal to the angle between the probe and the weld in the operation manual; hold the handle and place the scanning device on one side of the welded joint of the pipeline to be inspected, and the magnetic wheel will adhere to the surface of the pipeline to be inspected. 4) Take the control cable, insert one end of the cable into the control cable interface, and the other end into the phased array detector interface; insert the phased array probe cable connector into the corresponding probe interface of the phased array detector. 5) Turn on the phased array detector, and follow the software operation procedures to enter the test parameters and calibrate the instrument. Once the preparation is complete, click the "Start" button on the phased array detector screen to begin scanning until the test is complete. Alternatively: When it is necessary to simultaneously perform unidirectional tilt scanning on both sides of the pipe weld joint, take two scanning device modules, insert the connecting rods into the connecting rod holes of the main unit of the scanning device on the left and right sides respectively, tighten the knobs in sequence, fix the main unit of the scanning device at both ends of the connecting rod to the connecting rod, and complete the scanning device assembly one; place the assembled scanning device on both sides of the weld joint, and repeat the above detection steps until the detection is completed; Alternatively: When it is necessary to simultaneously perform bidirectional inclined scanning on one side of the pipe weld joint, take two scanning device main units, pull out the spring pin of one scanning device, lower the Z-shaped support arm, and release the spring pin of the scanning device; then pull out the spring pin of the other scanning device, insert the through hole at the other end of the Z-shaped support arm into the spring pin of the scanning device, and release the spring pin of the scanning device to complete the second combination of scanning devices; place the combined scanning device on one side of the weld joint, and repeat the above inspection steps until the inspection is completed; Alternatively: If all transverse defects need to be detected at once, i.e., when the pipe weld joint is inspected on both sides at the same time, take four scanning device main units, first assemble them according to the process described in Combination 1, then assemble them according to the process described in Combination 2, and finally assemble the four scanning devices according to the method described in Combination 3; place the assembled scanning devices on both sides of the weld joint of the pipe to be inspected, and repeat the above detection steps until the detection is completed.
[0013] Beneficial Effects: This invention powers the phased array detector without a built-in battery. Each module is compact and portable, safe, reliable, and widely applicable, especially suitable for detecting transverse defects in welded joints of medium and large diameter pipes. It is also suitable for routine scanning of pipe welded joints. Using only this scanning device, all standard scanning procedures can be completed without the need for additional manual scanning, truly automating the entire scanning process and overcoming the drawbacks of manual scanning. The probe clamping module of this invention can freely rotate the phased array probe angle according to the detection process requirements. An arc-shaped guide rail is set in the middle of the probe clamping module, forming a self-stabilizing system, so the lower surface of the probe can fit well against the outer surface of the inspected pipe. In addition, the device is designed with a spring bracket to provide stable downward pressure for the probe, ensuring coupling effect and making it suitable for detecting welded joints of pipes of different diameters, exhibiting good process applicability. This invention boasts strong versatility, high detection accuracy, and good economic benefits. The phased array detector can monitor probe attitude parameters in real time, providing feedback to adjust the detection focusing law accordingly. After receiving detection data, it can dynamically adjust the detection imaging, ensuring perfect reproduction of the detection process without data distortion. Furthermore, it features simultaneous multi-view display, providing intuitive defect display and a large amount of defect feature data, significantly improving defect detection rate and accuracy. The modular design allows for independent use of a single scanning device as the smallest scanning unit, enabling the addition of multiple scanning devices based on the welded joints of the inspected pipeline. This allows for various scanning scenarios, with up to four scanning devices forming a frame-based composite scanning system. This system carries four phased array probes, enabling the completion of the standard four-directional transverse defect detection process in a single scan, greatly improving detection efficiency. The modular design also facilitates future maintenance and upgrades, resulting in low manufacturing and operating costs. This invention enables rapid and efficient comprehensive inspection of welded joints using multiple scanning methods. It is particularly suitable for inclined scanning of transverse defects in welded joints, and is also applicable to longitudinal and transverse scanning. It is a multi-purpose machine that meets the application requirements of various scanning methods according to standards. It features fast detection speed and high detection accuracy, making it an intelligent inspection system. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the overall structure of the present invention. Figure 1 ; Figure 2 This is a schematic diagram of the overall structure of the present invention. Figure 2 ; Figure 3 This is a schematic diagram of the probe clamping module of the present invention; Figure 4 This is an assembly diagram of the probe clamping module of the present invention; Figure 5 This is a schematic diagram of the spring support rod of the present invention; Figure 6This is a schematic diagram of the assembly of the magnetic wheel and the servo motor of the present invention; Figure 7 This is a schematic diagram of the detection interface of the detection instrument software system of the present invention; Figure 8 This is a schematic diagram of the field application of the scanning system of the present invention; Figure 9 This is a schematic diagram of the field application of the first combination of the present invention; Figure 10 This is a schematic diagram of the field application of the second combination of the present invention; Figure 11 This is a schematic diagram of the field application of the third combination of the present invention.
[0015] In the diagram: 1. Handle; 2. Scanning device main unit; 3. Probe clamping module; 4. Knob; 5. Linkage hole; 6. Magnetic wheel; 7. Z-shaped support arm; 8. Control cable interface; 9. Spring pin; 10. Servo motor; 31. Pointer knob; 32. Support rod frame; 33. Spring support rod; 34. Support arm pin; 35. Probe frame; 36. Screw; 01. Phased array probe; 02. Phased array detector; 03. Control cable; 04. Pipe welding joint; 05. Linkage rod. Detailed Implementation
[0016] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.
[0017] like Figures 1-11As shown, this invention provides a phased array ultrasonic scanning device for detecting transverse defects in welded joints of medium and large diameter pipelines. Its overall shape is a cuboid cart with a handle, including a handle 1, a scanning device main unit 2, a probe clamping module 3, magnetic wheels 6, a control cable interface 8, and a matching phased array detector 02. The scanning device main unit 2 is the main body of the scanning device, with a U-shaped handle 1 on the upper part for easy handling and carrying by inspection personnel, facilitating rapid deployment and dismantling of the scanning device. The probe clamping module 3 is located in the center of the scanning device main unit 2. The probe clamping module 3 clamps the phased array probe 01 and can rotate the phased array probe 01 to achieve a preset angle between the probe and the weld seam of the inspected pipeline joint. The scanning... The lower part of the main unit 2 is equipped with four magnetic wheels 6 with built-in powerful permanent magnets, which can stably adhere to the surface of the inspected pipe and rotate along the pipe surface, driving the scanning device to move smoothly along the surface of the inspected pipe. The magnetic wheels 6 are connected to a servo motor 10 set inside the main unit 2 of the scanning device, and the servo motor 10 provides power to the magnetic wheels 6. A cylindrical multi-core control cable interface 8 is provided at the center of the upper rear side of the main unit 2 of the scanning device. The control cable interface 8 is matched with the control cable 03. One end of the control cable 03 is inserted into the control cable interface 8, and the other end is inserted into the interface of the phased array detector 02. The phased array probe cable connector is inserted into the corresponding probe interface of the phased array detector 02 to realize the connection and communication between the scanning device and the phased array detector 02.
[0018] The probe clamping module 3 includes a pointer knob 31, a support frame 32, spring support rods 33, support pins 34, a probe holder 35, and screws 36. The uppermost part of the probe clamping module 3 is the pointer knob 31, which has a triangular longitudinal section. The pointer knob 31 is connected to the lower support frame 32 via a rotating shaft. A cylindrical spring support rod 33 is provided on each side of the lower part of the support frame 32, and the lower parts of the spring support rods 33 are connected via support pins 34. The probe holder 35... 5. An arc-shaped slide is machined on the upper part, and the support pin 34 passes through the arc-shaped slide to connect the probe frame 35 to the spring support rod 33; two screws 36 are symmetrically provided on the lower part of the probe frame 35. By screwing in and out of the screws 36, the phased array probe 01 can be clamped and disassembled; the support pin 34 slides relative to each other in the arc-shaped slide, so that the probe frame 35 can be freely adjusted in angle, thereby allowing the lower surface of the phased array probe 01 to rotate by an angle, so as to meet the requirements of phased array detection of pipelines with different curvatures.
[0019] The spring support rod 33 has a double-layer structure with an inner and outer layer. The central part has a built-in spring that can extend and retract freely. The spring support rod 33 applies a clamping force to the lower probe frame 35 through the support arm pin 34, so as to achieve a stable contact state between the phased array probe 01 and the surface of the inspected pipeline.
[0020] The servo motor 10 has a built-in Hall sensor that can acquire the rotational state parameters of the magnetic wheel 6 in real time, convert them into the moving direction and distance data of the magnetic wheel 6, and transmit them to the phased array detector 02 through the control cable 03.
[0021] A cylindrical connecting rod hole 5 is machined at the center of the upper front part of the main body 2 of the scanning device. The connecting rod hole 5 is a blind hole, and its size matches the size of the connecting rod 05, which can be inserted into it. A cylindrical knob 4 is provided on the upper part of the connecting rod hole 5. The upper part of the knob 4 is a cylindrical knob cap, and the lower part is a screw. By rotating the knob 4, the connecting rod 05 can be tightened or loosened, so as to achieve the detection effect of the combined operation of the two scanning devices.
[0022] The scanning device main unit 2 has semi-circular grooves of the same size machined on both sides. A spring pin 9 is set in the center of the groove. The spring pin 9 consists of two parts: a cylindrical pin cap and a pin. Pulling the pin cap can pull out the internal pin. When the pin cap is released, the pin can automatically return to its original position under the action of the internal spring. Z-shaped support arms 7 are set inside the semi-circular grooves on both sides. Cylindrical through holes are machined at both ends of the Z-shaped support arms 7. The diameter of the through holes matches the diameter of the pin of the spring pin 9. The spring pin 9 is inserted into the through holes of the Z-shaped support arms 7. After the pin returns to its original position, the Z-shaped support arms 7 are combined with the scanning device main unit 2. The Z-shaped support arms 7 can rotate along the pin of the spring pin 9.
[0023] The phased array detector 02 has five data windows: an S-scan view window, an A-scan view window, a B-scan view window, a C-scan view window, and a D-scan view window. The S-scan view window displays the current probe position sector scan image in real time. The system operation process is as follows: the system acquires the rotation angle data of the probe clamping module and the probe attitude data in real time. The system calculates and generates the phased array focusing law in real time according to the preset weld joint size parameters, accurately controls the phased array probe sound beam, and back-fits the received detection data to the S-scan view window to accurately reconstruct the internal quality image of the inspected workpiece through precise data calculation. The A-scan view window displays the waveform data of the target sound beam in real time. The B-scan view window displays the longitudinal section scan image of the inspected pipe weld joint in real time. The C-scan view window displays the longitudinal top view projection image of the inspected pipe weld joint in real time. The D-scan view window displays the side view projection image of the inspected pipe weld joint in real time. The instrument interface is reasonably divided into functional areas, the data display is clear and intuitive, the operation buttons are centrally arranged, multiple scan views are displayed simultaneously, and defect analysis and judgment are convenient.
[0024] The phased array detector 02 has operation buttons centrally located in the upper right corner, allowing inspectors to easily control the scanning device to "start" and "pause" movement. After scanning, clicking the "End" button locks the scan data; clicking the "Save" button automatically saves the data. To review the test data, click the "Review" button, select the relevant data from the data list, and open it. If incorrect test parameters are found before starting the test, click the "Parameter Settings" button to modify the corresponding parameters. If module data is found to be uncalibrated before starting the test, click the "Return" button to return to the previous instrument debugging interface for appropriate adjustments.
[0025] This invention also provides a phased array ultrasonic scanning system for detecting transverse defects in welded joints of medium and large-diameter pipes. The phased array ultrasonic scanning system comprises multiple phased array ultrasonic scanning devices, which are connected via a connecting device. These devices are also connected to the phased array detector software system via a splitter with multiple probe interfaces. Three combination methods are included: Combination 1: Two scanning devices are inserted into the connecting rod holes 5 of the main body 2 of the left and right scanning devices respectively through the cylindrical connecting rod 05. The knobs 4 are tightened in sequence to fix the main body 2 of the scanning device at both ends of the connecting rod 05 to the connecting rod 05, thus completing the scanning device combination 1. Combination 2: The two scanning devices are connected by Z-shaped support arm 7 and fixed by spring pin 9 to complete the scanning device combination 2; Combination 3: The four scanning devices are divided into two groups. First, they are combined according to Combination 1, and then they are combined according to Combination 2. Finally, the four scanning device modules are combined together to form Combination 3.
[0026] The present invention also provides a method for using the phased array ultrasonic scanning device and system for detecting transverse defects in welded joints of medium and large diameter pipes as described above, comprising the following steps: 1) Based on the specifications of the welded joint 04 of the inspected pipeline, prepare the testing process and operation instructions in accordance with the requirements of the phased array ultrasonic testing standard; 2) According to the operation manual, select the corresponding model of phased array probe 01. The phased array probe 01 is fixed to the lower part of the probe holder 35 by screws 36. Combine the phased array probe 01 with the probe clamping module 3. 3) Rotate the pointer knob 31 to rotate the phased array probe 01 by a certain angle. This angle value is equal to the angle between the probe and the weld in the operation manual. Hold the handle 1 and place the scanning device on one side of the welded joint 04 of the pipeline to be inspected. The magnetic wheel 6 is attracted to the surface of the pipeline to be inspected. 4) Take control cable 03, insert one end of the cable into control cable interface 8, and the other end into interface 02 of phased array detector; insert the phased array probe cable connector into the corresponding probe interface of phased array detector 02. 5) Turn on the phased array detector 02. Follow the software operation procedures to enter the test parameters and calibrate the instrument. Once preparation is complete, click the "Start" button on the phased array detector 02 screen. The magnetic wheel 6 will rotate, driving the scanning device to move and begin scanning until the test is complete. If you need to pause during the process, press the "Pause" button. After completing all scanning work, click "End," enter the data name, and click the "Save" button. If you need to view the data, click the "Review" button to open the corresponding test data. If you need to adjust the test parameters, click the "Parameter Settings" button. If you need to recalibrate the instrument, click "Return" to the previous screen for debugging and calibration. Alternatively: When it is necessary to simultaneously complete the unidirectional tilting scan of both sides of the pipe weld joint 04, take two scanning device modules, insert the connecting rod 05 into the connecting rod hole 5 of the scanning device main unit 2 on the left and right sides respectively, tighten the knob 4 in sequence, fix the scanning device main unit 2 at both ends of the connecting rod 05 to the connecting rod 05, and complete the scanning device assembly one; place the assembled scanning device on both sides of the weld joint, and repeat the above detection steps until the detection is completed; Alternatively: When it is necessary to simultaneously complete the single-sided bidirectional inclined scanning of the pipe weld joint 04, take two scanning device main units 2, pull out the spring pin 9 of one scanning device, lower the Z-shaped support arm 7, and loosen the spring pin 9 of the scanning device; then pull out the spring pin 9 of the other scanning device, insert the other end through hole of the Z-shaped support arm 7 into the spring pin 9 of the scanning device, and loosen the spring pin 9 of the scanning device to complete the second combination of scanning devices; place the combined scanning device on one side of the weld joint, and repeat the above detection steps until the detection is completed; Alternatively: If all transverse defects need to be detected at once, i.e., when the double-sided bidirectional inclined scanning of the pipe weld joint 04 is completed simultaneously, take four scanning device main units 2, first assemble them according to the process described in Combination 1, then assemble them according to the process described in Combination 2, and finally assemble the four scanning devices according to the method of Combination 3; place the assembled scanning devices on both sides of the inspected pipe weld joint 04, and repeat the above detection steps until the detection is completed.
[0027] This invention powers a phased array detector without a built-in battery. Each module is compact, portable, safe, reliable, and widely applicable, especially suitable for detecting transverse defects in welded joints of medium and large diameter pipes. It is also suitable for routine scanning of pipe welded joints. Using only this scanning device, all standard scanning procedures can be completed without additional manual scanning, truly automating the entire scanning process and overcoming the drawbacks of manual scanning. The probe clamping module can freely rotate the phased array probe angle according to the detection process requirements. An arc-shaped guide rail in the middle of the probe clamping module forms a self-stabilizing system, ensuring the lower surface of the probe fits well against the outer surface of the inspected pipe. Furthermore, the device features a spring support to provide stable downward pressure on the probe, ensuring effective coupling and applicability to welded joints of pipes with different diameters. It has good process applicability and versatility. This invention boasts high performance, high detection accuracy, and excellent economic benefits. The phased array detector can monitor probe attitude parameters in real time, providing feedback to adjust the detection focusing law accordingly. After receiving detection data, it can dynamically adjust the detection imaging, ensuring perfect reproduction of the detection process without data distortion. Furthermore, it features simultaneous multi-view display, providing intuitive defect display and a large amount of defect feature data, significantly improving defect detection rate and accuracy. The modular design allows for independent use of a single scanning device as the smallest scanning unit, enabling the addition of multiple scanning devices to accommodate various scanning conditions, up to four devices forming a frame-based composite scanning system. This system carries four phased array probes, allowing for the completion of the standard four-directional transverse defect detection process in a single scan, greatly improving detection efficiency. The modular design also facilitates future maintenance and upgrades, resulting in low manufacturing and operating costs. This invention enables rapid and efficient comprehensive inspection of welded joints using multiple scanning methods. It is particularly suitable for inclined scanning of transverse defects in welded joints, and is also applicable to longitudinal and transverse scanning. It is a multi-purpose machine that meets the application requirements of various scanning methods according to standards, with fast detection speed and high detection accuracy.
[0028] The above embodiments of the present invention are merely illustrative examples and are not the only ones. All modifications within the scope of the present invention or equivalent to the scope of the present invention are encompassed by the present invention.
Claims
1. A phased array ultrasonic scanning device for detecting transverse defects in welded joints of medium and large diameter pipes, characterized in that: Its overall shape is a rectangular trolley with a handle, including a handle (1), a scanning device main unit (2), a probe clamping module (3), magnetic wheels (6), and a control cable interface (8). The scanning device main unit (2) is the main body of the scanning device, with a U-shaped handle (1) on the upper part. The probe clamping module (3) is located in the center of the scanning device main unit (2). The probe clamping module (3) clamps the phased array probe (01) and can drive the phased array probe (01) to rotate. The lower part of the scanning device main unit (2) is equipped with four magnetic wheels with built-in strong permanent magnets. 6) The magnetic wheel (6) is connected to the servo motor (10) inside the scanning device host (2); the scanning device host (2) is provided with a cylindrical multi-core control cable interface (8) at the center of the upper rear side. The control cable interface (8) is matched with the control cable (03). One end of the control cable (03) is inserted into the control cable interface (8), and the other end is inserted into the interface of the phased array detector (02). The phased array probe cable connector is inserted into the corresponding probe interface of the phased array detector (02) to realize the connection and communication between the scanning device and the phased array detector (02).
2. The phased array ultrasonic scanning device for detecting transverse defects in welded joints of medium and large diameter pipelines according to claim 1, characterized in that: The probe clamping module (3) includes a pointer knob (31), a support frame (32), a spring support rod (33), a support pin (34), a probe holder (35), and screws (36). The uppermost part of the probe clamping module (3) is the pointer knob (31), and the longitudinal section of the pointer knob (31) is triangular. The pointer knob (31) is connected to the lower support frame (32) as a whole through a rotating shaft. A cylindrical spring support rod (33) is provided on each side of the lower part of the support frame (32). The lower part of the spring support rod (33) is supported by a support. The probe frame (35) is connected by an arm pin (34). The upper part of the probe frame (35) is machined with an arc-shaped slide. The arm pin (34) passes through the arc-shaped slide to connect the probe frame (35) with the spring support rod (33). Two screws (36) are symmetrically provided at the lower part of the probe frame (35) to clamp the phased array probe (01). The arm pin (34) slides relative to the arc-shaped slide, so that the probe frame (35) can be freely adjusted in angle, thereby allowing the lower surface of the phased array probe (01) to be rotated by an angle to meet the requirements of phased array detection of pipelines with different curvatures.
3. The phased array ultrasonic scanning device for detecting transverse defects in welded joints of medium and large diameter pipelines according to claim 2, characterized in that: The spring support rod (33) has an inner and outer double-layer structure. The central part has a built-in spring that can extend and retract freely. The spring support rod (33) applies a clamping force to the lower probe frame (35) through the support arm pin (34) to achieve a stable contact state between the phased array probe (01) and the surface of the inspected pipeline.
4. The phased array ultrasonic scanning device for detecting transverse defects in welded joints of medium and large diameter pipelines according to claim 1, characterized in that: The servo motor (10) has a built-in Hall sensor that can acquire the rotational state parameters of the magnetic wheel (6) in real time, convert them into the moving direction and distance data of the magnetic wheel (6), and transmit them to the phased array detector (02) through the control cable (03).
5. The phased array ultrasonic scanning device for detecting transverse defects in welded joints of medium and large diameter pipelines according to claim 1, characterized in that: The scanning device host (2) has a cylindrical connecting rod hole (5) machined at the center of the upper front side. The connecting rod hole (5) is a blind hole, and its size matches the size of the connecting rod (05). The connecting rod (05) can be inserted into it. The upper part of the connecting rod hole (5) is provided with a cylindrical knob (4). By rotating the knob (4), the connecting rod (05) can be tightened or loosened, so as to realize the combination of the two sets of scanning devices.
6. The phased array ultrasonic scanning device for detecting transverse defects in welded joints of medium and large diameter pipelines according to claim 1, characterized in that: The scanning device host (2) has semi-circular grooves of the same size on both sides. A spring pin (9) is provided in the center of the groove. The pin can automatically reset under the action of the internal spring. Z-shaped support arms (7) are provided inside the semi-circular grooves on both sides. Cylindrical through holes are processed at both ends of the Z-shaped support arms (7). The spring pin (9) is inserted into the through hole of the Z-shaped support arm (7) to combine the Z-shaped support arm (7) with the scanning device host (2). The Z-shaped support arm (7) can rotate along the spring pin (9).
7. A phased array ultrasonic scanning system for detecting transverse defects in welded joints of medium and large diameter pipes, characterized in that: The phased array ultrasonic scanning system includes multiple phased array ultrasonic scanning devices, which are connected by a connecting device.
8. The phased array ultrasonic scanning system for detecting transverse defects in welded joints of medium and large diameter pipelines according to claim 7, characterized in that: Includes three combination methods: Combination 1: Two scanning devices are inserted into the connecting rod holes (5) of the main scanning device (2) on the left and right sides respectively through the cylindrical connecting rod (05). The knobs (4) are tightened in sequence to fix the main scanning device (2) at both ends of the connecting rod (05) to the connecting rod (05), thus completing the scanning device combination 1. Combination 2: The two scanning devices are connected by a Z-shaped support arm (7) and fixed by a spring pin (9) to complete the second combination of scanning devices; Combination 3: The four scanning devices are divided into two groups. First, they are combined according to Combination 1, and then they are combined according to Combination 2. Finally, the four scanning device modules are combined together to form Combination 3.
9. A method of using a phased array ultrasonic scanning device and system for detecting transverse defects in welded joints of medium-to-large diameter pipes as described in any one of claims 1-8, characterized in that, Includes the following steps: 1) Based on the specifications of the welded joint (04) of the inspected pipeline, prepare the testing process and operation instructions in accordance with the requirements of the phased array ultrasonic testing standard; 2) Select the corresponding model of phased array probe (01). The phased array probe (01) is fixed to the lower part of the probe holder (35) by screws (36). Combine the phased array probe (01) with the probe clamping module (3). 3) Rotate the pointer knob (31) to rotate the phased array probe (01) by a certain angle. The angle value is equal to the angle between the probe and the weld in the operation manual. Hold the handle (1) and place the scanning device on one side of the welded joint (04) of the pipeline to be inspected. The magnetic wheel (6) is attracted to the surface of the pipeline to be inspected. 4) Take the control cable (03), insert one end of the cable into the control cable interface (8), and the other end into the interface of the phased array detector (02); insert the phased array probe cable connector into the corresponding probe interface of the phased array detector (02); 5) Turn on the phased array detector (02), and enter the test parameters and calibrate the instrument and equipment in sequence according to the software operation procedure. The preparation work is completed. Click the "Start" button on the screen of the phased array detector (02). The magnetic wheel (6) rotates and drives the scanning device to move. The scanning begins until the test is completed. Alternatively: When it is necessary to simultaneously perform unidirectional tilt scanning on both sides of the pipe weld joint (04), take two scanning device modules, insert the connecting rod (05) into the connecting rod hole (5) of the scanning device host (2) on the left and right sides respectively, tighten the knob (4) in sequence, fix the scanning device host (2) at both ends of the connecting rod (05) to the connecting rod (05), and complete the scanning device assembly one; place the assembled scanning device on both sides of the weld joint, repeat the above detection steps until the detection is completed; Alternatively: When it is necessary to simultaneously complete the single-sided bidirectional tilting scan of the pipe weld joint (04), take two scanning device main units (2), pull out the spring pin (9) of one scanning device, put down the Z-shaped support arm (7), and loosen the spring pin (9) of the scanning device; then pull out the spring pin (9) of the other scanning device, insert the other end through hole of the Z-shaped support arm (7) into the spring pin (9) of the scanning device, and loosen the spring pin (9) of the scanning device to complete the second combination of scanning devices; place the combined scanning device on one side of the weld joint, and repeat the above detection steps until the detection is completed; Alternatively: If all transverse defects need to be detected at once, that is, when the pipe weld joint (04) is inspected on both sides at the same time, take four scanning device main units (2), first assemble them according to the process described in Combination 1, then assemble them according to the process described in Combination 2, and finally assemble the four scanning devices according to the method of Combination 3; place the assembled scanning devices on both sides of the inspected pipe weld joint (04), and repeat the above detection steps until the detection is completed.