Local stress regulation and control and magnetic flux leakage detection integrated device and method for in-service pressure-bearing equipment

Abstract

The invention relates to an in-service pressure-bearing equipment local stress regulation and control and magnetic flux leakage detection integrated device and method, the integrated device comprises a stress regulation and control and magnetization integrated mechanism and a magnetic flux leakage detection mechanism, the stress regulation and control and magnetization integrated mechanism comprises a stress regulation and control applying assembly and a fixed magnetization integrated assembly, the two ends of the stress regulating and applying assembly are adsorbed to the upper part of the first end and the lower part of the second end of the sample through the two fixed magnetization integrated assemblies; the magnetic flux leakage detection mechanism further comprises a vacuum adsorption module and a sensor lifting frame which are connected with each other; and the Hall sensor directly faces a local target regulation and control area of the sample through the sensor lifting frame and the vacuum adsorption module and can adjust the lift-off value. The problems that in the prior art, stress regulation and control, magnetization and magnetic flux leakage detection are independently separated, local pertinence is lacked, simulation authenticity is insufficient, installation adaptability is poor, regulation and control precision is low, and a matched stress regulation and control + magnetization + magnetic flux leakage detection integrated method does not exist can be solved. And meanwhile, the stress-magnetization-defect collaborative research requirement of the in-service pressure-bearing equipment of the ferromagnetic material cannot be accurately adapted.

Description

Technical Field

[0001] This invention relates to the field of stress regulation and magnetic flux leakage detection technology for in-service pressure-bearing equipment made of ferromagnetic materials. More specifically, it relates to an integrated device and method for local stress regulation and magnetic flux leakage detection of in-service pressure-bearing equipment. Background Technology

[0002] In-service pressure-bearing equipment is a core infrastructure in industrial production, and its operating status directly affects production safety and efficiency. Ferromagnetic materials, due to their high strength, corrosion resistance, and stable magnetic properties, are widely used in the manufacture of in-service pressure-bearing equipment such as pipelines, pressure vessels, and boilers. During long-term service, these ferromagnetic materials are susceptible to dynamic stress concentration in localized areas (such as welds, openings, and stress concentration points) due to factors such as medium pressure, vibration, temperature cycling, and corrosion. This stress concentration can lead to fatigue damage, crack initiation and propagation, ultimately causing equipment failure and safety accidents.

[0003] Defect detection in ferromagnetic material equipment relies on magnetic flux leakage (MF) detection technology. However, MF detection requires magnetization of the equipment beforehand, and defect propagation is closely related to dynamic stress. Therefore, accurately simulating the local dynamic stress state of in-service pressure-bearing equipment made of ferromagnetic materials, achieving stable magnetization, and simultaneously identifying defects in that area are of significant practical importance for equipment safety assessment and lifespan prediction.

[0004] Currently, in the relevant technologies for in-service pressure-bearing equipment using ferromagnetic materials, stress regulation, magnetization, and magnetic flux leakage detection are all independent technical systems that have not been effectively integrated. Moreover, existing technologies are mostly single-function patents and have significant limitations.

[0005] (a) Existing patents are only for stress control.

[0006] Taking the method and mold for controlling the springback of corrugated pipe forming based on stress regulation disclosed in patent CN119794148B as an example, its core function is only to control the axial stress and springback during the corrugated pipe forming process. Stress regulation is achieved by adjusting the position of the corrugation trough through the mold. However, it has three major limitations: First, it has a single function and no defect detection function. It needs to be combined with other detection equipment to complete the safety assessment, resulting in a fragmented process. Second, it has poor adaptability and relies on customized molds. It is only applicable to corrugated pipes of specific specifications and cannot be adapted to the local stress regulation needs of other in-service pressure-bearing equipment such as pipelines and pressure vessels. Third, the data is isolated. It only outputs stress parameters and cannot be associated with defect status. It cannot determine whether "there is still a risk of expansion of defects after stress regulation", resulting in an incomplete safety assessment.

[0007] (ii) Existing patents only cover magnetic flux leakage detection

[0008] Taking the classification method and device for magnetic flux leakage signals in rail magnetic flux leakage detection disclosed in patent CN202210074923.6 as an example, it can only classify rail magnetic flux leakage signals and identify defect types through support vector machines, but it has obvious shortcomings: First, it has no stress control capability, can only identify defects statically, cannot simulate the dynamic stress environment during equipment operation, and cannot analyze the "influence of stress changes on defect propagation", resulting in a large deviation between the detection results and the actual working conditions; Second, magnetization depends on external equipment, requiring an additional independent magnetization device, and the magnetization area and the detection area are prone to misalignment, resulting in poor stability of the magnetic flux leakage signal; Third, the adjustment structure is rudimentary, the lift-off value depends on rough manual adjustment, there is no rigid fixing structure, and the sensor is prone to displacement due to vibration during the detection process, affecting the detection accuracy.

[0009] (iii) In addition, existing independent stress control devices generally suffer from problems such as insufficient dynamic simulation realism and low control accuracy; independent magnetization and magnetic flux leakage detection technologies lack the ability to link and analyze stress environment. The separation of the three and the limitation of single function result in the lack of coordinated data support of "stress state + magnetization environment + defect distribution" for the safety assessment of in-service pressure-bearing equipment made of ferromagnetic materials, which cannot meet the needs of refined and comprehensive safety operation and maintenance.

[0010] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0011] This invention aims to at least partially address one of the technical problems in related technologies. To this end, this invention proposes an integrated device and method for local stress regulation and magnetic flux leakage detection in in-service pressure-bearing equipment. This device organically combines the functions of local dynamic stress regulation, stable magnetization, and magnetic flux leakage detection in in-service pressure-bearing equipment made of ferromagnetic materials. It possesses the integrated advantages of local targeting, accurate simulation, wide installation adaptability, and convenient operation. This effectively solves the pain points of existing technologies where the three functions exist independently, data is disconnected, mutual interference occurs, and single-function patents cannot meet the needs of collaborative research.

[0012] In one aspect of the present invention, an integrated device for local stress regulation and magnetic flux leakage detection of in-service pressure-bearing equipment is provided, comprising:

[0013] The stress modulation and magnetization integrated mechanism includes a stress modulation application component and a fixed magnetization integrated component. Two fixed magnetization integrated components are detachably adsorbed onto the upper part of the first end and the lower part of the second end of the sample, respectively. The stress modulation application component is located on one side of the sample, with both ends connected to the two fixed magnetization integrated components. The fixed magnetization integrated component is configured to move to a fixed position on the sample until it reaches the corresponding surface near its local target modulation region and applies a magnetic field for magnetization. The stress modulation application component has a pressure sensor configured to apply and collect dynamic stress to the local target modulation region of the sample.

[0014] The magnetic flux leakage detection mechanism includes a vacuum adsorption module and a sensor lifting frame. The vacuum adsorption module is detachably fixed to the local target control area of ​​the sample. The sensor lifting frame is equipped with a Hall sensor and the lift-off value of the Hall sensor can be adjusted. The sensor lifting frame is connected to the vacuum adsorption module and the Hall sensor is facing the local target control area of ​​the sample.

[0015] According to the present invention, an integrated device for local stress regulation and magnetic flux leakage detection in in-service pressure-bearing equipment utilizes an integrated stress regulation and magnetization mechanism comprising a stress regulation application component and a fixed magnetization integrated component, in conjunction with a magnetic flux leakage detection mechanism comprising a vacuum adsorption module and a sensor lifting frame. This device is adapted for in-service pressure-bearing equipment made of ferromagnetic materials, forming an integrated design that combines precise local stress regulation, stable magnetization, and synchronous detection of magnetic flux leakage signals. Furthermore, the fixed magnetization integrated component achieves a triple function of "fixation-stress transmission-stable magnetization," eliminating the need for an additional magnetization device and avoiding magnetic interference.

[0016] In some embodiments, the fixed magnetization integrated assembly includes a permanent magnet chuck and a manual rod fixedly connected to the side of the permanent magnet chuck. The permanent magnet chuck is a chuck body with a built-in permanent magnet, and the manual rod is fixedly connected to the chuck body.

[0017] In some embodiments, the stress regulation and application component includes an electro-hydraulic jack and two adjustable force transmission modules symmetrically connected to both ends of the electro-hydraulic jack.

[0018] Each adjustable force transmission module consists of a first telescopic component, a pressure sensor, a connecting plate, a second telescopic component, and a connecting ring, all connected end to end.

[0019] In some embodiments, the vacuum adsorption module includes four vacuum suction cups, four support rods, and two connecting rods; the four vacuum suction cups are symmetrically adsorbed and fixed around the local target control area of ​​the sample, and a support rod is fixedly connected above each vacuum suction cup, and the two connecting rods are respectively horizontally mounted between the four support rods to form a frame structure.

[0020] In some embodiments, the sensor lifting frame includes four connecting rods, a mounting plate, and adjusting bolts; each vacuum adsorption module has four through holes on its connecting rod, and the four connecting rods pass through the through holes respectively. The upper end of each connecting rod is connected to the corresponding connecting rod in a liftable manner through an adjusting bolt. The lower ends of the four connecting rods are fixedly connected to the perimeter of the mounting plate, and the Hall sensor is detachably installed in the central slot of the mounting plate.

[0021] In some embodiments, the connecting rod is made of a rigid non-magnetic material; the mounting plate is made of a non-magnetic insulating material.

[0022] In another aspect of the present invention, an integrated method for local stress regulation and magnetic flux leakage detection of in-service pressure-bearing equipment is also provided. The method utilizes the aforementioned integrated device for local stress regulation and magnetic flux leakage detection of in-service pressure-bearing equipment for detection, and includes the following steps:

[0023] S10. Installation and adaptation:

[0024] Based on the size of the local target area of ​​the sample and the installation environment, adjust the length of the stress control application component so that its force direction is consistent with the preset force direction of the sample;

[0025] The vacuum adsorption module is adsorbed around the stress concentration area of ​​the sample, ensuring that the sensor is facing the target area. The lift-off value of the Hall sensor is adjusted to the set value by the sensor lifting frame, and then the position is locked.

[0026] S20, Sample fixation and stable magnetization:

[0027] The fixed magnetization integrated component is adsorbed onto the local target area of ​​the sample, and magnetization begins;

[0028] S30, Parameter Settings:

[0029] Dynamic stress parameters are set for the stress regulation application component; the sampling frequency of the Hall sensor is started and set.

[0030] S40, Synchronous Operation:

[0031] The stress control application component is activated, and the output stress is transferred to the local area of ​​the sample to start stress loading; stress data and leakage magnetic field signals are collected in real time by pressure sensor and Hall sensor respectively, and transmitted to external display terminal simultaneously;

[0032] S50, Precise Control and Collaborative Analysis:

[0033] Based on the feedback stress data and leakage magnetic field signal, the external control terminal dynamically adjusts the output parameters of the stress regulation application component and performs linkage analysis on stress data, magnetization state and leakage magnetic field signal.

[0034] S60. Experiment ends:

[0035] Shutdown device.

[0036] According to the present invention, an integrated method for local stress control and magnetic flux leakage detection of in-service pressure-bearing equipment can be used to complete a clear integrated method flow. It can realize real-time monitoring, precise control, stable magnetization and simultaneous defect detection of local stress in ferromagnetic material equipment. Thus, it can complete the three-data collaborative analysis based on stress data, magnetization state and magnetic flux leakage signal, and finally quantify the influence law of dynamic stress on defect propagation. It provides a real mechanical environment and reliable technical support for local stress research, defect detection, performance evaluation and safe operation and maintenance of in-service pressure-bearing equipment made of ferromagnetic materials.

[0037] In summary, the integrated device and method for local stress regulation and magnetic flux leakage detection of in-service pressure equipment of the present invention differs significantly from the prior art in the following aspects:

[0038] Firstly, the integrated structure of the integrated device of the present invention, which combines "precise local stress control + stable magnetization + synchronous detection of magnetic leakage signal", is integrated with the collaborative working method of the integrated method of the present invention, which combines "stress control + magnetization + magnetic leakage detection". This is clearly different from existing independent stress control, magnetization or magnetic detection technologies.

[0039] Secondly, the triple functions of "sample fixation, stress transmission, and stable magnetization" of the fixed magnetization integrated component in the integrated device of the present invention, together with the double-sided symmetrical stress application structure of the stress regulation and application component in the integrated device of the present invention and the three-data collaborative analysis process of "stress data + magnetization state + leakage magnetic signal" in the integrated method of the present invention, form a unique technical combination.

[0040] Thirdly, the integrated device and integrated method of this invention also have the combined technical effects of "convenient operation, stable operation, and controllable cost", which can be widely applied to multiple scenarios of in-service pressure-bearing equipment made of ferromagnetic materials. It can save enterprises experimental costs, improve operation and maintenance efficiency, and reduce safety risks, which meets the actual needs of the industry and has significant progressive significance and strong industrial application value.

[0041] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0042] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0043] Figure 1 This is a front view schematic diagram of some embodiments of the integrated device for local stress regulation and magnetic flux leakage detection in in-service pressure equipment according to the present invention.

[0044] Figure 2 This is a top view schematic diagram of some embodiments of the integrated device for local stress regulation and magnetic flux leakage detection in in-service pressure equipment according to the present invention.

[0045] Figure 3 This is a side view of some embodiments of the integrated device for local stress regulation and magnetic flux leakage detection in in-service pressure equipment according to the present invention.

[0046] Meaning of the labels in the attached diagram:

[0047] 1-Integrated stress regulation and magnetization mechanism;

[0048] 11-Stress regulation application component;

[0049] 111-Electric hydraulic jack;

[0050] 112-Adjustable force transmission module; 1121-First telescopic component; 1122-Pressure sensor; 1123-Connecting plate; 1124-Second telescopic component; 1125-Connecting ring;

[0051] 12-Fixed magnetization integrated assembly;

[0052] 121 - Permanent magnet chuck;

[0053] 122 - Manual lever;

[0054] 2- Magnetic flux leakage detection agency;

[0055] 21-Vacuum adsorption module;

[0056] 211-Vacuum suction cup;

[0057] 212-Support rod;

[0058] 213-Connecting rod;

[0059] 22-Sensor lifting frame;

[0060] 221-Connecting rod;

[0061] 222-Mounting plate; 222-1-Center slot;

[0062] 223 - Adjusting bolt;

[0063] 23-Hall sensor;

[0064] 3-sample. Detailed Implementation

[0065] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0066] Example 1

[0067] The following is based on Figures 1-3 The present invention provides a detailed description of the integrated device for local stress regulation and magnetic flux leakage detection in in-service pressure equipment.

[0068] Please refer to Figure 1-3 Embodiment 1 of the present invention provides an integrated device for local stress regulation and magnetic flux leakage detection in in-service pressure-bearing equipment, comprising a stress regulation and magnetization integrated mechanism 1 and a magnetic flux leakage detection mechanism 2. Wherein:

[0069] The stress regulation and magnetization integrated mechanism 1 further includes a stress regulation application component 11 and a fixed magnetization integrated component 12; the two fixed magnetization integrated components 12 are detachably adsorbed onto the upper part of the first end and the lower part of the second end of the sample 3, respectively; the stress regulation application component 11 is located on one side of the sample 3 and its two ends are respectively connected to the two fixed magnetization integrated components 12; the fixed magnetization integrated component 12 is configured to move to a fixed position on the sample 3 until it is located on the corresponding surface near its local target regulation area (e.g., weld, opening, etc.) and apply a magnetic field to magnetize it; the stress regulation application component 11 has a pressure sensor 1122, which is configured to apply and collect dynamic stress to the local target regulation area of ​​the sample 3.

[0070] The magnetic flux leakage detection mechanism 2 includes a vacuum adsorption module 21 and a sensor lifting frame 22. The vacuum adsorption module 21 is detachably fixed to the local target control area of ​​the sample 3. The sensor lifting frame 22 is equipped with a Hall sensor 23 and the lift-off value of the Hall sensor 23 can be adjusted. The sensor lifting frame 22 is connected to the vacuum adsorption module 21 and the Hall sensor 23 is facing the local target control area of ​​the sample 3.

[0071] In the integrated device of Embodiment 1 of the present invention, Sample 3 is an in-service pressure-bearing equipment component made of ferromagnetic material, such as a ferromagnetic pipe, pressure vessel, or local area of ​​a boiler, which is a common object for stress application, magnetization, and leakage magnetic field detection.

[0072] This invention, in Embodiment 1, discloses an integrated device for local stress regulation and magnetic flux leakage detection in in-service pressure-bearing equipment. The stress regulation and magnetization integrated mechanism 1 combines the functions of applying local dynamic stress, fixing samples, and stabilizing magnetization. The magnetic flux leakage detection mechanism 2 synchronously acquires magnetic flux leakage signals based on a stable magnetization environment. Furthermore, through the deep integration design of the "stress regulation and magnetization integrated mechanism 1 + magnetic flux leakage detection mechanism 2," this innovative device achieves a three-in-one collaborative operation of "precise local stress regulation, stable magnetization, and magnetic flux leakage defect detection" in in-service pressure-bearing equipment made of ferromagnetic materials. This solves the pain points of existing technologies where the three components exist independently, data is disconnected, mutual interference occurs, and single-function patents cannot meet the needs of collaborative research.

[0073] Furthermore, the integrated device for local stress regulation and magnetic flux leakage detection of in-service pressure equipment in Embodiment 1 of the present invention, through the collaborative design of "stress regulation and magnetization integrated mechanism 1 + magnetic flux leakage detection mechanism 2", realizes the integrated collaborative operation of "local stress regulation - stable magnetization - magnetic flux leakage detection" of ferromagnetic materials in in-service pressure equipment. It also utilizes the collaborative cooperation of pressure sensor 1122 and Hall sensor 23 to achieve synchronous acquisition and closed-loop control. Specifically, pressure sensor 1122 and Hall sensor 23 synchronously acquire stress data and magnetic flux leakage signals in real time, and feed the data back to the external terminal. The operator can achieve precise stress regulation by adjusting the parameters of electric hydraulic jack 111. At the same time, the data of the two mechanisms are combined to quantify the impact of dynamic stress on defect propagation, providing in-depth data support for equipment safety assessment.

[0074] Please continue to refer to Figure 1-3 The fixed magnetization integrated assembly 12 of Embodiment 1 of the present invention may include a permanent magnet chuck 121 and a manual rod 122 fixedly connected to the side of the permanent magnet chuck 121. The permanent magnet chuck 121 is a chuck body with a built-in permanent magnet, and the manual rod 122 is fixedly connected to the chuck body.

[0075] In practice, two permanent magnet chucks 121 are respectively set on the upper left surface and the lower right surface of the sample 3, and are precisely aligned with the local target control area (i.e. stress concentration area) of the sample 3. The adsorption or separation state is controlled by the manual rod 122 to achieve rapid fixation or separation from the local area of ​​the sample.

[0076] The permanent magnet chuck 121 has a built-in permanent magnet that can generate a stable magnetizing magnetic field of 0.5-1.5T. While adsorbing and fixing, it can uniformly magnetize a local area of ​​the sample, so that the fixed magnetizing integrated component 12 has the triple functions of "fixation-stress transfer-stable magnetization".

[0077] Please continue to refer to Figure 1-3The stress control application component 11 of Embodiment 1 of the present invention may include an electric hydraulic jack 111 and two adjustable force transmission modules 112 symmetrically connected to both ends of the electric hydraulic jack 111; each adjustable force transmission module 112 is composed of a first telescopic member 1121 connected end to end, a pressure sensor 1122, a connecting plate 1123, a second telescopic member 1124 and a connecting ring 1125.

[0078] In specific implementation, the outer side of the permanent magnet chuck 121 adsorbed on the lower left surface of sample 3 is fixedly connected to one end of the second telescopic member 1124 by bolts, and the other end of the second telescopic member 1124 is welded and fixed to one side of the connecting plate 1123; the other side of the connecting plate 1123 is connected to the input end of the pressure sensor 1122 by threads, and the output end of the pressure sensor 1122 is fixedly connected to one end of the first telescopic member 1121; the other end of the first telescopic member 1121 is connected to the output end of the electric hydraulic jack 111 by a flange. The permanent magnet chuck 121 on the lower right surface of sample 3 is connected to the electric hydraulic jack 111 through another set of second telescopic members 1124, connecting plate 1123, pressure sensor 1122, and first telescopic member 1121 in the same connection sequence as described above, forming a bilaterally symmetrical local stress application structure.

[0079] More specifically, both the first telescopic component 1121 and the second telescopic component 1124 can be telescopic rod structures with a length adjustment range of 0-50cm and an adjustment accuracy of ≤1mm. For example, the first telescopic component 1121 can be a straight bidirectional telescopic rod as shown in the figure, the second telescopic rod can be a U-shaped telescopic rod as shown in the figure, the connecting plate 1123 can be a steel plate, one end of the connecting ring 1125 is fastened to the U-shaped telescopic rod, and the other end of the connecting ring 1125 is hinged to the corresponding permanent magnet chuck 121.

[0080] Further preferably, the pressure sensor 1122 has a range of 0-500kN, a measurement accuracy of ±0.5%FS, and a data feedback delay of ≤0.1s; the electric hydraulic jack 111 has an output stress of 0-500kN and a dynamic adjustment frequency of 0.1-10Hz; the permanent magnet chuck 121 has an adsorption force of ≥80kN and an adsorption surface fitting accuracy of ≤0.1mm; the steel plate is made of Q235 material, with dimensions of 50-100mm×30-50mm×10-20mm and a flatness of ≤0.05mm.

[0081] In summary, the stress regulation and magnetization integrated mechanism 1 of Embodiment 1 of the present invention, based on the combination of the fixed magnetization integrated component 12 and the stress regulation application component 11, pioneers the integrated design of "stress regulation-magnetization". It reuses the permanent magnet chuck 121 to achieve the triple functions of "sample fixation, stress transmission and stable magnetization", without the need for additional magnetization device, and forms a non-interference collaboration with the leakage magnetic field detection mechanism 2. The combined design and technical effect are obvious.

[0082] Please continue to refer to Figure 1-3 The vacuum adsorption module 21 of Embodiment 1 of the present invention may include four vacuum suction cups 211, four support rods 212 and two connecting rods 213; the four vacuum suction cups 211 are symmetrically adsorbed and fixed around the local target control area of ​​the sample, and a support rod 212 is fixedly connected above each vacuum suction cup 211. The two connecting rods 213 are respectively horizontally mounted between the four support rods 212 to form a frame structure.

[0083] In practice, four vacuum suction cups 211 are symmetrically adsorbed around the stress concentration area of ​​the sample, and are tightly fixed to the surface of the sample 3 through vacuum negative pressure, without magnetic interference, and are compatible with various surface shapes such as planes and arcs of ferromagnetic materials; at the same time, a support rod 212 is fixedly connected to the top of each vacuum suction cup 211 by bolts, and the support rod 212 is made of rigid material to ensure structural stability; two connecting rods 213 are respectively horizontally mounted between the four support rods 212, and are fixed by buckles to form a stable frame structure.

[0084] Further preferably, the vacuum suction cup 211 has an adsorption force ≥50kN and a vacuum stability range of -0.08-0.1MPa.

[0085] Please continue to refer to Figure 1-3 The sensor lifting frame 22 of Embodiment 1 of the present invention may include four connecting rods 221, a mounting plate 222 and adjusting bolts 223; each vacuum adsorption module 21 has four through holes on its connecting rod 213, and the four connecting rods 221 pass through the through holes respectively. The upper end of each connecting rod 221 is connected to the corresponding connecting rod 213 in a height-adjustable manner through an adjusting bolt 223. The lower ends of the four connecting rods 221 are fixedly connected to the periphery of the mounting plate 222. The Hall sensor 23 is detachably installed in the central slot 222-1 of the mounting plate 222.

[0086] In use, the height of the connecting rod 221 can be adjusted by tightening the adjusting bolt 223. After adjustment, tighten the adjusting bolt 223 to achieve a stable fixation of the connecting rod 221 and prevent loosening or displacement during the testing process.

[0087] Further preferably, the Hall sensor 23 has a magnetic field measurement range of 0-2T, a measurement accuracy of ±1%FS, and supports real-time acquisition of leakage magnetic signals.

[0088] In Embodiment 1 of the present invention, the connecting rod 221 is preferably made of a rigid non-magnetic material, such as stainless steel; furthermore, the height adjustment range of the connecting rod 221 is 0-30cm, the adjustment accuracy is ≤0.5mm, and the diameter is 8-12mm.

[0089] In Embodiment 1 of the present invention, the mounting plate 222 is made of a non-magnetic insulating material, such as polytetrafluoroethylene. More specifically, the four connecting rods 221 can be bolted together to fix the mounting plate 222 in the form of a plastic sheet. The thickness of the plastic sheet can be 3-5mm, and a hollow square area with a side length of 20-30mm is opened in the center as a central slot 222-1. The Hall sensor 23 is placed in this area and is detachably connected to the plastic sheet. This ensures that the detection end is accurately aligned with the stress concentration area of ​​the sample 3 and captures the leakage magnetic signal generated by the defect after magnetization.

[0090] In summary, the magnetic flux leakage detection mechanism 2 of Embodiment 1 of the present invention innovatively adopts a frame design of "vacuum suction cup 211-support rod 212-connecting rod 213-through bolt adjustment connecting rod 221", which not only solves the problem of detection adaptation in local areas of different equipment, but also improves the adjustment stability and accuracy through the bolt locking structure. Combined with the sensor fixing method of non-magnetic plastic sheet, it avoids interference with the magnetization environment and magnetic flux leakage signal, which is significantly innovative.

[0091] Therefore, the integrated device for local stress regulation and magnetic flux leakage detection of in-service pressure equipment in Embodiment 1 of the present invention generally has the following characteristics:

[0092] Local Focusing and Multifunctional Integration: The stress control and magnetization integrated mechanism 1 uses a double-sided symmetrical structure to precisely attract the permanent magnet chuck 121, so that the stress is focused on a local area of ​​the equipment. At the same time, the permanent magnet chuck 121 simultaneously realizes the triple functions of "sample fixation, stress transmission and stable magnetization", without the need for additional magnetization devices, ensuring that magnetization and stress control are carried out in the same area and at the same time.

[0093] Interference-free fixation and precise adjustment: The magnetic flux leakage detection mechanism 2 is symmetrically fixed around the stress concentration area by the vacuum suction cup 211 to avoid magnetic interference; the connecting rod 221 adopts an innovative structure of "through connecting rod 213 + adjusting bolt 223", which not only achieves precise height adjustment (accuracy ≤0.5mm) but also ensures stability after fixation. Together with the "support rod 212-connecting rod 213" frame, it ensures that the Hall sensor 23 is always accurately aligned with the detection target.

[0094] Synergistic effect of dynamic stress and stable magnetization: Under the control of the hydraulic control system, the electric hydraulic jack 111 outputs dynamic stress with set parameters, which is applied to the sample through a stable transmission path; at the same time, the permanent magnet chuck 121 provides a stable magnetizing magnetic field of 0.5-1.5T, so that the sample is uniformly magnetized locally, and a clear leakage magnetic signal is formed at the defect, restoring the actual operating conditions of the equipment.

[0095] Example 2

[0096] like Figures 1 to 3As shown, Embodiment 2 of the present invention also provides an integrated method for local stress control and magnetic flux leakage detection of in-service pressure-bearing equipment. The method uses the aforementioned integrated device for local stress control and magnetic flux leakage detection of in-service pressure-bearing equipment for detection, and includes the following steps:

[0097] S10. Installation and adaptation:

[0098] Based on the size of the local target area and the installation environment of sample 3, adjust the length of the stress control application component 11 so that its force application direction is consistent with the preset force direction of sample 3;

[0099] The vacuum adsorption module 21 is adsorbed around the stress concentration area of ​​the sample 3 to ensure that the sensor is facing the target area. The lift-off value of the Hall sensor 23 is adjusted to the set value by the sensor lifting frame 22, and then the position is locked.

[0100] In specific implementation of step S10 of Embodiment 2 of the present invention, according to the size, shape and installation environment of the local target control area (such as weld seam, opening) of the ferromagnetic material sample 3, the length of the telescopic rod and the telescopic rod are adjusted so that the force direction of the electric hydraulic jack 111 is consistent with the local preset force direction of the sample (deviation ≤ ±1°); at the same time, four vacuum suction cups 211 are symmetrically adsorbed around the stress concentration area, and the vacuum system is started to make the suction cups tightly adsorbed on the surface of the sample 3 to complete the fixation; the position of the support rod 212 and the connecting rod 213 is adjusted, the adjusting bolt 223 on the connecting rod 213 is loosened, and the connecting rod 221 is moved up and down to the preset height to set the lift-off value of the Hall sensor 23, ensuring that the Hall sensor 23 is aligned with the stress concentration area (direct alignment deviation ≤ ±2mm), and then the bolt is tightened to fix the connecting rod 221.

[0101] S20, Sample fixation and stable magnetization:

[0102] The fixed magnetization integrated component 12 is adsorbed onto a local target area of ​​the sample 3, and magnetization begins;

[0103] In specific implementation of step S20 of Embodiment 2 of the present invention, the manual lever 122 is operated to make the two permanent magnet chucks 121 firmly adsorb onto the corresponding surface of the local target control area of ​​the sample, with an adsorption surface fitting accuracy of ≤0.1mm; the permanent magnets built into the permanent magnet chucks 121 simultaneously apply a stable magnetic field of 0.5-1.5T to the local area of ​​the sample to achieve uniform magnetization; the adsorption state and vacuum degree of the four vacuum chucks 211, as well as the fixing status of the connecting rod 221, are checked to ensure that the leakage magnetic field detection mechanism 2 is not loose or offset.

[0104] S30, Parameter Settings:

[0105] Dynamic stress parameters are set for the stress regulation application component 11; the sampling frequency of the Hall sensor 23 is started and set.

[0106] In specific implementation of step S30 of embodiment 2 of the present invention, the local dynamic stress parameters (stress magnitude 0-500kN, change frequency 0.1-10Hz) are set through the hydraulic control system of the electric hydraulic jack 111; the Hall sensor 23 is activated, the signal acquisition link is calibrated, and the sampling frequency is set (adapted to the stress change frequency, sampling interval ≤0.01s).

[0107] S40, Synchronous Operation:

[0108] The stress control application component 11 is activated, and the output stress is transferred to the local part of the sample to start stress loading. Stress data and leakage magnetic signals are collected in real time by the pressure sensor 1122 and the Hall sensor 23, and transmitted synchronously to the external display terminal.

[0109] In specific implementation of step S40 of embodiment 2 of the present invention, the electric hydraulic jack 111 is activated, and the output stress is transmitted sequentially through the first telescopic member 1121, the pressure sensor 1122, the connecting plate 1123, the second telescopic member 1124, and the connecting ring 1125 to the permanent magnet chuck 121, thereby precisely acting on a local area of ​​the sample 3; the sample is localized; in this way, under the synergistic effect of "stable magnetization + dynamic stress", the internal defects (such as cracks and corrosion) of the sample 3 generate leakage magnetic signals, and the Hall sensor 23 collects the signal in real time, and transmits it synchronously with the stress data of the pressure sensor 1122 to the external display terminal.

[0110] S50, Precise Control and Collaborative Analysis:

[0111] Based on the feedback stress data and leakage magnetic field signal, the external control terminal dynamically adjusts the output parameters of the stress regulation and application component 11, and performs linkage analysis on the stress data, magnetization state and leakage magnetic field signal.

[0112] In the specific implementation of step S50 of Embodiment 2 of the present invention, the staff adjusts the output parameters of the electric hydraulic jack 111 in real time based on the data feedback from the stress regulation and magnetization integrated mechanism 1 and the magnetic flux leakage detection mechanism 2, so that the deviation between the actual value of local stress and the preset value is ≤±1%; at the same time, the computer quantifies the influence law of dynamic stress on the defect expansion of the stress concentration area of ​​sample 3, as well as the change characteristics of the magnetic flux leakage signal under the magnetization environment, based on the linkage analysis of stress data, magnetization state and magnetic flux leakage signal.

[0113] S60. Experiment ends:

[0114] Shutdown device.

[0115] In specific implementation of step S60 of Embodiment 2 of the present invention, the electric hydraulic jack 111 and Hall sensor 23 are turned off, the negative pressure of vacuum suction cup 211 is released, the manual lever 122 is operated to release permanent magnet suction cup 121, and the magnetization of sample 3 is simultaneously released. The four vacuum suction cups 211 are removed, the adsorption with sample 3 is released, the device is disassembled and the experimental data is saved.

[0116] The present invention provides an integrated method for local stress control and magnetic flux leakage detection in in-service pressure equipment. By utilizing a closed-loop process of "dynamic stress application - stable magnetization - synchronous acquisition of magnetic flux leakage signals - collaborative analysis of three data sources", it achieves a profound breakthrough from "operating condition simulation" to "regular quantification". Compared with the limitations of existing independent technologies that can only provide single data, the technical value is greatly improved.

[0117] In summary, the integrated device and method for local stress regulation and magnetic flux leakage detection of in-service pressure equipment provided in Embodiments 1 and 2 of the present invention can produce at least the following technical advantages in practical applications:

[0118] 1. Integrated Innovation: For the first time, it achieves deep integration of "precise local stress control + stable magnetization + magnetic leakage detection" in in-service pressure-bearing equipment using ferromagnetic materials. It reuses permanent magnet chucks to achieve triple functions, solving the industry pain points of existing technologies where the three functions exist independently, data is disconnected, and operation is cumbersome. It forms a complete technology chain of "control-magnetization-detection-collaborative analysis", filling the gap in related fields.

[0119] 2. Stable and precise adjustment structure: The connecting rod of the magnetic flux leakage detection mechanism adopts an innovative design of "through connecting rod + adjusting bolt 223", with an adjustment accuracy of 0.5mm. After locking, there is no loosening or offset, which solves the problems of unstable fixation and insufficient accuracy of existing adjustment structures, ensuring that the Hall sensor is always accurately aligned with the detection target.

[0120] 3. Strong local targeting and magnetization stability: Both the stress control and magnetization integrated mechanism and the magnetic flux leakage detection mechanism focus on the local stress concentration area of ​​the equipment. The symmetrical layout of the stress control mechanism on both sides ensures the stress concentration effect. The permanent magnet chuck provides a stable magnetization field of 0.5-1.5T, making the magnetic flux leakage signal at the defect clear and improving the detection sensitivity by more than 40%. The vacuum chuck of the magnetic flux leakage detection mechanism fixes the device to avoid magnetic interference and ensure the accuracy of the detection.

[0121] 4. Wide and flexible installation adaptability: The telescopic rod (0-50cm adjustable) and the connecting rod (0-30cm adjustable) are used in conjunction with vacuum suction cups and permanent magnet suction cups for adsorption and fixation, which can be adapted to ferromagnetic material equipment of different sizes and shapes. No complicated tooling is required, and installation and adaptation can be completed quickly.

[0122] 5. Accurate and synchronized data with enhanced value: Stress dynamic adjustment accuracy ±1kN, magnetic flux leakage signal measurement accuracy ±1%FS, and real-time synchronous acquisition of stress and magnetic flux leakage dual-mechanism data (time deviation ≤0.01s) not only realizes the synchronous monitoring of "stress state + magnetization environment + defect distribution", but also quantifies the influence of dynamic stress on defect propagation. The data value far exceeds that of single-function technology.

[0123] 6. Convenient, safe and efficient operation: The adsorption and separation of permanent magnet chuck and vacuum chuck are simple and fast. Non-contact magnetic flux leakage detection and non-invasive stress control are suitable for the non-stop testing needs of in-service equipment, avoiding production losses. The integrated process eliminates the need for step-by-step operation, improving testing efficiency by more than 50%.

[0124] 7. Wide range of applications: It can be widely used in the stress research, defect detection, safety assessment and life prediction of ferromagnetic materials in in-service pressure-bearing equipment in the fields of machinery, chemical industry, power, petroleum, etc., and has extremely strong industrial application value and promotion prospects.

[0125] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0126] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0127] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0128] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any way. Any simple modifications and equivalent changes made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. An integrated device for local stress regulation and magnetic flux leakage detection in in-service pressure-bearing equipment, characterized in that, include: The stress regulation and magnetization integrated mechanism further includes a stress regulation application component and a fixed magnetization integrated component; The two fixed magnetization integrated components are detachably adsorbed onto the upper part of the first end and the lower part of the second end of the sample, respectively; the stress regulation application component is located on one side of the sample and its two ends are respectively connected to the two fixed magnetization integrated components; the fixed magnetization integrated component is configured to move to a fixed position on the sample until it is located on the corresponding surface near its local target regulation area and a magnetic field is applied to magnetize it. The stress regulation application component has a pressure sensor and is configured to apply and acquire dynamic stress to a local target regulation region of the sample. The magnetic flux leakage detection mechanism includes a vacuum adsorption module and a sensor lifting frame. The vacuum adsorption module is detachably fixed to a local target control area of ​​the sample. A Hall sensor is installed on the sensor lifting frame and the lift-off value of the Hall sensor can be adjusted. The sensor lifting frame is connected to the vacuum adsorption module and the Hall sensor is facing the local target control area of ​​the sample.

2. The integrated device for local stress regulation and magnetic flux leakage detection of in-service pressure-bearing equipment according to claim 1, characterized in that, The fixed magnetization integrated assembly includes a permanent magnet chuck and a manual rod fixedly connected to the side of the permanent magnet chuck. The permanent magnet chuck is a chuck body with a built-in permanent magnet, and the manual rod is fixedly connected to the chuck body.

3. The integrated device for local stress regulation and magnetic flux leakage detection of in-service pressure-bearing equipment according to claim 2, characterized in that, The stress regulation and application component includes an electric hydraulic jack and two adjustable force transmission modules symmetrically connected to both ends of the electric hydraulic jack. Each of the adjustable force transmission modules consists of a first telescopic component, a pressure sensor, a connecting plate, a second telescopic component, and a connecting ring connected end to end.

4. The integrated device for local stress regulation and magnetic flux leakage detection of in-service pressure-bearing equipment according to claim 1, 2, or 3, characterized in that, The vacuum adsorption module includes four vacuum suction cups, four support rods, and two connecting rods. The four vacuum suction cups are symmetrically adsorbed and fixed around the local target control area of ​​the sample. Each vacuum suction cup is fixedly connected to a support rod above it, and the two connecting rods are horizontally mounted between the four support rods to form a frame structure.

5. The integrated device for local stress regulation and magnetic flux leakage detection of in-service pressure-bearing equipment according to claim 4, characterized in that, The sensor lifting frame includes four connecting rods, a mounting plate, and adjusting bolts. Each connecting rod of the vacuum adsorption module has four through holes, and the four connecting rods pass through the through holes respectively. The upper end of each connecting rod is connected to the corresponding connecting rod in a liftable manner through an adjusting bolt. The lower ends of the four connecting rods are fixedly connected to the perimeter of the mounting plate. The Hall sensor is detachably installed in the central slot of the mounting plate.

6. The integrated device for local stress regulation and magnetic flux leakage detection of in-service pressure-bearing equipment according to claim 5, characterized in that, The connecting rod is made of rigid non-magnetic material; the mounting plate is made of non-magnetic insulating material.

7. A method for integrating local stress control and magnetic flux leakage detection in in-service pressure-bearing equipment, characterized in that, The method of using the integrated device for local stress regulation and magnetic flux leakage detection of in-service pressure equipment as described in any one of claims 1 to 6 includes the following steps: S10. Installation and adaptation: Based on the size of the local target area of ​​the sample and the installation environment, adjust the length of the stress control application component so that its force application direction is consistent with the preset force direction of the sample; The vacuum adsorption module is adsorbed around the stress concentration area of ​​the sample, ensuring that the sensor is facing the target area. The lift-off value of the Hall sensor is adjusted to the set value by the sensor lifting frame, and then the position is locked. S20, Sample fixation and stable magnetization: The fixed magnetization integrated component is adsorbed onto the local target area of ​​the sample, and magnetization begins; S30, Parameter Settings: The stress regulation application component is dynamically stressed; the sampling frequency of the Hall sensor is activated and set. S40, Synchronous Operation: The stress regulation and application component is activated, and the output stress is transferred to the local area of ​​the sample to start stress loading; stress data and leakage magnetic field signals are collected in real time by pressure sensor and Hall sensor respectively, and transmitted synchronously to external display terminal; S50, Precise Control and Collaborative Analysis: Based on the feedback stress data and leakage magnetic field signal, the external control terminal dynamically adjusts the output parameters of the stress regulation and application component, and performs linkage analysis on the stress data, magnetization state and leakage magnetic field signal. S60. Experiment ends: Shutdown device.

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