Phased array ultrasonic detection device and automatic scanning system suitable for circumferential weld of small-diameter pipe

Abstract

The invention provides a phased array ultrasonic detection device and an automatic scanning system suitable for a circumferential weld of a small-diameter pipe. The automatic scanning system comprises a scanning frame, a path monitoring module, a coupling device, a driving device and a control device, the scanning frame comprises a cross rod and two probe clamping mechanisms arranged on the cross rod; the path monitoring module comprises an industrial camera, and the industrial camera is arranged on the cross rod, can perform angle adjustment and is used for monitoring a scanning path in real time; the coupling device can convey a coupling agent to the probe; the driving device is connected with the scanning frame and can walk; the control device can control walking of the driving device. The detection device comprises the automatic scanning system and a phased array ultrasonic detection instrument. According to the invention, while the requirements of stable coupling and constant-speed scanning are met, the double probes are symmetrically placed on the two sides of the welding seam for simultaneous scanning, and the scanning path is monitored in real time and the scanning track is remotely controlled and corrected by virtue of the industrial camera, so that the scanning precision is ensured.

Description

Technical Field

[0001] This invention relates to the field of nondestructive testing technology, specifically to an automatic scanning system and a phased array ultrasonic testing device adapted to small-diameter pipe circumferential welds. Background Technology

[0002] Phased array ultrasonic testing is a crucial method for inspecting weld quality during the manufacturing, installation, and periodic inspection of gathering and transportation pipelines. Small-diameter pipes are widely used in gathering and transportation pipelines; however, current phased array ultrasonic testing of these pipes typically employs a manual chain-type scanning frame. This method is prone to coupling instability and uneven scanning speeds, affecting encoder acquisition accuracy. The biggest problem is trajectory deviation during scanning, which impacts the accuracy of the test results. Furthermore, the manual chain-type scanning frame cannot accommodate simultaneous scanning with two probes symmetrically placed on both sides of the weld.

[0003] Therefore, it is of great significance to realize automatic scanning of circumferential welds in small-diameter pipes. Summary of the Invention

[0004] The purpose of this invention is to address at least one of the aforementioned shortcomings of the prior art. For example, one objective of this invention is to solve problems such as trajectory deviation and low detection accuracy caused by manual scanning in phased array ultrasonic testing.

[0005] To achieve the above objectives, the present invention provides an automatic scanning system for phased array ultrasonic testing of small-diameter pipe circumferential welds.

[0006] The system includes: a scanning frame, a path monitoring module, a coupling device, a drive device, and a control device. The scanning frame includes a crossbar and two probe clamping mechanisms mounted on the crossbar, each capable of holding one probe. The circumferential weld seam is located at the center of the two probes. The path monitoring module includes an industrial camera mounted on the crossbar of the scanning frame and capable of angle adjustment for real-time monitoring of the scanning path. The coupling device delivers coupling agent to the probes. The drive device is connected to the scanning frame and can move. The control device controls the movement of the drive device.

[0007] Alternatively, the crossbar may be provided with a graduated scale and a groove.

[0008] Alternatively, the scanning frame may further include a slide rail module, which is disposed in a slide groove and can be moved to adjust the position of the two probe clamping mechanisms, thereby ensuring that the circumferential weld is located at the center of the two probes.

[0009] Optionally, the scanning frame further includes a walking mechanism and an elastic mechanism; the walking mechanism includes a support and a walking pulley, one end of the support is installed at the middle position of the crossbar, and the walking pulley is installed at the other end of the support; the number of elastic mechanisms is two and corresponds one-to-one with the two clamping mechanisms; the two ends of each elastic mechanism are respectively connected to the crossbar and the corresponding probe clamping mechanism, and can apply radial positive pressure to the probe clamping mechanism to make the probe fit tightly against the outer wall of the small-diameter pipe.

[0010] Alternatively, the scanning frame may further include a first mounting adapter interface, which is installed at the center of the crossbar for connecting the drive device.

[0011] Alternatively, the path monitoring module may further include a first clamping mechanism, an angle adjustment mechanism, and a second clamping mechanism connected in sequence. The first clamping structure is disposed on the crossbar, and the second clamping structure is used to fix the industrial camera. The industrial camera is connected to a phased array ultrasonic testing instrument via a network port.

[0012] Alternatively, the angle adjustment mechanism may include a ball chain structure.

[0013] Alternatively, the coupling device is controlled by an automated water injection system. The coupling device is equipped with an on / off switch and a pressure regulating knob, and uses a water tank as the water source. The coupling device is connected to the water spray hole at the probe wedge to stably and continuously deliver the coupling agent to the probe, and can adjust the input water pressure of the coupling agent at any time.

[0014] Alternatively, the drive device includes an encoder and a magnetic roller; wherein the encoder is connected to a phased array ultrasonic testing instrument and can record the path and travel data of the magnetic roller; the magnetic roller can be adsorbed onto the outer wall surface of the pipe.

[0015] Alternatively, the control device includes a control box and a remote controller; the control box controls the drive device via a control line and is equipped with a power button and an emergency stop button; the remote controller enables remote control of the drive device via a signal transmitter and a signal receiver.

[0016] Another aspect of the present invention provides a phased array ultrasonic testing device adapted to circumferential welds of small-diameter pipes.

[0017] The device includes an automatic scanning system for phased array ultrasonic testing of small-diameter pipe circumferential welds as described above, and a phased array ultrasonic testing instrument. The industrial camera is connected to the phased array ultrasonic testing instrument via a network port. The phased array ultrasonic testing instrument has two probes, which can be fixed on two probe clamping mechanisms respectively.

[0018] Compared with the prior art, the beneficial effects of the present invention include at least one of the following: (1) The present invention reduces human influence factors, the telescopic spring mechanism avoids the coupling effect caused by uneven positive pressure during manual scanning, automatic scanning ensures uniform walking speed, and the encoder collects data accurately.

[0019] (2) The present invention uses an industrial camera device to ensure real-time monitoring of the path, which makes up for the limitation of the operator's field of vision when automatically scanning small-diameter pipes, and remotely controls and corrects the scanning trajectory to ensure scanning accuracy.

[0020] (3) The present invention improves the detection efficiency. The automatic scanning system can realize automatic scanning and water supply coupling. It can be operated remotely by remote control, which greatly reduces manpower and improves the detection speed.

[0021] (4) Compared with the prior art, the present invention does not simply combine phased array ultrasonic detection, automatic scanning device and visual monitoring means in parallel. Instead, it addresses the technical problems of large curvature of small diameter pipe ring welds, easy deviation of scanning path and difficulty in ensuring detection consistency by constructing a phased array ultrasonic automatic scanning system with path closed-loop control capability. Attached Figure Description

[0022] The above and other objects and / or features of the present invention will become clearer from the following description taken in conjunction with the accompanying drawings, in which: Figure 1 A schematic diagram of the automatic scanning system of the present invention is shown; Figure 2 An enlarged schematic diagram of the slide rail system in the scanning frame of the present invention is shown; Figure 3 The diagram shown is an enlarged schematic of the telescopic spring control in the scanning frame of the present invention; Figure 4 A schematic diagram showing an industrial camera device mounted on a scanning frame is shown. Figure 5 A schematic diagram showing the connection between the scanning frame and the drive unit via an adapter interface is shown. Figure 6 A schematic diagram of the control device is shown.

[0023] Explanation of key figure labels: A-Phase array ultrasonic testing scanning frame, A1-Horizontal bar, A2-Slide rail system, A3-First mounting adapter interface, A4-Walking mechanism, A5-Elastic mechanism, A51-Support shell, A52-Telescopic frame, A53-Spring, A54-Linear guide rail, A6-Probe clamping mechanism. B - Path monitoring module, B1 - First clamping mechanism, B2 - Ball chain structure, B3 - Second clamping mechanism, B4 - Industrial camera; C-Coupled device, C1-Inlet, C2-Outlet, C3-Pressure regulating knob, C4-On / off switch, C5-Water tank, C6-AC power interface; D - Control device; D1 - Remote control; D11 - Forward button; D12 - Backward button; D13 - Stop button; D14 - Speed ​​control button; D15 - Signal receiver; D2 - Control box; D21 - Power button; D22 - Emergency stop button; D23 - Charging port; D24 - Battery; D25 - Signal transmitter; D26 - Control cable connector. E1 - Mounting handle, E2 - Second mounting adapter interface, E3 - Encoder, E4 - Magnetic roller, E5 - Control line interface. Detailed Implementation

[0024] In the following description, the phased array ultrasonic testing device and automatic scanning system adapted to small-diameter pipe circumferential welds of the present invention will be explained in detail with reference to exemplary embodiments.

[0025] Exemplary Example 1 Because the radius of curvature of weld seams in small-diameter pipes is small, the impact of scanning path deviation on the detection results is amplified exponentially. Single-sided probe scanning makes it difficult to guarantee consistent acoustic beam coverage across the entire weld seam. This invention is specifically designed for the special application scenario of small-diameter pipe circumferential weld seams and provides an automatic phased array ultrasonic inspection system adapted to small-diameter pipe circumferential weld seams. It can be applied to circumferential weld seams of small-diameter (outer diameter 50 mm-300 mm) bimetallic composite pipes and effectively solves technical problems such as the difficulty of ensuring consistent acoustic beam coverage across the entire weld seam with single-sided probe scanning and the difficulties brought about by manual phased array ultrasonic inspection.

[0026] like Figure 1 As shown, the system includes: a phased array ultrasonic testing scanning frame (hereinafter referred to as the scanning frame) A, a path monitoring module B, a coupling device C, a control device D, and a drive device E. The scanning frame A can simultaneously clamp probes along both sides of the circumferential weld to complete the inspection; the path monitoring module B can be connected to the phased array ultrasonic testing instrument to monitor the scanning path in real time. The coupling device C can automatically supply water to ensure good coupling between the probe and the inspection surface. The control device D controls the movement of the drive device. The drive device E is connected to the scanning frame A to complete the scanning process.

[0027] In this embodiment, the scanning frame A is used to install the phased array ultrasonic detection probe. The scanning frame includes a crossbar A1, on which there is a slide rail system A2, a first mounting adapter interface A3, a walking mechanism A4, an elastic mechanism A5, and two probe clamping mechanisms A6.

[0028] The slide rail system A2 is installed on the crossbar A1. The crossbar A1 has a linear guide rail and a scale. The slide rail system A2 can precisely control the axial movement distance of the dual probes through the slide groove and the scale, ensuring that the weld is located in the center of the dual probes.

[0029] The first mounting adapter interface A3 is installed at the center of the crossbar A1 by two bolts and is used to connect the drive device.

[0030] The traveling mechanism A4 supports the scanning frame A against the outer wall of the small-diameter pipe, and contacts the outer wall through a sliding friction pair. The traveling mechanism A4 includes a bracket and traveling pulleys, and the number of traveling pulleys can be several, such as one, two, three, four, etc.

[0031] The elastic mechanism A5 applies radial positive pressure to the probe, ensuring the probe fits snugly against the outer wall of the small-diameter pipe. The elastic mechanism A5 includes a telescopic spring.

[0032] The probe clamping mechanism A6 is used to fix the probe, and the probe is fixed in the slot by tightening the locking mechanism.

[0033] In this embodiment, the dual probes can be connected to a conventional phased array ultrasonic testing instrument via a one-to-two junction box. The dual probes not only improve coverage but also allow simultaneous incidence from both sides of the weld, ensuring symmetrical consistency of the sound beam around the weld's central area, which is particularly suitable for small-diameter pipes with varying curvature. The dual probes ensure symmetrical force distribution, and combined with uniform scanning control path real-time correction, prevent probe slippage and jumping.

[0034] In this embodiment, the path monitoring module B includes a first clamping mechanism B1, a ball chain structure B2, a second clamping mechanism B3, and an industrial camera B4.

[0035] Among them, such as Figure 4 As shown, the path monitoring module B is mounted on the scanning rack A. Specifically, the path monitoring module B is mounted on the crossbar A1 of the scanning rack A via a first clamping mechanism B1. Figure 4 As shown, the first clamping mechanism B1 can clamp the path monitoring module industrial camera device onto the scanning frame crossbar by tightening the screw.

[0036] The ball chain structure B2 is a quick-disassembly and assembly connection structure that can be adjusted at any angle to meet the alignment and scanning path requirements of industrial cameras.

[0037] The second clamping mechanism B3 is a camera clamping mechanism that fixes the industrial camera B4.

[0038] The B4 industrial camera is an industrial CCD camera that connects to a phased array ultrasonic testing instrument via a network port. It replaces the infrared probe for real-time monitoring of the scanning path. The industrial camera mainly monitors the scanning path and the offset of the scanning frame relative to the weld centerline, which makes it easy for operators to monitor the scanning status in real time.

[0039] In this embodiment, the coupling device C is controlled by an automated water injection system. The device includes an on / off switch C4 and a pressure regulating knob C3. The automated water injection system uses a water tank C5 as its water source and features self-priming and filtration functions. It employs dual-path switching control via AC power and battery, and is connected to the spray hole at the probe wedge. This system provides a stable and continuous supply of coupling agent to the probe and allows for real-time adjustment of the input water pressure. The coupling device C also includes an inlet C1, an outlet C2, and an AC power interface C6.

[0040] In this embodiment, the control device D includes a remote controller D1 and a control box D2. The control device D controls the drive device E via a control line, employing dual-path switching control via AC power and battery. Figure 6 As shown, the control box D2 is equipped with a power button D21 and an emergency stop button D22. It may also be equipped with a charging port D23, a battery D24, a signal transmitter D25, and a control cable connector D26. Remote control D1 can remotely control the drive device E via the signal transmitter D25 and the signal receiver D15, including forward, backward, stop, and speed adjustment. The remote control D1 is equipped with corresponding forward button D11, backward button D12, stop button D13, and speed adjustment button D14.

[0041] The control device D can also provide electrical power to the drive device.

[0042] In this embodiment, the drive device E is equipped with a convenient mounting handle E1, a second mounting adapter interface E2, an encoder E3, a magnetic wheel E4, and a control line interface E5. A connection diagram of the scanning frame A and the drive device E is shown below. Figure 5 As shown.

[0043] Install handle E1 to facilitate the operator to lift the device and place it on the outer wall of the tube to be tested.

[0044] The second mounting adapter interface E2 and the first mounting adapter interface A3 of the scanning frame A are fixed together by tightening bolts. For example, the second mounting adapter interface E2 includes two bolts. When the first mounting adapter interface A3 is aligned and snapped in, the tightening bolt structure completes the fixation. Figure 5 As shown.

[0045] The encoder E3 is connected to the phased array ultrasonic testing instrument to record the path and movement data of the magnetic chuck E4.

[0046] The number of magnetic rollers E4 can be up to 4. They are made of high-strength permanent magnet material and are used to adhere to the outer wall surface of the pipe to ensure that the scanning frame can scan the weld seam and avoid the danger of the scanning system falling off the surface being inspected.

[0047] Exemplary Example 2 Based on Exemplary Example 1, the specific structure of the scanning rack is as follows: (1) Horizontal bar A1. Horizontal bar A1 is a square structure and is equipped with a linear guide rail to facilitate the movement of the slide rail system in the slide groove.

[0048] (2) Slide rail system A2, which is bolted to probe clamping mechanism A6. The slide rail system A2 moves one side of probe clamping mechanism A6 along the crossbar A1 via a sliding groove. Tightening the bolts on the slide rail system fixes its position. Figure 2 As shown.

[0049] (3) First mounting adapter A3, mounting adapter A3 snaps into the second mounting adapter E2 of drive device E, aligns with the hole, tightens the two screws of the interface, and completes the fixing, as shown. Figure 5 As shown.

[0050] (4) Walking mechanism A4. The walking pulley of the walking mechanism A4 is in a certain arc to ensure that the scanning frame A can walk along the outer wall of the small diameter pipe.

[0051] (5) Elastic mechanism A5, the support shell A51 of the elastic mechanism A5 can be fastened to the crossbar with bolts, the telescopic frame A52 and one end of the spring A53 are fixed with bolts, and the other end of the spring A53 is fixed to the support shell A51. The telescopic frame A52 is provided with a linear guide rail A54, and there are bolts in the support shell A51. The spring A53 guides the telescopic frame A52 to move up and down along the linear guide rail A54 in the support shell A51. After controlling the probe to be close to the outer wall, the spring A53 is tightened to fix it, so that the probe has a certain positive pressure in the vertical axis. Figure 3 As shown.

[0052] (6) Probe clamping mechanism A6. The probe clamping mechanism A6 is used to clamp the probe. The probe is fixed in the probe clamping mechanism A6 by screws. The probe clamping mechanism A6 is provided with a rotating mechanism at the connection between it and the upper telescopic frame. By rotating, the angle between the probe clamped by the probe clamping frame and the detection surface can be changed so that the probe is in contact with the detection surface.

[0053] To better understand the above exemplary embodiments, the working principle of the phased array ultrasonic automatic scanning system for small-diameter pipe circumferential welds of the present invention is further explained below: When inspecting the circumferential weld of a small-diameter pipe, the path monitoring module B is installed on the scanning frame A. By adjusting the ball chain structure B2, the industrial camera B4 is aligned with the probe scanning path, and the scanning path can be monitored in real time.

[0054] The scanning frame A and the drive device E are connected through the first mounting adapter interface A3 and the second mounting adapter interface E2, and the scanning frame system is attached to the outer wall of the pipe by the magnetic suction wheel E4.

[0055] The control device D provides power to the drive device E through the control line, and remotely controls the start and stop of the scanning system through the remote controller D1 to realize the automation of the scanning system.

[0056] Based on the specifications of the small-diameter pipe, determine the distance between the dual probes and the weld center, and adjust the slide rail system A2 to set the probes to the appropriate distance. The probe clamping mechanism A6 clamps the probes, and the telescopic spring keeps the probes tightly against the outer wall. Then, connect the water outlet pipe of the coupling device C to the water outlet hole of the probe wedge, adjust the appropriate water pressure, and complete the stable and continuous delivery of coupling agent to the probes.

[0057] After the drive unit E is started, the traveling mechanism A4 on the scanning frame moves, causing the scanning frame A to move the probe circumferentially against the pipe wall. The probe transmits the signal from the weld seam to the phased array detector. Data transmission transmits the probe's scanning position information to the phased array detector via a data cable. The resulting image is used to determine defects at the weld seam of the small-diameter pipe.

[0058] During this process, the drive device E drives the walking pulley of the walking mechanism A4 to rotate. The encoder E3 records the scanning path and walking data during the rotation. By analyzing the phased array pattern formed by the scanned data, the weld condition of the small-diameter pipe is determined.

[0059] Exemplary Example 3 This exemplary embodiment provides a phased array ultrasonic testing device adapted to circumferential welds of small-diameter pipes.

[0060] The device includes the phased array ultrasonic automatic scanning system adapted to small-diameter pipe circumferential welds as described in Exemplary Embodiment 1 or 2, and a phased array ultrasonic testing instrument.

[0061] The industrial camera is connected to the phased array ultrasonic testing instrument via a network port. The encoder is also connected to the phased array ultrasonic testing instrument.

[0062] The phased array ultrasonic testing instrument has two probes, which can be fixed on two probe clamping mechanisms respectively.

[0063] In summary, the automatic scanning system for small-diameter pipe circumferential welds and the phased array ultrasonic testing device adapted to small-diameter pipe circumferential welds developed in this invention are of great significance. Besides ensuring stable coupling and uniform scanning speed, it achieves simultaneous scanning with dual probes symmetrically placed on both sides of the weld. Furthermore, it relies on an industrial camera to monitor the scanning path in real time and remotely control and correct the scanning trajectory, ensuring scanning accuracy. Specifically, by symmetrically arranging dual phased array probes on both sides of the weld and simultaneously performing detection during the scanning process, this invention ensures that the sound beam incident on the weld area remains symmetrical and consistent, thereby significantly improving the stability and repeatability of small-diameter pipe circumferential weld inspection. Simultaneously, this invention incorporates an adjustable-angle industrial camera on the scanning frame to monitor the spatial position of the scanning frame relative to the weld centerline in real time, and feeds back the acquired path information to the control device, remotely correcting the travel trajectory of the drive device, forming a closed-loop control of the scanning path.

[0064] Although the present invention has been described above in conjunction with exemplary embodiments and accompanying drawings, those skilled in the art should understand that various modifications can be made to the above embodiments without departing from the spirit and scope of the claims.

Claims

1. An automatic phased array ultrasonic inspection system for small-diameter pipe circumferential welds, characterized in that, The system includes: a scanning frame, a path monitoring module, a coupling device, a drive device, and a control device; wherein, The scanning frame includes a crossbar and two probe clamping mechanisms mounted on the crossbar. Each probe clamping mechanism can fix one probe, and the circumferential weld is located at the center of the two probes. The path monitoring module includes an industrial camera, which is mounted on the crossbar of the scanning frame and can be angled for real-time monitoring of the scanning path. The coupling device can deliver coupling agent to the probe; The drive unit is connected to the scanning frame and is able to move. The control device can control the movement of the drive unit.

2. The automatic phased array ultrasonic inspection system for small-diameter pipe circumferential welds according to claim 1, characterized in that, The crossbar is equipped with a graduated scale and a sliding groove; The scanning frame also includes a slide rail module, which is set in a slide groove and can adjust the position of the two probe clamping mechanisms by moving, so that the circumferential weld is located at the center of the two probes.

3. The automatic phased array ultrasonic inspection system for small-diameter pipe circumferential welds according to claim 1, characterized in that, The scanning frame also includes a walking mechanism and a flexible mechanism. The walking mechanism includes a support frame and a walking pulley. One end of the support frame is installed at the middle position of the crossbar, and the walking pulley is installed at the other end of the support frame. There are two elastic mechanisms, each corresponding to one of the two clamping mechanisms. The two ends of each elastic mechanism are connected to the crossbar and the corresponding probe clamping mechanism, respectively, and can apply radial positive pressure to the probe clamping mechanism to make the probe fit tightly against the outer wall of the small-diameter pipe.

4. The automatic phased array ultrasonic inspection system for small-diameter pipe circumferential welds according to claim 1, characterized in that, The scanning frame also includes a first mounting adapter interface, which is installed at the center of the crossbar and is used to connect the drive device.

5. The automatic phased array ultrasonic inspection system for small-diameter pipe circumferential welds according to claim 1, characterized in that, The path monitoring module also includes a first clamping mechanism, an angle adjustment mechanism, and a second clamping mechanism connected in sequence. The first clamping mechanism is set on the crossbar, and the second clamping mechanism is used to fix the industrial camera. The industrial camera is connected to the phased array ultrasonic testing instrument through a network port.

6. The automatic phased array ultrasonic inspection system for small-diameter pipe circumferential welds according to claim 5, characterized in that, The angle adjustment mechanism includes a ball chain structure.

7. The automatic phased array ultrasonic inspection system for small-diameter pipe circumferential welds according to claim 1, characterized in that, The coupling device is controlled by an automated water injection system. The coupling device is equipped with an on / off switch and a pressure regulating knob, and uses a water tank as the water source. The coupling device is connected to the water spray hole at the probe wedge to stably and continuously deliver the coupling agent to the probe, and can adjust the input water pressure of the coupling agent at any time.

8. The automatic phased array ultrasonic inspection system for small-diameter pipe circumferential welds according to claim 1, characterized in that, The drive device includes an encoder and a magnetic roller; wherein... The encoder is connected to a phased array ultrasonic testing instrument, which can record the path and movement data of the magnetic chuck. Magnetic rollers can adhere to the outer surface of the pipe.

9. The automatic phased array ultrasonic inspection system for small-diameter pipe circumferential welds according to claim 1, characterized in that, The control device includes a control box and a remote control; The control box controls the drive device via a control line and is equipped with a power button and an emergency stop button; The remote controller enables remote control of the drive device through a signal transmitter and a signal receiver.

10. A phased array ultrasonic testing device adapted to circumferential welds of small-diameter pipes, characterized in that, The device includes an automatic scanning system for phased array ultrasonic testing of small-diameter pipe circumferential welds as described in any one of claims 1 to 9, and a phased array ultrasonic testing instrument, wherein the industrial camera is connected to the phased array ultrasonic testing instrument via a network port, and the phased array ultrasonic testing instrument has two probes that can be respectively fixed on two probe clamping mechanisms.

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