Method, device, equipment, medium and program for detecting defects of reducers

Abstract

The application relates to the technical field of nondestructive testing, in particular to a defect detection method, device, equipment, medium and program of a reducing pipe, wherein the method comprises the following steps: generating an actual defect position of the reducing pipe according to a reducing pipe taper, probe position data and defect display depth of ultrasonic wave data; generating an actual defect length of the reducing pipe according to the reducing pipe taper, a radius of an outer surface of the reducing pipe corresponding to the position of the defect and a radius of the outer surface of the reducing pipe at the probe incident point position; generating an actual defect height of the reducing pipe according to the reducing pipe taper and a defect height measurement value of the ultrasonic wave data; and generating a defect detection result of the reducing pipe according to the actual defect position, the actual defect length and the actual defect height of the reducing pipe. Therefore, the problems that, in the related art, ultrasonic detection is based on a flat plate or a fixed curvature assumption, cannot adapt to the continuously changing geometric curved surface of the reducing pipe, causes poor probe coupling, incomplete sound field coverage, poor measurement error and the like are solved.

Description

Technical Field

[0001] This application relates to the field of nondestructive testing technology, and in particular to a method, apparatus, equipment, medium and procedure for defect detection of reducers. Background Technology

[0002] In the energy conversion and transmission systems of power plants, pressure pipelines are subjected to harsh conditions of high temperature, high pressure, and alternating loads for extended periods, and their structural integrity is directly related to the safe operation of the power plant. To meet the requirements of fluid dynamics, reducers are widely used in pipeline systems to connect pipe sections of different diameters. Since reducers play a crucial role in guiding the smooth transition of the medium flow field, the weld area where they connect to the pipeline often becomes the geometrically most complex and stress-concentrated part, making it a high-risk area for dangerous defects such as cracks and lack of fusion.

[0003] In related technologies, non-destructive testing of such components, especially ultrasonic testing, mainly follows the testing standards and methods used for butt welds on flat plates or pipes with fixed curvature (such as equal-diameter elbows). However, ultrasonic testing typically assumes that the workpiece surface is flat or has a single fixed curvature. For tapered structures like reducing pipes, which have a continuously changing diameter from large to small, the bottom surface of a standard probe cannot simultaneously maintain good contact with the surface of varying curvature. This results in extremely poor coupling stability between the probe and the workpiece, a significant reduction in acoustic energy transmission efficiency, and a poor signal-to-noise ratio. During circumferential scanning, the encoder records the linear movement distance of the probe, while the defect actually lies on a curved surface that varies with the pipe diameter. If the straight-line distance is used directly to calculate the defect length, ignoring the arc length deviation caused by the pipe diameter difference, the measured defect length will be severely distorted. Summary of the Invention

[0004] This application provides a method, apparatus, equipment, medium, and procedure for defect detection of reducers, in order to solve the problems in related technologies where ultrasonic testing is based on the assumption of a flat plate or fixed curvature, which cannot adapt to the continuously changing geometric surface of reducers, resulting in poor probe coupling, incomplete sound field coverage, and poor measurement error.

[0005] The first aspect of this application provides a method, apparatus, device, medium, and program for detecting defects in a reducer, comprising the following steps: under at least one preset scanning path, identifying ultrasonic data, probe position data, and probe movement distance corresponding to the defect in the reducer; and obtaining the reducer taper, the outer surface radius of the reducer corresponding to the defect location, and the outer surface radius of the reducer at the probe incident point location based on the three-dimensional geometric model of the reducer; generating the actual defect location of the reducer based on the reducer taper, probe position data, and defect display depth of the ultrasonic data; generating the actual defect length of the reducer based on the reducer taper, the outer surface radius of the reducer corresponding to the defect location, and the outer surface radius of the reducer at the probe incident point location; generating the actual defect height of the reducer based on the reducer taper and the defect height measurement value of the ultrasonic data; and generating the defect detection result of the reducer based on the actual defect location, actual defect length, and actual defect height.

[0006] Optionally, based on the taper of the reducer, probe position data, and the defect display depth of the ultrasonic data, the actual defect location of the reducer is generated, including: using the defect display depth as the target sound path value, in the three-dimensional geometric model of the reducer, a tracking ray is generated extending along the direction of ultrasonic beam refraction, starting from the probe incident point; the intersection point of the tracking ray and the inner surface of the pipe wall in the three-dimensional geometric model of the reducer is identified, and the coordinates of the intersection point are obtained; the actual defect location of the reducer is generated based on the coordinates of the intersection point.

[0007] Optionally, generating the actual defect location of the reducer based on the reducer taper, probe position data, and defect display depth of ultrasonic data further includes: obtaining the probe axial coordinates in the axial direction of the reducer; calculating the axial coordinates of the reducer defect based on the probe axial coordinates, defect display depth, and reducer taper; calculating the depth coordinates of the reducer defect based on the defect display depth and reducer taper; and generating the actual defect location of the reducer based on the reducer defect's axial coordinates and depth coordinates.

[0008] Optionally, it also includes: acquiring the initial signal amplitude from the ultrasonic data; calculating the signal correction coefficient based on the taper of the reducer and a preset material attenuation coefficient; and compensating the initial signal amplitude based on the signal correction coefficient to generate a corrected defect signal amplitude.

[0009] Optionally, the defect detection result of the reducer is generated based on the actual defect location, actual defect length, actual defect height, and signal amplitude. This includes: querying a preset defect feature library based on the actual defect location, actual defect length, actual defect height, and defect signal amplitude to determine at least one corresponding defect feature, wherein the preset defect feature library stores the mapping relationship between the actual defect location, actual defect length, actual defect height, and defect signal amplitude and the defect features; determining the defect type and defect level based on at least one defect feature; and generating the defect detection result of the reducer based on the defect type and defect level.

[0010] Optionally, the taper of the reducer is obtained based on the three-dimensional geometric model of the reducer, including: obtaining the first end diameter, the second end diameter, and the axial length corresponding to the three-dimensional geometric model of the reducer; and calculating the taper of the reducer based on the first end diameter, the second end diameter, and the axial length.

[0011] A second aspect of this application provides a defect detection device for a reducing pipe, comprising: an identification module, configured to identify ultrasonic data, probe position data, and probe movement distance corresponding to a defect in the reducing pipe under at least one preset scanning path, and to obtain the tapered diameter of the reducing pipe, the outer surface radius of the reducing pipe corresponding to the defect location, and the outer surface radius of the reducing pipe at the probe incident point location based on a three-dimensional geometric model of the reducing pipe; a first generation module, configured to generate the actual defect location of the reducing pipe based on the defect display depth of the reducing pipe tapered diameter, probe position data, and ultrasonic data; a second generation module, configured to generate the actual defect length of the reducing pipe based on the tapered diameter, the outer surface radius of the reducing pipe corresponding to the defect location, and the outer surface radius of the reducing pipe at the probe incident point location; a third generation module, configured to generate the actual defect height of the reducing pipe based on the tapered diameter and the defect height measurement value of the ultrasonic data; and a fourth generation module, configured to generate the defect detection result of the reducing pipe based on the actual defect location, actual defect length, and actual defect height.

[0012] A third aspect of this application provides an electronic device, including: a memory, a processor, and a computer program stored in the memory and executable on the processor. The processor executes the program to perform the defect detection method for a reducer as described in the above embodiments.

[0013] A fourth aspect of this application provides a computer-readable storage medium having a computer program stored thereon, which is executed by a processor to perform a defect detection method for a reducer as described in the above embodiments.

[0014] The fifth aspect of this application provides a computer program product, including a computer program or instructions, which, when executed, implement the defect detection method for reducers as described in the above embodiments.

[0015] Therefore, this application has at least the following beneficial effects: This application embodiment can synchronously acquire ultrasonic data, probe position, and movement distance along a preset path, and extract the taper and radius parameters of key positions of the reducer based on a three-dimensional geometric model. First, using the taper, probe position data, and defect display depth, the actual position coordinates of the defect in three-dimensional space are calculated through geometric acoustic model inversion. Then, combining the taper and the radius difference between the defect location and the incident point, the arc length of the probe movement is geometrically corrected to accurately generate the actual circumferential length of the defect. At the same time, the sound path-depth conversion correction is performed on the defect height measurement value in the ultrasonic data based on the taper to obtain the true defect height. Finally, the corrected actual position, length, and height parameters are integrated to generate high-precision reducer defect detection results, realizing full-parameter accurate reconstruction of the defect morphology and coordinates in the reducer structure, and improving the accuracy of defect parameter measurement.

[0016] Additional aspects and advantages of this application 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 this application. Attached Figure Description

[0017] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: Figure 1 This is a flowchart of a defect detection method for a reducer according to an embodiment of this application; Figure 2 This is an example diagram of a defect detection method for reducers provided according to an embodiment of this application; Figure 3 This is a schematic diagram of a defect detection device for a reducer provided according to an embodiment of this application; Figure 4 This is a schematic diagram of the structure of an electronic device provided according to an embodiment of this application. Detailed Implementation

[0018] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0019] The following description, with reference to the accompanying drawings, describes a method, apparatus, device, medium, and procedure for detecting defects in reducers according to embodiments of this application.

[0020] Specifically, Figure 1 This is a schematic flowchart illustrating a defect detection method for a reducer provided in an embodiment of this application.

[0021] like Figure 1 As shown, the defect detection method for this reducer includes the following steps: In step S101, under at least one preset scanning path, the ultrasonic data, probe position data and probe movement distance corresponding to the defect of the reducer are identified, and the taper of the reducer, the outer surface radius of the reducer corresponding to the location of the defect and the outer surface radius of the reducer at the probe incident point are obtained based on the three-dimensional geometric model of the reducer.

[0022] It is understood that the embodiments of this application can collect ultrasonic data of the reducer weld, probe position coordinates and probe movement distance recorded by the encoder along a preset scanning path, and extract the reducer taper, the outer surface radius of the pipe at the defect location and the radius at the probe incident point by using a three-dimensional geometric model. This systematically corrects the measurement distortion caused by the gradual change of pipe diameter in traditional ultrasonic testing, significantly improves the accuracy of reducer weld defect detection, and provides a reliable data basis for the safety assessment of reducer structures.

[0023] It should be noted that the preset scanning path can be a trajectory planned before the inspection, in which the probe moves on the outer surface of the reducer. It is usually one or more arcs along the circumference of the pipe (around one lap). The position of each path is determined by the axial distance from the weld centerline, the scanning starting point, and the scanning direction. This guides the mechanical scanning mechanism to move the probe along the predetermined trajectory, ensuring that the sound beam covers the entire weld cross section and avoids missed inspections. In addition, in the embodiments of this application, the first end of the reducer is the large end and the second end is the small end.

[0024] Ultrasonic data refers to the raw measurement values ​​that the ultrasonic flaw detector acquires and displays in real time during the inspection process, reflecting the echo characteristics of defects. Specifically, it includes: initial signal amplitude, defect display depth, display axial position, and defect height measurement values. Among them, the initial signal amplitude is the echo signal intensity, reflecting the size and reflection characteristics of the defect; the defect display depth is the sound path length (i.e., the oblique distance from the probe incident point to the defect) calculated by the instrument based on the round-trip time of the sound wave; the display axial position is the distance of the defect displayed by the instrument along the pipe axis (usually with the weld centerline as a reference); and the defect height measurement value is the height of the defect itself (such as crack depth) calculated by the instrument based on the sound path difference.

[0025] The probe position data is the absolute coordinates of the probe incident point (or probe center point) in three-dimensional space at the moment of detection. The probe movement distance is the actual arc length traversed by the probe along the scanning path from the starting point to the current position, as recorded by the encoder.

[0026] The process of establishing the three-dimensional geometric model in this application is as follows: Figure 2As shown, the process includes: surface pretreatment of the reducer and corresponding reducer weld of the power plant pressure pipeline; laser scanning to measure weld parameters such as the large end diameter D1, small end diameter D2, joint length L, taper K, weld width, bevel angle, and wall thickness of the reducer; simultaneous acquisition of the X, Y, and Z three-dimensional coordinates of the reducer's central axis, with the X-axis along the pipeline axis, the Y-axis along the pipeline circumferential direction, and the Z-axis along the pipeline thickness direction; and recording the three-dimensional coordinates of each point on the weld centerline. Based on these parameters, a three-dimensional geometric model of the weld is established.

[0027] The pretreatment can be calculated based on the formula N•Ttanβ (where N is the ultrasonic wave number used to cover the weld cross section, T is the designed pipe wall thickness, and β is the selected probe refraction angle) to remove oxide scale, rust, oil, coating, and weld excess height from the weld and the surrounding area within the range of N•Ttanβ. For example, when D1=100mm, D2=200mm, L=150mm, and K=0.68, and T=50mm and β=45°, it is calculated that when the second wave can cover the entire weld cross section, the grinding range is the area around the weld that is 2×50×tan45°=100mm.

[0028] The data and measurement parameters obtained by laser scanning are imported into the modeling software to construct a 1:1 scale three-dimensional basic parameter model. The model must completely reproduce the reducer body, weld area, bevel structure, and pipe sections extending N•Ttanβ at both ends. Ten feature points (including the large end, small end, weld root, and bevel edge) are randomly selected, and the model coordinates are compared with the actual measured coordinates to ensure that the geometric error of the model is ≤0.05mm. After verification, it is used for subsequent sound field simulation and parameter correction.

[0029] Specifically, the constructed three-dimensional geometric model is imported into the simulation software, and ultrasonic parameters are set, such as frequency 2-10MHz, number of crystals 32 or 64, crystal size 0.8×12mm, coupling layer thickness (0.1-0.3mm), and base material parameters (density, sound velocity). In the base material area of ​​the reducing pipe at a certain distance from the weld centerline, two axial scanning paths are planned along the circumference (corresponding to the large end side weld and the small end side weld respectively) to ensure that the planned paths cover the entire weld cross-sectional area.

[0030] Based on the established three-dimensional geometric model, a sound field propagation model of the weld cross section is constructed using simulation software. One or more probe circumferential scanning paths are planned in the base material area of ​​the reducing pipe at a certain distance from the weld centerline. The propagation path of the ultrasonic beam through multiple reflections in the reducing pipe weld is simulated. The curvature and taper of the front and rear bottom surfaces of the wedge are optimized when the probe scans this path to ensure that the sound field fully covers the weld cross section without any blind spots. The bottom surface of the probe wedge is a composite curved surface. The curvature of the front and rear bottom surfaces of the probe wedge matches the curvature of the pipe corresponding to the scanning path, ensuring good probe coupling. The taper of the wedge is consistent with the taper K of the reducing pipe.

[0031] The propagation path of ultrasonic waves in the weld seam of a reducing pipe diameter was simulated using simulation software, optimizing the curvature and taper of the front and rear ends of the probe wedge. Specifically, the first wedge, used for the large-end scanning path, has a bottom surface designed as a composite curved surface with a larger curvature at the front and a smaller curvature at the back, with the radius of curvature matching the curvature of the outer pipe wall at the scanning path. The second wedge, used for the small-end scanning path, also has a bottom surface designed as a composite curved surface with a smaller curvature at the front and a larger curvature at the back, with the radius of curvature matching the curvature of the outer pipe wall at the corresponding scanning path. The taper of both wedges is consistent with the taper K of the reducing pipe, with a deviation of less than or equal to ±5%. The wedges were manufactured according to the simulation-optimized parameters, and the curvature and taper of the wedge bottom surface were detected using laser scanning to ensure that the deviation from the simulation parameters was less than or equal to 0.02 mm. The manufactured wedges were then installed on the probe, and coupling tests were performed on a test block to ensure good coupling between the probe and the test block surface, with no significant sound energy attenuation. The acoustic field distribution diagram of the weld cross section is output by simulation software to check that the acoustic field covers the entire weld cross section and ensure that there are no blind spots in the root, middle and surface of the weld. If there are blind spots, the scanning path position and wedge parameters are adjusted and the simulation is repeated until the full coverage requirement is met.

[0032] The probe is aligned with the planned scanning path, and the mechanical scanning mechanism is activated to move circumferentially along the weld. The ultrasonic flaw detector acquires defect signals (amplitude, depth, and distance) in real time, while the encoder synchronously records the probe's movement distance. The system automatically correlates the signal acquisition time with the probe's three-dimensional coordinates. Abnormal signals (signals with amplitude exceeding a threshold) occurring during the inspection process are marked, and the corresponding ultrasonic display coordinates (X, Y, F, Z) are recorded. 显 Z 显 ), probe real-time coordinates (X) 探 Y 探 Z 探 ) and encoder travel distance L encoder .

[0033] In this embodiment of the application, the tapered diameter of the reducer is obtained based on the three-dimensional geometric model of the reducer, including: obtaining the first end diameter, the second end diameter, and the axial length corresponding to the three-dimensional geometric model of the reducer; and calculating the tapered diameter of the reducer based on the first end diameter, the second end diameter, and the axial length.

[0034] It is understood that the embodiments of this application can construct a taper mathematical model by obtaining three basic geometric parameters in the three-dimensional geometric model of the reducer: the diameter of the first end, the diameter of the second end, and the axial length. The working principle is to abstract the geometric shape of the reducer into a truncated cone, and accurately derive the taper parameters of the reducer by calculating the ratio of the difference between the diameters of the two ends to the axial length. This method can not only quickly and accurately obtain the taper information of the reducer, but also provide a key geometric correction basis for subsequent defect location and quantitative analysis, significantly improving the accuracy and reliability of the detection results.

[0035] It should be noted that the taper of the reducer is K=(D1-D2) / L, where the diameter of the larger end of the reducer is D1, the diameter of the smaller end is D2, and the axial length of the joint is L.

[0036] In step S102, the actual defect location of the reducer is generated based on the taper of the reducer, the probe position data, and the defect display depth of the ultrasonic data.

[0037] It is understood that the embodiments of this application can achieve accurate generation of the actual spatial location of defects inside the reducer by comprehensively analyzing the defect display depth of the reducer taper, probe position data and ultrasonic data, effectively solving the problem of ultrasonic positioning deviation caused by pipe diameter changes, and significantly improving the spatial resolution and positioning accuracy of reducer defect detection.

[0038] It should be noted that, due to the continuous axial variation of the reducer's diameter, the ultrasonic beam will be deflected when propagating in the tapered pipe wall, causing a deviation between the oblique depth directly displayed by the instrument and the actual vertical depth and axial position. Therefore, this application determines the coordinates of the ultrasonic incident point on the reducer surface based on probe position data, and calculates the angle between the ultrasonic beam's propagation path in the pipe wall and the axis based on the reducer's taper. Then, based on this angle and the sound wave propagation distance corresponding to the defect display depth, the actual coordinate positions of the defect in the reducer's axial and radial directions are derived through trigonometric relationships. Finally, the defect depth display value, which was originally based on a planar assumption or a simple geometric model, is corrected to a spatial positioning result that conforms to the actual tapered structure of the reducer. This effectively solves the problem of ultrasonic positioning deviation caused by pipe diameter variation and significantly improves the spatial resolution and positioning accuracy of reducer defect detection.

[0039] It should be noted that, based on the ultrasonic display data, and combined with the spatial coordinates of the probe center point, the taper K of the reducing pipe, the wall thickness T, and the relative positional relationship between the probe and the defect, geometric calculations are used to correct the positioning deviation caused by the deflection of the ultrasonic wave propagation path in the conical wall and the difference in pipe diameter between the probe and the defect, thus obtaining the actual three-dimensional coordinates (X) of the defect. 实 Y 实 Z 实Alternatively, the ultrasonic display data can be corrected using the sound ray tracing method to obtain the actual three-dimensional coordinates of the defect.

[0040] Specifically, such as Figure 2 As shown, the acoustic ray tracing method is based on a three-dimensional fundamental parameter model and the ultrasonic beam refraction angle. It traces the beam along its propagation direction from the probe center point. When the tracing path length equals Z... 显 At that time, the coordinates of the intersection point are the actual three-dimensional coordinates of the defect (X). 实 Y 实 Z 实 ).

[0041] Geometric approximation formula correction: When inspecting the weld on the large end side, X 实 =X 探 -Z 显 ×sin(arctanK), Z 实 =Z 显 ×cos(arctanK); When inspecting the weld on the small end side, X 实 =X 探 +Z 显 ×sin(arctanK), Z 实 =Z 显 ×cos(arctanK), where X 实 X represents the actual horizontal position of the defect. 探 Z represents the horizontal position of the probe. 显 To show the depth of the defect, Z 实 The actual depth of the defect is K, where K is the taper of the reducer, and arctanK is the taper angle, which is the angle between the inclined surface of the pipe wall and the axis.

[0042] In this embodiment of the application, the actual defect location of the reducer is generated based on the taper of the reducer, probe position data, and the defect display depth of the ultrasonic data. This includes: using the defect display depth as the target sound path value, generating a tracking ray in the three-dimensional geometric model of the reducer, starting from the probe incident point and extending along the direction of ultrasonic beam refraction; identifying the intersection point between the tracking ray and the inner surface of the pipe wall in the three-dimensional geometric model of the reducer, obtaining the coordinates of the intersection point, and generating the actual defect location of the reducer based on the coordinates of the intersection point.

[0043] It is understood that the embodiments of this application can take the probe incident point as the origin, generate a virtual tracking ray based on the sound beam refraction law of ultrasonic waves in the material, and take the defect display depth as the termination target value of the ray, thereby accurately locking the extension length of the ray in the three-dimensional geometric model. The algorithm identifies the geometric intersection of the tracking ray and the inner surface of the reducer wall, obtains the three-dimensional coordinates of the intersection, and finally maps the coordinate data to the specific location of the actual defect on the reducer, realizing the complete derivation from acoustic signal to spatial coordinates. This effectively solves the problem of defect positioning deviation caused by the complex geometry of the pipe fitting, and significantly improves the intuitiveness and accuracy of the detection results.

[0044] It should be noted that the defect display depth displayed by the ultrasonic instrument is used as the target sound path value. Starting from the probe's incident point, a virtual ray is gradually extended in the three-dimensional geometric model, strictly following the refraction direction of the ultrasonic wave in the workpiece. Due to the continuous conical geometry of the inner surface of the reducing pipe wall, the ray intersects the inner surface during its extension. When the extension length of the ray is exactly equal to the defect display depth, the coordinates of the intersection point between the ray and the inner surface of the pipe wall are the actual three-dimensional position of the defect. By integrating the measured sound path with the geometrically constrained depth of the three-dimensional model, the deflection and reflection behavior of the sound beam in the conical pipe wall is directly simulated without relying on approximate formulas, and it can adapt to arbitrarily complex gradually changing surface shapes. Through this precise geometric tracking, the positioning deviation caused by pipe diameter changes in traditional methods is completely eliminated, achieving high-precision reconstruction of the defect position and providing a reliable spatial reference for subsequent evaluation of defect length, height, and properties.

[0045] Specifically, such as Figure 2 As shown, an arc-length conversion algorithm based on real-time curvature radius is used to query the radius of the highest wave location of the defect through a three-dimensional basic parameter model. and the radius of the outer surface of the pipe at the location of the probe incident point Substitute the values ​​into the arc length conversion algorithm to calculate the actual length of the defect: ;in, The distance the probe moves, as recorded by the encoder.

[0046] In this embodiment of the application, the actual defect location of the reducer is generated based on the taper of the reducer, probe position data, and defect display depth of the ultrasonic data. The method further includes: obtaining the probe axial coordinates in the axial direction of the reducer; calculating the axial coordinates of the reducer defect based on the probe axial coordinates, defect display depth, and reducer taper; calculating the depth coordinates of the reducer defect based on the defect display depth and reducer taper; and generating the actual defect location of the reducer based on the axial coordinates and depth coordinates of the reducer defect.

[0047] It is understood that the embodiments of this application can obtain the coordinates of the probe in the axial direction of the reducer. Based on this, and combined with the defect display depth and the known taper of the reducer, the specific axial position of the defect is derived through geometric relationships. At the same time, the depth coordinates of the defect are calculated based on the relationship between sound path depth and taper. The entire derivation process strictly follows the principles of trigonometric functions and geometric optics. The incident point of the probe is taken as the origin of the coordinate system. Using the mathematical relationship between the refraction angle and the pipe wall inclination angle, the sound wave propagation path is transformed into precise spatial coordinates. Finally, through the combination of axial coordinates and depth coordinates, the actual defect position of the reducer is generated, realizing a precise mapping from acoustic signals to spatial positions, effectively improving the accuracy and reliability of defect location in complex pipe fittings.

[0048] Specifically, such as Figure 2 As shown, the defect height correction is substituted into formula H. 修 =H 原 ×(1 / cosK), where H 原 H is the original measurement height of the ultrasonic flaw detector. 修 This is the corrected defect height.

[0049] In step S103, the actual defect length of the reducer is generated based on the taper of the reducer, the outer surface radius of the reducer corresponding to the location of the defect, and the outer surface radius of the reducer at the probe incident point.

[0050] It is understood that, based on the outer surface radius of the probe incident point and the taper of the reducer, the wall thickness and geometric inclination at the probe location can be derived. Then, combined with the outer surface radius of the defect location, the local radius and circumferential curvature at the defect depth can be determined. By calculating the axial projection difference of the two radii on the tapered pipe wall, and combining the propagation path and refraction angle of the ultrasonic beam in the material, the unfolded length of the defect on the pipe wall surface can be derived. Following the geometric trigonometric relationship and the acoustic propagation principle, the spatial curved surface length is transformed into a measurable linear parameter, and finally the actual defect length of the reducer is generated, effectively improving the accuracy and reliability of defect size assessment in variable diameter structures.

[0051] It should be noted that in this embodiment, the scanning mechanism of the integrated encoder drives the probe to move circumferentially along the scanning path and records the probe's moving distance in real time; the Y and Z axis coordinates of the center axis of the probe and the weld defect are extracted respectively, the arc length deviation of the extension direction caused by the difference in pipe diameter between the moving trajectory of the probe at the pipe diameter and the pipe diameter at the defect depth is calculated, and the moving distance recorded by the encoder is corrected by the deviation to obtain the actual length of the weld defect.

[0052] In step S104, the actual defect height of the reducer is generated based on the taper of the reducer and the defect height measurement value of the ultrasonic data.

[0053] It is understood that the embodiments of this application can calculate and analyze the echo path of the upper and lower ends of the defect based on the linear propagation characteristics of ultrasound in the material and the time difference of the reflected echo, determine the initial height measurement value in combination with the sound velocity of the material, and then derive the height measurement deviation coefficient caused by the inclination of the pipe wall based on the taper angle of the reducer. By performing mathematical operations on the measured value and the coefficient, the geometric projection error caused by the tapered structure is compensated, thereby accurately calculating the actual height of the defect in the direction perpendicular to the pipe wall. This effectively eliminates the positioning error caused by ignoring the geometric shape in the diameter-changing area of ​​the traditional detection method, and significantly improves the accuracy and reliability of the defect assessment of the reducer.

[0054] In this embodiment of the application, the method further includes: acquiring the initial signal amplitude in the ultrasonic data; calculating the signal correction coefficient based on the taper of the reducer and the preset material attenuation coefficient; and compensating the initial signal amplitude based on the signal correction coefficient to generate the corrected defect signal amplitude.

[0055] The preset material attenuation coefficient can be determined by querying the corresponding database for the material. For example, carbon steel α=0, stainless steel α=0.01, alloy steel α=0.02, without specific limitations.

[0056] It is understood that the embodiments of this application can extract the initial signal amplitude from the ultrasonic data as a benchmark, accurately calculate the actual propagation path length of the sound wave within the pipe wall based on the taper change of the reducer, and derive the signal correction coefficient at a specific location by combining the inherent attenuation characteristics of the material. This quantifies the sound energy loss caused by the increase in sound path and the tilt of the pipe wall. The initial signal amplitude is mathematically compensated using this coefficient to generate the corrected defect signal amplitude. By separating the signal attenuation caused by the geometric shape from the true reflectivity of the defect, the evaluation standard for the severity of defects at different pipe diameters and depths is ensured to be uniform, significantly improving the accuracy and reliability of quantitative detection of defects in reducers.

[0057] Specifically, such as Figure 2 As shown, image distortion correction is substituted into formula A. 修 =A 原 ×(1-K×0.3)×(1+α), where α is the material attenuation compensation coefficient (carbon steel α=0, stainless steel α=0.01, alloy steel α=0.02), A 修 For the corrected signal amplitude, A 原 The original signal amplitude is directly measured and displayed by the ultrasonic flaw detector, and K is the taper of the reducing pipe to eliminate signal distortion caused by multiple reflections.

[0058] In step S105, the defect detection results of the reducer are generated based on the actual defect location, actual defect length, and actual defect height.

[0059] It is understood that the embodiments of this application can map the actual defect location, after geometric correction, to the three-dimensional coordinate system of the reducer, establish the spatial distribution characteristics of the defect, and then introduce the actual defect length and height data to construct a three-dimensional geometric model of the defect. Based on preset industrial safety standards or acceptance specifications, weighted analysis and grade assessment are performed on defects of different locations, sizes, and depths, comprehensively considering the potential risks of defects in stress concentration areas, and finally generating a complete inspection result including defect nature determination, severity classification, and maintenance suggestions. This eliminates the evaluation blind spots caused by the complex geometry of the pipe fittings, ensuring that the inspection conclusions can truly reflect the structural integrity and safety status of the reducer, and providing accurate and reliable data support for equipment maintenance decisions.

[0060] In this embodiment, generating a defect detection result for the reducer based on its actual defect location, actual defect length, actual defect height, and defect signal amplitude includes: querying a preset defect feature library based on the actual defect location, actual defect length, actual defect height, and defect signal amplitude to determine at least one corresponding defect feature, wherein the preset defect feature library stores the mapping relationship between the actual defect location, actual defect length, actual defect height, and defect signal amplitude and the defect features; determining the defect type and defect level based on at least one defect feature; and generating the defect detection result for the reducer based on the defect type and defect level.

[0061] It is understood that, according to the actual defect location, actual defect length, actual defect height, and defect signal amplitude of the reducer, the present application embodiment can accurately locate at least one defect feature corresponding to the current defect using a preset defect feature library. Based on the matched feature information, combined with material mechanics and failure analysis logic, the specific type of defect (such as crack, lack of fusion, or porosity) is determined and its severity level is classified. Finally, the reducer defect detection result containing qualitative analysis and quantitative evaluation is generated by comprehensively considering the type and level information. This realizes the automated derivation from physical quantity measurement to defect nature determination, effectively solving the problems of high misjudgment rate and difficulty in qualitative analysis caused by relying on a single parameter in traditional detection, and significantly improving the intelligence level and decision reliability of reducer defect detection.

[0062] It should be noted that the preset defect feature library pre-stores multiple sets of defect feature samples. Each set of samples includes the actual defect location (axial coordinates, circumferential angle, depth), actual defect length, actual defect height, defect signal amplitude, and the corresponding defect type (such as crack, lack of fusion, incomplete penetration, porosity, slag inclusion) and defect level (such as level I, level II, level III). This feature library can be constructed through three methods: first, by performing ultrasonic testing on a comparison test block of a reducing pipe containing artificial defects, obtaining the corrected defect parameters, and recording the actual defect type and level; second, by collecting a large amount of historical data from field testing and destructive verification; and third, by using finite element simulation to simulate the ultrasonic response of different defects and generate theoretical feature samples.

[0063] During actual inspection, for each defect detected in the weld of the reduced pipe, its corresponding actual defect location, actual defect length, actual defect height, and corrected signal amplitude are used as a query vector. This vector is then matched against a pre-defined defect feature library. The matching strategy can employ multi-dimensional interval search: for example, dividing the axial position into the weld root zone, heat-affected zone, and filling zone; dividing the depth into the near-surface zone, middle zone, and near-inner wall zone; segmenting the length and height according to thresholds (e.g., length < 5mm, 5~10mm, > 10mm; height < 1mm, 1~3mm, > 3mm); and segmenting the amplitude according to dB values. The system searches the feature library for all samples that fall within the same or adjacent intervals as the current defect parameters and calculates the probability of each defect type occurring.

[0064] If the probability of a certain type of defect (such as a crack) exceeds a preset threshold (e.g., 70%), it is identified as that type. If the probability is dispersed or below the threshold, a weighted Euclidean distance is used to calculate the similarity between the current defect vector and each sample vector, and the defect type (crack, lack of fusion, porosity, inclusion, etc.) of the most similar sample is selected as the identification result. The defect level is comprehensively evaluated according to standard requirements, combining defect type, length, height, and location: for example, for cracks, when the length is ≤10mm and the height is ≤1mm, it is Level I; when the length is ≤20mm and the height is ≤2mm, it is Level II; otherwise, it is Level III. For porosity, it is rated according to the diameter and density of individual pores.

[0065] In the embodiments of this application, such as Figure 2 As shown, it also includes: importing the corrected actual length, actual three-dimensional coordinates, corrected height, and defect properties into the three-dimensional modeling software, integrating it with the previously established three-dimensional basic parameter model of the weld, and constructing a 1:1 scale three-dimensional visualization model of the defect; the model is labeled with information such as defect number, size parameters, properties, and inspection time, supports export in at least one format, and can be seamlessly integrated with the pipeline model.

[0066] A database management system was used to build a 3D model lifecycle database for reducer welds. Basic reducer data and inspection data models were entered into the database. Basic reducer parameters included: inspection object number, material, specifications, taper K, inspection time, and equipment parameters. 3D model data included: a 3D basic parameter model of the weld and a 3D visualization model of defects. Defect parameters included: actual 3D coordinates, length, width, height, depth, defect type, and defect level. The database was integrated with the power plant equipment management system to achieve linked management of inspection data and equipment operation and maintenance data, providing accurate data support for pipeline safety assessment, serviceability evaluation, and lifespan prediction.

[0067] In summary, this application addresses the challenge of inspecting the gradual diameter welds of reducers in power plant pressure pipelines. It establishes a 3D model by accurately measuring the actual geometric parameters of the reducer and weld, and then simulates and optimizes the probe scanning path to achieve full sound field coverage. To address the continuously changing curvature of the reducer, an innovative composite curved surface wedge with different radii of curvature at both ends is designed: a wedge with a larger front and smaller rear radius on the larger end, and a wedge with a smaller front and larger rear radius on the smaller end. This ensures that the curvature of the wedge's bottom surface precisely matches the curvature of the corresponding pipeline along the scanning path, significantly improving the coupling stability between the probe and the variable curvature surface and ensuring efficient sound energy transmission. For defect localization, combining the probe's spatial coordinates with the reducer's tapered characteristics, sound ray tracing or geometric conversion methods are used to accurately compensate for the deflection effect of the sound beam propagating within the tapered pipe wall. Regarding defect length measurement, based on the curvature difference between the defect and the probe's location, an arc length conversion model is constructed, correcting the probe's linear movement distance to the actual arc length of the defect, thus accurately reproducing the defect size. To address signal distortion caused by multiple reflections of ultrasonic waves within tapered pipe walls, a dedicated correction model is established by combining the taper and wall thickness of the reducing pipe, effectively eliminating spurious signal interference. Simultaneously, defect height correction is implemented to compensate for measurement deviations caused by gradual pipe diameter changes, providing a clear and reliable signal foundation for accurate defect identification. This assists intelligent algorithms in accurately determining defect types, ultimately providing reliable data support for pipeline safety assessment and lifespan prediction.

[0068] According to the defect detection method for reducers proposed in this application, ultrasonic data, probe position data, and probe movement distance corresponding to the reducer defect are simultaneously collected under at least one preset scanning path. The taper parameters of the reducer body, the outer surface radius at the defect projection position, and the outer surface radius at the ultrasonic probe incident point are accurately obtained by combining the three-dimensional geometric model of the reducer. Then, using the taper, probe position data, and defect display depth in the ultrasonic data, the actual coordinate position of the defect in three-dimensional space is calculated through a geometric path correction algorithm. Furthermore, based on the taper and the difference in outer surface radius between the defect location and the probe incident point, a conversion model between arc length and chord length is constructed to accurately derive the actual circumferential and axial lengths of the defect. Simultaneously, the slope of the original defect height value measured by the ultrasonic data is corrected using the taper parameters to restore the true height dimension of the defect. Finally, a high-precision reducer defect detection result is generated by combining the actual defect location, actual defect length, and actual defect height. This effectively overcomes the positioning and quantitative errors caused by the complex geometric shape of traditional ultrasonic testing in reducer structures, significantly improving the accuracy and reliability of reducer defect detection.

[0069] Next, referring to the accompanying drawings, a defect detection device for a reducer according to an embodiment of this application is described.

[0070] Figure 3 This is a block diagram of a defect detection device for a reducer according to an embodiment of this application.

[0071] like Figure 3 As shown, the defect detection device 10 for the reducer includes: an identification module 100, a first generation module 200, a second generation module 300, a third generation module 400, and a fourth generation module 500.

[0072] The identification module 100 is used to identify the ultrasonic data, probe position data, and probe movement distance corresponding to the defect of the reducer under at least one preset scanning path, and to obtain the taper of the reducer, the outer surface radius of the reducer corresponding to the defect location, and the outer surface radius of the reducer at the probe incident point based on the three-dimensional geometric model of the reducer; the first generation module 200 is used to generate the actual defect location of the reducer based on the taper of the reducer, the probe position data, and the defect display depth of the ultrasonic data; the second generation module 300 is used to generate the actual defect length of the reducer based on the taper of the reducer, the outer surface radius of the reducer corresponding to the defect location, and the outer surface radius of the reducer at the probe incident point; the third generation module 400 is used to generate the actual defect height of the reducer based on the taper of the reducer and the defect height measurement value of the ultrasonic data; and the fourth generation module 500 is used to generate the defect detection result of the reducer based on the actual defect location, actual defect length, and actual defect height.

[0073] According to the defect detection device for reducing pipes proposed in this application, ultrasonic data, probe position data, and probe movement distance corresponding to the defect of the reducing pipe are collected simultaneously under at least one preset scanning path. Combined with the three-dimensional geometric model of the reducing pipe, the taper parameters of the pipe body, the outer surface radius at the defect projection position, and the outer surface radius at the ultrasonic probe incident point are accurately obtained. Then, using the taper, probe position data, and defect display depth in the ultrasonic data, the actual coordinate position of the defect in three-dimensional space is calculated through a geometric path correction algorithm. Further, based on the taper and the difference in outer surface radius between the defect location and the probe incident point, a conversion model of arc length and chord length is constructed to accurately derive the actual circumferential and axial lengths of the defect. Simultaneously, the slope of the original defect height value measured by the ultrasonic data is corrected using the taper parameters to restore the true height dimension of the defect. Finally, by combining the actual defect location, actual defect length, and actual defect height, a high-precision defect detection result for the reducing pipe is generated. This effectively overcomes the positioning and quantitative errors caused by the complex geometric shape of traditional ultrasonic testing in reducing pipe structures, significantly improving the accuracy and reliability of reducing pipe defect detection.

[0074] Figure 4 A schematic diagram of the structure of an electronic device provided in an embodiment of this application. The electronic device may include: The memory 401, the processor 402, and the computer program stored on the memory 401 and capable of running on the processor 402.

[0075] When the processor 402 executes the program, it implements the defect detection method for reducers provided in the above embodiments.

[0076] Furthermore, electronic devices also include: Communication interface 403 is used for communication between memory 401 and processor 402.

[0077] The memory 401 is used to store computer programs that can run on the processor 402.

[0078] Memory 401 may include high-speed RAM memory, and may also include non-volatile memory, such as at least one disk storage device.

[0079] If the memory 401, processor 402, and communication interface 403 are implemented independently, then the communication interface 403, memory 401, and processor 402 can be interconnected via a bus to complete communication between them. The bus can be an Industry Standard Architecture (ISA) bus, a Peripheral Component Interconnect (PCI) bus, or an Extended Industry Standard Architecture (EISA) bus, etc. Buses can be categorized into address buses, data buses, control buses, etc. For ease of representation, Figure 4 The bus is represented by a single thick line, but this does not mean that there is only one bus or one type of bus.

[0080] Optionally, in a specific implementation, if the memory 401, processor 402, and communication interface 403 are integrated on a single chip, then the memory 401, processor 402, and communication interface 403 can communicate with each other through an internal interface.

[0081] Processor 402 may be a central processing unit (CPU), an application specific integrated circuit (ASIC), or one or more integrated circuits configured to implement the embodiments of this application.

[0082] This application also provides a computer-readable storage medium storing a computer program or instructions thereon, which, when executed by a processor, implements the above-described defect detection method for reducers.

[0083] This application also provides a computer program product, including a computer program or instructions, which, when executed, implement the above-described method for detecting defects in reducers.

[0084] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0085] 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 application, "N" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0086] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or N executable instructions for implementing custom logic functions or processes, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0087] It should be understood that the various parts of this application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiments, the N steps or methods can be implemented using software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or more of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0088] Those skilled in the art will understand that all or part of the steps of the methods in the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, the program includes one or a combination of the steps of the method embodiments.

Claims

1. A method for detecting defects in a reducer, characterized in that, Includes the following steps: Under at least one preset scanning path, identify the ultrasonic data, probe position data and probe movement distance corresponding to the defect of the reducer, and obtain the taper of the reducer, the outer surface radius of the reducer corresponding to the location of the defect and the outer surface radius of the reducer at the probe incident point based on the three-dimensional geometric model of the reducer. Based on the taper of the reducer, the probe position data, and the defect display depth of the ultrasonic data, the actual defect location of the reducer is generated. The actual defect length of the reducer is generated based on the taper of the reducer, the outer surface radius of the reducer corresponding to the location of the defect, and the outer surface radius of the reducer at the probe incident point. The actual defect height of the reducer is generated based on the taper of the reducer and the measured defect height value from the ultrasonic data. The defect detection results of the reducer are generated based on the actual defect location, actual defect length, and actual defect height.

2. The defect detection method for reducers according to claim 1, characterized in that, The step of generating the actual defect location of the reducer based on the reducer taper, the probe position data, and the defect display depth of the ultrasonic data includes: Using the defect display depth as the target sound path value, a tracking ray is generated in the three-dimensional geometric model of the reducer, starting from the probe incident point and extending along the direction of ultrasonic beam refraction. The intersection point between the tracking ray and the inner surface of the pipe wall in the three-dimensional geometric model of the reducer is identified, and the coordinates of the intersection point are obtained. Based on the coordinates of the intersection point, the actual defect location of the reducer is generated.

3. The defect detection method for reducers according to claim 2, characterized in that, The step of generating the actual defect location of the reducer based on the reducer taper, the probe position data, and the defect display depth of the ultrasonic data further includes: Obtain the probe's axial coordinates in the axial direction of the reducer; The axial coordinates of the reducer defect are calculated based on the probe axial coordinates, the defect display depth, and the reducer taper; the depth coordinates of the reducer defect are calculated based on the defect display depth and the reducer taper. The actual defect location of the reducer is generated based on the axial coordinates and depth coordinates of the reducer defect.

4. The defect detection method for reducers according to claim 3, characterized in that, Also includes: Obtain the initial signal amplitude from the ultrasonic data; The signal correction coefficient is calculated based on the taper of the reducer and the preset material attenuation coefficient; The initial signal amplitude is compensated according to the signal correction coefficient to generate a corrected defective signal amplitude.

5. The defect detection method for reducers according to claim 4, characterized in that, The process of generating defect detection results for the reducer based on the actual defect location, actual defect length, actual defect height, and defect signal amplitude includes: Based on the actual defect location, actual defect length, actual defect height, and defect signal amplitude of the reducer, a preset defect feature library is queried to determine at least one corresponding defect feature. The preset defect feature library stores the mapping relationship between the actual defect location, actual defect length, actual defect height, and defect signal amplitude and the defect features. Determine the defect type and defect level based on at least one defect feature; The defect detection results of the reducer are generated based on the defect type and the defect level.

6. The defect detection method for reducers according to claim 1, characterized in that, The method of obtaining the taper of the reducer based on the three-dimensional geometric model includes: Obtain the first end diameter, second end diameter, and axial length corresponding to the three-dimensional geometric model of the reducer; The taper of the reducer is calculated based on the diameter of the first end pipe, the diameter of the second end pipe, and the axial length.

7. A defect detection device for a reducer, characterized in that, include: The identification module is used to identify the ultrasonic data, probe position data and probe movement distance corresponding to the defect of the reducer under at least one preset scanning path, and to obtain the taper of the reducer, the outer surface radius of the reducer corresponding to the location of the defect and the outer surface radius of the reducer at the probe incident point based on the three-dimensional geometric model of the reducer. The first generation module is used to generate the actual defect location of the reducer based on the taper of the reducer, the probe position data, and the defect display depth of the ultrasonic data. The second generation module is used to generate the actual defect length of the reducer based on the taper of the reducer, the outer surface radius of the reducer corresponding to the location of the defect, and the outer surface radius of the reducer at the probe incident point. The third generation module is used to generate the actual defect height of the reducer based on the taper of the reducer and the defect height measurement value of the ultrasonic data. The fourth generation module is used to generate the defect detection results of the reducer based on the actual defect location, the actual defect length, and the actual defect height.

8. An electronic device, characterized in that, include: The device includes a memory, a processor, and a computer program stored in the memory and executable on the processor, the processor executing the program to implement the defect detection method for reducers as described in any one of claims 1-6.

9. A computer-readable storage medium having a computer program or instructions stored thereon, characterized in that, When the computer program or instructions are executed by a processor, they are used to implement the defect detection method for reducers as described in any one of claims 1-6.

10. A computer program product, comprising a computer program or instructions, characterized in that, When the computer program or instructions are executed, they implement the defect detection method for reducers as described in any one of claims 1-6.

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