An in-situ non-destructive testing device and method for traversing obstacles to inspect corroded steel pipes.

Abstract

This invention discloses an in-situ non-destructive testing device and method for traversing obstacles on corroded steel pipes. The device includes a ring-shaped testing vehicle formed by multiple arc-shaped testing vehicle units connected end-to-end via electromagnetic interfaces. Each arc-shaped testing vehicle unit has upper and lower working platforms, equipped with axial climbing wheel sets, circumferential rotating wheel sets, an electric sliding rail telescopic connecting bridge, a spacing adjustment mechanism, obstacle detection sensors, electromagnetic and ultrasonic scanning modules, a processing module, and a power supply module. This invention achieves active adjustment of the ring-shaped testing vehicle diameter and controllable connection or disconnection of adjacent arc-shaped testing vehicle units through the electric sliding rail telescopic connecting bridge. Combined with the upper and lower working platforms and the spacing adjustment mechanism, the device can automatically traverse obstacles such as welds, flanges, and beams on the steel pipe surface, achieving full-coverage continuous testing of in-service steel pipes and overcoming the shortcomings of traditional testing devices in terms of obstacle-crossing capability.

Description

Technical Field

[0001] This invention relates to the field of nondestructive testing technology, specifically to an in-situ nondestructive testing device and method for rusted steel pipes that can overcome obstacles. Background Technology

[0002] Steel structures are widely used in various structural applications due to their advantages such as convenient construction, lightweight and high strength, diverse cross-sectional options, cost savings, and reliable quality. However, some steel structures operate in relatively harsh environments, necessitating corrosion assessment and maintenance of critical components. This is especially true for steel pipe components (such as tubular structures on offshore platforms, petrochemical pipelines, and arch ribs of long-span bridges), which are exposed to high humidity, high salt, or corrosive environments for extended periods, making corrosion a particularly prominent issue. Non-destructive in-situ testing (NDT) is increasingly valued as a crucial method for inspecting critical steel components in service. However, in actual engineering projects, some critical steel pipe components cannot be disassembled or sampled, and obstacles such as welds, flanges, and supporting beams often exist along the inspection path. Traditional testing devices struggle to achieve continuous and comprehensive inspection, leading to insufficient corrosion assessment and potential risks of accidents.

[0003] The existing technology for in-situ non-destructive testing of in-service steel pipes has the following problems:

[0004] 1. For corrosion detection equipment applicable to steel pipe components, its compatibility and obstacle-crossing ability are insufficient, making it difficult to meet the requirements of annular detection on the surface of steel pipes, resulting in low detection efficiency and poor accuracy.

[0005] 2. For steel pipe corrosion detection, most methods still rely on manual handheld detectors, which are prone to missing defects and are time-consuming and labor-intensive, especially for long-distance pipelines or high-altitude pipe corridors, where the detection is difficult.

[0006] 3. For bridges and high-rise buildings, the inspection of corrosion of some steel components is highly dangerous.

[0007] 4. The test results for the remaining load-bearing capacity of rusted steel in corroded structures are not very intuitive. Summary of the Invention

[0008] To address the problems of existing detection technologies and devices, this invention proposes an in-situ non-destructive testing device for rusted steel pipes capable of overcoming obstacles and a method for assessing residual load-bearing capacity. The device, through a processing module, automatically climbs and rotates according to preset working conditions, automatically scans and processes data, and automatically assesses parameters such as the residual load-bearing capacity of the tested component. This device can sense obstacles through sensors and control an electric sliding rail telescopic connecting bridge and climbing power wheel set to adapt to steel pipe components of different sizes, while also possessing a certain degree of obstacle-crossing capability.

[0009] To achieve the above-mentioned technical objectives, the technical solution adopted by this invention is as follows:

[0010] An in-situ non-destructive testing device for rusted steel pipes capable of overcoming obstacles, comprising:

[0011] The circular inspection vehicle is formed by connecting multiple arc-shaped inspection vehicle units end to end via electromagnetic interfaces. Each arc-shaped inspection vehicle unit is a double-layer frame structure with upper and lower working platforms. Each arc-shaped inspection vehicle unit is equipped with:

[0012] Axial climbing wheel set drives the arc-shaped inspection vehicle unit to move axially along the steel pipe;

[0013] A circumferentially rotating wheel assembly drives the arc-shaped inspection vehicle unit to rotate circumferentially along the steel pipe;

[0014] The electric sliding rail telescopic connecting bridge can extend and retract circumferentially along the arc-shaped inspection vehicle unit to adjust the diameter of the annular inspection vehicle, and has the function of controllable connection and disconnection with adjacent arc-shaped inspection vehicle units;

[0015] One electric telescopic pole is connected between the upper and lower layers of the arc-shaped inspection vehicle unit and is used to adjust the vertical distance between the two layers;

[0016] An obstacle detection sensor, mounted on the curved detection vehicle unit, is used to detect obstacles in the direction of travel.

[0017] The electromagnetic and ultrasonic scanning module, installed on the arc-shaped inspection vehicle unit, is used to acquire data on the oxide layer and remaining substrate thickness of the steel pipe.

[0018] The processing module, built into the arc-shaped inspection vehicle unit, is used to receive and process the scanning data from the electromagnetic and ultrasonic scanning modules;

[0019] The signal input terminal of the processing module is connected to the obstacle detection sensor and the electromagnetic and ultrasonic scanning module, and the signal output terminal is connected to the electromagnetic interface, the axial climbing wheel set, the circumferential rotating wheel set, the spacing adjustment mechanism, and the electric sliding rail telescopic connecting bridge.

[0020] The power module, built into the arc-shaped inspection vehicle unit, is used for global power supply.

[0021] Furthermore, both the axial climbing wheel assembly and the circumferential rotating wheel assembly include:

[0022] The second electric telescopic pole has its fixed end installed on the frame of the arc-shaped inspection vehicle unit, and its movable end extends radially toward the surface of the steel pipe.

[0023] An electric wheel is installed at the movable end of the electric telescopic rod and is driven to rotate by a built-in motor. It is used to contact the surface of the steel pipe and provide driving force.

[0024] A pressure sensor, either built into the electric wheel and the movable end or integrated into the electric telescopic rod, is used to detect the contact pressure between the electric wheel and the surface of the steel pipe and to feed the pressure signal back to the processing module.

[0025] The processing module controls the extension amount of the electric telescopic rod II according to the pressure signal to maintain the set contact pressure, and controls the electric telescopic rod II of the axial climbing wheel set and the circumferential rotating wheel set to extend and retract alternately.

[0026] Furthermore, it also includes a variable pressure cleaning module, which is detachably connected to the upper working platform of the arc-shaped inspection vehicle unit via an electromagnetic interface and a power supply and communication interface, and is used to grind, remove rust or clean the surface of the steel pipe to be tested.

[0027] The variable pressure cleaning module includes:

[0028] The module housing has an opening on the side facing the steel pipe surface;

[0029] The sweeping wheel is rotatably mounted inside the module housing, with its rim extending from the opening to contact the surface of the steel pipe, and is driven to rotate by a built-in motor;

[0030] An expansion joint, installed between the module housing and the arc-shaped detection vehicle unit, is used to drive the entire cleaning module to move radially along the steel pipe;

[0031] A shock-absorbing spring is disposed between the telescopic member and the module housing;

[0032] An air curtain outlet is located at the edge of the opening of the module housing and below the sweeping wheel. Its air outlet direction is towards the surface of the steel pipe to form an air curtain to prevent dust accumulation.

[0033] Furthermore, the electromagnetic and ultrasonic scanning module includes:

[0034] The module base plate is detachably connected to the lower working platform of the arc-shaped inspection vehicle unit through an electromagnetic interface and a power supply and communication interface, and the side facing the steel pipe surface is the inspection surface.

[0035] An array-type electromagnetic probe and a phased array ultrasonic probe are alternately arranged and embedded in the detection surface of the module substrate. The array-type electromagnetic probe is used to obtain the oxide layer thickness data of the steel pipe, and the phased array ultrasonic probe is used to obtain the remaining substrate thickness data of the steel pipe.

[0036] A water mist coupling agent slit is disposed on the detection surface of the module substrate, located on the upper and lower sides of the centerline area of ​​the alternately arranged probe area, for spraying water mist to provide a coupling environment for the ultrasonic probe.

[0037] Furthermore, the electric sliding rail telescopic connecting bridge includes:

[0038] The connecting bridge body is slidably mounted on a slide rail within the frame of the arc-shaped inspection vehicle unit;

[0039] A magnetic force generator is fixedly installed within the frame of the arc-shaped inspection vehicle unit to generate magnetic force.

[0040] A magnetic slider is slidably mounted on one side of the magnetic generator and fixedly connected to the connecting bridge body;

[0041] A flexible screw, bendable in configuration, has one end connected to the magnetized slider and the other end used to mate with a threaded hole on the connecting bridge of an adjacent arc-shaped detection vehicle unit;

[0042] The spring is retracted, with one end abutting against the magnetized slider and the other end abutting against the magnetic generator;

[0043] The motor is fixedly installed inside the frame of the arc-shaped detection vehicle unit, and its output shaft is connected to the flexible screw through a transmission gear set to drive the flexible screw to rotate in both directions.

[0044] A limiting block is fixedly installed within the frame of the arc-shaped detection vehicle unit to limit the extension and retraction of the magnetic slider or the connecting bridge body.

[0045] When the magnetic generator is powered on, it generates a magnetic field with the same polarity as the magnetized slider, thereby generating a repulsive force that drives the flexible screw and pushes the connecting bridge body to slide out along the slide rail. After sliding out into place, the motor drives the flexible screw to rotate in the forward direction, so that the end of the flexible screw is screwed into the threaded hole on the connecting bridge of the adjacent arc-shaped detection vehicle unit to achieve a fixed connection.

[0046] When disconnection is required, the motor drives the flexible screw to rotate in the opposite direction, causing the end of the flexible screw to unscrew out of the threaded hole. Then, the magnetic generator is de-energized, and the retraction spring drives the connecting bridge body to retract.

[0047] Furthermore, the spacing adjustment mechanism is an electric telescopic rod.

[0048] This invention further discloses a detection method based on the aforementioned obstacle-crossing non-destructive testing device for corroded steel pipes, comprising:

[0049] S1. Drive the circumferential rotating wheel group to make the device rotate around the steel pipe, and at the same time use the electromagnetic and ultrasonic scanning module to obtain the oxide layer and remaining substrate thickness data of the steel pipe.

[0050] S2. Drive the axial climbing wheel assembly to move the device a preset distance along the axial direction of the steel pipe, and repeat step S1 until the scanning of the preset range is completed.

[0051] S3. The processing module processes the acquired thickness data to generate a thickness distribution map.

[0052] Furthermore, the processing in step S3 includes: noise reduction of the scanned data, deduplication of overlapping regions, circumferential and axial interpolation fitting, and surface reconstruction.

[0053] This invention further discloses an obstacle-crossing method based on the aforementioned obstacle-crossing in-situ non-destructive testing device for corroded steel pipes, comprising:

[0054] T1. When the obstacle detection sensor detects an obstacle, the processing module controls the axial climbing wheel assembly to stop and controls the electric sliding rail telescopic connecting bridge to extend to expand the diameter of the ring detection vehicle. At the same time, it controls the orientation of the circumferential rotating wheel assembly adjustment device so that the electric sliding rail telescopic connecting bridge automatically disconnects after aligning with the gap of the obstacle.

[0055] T2. The processing module controls the spacing adjustment mechanism to increase the spacing between the upper and lower working platforms and drives the axial climbing wheel group so that the upper working platform climbs upward and crosses the obstacle first.

[0056] T3. After the upper working platform overcomes the obstacle, the processing module controls the electric sliding rail telescopic connecting bridge to reconnect and drives the axial climbing wheel group again, so that the lower working platform can climb upward and overcome the obstacle.

[0057] T4. After overcoming the obstacle, the processing module controls the spacing adjustment mechanism and the electric sliding rail telescopic connecting bridge to return to their original diameter, so that the diameter of the ring inspection vehicle is restored to its original diameter and re-fits the surface of the steel pipe.

[0058] Compared with existing equipment and technology, the present invention has the following beneficial effects:

[0059] First, this invention proposes an in-situ non-destructive testing device for rusted steel pipes that can overcome obstacles. It achieves active adjustment of the diameter of the ring-shaped testing vehicle and controllable connection / disconnection of adjacent testing vehicle units through an electric sliding rail telescopic connecting bridge. With the help of upper and lower working platforms and spacing adjustment mechanism, the device can automatically cross obstacles such as welds, flanges, and beams on the surface of the steel pipe, realizing full-coverage continuous testing of in-service steel pipes and overcoming the shortcomings of insufficient obstacle-crossing ability of traditional testing devices.

[0060] Secondly, this invention integrates an axial climbing wheel set and a circumferential rotating wheel set, enabling bidirectional movement of the steel pipe in both the axial and circumferential directions. Combined with an electromagnetic and ultrasonic composite scanning module, it can simultaneously acquire data on the thickness of the oxide layer and the remaining substrate thickness of the steel pipe. Through a processing module, it performs noise reduction, overlap removal, cubic spline fitting, and bicubic spline surface reconstruction to generate an intuitive thickness distribution map or a three-dimensional mesh model, thereby improving the detection accuracy and the visualization of the results.

[0061] Third, the variable pressure cleaning module and the electromagnetic and ultrasonic scanning module of the present invention are both modularly designed. They can be detachably installed on the upper or lower working platform of the arc-shaped inspection vehicle unit through the electromagnetic interface and the power supply and communication interface. Users can flexibly configure the cleaning and scanning functions according to engineering needs. The variable pressure cleaning module has three modes: cleaning, rust removal and grinding. The device has high applicability.

[0062] Fourth, this invention integrates automatic climbing, automatic obstacle crossing, automatic detection and data processing, and can be remotely controlled and managed, reducing the labor intensity and safety risks of manual inspection, and improving the efficiency and accuracy of rust detection. Attached Figure Description

[0063] Figure 1 This is a schematic diagram of the overall structure of an in-situ non-destructive testing device for rusted steel pipes that can overcome obstacles, according to the present invention.

[0064] The components include: 1. Arc-shaped inspection vehicle unit; 2. Variable pressure cleaning module; 3. Electromagnetic and ultrasonic scanning module;

[0065] Figure 2 This is a schematic diagram of the overall structure of the device of the present invention when it overcomes obstacles;

[0066] Figure 3 This is a schematic diagram of the arc-shaped detection vehicle unit of the present invention;

[0067] Among them: 4. Obstacle detection sensor; 5. Electric sliding rail telescopic connecting bridge; 6. Electromagnetic interface; 7. Power supply and communication interface; 8. Circumferential rotating wheel set; 9. Electric telescopic pole one; 10. Axial climbing wheel set;

[0068] Figure 4 This is a schematic diagram of the variable pressure cleaning module of the present invention;

[0069] Among them: 201, sweeping wheel; 202, air curtain outlet; 203, shock-absorbing spring; 204, telescopic device;

[0070] Figure 5 This is a schematic diagram of the backplate structure of the variable pressure cleaning module and the electromagnetic and ultrasonic scanning module of the present invention.

[0071] Figure 6This is a schematic diagram of the electromagnetic and ultrasonic scanning module of the present invention;

[0072] Among them: 301, water mist coupling agent slit; 302, array electromagnetic probe; 303, phased array ultrasonic probe; 304, water inlet;

[0073] Figure 7 This is a schematic diagram of the climbing power wheel of the present invention;

[0074] Among them: 11. Electric telescopic pole II; 12. Electric wheel;

[0075] Figure 8 This is a diagram of the internal structure of an electric sliding rail telescopic connecting bridge;

[0076] Among them: 501, connecting bridge body; 502, magnetic force generator; 503, retraction spring; 504, magnetized slider; 505, flexible screw; 506, flexible smooth rod;

[0077] Figure 9 This is a magnified view of the internal structure of the electric sliding rail telescopic connecting bridge;

[0078] Among them: 507, motor; 508, limit block;

[0079] Figure 10 This is a top view of the non-destructive testing device for in-situ corrosion of steel pipes that can overcome obstacles, under normal operating conditions.

[0080] Figure 11 This is a top view of the obstacle-crossing in-situ non-destructive testing device for rusted steel pipes according to the present invention under obstacle-crossing conditions.

[0081] Figure 12 This is a schematic diagram of the detection under normal working conditions of the obstacle-crossing in-situ non-destructive testing device for corroded steel pipes of the present invention.

[0082] Figure 13 This is a schematic diagram of the structure of the in-situ non-destructive testing device for rusted steel pipes that can overcome obstacles under obstacle-crossing conditions according to the present invention.

[0083] Figure 14 This is a schematic diagram illustrating the retention of data from the previously acquired circles during axial overlapping scanning. Detailed Implementation

[0084] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0085] I. Device Structure

[0086] refer to Figures 1-14A non-destructive testing device for in-situ corrosion-resistant steel pipes capable of overcoming obstacles is disclosed, comprising a ring-shaped testing vehicle. The ring-shaped testing vehicle is formed by connecting multiple arc-shaped testing vehicle units 1 end-to-end via electromagnetic interfaces 6. Each arc-shaped testing vehicle unit 1 is a double-layered frame structure with upper and lower working platforms. This embodiment takes a circular steel pipe and a circular steel pipe with obstacles as examples, employing four arc-shaped testing vehicle units connected together, with each arc-shaped testing vehicle unit equipped with electromagnetic and ultrasonic scanning modules 3.

[0087] The arc-shaped inspection vehicle unit 1 is equipped with an axial climbing wheel set 10 and a circumferential rotating wheel set 8. The axial climbing wheel set 10 drives the arc-shaped inspection vehicle unit to move axially along the steel pipe, and the circumferential rotating wheel set 8 drives the arc-shaped inspection vehicle unit to rotate circumferentially along the steel pipe. The wheel sets are controlled by the arc-shaped inspection vehicle unit. When the device climbs, the circumferential rotating wheel set 8 retracts, and when it reaches the desired position, the axial climbing wheel set 10 retracts. This alternating operation allows the device to complete the inspection.

[0088] like Figure 7 As shown, both the axial climbing wheel assembly 10 and the circumferential rotating wheel assembly 8 include: an electric telescopic rod (electric telescopic rod 11 in this embodiment), whose fixed end is mounted on the frame of the arc-shaped inspection vehicle unit 1, and whose movable end extends radially toward the surface of the steel pipe; an electric wheel 12, mounted on the movable end of the electric telescopic rod, driven to rotate by a built-in motor, used to contact the surface of the steel pipe and provide driving force; and a pressure sensor, built into the electric wheel 12 and the movable end (or integrated into the electric telescopic rod), used to detect the contact pressure between the electric wheel and the surface of the steel pipe, and to feed the pressure signal back to the processing module. The processing module controls the extension amount of the electric telescopic rod according to the pressure signal to maintain the set contact pressure, and controls the electric telescopic rods of the axial climbing wheel assembly 10 and the circumferential rotating wheel assembly 8 to extend and retract alternately.

[0089] Adjacent arc-shaped inspection vehicle units are connected by an electric sliding rail telescopic connecting bridge 5. For example... Figure 3 , Figure 8 , Figure 9As shown, the electric sliding rail telescopic connecting bridge 5 can extend and retract along the circumference of the arc-shaped inspection vehicle unit 1 to adjust the diameter of the annular inspection vehicle, and has the function of controllable connection and disconnection with adjacent arc-shaped inspection vehicle units. Its specific structure includes: a connecting bridge body 501, which is slidably mounted on a slide rail within the frame of the arc-shaped detection vehicle unit 1; a magnetic generator 502, which is fixedly mounted within the frame of the arc-shaped detection vehicle unit and used to generate magnetic force; a magnetized slider 504, which is slidably mounted on one side of the magnetic generator and fixedly connected to the connecting bridge body; a flexible screw 505 (a rubber screw is used in this embodiment), which is bendable, with one end connected to the magnetized slider and the other end used to mate with a threaded hole on the connecting bridge of an adjacent arc-shaped detection vehicle unit; a retraction spring 503, with one end abutting against the magnetized slider and the other end abutting against the magnetic generator 502; a motor 507, which is fixedly mounted within the frame of the arc-shaped detection vehicle unit, and whose output shaft is connected to the flexible screw via a transmission gear set to drive the flexible screw to rotate in both directions; and a limiting block 508, which is fixedly mounted within the frame of the arc-shaped detection vehicle unit and used to limit the extension and retraction stroke of the magnetized slider or the connecting bridge body. Both the magnetic generator 502 and the motor 507 are powered by the power module.

[0090] The working process of the electric sliding rail telescopic connecting bridge is as follows: when the magnetic generator is energized, it generates a repulsive force with the magnetized slider, driving the flexible screw and thus pushing the connecting bridge body to slide out along the slide rail; after sliding out to the correct position, the motor drives the flexible screw to rotate in the forward direction, so that the end of the flexible screw is screwed into the threaded hole on the connecting bridge of the adjacent arc-shaped detection vehicle unit, thus achieving a fixed connection; when it is necessary to disconnect the connection, the motor drives the flexible screw to rotate in the reverse direction, so that the end of the flexible screw is screwed out of the threaded hole, then the magnetic generator is de-energized, and the retraction spring drives the connecting bridge body to retract.

[0091] A spacing adjustment mechanism is provided between the upper and lower working platforms of the arc-shaped inspection vehicle unit. In this embodiment, the spacing adjustment mechanism is an electric telescopic rod 9, used to adjust the vertical spacing between the two platforms.

[0092] The curved detection vehicle unit is also equipped with an obstacle detection sensor 4 (in this embodiment, a lidar sensor) for detecting obstacles in the direction of travel. The obstacle detection sensor 4 is integrated with the curved detection vehicle unit, and the processing module controls the distance the curved detection vehicle unit climbs each time to ensure detection efficiency and stability. It is powered internally by a power module.

[0093] The electromagnetic and ultrasonic scanning module 3 is installed on the arc-shaped inspection vehicle unit and is used to acquire data on the oxide layer and remaining substrate thickness of the steel pipe. Figure 6As shown, the scanning module includes: a module base plate, detachably connected to the lower working platform of the arc-shaped inspection vehicle unit 1 via an electromagnetic interface 6 and a power supply and communication interface 7, with the side facing the steel pipe surface serving as the inspection surface; an array-type electromagnetic probe 302 and a phased array ultrasonic probe 303, alternately arranged and embedded within the inspection surface of the module base plate. The array-type electromagnetic probe is used to acquire data on the oxide layer thickness of the steel pipe, and the phased array ultrasonic probe is used to acquire data on the remaining substrate thickness of the steel pipe; and a water mist coupling agent slit 301, located on the inspection surface of the module base plate, situated above and below the centerline area of ​​the alternately arranged probe area, used to spray water mist to provide a coupling environment for the ultrasonic probe. The water mist coupling agent slit is supplied with water through the built-in water tank of the electromagnetic and ultrasonic scanning module 3, and the coupling agent is replenished through the water inlet 304. The coupling agent is converted into a mist through the slit and high-pressure conditions, working in conjunction with the phased array ultrasonic probe 303 to complete the measurement. The electromagnetic and ultrasonic scanning module 3 is mainly responsible for executing the scanning commands and response feedback of the arc-shaped inspection vehicle unit 1, and simultaneously packaging and transmitting the scanning data to the processing module.

[0094] In this embodiment, the flexible screw 505 is made of rubber.

[0095] In addition, the device also includes a variable pressure cleaning module 2 (optional), such as Figure 4 As shown. The variable pressure cleaning module is detachably connected to the upper working platform of the arc-shaped inspection vehicle unit 1 via electromagnetic interface 6 and power supply communication interface 7, and is used to grind, remove rust, or clean the surface of the steel pipe to be tested. Its specific structure includes: a module housing with an opening on the side facing the steel pipe surface; a sweeping wheel 201, rotatably mounted inside the module housing, with its rim extending from the opening to contact the steel pipe surface, and driven to rotate by a built-in motor; a telescopic device 204, installed between the module housing and the arc-shaped inspection vehicle unit, used to drive the entire cleaning module to move radially along the steel pipe; a shock-absorbing spring 203, disposed between the telescopic device and the module housing; and an air curtain outlet 202, disposed at the edge of the opening of the module housing and below the sweeping wheel, with its air outlet direction facing the steel pipe surface, used to form an air curtain to prevent dust accumulation.

[0096] The sweeping wheel 201 offers three modes: grinding, rust removal, and sweeping. The processing module switches between sweeping and rust removal modes by controlling the extension pressure of the telescopic device 204 and the rotational speed of the sweeping wheel; switching between rust removal and grinding modes is achieved by replacing the sweeping wheel with one of different materials (e.g., replacing it with a coarse grinding sweeping wheel). The air curtain outlet 202 reduces dust generated during sweeping from interfering with the device's operation; in conjunction with the water mist coupling agent slit 301, it achieves dust suppression during sweeping.

[0097] The processing module is built into the arc-shaped detection vehicle unit 1 and is used to receive and process scan data from the electromagnetic and ultrasonic scanning modules. The signal input terminal of the processing module is connected to the obstacle detection sensor 4 and the electromagnetic and ultrasonic scanning modules, and the signal output terminal is connected to the electromagnetic interface 6, the axial climbing wheel set 10, the circumferential rotating wheel set 8, the spacing adjustment mechanism (electric telescopic rod 9), and the electric sliding rail telescopic connecting bridge 5. The arc-shaped detection vehicle unit is charged through the power supply and communication interface 7, and is activated and connected via mobile or PC software using the built-in wireless connection chip.

[0098] The power module is built into the arc-shaped inspection vehicle unit and is used for global power supply.

[0099] The installation method of the in-situ non-destructive testing device for obstacle-crossing rusted steel pipes according to the present invention includes the following steps:

[0100] SA. Based on different working conditions, the arc-shaped inspection vehicle unit is started. The variable pressure cleaning module and the electromagnetic and ultrasonic scanning module are connected and fixed to the arc-shaped inspection vehicle unit through the electromagnetic interface and the power supply and communication interface, and communication is automatically established.

[0101] SB, according to the scanning and testing requirements, the arc-shaped testing vehicle units equipped with electromagnetic and ultrasonic scanning modules are connected end to end in sequence, and locked through the electromagnetic interfaces at both ends of the arc-shaped testing vehicle units, and the above-mentioned electric sliding rail telescopic connecting bridge is automatically connected.

[0102] The SC device automatically adapts to the outer diameter of the steel pipe to be tested through the electric sliding rail telescopic connecting bridge and the pressure adaptive function of the climbing power wheel set, so that the wheel set is closely attached to the outer surface of the steel pipe. After the arc-shaped detection vehicle units communicate with each other, the rotation distance (full circle, semi-circle, 1 / 4 circle, etc.) is automatically determined according to the number of electromagnetic and ultrasonic scanning modules connected and the outer diameter of the steel pipe to be tested.

[0103] II. Obstacle Overcoming Process

[0104] When the detection device encounters an obstacle during its ascent (see reference) Figure 2 , Figure 11 , Figure 13 The obstacle detection sensor 4 collects data, which is then processed by the processing module, which then executes the obstacle-crossing method.

[0105] First, the processing module controls the axial climbing wheel assembly to stop and controls the electric sliding rail telescopic connecting bridge 5 to extend, thus expanding the diameter of the ring detection vehicle. At the same time, it controls the circumferential rotating wheel assembly 8 to adjust the position of the device in the circumferential direction of the steel pipe, so that the electric sliding rail telescopic connecting bridge is aligned with the gap of the obstacle and automatically disconnects the connection (i.e., the motor drives the flexible screw to rotate in the opposite direction to unscrew the threaded hole, the magnetic generator is de-energized, and the retracting spring retracts the connecting bridge body).

[0106] Secondly, the processing module controls the spacing adjustment mechanism (electric telescopic rod 9) to increase the spacing between the upper and lower working platforms, and drives the axial climbing wheel assembly so that the upper working platform climbs upwards and crosses the obstacle first.

[0107] After the upper working platform overcomes the obstacle, the processing module controls the electric sliding rail telescopic connecting bridge to reconnect (i.e., the magnetic generator is energized to drive the flexible screw to extend and rotate in the forward direction to screw into the threaded hole), and drives the axial climbing wheel assembly again, so that the lower working platform can climb upward and overcome the obstacle.

[0108] After overcoming the obstacle, the processing module controls the spacing adjustment mechanism and the electric sliding rail telescopic connecting bridge to return to their original positions, so that the diameter of the ring inspection vehicle is restored to its original diameter, re-fits the surface of the steel pipe, and continues the inspection.

[0109] III. Detection Methods

[0110] The detection method of the present invention includes the following steps:

[0111] S1. Drive the circumferential rotating wheel group to make the device rotate around the steel pipe, and at the same time use the electromagnetic and ultrasonic scanning module to obtain data on the thickness of the steel pipe oxide layer and the thickness of the remaining steel substrate.

[0112] S2. Drive the axial climbing wheel assembly to move the device a preset distance along the axial direction of the steel pipe, and repeat step S1 until the scanning of the preset range is completed.

[0113] S3. The processing module processes the acquired thickness data to generate a thickness distribution map.

[0114] Data processing: The processing module performs preliminary noise reduction and impurity removal on the data packaged and sent by the electromagnetic and ultrasonic scanning modules: For the discrete point data obtained by each ring scan (each point includes circumferential angle θ, axial coordinate z, and thickness value T), a 3×3 median filter is used to remove isolated noise points; outliers exceeding ±3 times the mean of adjacent points are removed or corrected.

[0115] S301. To avoid missed scans or tomographic breaks in the scan data, local overlapping scans are performed during axial ascent. The overlapping region with the best signal-to-noise ratio is selected, calculated as follows:

[0116] (1) Overlap rate calculation:

[0117] ;

[0118] in,

[0119] η: Axial overlap rate, ranging from 10% to 50%;

[0120] W: Axial coverage width of the array probe (unit: mm);

[0121] L: The step distance (in mm) of the detection device in each climb, and L < W.

[0122] (2) Determination of overlapping intervals:

[0123] The axial coverage area of ​​the i-th scan is [Z i Z i +W], the (i+1)th cycle is [Z] i +L,Z i +L+W], then the overlapping interval is [Z i +L,Z i +W]. Among them, Z i Here is the axial coordinate (in mm) of the starting position of the i-th scan.

[0124] (3) Deduplication rules

[0125] For two data points at the same coordinate (θ, z) within the overlapping interval, calculate their signal-to-noise ratios (SNR1 and SNR2) respectively, and retain the one with the larger SNR. Here, θ is the circumferential angle (° or rad), and z is the axial coordinate (mm). If:

[0126] ;

[0127] The scan data of the first collected circle is retained, as shown in the diagram. Figure 14 As shown.

[0128] S302, Circumferential data fitting

[0129] For each fixed axial coordinate z, extract the discrete points of the circle to remove weight. , ), k=1,2,3…,n, where To measure the thickness, periodic cubic spline interpolation is used, with the spline function... In each sub-interval [ , The above is a cubic polynomial:

[0130] ;

[0131] Boundary conditions (periodic):

[0132] , ;

[0133] Solving for coefficients , , , Then, the continuous function T= is obtained. This allows us to obtain the thickness value at any circumferential angle, where...

[0134] : The circumferential angle (° or rad) of the kth discrete point;

[0135] : The thickness value (mm) corresponding to this point;

[0136] : Circumferential thickness distribution function;

[0137] S303, Axial Data Fitting

[0138] For each fixed circumferential angle θ, extract discrete points on that generatrix. T j ), j=1,2,3,…,m. Where T j To measure the thickness, cubic spline interpolation with natural boundaries is used. The spline function S(z) is applied in each subinterval [z]. k , z k+1 The above is a cubic polynomial:

[0139] ;

[0140] Boundary conditions (periodic):

[0141] , ;

[0142] Solving for coefficients , j , , Then, a continuous function T = S(z) is obtained, thus yielding the thickness value at any circumferential angle, where,

[0143] z j : The sampling coordinate of the j-th axis (mm);

[0144] T j : The thickness value (mm) corresponding to this point;

[0145] S(z): Axial thickness distribution function;

[0146] S304, Surface Reconstruction

[0147] All discrete points (θ) after deduplication i , z j T ij Using θ as input, a continuous two-dimensional surface T=H(θ,z) is constructed using bicubic spline interpolation. In each submatrix [θ... i , θ i+1 ]×[zj , z j+1 On the surface, the function form is:

[0148] ;

[0149] Where the coefficient The value is uniquely determined by discrete point values ​​and the continuity condition of the first and second-order mixed partial derivatives. The final output is a pseudo-color contour map or a 3D mesh model, which intuitively displays the thickness of the oxide layer and the remaining substrate of the steel, as well as the corrosion depth distribution curves.

[0150] θ i : The i-th circumferential sampling angle;

[0151] T ij : in (θ i , z j The thickness value (oxide layer or steel substrate) measured at ) ;

[0152] H(θ,z): Thickness distribution function of a two-dimensional continuous surface;

[0153] Preferably, after the above data processing, the processing module outputs the results (including two-dimensional surfaces, three-dimensional models, and preliminary detection reports) to a mobile terminal or web page via a wireless network for users to view and manage remotely.

[0154] Based on the operating requirements, after connecting the curved inspection vehicle unit 1, the variable pressure cleaning module 2, and the electromagnetic and ultrasonic scanning module 3 around the steel pipe to be tested, the operating terminal (APP) can be started to configure more detailed parameters, such as: the module to be started, the cleaning intensity, and the data types to be scanned. Then, the device can be started to perform detection. The variable pressure cleaning module 2 is mainly responsible for executing cleaning commands and responding to feedback. It does not have the function of collecting data, but it has the same bending capability as the curved inspection vehicle unit.

Claims

1. An in-situ non-destructive testing device for rusted steel pipes capable of overcoming obstacles, characterized in that, include: The circular inspection vehicle is formed by connecting multiple arc-shaped inspection vehicle units (1) end to end via electromagnetic interfaces. Each arc-shaped inspection vehicle unit is a double-layer frame structure with upper and lower working platforms. Each arc-shaped inspection vehicle unit (1) is equipped with: Axial climbing wheel assembly (10) drives the arc-shaped inspection vehicle unit (1) to move along the steel pipe axis; The circumferential rotating wheel set (8) drives the arc-shaped inspection vehicle unit (1) to rotate circumferentially along the steel pipe; The electric sliding rail telescopic connecting bridge (5) can extend and retract circumferentially along the arc-shaped inspection vehicle unit (1) to adjust the diameter of the ring inspection vehicle, and has the function of controllable connection and disconnection with the adjacent arc-shaped inspection vehicle unit; The spacing adjustment mechanism is connected between the upper and lower layers of the arc-shaped detection vehicle unit (1) and is used to adjust the vertical spacing between the two layers. An obstacle detection sensor (4) is installed on the arc-shaped detection vehicle unit (1) to detect obstacles in the direction of travel; The electromagnetic and ultrasonic scanning module is installed on the arc-shaped inspection vehicle unit (1) to obtain data on the oxide layer and remaining substrate thickness of the steel pipe; The processing module, built into the arc-shaped inspection vehicle unit (1), is used to receive and process the scanning data from the electromagnetic and ultrasonic scanning modules; The signal input end of the processing module is connected to the obstacle detection sensor (4) and the electromagnetic and ultrasonic scanning module, and the signal output end is connected to the electromagnetic interface, the axial climbing wheel group (10), the circumferential rotating wheel group (8), the spacing adjustment mechanism and the electric sliding rail telescopic connecting bridge (5). The power supply module is built into the arc-shaped detection vehicle unit (1) and is used for global power supply.

2. The obstacle-crossing in-situ non-destructive testing device for corroded steel pipes according to claim 1, characterized in that, Both the axial climbing wheel assembly (10) and the circumferential rotating wheel assembly (8) include: The electric telescopic pole 2 (11) has its fixed end installed on the frame of the arc-shaped detection vehicle unit (1) and its movable end extends radially toward the surface of the steel pipe. An electric wheel (12) is installed at the movable end of the electric telescopic rod (11) and is driven to rotate by a built-in motor to contact the surface of the steel pipe and provide driving force. A pressure sensor is built into the electric wheel (12) and the movable end of the electric telescopic rod (11) or integrated on the electric telescopic rod (11) to detect the contact pressure between the electric wheel (12) and the surface of the steel pipe and to feed the pressure signal back to the processing module. The processing module controls the extension amount of the electric telescopic rod two (11) according to the pressure signal to maintain the set contact pressure, and controls the electric telescopic rod two (11) of the axial climbing wheel set (10) and the circumferential rotating wheel set (8) to extend and retract alternately.

3. The obstacle-crossing in-situ non-destructive testing device for corroded steel pipes according to claim 1, characterized in that, It also includes a variable pressure cleaning module (2), which is detachably connected to the upper working platform of the arc-shaped inspection vehicle unit through an electromagnetic interface and a power supply and communication interface, and is used to grind, remove rust or clean the surface of the steel pipe to be tested; The variable pressure cleaning module (2) includes: The module housing has an opening on the side facing the steel pipe surface; The sweeping wheel (201) is rotatably mounted inside the module housing, with its rim extending from the opening to contact the surface of the steel pipe, and is driven to rotate by a built-in motor; The telescopic device (204) is installed between the module housing and the arc-shaped detection vehicle unit (1) to drive the entire cleaning module to move radially along the steel pipe; A shock-absorbing spring (203) is disposed between the telescopic member (204) and the module housing; An air curtain outlet (202) is located at the edge of the opening of the module housing and below the sweeping wheel (201), with its air outlet direction facing the surface of the steel pipe, in order to form an air curtain to prevent dust accumulation.

4. The obstacle-crossing in-situ non-destructive testing device for corroded steel pipes according to claim 1, characterized in that, The electromagnetic and ultrasonic scanning module includes: The module base plate is detachably connected to the lower working platform of the arc-shaped inspection vehicle unit (1) through an electromagnetic interface and a power supply and communication interface, and the side facing the steel pipe surface is the inspection surface; An array-type electromagnetic probe (302) and a phased array ultrasonic probe (303) are alternately arranged and embedded in the detection surface of the module substrate. The array-type electromagnetic probe (302) is used to acquire the oxide layer thickness data of the steel pipe, and the phased array ultrasonic probe (303) is used to acquire the remaining substrate thickness data of the steel pipe. A water mist coupling agent slit (301) is disposed on the detection surface of the module substrate, located on the upper and lower sides of the centerline area of ​​the alternating probe area, for spraying water mist to provide a coupling environment for the phased array ultrasonic probe (303).

5. The obstacle-crossing in-situ non-destructive testing device for corroded steel pipes according to claim 1, characterized in that, The electric sliding rail telescopic connecting bridge (5) includes: The connecting bridge body (501) is slidably mounted on a slide rail within the frame of the arc-shaped inspection vehicle unit (1); A magnetic force generator (502) is fixedly installed inside the frame of the arc-shaped detection vehicle unit (1) to generate magnetic force; The magnetic slider (504) is slidably mounted on one side of the magnetic generator (502) and fixedly connected to the connecting bridge body (501); The flexible screw (505) is bendably configured, with one end connected to the magnetic slider (504) and the other end used to mate with the threaded hole on the connecting bridge of the adjacent arc-shaped detection vehicle unit (1); The spring (503) is retracted, with one end abutting against the magnetized slider (504) and the other end abutting against the magnetic generator (502). The motor (507) is fixedly installed in the frame of the arc-shaped detection vehicle unit (1), and its output shaft is connected to the flexible screw (505) through a transmission gear set to drive the flexible screw (505) to rotate in both directions. The limiting block (508) is fixedly installed in the frame of the arc-shaped detection vehicle unit (1) to limit the extension and retraction stroke of the magnetic slider (504) or the connecting bridge body (501). When the magnetic generator (502) is powered on, it generates a magnetic field with the same polarity as the magnetized slider (504), thereby generating a repulsive force that drives the flexible screw (505) and pushes the connecting bridge body (501) to slide out along the slide rail. After sliding out into place, the motor drives the flexible screw (505) to rotate in the forward direction, so that the end of the flexible screw (505) is screwed into the threaded hole on the connecting bridge of the adjacent arc-shaped detection vehicle unit (1) to achieve a fixed connection. When disconnection is required, the motor drives the flexible screw (505) to rotate in the opposite direction, causing the end of the flexible screw (505) to unscrew out of the threaded hole. Then, the magnetic generator (502) is de-energized, and the retraction spring (503) drives the connecting bridge body (501) to retract.

6. The obstacle-crossing in-situ non-destructive testing device for corroded steel pipes according to claim 1, characterized in that, The spacing adjustment mechanism is an electric telescopic rod (9).

7. A detection method for an in-situ non-destructive testing device for rusted steel pipes capable of overcoming obstacles as described in any one of claims 1 to 6, characterized in that, include: S1. Drive the circumferential rotating wheel group to make the device rotate around the steel pipe, and at the same time use the electromagnetic and ultrasonic scanning module to obtain the oxide layer and remaining substrate thickness data of the steel pipe. S2. Drive the axial climbing wheel assembly to move the device a preset distance along the axial direction of the steel pipe, and repeat step S1 until the scanning of the preset range is completed. S3. The processing module processes the acquired thickness data to generate a thickness distribution map.

8. The detection method according to claim 7, characterized in that, The processing in step S3 includes: noise reduction of the scanned data, deduplication of overlapping regions, circumferential and axial interpolation fitting, and surface reconstruction.

9. A method for overcoming obstacles based on the in-situ non-destructive testing device for rusted steel pipes capable of overcoming obstacles as described in any one of claims 1 to 6, characterized in that, include: T1. When the obstacle detection sensor (4) detects an obstacle, the processing module controls the axial climbing wheel assembly (10) to stop and controls the electric sliding rail telescopic connecting bridge (5) to extend to expand the diameter of the ring detection vehicle. At the same time, it controls the circumferential rotating wheel assembly (8) to adjust the orientation of the device so that the electric sliding rail telescopic connecting bridge (5) automatically disconnects after aligning with the gap of the obstacle. T2. The processing module controls the spacing adjustment mechanism to increase the spacing between the upper and lower working platforms and drives the axial climbing wheel group (10) so that the upper working platform climbs upward and crosses the obstacle first. T3. After the upper working platform overcomes the obstacle, the processing module controls the electric sliding rail telescopic connecting bridge (5) to reconnect and drives the axial climbing wheel group (10) again, so that the lower working platform can climb upward and overcome the obstacle. T4. After overcoming the obstacle, the processing module controls the spacing adjustment mechanism and the electric sliding rail telescopic connecting bridge (5) to restore the diameter of the ring detection vehicle to its original diameter and re-fit the surface of the steel pipe.

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