Large-diameter stainless steel pipe automatic ultrasonic flaw detection device and method

Abstract

The application discloses a large-diameter stainless steel pipe automatic ultrasonic flaw detection device and method, wherein the device comprises a rack, a detection box for containing liquid medium for detection, a detection carrier plate driven by a lifting driving mechanism to move up and down between a contact detection position and a water immersion detection position, a pipe supporting mechanism comprising a supporting roller group and a pipe supporting driving mechanism, a feeding mechanism, and a detection switching mechanism comprising an ultrasonic probe module and a detection driving mechanism for driving the ultrasonic probe module to move, wherein the ultrasonic probe module comprises a first probe group, a second probe group and a switching driving assembly. The application can adopt a suitable detection mode for ultrasonic flaw detection according to actual detection needs, and can realize combined detection of the two modes without replacing equipment, simplifying the operation process, and further improving the accuracy and reliability of the detection results.

Description

Technical Field

[0001] This invention relates to the field of steel pipe processing technology, and in particular to an automated ultrasonic flaw detection device and method for large-diameter stainless steel pipes. Background Technology

[0002] Currently, stainless steel pipes are widely used in various industries such as petroleum, chemical, power, marine engineering, construction, and transportation. Ultrasonic testing is an essential inspection process after stainless steel pipe processing. Its core principle is that when ultrasonic waves propagate through the pipe, they encounter discontinuous defects such as cracks, pores, inclusions, or internal and external walls. Due to changes in acoustic impedance, some sound waves are reflected, scattered, or attenuated. By receiving these echo signals with a probe and analyzing their amplitude, propagation time (sound path), and waveform characteristics, the presence, location, size, and equivalent of the defect can be determined. Through ultrasonic testing, defects in stainless steel pipes can be detected promptly, ensuring the quality of the stainless steel pipes leaving the factory.

[0003] Ultrasonic testing methods typically include: 1) Contact method: The ultrasonic probe directly contacts the pipe wall via a coupling agent (such as glycerin) or a delay block to emit and receive ultrasonic waves. Defects are determined by analyzing the received ultrasonic waves; 2) Water immersion method: The stainless steel pipe to be tested is immersed in water or a stable water column is formed. The sound beam is incident on the pipe wall at an angle through the water, mainly generating transverse waves for detection. Existing ultrasonic flaw detection methods usually only support one type of inspection. However, in practical applications, it may be necessary to combine two methods. For example, the water immersion method may be used for initial inspection, followed by the contact method for precise local re-inspection; or different inspection methods may be used for different batches or applications of stainless steel pipes. Especially for large-diameter stainless steel pipes, different inspection methods need to be combined to ensure the reliability of the test results. Currently, both methods need to be tested on different testing equipment, which is a relatively cumbersome operation. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the purpose of this invention is to provide an automated ultrasonic flaw detection device and method for large-diameter stainless steel pipes, which can effectively combine the two methods to improve efficiency.

[0005] The objective of this invention is achieved through the following technical solution: According to a first aspect of the present disclosure, an automated ultrasonic flaw detection device for large-diameter stainless steel pipes is provided, comprising: The frame is provided with a loading area for placing steel pipes to be tested and a unloading area for placing steel pipes that have been tested. The detection chamber, which is supported on the frame and used to hold the liquid medium for detection, has a contact detection position near the top of the detection chamber and a water immersion detection position near the bottom of the detection chamber; The detection carrier plate, which is supported on the detection box, is driven by a lifting drive mechanism to move up and down between the contact detection position and the water immersion detection position. The support mechanism, which is supported on the detection carrier plate and used to support the steel pipe to be tested and drive the steel pipe to be tested to rotate, includes: a support roller group for supporting the steel pipe to be tested, and a support drive mechanism for driving the support roller group to rotate. A feeding mechanism supported on the frame for transferring the steel pipe to be tested from the loading area to the hosting mechanism or from the hosting mechanism to the unloading area; and... The detection switching mechanism supported on the frame includes: an ultrasonic probe module and a detection drive mechanism for driving the ultrasonic probe module to move to a predetermined position for ultrasonic flaw detection. The ultrasonic probe module includes: a first probe group for performing contact detection, a second probe group for performing water immersion detection, and a switching drive component, which drives the first probe group and the second probe group to switch between a detection position for performing detection and a avoidance position for performing avoidance.

[0006] To achieve the above technical solution, when performing ultrasonic flaw detection, the detection carrier plate is initially located at the contact detection position to facilitate the feeding of steel pipes. The feeding mechanism moves the steel pipe to be tested from the feeding area to the support mechanism and places it on the support roller group, thus completing the feeding process. The specific testing method is determined according to the testing requirements of the steel pipe to be tested. Simultaneously, the testing position of the ultrasonic probe module is determined based on the size of the steel pipe. If contact ultrasonic testing is required, the first probe group is switched to the testing position by the switching drive assembly. At this time, the second probe group is in the avoidance position and will not affect the testing process. The lifting drive mechanism keeps the testing plate in the contact testing position, and the testing drive mechanism drives the first probe group to move to the predetermined testing position and align it with the steel pipe to be tested, thus completing the testing positioning process. If immersion ultrasonic testing is required, the second probe group is switched to the testing position by the switching drive assembly. At this time, the first probe group is in the avoidance position and will not affect the testing process. The lifting drive mechanism lowers the testing plate to the immersion testing position, and the testing drive mechanism drives the second probe group to move to the predetermined testing position and immerse it in the testing liquid medium, thus completing the testing positioning process. During the inspection process, the support roller group is driven to rotate by the host drive mechanism, which in turn drives the steel pipe to be inspected to rotate slowly. At the same time, the inspection drive mechanism drives the ultrasonic probe module to move along the axial direction of the steel pipe to perform scanning inspection. The ultrasonic probe module emits ultrasonic detection signals to the steel pipe and receives echo signals, thereby realizing the online inspection process of the steel pipe. The inspection is completed by moving the ultrasonic probe module from one end of the steel pipe to the other end. If it is necessary to perform the two inspection methods in sequence, the second inspection positioning and scanning inspection can be performed again after the first inspection is completed. After the inspection is completed, the lifting drive mechanism controls the inspection plate to return to the contact inspection position, and the feeding mechanism moves the steel pipe from the support roller group to the unloading area, thus completing the unloading process. This invention can perform ultrasonic flaw detection by adopting appropriate detection methods according to actual detection needs, and can achieve a combination of two methods without changing equipment, simplifying the operation process. Furthermore, the combined detection method can further improve the accuracy and reliability of the detection results.

[0007] In some exemplary embodiments, a feeding conveyor line is provided at the feeding area, and a first positioning plate is provided on the feeding conveyor line. The first positioning plate is provided with a first positioning groove for restricting the rolling of the steel pipe. The unloading area is provided with an unloading conveyor line, and the unloading conveyor line is provided with a second positioning carrier plate, and the second positioning carrier plate is provided with a second positioning groove for restricting the rolling of the steel pipe.

[0008] The above technical solution facilitates the loading and unloading of steel pipes and ensures the stability of the steel pipes during placement.

[0009] In some exemplary embodiments, the lifting drive mechanism is selected individually or in combination from the following structures: a lead screw drive mechanism or a sprocket drive mechanism.

[0010] In some exemplary embodiments, the support roller assembly includes: A rotating active roller is mounted on the detection carrier plate. This active roller is driven by the support drive mechanism and is used to form a friction drive with the steel pipe to be detected. A driven roller, which is rotatably mounted on the detection carrier plate, is used to support the steel pipe to be detected and rotates with the steel pipe to be detected.

[0011] To achieve the above technical solution, when the steel pipe to be tested is placed on the support roller group, it is supported by both the active and driven rollers. At this time, a stable frictional force is formed between the steel pipe to be tested and the active and driven rollers. The active roller is driven to rotate by the support roller drive mechanism, and the frictional force between the two can drive the steel pipe to rotate synchronously. The driven roller follows the rotation of the steel pipe to be tested and always plays the role of support, thus facilitating comprehensive testing of the steel pipe.

[0012] In some exemplary embodiments, the managed drive mechanism includes: a first managed drive motor disposed near the top of the detection box, and a second managed drive motor disposed near the bottom of the detection box; The power output shafts of the first and second host drive motors pass into the detection box, and the active idler roller is provided with drive grooves that are adapted to the power output shafts of the first and second host drive motors. When the detection carrier plate is located at the contact detection position, the power output shaft of the first drive motor is inserted into the drive slot and is concentrically arranged. When the detection carrier plate is located at the water immersion detection position, the power output shaft of the second drive motor is inserted into the drive slot and is concentrically arranged.

[0013] To achieve the above technical solution, the first and second drive motors are placed on the outside of the detection box, which saves internal space in the detection box without having to consider the waterproofness of the drive mechanism. By setting drive grooves on the active roller, drive connections are achieved at the contact detection position and the water immersion detection position, respectively.

[0014] In some exemplary embodiments, the driven roller is slidably mounted to the detection carrier plate via a driven bearing seat. The driven roller is slidable relative to the driving roller to adjust the support gap, and the driven bearing seat is provided with sliding fasteners for locking and fixing relative to the detection carrier plate.

[0015] By implementing the above technical solution, the position of the driven roller can be adjusted according to the size of the steel pipe to be tested, thereby meeting the support requirements of steel pipes of different sizes.

[0016] In some exemplary embodiments, the feeding mechanism includes: Clamping and lifting tools are used to clamp and lift steel pipes; A clamping drive module is used to drive the clamping lifting device to move up and down to clamp or release the steel pipe; The feeding drive module is used to drive the clamping and lifting device to reciprocate in order to transfer the steel pipe.

[0017] To achieve the above technical solution, during loading and unloading, the clamping drive module first lowers the steel pipe to a predetermined position, then the clamping lifting device clamps and fixes it. Subsequently, the clamping drive module drives the clamping lifting device and the steel pipe to rise a certain distance. Then, the feeding drive module drives the clamping lifting device and the steel pipe to move to the support roller group or unloading area. The clamping drive module then drives the clamping lifting device to descend, and the clamping lifting device releases the steel pipe, thus completing the loading and unloading process of the steel pipe.

[0018] In some exemplary embodiments, the switching drive assembly includes: a switching drive member and a switching mounting block fixed to the power output end of the switching drive member, wherein the first probe group and the second probe group are respectively mounted on two adjacent or opposite sides of the switching mounting block, and the switching drive member drives the switching mounting block to rotate to switch the positions of the first probe group and the second probe group.

[0019] To achieve the above technical solution, the position switching of the first probe group and the second probe group can be realized by switching the driving component to drive the mounting block to rotate by a predetermined angle.

[0020] In some exemplary embodiments, the detection driving mechanism includes: A height adjustment drive module is used to drive the switching drive component to move up and down to adjust the detection height; A scanning drive module is used to drive the switching drive component to reciprocate along the axial direction of the steel pipe to achieve scanning detection; and... A lateral drive module is used to drive the height adjustment drive module and the feeding drive module to move in the same direction to avoid the feeding mechanism.

[0021] To achieve the above technical solution, the height adjustment drive module controls the height position of the switching drive component and the ultrasonic probe module according to the determined detection position. The scanning drive module drives the switching drive component and the ultrasonic probe module to move along the axial direction of the steel pipe, thereby realizing the scanning and detection of the entire steel pipe. The lateral drive module can adjust the position of the height adjustment drive module and the ultrasonic probe module, thereby avoiding the feeding mechanism or adjusting the lateral position of the detection.

[0022] According to a second aspect of the present disclosure, an automated ultrasonic flaw detection method for large-diameter stainless steel pipes is provided, the method being implemented based on the apparatus described in the first aspect, comprising: The feeding mechanism transfers the steel pipe to be inspected from the loading area to the support roller assembly; The detection mode is determined according to the detection requirements, and the detection position of the ultrasonic probe module is determined according to the size of the steel pipe to be tested. The detection modes include contact detection mode and water immersion detection mode. If the contact detection mode is determined to be adopted, the lifting drive mechanism controls the detection plate to remain at the contact detection position, the switching drive component controls the first probe group to switch to the detection position, and the detection drive mechanism drives the first probe group to move to the predetermined detection position to fit against the steel pipe to be detected. If the water immersion detection mode is selected, the lifting drive mechanism controls the detection carrier plate to descend to the water immersion detection position, the switching drive component controls the second probe group to switch to the detection position, and the detection drive mechanism drives the second probe group to move to the predetermined detection position and immerse it in the detection liquid medium. The support roller group is driven to rotate to slowly rotate the steel pipe to be tested, and the detection drive mechanism drives the ultrasonic probe module to move along the axial direction of the steel pipe to be tested for scanning and detection. After the inspection is completed, the feeding mechanism will transfer the steel pipe from the support roller group to the unloading area.

[0023] By implementing the above technical solution and through the above process, appropriate testing methods can be used for ultrasonic flaw detection according to actual testing needs, and two methods can be combined for testing without changing equipment, simplifying the operation process. Furthermore, the combined testing method can further improve the accuracy and reliability of the test results.

[0024] In summary, compared with the prior art, the present invention has the following beneficial effects: This invention provides an automated ultrasonic flaw detection device and method for large-diameter stainless steel pipes. During ultrasonic flaw detection, the initial state is such that the detection carrier plate is in the contact detection position to facilitate pipe loading. The feeding mechanism moves the pipe to be tested from the loading area to the support mechanism and places it on the support roller group, thus completing the loading process. The specific detection method is determined according to the detection requirements of the pipe, and the detection position of the ultrasonic probe module is determined according to the size of the pipe. If contact ultrasonic flaw detection is required, the first probe group is switched to the detection position by the switching drive assembly. At this time, the second probe group is in the avoidance position and will not affect the detection process. The lifting drive mechanism keeps the detection carrier plate in the contact detection position, and the detection drive mechanism drives the first probe group to move to the predetermined detection position to fit against the pipe, thus completing the detection positioning process. If water immersion ultrasonic flaw detection is required, the second probe group is switched to the detection position by the switching drive assembly. At this time, the first probe group is in the avoidance position and will not affect the detection process. The lifting drive mechanism lowers the detection carrier plate to the water immersion detection position, and the detection... The drive mechanism moves the second probe group to the predetermined detection position and immerses it in the detection liquid medium, thus completing the detection positioning process. During the detection process, the support roller group is driven to rotate by the support drive mechanism, which in turn drives the steel pipe to be tested to rotate slowly. At the same time, the detection drive mechanism drives the ultrasonic probe module to move along the axial direction of the steel pipe to perform scanning detection. The ultrasonic probe module emits ultrasonic detection signals to the steel pipe and receives echo signals, thereby realizing the online detection process of the steel pipe. The detection is completed by moving the ultrasonic probe module from one end of the steel pipe to the other. If it is necessary to perform the two detection methods in sequence, the second detection positioning and scanning detection can be performed again after the first detection is completed. After the detection is completed, the lifting drive mechanism controls the detection carrier plate to return to the contact detection position, and the feeding mechanism moves the steel pipe from the support roller group to the unloading area, thus completing the unloading process. This invention can use appropriate detection methods for ultrasonic flaw detection according to actual detection needs, and can realize the combination of two detection methods without changing equipment, simplifying the operation process. Moreover, the combined detection method can further improve the accuracy and reliability of the detection results. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of the automated ultrasonic flaw detection device for large-diameter stainless steel pipes in an embodiment of the present invention.

[0026] Figure 2 This is a schematic diagram of another embodiment of the automated ultrasonic flaw detection device for large-diameter stainless steel pipes in this invention.

[0027] Figure 3 This is a schematic diagram of the structure of the detection box, detection carrier plate and hosting mechanism in an embodiment of the present invention.

[0028] Figure 4This is a top view of the detection carrier plate and the support roller assembly in an embodiment of the present invention.

[0029] Figure 5 This is a schematic diagram of the assembly structure of the first host drive motor and the active idler roller in an embodiment of the present invention.

[0030] Figure 6 This is a schematic diagram of the detection switching mechanism in an embodiment of the present invention.

[0031] The numbers and letters in the diagram represent the names of the corresponding components: 10. Frame; 11. Feeding conveyor line; 12. First positioning carrier plate; 13. First positioning groove; 14. Unloading conveyor line; 15. Second positioning carrier plate; 16. Second positioning groove; 20. Detection box; 30. Detection carrier plate; 31. Lifting drive mechanism; 40. Hosting mechanism; 41. Support roller group; 411. Drive roller; 4111. Drive groove; 412. Driven roller; 4121. Driven bearing seat; 4122. Sliding fastener; 42. Hosting drive mechanism; 421. First hosting drive mechanism 422. Second drive motor; 50. Feeding mechanism; 51. Clamping and lifting device; 52. Clamping drive module; 53. Feeding drive module; 60. Detection switching mechanism; 61. Ultrasonic probe module; 611. First probe group; 612. Second probe group; 613. Switching drive assembly; 6131. ​​Switching drive component; 6132. Switching mounting block; 62. Detection drive mechanism; 621. Height adjustment drive module; 622. Scanning drive module; 623. Lateral drive module. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] like Figures 1 to 6As shown, the first aspect of the present invention provides an automated ultrasonic flaw detection device for large-diameter stainless steel pipes, comprising: a frame 10, wherein the frame 10 is provided with a loading area for placing steel pipes to be tested and a unloading area for placing steel pipes that have been tested; a detection box 20 supported on the frame 10 for holding a liquid medium for testing, wherein a contact detection position is formed near the top of the detection box 20 and a water immersion detection position is formed near the bottom of the detection box 20; a detection carrier plate 30 supported on the detection box 20, wherein the detection carrier plate 30 is driven by a lifting drive mechanism 31 to move up and down between the contact detection position and the water immersion detection position; a support mechanism 40 supported on the detection carrier plate 30 for supporting the steel pipes to be tested and driving the steel pipes to be tested to rotate; a feeding mechanism 50 supported on the frame 10 for transferring the steel pipes to be tested from the loading area to the support mechanism 40 or from the support mechanism 40 to the unloading area; and a detection switching mechanism 60 supported on the frame 10.

[0034] Specifically, a feeding conveyor line 11 is provided in the feeding area. A first positioning carrier plate 12 is provided on the feeding conveyor line 11. A first positioning groove 13 for restricting the rolling of the steel pipe is provided on the first positioning carrier plate 12. The feeding conveyor line 11 can be an existing chain conveyor line. Multiple sets of first positioning carrier plates 12 are evenly distributed on the feeding conveyor line 11. Each set includes at least two first positioning carrier plates 12 arranged side by side and spaced at a certain distance, so as to support at least two positions on the steel pipe and realize the stable placement of the steel pipe. The first positioning carrier plate 12 is supported by the feeding conveyor line 11 and driven by the feeding conveyor line 11 to circulate and move, so as to move the steel pipe to the feeding position for convenient steel pipe feeding. The first positioning groove 13 is preferably set as an arc groove or a V-shaped groove, so as to meet the restriction requirements of steel pipes of different sizes.

[0035] A feeding conveyor line 14 is provided at the feeding area. A second positioning carrier plate 15 is provided on the feeding conveyor line 14. A second positioning groove 16 for restricting the rolling of the steel pipe is provided on the second positioning carrier plate 15. Similarly, the feeding conveyor line 14 can also be an existing chain conveyor line. Multiple sets of second positioning carrier plates 15 are evenly distributed on the feeding conveyor line 14. Each set includes at least two second positioning carrier plates 15 arranged side by side and spaced at a certain distance, so as to support at least two positions on the steel pipe and realize the stable placement of the steel pipe. The second positioning carrier plate 15 is supported by the feeding conveyor line 14 and driven by the feeding conveyor line 14 to circulate and move, so as to move the steel pipe to the feeding position for easy feeding. The second positioning groove 16 is also preferably set as an arc groove or a V-shaped groove, so as to meet the restriction requirements of steel pipes of different sizes.

[0036] like Figure 1 As shown, the feeding conveyor line 11 and the unloading conveyor line 14 can be set on opposite sides of the inspection box 20. In this case, the feeding conveyor line 11 can be set at the same height as the unloading conveyor line 14 to facilitate the unloading of steel pipes; or, as shown... Figure 2As shown, in another embodiment, the feeding conveyor line 11 and the unloading conveyor line 14 can also be arranged on the same side and stacked vertically. Preferably, the feeding conveyor line 11 is located on top and the unloading conveyor line 14 is located on top. In this case, the feeding conveyor area should be spaced sufficiently apart from the inspection box 20, while the unloading conveyor line 14 is arranged close to the inspection box 20 so that the steel pipe is placed on the unloading conveyor line 14 when it is unloaded. The length of the unloading conveyor line 14 should be greater than that of the feeding conveyor line 11 and extend beyond the feeding conveyor line 11 so that the steel pipe after inspection can be removed later.

[0037] The testing box 20 is typically set to be roughly the same height as the feeding conveyor line 11, and the total depth inside the testing box 20 should be at least 1.5-2 times the maximum diameter of the steel pipe to be tested, to ensure sufficient immersion depth during water immersion testing. The testing liquid medium can be water or other liquids that meet the testing requirements. Furthermore, the testing box 20 can also be equipped with a drainage mechanism and a water replenishment mechanism. The drainage device can be, for example, a drainage pipe with a drainage valve connected to the bottom of the testing box 20. The water replenishment mechanism can be, for example, a water replenishment pipe with a water replenishment valve connected to the top of the testing box 20 and connected to the water replenishment device. The water replenishment device can be, for example, a conventional device such as a water replenishment pump. Usually, before testing, the water replenishment device injects a predetermined level of liquid medium into the testing box 20.

[0038] The detection carrier plate 30 is slidably assembled in the detection box 20 along the vertical direction, and the detection carrier plate 30 is provided with several water channels to reduce water resistance generated during descent. It is understood that, while ensuring the structural strength and installation requirements of the detection carrier plate 30, as many water channels as possible should be provided. To enhance the structural strength of the detection carrier plate 30, several reinforcing ribs can also be provided at the bottom of the detection carrier plate 30. It is understood that the contact detection position and the water immersion detection position are two predetermined height positions for matching contact detection and water immersion detection. The contact detection position should be in a liquid-free state. Usually, the highest position of the detection carrier plate 30 is set as the contact detection position, and the lowest position of the detection carrier plate 30 is set as the water immersion detection position.

[0039] To meet the heavy-load requirements of large-diameter stainless steel pipes, the lifting drive mechanism 31 can be selected individually or in combination from the following structures: a screw drive mechanism or a sprocket drive mechanism. In this embodiment, the lifting drive mechanism 31 adopts a screw drive mechanism. The detection plate 30 is slidably assembled on the detection box 20 through several guide columns. The screw drive mechanism includes: a lifting motor, a vertically arranged transmission screw connected to the lifting motor, and a screw nut fixed to the detection plate 30 and threadedly connected to the transmission screw. The lifting motor can be set outside the detection box 20, and its power output shaft passes through the detection box 20 and transmits power to the transmission screw through a bevel gear set. Preferably, two sets of the screw drive mechanism are symmetrically arranged to ensure sufficient driving force and lifting stability.

[0040] The support mechanism 40 includes: a support roller group 41 for supporting the steel pipe to be tested, and a support drive mechanism 42 for driving the support roller group 41 to rotate.

[0041] Specifically, the support roller assembly 41 includes: an active support roller 411 rotatably mounted on the detection carrier plate 30, the active support roller 411 being drivenly connected to the support drive mechanism 42 and used to form friction transmission with the steel pipe to be detected; and a driven support roller 412 rotatably mounted on the detection carrier plate 30, used to support the steel pipe to be detected and follow the rotation of the steel pipe to be detected.

[0042] The active idler roller 411 and the driven idler roller 412 may be covered with a rubber layer or multiple rubber rollers may be provided to ensure sufficient friction between them and the steel pipe to be tested. It should be noted that the active idler roller 411 and the driven idler roller 412 should have sufficient rigidity to meet the load-bearing requirements. Both the active idler roller 411 and the driven idler roller 412 can be rotatably connected to the testing carrier plate 30 through bearing seats.

[0043] When the steel pipe to be inspected is placed on the support roller group 41, it is supported by the active roller 411 and the driven roller 412 simultaneously. At this time, a stable frictional force is formed between the steel pipe to be inspected and the active roller 411 and the driven roller 412. The active roller 411 is driven to rotate by the support roller drive mechanism 42. The frictional force between the two can drive the steel pipe to rotate synchronously. The driven roller 412 follows the rotation of the steel pipe to be inspected and always plays the role of support, thus facilitating the comprehensive inspection of the steel pipe.

[0044] The drive mechanism 42 includes a first drive motor 421 located near the top of the detection box 20 and a second drive motor 422 located near the bottom of the detection box 20. Both the first drive motor 421 and the second drive motor 422 can be fixed on the outside of the detection box 20. The power output shafts of the first drive motor 421 and the second drive motor 422 pass into the detection box 20 and are provided with drive grooves 4111 on the active roller 411 that are adapted to the power output shafts of the first drive motor 421 and the second drive motor 422. When the detection plate 30 is in the contact detection position, the power output shaft of the first drive motor 421 is inserted into the drive groove 4111 and is concentrically arranged. When the detection plate 30 is in the water immersion detection position, the power output shaft of the second drive motor 422 is inserted into the drive groove 4111 and is concentrically arranged.

[0045] In this embodiment, the drive groove 4111 is a C-shaped through groove, and the end of the power output shaft of the first drive motor 421 and the second drive motor 422 that extends into the detection box 20 is oval. When the first drive motor 421 and the second drive motor 422 are not running, the oval shape on their power output shafts is vertical so as to be able to be inserted and cooperate with the drive groove 4111. For example, the angle of the power output shaft of the first drive motor 421 and the second drive motor 422 when they are not running can be controlled by an encoder. Of course, in some embodiments, a waterproof motor that is directly connected to the drive roller 411 can also be fixed on the detection carrier plate 30.

[0046] The first host drive motor 421 and the second host drive motor 422 are set on the outside of the detection box 20. This saves internal space in the detection box 20 without having to consider the waterproofness of the host drive mechanism 42. By setting a drive groove 4111 on the active roller 411, drive connection is achieved at the contact detection position and the water immersion detection position respectively.

[0047] Furthermore, the driven roller 412 is slidably mounted on the detection carrier plate 30 via the driven bearing housing 4121. The driven roller 412 can slide relative to the driving roller 411 to adjust the support gap. The driven bearing housing 4121 is provided with a sliding fastener 4122 for locking and fixing relative to the detection carrier plate 30. This sliding fastener 4122 can be, for example, a bolt. The sliding fastener 4122 can be threaded to the driven bearing housing 4121 and abut against the detection carrier plate 30 to fix the driven roller by abutment. The bearing housing 4121 can also have several threaded positioning holes on the detection carrier plate 30. The sliding fastener 4122 passes through the driven bearing housing 4121 and is threadedly connected to the threaded positioning holes. Thus, when connected to different threaded positioning holes, different support gaps can be defined. The support gap is the distance between the active roller 411 and the driven roller 412. By setting the driven roller 412 to be slidingly adjustable, the position of the driven roller 412 can be adjusted according to the size of the steel pipe to be detected, so as to meet the support requirements of steel pipes of different sizes.

[0048] The feeding mechanism 50 includes: a clamping and lifting device 51 for clamping and lifting steel pipes; a clamping drive module 52 for driving the clamping and lifting device 51 to move up and down to clamp or release the steel pipes; and a feeding drive module 53 for driving the clamping and lifting device 51 to move back and forth to transfer the steel pipes.

[0049] Specifically, the clamping and lifting device 51 can be, for example, an electric hoist, an electric clamp, or other devices capable of clamping steel pipes. In this embodiment, an electric clamp is used. The electric clamp includes an electric telescopic cylinder and a jaw connected to the power output end of the electric telescopic cylinder. The jaw is an arc-shaped jaw that can open and close to fit the steel pipe. The telescopic movement of the electric telescopic cylinder can drive the jaw to open and close, thereby clamping or releasing the steel pipe. The electric clamp can use an existing structure, which will not be described in detail here. Usually, to ensure the stability of clamping, two or more sets of clamping and lifting devices 51 can be set up. Two or more sets of clamping and lifting devices 51 are fixed on a mounting plate, which is used to drive the clamping drive module 52.

[0050] The clamping drive module 52 is used to drive the clamping lifting device 51 to move up and down. The clamping drive module 52 can be, for example, an electric hoist, a chain jack, or a screw jack. It should be noted that the mounting plate supporting the lifting device can be slidably connected to the mounting base of the clamping drive module 52 in the vertical direction. The feeding drive module 53 is arranged laterally along the frame 10 and can move the steel pipe from the loading area to the support roller group 41 or from the support roller group 41 to the unloading area. The feeding drive module 53 can be a chain conveyor belt or a screw conveyor mechanism. The mounting base of the clamping drive module 52 is driven to connect with the feeding drive module 53. Taking the feeding drive module 53 as an example, the chain conveyor belt is connected to a transmission link. The mounting base of the clamping drive module 52 is fixed to the transmission link. The chain conveyor belt moves by driving the transmission link to realize the lateral reciprocating movement of the clamping drive module 52.

[0051] During loading and unloading, the clamping drive module 52 first descends to the predetermined position, and then the clamping lifting device 51 clamps and fixes the steel pipe. Subsequently, the clamping drive module 52 drives the clamping lifting device 51 and the steel pipe to rise a certain distance. Then, the feeding drive module 53 drives the clamping lifting device 51 and the steel pipe to move to the support roller group 41 or the unloading area. The clamping drive module 52 drives the clamping lifting device 51 to descend, and the clamping lifting device 51 releases the steel pipe, thus completing the loading and unloading process of the steel pipe.

[0052] The detection switching mechanism 60 includes: an ultrasonic probe module 61, and a detection drive mechanism 62 for driving the ultrasonic probe module 61 to a predetermined position for ultrasonic flaw detection.

[0053] Specifically, the ultrasonic probe module 61 includes: a first probe group 611 for performing contact detection, a second probe group 612 for performing water immersion detection, and a switching drive component 613, which drives the first probe group 611 and the second probe group 612 to switch between a detection position for performing detection and a avoidance position for performing avoidance.

[0054] The first probe group 611 and the second probe group 612 can both use existing ultrasonic detection probes, and their specific structures will not be described in detail here. The switching drive assembly 613 includes: a switching drive component 6131 and a switching mounting block 6132 fixed to the power output end of the switching drive component 6131. ​​The first probe group 611 and the second probe group 612 are respectively mounted on two adjacent or opposite sides of the switching mounting block 6132. The switching drive component 6131 drives the switching mounting block 6132 to rotate to switch the positions of the first probe group 611 and the second probe group 612.

[0055] Taking a specific example, the switching drive 6131 uses a servo motor, and the switching mounting block 6132 is fixed to the power output shaft of the servo motor. The switching mounting block 6132 is C-shaped, and the first probe group 611 and the second probe group 612 are respectively located on two opposite sides of the switching mounting block 6132. The switching of the positions of the first probe group 611 and the second probe group 612 is achieved by driving the switching mounting block 6132 to rotate 180° through the servo motor. In some embodiments, the second probe group 612 can also be set on an extension rod, which facilitates the switching of the first probe group 611 and the second probe group 612 when the second probe group 612 is immersed in water. The head group 611 remains above the liquid surface. In some embodiments, the switching mounting block 6132 can also be configured as an isosceles right triangle. The servo motor is connected to the inclined surface of the cutting block. The first probe group 611 and the second probe group 612 are respectively set on two adjacent right-angled surfaces. By driving the switching mounting block 6132 to rotate by a predetermined angle through the switching drive unit 6131, the position switching of the first probe group 611 and the second probe group 612 can be realized. It can be understood that the detection position is the position where the probe faces the steel pipe to be detected, which is usually set to a vertically downward position. The position opposite to the detection position is the avoidance position.

[0056] The detection drive mechanism 62 includes: a height adjustment drive module 621 for driving the switching drive component 6131 to move up and down to adjust the detection height; a scanning drive module 622 for driving the switching drive component 6131 to reciprocate along the steel pipe axis to achieve scanning detection; and a lateral drive module 623 for driving the height adjustment drive module 621 and the feeding drive module 53 to move in the same direction to avoid the feeding mechanism 50.

[0057] The height adjustment drive module 621, scanning drive module 622, and lateral drive module 623 can all employ a lead screw drive mechanism. The lateral drive module 623 is fixed to the frame 10, the scanning drive module 622 is fixed to the power output end of the lateral drive module 623, and the height adjustment drive module 621 is fixed to the power output end of the scanning drive module 622. The detection drive mechanism 62 spans across the detection box 20, and the lateral drive module 623 is located outside the detection box 20, allowing the height adjustment drive module 621 and scanning drive module 622 to move... The sensor moves to the edge of the detection box 20. For example, the scanning drive module 622 drives the height adjustment drive module 621 to move to one end and to the outside of the detection box 20. The lateral drive module 623 drives the scanning drive module 622 to move to one end and to the outside of the detection box 20. The feeding mechanism 50 drives the steel pipe to move in the space between the lateral drive modules 623 and across the scanning drive module 622, thereby avoiding interference with the steel pipe during loading and unloading. It can be understood that the area that the detection drive mechanism 62 can drive the ultrasonic probe module to move is sufficient to cover the entire detection box.

[0058] In some embodiments, the detection drive mechanism 62 may be an integrated three-axis manipulator, thereby enabling the ultrasonic probe module 61 to move along the X, Y, and Z directions; or, in some embodiments, the lateral drive module 623 may share a set with the feeding drive module 53, and the lateral position of the ultrasonic probe module 61 and the lateral position of the clamping hanger 51 change simultaneously, so that the two are linked and do not interfere with each other.

[0059] The height adjustment drive module 621 controls the height position of the switching drive component 6131 and the ultrasonic probe module 61 according to the determined detection position. The scanning drive module 622 drives the switching drive component 6131 and the ultrasonic probe module 61 to move along the axial direction of the steel pipe, thereby realizing the scanning detection of the entire steel pipe. The lateral drive module 623 can adjust the position of the height adjustment drive module 621 and the ultrasonic probe module 61, thereby avoiding the feeding mechanism 50 or adjusting the lateral position of the detection.

[0060] When performing ultrasonic flaw detection, the detection carrier plate 30 is initially located in the contact detection position to facilitate the feeding of steel pipes. The feeding mechanism 50 moves the steel pipe to be tested from the feeding area to the support mechanism 40 and places it on the support roller group 41, thus completing the feeding process. The specific testing method is determined according to the testing requirements of the steel pipe to be tested. Simultaneously, the testing position of the ultrasonic probe module 61 is determined based on the size of the steel pipe. If contact ultrasonic testing is required, the first probe group 611 is switched to the testing position via the switching drive assembly 613. At this time, the second probe group 612 is in a clearance position and will not affect the testing process. The lifting drive mechanism 31 keeps the testing carrier plate 30 in the contact testing position, and the testing drive mechanism 62 drives the first probe group 611 to move to the predetermined testing position and fit against the steel pipe to be tested, thus completing the testing positioning process. If immersion ultrasonic testing is required, the second probe group 612 is switched to the testing position via the switching drive assembly 613. At this time, the first probe group 611 is in a clearance position and will not affect the testing process. The lifting drive mechanism 31 lowers the testing carrier plate 30 to the immersion testing position, and the testing drive mechanism 62 drives the second probe group 612 to move to the predetermined testing position and immerse it in the testing liquid medium, thus completing the testing positioning process. During the inspection process, the support roller group 41 is driven to rotate by the drive mechanism 42, which in turn drives the steel pipe to be inspected to rotate slowly. At the same time, the inspection drive mechanism 62 drives the ultrasonic probe module 61 to move along the axial direction of the steel pipe to be inspected for scanning inspection. The ultrasonic probe module 61 emits ultrasonic detection signals to the steel pipe and receives echo signals, thereby realizing the online inspection process of the steel pipe. The inspection can be completed by moving the ultrasonic probe module 61 from one end of the steel pipe to the other end. If it is necessary to perform the two inspection methods in sequence, the second inspection positioning and scanning inspection can be performed again after the first inspection is completed. After the inspection is completed, the lifting drive mechanism 31 controls the inspection plate 30 to return to the contact inspection position, and the feeding mechanism 50 moves the steel pipe from the support roller group 41 to the unloading area, thus completing the unloading process. This invention can perform ultrasonic flaw detection by adopting appropriate detection methods according to actual detection needs, and can achieve a combination of two methods without changing equipment, simplifying the operation process. Furthermore, the combined detection method can further improve the accuracy and reliability of the detection results.

[0061] A second aspect of this invention provides an automated ultrasonic flaw detection method for large-diameter stainless steel pipes. The method is implemented based on the apparatus described in the first aspect and includes: S100, the feeding mechanism 50 moves the steel pipe to be tested from the feeding area to the support roller group 41. Usually, the steel pipe to be tested is moved to a fixed position by the feeding conveyor line 11. The feeding mechanism 50 clamps the steel pipe to be tested from the fixed position and moves the steel pipe to be tested to be placed on the support roller group 41. The position of the support roller group 41 is fixed, so the placement position is also fixed.

[0062] S200. Determine the detection mode according to the detection requirements, and determine the detection position of the ultrasonic probe module 61 according to the size of the steel pipe to be detected. The detection modes include contact detection mode and water immersion detection mode.

[0063] Specifically, the testing requirements for stainless steel pipes of different diameters and models vary. For example, small-diameter stainless steel pipes may require water immersion testing to achieve rapid testing, while large-diameter stainless steel pipes may require contact testing to improve testing accuracy. Alternatively, water immersion testing may be used for initial inspection, and then contact testing may be used for secondary inspection of potentially defective locations based on the test results.

[0064] The detection position can be, for example, the highest point of the steel pipe to be tested, the outer contour of the steel pipe to be tested, the depth of the second probe group 612 immersed in the liquid medium, the distance between the second probe group 612 and the surface of the steel pipe to be tested, etc. These detection positions can be set according to the actual detection requirements of the steel pipe to be tested, and can be reset when changing to different batches and models of stainless steel pipes.

[0065] Step S200 specifically includes: S201. If the contact detection mode is determined to be adopted, the lifting drive mechanism 31 controls the detection carrier plate 30 to remain in the contact detection position, the switching drive component 613 controls the first probe group 611 to switch to the detection position, and the detection drive mechanism 62 drives the first probe group 611 to move to the predetermined detection position to fit against the steel pipe to be detected.

[0066] S202. If the water immersion detection mode is selected, the lifting drive mechanism 31 controls the detection carrier plate 30 to descend to the water immersion detection position, the switching drive component 613 controls the second probe group 612 to switch to the detection position, and the detection drive mechanism 62 drives the second probe group 612 to move to the predetermined detection position and immerse it in the detection liquid medium.

[0067] Of course, if it is determined that two modes should be used in combination for detection, the detection of one mode should be completed first, and then the position and state required by the other detection mode should be adjusted before the second detection is performed.

[0068] S300, the support drive mechanism 42 drives the support roller group 41 to rotate so as to drive the steel pipe to be tested to rotate slowly, and the detection drive mechanism 62 drives the ultrasonic probe module 61 to move along the axial direction of the steel pipe to be tested for scanning detection.

[0069] In practice, the following two methods can be used for testing: 1) First, control the ultrasonic probe module 61 to be located at the first end of the steel pipe to be tested. The support drive mechanism 42 drives the support roller group 41 to rotate continuously. The steel pipe to be tested rotates synchronously and continuously. After the test starts, the test drive mechanism 62 controls the ultrasonic probe module 61 to move intermittently at a certain step distance. For every one revolution of the steel pipe to be tested, the test drive mechanism 62 controls the ultrasonic probe module 61 to move one step until the ultrasonic probe module 61 moves to the second end of the steel pipe to be tested, thus completing the test.

[0070] 2) First, control the ultrasonic probe module 61 to be positioned at the first end of the steel pipe to be tested. The support drive mechanism 42 does not move. After the steel pipe is in the start of testing, the testing drive mechanism 62 controls the ultrasonic probe module 61 to slowly move to the second end of the steel pipe to be tested at a certain speed. Then, according to the radiation range of the ultrasonic probe module 61, control the support drive mechanism 42 to drive the steel pipe to rotate at a predetermined angle. The testing drive mechanism 62 controls the ultrasonic probe module 61 to slowly move back from the second end of the steel pipe to the first end of the steel pipe to be tested at a certain speed. Repeat the above steps until the steel pipe to be tested rotates one full turn, thus completing the testing of all positions.

[0071] S400 After the inspection is completed, the feeding mechanism 50 moves the steel pipe from the support roller group 41 to the unloading area. Similarly, the unloading conveyor line 14 drives the last second positioning plate 15 to move to a fixed position. The feeding mechanism 50 clamps the inspected steel pipe from the support roller group 41 and moves it to the second positioning plate 15 located at the fixed position, thus completing the unloading process.

[0072] Through the above process, the present invention can perform ultrasonic flaw detection by adopting appropriate detection methods according to actual detection needs, and can realize the combination of two methods without changing equipment, simplifying the operation process. Moreover, the combined detection method can further improve the accuracy and reliability of the detection results.

[0073] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the invention patent. It should be noted that, for those skilled in the art, several modifications and improvements can be made without departing from the concept of the present invention. These are all equivalent modifications and improvements made to the above embodiments based on the essential technology of the present invention, and all of these fall within the protection scope of the present invention.

Claims

1. An automated ultrasonic flaw detection device for large-diameter stainless steel pipes, characterized in that, include: The frame is provided with a loading area for placing steel pipes to be tested and a unloading area for placing steel pipes that have been tested. The detection chamber, which is supported on the frame and used to hold the liquid medium for detection, has a contact detection position near the top of the detection chamber and a water immersion detection position near the bottom of the detection chamber. The detection carrier plate, which is supported on the detection box, is driven by a lifting drive mechanism to move up and down between the contact detection position and the water immersion detection position. The support mechanism, which is supported on the detection carrier plate and used to support the steel pipe to be tested and drive the steel pipe to be tested to rotate, includes: a support roller group for supporting the steel pipe to be tested, and a support drive mechanism for driving the support roller group to rotate. A feeding mechanism supported on the frame for transferring the steel pipe to be tested from the loading area to the hosting mechanism or from the hosting mechanism to the unloading area; and... The detection switching mechanism supported on the frame includes: an ultrasonic probe module and a detection drive mechanism for driving the ultrasonic probe module to move to a predetermined position for ultrasonic flaw detection. The ultrasonic probe module includes: a first probe group for performing contact detection, a second probe group for performing water immersion detection, and a switching drive component, which drives the first probe group and the second probe group to switch between a detection position for performing detection and a avoidance position for performing avoidance.

2. The automated ultrasonic flaw detection device for large-diameter stainless steel pipes according to claim 1, characterized in that, The feeding area is provided with a feeding conveyor line, and the feeding conveyor line is provided with a first positioning plate, and the first positioning plate is provided with a first positioning groove for restricting the rolling of the steel pipe. The unloading area is provided with an unloading conveyor line, and the unloading conveyor line is provided with a second positioning carrier plate, and the second positioning carrier plate is provided with a second positioning groove for restricting the rolling of the steel pipe.

3. The automated ultrasonic flaw detection device for large-diameter stainless steel pipes according to claim 1, characterized in that, The lifting drive mechanism is selected individually or in combination from the following structures: a lead screw drive mechanism or a sprocket drive mechanism.

4. The automated ultrasonic flaw detection device for large-diameter stainless steel pipes according to claim 1, characterized in that, The support roller assembly includes: A rotating active roller is mounted on the detection carrier plate. This active roller is driven by the support drive mechanism and is used to form a friction drive with the steel pipe to be detected. A driven roller, which is rotatably mounted on the detection carrier plate, is used to support the steel pipe to be detected and rotates with the steel pipe to be detected.

5. The automated ultrasonic flaw detection device for large-diameter stainless steel pipes according to claim 4, characterized in that, The managed drive mechanism includes: a first managed drive motor disposed near the top of the detection box, and a second managed drive motor disposed near the bottom of the detection box; The power output shafts of the first and second host drive motors pass into the detection box, and the active idler roller is provided with drive grooves that are adapted to the power output shafts of the first and second host drive motors. When the detection carrier plate is located at the contact detection position, the power output shaft of the first drive motor is inserted into the drive slot and is concentrically arranged. When the detection carrier plate is located at the water immersion detection position, the power output shaft of the second drive motor is inserted into the drive slot and is concentrically arranged.

6. The automated ultrasonic flaw detection device for large-diameter stainless steel pipes according to claim 4 or 5, characterized in that, The driven roller is slidably mounted on the detection carrier plate via a driven bearing seat. The driven roller can slide relative to the driving roller to adjust the support gap, and the driven bearing seat is provided with a sliding fastener for locking and fixing relative to the detection carrier plate.

7. The automated ultrasonic flaw detection device for large-diameter stainless steel pipes according to claim 1, characterized in that, The feeding mechanism includes: Clamping and lifting devices are used to clamp and lift steel pipes; A clamping drive module is used to drive the clamping lifting device to move up and down to clamp or release the steel pipe; The feeding drive module is used to drive the clamping and lifting device to reciprocate in order to transfer the steel pipe.

8. The automated ultrasonic flaw detection device for large-diameter stainless steel pipes according to claim 7, characterized in that, The switching drive assembly includes: a switching drive component and a switching mounting block fixed to the power output end of the switching drive component. The first probe group and the second probe group are respectively mounted on two adjacent or opposite sides of the switching mounting block. The switching drive component drives the switching mounting block to rotate to switch the positions of the first probe group and the second probe group.

9. The automated ultrasonic flaw detection device for large-diameter stainless steel pipes according to claim 8, characterized in that, The detection driving mechanism includes: A height adjustment drive module is used to drive the switching drive component to move up and down to adjust the detection height; A scanning drive module is used to drive the switching drive component to reciprocate along the axial direction of the steel pipe to achieve scanning detection; and... A lateral drive module is used to drive the height adjustment drive module and the feeding drive module to move in the same direction to avoid the feeding mechanism.

10. An automated ultrasonic flaw detection method for large-diameter stainless steel pipes, characterized in that, The method is implemented based on the apparatus as described in any one of claims 1-9, comprising: The feeding mechanism transfers the steel pipe to be inspected from the loading area to the support roller assembly; The detection mode is determined according to the detection requirements, and the detection position of the ultrasonic probe module is determined according to the size of the steel pipe to be tested. The detection modes include contact detection mode and water immersion detection mode. If the contact detection mode is determined to be adopted, the lifting drive mechanism controls the detection plate to remain at the contact detection position, the switching drive component controls the first probe group to switch to the detection position, and the detection drive mechanism drives the first probe group to move to the predetermined detection position to fit against the steel pipe to be detected. If the water immersion detection mode is selected, the lifting drive mechanism controls the detection carrier plate to descend to the water immersion detection position, the switching drive component controls the second probe group to switch to the detection position, and the detection drive mechanism drives the second probe group to move to the predetermined detection position and immerse it in the detection liquid medium. The support roller group is driven to rotate to slowly rotate the steel pipe to be tested, and the detection drive mechanism drives the ultrasonic probe module to move along the axial direction of the steel pipe to be tested for scanning and detection. After the inspection is completed, the feeding mechanism will transfer the steel pipe from the support roller group to the unloading area.

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