A flexible coupling ultrasonic testing device and method for non-destructive testing of a cable

Abstract

The present application relates to the technical field of power cable encapsulation layer ultrasonic detection, in particular to a flexible coupling ultrasonic detection device and method for cable nondestructive testing, a flexible coupling ultrasonic detection device for cable nondestructive testing, comprising an ultrasonic sensor, a sensor probe, a flexible silica gel water sac and an upper computer, a flexible coupling ultrasonic detection method for cable nondestructive testing, when the ultrasonic sensor is used to detect the cable encapsulation layer, a flexible silica gel water sac with a hollow internal area filled with coupling liquid and a soft external shell capable of adhering to the outer surface of cables with different shapes and sizes is placed between the sensor probe of the ultrasonic sensor and the outer surface of the cable encapsulation layer to be detected. The present application not only improves the safety of the detection process, but also enhances the flexibility of the device in practical application.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic testing technology for power cable encapsulation layers, specifically to a flexible coupling ultrasonic testing device and method for non-destructive testing of cables. Background Technology

[0002] Write a background description for the device, highlighting the shortcomings of the prior art that the device addresses. Summary of the Invention

[0003] The purpose of this invention is to provide a flexible coupling ultrasonic testing device and method for non-destructive testing of cables, so as to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

[0005] A flexible coupling ultrasonic testing device for non-destructive testing of cables includes an ultrasonic sensor, a sensor probe, a flexible silicone water bladder, and a host computer. The ultrasonic sensor is located at the top of the flexible coupling ultrasonic testing device and has a built-in sound wave transmitting module, signal receiving module, signal amplifier, and signal filter. The flexible coupling ultrasonic testing device is electrically connected to the host computer via a digital controller. The digital controller converts the ultrasonic signals of the flexible coupling ultrasonic testing device into electrical signals and displays them on the host computer. The sensor probe is located at the bottom of the ultrasonic sensor, and the flexible silicone water bladder is located below the sensor probe. The hollow area inside the flexible silicone water bladder is filled with coupling liquid, and the outer shell is flexible enough to conform to the outer surface of cables of different shapes and sizes.

[0006] Furthermore, the ultrasonic sensor is equipped with a shielding shell to prevent external interference and ensure signal stability.

[0007] Furthermore, the sensor probe is an integrated sensor probe, comprising 12 piezoelectric crystals.

[0008] Furthermore, the flexible silicone water bladder is detachably mounted below the integrated sensor probe.

[0009] Furthermore, the flexible silicone water bladder is equipped with a water injection hole for filling the flexible silicone water bladder with coupling liquid.

[0010] A flexible coupling ultrasonic testing method for non-destructive testing of cables involves placing a flexible silicone water bladder between the sensor probe of the ultrasonic sensor and the outer surface of the cable encapsulation layer. The bladder has a hollow internal area filled with coupling liquid and a flexible outer shell that can conform to the outer surface of cables of different shapes and sizes. During the testing process, the surface of the flexible silicone water bladder is kept in close contact with the sensor probe and the outer surface of the cable encapsulation layer without any gaps.

[0011] Furthermore, an ultrasonic coupling agent is coated on the surface of the flexible silicone water bladder before testing to further ensure a seamless connection between the surface of the flexible silicone water bladder and the outer surface of the sensor probe and cable encapsulation layer.

[0012] Compared with the prior art, the beneficial effects of the present invention are:

[0013] 1. This invention utilizes ultrasonic technology for non-invasive testing of cable samples, thus avoiding any physical damage to the cable. The use of flexible coupling units allows it to adapt to cable surfaces of various shapes and sizes, significantly expanding its applicability. The terminal system provides detailed real-time data display and in-depth analysis functions, enabling users to fully understand the cable condition and ensuring the accuracy and reliability of the test results. This invention not only improves the safety of the testing process but also enhances the flexibility of the device in practical applications.

[0014] 2. This invention, by combining real-time data processing algorithms, can process and analyze ultrasonic data instantly, providing accurate results rapidly. The ultrasonic sensor is connected to a digital controller on a host computer, enabling the acquisition of ultrasonic signals to be converted into electrical signals in real time, and then displayed and processed on the host computer. Programmable control of the ultrasonic sensor and other equipment via the host computer allows for comprehensive scanning of the cable's internal structure.

[0015] 3. In this invention, the flexible silicone water bag is detachably installed below the integrated sensor probe, which facilitates the replacement or maintenance of the flexible silicone water bag.

[0016] 4. In this invention, the flexible silicone water bladder is equipped with a water injection hole, which makes it easy to keep the inside of the water bladder full of water during the detection process, preventing noise in the detection signal caused by water evaporation. In addition, the water injection hole is not only used to inject coupling liquid, but also has a sewage discharge function to keep the inside of the water bladder clean and effective.

[0017] 5. In this invention, the sensor can provide higher spatial resolution than a single sensor by collecting data from multiple sensor probes. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the frame of a flexible coupling ultrasonic testing device for non-destructive testing of cables;

[0019] Figure 2 This is a physical image of an integrated ultrasonic sensor.

[0020] Figure 3 This is a picture of a detachable flexible silicone water bag.

[0021] Figure 4 This is a physical image of a flexible coupling ultrasonic testing device;

[0022] Figure 5 This is a photograph of the actual cable used in the flexible coupling ultrasonic testing sample.

[0023] Figure 6 Signal images of defective areas in a sample cable detected by a flexible coupled ultrasonic testing device;

[0024] Figure 7 Waveform signal images of defective sample cables detected by a flexible coupling ultrasonic testing device;

[0025] Figure 8 Signal images of defect-free areas in a sample cable detected by a flexible coupled ultrasonic testing device;

[0026] Figure 9 The image shows a wavy signal pattern of a defect-free sample cable detected by a flexible coupled ultrasonic testing device.

[0027] In the figure: 1. Flexible coupling ultrasonic testing device; 2. Ultrasonic sensor; 3. Sensor probe; 4. Water injection hole; 5. Flexible silicone water bladder; 6. Digital controller; 7. Host computer; 8. Cable sample; 9. Cable tail tube; 10. Heat shrink tubing; 11. Encapsulation layer; 12. Aluminum sheath; 13. Interlayer defect; 14. Internal defect; 15. Power supply. Detailed Implementation

[0028] 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.

[0029] Example 1: Please refer to Figures 1-9 A flexible coupling ultrasonic testing device for non-destructive testing of cables is characterized by comprising an ultrasonic sensor 2, a sensor probe 3, a flexible silicone water bladder 5, and a host computer 7. The ultrasonic sensor 2 is disposed on the top of the flexible coupling ultrasonic testing device 1 and has a built-in sound wave transmitting module, a signal receiving module, a signal amplifier, and a signal filter. The flexible coupling ultrasonic testing device 1 is electrically connected to the host computer 7 via a digital controller 6. The digital controller 6 converts the ultrasonic signals of the flexible coupling ultrasonic testing device 1 into electrical signals and displays them on the host computer 7. The sensor probe 3 is disposed at the bottom of the ultrasonic sensor 2, and the flexible silicone water bladder 5 is disposed below the sensor probe 3. The hollow area inside the flexible silicone water bladder 5 is filled with coupling liquid, and the outer shell is flexible enough to conform to the outer surface of cables of different shapes and sizes.

[0030] Working principle of this embodiment:

[0031] The ultrasonic sensor 2 includes a sound wave emitting module, a signal receiving module, a signal amplifier, and a signal filter. These modules work together to enable the ultrasonic sensor 2 to efficiently emit, receive, and process ultrasonic signals, thereby achieving accurate and non-destructive testing of the internal structure of the cable.

[0032] The flexible silicone water bladder 5, positioned below the sensor probe 3, provides excellent acoustic coupling, ensuring effective transmission of ultrasonic signals and thus improving imaging quality and measurement accuracy. Through flexible modular assembly and replacement, the device can be applied not only to power cable measurement but also to a variety of other scenarios. This flexibility allows the device to be customized to meet different needs, enabling it to function in areas such as pipe inspection, material thickness measurement, weld joint inspection, and building structure inspection. Each module can be replaced or adjusted according to specific application requirements, thus expanding its application to multiple scenarios.

[0033] Digital controller 6 is electrically connected to ultrasonic sensor 2 to receive, process, and analyze sound wave signals. Utilizing its advanced control and processing capabilities, digital controller 6 performs detailed analysis of the sound wave data collected by ultrasonic sensor 2. It can accurately extract key data information, such as sound wave propagation time and reflection intensity, and comprehensively process this information. The processed monitoring data is then transmitted in real-time to host computer 7 via communication between digital controller 6 and host computer 7. This process not only ensures accurate data transmission but also enables host computer 7 to receive comprehensive information about the cable's condition in a timely manner, allowing for further monitoring, analysis, and decision-making.

[0034] The host computer 7 is a universal terminal device, which can be a laptop, desktop computer, or any compatible microcontroller system. It is tightly connected to the ultrasonic sensor 2 via the digital controller 6 to achieve real-time monitoring and processing of ultrasonic signals. Specifically, the ultrasonic sensor 2 converts the acquired ultrasonic signals into electrical signals, which are then transmitted to the host computer 7 via the digital controller 6. On the host computer 7, after receiving the electrical signals, the system further processes them. Through advanced software algorithms and a graphical interface, the host computer 7 can convert the processed data into detailed images or data reports of the cable's internal structure. These images and reports show the actual condition inside the cable, including potential defects, cracks, bubbles, and other problems. The real-time internal condition of the power cable presented by the host computer 7 allows for continuous monitoring and analysis of the cable's status. Utilizing advanced data acquisition and display technology, this system can transmit data from the detection process to the host computer 7 in real time. This function allows operators to view various information about the cable's internal structure in detail through the interface of the host computer 7, including the water bladder's filling status, signal strength, and other potential anomalies. The real-time data display not only provides immediate feedback on cable operation, but also supports operators in quickly diagnosing problems and performing necessary maintenance and adjustments, thereby improving the system's operational safety and reliability.

[0035] This embodiment utilizes ultrasonic technology for non-invasive testing of cable samples, thus avoiding any physical damage to the cable. The use of flexible coupling units allows it to adapt to cable surfaces of various shapes and sizes, significantly expanding its applicability. The terminal system provides detailed real-time data display and in-depth analysis functions, enabling users to fully understand the cable condition and ensuring the accuracy and reliability of the test results. This embodiment not only improves the safety of the testing process but also enhances the flexibility of the device in practical applications.

[0036] In addition, the ultrasonic sensor 2 in this embodiment is equipped with a shielding shell to prevent external interference and ensure signal stability.

[0037] Furthermore, in this embodiment, sensor probe 3 is an integrated sensor probe, comprising 12 piezoelectric crystals. These piezoelectric crystals convert electrical signals into ultrasonic signals and emit sound waves towards the target area. The emitted ultrasonic signals are typically short pulses or frequency-modulated signals. By acquiring data from multiple sensor probes, the sensor can provide higher spatial resolution than a single sensor.

[0038] In addition, in this embodiment, the flexible silicone water bag 5 can be detachably installed below the integrated sensor probe 3, which facilitates the replacement or maintenance of the flexible silicone water bag 5.

[0039] In addition, in this embodiment, the flexible silicone water bladder 5 is equipped with a water injection hole 4 to fill the flexible silicone water bladder 5 with coupling liquid. The water injection hole 4 facilitates keeping the inside of the water bladder full of water during the detection process, preventing noise in the detection signal caused by water evaporation. Furthermore, the water injection hole not only injects coupling liquid but also has a drainage function, maintaining the cleanliness and effectiveness of the inside of the water bladder.

[0040] Example 2: Please refer to Figures 1-9 A flexible coupling ultrasonic testing method for non-destructive testing of cables is proposed. When ultrasonic testing is performed on the cable encapsulation layer using an ultrasonic sensor 2, a flexible silicone water bladder 5 with an internal hollow area filled with coupling liquid and an outer shell that is flexible enough to conform to the outer surface of cables of different shapes and sizes is placed between the sensor probe 3 of the ultrasonic sensor 2 and the outer surface of the cable encapsulation layer under test. During the testing process, the surface of the flexible silicone water bladder 5 is kept in close contact with the sensor probe 3 and the outer surface of the cable encapsulation layer without leaving any gaps.

[0041] Furthermore, before testing, an ultrasonic coupling agent is coated on the surface of the flexible silicone water bladder 5 to further ensure that there are no gaps between the surface of the flexible silicone water bladder 5 and the sensor probe 3 and the outer surface of the cable encapsulation layer.

[0042] In this embodiment, a flexible silicone water bladder 5 is placed between the sensor probe 3 of the ultrasonic sensor 2 and the outer surface of the cable encapsulation layer under test. This allows for a tight fit to irregular surfaces, effectively adapting to cable accessory encapsulation layers of different shapes and sizes, and supporting modular replacement. This method not only improves the versatility of the device but also reduces limitations on the testing environment, enabling it to perform exceptionally well in a variety of complex practical applications.

[0043] Before testing, an ultrasonic coupling agent is coated on the surface of the flexible silicone water bladder 5. This enhances the adhesion between the surface of the flexible silicone water bladder 5 and the sensor probe 3 and the outer surface of the cable encapsulation layer, further reducing the presence of gaps and impurities, thereby improving the testing effect.

Claims

1. A flexible coupling ultrasonic testing device for non-destructive testing of cables, characterized in that, The device includes an ultrasonic sensor (2), a sensor probe (3), a flexible silicone water bladder (5), and a host computer (7). The ultrasonic sensor (2) is located on the top of the flexible coupling ultrasonic detection device (1). The ultrasonic sensor (2) has a built-in sound wave emission module, a signal receiving module, a signal amplifier, and a signal filter. The flexible coupling ultrasonic detection device (1) is electrically connected to the host computer (7) through a digital controller (6). The digital controller (6) converts the ultrasonic signal of the flexible coupling ultrasonic detection device (1) into an electrical signal and displays it on the host computer (7). The sensor probe (3) is located at the bottom of the ultrasonic sensor (2). The flexible silicone water bladder (5) is located below the sensor probe (3). The hollow area inside the flexible silicone water bladder (5) is filled with coupling liquid, and the outer shell is soft and can fit the outer surface of cables of different shapes and sizes.

2. The flexible coupling ultrasonic testing device for non-destructive testing of cables according to claim 1, characterized in that: The ultrasonic sensor (2) is equipped with a shielding shell to prevent external interference and ensure signal stability.

3. The flexible coupling ultrasonic testing device for non-destructive testing of cables according to claim 1, characterized in that: The sensor probe (3) is an integrated sensor probe, which includes 12 piezoelectric crystals.

4. The flexible coupling ultrasonic testing device for non-destructive testing of cables according to claim 1, characterized in that: The flexible silicone water bag (5) can be detachably installed below the integrated sensor probe (3).

5. A flexible coupling ultrasonic testing device for non-destructive testing of cables according to claim 1, characterized in that: The flexible silicone water bladder (5) is equipped with a water injection hole (4) for filling the flexible silicone water bladder (5) with coupling liquid.

6. A flexible coupling ultrasonic testing method for non-destructive testing of cables, applicable to the flexible coupling ultrasonic testing device described in any one of claims 1 to 5, characterized in that, When using an ultrasonic sensor (2) to perform ultrasonic testing on the cable encapsulation layer, a flexible silicone water bladder (5) with an internal hollow area filled with coupling liquid and an external shell that is soft enough to fit the outer surface of cables of different shapes and sizes is placed between the sensor probe (3) of the ultrasonic sensor (2) and the outer surface of the cable encapsulation layer under test. During the test, the surface of the flexible silicone water bladder (5) is kept in close contact with the sensor probe (3) and the outer surface of the cable encapsulation layer without any gaps.

7. The flexible coupling ultrasonic testing method for non-destructive testing of cables according to claim 6, characterized in that, Before testing, an ultrasonic coupling agent is coated on the surface of the flexible silicone water bladder (5) to further ensure that there is no gap between the surface of the flexible silicone water bladder (5) and the sensor probe (3) and the outer surface of the cable encapsulation layer.

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