A steel joint detection device and method for a high-temperature reheater

Abstract

The application discloses a high-temperature reheater steel joint detection device in the technical field of boiler detection, which comprises a stepped support seat, a workbench is installed on the upper end of the stepped support seat through a lifting assembly, the workbench is a whole semicircular ring type, and front and rear guardrails are arranged on the inner and outer sides of the workbench, the front guardrail is provided with a rotary detection piece, the rotary detection piece comprises a circular slide rail and a connecting circular arc rod, the connecting circular arc rod is slidably connected to the circular slide rail through a power sliding block, the circular slide rail is fixedly installed on the upper surface of the front guardrail, one end of the connecting circular arc rod can form a closed circular ring with the circular slide rail after being rotated to the limit, and ultrasonic phased array scanners are fixedly installed at the two ends of the connecting circular arc rod, and the application can improve the detection precision through the reciprocating multiple weld scanning detection of the adjustable selection detection piece.

Description

Technical Field

[0001] This invention relates to the field of boiler testing technology, specifically to a testing device and method for steel joints of high-temperature reheaters. Background Technology

[0002] In actual boiler operation, reheaters are generally divided into low-temperature reheaters and high-temperature reheaters. The temperature ranges of low-temperature and high-temperature reheaters differ significantly, requiring the selection of different tubing materials for each section in the design. The welds between the two tubing materials are made of shaped steel. The performance of these two types of steel differs greatly, making them highly susceptible to failure under long-term high-temperature operation.

[0003] During construction inspection, the welded seams of these irregularly shaped steel sections are a key focus, requiring regular testing for wall thickness, hardness, metallography, and non-destructive testing. During maintenance, the focus is on surface polishing and checking for circumferential cracks along the fusion line. Currently, due to the narrow spacing between pipes, conventional probes and X-ray equipment cannot be placed for the inspection of these welded seams; therefore, ultrasonic phased array scanners are used. However, this still requires manual assistance, and the accuracy of the scanned data is limited, making it prone to omissions.

[0004] Based on this, the present invention designs a steel joint detection device and method for high-temperature reheaters to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a steel joint inspection device for high-temperature reheaters, which improves inspection accuracy by repeatedly scanning and inspecting welds using an adjustable selection of inspection components.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A steel joint testing device for a high-temperature reheater includes a stepped support base. A worktable is mounted on the upper end of the stepped support base via a lifting assembly. The worktable is semi-circular in shape, with a front guardrail and a rear guardrail on its inner and outer sides, respectively. A rotating detection component is provided on the front guardrail. The rotating detection component includes a circular slide rail and a connecting arc rod. The connecting arc rod is slidably connected to the circular slide rail via a power slider. The circular slide rail is fixedly installed on the upper surface of the front guardrail. When one end of the connecting arc rod is rotated to its maximum extent, it can form a closed loop with the circular slide rail. Ultrasonic phased array scanners are fixedly installed on both ends of the connecting arc rod.

[0007] Preferably, the ultrasonic phased array scanner includes a vertical arc plate and ultrasonic probes. Multiple sets of ultrasonic probes are arranged at equal intervals inside the vertical arc plate. A cylinder is fixedly installed on the top of each vertical arc plate, and a temperature sensor is fixedly installed on the free end of each cylinder.

[0008] Preferably, the lifting assembly includes a side connecting frame, a side telescopic cylinder, and a rear telescopic cylinder. The lower end of the side connecting frame is fixedly installed on both sides of the stepped support base, and the upper end is located below the worktable. The side telescopic cylinder is fixedly installed on the upper surface of the side connecting frame, and its upper end is rotatably connected to the worktable through a spherical connecting seat. The rear telescopic cylinder is fixedly installed on the upper surface of the stepped support base, and its upper end is also rotatably connected to the lower surface of the worktable through a spherical connecting seat.

[0009] Preferably, a movable railing is provided in the middle of the rear guardrail, one end of which is hinged to the rear guardrail, and the other end is provided with a snap-fit ​​buckle that can snap into the rear guardrail.

[0010] Preferably, the lower surface of the stepped support base is provided with an installation groove, a self-locking wheel is fixedly installed in the installation groove, and a front crossbar is fixedly installed between the upper ends of the two sets of side connecting frames. The front crossbar is elastic and can bend and deform to conform to the outer contour of the boiler shell.

[0011] Preferably, a level detector is provided on the upper surface of the workbench, which can detect the front-to-back tilt of the workbench.

[0012] Preferably, the bottom of the power slider is provided with a drive gear, and the inner side of the groove of the circular slide rail is provided with teeth, and the drive gear can mesh with the teeth.

[0013] Another objective of this invention is to provide a technical solution: A method for testing steel joints in a high-temperature reheater includes the following steps: Step 1: Move the stepped support to the weld seam of the steel joint of the high-temperature reheater and lock the bottom self-locking wheel to secure the whole machine; Step 2: Activate the side telescopic cylinder and rear telescopic cylinder to adjust the height of the worktable, and use the leveling instrument to level the worktable so that the rotating inspection piece is aligned with the circumferential weld seam of the steel joint; close the movable rail and lock the buckle. Step 3: The power slider drives the connecting arc rod to rotate circumferentially along the circular slide rail through gear meshing, driving the ultrasonic phased array scanners at both ends to complete a full-coverage ultrasonic scan around the weld; the cylinder drives the temperature sensor to be in close contact with the weld surface to synchronously collect the workpiece temperature; Step 4: Correct the ultrasonic testing parameters based on the real-time temperature data collected by the temperature sensor. At the same time, adjust the speed of the power slider and fine-tune the height and tilt of the worktable by controlling the lifting component, and collect complete scan data of the weld seam in layers and from multiple angles. Step 5: After completing the circumferential scan, store the imaging data, release the movable rail clip, remove the rotating inspection piece, push the stepped support to remove the workpiece, and complete the single joint non-destructive testing.

[0014] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention uses a power slider to drive a connecting arc rod to reciprocate around a circular slide rail, thereby achieving a comprehensive scan of the weld seam without manual assistance. Furthermore, both ends of the connecting arc rod are equipped with ultrasonic phased array scanners, which can simultaneously acquire two sets of scan data during each rotation scan. By comparing the two sets of data, the acquired data is more accurate, and the possibility of ultrasonic phased array scanner failure and invalid scans is reduced.

[0015] 2. In this invention, the scanning angle and scanning speed of the ultrasonic phased array scanner can be adjusted. During the initial scan, the ultrasonic phased array scanner is parallel to the weld seam. After the initial scan is completed, the lifting component adjusts the tilt angle of the worktable, thereby changing the ultrasonic phased array scanner and the weld seam from a parallel state to a state with a certain angle. Combined with the scanning data of the ultrasonic phased array scanner tilting upward and downward, the weld seam detection results are more accurate. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure from a side view of the present invention; Figure 2 This is a schematic diagram of the rear view structure of the present invention; Figure 3 This is a schematic diagram of the rotating detection element in this invention; Figure 4 This is a flowchart of the detection process of the present invention.

[0018] The attached diagram lists the components represented by each number as follows: 1. Stepped support base; 2. Side connecting frame; 3. Front crossbar; 4. Side telescopic cylinder; 5. Rear telescopic cylinder; 6. Workbench; 601. Rear guardrail; 602. Front guardrail; 603. Movable rail; 7. Rotating detection component; 701. Circular slide rail; 702. Power slider; 703. Ultrasonic phased array scanner; 704. Temperature sensor; 705. Cylinder; 706. Connecting arc rod. Detailed Implementation

[0019] 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.

[0020] Please see Figures 1-4 The present invention provides a technical solution: A steel joint testing device for a high-temperature reheater includes a stepped support base 1. A worktable 6 is mounted on the upper end of the stepped support base 1 via a lifting assembly. The worktable 6 is semi-circular in shape, with a front guardrail 602 and a rear guardrail 601 on its inner and outer sides, respectively. A rotating testing component 7 is provided on the front guardrail 602. The rotating testing component 7 includes a circular slide rail 701 and a connecting arc rod 706. The connecting arc rod 706 is slidably connected to the circular slide rail 701 via a power slider 702. The circular slide rail 701 is fixedly installed on the upper surface of the front guardrail 602. When one end of the connecting arc rod 706 is rotated to its maximum extent, it can form a closed loop with the circular slide rail 701. An ultrasonic phased array scanner 703 is fixedly installed on both ends of the connecting arc rod 706.

[0021] In this invention, a stepped support base 1 is used as a scaffold for weld seam inspection. The stepped support base 1 is moved to the weld seam of the steel joint of the high-temperature reheater, and the bottom self-locking wheel is locked to fix the whole machine. Then, the height is adjusted by the lifting component to ensure that the rotating inspection piece 7 is at the height of the weld seam. Finally, the connecting arc rod 706 is driven by the power slider 702 to reciprocate around the circular slide rail 701 to achieve a comprehensive scan of the weld seam without manual assistance. Both ends of the connecting arc rod 706 are equipped with ultrasonic phased array scanners 703. Two sets of scan data can be acquired simultaneously during each rotation scan. By comparing the two sets of data, the acquired data is more accurate and the possibility of ultrasonic phased array scanner 703 failure and invalid scan is reduced. In this invention, the scanning angle and scanning speed of the ultrasonic phased array scanner 703 can be adjusted. During the initial scan, the ultrasonic phased array scanner 703 is parallel to the weld seam. After the initial scan is completed, the lifting component adjusts the tilt angle of the worktable 6, thereby changing the ultrasonic phased array scanner 703 from a parallel state to a state with a certain angle to the weld seam. Combined with the scanning data of the ultrasonic phased array scanner 703 tilting upward and downward, the weld seam detection results are more accurate.

[0022] The ultrasonic phased array scanner 703 includes a vertical arc-shaped plate and ultrasonic probes. Multiple sets of ultrasonic probes are arranged equidistantly inside the vertical arc-shaped plate. A cylinder 705 is fixedly mounted on the top of each vertical arc-shaped plate, and a temperature sensor 704 is fixedly mounted on the free end of each cylinder 705. This invention corrects the ultrasonic detection parameters based on real-time temperature data collected by the temperature sensor 704. Simultaneously, by adjusting the travel speed of the power slider 702 and fine-tuning the height and tilt angle of the lifting assembly, it acquires complete weld scan data in layers and from multiple angles.

[0023] The lifting assembly includes a side connecting frame 2, a side telescopic cylinder 4, and a rear telescopic cylinder 5. The lower end of the side connecting frame 2 is fixedly installed on both sides of the stepped support base 1, and the upper end is located below the worktable 6. The side telescopic cylinder 4 is fixedly installed on the upper surface of the side connecting frame 2, and its upper end is rotatably connected to the worktable 6 through a spherical connecting seat. The rear telescopic cylinder 5 is fixedly installed on the upper surface of the stepped support base 1, and its upper end is also rotatably connected to the lower surface of the worktable 6 through a spherical connecting seat. In this invention, activating the side telescopic cylinder 4 and the rear telescopic cylinder 5 adjusts the lifting height of the worktable 6. A leveling instrument is used to level the worktable. When the side telescopic cylinder 4 is higher than the rear telescopic cylinder 5, the rotating detection component 7 is tilted and positioned below the weld; when the side telescopic cylinder 4 is lower than the rear telescopic cylinder 5, the rotating detection component 7 is tilted and positioned above the weld.

[0024] The rear guardrail 601 has a movable railing 603 located in the middle. One end of the movable railing 603 is hinged to the rear guardrail 601, and the other end has a snap-fit ​​buckle that can engage with the rear guardrail 601. After completing the circumferential scan and storing the imaging data, the snap-fit ​​buckle of the movable railing 603 is released, the rotating inspection piece 7 is removed, and the stepped support base 1 is pushed to detach the workpiece, thus completing the single-time non-destructive testing of the joint.

[0025] Among them, the lower surface of the stepped support 1 is provided with an installation groove, and a self-locking wheel is fixedly installed in the installation groove. A front crossbar 3 is fixedly installed between the upper ends of the two sets of side connecting frames 2. The front crossbar 3 is elastic and can bend and deform to conform to the outer contour of the boiler shell.

[0026] The upper surface of the worktable 6 is equipped with a level detector, which can detect the front-to-back tilt of the worktable 6. The lifting assembly, combined with the data from the level detector, can more accurately adjust the tilt angle of the worktable 6.

[0027] The power slider 702 has a drive gear at its bottom, and the inner side of the groove of the circular slide rail 701 has teeth, which the drive gear can mesh with. In this invention, the power slider 702 drives the connecting arc rod 706 to rotate circumferentially along the circular slide rail 701 through the meshing of the gear teeth.

[0028] Another objective of this invention is to provide a technical solution: A method for testing steel joints in a high-temperature reheater includes the following steps: Step 1: Move the stepped support 1 to the weld seam of the steel joint of the high-temperature reheater, and lock the bottom self-locking wheel to fix the whole machine; Step 2: Start the side telescopic cylinder 4 and the rear telescopic cylinder 5 to adjust the height of the worktable 6, and use the leveling instrument to level the worktable so that the rotating testing piece 7 is aligned with the circumferential weld seam of the steel joint; close the movable rail 603 and lock the buckle. Step 3: The power slider 702 drives the connected arc rod 706 to rotate circumferentially along the circular slide rail 701 through gear meshing, which drives the ultrasonic phased array scanners 703 at both ends to complete the full coverage ultrasonic scan around the weld; the cylinder 705 drives the temperature sensor 704 to collect the workpiece temperature in close contact with the weld surface. Step 4: Correct the ultrasonic testing parameters based on the real-time temperature data collected by the temperature sensor 704. At the same time, adjust the walking speed of the power slider 702 and the height and tilt of the worktable 6 by adjusting the lifting component to collect complete scan data of the weld in layers and from multiple angles. Step 5: After completing the circumferential scan, store the imaging data, release the latch of the movable column 603, remove the rotating inspection piece 7, push the stepped support 1 to remove the workpiece, and complete the single joint non-destructive testing.

[0029] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0030] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A steel joint testing device for a high-temperature reheater, comprising a stepped support base (1), characterized in that: The stepped support base (1) has a worktable (6) installed on its upper end via a lifting assembly. The worktable (6) is a semi-circular ring, with a front guardrail (602) and a rear guardrail (601) on its inner and outer sides respectively. The front guardrail (602) is equipped with a rotation detection component (7). The rotation detection component (7) includes a circular slide rail (701) and a connecting arc rod (706). The connecting arc rod (706) is slidably connected to the circular slide rail (701) via a power slider (702). The circular slide rail (701) is fixedly installed on the upper surface of the front guardrail (602). When one end of the connecting arc rod (706) is rotated to its maximum extent, it can form a closed ring with the circular slide rail (701). Both ends of the connecting arc rod (706) are fixedly installed with ultrasonic phased array scanners (703).

2. The steel joint testing device for a high-temperature reheater according to claim 1, characterized in that: The ultrasonic phased array scanner (703) includes a vertical arc plate and an ultrasonic probe. Multiple sets of ultrasonic probes are arranged at equal intervals on the inner side of the vertical arc plate. A cylinder (705) is fixedly installed on the top of each vertical arc plate, and a temperature sensor (704) is fixedly installed on the free end of the cylinder (705).

3. The steel joint testing device for a high-temperature reheater according to claim 1, characterized in that: The lifting assembly includes a side connecting frame (2), a side telescopic cylinder (4), and a rear telescopic cylinder (5). The lower end of the side connecting frame (2) is fixedly installed on both sides of the stepped support base (1), and the upper end is located below the worktable (6). The side telescopic cylinder (4) is fixedly installed on the upper surface of the side connecting frame (2), and its upper end is rotatably connected to the worktable (6) through a spherical connecting seat. The rear telescopic cylinder (5) is fixedly installed on the upper surface of the stepped support base (1), and its upper end is also rotatably connected to the lower surface of the worktable (6) through a spherical connecting seat.

4. The steel joint testing device for a high-temperature reheater according to claim 1, characterized in that: A movable railing (603) is provided in the middle of the rear guardrail (601). One end of the movable railing (603) is hinged to the rear guardrail (601), and the other end is provided with a snap fastener that can snap onto the rear guardrail (601).

5. The steel joint testing device for a high-temperature reheater according to claim 3, characterized in that: The stepped support base (1) has an installation groove on its lower surface. A self-locking wheel is fixedly installed in the installation groove. A front crossbar (3) is fixedly installed between the upper ends of the two sets of side connecting frames (2). The front crossbar (3) is elastic and can bend and deform to conform to the outer contour of the boiler shell.

6. The steel joint testing device for a high-temperature reheater according to claim 1, characterized in that: The upper surface of the workbench (6) is equipped with a level detector, which can detect the front-to-back tilt of the workbench (6).

7. The steel joint testing device for a high-temperature reheater according to claim 1, characterized in that: The bottom of the power slider (702) is provided with a drive gear, and the inner side of the groove of the circular slide rail (701) is provided with teeth, and the drive gear can mesh with the teeth.

8. A method for testing steel joints in a high-temperature reheater, applicable to the steel joint testing device for any of the high-temperature reheaters described in claims 1-7, characterized in that, Including the following steps: Step 1: Move the stepped support (1) to the weld seam of the steel joint of the high-temperature reheater and lock the bottom self-locking wheel to fix the whole machine; Step 2: Start the side telescopic cylinder (4) and the rear telescopic cylinder (5) to adjust the height of the worktable (6), and use the leveling instrument to level the worktable so that the rotating test piece (7) is aligned with the annular weld seam of the steel joint; close the movable rail (603) and lock the buckle. Step 3: The power slider (702) drives the connecting arc rod (706) to rotate circumferentially along the circular slide rail (701) through gear meshing, thereby driving the ultrasonic phased array scanners (703) at both ends to complete the full-coverage ultrasonic scan around the weld; the cylinder (705) drives the temperature sensor (704) to collect the workpiece temperature synchronously in close contact with the weld surface. Step 4: Correct the ultrasonic testing parameters based on the real-time temperature data collected by the temperature sensor (704), and at the same time, adjust the walking speed of the power slider (702) and the height and tilt of the worktable (6) by adjusting the lifting component, and collect complete scan data of the weld in layers and from multiple angles. Step 5: After completing the circumferential scan, store the imaging data, release the latch of the movable column (603), remove the rotating inspection piece (7), push the stepped support base (1) to remove the workpiece, and complete the single joint non-destructive testing.

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