Multi-point online wall thickness monitoring device

Abstract

The utility model discloses a multi-point on-line wall thickness monitoring device. The utility model relates to the technical field of industrial pipeline nondestructive testing, and solves the problems that a single-point monitoring structure in the prior art cannot cover a whole pipe section and is insufficient in installation stability. The utility model relates to a multi-point on-line wall thickness monitoring device, which comprises a host, a probe module and a mounting structure, the host comprises a data acquisition and processing module and a plurality of probe interface modules, and the plurality of probe interface modules are respectively connected with the data acquisition and processing module. The probe module comprises an ultrasonic probe and a temperature compensation sensor, and the temperature compensation sensor is packaged in the ultrasonic probe. The mounting structure comprises an adjustable hoop, an arc-shaped base, a compression bolt, a nut and a disc spring assembly. The industrial pipeline wall thickness monitoring system effectively improves comprehensiveness, stability and precision of industrial pipeline wall thickness monitoring, and provides reliable guarantee for safe operation of equipment.

Description

Technical Field

[0001] The utility model relates to the technical field of non-destructive testing of industrial pipelines, in particular to a multi-point online wall thickness monitoring device. Background Art

[0002] In industrial fields such as petrochemical and energy transportation, online wall thickness monitoring of pipelines is a key technology to ensure the safe operation of equipment. Traditional wall thickness monitoring devices usually adopt a single-point sensor structure, and a single probe is used to perform fixed-point measurement on a specific position of the pipe wall. This structural design results in the monitoring range being limited to the fixed position of the probe, and it is impossible to synchronously obtain the wall thickness data of different regions of the pipe section. In actual industrial applications, operators often need to adjust the probe position multiple times or add multiple independent monitoring points to achieve full pipe section coverage, which not only increases the equipment layout cost but also causes the risk of missed detection due to positioning errors during the probe switching process. Especially when the distribution of corrosion or wear areas in the pipeline system is irregular, the spatial coverage defect of the single-point monitoring structure is more prominent, and it is difficult to meet the reliability requirements of continuous online monitoring. In addition, the probes in existing devices are usually fixed by bolts or buckles, and are prone to coupling looseness during pipeline vibration or severe temperature fluctuations, resulting in distorted or even completely invalid measurement signals. Although some improvement schemes attempt to improve stability by increasing the fixed points or optimizing the installation method, due to the inherent defects of the single-point structure, the problems of low monitoring efficiency and many coverage blind spots cannot be fundamentally solved. Summary of the Utility Model

[0003] The purpose of the utility model is to provide a multi-point online wall thickness monitoring device to solve the problems that the single-point monitoring structure in the prior art cannot cover the entire pipe section and has insufficient installation stability.

[0004] The multi-point online wall thickness monitoring device of the utility model includes a host, a probe module and an installation structure. The host includes a data acquisition and processing module and a plurality of probe interface modules, and the plurality of probe interface modules are respectively connected to the data acquisition and processing module. The probe module includes an ultrasonic probe and a temperature compensation sensor, and the temperature compensation sensor is encapsulated in the ultrasonic probe. The installation structure includes an adjustable clamp, an arc-shaped base, a compression bolt, a nut and a disc spring assembly; the arc-shaped base includes an arc-shaped bottom plate and a probe installation cylinder connected to the arc-shaped bottom plate; the adjustable clamp fixes a plurality of arc-shaped bases in a circular distribution on the pipeline, so that the arc-shaped bottom plate fits the pipeline surface, the probe module is installed in the probe installation cylinder, the compression bolt passes through the disc spring assembly and is threadedly connected to the inside of the probe installation cylinder, the compression bolt abuts against the probe module, the nut is threadedly connected to the compression bolt, and the nut presses the disc spring assembly against the probe installation cylinder.

[0005] Further, the number of the probe interface modules is 16. The probe interface modules adopt anti-misplug aviation sockets arranged in a matrix. Each socket integrates an independent signal conditioning circuit. The probe interface modules are provided with various size specifications, and different specifications of expansion boards are built in the probe interface modules.

[0006] Further, the probe module includes a housing, a heat insulation sleeve, a temperature compensation sensor, a coupling surface, a fast epoxy layer, damping, a piezoelectric ceramic wafer, a sound insulation layer, and a delay block; the housing is located on the outermost layer of the probe module, and the heat insulation sleeve is arranged inside the housing; the temperature compensation sensor, the piezoelectric ceramic wafer, and the delay block are encapsulated to form an inner layer; the sound insulation layer is located in the middle layer, and the fast epoxy layer is covered outside the sound insulation layer; the coupling surface is located at the bottom of the probe module, and the damping is located on the piezoelectric ceramic wafer.

[0007] Further, the coupling surface adopts a composite structure of a nano-level alumina matte layer and a hydrogel patch.

[0008] Further, the host is provided with an RS485 wired interface and a LoRa wireless unit.

[0009] The beneficial effects of the present utility model: The multi-point online wall thickness monitoring device of the present utility model realizes synchronous monitoring of the entire pipe section through a plurality of annularly distributed probe modules, solves the problems of limited coverage range and easy missed detection of traditional single-point measurement devices; the combination of the adjustable clamp and the disc spring assembly in the installation structure ensures that the probe module maintains stable coupling during pipeline vibration or temperature difference change, avoiding loosening and failure; the temperature compensation sensor is encapsulated inside the probe module, which can be used in combination with the dynamic temperature compensation function of the host to reduce the influence of environmental temperature drift on the measurement accuracy. At the same time, the matrix-type probe interface module supports hot-plug expansion, adapts to different specifications of sensors, and improves the expandability and maintenance convenience of the device. The present utility model effectively improves the comprehensiveness, stability and accuracy of industrial pipeline wall thickness monitoring, and provides a reliable guarantee for the safe operation of equipment. Description of the Drawings

[0010] In order to more clearly illustrate the technical solutions of the present utility model, the drawings required for use in the embodiments will be briefly introduced below. Obviously, for those of ordinary skill in the art, other drawings can also be obtained based on these drawings without creative efforts.

[0011] Figure 1 It is a schematic diagram of the overall structure of the multi-point online wall thickness monitoring device of the present utility model;

[0012] Figure 2 It is a schematic diagram of the host structure of the multi-point online wall thickness monitoring device of the present utility model;

[0013] Figure 3Internal structure sectional view of the probe module of the multi-point online wall thickness monitoring device of the present utility model;

[0014] Figure 4 Schematic installation structure diagram of the multi-point online wall thickness monitoring device of the present utility model.

[0015] Illustration: 1 - Host; 2 - Probe module; 3 - Installation structure; 11 - Data acquisition and processing module; 12 - Probe interface module; 21 - Shell; 22 - Heat insulation sleeve; 23 - Temperature compensation sensor; 24 - Coupling surface; 25 - Quick epoxy layer; 26 - Damping; 27 - Piezoelectric ceramic wafer; 28 - Sound insulation layer; 29 - Delay block; 31 - Pipeline; 32 - Adjustable clamp; 33 - Arc-shaped base; 35 - Compression bolt; 36 - Nut; 37 - Disc spring assembly; 331 - Arc-shaped bottom plate; 332 - Probe installation cylinder. Detailed implementation manners

[0016] It should be noted that, without conflict, the embodiments in the present application and the features in the embodiments may be combined with each other. The present utility model will be described in detail below with reference to the drawings and in combination with the embodiments. It should be pointed out that the following detailed description is illustrative and is intended to provide further description of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present application belongs.

[0017] Please refer to Figures 1 to 4 , the embodiment of the present utility model provides a multi-point online wall thickness monitoring device, including a host 1, a probe module 2 and an installation structure 3.

[0018] The host 1 includes a data acquisition and processing module 11 and a plurality of probe interface modules 12, and the plurality of probe interface modules 12 are respectively connected to the data acquisition and processing module 11. The function of the data acquisition and processing module 11 is data acquisition, multi-channel signal processing, and communication management. The probe interface modules 12 are of various specifications and can be configured with corresponding quantities according to the actual channel number requirements.

[0019] In this embodiment, the number of the probe interface modules 12 is 16, which supports parallel data acquisition of 1 - 16 probe modules and automatically allocates data channels. The probe interface modules 12 adopt matrix-arranged anti-misinsertion aviation sockets, and each socket integrates an independent signal conditioning circuit. The probe interface modules 12 are provided with various size specifications, and flexible configuration of 1 - 16 probe modules is achieved through built-in expansion boards of different specifications. The split probe management architecture separates the 16 probe modules, and each group is equipped with a quick-release locking mechanism, so that the replacement of a single probe module does not affect the work of other groups, improving the maintenance efficiency.

[0020] The probe module 2 includes an ultrasonic probe and a temperature compensation sensor 23 encapsulated inside it. The temperature compensation sensor 23 uses a PT1000 temperature sensor. The inner layer of the ultrasonic probe is encapsulated in the same plane with a piezoelectric ceramic wafer 27, a delay block 29, a sound insulation layer 28, and the temperature compensation sensor 23. The middle layer is a sound insulation layer 28 covered with a fast epoxy layer 25, and the outer layer is provided with a heat insulation sleeve 22 and a housing 21.

[0021] In this embodiment, a polyimide heat insulation sleeve and a stainless steel protective shell are used. The housing 21 constitutes the main frame of the probe, providing rigid support and positioning protection for internal components. The heat insulation sleeve 22 is wrapped inside the housing, effectively blocking the transfer of external heat to the core sensing unit. The temperature compensation sensor 23 monitors the temperature change of the pipeline to be measured in real time, providing a calibration reference for the dynamic compensation of the host. The coupling surface 24 adopts a composite structure of a nano-level alumina abrasive layer and a hydrogel patch to ensure the acoustic impedance matching between the probe and the pipeline surface. The fast epoxy layer 25 is cured on the outside of the sound insulation layer, used to fix the internal components of the probe and prevent displacement caused by mechanical stress. The damping 26 adopts a double-group symmetrical layout design to suppress the internal vibration interference of the probe. The piezoelectric ceramic wafer 27 works in cooperation with two groups of wafers to realize the functions of high-frequency emission and echo reception of ultrasonic waves. The sound insulation layer 28 is located between the two groups of wafers, blocking the mutual interference between the transmitted wave and the reflected wave, and narrowing the pulse, thereby improving the resolution and reducing clutter interference. The delay block 29 optimizes the acoustic wave propagation path through two groups of delay structures, improving the detection resolution. By isolating external temperature interference through a three-layer composite structure, it can be used in combination with the dynamic temperature compensation function of the host to reduce the influence of environmental temperature drift on the measurement accuracy, and control the measurement error within ±0.01 mm under the working conditions of -40°C to 85°C.

[0022] The installation structure 3 includes an adjustable clamp 32, an arc-shaped base 33, a compression bolt 35, a nut 36, and a disc spring assembly 37. The arc-shaped base 33 is composed of an arc-shaped bottom plate 331 and a probe installation cylinder 332. The adjustable clamp 32 annularly fixes multiple arc-shaped bases 33 on the surface of the pipeline 31, and can adapt to pipe diameters from DN50 to DN1200. The probe module 2 is installed inside the probe installation cylinder 332. The compression bolt 35 passes through the disc spring assembly 37 and presses against the probe module 2, and the nut 36 presses the disc spring assembly 37. The disc spring assembly 37 uses a shape memory alloy material to provide a continuous pre-tightening force to prevent the probe from loosening due to pipeline vibration or temperature difference changes. The coupling surface 24 adopts a composite structure of a nano-level alumina abrasive layer and a hydrogel patch, which can make the contact impedance between the probe module 2 and the pipeline 31 stable within the range of 2.0 - 3.5 MRayl, ensuring long-term coupling reliability.

[0023] The adjustable clamp 32 fastens the arc-shaped base 33 to the surface of the pipeline 31 to adapt to the installation requirements of different pipe diameters. The arc-shaped base 33 fits the pipeline surface through its arc-shaped contour, providing an accurate installation positioning reference for the probe module 2. The probe module 2 integrates a temperature compensation sensor, and its coaxial cable is connected to an anti-misinsertion aviation connector, supporting hot plugging for quick replacement and maintenance. The compression bolt 35 and the nut 36 cooperate with the disc spring assembly 37 to form a pre-tightening force closed-loop adjustment system. The disc spring assembly 37 is made of shape memory alloy, which adaptively adjusts the compression force during pipeline vibration or thermal expansion and contraction to ensure continuous and stable contact between the probe and the pipeline coupling surface 24.

[0024] The host 1 integrates an RS485 wired interface and a LoRa wireless unit to achieve dual-channel redundant transmission. By default, RS485 transmission is adopted. When the communication is interrupted, it switches to the LoRa wireless link. The data packet verification mechanism ensures zero loss during the switching process, and the communication interruption rate is less than 0.1%.

[0025] When the multi-point online wall thickness monitoring device of the embodiment of the present utility model works, multiple probe modules 2 are annularly fixed on the surface of the pipeline 31 through the installation structure 3 to synchronously collect wall thickness data in different areas. The temperature compensation sensor 23 monitors the ambient temperature in real time and transmits it to the host 1, so that the data acquisition and processing module 11 can dynamically correct the measured value according to the built-in temperature-wall thickness correction model to eliminate the temperature drift error. The corrected data can be transmitted to the monitoring terminal through the dual-redundancy communication unit. If the RS485 link is abnormal, the LoRa wireless unit can complete the switching within 0.5 seconds, and the historical data is cached in the host Flash memory to ensure integrity.

[0026] In summary, the present utility model realizes full pipe section coverage through multi-point synchronous monitoring, solving the problem of missed detection in traditional single-point detection; the temperature sensor of the probe module 2 supports the dynamic temperature compensation function, which can significantly improve the measurement accuracy under the temperature change of the measured pipeline; the disc spring assembly 37 and the composite coupling surface design of the installation structure 3 effectively resist the coupling failure caused by vibration and temperature difference, ensuring long-term stable monitoring; the dual-redundancy communication mechanism and the modular probe interface design take into account both the reliability of data transmission and the convenience of maintenance, and are suitable for the online monitoring requirements of complex industrial environments such as petroleum and chemical industries.

[0027] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular forms are also intended to include the plural forms. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0028] It should be noted that the terms "first", "second", etc. in the description, claims and above-mentioned drawings of this application are used to distinguish similar objects and do not necessarily describe a specific order or sequence. It should be understood that the data used in this way can be interchanged under appropriate circumstances so that the embodiments of this application described herein can be implemented in an order other than those illustrated or described herein.

[0029] The above are only the preferred embodiments of the present utility model and are not intended to limit the present utility model. For those skilled in the art, the present utility model can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. A multi-point online wall thickness monitoring device, characterized in that, Comprising: a main unit (1), a probe module (2) and a mounting structure (3); The main unit (1) includes a data acquisition and processing module (11) and a plurality of probe interface modules (12), and the plurality of probe interface modules (12) are respectively connected to the data acquisition and processing module (11); The probe module (2) includes an ultrasonic probe and a temperature compensation sensor (23), and the temperature compensation sensor (23) is encapsulated in the ultrasonic probe; The mounting structure (3) includes an adjustable clamp (32), an arc-shaped base (33), a compression bolt (35), a nut (36) and a disc spring assembly (37); the arc-shaped base (33) includes an arc-shaped bottom plate (331) and a probe mounting cylinder (332) connected to the arc-shaped bottom plate (331); the adjustable clamp (32) fixes a plurality of arc-shaped bases (33) in a circular distribution on a pipeline (31) so that the arc-shaped bottom plate (331) fits the surface of the pipeline (31), the probe module (2) is installed in the probe mounting cylinder (332), the compression bolt (35) passes through the disc spring assembly (37) and then is threadedly connected to the inside of the probe mounting cylinder (332), the compression bolt (35) abuts against the probe module (2), the nut (36) is threadedly connected to the compression bolt (35), and the nut (36) presses the disc spring assembly (37) against the probe mounting cylinder (332).

2. The multi-point online wall thickness monitoring device according to claim 1, characterized in that, The number of the probe interface modules (12) is 16, the probe interface modules (12) adopt anti-misinsertion aviation sockets arranged in a matrix, each socket integrates an independent signal conditioning circuit, the probe interface modules (12) are provided with various size specifications, and the probe interface modules (12) are internally provided with extension boards of different specifications.

3. The multi-point online wall thickness monitoring device according to claim 1, characterized in that The probe module (2) includes a housing (21), a heat insulation sleeve (22), a temperature compensation sensor (23), a coupling surface (24), a fast epoxy layer (25), a damping (26), a piezoelectric ceramic wafer (27), a sound insulation layer (28) and a delay block (29); The housing (21) is located on the outermost layer of the probe module (2), and the heat insulation sleeve (22) is arranged inside the housing (21); the temperature compensation sensor (23) is encapsulated with the piezoelectric ceramic wafer (27) and the delay block (29) to form an inner layer; the sound insulation layer (28) is located in the middle layer, and the sound insulation layer (28) is covered with a fast epoxy layer (25); the coupling surface (24) is located at the bottom of the probe module (2), and the damping (26) is located on the piezoelectric ceramic wafer (27).

4. The multi-point on-line wall thickness monitoring device according to claim 3, characterized in that, The coupling surface (24) adopts a composite structure of a nano-level alumina abrasive layer and a hydrogel patch.

5. The multi-point online wall thickness monitoring device according to claim 1, characterized in that, The main unit (1) is provided with an RS485 wired interface and a LoRa wireless unit.

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