Real-time visual device for ultrasonic detection of weld defects

Abstract

The utility model discloses a real-time visual device for ultrasonic detection of weld defects, which is used for nondestructive detection of metal weld defects and comprises a metal film track groove, a detection vehicle, a single chip microcomputer, a rotary hinge, a sampling plate and a computer. The small magnetic wheels are arranged on the two sides of the metal film track groove correspondingly, and the detection vehicle is arranged in a hollow structure of the metal film track groove and connected with the metal film track groove in a sliding fit mode through the auxiliary track clamping groove. And the detection vehicle is also provided with an inertial sensor, a coupling agent spraying device, a magnetic pressure elastic supporting column, an angle probe clamping groove and an angle probe located in the angle probe clamping groove. According to the utility model, the visualization of the ultrasonic nondestructive testing process is realized, the requirements on testing personnel are reduced, and the reliability of defects and evaluation thereof is improved; the detection efficiency is improved, including the detection efficiency and the efficiency of forming an evaluation report, the detection period is shortened, and the influence period on production is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of nondestructive detection of metal weld defects, in particular to a real-time visualization device for ultrasonic detection of weld defects. Background Art

[0002] Equipment is a key symbol of modern civilization and a crucial foundation for social development. Without it, humanity would revert to the ancient agricultural and pastoral era of manual labor. Welding is a fundamental process in nearly all equipment manufacturing processes. Equipment involving critical safety issues, such as boilers, pressure vessels, pressure piping, elevators, lifting machinery, amusement rides, and motor vehicles, has been regulated by the state as special equipment. Welds are a key component in determining the safety and reliability of welded equipment or structures. Therefore, the Regulations on the Safety Management of Special Equipment and relevant national standards require not only nondestructive testing of welds after equipment manufacturing is complete, but also regular nondestructive testing and evaluation of welds on in-service equipment or structures. The petroleum and chemical industries operate a vast number of special equipment, posing a heavy burden of regular inspections. These inspections require production suspensions, require a large number of professionals and equipment, are labor-intensive, and require long inspection cycles.

[0003] Ultrasonic testing technology, with its advantages of low cost, high accuracy, environmental friendliness, and portability, has long been the primary method for nondestructive testing of welds. However, traditional ultrasonic testing has issues such as high requirements for the quality of inspectors, long weld assessment and reporting cycles, poor traceability of test data, and the inability to verify them. Visualizing ultrasonic information during weld inspection can improve the evaluation efficiency of the inspection process, reduce the requirements for inspectors, improve data traceability, and shorten the reporting cycle.

[0004] Currently, in the literature research on ultrasonic testing of welds, "Analysis of Nondestructive Testing Methods for Finished Oil Pipelines," a comparative analysis shows that ultrasonic testing has advantages over phased array ultrasonic testing in terms of detection calibration, adjustment, and technical requirements. At the same time, most phased array devices have complex structures. For example, the "Pressure Vessel Defect Detection Device" (CN201720851191.1) uses the circumferential motion of a stepper motor on a gear groove to automatically detect girth welds; the "Weld Flaw Detection Device and Method for Use for Pressure Vessels" (CN202211174021.6) designs a large-scale ultrasonic sliding ultrasonic testing device. By transporting the pressure vessel into the device, the device can complete the inspection and mark the defective areas; and the "Automatic Ultrasonic Testing Device for Girth Welds of Through-Parts" (CN202211103419. 0) It adopts a segmented splicing structure, which contains a laser paint removal module inside to automatically complete the defect detection of the weld; "An ultrasonic automatic detection device for girth welds" (CN202222485787.8) uses a tram method to automatically complete the defect detection of the weld, ensuring the accuracy of the movement trajectory of the trolley and the relevant information of the defect; "An ultrasonic detection device for annular welds" (CN202320130479.5) designs a set of mobile ultrasonic girth weld detection boxes, which can complete the detection of welds through cylinders and translation structures, and are equipped with a vacuum cleaner to clean the detection surface. However, the existing technology still has the following limitations:

[0005] (1) There is a lack of real-time visualization of the ultrasonic propagation process, which requires high reliability in judging defects and their evaluation;

[0006] (2) It is impossible to form a visual database for ultrasonic detection of weld defects and their positioning, which makes it difficult to achieve traceability and cannot provide support for dynamic monitoring of weld safety of equipment in the production process.

[0007] In order to solve the above problems, the present invention uses theoretical and experimental methods combined with the principle of ultrasonic detection to design a real-time visualization method and device for ultrasonic detection of weld defects. The overall structure of the device is simple and low-cost. It can not only realize the visualization of ultrasonic propagation and defects, but also establish a complete weld database with defect locations, laying the foundation for in-service dynamic monitoring and real-time analysis of related equipment. Utility Model Content

[0008] The utility model overcomes the shortcomings of the existing technology and provides a real-time visualization device for ultrasonic detection of weld defects. It aims to solve the problem of visualization of ultrasonic propagation in the detection process and volumetric visualization of weld defects through data from ultrasonic and inertial sensors, establish a weld visualization database with defect positioning, and avoid the problems of manual missed detection and false detection.

[0009] In view of the above problems of the prior art, according to one aspect of the present invention, in order to solve the above technical problems, the present invention adopts the following technical solutions:

[0010] A real-time visualization device for ultrasonic detection of weld defects, comprising:

[0011] The metal film track groove has small magnetic wheels on both sides, and the middle part of the metal film track groove is a hollow structure;

[0012] An inspection vehicle is disposed within the hollow structure of the metal film track groove and is slidably connected to the metal film track groove via an auxiliary rail slot; the inspection vehicle is provided with a large magnetic wheel for contacting and rolling on the surface of the pressure vessel to be inspected, the large magnetic wheel being driven by an encoder motor; and the inspection vehicle is further provided with an inertial sensor, a coupling agent spraying device, a magnetic pressure spring support, an angle probe slot, and an angle probe located in the angle probe slot;

[0013] A single chip microcomputer, in which a transformer module is provided, for supplying power to the detection vehicle; and receiving signals from the inertial sensor and the oblique probe;

[0014] A sampling board connected to the single chip microcomputer;

[0015] The computer is connected to the sampling board, receives the waveform signal from the sampling board and displays it.

[0016] In order to better realize the utility model, a further technical solution is:

[0017] Furthermore, the sampling board is an FPGA sampling board.

[0018] Furthermore, it also includes a rotating hinge, and the large magnetic wheel is connected to the rotating hinge.

[0019] Compared with the prior art, one of the beneficial effects of the present invention is:

[0020] (1) It solves the visualization of the ultrasonic nondestructive testing process, reduces the requirements for testing personnel, and improves the reliability of defects and their evaluation;

[0021] (2) Improved the efficiency of regular inspection, including improving the efficiency of inspection and the efficiency of forming evaluation reports, shortening the inspection cycle, and reducing the impact on production cycle;

[0022] (3) The visualization database of ultrasonic detection of weld defects and their positioning provides basic support for the traceability of weld safety evaluation and dynamic monitoring of equipment weld safety, which is conducive to further improving production safety.

[0023] (4) The practical device has a simple structure, good portability, low cost, and can also identify the type of weld defects. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the embodiments of this application document or the technical solutions in the prior art, the following is a brief introduction to the drawings required for the description of the embodiments or the prior art. Obviously, the drawings described below are only references to some embodiments in this application document. For those skilled in the art, other drawings can be obtained based on these drawings without creative work.

[0025] Figure 1 The figure is a schematic structural diagram of a real-time visualization device for ultrasonic detection of weld defects according to one embodiment of the present invention.

[0026] Figure 2 The figure is a schematic structural diagram of a real-time visualization device for ultrasonic detection of weld defects according to one embodiment of the present invention.

[0027] Figure 3 Schematic diagram of device detection according to one embodiment of the present invention.

[0028] The names corresponding to the reference numerals in the accompanying drawings are:

[0029] 1-Computer, 2-Sampling board, 3-Single-chip microcomputer, 301-220V to 24V transformer, 302-Ultrasonic echo signal sampling point, 4-Small magnetic wheel, 5-Metal film track groove, 6-Magnetic pressure spring support, 7-Couplant spray device, 8-Inertial sensor, 9-Encoder motor, 10-Rotary hinge, 11-Auxiliary rail slot, 12-Large magnetic wheel, 13-Detection vehicle, 14-Angle probe slot. DETAILED DESCRIPTION

[0030] The present invention will be further described in detail below with reference to the embodiments, but the embodiments of the present invention are not limited thereto.

[0031] like Figure 1 、 Figure 2 and Figure 3As shown, a real-time visualization device for ultrasonic detection of weld defects includes a metal film track groove 5, a detection vehicle 13, a single-chip computer 3, a rotary hinge 10, a sampling plate 2 and a computer 1; small magnetic wheels 4 are respectively provided on both sides of the metal film track groove 5, and the middle part of the metal film track groove 5 is a hollow structure; the detection vehicle 13 is provided in the hollow structure of the metal film track groove 5, and the detection vehicle 13 is slidably connected to the metal film track groove 5 through an auxiliary rail slot 11; the detection vehicle 13 is provided with a device for detecting the surface of the pressure vessel to be detected. A large magnetic wheel 12, which is surface-contacting and rolling, is driven by an encoder motor 9. The inspection vehicle 13 is also equipped with an inertial sensor 8, a coupling agent spray device 7, a magnetic pressure spring support 6, an angle probe slot 14, and an angle probe located within the angle probe slot 14. A transformer module is provided within the single-chip microcomputer 3 to supply power to the inspection vehicle 13 and receive signals from the inertial sensor 8 and the angle probe. A sampling board 2 is connected to the single-chip microcomputer 3. A computer 1 is connected to the sampling board 2 to receive and display waveform signals from the sampling board 2. The large magnetic wheel 12 is connected to the rotary hinge 10.

[0032] The sampling board 2 may preferably be an FPGA sampling board.

[0033] This new device, based on ultrasonic pulse reflection technology and probe inertial data, uses the real-time visualization of weld defects in circumferential and longitudinal welds of pressure vessels. Using quadratic integration of acceleration, it acquires ultrasonic waveform data from the ultrasonic probe at different weld locations and analyzes the characteristic signals of different defect types. Based on the test results, it creates parametric modeling of the defect location, performs ultrasonic waveform simulation, and compares the results with actual circumferential waveform data to avoid missed and false detections.

[0034] Detection method:

[0035] (1) Pressure vessel defect detection method: Calibrate the accelerometer and gyroscope of the inertial sensor 8 and reset the carrier coordinate system. Based on the specific parameters of the inspection object (wall thickness), select appropriate angle probe parameters (K value, frequency), and insert the selected angle probe into the angle probe slot 14 of the inspection vehicle 13. According to the industry standard NBT47013.3-2015, determine the inspection range of the weld, fit the small magnetic wheel 4 and the large magnetic wheel 12 to the pressure vessel to be inspected, and fill the coupling agent spray device 7. The coupling agent spray device 7 is turned on and ultrasonic excitation is started. After the waveform signal at this point is transmitted to the computer 1, the encoder motor 9 is started to slowly move the inspection vehicle 13 from the left end to the right end of the metal film track groove 5. Each time the inspection vehicle 13 moves, an ultrasonic excitation signal is emitted, and the sampling plate 2 is used to collect ultrasonic waveform data at high speed. When the inspection vehicle 13 moves to the right end, the metal film track groove 5 is moved along the circumferential direction of the pressure vessel. Without the inspection vehicle 13 moving, the track is laid forward, so that the inspection vehicle 13 is again at the left end of the metal film track groove 5. This operation is repeated until the entire circumferential inspection is completed. After the circumferential inspection is complete, the magnetic spring-loaded support 6 on top of the inspection vehicle 13 is pressed to lift the vehicle 13. The hinge 10 then rotates the four large magnetic wheels 12 of the inspection vehicle 13 parallel to the pressure vessel's axis. The magnetic spring-loaded support 6 is pressed again, causing the large magnetic wheels 12 to align with the pressure vessel and complete the axial displacement. The displacement is recorded by the encoder motor 9 and controlled by the computer 1. The circumferential inspection method is repeated until the nondestructive testing of the entire girth weld to be inspected is complete. (Note: Pressure vessels primarily have girth welds and longitudinal welds. Since the metal track groove 5 is made of a softer material, it can also be paved to complete the longitudinal weld inspection.)

[0036] (2) Method for determining the spatial location and category of defects: The inertial data of the probe and the movement data of the encoder motor 9 are obtained through the inertial sensor 8, and the discrete ultrasonic three-dimensional sampling points on the pressure vessel are matched one by one with the discrete ultrasonic amplitude curves in the computer 1.

[0037] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0038] References in this specification to "one embodiment," "another embodiment," "an embodiment," etc., refer to specific features, structures, or characteristics described in conjunction with that embodiment as included in at least one embodiment generally described in this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in conjunction with any embodiment, it is intended that such feature, structure, or characteristic, when implemented in conjunction with other embodiments, also fall within the scope of the present invention.

[0039] Although the present invention has been described herein with reference to a number of illustrative embodiments thereof, it will be understood that numerous other modifications and implementations may be devised by those skilled in the art that fall within the scope and spirit of the principles disclosed herein. More specifically, within the scope of the present disclosure, the drawings, and the claims, numerous variations and modifications may be made to the components and / or arrangement of the subject combination arrangement. In addition to variations and modifications to the components and / or arrangement, other uses will also be apparent to those skilled in the art.

Claims

1. A real-time visualization device for ultrasonic detection of weld defects, characterized in that: include: A metal film track groove (5) is provided with small magnetic wheels (4) on both sides thereof, and the middle portion of the metal film track groove (5) is a hollow structure; An inspection vehicle (13) is provided in the hollow structure of the metal film track groove (5), and the inspection vehicle (13) is connected to the metal film track groove (5) by sliding cooperation via an auxiliary rail slot (11); a large magnetic wheel (12) is provided on the inspection vehicle (13) for fitting and rolling on the surface of the pressure vessel to be inspected, and the large magnetic wheel (12) is driven by an encoding motor (9); and an inertial sensor (8), a coupling agent spraying device (7), a magnetic pressure spring support (6), an oblique probe slot (14), and an oblique probe located in the oblique probe slot (14); A single chip microcomputer (3) is provided with a voltage conversion module therein for supplying power to the detection vehicle (13); and receiving signals from the inertial sensor (8) and the oblique probe; A sampling plate (2) connected to the single chip computer (3); A computer (1) is connected to the sampling board (2) and receives the waveform signal from the sampling board (2) and displays it.

2. The real-time visualization device for ultrasonic detection of weld defects according to claim 1, characterized in that: The sampling board (2) is an FPGA sampling board.

3. The real-time visualization device for ultrasonic detection of weld defects according to claim 1, characterized in that: It also includes a rotary hinge (10), and the large magnetic wheel (12) is connected to the rotary hinge (10).

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