High-temperature pipeline electromagnetic ultrasonic online detection device based on Internet of Things

Abstract

The utility model discloses a high-temperature pipeline electromagnetic ultrasonic online detection device based on the Internet of Things. The high-temperature pipeline electromagnetic ultrasonic online detection device comprises a continuous high-temperature-resistant electromagnetic ultrasonic probe, an electromagnetic ultrasonic in-situ monitoring node, an Internet of Things communication device, a cloud server and a client server, the continuous high-temperature-resistant electromagnetic ultrasonic detection probe is used for realizing excitation and receiving of ultrasonic waves on the surface of the working steel pipe through a magnetic-acoustic effect; the electromagnetic ultrasonic in-situ monitoring node is used for providing strong transient current and similar direct current for ultrasonic excitation, providing low-noise and high-gain amplification for ultrasonic receiving, simultaneously realizing analog-to-digital conversion of ultrasonic echo signals to obtain corresponding detection data, and transmitting the detection data to the Internet of Things communication device; the Internet of Things communication device, the cloud server and the client server are in communication connection in sequence. According to the utility model, the continuous high-temperature-resistant electromagnetic ultrasonic probe is adopted to realize continuous detection of a high-temperature pipeline; and remote online monitoring of defect expansion data of the high-temperature and high-pressure pipeline based on wireless networking of the Internet of Things is realized.

Description

Technical Field

[0001] The utility model relates to the technical field of ultrasonic detection, in particular to an electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things. Background Art

[0002] High-temperature and high-pressure pipelines widely used in power plants, petrochemicals, steel, nuclear power and other industries cannot provide timely pipeline burst warnings and remaining life assessments due to the lack of online non-destructive monitoring technology. This has led to forced shutdowns of units and even serious accidents such as pipeline cracking, leakage, and bursts, resulting in significant casualties and economic losses.

[0003] Currently, many pipelines in power plants and petrochemical plants have a service life exceeding 20 years, far exceeding their design lifespan. However, high-temperature pipelines are often difficult to replace. For example, the main pipelines of power plant boilers must remain in operation at all times. Furthermore, for complete sets of equipment, large-scale replacements involve significant costs and production downtime. Because high-temperature, high-pressure pipelines reach temperatures as high as 550°C and are covered with insulation, conventional testing methods such as thickness measurement, ultrasonic testing, and on-site metallographic examinations are difficult to implement.

[0004] However, the difficulties in achieving remaining life and hazard warning of high-temperature and high-pressure steam pipelines with existing technologies are: ① Traditional sensor technology is difficult to achieve continuous high-temperature online detection and monitoring at 550°C, and the corresponding ultra-high-temperature piezoelectric sensors are still in the experimental research and development stage, with extremely high costs and difficult to achieve large-scale application; ② The existing detection methods are difficult to adapt to the special pipeline structure of "outer steel pipe-30~70mm insulation layer-working steel pipe", and it is difficult to achieve corrosion thinning measurement and defect detection of the working steel pipe without damaging the outer steel pipe and insulation layer; ③ The existing high-temperature and high-pressure pipelines are mostly regular non-destructive testing and inspection in a shutdown state. Usually, the pipelines are large in scale and complex in layout, with poor detection accessibility. Manual inspection is mostly used, with low detection efficiency and heavy detection tasks. In addition, it is difficult to achieve process records of the pipeline wall corrosion thinning rate and defect expansion, which brings great difficulties to regular inspection and maintenance.

[0005] There are many different traditional ultrasonic testing technologies, such as piezoelectric ultrasound, high-temperature moiré ultrasound, electromagnetic ultrasound, laser ultrasound, and air-coupled ultrasound, which are all commonly used non-destructive testing methods. For high-temperature castings and forgings, the special feature of piezoelectric ultrasonic testing that requires a coupling agent determines that traditional piezoelectric ultrasound cannot detect castings and forgings under high-temperature conditions. As for air-coupled ultrasound, which does not require a coupling agent, its ultrasonic initial wave signal resonates too long, and it mostly uses the transmission method for testing, so it is only applicable to loose and porous materials such as composite materials, wood, and ceramics and cannot be adopted for use.

[0006] Laser ultrasound and electromagnetic ultrasound have the advantages of being non-contact, requiring no coupling agent, and easily exciting various ultrasonic waves. They are unanimously considered by domestic and foreign scholars to be the most suitable and key technologies for non-destructive testing in ultra-high temperature environments. However, the laser of the former is too large and expensive, and its detection principle, which is mainly based on the ablation effect, will cause damage to the surface of the test piece, so it cannot be adopted and used. The latter electromagnetic ultrasound is based on the Lorentz force and magnetostrictive effect. Its probe can directly excite ultrasonic waves on the metal test block without contact and coupling, which is very suitable for non-destructive testing of pipelines in high-temperature closed environments.

[0007] Therefore, a new wireless transmission non-destructive testing technology is urgently needed to monitor key parts of pipelines in real time, such as the local wall thickness thinning of elbows and the defect expansion of butt welds, so as to evaluate the remaining life of the pipeline and provide dangerous warnings for pipeline bursts. Utility Model Content

[0008] The purpose of this utility model is to provide an electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things. The device adopts a continuously high-temperature resistant electromagnetic ultrasonic probe with high energy conversion efficiency to achieve continuous detection of high-temperature pipelines at 550°C. An Internet of Things communication device is set to realize remote wireless communication, breaking through the limitation of the traditional detection terminal being a local PC terminal, and realizing online monitoring of high-temperature and high-pressure pipeline defects based on the wireless networking of the Internet of Things.

[0009] To achieve the above purpose, the present invention provides the following solutions:

[0010] An Internet of Things-based electromagnetic ultrasonic online detection device for high-temperature pipelines, comprising: a continuous high-temperature-resistant electromagnetic ultrasonic probe, an electromagnetic ultrasonic in-situ monitoring node, an Internet of Things communication device, a cloud server, and a client server; the continuous high-temperature-resistant electromagnetic ultrasonic probe is electrically connected to the electromagnetic ultrasonic in-situ monitoring node, the electromagnetic ultrasonic in-situ monitoring node is communicatively connected to the Internet of Things communication device, the Internet of Things communication device is communicatively connected to the cloud server, and the cloud server is communicatively connected to the client server;

[0011] The continuous high temperature resistant electromagnetic ultrasonic detection probe is used to realize the excitation and reception of ultrasonic waves on the surface of the working steel pipe through the magneto-acoustic effect;

[0012] The electromagnetic ultrasonic in-situ monitoring node includes an electromagnetic ultrasonic detection circuit and a wireless communication module; the electromagnetic ultrasonic in-situ monitoring node is used to provide strong transient current and quasi-DC for ultrasonic excitation of the continuous high-temperature resistant electromagnetic ultrasonic detection probe, provide low-noise and high-gain amplification for ultrasonic reception of the continuous high-temperature resistant electromagnetic ultrasonic probe, and simultaneously realize analog-to-digital conversion of the ultrasonic echo signal to obtain corresponding detection data, and is used to transmit the detection data to the Internet of Things communication device;

[0013] The IoT communication device is used to collect detection data of each electromagnetic ultrasonic in-situ monitoring node and transmit it to the cloud server;

[0014] The cloud server is used for storing and managing detection data;

[0015] The client server is used to read the detection data in the cloud server and display it on the user end. The displayed information includes the location and equivalent of the thinning wall thickness and welding part defects of the high-temperature pipeline.

[0016] Furthermore, the Internet of Things communication device includes a LoRa relay and a LoRa gateway, the wireless communication module in the electromagnetic ultrasonic in-situ monitoring node is a LoRa wireless transmission module, the LoRa wireless transmission module is connected to the LoRa relay, the LoRa relay is connected to the LoRa gateway, and the LoRa gateway is connected to the cloud server;

[0017] The LoRa relay is used to provide wireless transmission energy for the LoRa wireless transmission module of the electromagnetic ultrasonic in-situ monitoring node when the distance between the electromagnetic ultrasonic in-situ monitoring node and the LoRa gateway exceeds the limit distance;

[0018] The LoRa gateway is a device that connects each electromagnetic ultrasonic in-situ monitoring node with the LoRa WLAN network. It is responsible for collecting data from each electromagnetic ultrasonic in-situ monitoring node and transmitting it to the cloud server.

[0019] Furthermore, the Internet of Things communication device includes a wireless router and a communication base station. The wireless communication module in the electromagnetic ultrasonic in-situ monitoring node is a WiFi communication module. Communication connections are established in sequence among the WiFi communication module, the wireless router, the communication base station, and the cloud server.

[0020] Furthermore, the continuous high-temperature resistant electromagnetic ultrasonic probe includes: a butterfly coil, a magnetostrictive patch, and a waveguide rod; the butterfly coil is located above the magnetostrictive patch; and the magnetostrictive patch is located above the waveguide rod.

[0021] Furthermore, the high-temperature resistant electromagnetic ultrasonic detection probe includes a probe housing, a butterfly coil, and a corundum sheet; the corundum sheet is arranged at the bottom of the probe housing; the butterfly coil is arranged in the probe housing and located above the corundum sheet; the cavity formed by the probe housing and the corundum sheet is filled with ceramic filler.

[0022] Furthermore, the butterfly coil in the continuous high-temperature resistant electromagnetic ultrasonic probe is a planar butterfly coil, which is composed of 2-4 butterfly coils in series; the magnetostrictive patch in the continuous high-temperature resistant electromagnetic ultrasonic probe is made of giant magnetostrictive material terbium dysprosium iron TbDyFe, and the magnetostriction coefficient is as high as 1200PPM.

[0023] Furthermore, the waveguide rod in the continuous high-temperature resistant electromagnetic ultrasonic probe is made of stainless steel. One end of the waveguide rod passes through the insulation layer of the high-temperature pipeline and is directly welded to the outer wall surface of the working steel pipe, and the other end is connected to the magnetostrictive patch through an adhesive with good sound conductivity.

[0024] Furthermore, the electromagnetic ultrasonic in-situ monitoring node is electrically connected to the continuous high-temperature resistant electromagnetic ultrasonic probe, and the electromagnetic ultrasonic in-situ monitoring node passes a discharge current including a strong transient current and a DC-like current into the butterfly coil in the continuous high-temperature resistant electromagnetic ultrasonic probe, and detects the ultrasonic echo signal received by the butterfly coil.

[0025] Furthermore, the electromagnetic ultrasonic detection circuit is a pulsed electromagnet type electromagnetic ultrasonic detection circuit, including a high-voltage strong pulse excitation module, a low-voltage DC excitation module, an echo detection module and an impedance matching module of a butterfly coil. The capacitor group of the high-voltage strong pulse excitation module is transiently charged and discharged under the control of the MOS tube switch, and the low-voltage DC excitation module is controlled by the IBGT switch module for charging and discharging; the high-voltage excitation strong pulse module and the low-voltage DC excitation module are connected in parallel to each other and are electrically connected to the butterfly coil through the probe interface respectively; the echo detection module is electrically connected to the butterfly coil through the probe interface.

[0026] Furthermore, the electromagnetic ultrasonic in-situ monitoring node also includes an FPGA control module and an AD acquisition module. The FPGA control module is electrically connected to the AD acquisition module, and the AD acquisition module is electrically connected to the electromagnetic ultrasonic detection circuit. The AD acquisition module is used to realize analog-to-digital conversion of the ultrasonic echo signal; the FPGA control module is electrically connected to the MOS tube switch and the IBGT switch module respectively.

[0027] According to the specific embodiments provided by the present invention, the present invention discloses the following technical effects: the electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things provided by the present invention, first, adopts a continuous high-temperature resistant electromagnetic ultrasonic detection probe, whose detection sensitivity and detection resolution are higher than those of general electromagnetic ultrasonic probes, and does not have a permanent magnet. The device is small in size and has high conversion efficiency. The residual magnetic induction intensity of the permanent magnet will not be weakened or dissipated in a high-temperature environment due to the influence of the Curie temperature. Therefore, it can avoid the influence of high temperature and narrow space on it, thereby realizing imaging detection of internal defects of high-temperature and high-pressure steam pipelines; second, the electromagnetic ultrasonic in-situ monitoring node is provided with a wireless communication module, and wireless communication connection is realized through the Internet of Things communication device based on the Internet of Things technology, breaking through the limitation of the traditional detection method that the detection terminal is a local PC terminal, avoiding the weak mobility of traditional local PC terminal detection and the complexity of laying a large number of lines, improving the intelligence and flexibility of industrial detection, thereby meeting the application of unmanned real-time online defect analysis and monitoring based on the Internet of Things wireless networking in high-temperature and high-pressure nuclear power steam pipeline detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the utility model or the technical solutions in the prior art, the following is a brief introduction to the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0029] Figure 1 This is a structural diagram of an electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things in accordance with the first embodiment of the present invention;

[0030] Figure 2 This is a schematic diagram of the installation of an electromagnetic ultrasonic monitoring probe for a high-temperature pipeline according to a first embodiment of the present utility model;

[0031] Figure 3 Schematic diagram of the electromagnetic ultrasonic transduction mechanism based on the Lorentz force in Example 1 of the present invention, wherein (a) is a discharge current curve diagram containing high-frequency strong pulse components and quasi-DC components, (b) is a butterfly coil, and (c) is a schematic diagram of the electromagnetic ultrasonic transduction mechanism based on the Lorentz force;

[0032] Figure 4 This is a schematic diagram of the electromagnetic ultrasonic transducer mechanism based on the magnetostrictive effect according to the first embodiment of the present invention;

[0033] Figure 5 This is a functional schematic diagram of a pulsed electromagnet type electromagnetic ultrasonic detection circuit of an electromagnetic ultrasonic in-situ monitoring node in accordance with a first embodiment of the present invention;

[0034] Figure 6This is a structural diagram of a high-temperature pipeline electromagnetic ultrasonic online detection device based on the Internet of Things in Example 2 of the present utility model;

[0035] Figure 7 This is a schematic structural diagram of an electromagnetic ultrasonic monitoring probe for a high-temperature pipeline according to a second embodiment of the present invention, wherein (a) is a cross-sectional view of the probe and (b) is a top view of the probe.

[0036] Description of reference numerals:

[0037] 101 - High-temperature pipe with coating; 102 - Continuously high-temperature-resistant electromagnetic ultrasonic probe; 103 - Electromagnetic ultrasonic in-situ monitoring node; 104 - LoRa relay; 105 - LoRa gateway; 106 - Cloud server; 107 - Client server;

[0038] 201-working steel pipe; 202-outer pipe; 203-butterfly coil (straight segment); 204-magnetostrictive patch; 205-waveguide rod; 206-insulation layer;

[0039] 301-waveguide rod; 302-magnetostrictive patch; 303-butterfly coil (straight segment);

[0040] 401-waveguide rod; 402-magnetostrictive patch; 403-butterfly coil (straight segment);

[0041] 501-Echo detection module; 502-High voltage pulse excitation module; 503-Low voltage DC excitation module; 504-Butterfly coil and its impedance matching module;

[0042] 601-device hardware circuit part; 602-WiFi communication module; 603-wireless router; 604-communication base station; 605-cloud platform; 606-cloud server; 607-client server;

[0043] 701-butterfly coil; 702-corundum sheet; 703-probe housing; 704-ceramic filler; 705-probe interface; 706-copper guide wheel. DETAILED DESCRIPTION

[0044] The following will clearly and completely describe the technical solutions in the utility model embodiments in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the utility model embodiments, not all of the embodiments. Based on the utility model embodiments, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of utility model protection.

[0045] In the description of utility model patents, it is important to understand that the terms "upper", "lower", "front", "back",

[0046] The directions or positional relationships indicated by “left,” “right,” “top,” “bottom,” “inside,” “outside,” “center,” “longitudinal,” “lateral,” “vertical,” and “horizontal” are based on the directions or positional relationships shown in the accompanying drawings and are intended only to facilitate the description of the utility model and simplify the description. They do not indicate or imply that the devices or elements referred to must have a specific direction, be constructed and operate in a specific direction, and therefore should not be understood as limitations on the utility model. When an element is referred to as being “fixed to” another element, it may be directly on the other element or there may be an element centered therebetween. When an element is considered to be “connected to” another element, it may be directly connected to the other element or there may be an element centered therebetween.

[0047] The purpose of the utility model is to provide an electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things. The device adopts an organic combination of a butterfly coil, a magnetostrictive patch, a waveguide rod and an electromagnetic ultrasonic detection circuit with quasi-DC excitation to achieve the excitation and reception of ultrasonic waves in 550°C high-temperature pipelines, realize the online monitoring of local thinning of pipeline bends and weld crack equivalents, and provide data reference for the remaining life assessment and hazard warning of high-temperature and high-pressure pipelines.

[0048] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is further described in detail below with reference to the accompanying drawings and specific implementation methods.

[0049] like Figure 1 As shown, preferably, an electromagnetic ultrasonic online detection device for a high-temperature pipeline based on the Internet of Things provided in Example 1 of the present invention includes: a high-temperature pipeline with a coating layer 101, a continuous high-temperature resistant electromagnetic ultrasonic probe 102, an electromagnetic ultrasonic in-situ monitoring node 103, a LoRa relay 104, a LoRa gateway 105, a cloud server 106, and a client server 107; the continuous high-temperature resistant electromagnetic ultrasonic probe 102 is electrically connected to the electromagnetic ultrasonic in-situ monitoring node 103, the electromagnetic ultrasonic in-situ monitoring node 103 is electrically connected to the LoRa relay 104, the LoRa relay 104 is connected to the LoRa gateway 105, the LoRa gateway 105 is connected to the cloud server 106, and the cloud server 106 is connected to the client server 107;

[0050] The LoRa relay 104 and the LoRa gateway 105 constitute an Internet of Things communication device, and the wireless communication module in the electromagnetic ultrasonic in-situ monitoring node is a LoRa wireless transmission module, which is connected to the LoRa relay 104;

[0051] The continuous high temperature resistant electromagnetic ultrasonic detection probe 102 is used to realize the excitation and reception of ultrasonic waves on the surface of the working steel pipe 101 through the magneto-acoustic effect;

[0052] The electromagnetic ultrasonic in-situ monitoring node 103 is used to provide strong transient current and quasi-DC for ultrasonic excitation of the continuous high-temperature resistant electromagnetic ultrasonic detection probe 102, provide low-noise and high-gain amplification for ultrasonic reception of the continuous high-temperature resistant electromagnetic ultrasonic detection probe 102, and realize analog-to-digital conversion of ultrasonic echo signals. It integrates a LoRa wireless transmission module to realize wireless transmission of data.

[0053] The LoRa relay 104 is used to provide wireless transmission energy for the LoRa wireless transmission module of the electromagnetic ultrasonic in-situ monitoring node 103 when the distance between the electromagnetic ultrasonic in-situ monitoring node 103 and the LoRa gateway 105 exceeds the limit distance;

[0054] The LoRa gateway 105 is a device that connects each electromagnetic ultrasonic in-situ monitoring node 103 with the LoRa WLAN network, and is responsible for collecting data from each electromagnetic ultrasonic in-situ monitoring node and transmitting it to the cloud server 106;

[0055] The cloud server 106 is used for data storage and management;

[0056] The client server 107 is used to read data from the cloud server and display it on the user end, mainly including data such as the thinning wall thickness of the high-temperature pipeline and the location and equivalent of defects in the welding part.

[0057] like Figure 2 Schematic diagram of the installation of the electromagnetic ultrasonic detection probe 102 for continuous high-temperature pipeline high-temperature resistance, including a working steel pipe 201 (e.g., a carbon steel pipe); an outer casing pipe 202 (e.g., a steel pipe or an aluminum pipe); a butterfly coil 203 (e.g., a flexible printed circuit board or high-temperature enameled wire); a magnetostrictive patch 204 (e.g., a giant magnetostrictive material, terbium dysprosium iron); a waveguide rod 205 (e.g., 304 stainless steel); and an insulation layer 206 (e.g., cork, aluminum silicate, polystyrene, or polyurethane). One end of the waveguide rod 205 is brazed, bonded, or welded to the working steel pipe 201, ensuring weld quality (no defects and reliable transmission of acoustic energy). The other end is bonded to the magnetostrictive patch 204. The butterfly coil 203 is located above the magnetostrictive patch 204.

[0058] The advantages of the continuous high-temperature-resistant electromagnetic ultrasonic detection probe 102 in this embodiment are as follows: First, the magnetostrictive patch is made of giant magnetostrictive material (terbium-dysprosium-iron), which can improve its energy conversion efficiency by more than ten times compared to traditional piezoelectric ultrasonic sensors. Second, in addition to passing short pulses of current through the butterfly coil, a long-duration quasi-DC current is also required to provide a static bias magnetic field for the magnetostrictive patch, orienting and controlling the magnetic domains within the magnetostrictive patch, thereby enhancing the magnetostrictive effect. Compared with traditional magnetostrictive sensors, this method does not require an external permanent magnet or periodic magnetization, offering advantages such as ease of use, compact size, and permanent installation. Third, a waveguide with weak thermal conductivity is used, with one end passing through the insulation layer and connected to the working steel pipe, and the other end connected to the magnetostrictive patch. The magnetostrictive patch is made of terbium-dysprosium-iron material. Terbium-dysprosium-iron and the butterfly coil can achieve continuous high-temperature resistance of at least 300°C. The waveguide rod is made of 304 stainless steel with poor thermal conductivity and small grains. The combination of the above methods can achieve continuous monitoring of high-temperature pipelines at 550°C.

[0059] Specifically, the coil 201 described in the embodiment of the utility model is a butterfly coil. The butterfly coil is very suitable for forming a uniform gathering at the end of a rod or shaft, and its focusing property is far better than other types of coils. The butterfly coil has two specially formed circular coils, and the center turns must be wound in the same direction, so its current path is additive. The butterfly coil specifically refers to a planar butterfly coil, which is formed by two circular coils connected in series. The butterfly coil can be formed by connecting multiple coils in series. The butterfly coil is wound on a flexible printed circuit board or high-temperature enameled wire. When high-temperature enameled wire is used for winding, the diameter of the cylindrical wire is Φ0.15mm-0.55mm, and the number of turns is 5-10 turns. When a flexible printed circuit board is used, the height of the square wire is 1OZ, the width is 0.1mm-0.3mm, the number of turns is 5-30 turns, and the boundary distance between adjacent wires is 0.1mm.

[0060] In order to improve the continuous high-temperature resistance of the electromagnetic ultrasonic detection probe, the magnetostrictive patch is made of terbium-dysprosium-iron material. Terbium-dysprosium-iron and the butterfly coil can achieve continuous high-temperature resistance of at least 300°C. The waveguide rod is made of 304 stainless steel with poor thermal conductivity and small grains. The combination of the above methods can achieve continuous monitoring of high-temperature pipelines at 550°C.

[0061] Figure 3 Schematic diagram of electromagnetic ultrasonic transduction mechanism based on Lorentz force. When a discharge current containing a high-frequency strong pulse component and a quasi-DC component is passed through the butterfly coil 303, a static magnetic induction intensity B can be generated in the magnetostrictive patch 302 under the action of the quasi-DC component. s Under the action of high-frequency strong pulse components, eddy current J can be generated in the magnetostrictive patch izThe combined effect of the static magnetic field and eddy currents generates a Lorentz force on the sample surface, driving the surface particles to vibrate vertically, thus generating longitudinal waves. These longitudinal waves propagate downward along the waveguide rod 301, enabling testing of the working steel pipe 201.

[0062] Figure 4 Schematic diagram of electromagnetic ultrasonic transducer mechanism based on magnetostrictive effect. When a discharge current containing high-frequency strong pulse components and quasi-DC components is passed through the butterfly coil 403, a static magnetic field H can be generated in the magnetostrictive patch 402 under the action of the quasi-DC component. s , orienting the magnetic domains in the magnetostrictive patch to enhance the magnetostrictive effect. Under the action of high-frequency strong pulse components, the butterfly coil can generate a dynamic magnetic field H in the magnetostrictive patch 402. d , driving the magnetostrictive patch 402 to produce strain deformation in the horizontal direction, thereby generating shear waves. The shear waves propagate downward along the waveguide rod 401, thus enabling the detection of the working steel pipe.

[0063] like Figure 5 As shown, the pulsed electromagnet electromagnetic ultrasonic detection circuit of the electromagnetic ultrasonic in-situ monitoring node includes an echo detection module 501, a high-voltage strong pulse excitation module 502, a low-voltage DC excitation module 503, a butterfly coil, and an impedance matching module 504. The capacitor bank of the high-voltage strong pulse excitation module 501 is transiently charged and discharged under the control of a MOS transistor switch, while the low-voltage DC excitation module 503 is charged and discharged by an IBGT switch module. The high-voltage strong pulse excitation module 502 and the low-voltage DC excitation module 503 are connected in parallel and electrically connected to the butterfly coil via a probe interface. The echo detection module 501 is electrically connected to the butterfly coil via the probe interface.

[0064] The high-voltage excitation strong pulse module 501 and the low-voltage quasi-DC excitation module 502 are connected in parallel and use independent timing control. When the quasi-DC component reaches its maximum, the high-voltage excitation strong pulse module 501 is activated to generate a strong pulse, which can greatly increase the excitation efficiency of the ultrasonic wave.

[0065] The echo detection module 501 picks up defects or end face echoes, and has the functions of direct isolation and bandpass filtering when receiving weak signals, and shortening the high-voltage pulse excitation time when high-voltage excitation is performed;

[0066] The capacitance of capacitor C1 in the high-voltage excitation strong pulse module 502 needs to be small, typically 1nF to 300nF. This allows for rapid discharge and a high amplitude pulse current. The capacitance of capacitor C2 in the low-voltage quasi-DC excitation module 503, which provides the quasi-DC current, needs to be large, typically 500μF to 3000μF. This allows the quasi-DC current to be maintained for a long time, providing a strong bias magnetic field when receiving echoes.

[0067] The electromagnetic ultrasonic in-situ monitoring node also includes an FPGA control module and an AD acquisition module. The FPGA control module is electrically connected to the AD acquisition module, and the AD acquisition module is electrically connected to the electromagnetic ultrasonic detection circuit. The AD acquisition module is used to realize analog-to-digital conversion of ultrasonic echo signals; the FPGA control module is electrically connected to the MOS tube switch and the IBGT switch module respectively.

[0068] The working process of the electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things provided by this utility model is as follows:

[0069] First, the FPGA control module inputs a low-voltage pulse trigger signal to the isolated driver chip. The driver chip can enhance the power of the trigger signal generated by the FPGA chip, enabling it to quickly increase the G-pole voltage of the MOS, thereby quickly turning on / off the MOS tube. Under the control of the MOS tube switch, the capacitor group of the high-voltage excitation strong pulse module can transiently charge and discharge to generate an alternating strong excitation current in the butterfly coil. According to the Lorentz force and magnetostrictive effect, Lorentz force and magnetostrictive strain can be generated in the magnetostrictive patch, driving the surface particles to vibrate, thereby generating ultrasonic waves.

[0070] The low-voltage DC excitation module is controlled by a switch module containing an IBGT for charging and discharging. The charging and discharging time is relatively long. The low-voltage DC excitation module will generate a relatively long-lasting and relatively smooth DC-like excitation current in the coil, which can provide a static bias magnetic field and static bias magnetic induction intensity for the reception of ultrasonic echoes.

[0071] The high-voltage excitation strong pulse module and the low-voltage DC excitation module are connected in parallel. The low-voltage DC excitation module is turned on for a longer time than the high-voltage excitation module. At the same time, the high-voltage excitation strong pulse module will be turned on when the DC current in the coil rises to the highest value (that is, when the magnetic field excited by the DC current is the strongest) to make the excited ultrasonic amplitude reach the maximum value.

[0072] The impedance matching module can maximize the energy distribution of this induced electromotive force on the echo detection module, enhancing the amplitude and signal-to-noise ratio of the ultrasonic echo signal. The echo detection module can pick up the echo signal and filter and amplify it.

[0073] Next, the ultrasonic echo signal undergoes digital-to-analog conversion in the FPGA and is transmitted to the LoRa wireless module via the serial UART port for wireless data transmission. The LoRa relay then transmits the signal over long distances. Wireless communication between the LoRa wireless module, LoRa relay, and LoRa gateway all uses the LoRa protocol. Wired data communication between the LoRa gateway and the cloud server uses the IP protocol, while communication between the cloud server and the client server occurs via HTTPS / API.

[0074] Finally, the massive amount of ultrasonic echo data generated by online high-temperature pipeline monitoring is stored in a cloud server. The client server can access key thickness reduction information and weld crack growth information at any measurement point on the high-temperature pipeline, and based on this, it can determine the wall thickness reduction rate and the equivalent size growth rate of the defect.

[0075] like Figure 3 As shown in the figure, the electromagnetic ultrasonic transducer mechanism based on the Lorentz force is as follows: when a discharge current containing a high-frequency strong pulse component and a quasi-DC component is passed through the butterfly coil, a static magnetic induction intensity B can be generated in the magnetostrictive patch under the action of the quasi-DC component. s Under the action of high-frequency strong pulse components, eddy current J can be generated in the magnetostrictive patch iz The combined effect of the static magnetic field and eddy currents generates a Lorentz force on the sample surface, driving the surface particles to vibrate vertically, thus generating longitudinal waves. These longitudinal waves propagate downward along the waveguide rod, enabling testing of the working steel pipe.

[0076] like Figure 4 As shown in the figure, the electromagnetic ultrasonic transducer mechanism based on the magnetostrictive effect is as follows: when a discharge current containing a high-frequency strong pulse component and a quasi-DC component is passed through the butterfly coil, a static magnetic field H can be generated in the magnetostrictive patch under the action of the quasi-DC component. s , to orient the magnetic domains in the magnetostrictive patch, thereby enhancing the magnetostrictive effect. Under the action of high-frequency strong pulse components, the butterfly coil can generate a dynamic magnetic field H in the magnetostrictive patch. d , driving the magnetostrictive patch to produce strain deformation in the horizontal direction, thus generating shear waves. The shear waves propagate downward along the waveguide rod, which can be used to detect the working steel pipe.

[0077] The first embodiment of the present invention breaks through the limitation of the traditional detection method that the detection terminal is a local PC terminal through the above multiple technologies, avoids the weak mobility of traditional PC terminal detection and the complexity of laying a large number of lines, and improves the intelligence and flexibility of industrial detection.

[0078] The first embodiment of the present invention utilizes a magnetostrictive patch made of a giant magnetostrictive material, terbium-dysprosium-iron (TdFe), to increase its energy conversion efficiency by more than tenfold compared to traditional piezoelectric ultrasonic sensors. A long-duration, quasi-direct current is passed through the butterfly coil to enhance the magnetostrictive effect. The waveguide is made of 304 stainless steel, which has poor thermal conductivity and small grains. Compared to traditional magnetostrictive ultrasonic sensors, the required excitation current is lower, typically only a few amperes. This device enables continuous monitoring of high-temperature pipelines at 550°C, enabling non-destructive monitoring without shutting down the pipeline. This provides an evaluation basis for remaining life assessment and structural damage warnings in high-temperature, high-pressure service environments. Installing a device every 100 meters along a long, high-temperature pipeline or at locations with a particularly high risk of burst, and connecting each device to the IoT cloud, essentially enables continuous, online monitoring of the pipeline. The use of IoT technology can help automate detection and significantly reduce testing costs. IoT technology also significantly aids in processing test data, enabling classification, statistics, and analysis.

[0079] In addition, the present invention also provides a second embodiment, which differs from the first embodiment in the wireless communication method and the specific structure of the continuous high-temperature resistant electromagnetic ultrasonic detection probe.

[0080] For example, Figure 6 As shown, the electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things provided in Example 2 includes a device hardware circuit portion 601, a WiFi communication module 602, a wireless router 603, a communication base station 604, a cloud platform 605, a cloud server 606, and client servers (1, 2, 3) 607. The wireless router 603 and the communication base station 604 constitute the Internet of Things communication device, and the wireless communication module in the electromagnetic ultrasonic in-situ monitoring node is the WiFi communication module 602. Communication connections are established sequentially among the WiFi communication module 602, the wireless router 603, the communication base station 604, and the cloud server 605. The device hardware circuit portion 601 includes a continuous high-temperature resistant electromagnetic ultrasonic probe and an electromagnetic ultrasonic in-situ monitoring node.

[0081] like Figure 7 The continuous high-temperature resistant electromagnetic ultrasonic detection probe described in Example 2 includes a probe housing 703 (e.g., a brass housing), a butterfly coil 701 (e.g., a ceramic coil), a corundum sheet 702, and a probe interface 705 (e.g., a 16-core LEMO interface); the corundum sheet 702 is arranged at the bottom of the probe housing 703; the butterfly coil 701 is arranged in the probe housing 703 and located above the corundum sheet 702; the probe interface 705 is arranged on the probe housing 703 and electrically connected to the butterfly coil 701; the cavity formed by the probe housing 703 and the corundum sheet 702 is filled with a ceramic filler 704 (e.g., high-temperature resistant ceramic glue).

[0082] For example, the structure and principle of the high-temperature resistant electromagnetic ultrasonic detection probe may refer to the high-temperature resistant electromagnetic ultrasonic detection probe disclosed in the utility model patent CN 115469021 A or the utility model patent CN 218099023 U previously applied for by the applicant.

[0083] In this embodiment, the continuous high-temperature resistant electromagnetic ultrasonic detection probe does not require a water cooling cycle and a permanent magnet. A single coil is used to achieve ultrasonic excitation and reception. A quasi-DC current is simultaneously passed through the coil to generate a bias magnetic field. Therefore, a permanent magnet is not required to provide the bias magnetic field required for ultrasonic excitation and reception, and it will not be affected by the Curie point, making it suitable for non-destructive testing in high-temperature environments. Due to its greatly reduced size, it can be tested in narrow environments. Using high-melting-point silver wire and external ceramic materials as isolation, it has a strong ability to withstand high temperatures continuously, and can continuously perform online non-destructive testing and monitoring in high-temperature environments. By increasing the amplitude of the current in the coil, the magnetic field can be greatly enhanced, thereby improving the energy conversion efficiency of the electromagnetic ultrasonic probe.

[0084] The ultrasonic echo signals collected by the hardware circuit part of the device are transmitted at the Internet of Things network layer through the WiFi communication module. The WiFi communication module uploads the data to the cloud through the TCP / IP protocol via a wireless router and a communication base station using cloud computing technology and stores it in the cloud server. After obtaining the data, the cloud server presents the results of big data mathematical modeling analysis and data mining algorithm processing to the user on the remote client server in a user-friendly manner at the request of the remote client terminal, thereby realizing online positioning and quantification of defects and online monitoring of pipeline defect thinning; wherein, the big data mathematical modeling analysis and data mining algorithms include but are not limited to a pipe wall thickness thinning warning algorithm based on gray prediction, a crack and other defect expansion calculation algorithm, and a data-driven intelligent recognition algorithm based on Python deep learning.

[0085] The IoT networking component of this utility model closely integrates IoT technologies, automated monitoring technologies, and cloud computing. Using FPGAs as core components, this system collects pipeline monitoring data to enable full-process information monitoring of localized thinning and crack expansion defects in high-temperature, high-pressure nuclear power steam pipelines. This system builds a cloud-based system that uploads data on localized thinning and crack expansion to the cloud, facilitating subsequent storage and analysis of this information. This system achieves real-time synchronization of this data, as well as efficient and integrated data management.

[0086] This document uses specific examples to illustrate the principles and implementation methods of the utility model. The above examples are only intended to help understand the method and core concept of the utility model. At the same time, those skilled in the art will find that the specific implementation methods and application scopes may vary based on the concept of the utility model. In summary, the contents of this specification should not be construed as limiting the utility model.

Claims

1. An electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things, characterized in that: include: A continuous high-temperature resistant electromagnetic ultrasonic probe, an electromagnetic ultrasonic in-situ monitoring node, an Internet of Things communication device, a cloud server, and a client server; the continuous high-temperature resistant electromagnetic ultrasonic probe is electrically connected to the electromagnetic ultrasonic in-situ monitoring node, the electromagnetic ultrasonic in-situ monitoring node is communicatively connected to the Internet of Things communication device, the Internet of Things communication device is communicatively connected to the cloud server, and the cloud server is communicatively connected to the client server; The continuous high temperature resistant electromagnetic ultrasonic probe is used to realize the excitation and reception of ultrasonic waves on the surface of the working steel pipe through the magneto-acoustic effect; The electromagnetic ultrasonic in-situ monitoring node includes an electromagnetic ultrasonic detection circuit and a wireless communication module; the electromagnetic ultrasonic in-situ monitoring node is used to provide strong transient current and quasi-DC for ultrasonic excitation of the continuous high-temperature resistant electromagnetic ultrasonic detection probe, provide low-noise and high-gain amplification for ultrasonic reception of the continuous high-temperature resistant electromagnetic ultrasonic probe, and simultaneously realize analog-to-digital conversion of the ultrasonic echo signal to obtain corresponding detection data, and is used to transmit the detection data to the Internet of Things communication device; The IoT communication device is used to collect detection data of each electromagnetic ultrasonic in-situ monitoring node and transmit it to the cloud server; The cloud server is used for storing and managing detection data; The client server is used to read the detection data in the cloud server and display it.

2. The electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things according to claim 1 is characterized in that: The Internet of Things communication device includes a LoRa relay and a LoRa gateway. The wireless communication module in the electromagnetic ultrasonic in-situ monitoring node is a LoRa wireless transmission module. The LoRa wireless transmission module is connected to the LoRa relay, the LoRa relay is connected to the LoRa gateway, and the LoRa gateway is connected to the cloud server.

3. The electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things according to claim 1 is characterized in that: The Internet of Things communication device includes a wireless router and a communication base station. The wireless communication module in the electromagnetic ultrasonic in-situ monitoring node is a WiFi communication module. Communication connections are established in sequence among the WiFi communication module, wireless router, communication base station, and cloud server.

4. The electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things according to claim 1 is characterized in that: The continuous high-temperature resistant electromagnetic ultrasonic probe comprises: a butterfly coil, a magnetostrictive patch, and a waveguide rod; the butterfly coil is located above the magnetostrictive patch; and the magnetostrictive patch is located above the waveguide rod.

5. The electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things according to claim 1 is characterized in that: The high-temperature resistant electromagnetic ultrasonic detection probe includes a probe housing, a butterfly coil, and a corundum sheet; the corundum sheet is arranged at the bottom of the probe housing; the butterfly coil is arranged in the probe housing and located above the corundum sheet; the cavity formed by the probe housing and the corundum sheet is filled with ceramic filler.

6. The electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things according to claim 4 is characterized in that: The butterfly coil in the continuous high-temperature resistant electromagnetic ultrasonic probe is a planar butterfly coil, which is composed of 2-4 butterfly coils connected in series; the magnetostrictive patch in the continuous high-temperature resistant electromagnetic ultrasonic probe is made of giant magnetostrictive material terbium dysprosium iron TbDyFe, and the magnetostriction coefficient is as high as 1200PPM.

7. The electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things according to claim 4 is characterized in that: The waveguide rod in the continuous high-temperature resistant electromagnetic ultrasonic probe is made of stainless steel. One end of the waveguide rod passes through the insulation layer of the high-temperature pipeline and is directly welded to the outer wall surface of the working steel pipe. The other end is connected to the magnetostrictive patch through an adhesive with good sound conductivity.

8. The electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things according to claim 4 or 5, characterized in that: The electromagnetic ultrasonic in-situ monitoring node is electrically connected to the continuous high-temperature resistant electromagnetic ultrasonic probe. The electromagnetic ultrasonic in-situ monitoring node passes a discharge current including a strong transient current and a DC-like current into the butterfly coil in the continuous high-temperature resistant electromagnetic ultrasonic probe, and detects the ultrasonic echo signal received by the butterfly coil.

9. The electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things according to claim 4 or 5, characterized in that: The electromagnetic ultrasonic detection circuit is a pulsed electromagnet electromagnetic ultrasonic detection circuit, including a high-voltage strong pulse excitation module, a low-voltage DC excitation module, an echo detection module, and an impedance matching module for a butterfly coil. The capacitor group of the high-voltage strong pulse excitation module is transiently charged and discharged under the control of the MOS tube switch, and the low-voltage DC excitation module is controlled by the IBGT switch module to control charging and discharging; the high-voltage excitation strong pulse module and the low-voltage DC excitation module are connected in parallel and are electrically connected to the butterfly coil through a probe interface respectively; the echo detection module is electrically connected to the butterfly coil through the probe interface.

10. The electromagnetic ultrasonic online detection device for high-temperature pipelines based on the Internet of Things according to claim 9 is characterized in that: The electromagnetic ultrasonic in-situ monitoring node also includes an FPGA control module and an AD acquisition module. The FPGA control module is electrically connected to the AD acquisition module, and the AD acquisition module is electrically connected to the electromagnetic ultrasonic detection circuit. The AD acquisition module is used to realize analog-to-digital conversion of ultrasonic echo signals; the FPGA control module is electrically connected to the MOS tube switch and the IBGT switch module respectively.

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