Large-diameter pipe welding seam ultrasonic online automatic detection device
By designing a multi-axis ultrasonic detection device, the problems of image distortion and position error caused by manual scanners in the inspection of large-diameter pipe girth welds are solved, automatic imaging and high-precision defect quantification are achieved, meeting the various detection needs of manufacturers.
Patent Information
- Application Number
- CN202422281965.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-19
- Publication Date
- 2025-09-23
- Estimated Expiration
- 2034-09-19
AI Technical Summary
Existing manual scanners are prone to image distortion and large position recording errors when inspecting girth welds on large-diameter pipes, affecting both the quantitative and qualitative characterization of defects. They are unable to meet manufacturers' diverse inspection needs, leading to problems with inspection accuracy and efficiency.
An ultrasonic online automatic inspection device for large-diameter pipe welds was designed. It includes a support frame, X-axis system, Z-axis system, Y-axis system, R-axis rotation system, shift fork flip system, hydraulic system, and V-type conveyor roller system. It realizes multi-axis linkage, automatically displays and records defect locations through imaging, and produces neat images, complete morphologies of defects such as cracks, with high quantitative accuracy and fast inspection speed.
It realizes automatic detection of large-diameter pipe welds, with clear images and accurate recording of defect locations, meeting the manufacturer's various detection needs and improving detection accuracy and efficiency.
Smart Images
Figure CN223377261U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of detection devices, in particular to an ultrasonic online automatic detection device for large-diameter pipe welds. Background Art
[0002] Most existing girth weld inspections use manual scanners. For larger diameter pipe girth welds, the force and angle of the hand push can easily cause image distortion, leading to missed inspections. The encoder also records position errors, significantly impacting both the quantitative and qualitative characterization of defects. Most existing weld inspections use manual scanners. For larger diameter pipe welds, the force and angle of the hand push can easily lead to image distortion, failing to meet manufacturers' inspection requirements, significantly impacting both the quantitative and qualitative characterization of defects. Utility Model Content
[0003] In response to the shortcomings of the above problems, the utility model provides an ultrasonic online automatic detection device for large-diameter pipe welds, which can detect workpieces such as conventional pipes, thick-walled pipes and small-diameter thin-walled pipes. It has multi-axis linkage and can automatically image and display and record the defect positions. The images are very neat, the morphology of defects such as cracks is very complete, the quantitative accuracy is high, and the detection speed is fast, which can meet the various detection needs of manufacturers.
[0004] In order to solve the above problems, the utility model provides an ultrasonic online automatic detection device for large-diameter pipe welds, including a support frame, wherein the support frame is provided with an X-axis system, a Z-axis system, a Y-axis system, an R-axis rotation system, a fork flipping system, a hydraulic system and a V-type conveyor roller system, the X-axis system is arranged at the top of the support frame, the Z-axis system is arranged at the front end of the support frame, and the Y-axis system, R-axis rotation system, fork flipping system, hydraulic system and V-type conveyor roller system are all arranged at the bottom end of the support frame.
[0005] Preferably, the X-axis system includes an X-axis motor, an X-axis bevel gear, an X-axis bevel rack and an X-axis linear guide, and the X-axis motor drives the X-axis bevel gear to rotate and move on the X-axis bevel rack.
[0006] Preferably, the Z-axis system includes a Z-axis motor, a Z-axis ball screw, a Z-axis linear guide and a Z-axis organ protective cover. The Z-axis motor drives the Z-axis ball screw to rotate. A slider is provided on the Z-axis ball screw, and the slider moves up and down on the Z-axis linear guide.
[0007] Preferably, the Y-axis system includes a Y-axis motor, a Y-axis bidirectional trapezoidal lead screw, a Y-axis linear guide and a Y-axis protective cover. The Y-axis motor drives the Y-axis bidirectional trapezoidal lead screw to rotate. A slider is provided on the Y-axis bidirectional trapezoidal lead screw, and the slider moves up and down on the Y-axis linear guide.
[0008] Preferably, the R-axis rotation system includes a reduction motor, a driven roller, an active roller, a roller spacing adjustment mechanism, a connecting rod mechanism, a fixed frame and a lifting cylinder. A lifting cylinder is provided on the fixed frame. The output end of the lifting cylinder is connected to the fixed plate through a connecting rod mechanism. A roller spacing adjustment mechanism is provided on the fixed plate. The reduction motor, the driven roller and the active roller are all arranged on the roller spacing adjustment mechanism, and the reduction motor drives the active roller to rotate through the sprocket chain, and the active roller drives the driven roller to rotate.
[0009] Preferably, the shift fork flipping system includes a shift fork arm, a shift fork cylinder, a shift fork shaft and a fixed seat, a shift fork arm is provided at the upper end of the fixed seat and the right end of the shift fork arm is connected to the right end of the fixed seat through the shift fork shaft, a shift fork cylinder is provided at the left end of the fixed seat, and the shift fork cylinder drives the shift fork arm to rotate along the shift fork shaft through the cylinder rod.
[0010] Preferably, the V-shaped conveying roller system includes multiple groups of V-shaped conveying rollers, and the V-shaped conveying rollers include a V-shaped roller reduction motor, a V-shaped conveying roller and a V-shaped roller fixing seat.
[0011] Compared with the prior art, the utility model has the following advantages:
[0012] This utility model detects workpieces such as conventional pipes, thick-walled pipes and small-diameter thin-walled pipes. It has multi-axis linkage and can automatically image and display and record the defect positions. The images are very neat, and the shapes of defects such as cracks are very complete. It has high quantitative accuracy and fast detection speed, which can meet the various detection needs of manufacturers. BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present utility model;
[0014] Figure 2 It is a partial structural diagram of an embodiment of the utility model;
[0015] Figure 3 This is a schematic structural diagram of the R-axis rotation system of an embodiment of the present utility model;
[0016] Figure 4 It is a structural schematic diagram of a shift fork flipping system according to an embodiment of the present utility model. DETAILED DESCRIPTION
[0017] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and examples, but the examples are not intended to limit the present invention.
[0018] like Figures 1 to 4As shown, an embodiment of the present invention includes a support frame 1, an X-axis system 2, a Z-axis system 3, a Y-axis system 4, an R-axis rotation system 5, a fork flipping system 6, a V-type conveyor roller system 7, a hydraulic system 8, a water circulation system, a coding and counting system 9, and a marking and dotting system 10.
[0019] In this embodiment, the support frame 1 is composed of three groups of profile welded frames; the support frame 1 supports the X-axis system 2, the Z-axis system 3, the Y-axis system 4 and the probe box device 11 for stable operation.
[0020] In this embodiment, the X-axis system 2 is composed of an X-axis motor, an X-axis bevel gear, an X-axis bevel rack, an X-axis linear guide, etc. The X-axis motor drives the X-axis bevel gear to rotate and move on the X-axis bevel rack.
[0021] In this embodiment, the Z-axis system 3 is composed of a Z-axis motor, a Z-axis ball screw, a Z-axis linear guide, a Z-axis organ protective cover, etc.; the Z-axis motor drives the Z-axis ball screw to rotate, and the Z-axis slider moves up and down on the Z-axis linear guide.
[0022] In this embodiment, the Y-axis system 4 is composed of a Y-axis motor, a Y-axis bidirectional trapezoidal lead screw, a Y-axis linear guide, a Y-axis protective cover, etc.; the Y-axis motor drives the Y-axis bidirectional trapezoidal lead screw to rotate, and the two sets of Y-axis sliders respectively drive the probe box to move closer or apart centripetally and equidistantly.
[0023] In this embodiment, the R-axis rotation system 5 is composed of a reduction motor 12, a driven roller 13, an active roller 14, a roller gap adjustment mechanism 15, a connecting rod mechanism 16, a fixing frame 17, a lifting cylinder 18, a waterproof curtain, etc., wherein the roller gap adjustment mechanism 15 is composed of a ball screw, a linear guide rail, and a support plate; the lifting cylinder 18 extends to drive the connecting rod mechanism 16 to operate to make the R-axis rotation mechanism rise, so that the welded steel pipe is separated from the V-shaped conveyor roller system 7, and the reduction motor 12 drives the active roller 14 to rotate through the sprocket chain, thereby rotating the welded steel pipe and driving the driven roller 13 to rotate, thereby achieving the purpose of rotating the welded steel pipe in place; manually rotating the roller gap adjustment mechanism 15 increases or decreases the distance between the active roller 14 and the driven roller 13 to adapt to the rotation of welded steel pipes of different diameters on the R-axis; the lower half of the R-axis rotation mechanism is located in the pit, and the waterproof curtain backflows water to the outside of the pit edge to prevent water from flowing into the pit and damaging the corrosive equipment.
[0024] In this embodiment, the shift fork flipping system 6 is composed of a shift fork arm 19, a shift fork cylinder 20, a shift fork shaft 21, and a fixing seat 22; the shift fork cylinder 20 extends to drive the shift fork arm 19 to rotate along the shift fork shaft 21, flipping the welded steel pipe horizontally from the V-shaped conveyor roller.
[0025] In this embodiment, the V-shaped conveyor roller system 7 is composed of multiple groups of V-shaped conveyor rollers, which are composed of V-shaped roller reduction motors, V-shaped conveyor rollers, and V-shaped roller fixing seats; multiple groups of conveyor roller motors are started at the same time to drive the welded steel pipe forward or backward longitudinally.
[0026] In this embodiment, the hydraulic system 8 is composed of a hydraulic station, a hydraulic cylinder and pipelines; the pressurized hydraulic oil in the hydraulic station is used as a power source to drive the hydraulic cylinder to extend or retract.
[0027] In this embodiment, the water circulation system is composed of valves, pipes, water pumps, and a sump. Since the equipment does not consume much water during weld detection, tap water is used as the water supply source, and the water flows through the valve and pipes to the probe box for use in weld detection. The used water flows along the welded steel pipe to the ground, and there is a ditch around the equipment to collect the water into the sump. When the water level in the sump reaches a certain height, the water pump in the sump starts to drain the accumulated water in the pit. When the water level drops to a certain height, the water pump stops working.
[0028] In this embodiment, the encoding counting system 9 is composed of an encoding cylinder, a roller, and an encoder; it records the side length of the detected weld in real time and feeds it back to the industrial computer for use; the encoding cylinder extends to cause the roller to contact and rotate with the welded steel pipe, and the roller drives the encoder to rotate to achieve the purpose of measuring the length.
[0029] In this embodiment, the marking system 10 is composed of a marking cylinder, a marking pen, and a marking fixing base. When the marking cylinder is extended, the marking pen contacts the steel pipe, the sealing ball on the marking pen retracts, and after the ink flows onto the welded steel pipe, the marking cylinder quickly retracts, thereby achieving the purpose of marking.
[0030] In this embodiment, the motion process is described as follows:
[0031] 1. Initial position of the equipment: X, Y, and Z axes are at the origin, the R-axis rotation mechanism is in the low position, and the fork flip mechanism is in the retracted state;
[0032] 2. Exercise process:
[0033] 2.1. The welded steel pipe to be inspected is transported to the inspection position by the V-shaped conveyor roller. The R-axis rotating mechanism rises, allowing the welded steel pipe to separate from the V-shaped conveyor roller and reach the upper limit position. The reduction motor in the R-axis rotating mechanism starts, and the active roller rotates to drive the welded steel pipe to rotate, rotating the weld seam of the welded steel pipe to the top position. The reduction motor stops, fixing the weld seam of the steel pipe at the top position for inspection.
[0034] 2.2. The X and Z axis motors start and move to the detection starting position; the probe box cylinder extends so that the probe contacts the welded steel pipe and is distributed on both sides of the weld. At the same time, the water circulation system starts and starts to supply water to the probe box; the X axis runs at a certain speed and begins to detect the steel pipe weld; when the end of the steel pipe weld is detected, the Y axis motor starts, driving the probe boxes on both sides to move away from the weld position by the probe detection width. The X axis motor starts in the reverse direction and continues to detect the weld with the probe box. According to the depth of the welded steel pipe weld, the probe box needs to be moved outward several times to complete the weld inspection;
[0035] 2.3. When the steel pipe weld inspection is completed, the water circulation system stops supplying water to the probe box. At the same time, the X and Z axes quickly move to the origin position.
[0036] 2.4. When the steel pipe weld is found to be qualified, the shift fork flipping mechanism starts to flip the welded steel pipe to the next station; when the steel pipe weld is found to be unqualified, the V-shaped conveyor roller starts to transport the welded steel pipe to the rework and repair position; the welded steel pipe inspection equipment waits to inspect the weld of the next steel pipe.
[0037] Through the use of wires by those skilled in the art, all electrical components in this case are connected to their corresponding power supplies, and appropriate controllers should be selected according to actual conditions to meet control requirements. The specific connection and control sequence should refer to the following working principle, in which the electrical components are electrically connected in sequence. The detailed connection means are well-known technologies in this field. The following mainly introduces the working principle and process, and does not explain the electrical control.
[0038] Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are illustrative and cannot be understood as limitations on the present invention. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present invention.
[0039] In the description of this specification, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the technical solutions of this patent and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this patent application.
[0040] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of such features. In the description of this patent application, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.
[0041] In this specification, unless otherwise specified or limited, the terms "mounted," "connected," "connect," "fixed," etc. should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two components or interaction between two components, unless otherwise specified. Those skilled in the art will understand the specific meanings of the above terms in this specification based on specific circumstances.
[0042] In this specification, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it can mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediary. Furthermore, when a first feature is "above," "above," or "above" a second feature, it can mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is at a higher level than the second feature. When a first feature is "below," "below," or "below" a second feature, it can mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is at a lower level than the second feature.
[0043] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and features of different embodiments or examples without contradiction.
[0044] Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations on the present invention. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present invention.
Claims
1. An ultrasonic online automatic detection device for large diameter pipe welds, comprising a support frame, characterized in that: The support frame is provided with an X-axis system, a Z-axis system, a Y-axis system, an R-axis rotation system, a shift fork flip system, a hydraulic system and a V-shaped conveyor roller system. The X-axis system is arranged at the top of the support frame, the Z-axis system is arranged at the front end of the support frame, and the Y-axis system, the R-axis rotation system, the shift fork flip system, the hydraulic system and the V-shaped conveyor roller system are all arranged at the bottom end of the support frame.
2. The large diameter pipe weld ultrasonic online automatic detection device according to claim 1, characterized in that: The X-axis system includes an X-axis motor, an X-axis bevel gear, an X-axis bevel rack and an X-axis linear guide. The X-axis motor drives the X-axis bevel gear to rotate and move on the X-axis bevel rack.
3. The large diameter pipe weld ultrasonic online automatic detection device according to claim 1, characterized in that: The Z-axis system includes a Z-axis motor, a Z-axis ball screw, a Z-axis linear guide and a Z-axis organ protective cover. The Z-axis motor drives the Z-axis ball screw to rotate. A slider is provided on the Z-axis ball screw, and the slider moves up and down on the Z-axis linear guide.
4. The large diameter pipe weld ultrasonic online automatic detection device according to claim 1, characterized in that: The Y-axis system includes a Y-axis motor, a Y-axis bidirectional trapezoidal lead screw, a Y-axis linear guide and a Y-axis protective cover. The Y-axis motor drives the Y-axis bidirectional trapezoidal lead screw to rotate. A slider is provided on the Y-axis bidirectional trapezoidal lead screw, and the slider moves up and down on the Y-axis linear guide.
5. The large diameter pipe weld ultrasonic online automatic detection device according to claim 1, characterized in that: The R-axis rotation system includes a reduction motor, a driven roller, an active roller, a roller gap adjustment mechanism, a connecting rod mechanism, a fixed frame and a lifting cylinder. The fixed frame is provided with a lifting cylinder. The output end of the lifting cylinder is connected to the fixed plate through a connecting rod mechanism. The fixed plate is provided with a roller gap adjustment mechanism. The reduction motor, the driven roller and the active roller are all arranged on the roller gap adjustment mechanism, and the reduction motor drives the active roller to rotate through the sprocket chain, and the active roller drives the driven roller to rotate.
6. The large diameter pipe weld ultrasonic online automatic detection device according to claim 1, characterized in that: The shift fork flipping system includes a shift fork arm, a shift fork cylinder, a shift fork rotating shaft and a fixed seat. The shift fork arm is provided at the upper end of the fixed seat and the right end of the shift fork arm is connected to the right end of the fixed seat through the shift fork rotating shaft. The shift fork cylinder is provided at the left end of the fixed seat, and the shift fork cylinder drives the shift fork arm to rotate along the shift fork rotating shaft through the cylinder rod.
7. The large diameter pipe weld ultrasonic online automatic detection device according to claim 1, characterized in that: The V-shaped conveying roller system includes multiple groups of V-shaped conveying rollers, and the V-shaped conveying rollers include a V-shaped roller reduction motor, a V-shaped conveying roller and a V-shaped roller fixing seat.