A pipe end ultrasonic phased array detection mechanism

Abstract

The utility model discloses a kind of pipe end ultrasonic phased array detection mechanism, it is related to ultrasonic phased array detection technical field.The detection mechanism includes six-axis robot, probe water bag clamping end, steel pipe fixing device, steel pipe and detection camera;Probe water bag clamping end is provided with sliding table pneumatic cylinder, clamping pneumatic cylinder, pipe end rotating end, drying air knife, two groups of side probe water bag and middle probe water bag, probe water bag is composed of ultrasonic probe, water bag, rotary sealing device and guide wheel.The ultrasonic probe is phased array probe, three groups of probes work cooperatively, realize full coverage detection to weld, base material and bevel surface by multi-angle beam control.Detection, steel pipe is fixed by motor and cylinder and can rotate, six-axis robot drives probe to operate according to preset trajectory, complete pipe end edge twice scanning and weld area Z-shaped trajectory scanning, ensure detection accuracy and integrity.

Description

Technical Field

[0001] This utility model belongs to the field of ultrasonic phased array testing technology, specifically relating to a tube-end ultrasonic phased array testing mechanism. Background Technology

[0002] In the steel pipe manufacturing process, the quality of the pipe end area directly affects the product's service reliability. Typically, the weld within 300mm of the pipe end requires longitudinal and transverse ultrasonic testing. Additionally, it is necessary to inspect the base metal delamination within approximately 25mm on both sides of the weld, the base metal delamination and non-delamination defects within 50mm of the pipe end, and the pipe end bevel surface. These inspection steps are crucial for ensuring weld integrity and preventing potential defects from propagating into service.

[0003] In existing technologies, the industry commonly uses manual ultrasonic testing methods, where inspectors use a handheld probe to inspect the pipe end step by step. While this method can accomplish the inspection task to a certain extent, it has significant shortcomings: First, the inspection accuracy is highly dependent on the operator's skill level, and the results are easily affected by human factors; second, manual inspection is labor-intensive, especially in the inspection of large-diameter steel pipes, where efficiency is significantly insufficient; third, manual inspection has poor repeatability, easily leading to missed detections or misjudgments, increasing quality risks; and finally, the inspection process has a low degree of matching with the production cycle, which is not conducive to large-scale continuous production.

[0004] Meanwhile, while phased array ultrasonic technology offers advantages in signal coverage and image accuracy, effectively integrating it into automated inspection mechanisms remains challenging. Specifically: insufficient probe-to-pipe wall contact leads to unstable detection coupling; probe position adjustment is complex for different pipe diameters, making consistency difficult to guarantee; weld seams and edge base material areas often require multiple scans for coverage, increasing inspection time; furthermore, residual moisture on the workpiece surface after inspection can affect the quality of subsequent processes.

[0005] In summary, existing pipe end inspection methods are inadequate in terms of efficiency, accuracy, stability, and compatibility with production lines. Utility Model Content

[0006] To address the problems existing in the prior art, the purpose of this utility model is to provide a tube-end ultrasonic phased array testing mechanism that can realize multi-probe collaborative testing, adaptive adjustment, and automation, thereby solving the aforementioned problems in the prior art.

[0007] To achieve the above objectives, this utility model provides the following technical solution: A tube-end ultrasonic phased array testing mechanism, comprising: A six-axis robot used to drive the probe to perform multi-degree-of-freedom motion; The probe water bag clamping end is mounted on the six-axis robot and is used to fix and adjust the ultrasonic probe. The probe water bag clamping end includes a slide cylinder, a clamping cylinder, a tube end rotating end, a drying air knife, a side probe water bag, and an intermediate probe water bag. The probe water bag consists of an ultrasonic probe, a water bag, a rotating sealing device, and a guide wheel; A steel pipe fixing device, including a motor and rollers, is used to fix the steel pipe at the detection position; Inspection camera, used to inspect the condition of the outer surface of the pipe end.

[0008] Furthermore, the ultrasonic probe is a phased array probe, each probe has a channel, and the detection mechanism uses three sets of identical channel phased array probes working together.

[0009] Furthermore, the probe of the intermediate probe water bag is installed perpendicular to the pipe wall, and the scanning direction is vertically downward and scanning to both sides; the probes of the two sets of side probe water bags are installed at an angle of 45° to the tangent of the pipe wall, and are used for longitudinal scanning.

[0010] Furthermore, for the inspection within 50mm of the pipe end edge, two scans are used to complete the inspection; for the weld area, the probe is scanned along the weld direction using a Z-shaped trajectory.

[0011] Furthermore, the probe is connected to the water bag via a rotating shaft, and the angle between the probe and the pipe wall can be adjusted within the range of 40° to 75°; the contact parts between the water bag and the pipe wall are made of flexible material to maintain watertightness.

[0012] Furthermore, the side probe water bag is installed via a connecting plate, which can move up and down and be reset by a spring and a sliding groove structure; the water bag is provided with guide wheels at both ends, so that the water bag can automatically fit against the pipe wall when the detection mechanism is pressed down.

[0013] Furthermore, the drying air knife dries the surface of the steel pipe after the inspection is completed.

[0014] Compared with the prior art, the beneficial effects of this utility model are: By employing a cooperative structure between a six-axis robot and the probe's water bag clamping end, the probe can achieve precise movement in multiple degrees of freedom, eliminating reliance on manual operation experience during the detection process. This effectively reduces the impact of human factors on detection accuracy, thereby improving the consistency and reliability of the detection.

[0015] By incorporating a sliding cylinder, a clamping cylinder, and a rotating end at the tube end of the probe's water jacket clamping end, stable contact between the probe and the steel pipe wall can be ensured during the inspection process. Furthermore, the design of the guide wheel and flexible contact component allows the probe to adapt to the outer wall of steel pipes of different diameters, thereby solving the signal instability problem caused by insufficient probe fit in traditional manual inspection.

[0016] By employing a collaborative detection scheme consisting of three sets of phased array probes, with the middle probe and the two side probes responsible for vertical and longitudinal scanning respectively, the weld, the edge of the base material, and the bevel surface can be fully covered for detection, further solving the shortcomings of incomplete detection range and easy omissions in manual inspection.

[0017] By employing two scans on the pipe end edge area and a Z-shaped scanning path on the weld area, the detection range can be ensured to be without blind spots, and the defect detection rate can be significantly improved, thus solving the problem of low detection rate in the weld transition area and edge area of ​​manual inspection.

[0018] The probe and water tank are connected by a rotating shaft, and the included angle can be adjusted within the range of 40° to 75° to meet the inspection needs of steel pipes with different thicknesses and bevel angles. At the same time, the water tank adopts a flexible sealing design to ensure the stability of water coupling, thereby solving the problem of signal distortion and misjudgment caused by poor coupling in manual inspection.

[0019] By using a drying air knife to dry the surface of the steel pipe after inspection, the residual moisture can be avoided from adversely affecting subsequent production processes. This solves the problem that traditional inspection methods cannot clean the inspection medium in a timely manner and improves the continuous operation capability of the production line.

[0020] By setting up a detection camera on the testing facility, the location information of the steel pipe can be located in real time, and the ultrasonic testing results can be combined for auxiliary analysis, thereby improving the integrity of the testing and the accuracy of the results, and effectively solving the problem that traditional testing cannot achieve multi-dimensional data support. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a side view schematic diagram of the structure of this utility model; Figure 3 This is a schematic diagram of the probe water bag clamping end of this utility model; Figure 4 This is a schematic diagram of the detection trajectory of the present invention; Figure 5 This is an exploded view of the water-filled structure of the probe of this utility model.

[0022] The attached diagram lists the components represented by each number as follows: 1. Six-axis robot 2. Probe water jacket clamping end; 201. Slide table cylinder; 202. Clamping cylinder; 203. Tube end rotating end; 204. Drying air knife; 205. Side probe water jacket; 2501. Ultrasonic probe; 2502. Water jacket; 2503. Rotating sealing device; 2504. Guide wheel; 206. Intermediate probe water jacket. 3. Steel pipe fixing device, 301. Motor, 302. Roller. 4. Steel pipe; 5. Inspection camera. Detailed Implementation

[0023] To make the objectives and advantages of this utility model clearer, the following detailed description is provided in conjunction with embodiments. It should be understood that the following text is merely used to describe one or more specific embodiments of this utility model and does not strictly limit the scope of protection specifically claimed by this utility model. Example 1

[0024] See Figure 1-5 A tube-end ultrasonic phased array testing mechanism, comprising: A six-axis robot 1 is used to drive the probe to perform multi-degree-of-freedom motion. The six-axis robot 1 achieves precise positioning and trajectory control of the probe water-bag clamping end 2 through multi-axis linkage, ensuring the stability and repeatability of the probe under different detection paths. The probe water-bag clamping end 2, mounted on the six-axis robot 1, is used to fix and adjust the ultrasonic probe. The probe water-bag clamping end 2 includes a sliding cylinder 201, a clamping cylinder 202, a pipe-end rotating end 203, a drying air knife 204, a side probe water-bag 205, and a middle probe water-bag 206. The sliding cylinder 201 drives the probe to move vertically or radially to adapt to different steel pipe diameters. The clamping cylinder 202 controls the probe clamping force to ensure stable contact between the probe and the pipe wall. The pipe-end rotating end 203 fixes the detection device to the steel pipe end to prevent positional displacement during detection. The drying air knife 204 is installed at the edge of the probe water-bag clamping end for quickly drying the steel pipe surface after detection. The side probe... Water jackets 205 are arranged on both sides of the clamping end to cover the longitudinal area of ​​the pipe end; the intermediate probe water jacket 206 is located in the center of the clamping end to cover the radial and transverse areas of the pipe end; the probe water jackets 205 and 206 consist of an ultrasonic probe 2501, a water jacket 2502, a rotating sealing device 2503, and a guide wheel 2504; the ultrasonic probe 2501 is responsible for transmitting and receiving detection signals, the water jacket 2502 provides a stable water coupling medium, the rotating sealing device 2503 is used to ensure that no water leakage occurs during probe adjustment, and the guide wheel 2504 ensures the fit between the water jacket and the steel pipe wall; the steel pipe rotating device 3 includes a motor 301 and a roller 302 for rotating the steel pipe 4; the motor 301 drives the roller 302 to rotate, realizing the rotational adjustment of the steel pipe 4, thereby cooperating with the multi-angle scanning of the probe; the detection camera 5 is installed on the other side of the end of the steel pipe 4 for infrared detection of the pipe end surface to ensure real-time monitoring of the appearance during the detection process.

[0025] See Figure 5 The ultrasonic probe 2501 is a phased array probe, with each probe having 32 channels. The detection mechanism uses three identical phased array probes working together. The three sets of ultrasonic probes 2501 are respectively arranged in the water jacket 206 of the middle probe and the water jackets 205 of the two side probes. Multi-angle beam control is achieved through phased array technology, which can perform full-coverage detection of welds, base materials and bevel surfaces. The phased array design improves the signal acquisition density and imaging accuracy, and solves the problems of detection instability and insufficient resolution in traditional manual flaw detection.

[0026] See Figure 3The probe of the middle probe water tank 206 is installed perpendicular to the pipe wall, and the scanning direction is vertically downward and scanning to both sides. This arrangement can cover the base material and bevel surface area of ​​the pipe end. The probes of the two sets of side probe water tanks 205 are installed at an angle of 45° to the tangent of the pipe wall for longitudinal scanning. This probe installation method can perform in-depth detection on the weld area and the edge of the pipe end, ensuring that the detection range covers the base material of 25mm on both sides of the weld and the edge area of ​​50mm, effectively solving the problem of easy omission in the weld transition area of ​​traditional detection.

[0027] See Figure 1-5 For the inspection within 50mm of the pipe end edge, two scans are used. The first scan covers the base material area close to the weld, and the second scan covers the outer part of the pipe end, thus ensuring that there are no blind spots in the entire edge area. For the weld area, the probe scans along the weld direction using a Z-shaped trajectory. This trajectory design enables the ultrasonic waves to cover the weld area multiple times, improving the defect detection rate, while ensuring the integrity and reliability of the phased array detection data.

[0028] See Figure 3-5 The probe and water jacket are connected by a rotating shaft, and the angle between the probe and the pipe wall can be adjusted within the range of 40° to 75°. This adjustment range can adapt to the testing requirements of steel pipes with different thicknesses and different bevel angles. The contact parts between the water jacket and the pipe wall are made of flexible material to maintain water tightness. The flexible contact parts can compensate for local unevenness of the pipe wall and ensure that a stable coupling is formed between the probe and the pipe wall, thereby avoiding signal distortion or interruption.

[0029] See Figure 2-5 The side probe water tank 205 is installed via a connecting plate, which can move up and down and be reset by a spring and a sliding groove structure. When the diameter of the steel pipe changes, the connecting plate automatically adjusts the probe position under the action of the spring to ensure consistent detection. Guide wheels 2504 are provided at both ends of the water tank. When the detection mechanism is pressed down, the guide wheels 2504 guide the water tank to fit against the steel pipe wall, ensuring uniform pressure on the coupling surface and preventing signal waveform distortion due to poor contact, thereby improving the stability of the detection.

[0030] See Figure 1-3 After the inspection is completed, the drying air knife 204 dries the surface of the steel pipe 4. The high-speed airflow blows away the moisture remaining at the end of the steel pipe after the water-filled inspection, so as to avoid the moisture residue affecting the subsequent coating, welding or transportation process, while ensuring the cleanliness of the inspection site and improving the continuous operation capability of the entire production line. Example 2

[0031] See Figure 1-5This embodiment provides a tube-end ultrasonic phased array testing mechanism, which includes a six-axis robot 1, a probe water-bag clamping end 2, a steel pipe rotating device 3, a steel pipe 4, and a testing camera 5. The six-axis robot 1 controls the motion trajectory through a preset program to achieve multi-degree-of-freedom drive of the probe water-bag clamping end 2, ensuring that the probe runs accurately under different testing paths. The probe water bag clamping end 2 is mounted on the end effector of the six-axis robot 1. The structure includes a sliding cylinder 201, a clamping cylinder 202, a pipe end rotating end 203, a drying air knife 204, two sets of side probe water bags 205, and a middle probe water bag 206. The sliding cylinder 201 is used to drive the probe to move vertically to adapt to the detection requirements of different pipe diameters. The clamping cylinder 202 is used to provide radial pressure to ensure that the probe is stably pressed against the pipe wall. The pipe end rotating end 203 is used to assist in clamping the end of the steel pipe so that the probe does not shift during scanning. The drying air knife 204 is connected to an air source through an external compressed air pipeline. After the detection is completed, a high-speed airflow is blown out to dry the surface of the steel pipe 4 to prevent residual moisture from affecting subsequent processes. Both probe water tanks 205 and 206 consist of an ultrasonic probe 2501, a water tank 2502, a rotating sealing device 2503, and a guide wheel 2504. The ultrasonic probe 2501 adopts a phased array structure and forms ultrasonic beams at different angles through electronic delay control, achieving high-resolution detection of the weld and base material areas. The water tank 2502 provides a stable water medium as a coupling layer to ensure effective transmission of ultrasonic signals. The rotating sealing device 2503 is used to prevent water medium leakage when the probe and water tank are rotated and adjusted. The guide wheel 2504 is installed at both ends of the water tank, which makes the water tank fit smoothly against the outer wall of the steel pipe 4 when the detection mechanism is pressed down, ensuring detection stability. During operation, the probe of the intermediate probe water tank 206 is installed perpendicular to the pipe wall, enabling it to perform vertical downward and lateral scanning to cover the pipe end bevel surface and the base material area. The two sets of side probe water tanks 205 are arranged at a 45° angle to the pipe wall, responsible for longitudinal scanning, covering the base material area within a 25mm range on both sides of the weld. When inspecting the 50mm edge area of ​​the pipe end, the six-axis robot 1 drives the probe to perform two segmented scans to ensure no blind spots in the inspection. In the weld area, the probe moves according to a preset Z-shaped trajectory, improving the defect detection rate. The steel pipe rotating device 3 consists of a motor 301 and a drum 302. The steel pipe 4 is placed on the drum 302. The motor 301 drives the drum 302 to rotate, which can realize the angle adjustment of the steel pipe during the inspection process. This rotation method enables the ultrasonic probe to achieve full coverage inspection of the pipe end, while keeping the scanning path consistent with the weld direction. The inspection camera 5 is installed on the other side of the end of the steel pipe 4 to collect the position information of the steel pipe, thereby improving the reliability of the inspection; This embodiment achieves all-round automatic inspection of the pipe end through the automated control of the six-axis robot 1, the collaborative detection of the probe water tanks 205 and 206, the stable support of the steel pipe rotating device 3, and the data assistance of the inspection camera 5. After the entire inspection process is completed, the surface is dried by the drying air knife 204 to ensure stable and reliable inspection results, while improving the efficiency of the production line.

[0032] The working principle of this utility model is as follows: The present invention provides an ultrasonic phased array testing mechanism for pipe ends. The steel pipe 4 is stabilized in the testing position by a steel pipe rotation device 3. The motor 301 and the roller 302 work together to keep the steel pipe in a rotatable or stationary state so as to cooperate with the multi-angle scanning of the probe.

[0033] During the inspection, the six-axis robot 1 drives the probe water jacket clamping end 2 to the predetermined position at the end of the steel pipe. The sliding cylinder 201 and clamping cylinder 202 inside the probe water jacket clamping end 2 work together to control the probe to maintain stable contact with the pipe wall. The probe section includes a middle probe water jacket 206 and two side probe water jackets 205. The probe of the intermediate probe water bag 206 is perpendicular to the pipe wall and is responsible for scanning vertically downwards and to both sides; The probes of the two probe water jackets 205 are installed at a 45° angle to the tangent of the pipe wall and are responsible for longitudinal scanning.

[0034] The probe employs a phased array ultrasonic probe 2501, with three probes working together to achieve full coverage inspection of the pipe end weld, edge base material, and bevel surface. During inspection, the probe and water tank maintain water coupling through a rotating sealing device 2503, while guide wheels 2504 ensure the water tank remains in close contact with the pipe wall. The probes on both sides are mounted on a vertically movable connecting plate, achieving adaptive contact through a spring and sliding groove reset structure, ensuring consistent inspection results for different pipe diameters.

[0035] Regarding the scanning path, the inspection of a 50mm area at the pipe end is achieved through two scans; the weld area is scanned using a Z-shaped trajectory along the weld direction to improve the defect detection rate. The angle between the probe and the pipe wall can be adjusted from 40° to 75° to adapt to different inspection requirements.

[0036] After inspection, the surface of steel pipe 4 is dried using a drying air knife 204 to prevent residual moisture from affecting subsequent processes. An inspection camera 5 assists in monitoring the surface condition of the pipe ends, ensuring the integrity and accuracy of the inspection process.

[0037] The entire mechanism achieves efficient, stable, and accurate tube-end ultrasonic phased array testing through multi-probe collaboration, adaptive adjustment, and automated control.

[0038] The above description is merely a preferred embodiment of this utility model. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of this utility model, and these improvements and modifications should also be considered within the scope of protection of this utility model. Structures, devices, and operating methods not specifically described or explained in this utility model, unless otherwise specified or limited, shall be implemented using conventional methods in the field.

Claims

1. A tube-end ultrasonic phased array testing mechanism, characterized in that, include: A six-axis robot (1) is used to drive the probe to perform multi-degree-of-freedom motion; The probe water bag clamping end (2) is installed on the six-axis robot (1) and is used to fix and adjust the ultrasonic probe. The probe water bag clamping end (2) includes a slide cylinder (201), a clamping cylinder (202), a tube end rotating end (203), a drying air knife (204), a side probe water bag (205), and a middle probe water bag (206). The probe water tank (205, 206) consists of an ultrasonic probe (2501), a water tank (2502), a rotating sealing device (2503), and a guide wheel (2504); The steel pipe rotating device (3) includes a motor (301) and a drum (302) for rotating the steel pipe (4); The detection camera (5) is used for pipe end positioning.

2. The testing mechanism according to claim 1, characterized in that, The ultrasonic probe (2501) is a phased array probe, and the detection mechanism uses three identical phased array probes working together.

3. The testing mechanism according to claim 1, characterized in that, The intermediate probe water bag (206) is installed perpendicular to the pipe wall, and the scanning direction is vertically downward and scanning to both sides; the two sets of side probe water bags (205) are installed at a 45° angle to the tangent of the pipe wall, and are used for longitudinal scanning.

4. The testing mechanism according to claim 1, characterized in that, For the inspection within 50mm of the pipe end edge, two scans are used to complete the inspection; for the weld area, the probe is scanned along the weld direction using a Z-shaped trajectory.

5. The testing mechanism according to claim 1, characterized in that, The probe is connected to the water tank via a rotating shaft, and the angle between the probe and the pipe wall can be adjusted within the range of 40° to 75°. The contact parts between the water tank and the pipe wall are made of flexible material to maintain water tightness.

6. The testing mechanism according to claim 1, characterized in that, The side probe water bag (205) is installed through a connecting plate, which can move up and down and be reset by a spring and a sliding groove structure; the water bag is provided with guide wheels (2504) at both ends, and the water bag can automatically fit against the pipe wall when the detection mechanism is pressed down.

7. The testing mechanism according to claim 1, characterized in that, The drying air knife (204) dries the surface of the steel pipe (4) after the inspection is completed.

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