Flexible ultrasonic flaw detection probe rod connecting composite cable

Abstract

The utility model relates to a kind of flexible ultrasonic flaw detection probe rod connecting composite cable, comprising: first signal unit, second signal unit, third signal unit, electric unit and winding layer, first signal unit includes first center reinforcing member, multiple twisted pairs and first shielding layer;Second signal unit includes second center reinforcing member, multiple first signal lines and second shielding layer;Third signal unit includes third center reinforcing member and multiple second signal lines;Electric unit includes fourth center reinforcing member, multiple power lines and fourth shielding layer;Winding layer is coated outside first signal unit, second signal unit, third signal unit and electric unit, and the outside of winding layer is coated with outer sheath.The utility model realizes power supply and the integration of multiple signal transmission, reduces wiring complexity and improves space utilization;Cable overall soft, adapt to different working condition operating environment;Second, effectively ensure the stability of signal transmission, improve the accuracy and reliability of ultrasonic flaw detection.

Description

Technical Field

[0001] This utility model relates to the field of ultrasonic flaw detection cable technology, and in particular to a flexible ultrasonic flaw detection probe connecting composite cable. Background Technology

[0002] Ultrasonic flaw detection equipment is widely used in energy and power, petrochemical, aerospace, rail transportation and automobile manufacturing, heavy machinery and engineering machinery and other fields. The cable core driving the ultrasonic flaw detection equipment includes a signal unit and a power unit. The signal unit is mainly responsible for signal transmission, specifically responsible for the signal transmission of components such as ultrasonic probes, servo motor Hall sensors and servo motor encoders; the main function of the power unit is to provide the power required for the servo motor to operate, ensuring the stable operation of the servo motor.

[0003] In actual operation, the cable follows the probe into the tubular sealed cavity, with a telescopic length of approximately 2.5 meters. The telescopic movement is achieved by rotating the cable winch, and it is telescopic about 50 times per day. In existing technologies, due to the need for cables to extend into confined spaces for special testing scenarios, existing cables are unsuitable due to their large size and fixed structure. Furthermore, during complex movements such as rotation, existing cables, due to their low anti-interference capability and poor mechanical properties, are prone to signal transmission noise, and may even break, leading to increased signal attenuation and interference, thus affecting the accuracy of flaw detection. Utility Model Content

[0004] Therefore, the technical problem to be solved by this utility model is to overcome the defects of poor adaptability and poor signal transmission stability of ultrasonic flaw detection cables in the prior art.

[0005] To solve the above-mentioned technical problems, this utility model provides a flexible ultrasonic flaw detection probe connecting composite cable, comprising: The first signal unit includes a first central reinforcement, multiple twisted pairs, and a first shielding layer. The multiple twisted pairs are twisted together on the outside of the first central reinforcement, and the first shielding layer covers the outside of the multiple twisted pairs. The second signal unit includes a second central reinforcement, multiple first signal lines, and a second shielding layer. The multiple first signal lines are twisted together on the outside of the second central reinforcement, and the second shielding layer covers the outside of the multiple first signal lines. The third signal unit includes a third central reinforcement and multiple second signal lines. Each second signal line is sequentially covered with a third shielding layer and a sheath layer. The multiple second signal lines are coaxial on the outside of the third central reinforcement. An electrical unit, comprising a fourth central reinforcement, multiple power lines, and a fourth shielding layer, wherein the multiple power lines are twisted together on the outside of the fourth central reinforcement, and the fourth shielding layer covers the outside of the multiple power lines. The wrapping layer covers the outside of the first signal unit, the second signal unit, the third signal unit, and the electrical unit, and the outside of the wrapping layer is covered with an outer sheath.

[0006] In one embodiment of the present invention, the first signal unit further includes a first isolation layer and a second isolation layer, wherein the first isolation layer is disposed between the twisted pair and the first shielding layer, and the second isolation layer is disposed outside the first shielding layer.

[0007] In one embodiment of the present invention, the second signal unit further includes a third isolation layer and a fourth isolation layer, wherein the third isolation layer is disposed between the first signal line and the second shielding layer, and the fourth isolation layer is disposed outside the second shielding layer.

[0008] In one embodiment of the present invention, the third signal unit further includes a fifth isolation layer, which covers the outside of the plurality of second signal lines.

[0009] In one embodiment of the present invention, the electrical unit further includes a sixth isolation layer and a seventh isolation layer. The sixth isolation layer is disposed between the fourth shielding layer and the multiple power lines, and the seventh isolation layer is disposed outside the fourth shielding layer.

[0010] In one embodiment of the present invention, an oil pipe is also included, wherein the oil pipe, the first signal unit, the second signal unit, the third signal unit, and the electrical unit are all covered within the wrapping layer.

[0011] In one embodiment of the present invention, a filling layer is further provided inside the wrapping layer, and the filling layer is disposed in the gap between the oil pipe, the first signal unit, the second signal unit, the third signal unit and the electrical unit.

[0012] In one embodiment of this utility model, the outer side of the oil pipe is covered with an eighth isolation layer.

[0013] In one embodiment of the present invention, the first signal line includes a first conductor and a first insulating layer, the first insulating layer covering the outside of the first conductor; the second signal line includes a second conductor and a second insulating layer, the second insulating layer covering the outside of the second conductor, and the third shielding layer and the sheath layer are sequentially covered on the outside of the second insulating layer; the power line includes a third conductor and a third insulating layer, the third insulating layer covering the outside of the third conductor.

[0014] In one embodiment of the present invention, the twisted pair cable includes two third signal lines twisted together, each third signal line including a fourth conductor and a fourth insulating layer, the fourth insulating layer covering the outside of the fourth conductor.

[0015] The above-mentioned technical solution of this utility model has the following advantages compared with the prior art: This invention relates to a flexible ultrasonic flaw detection probe connecting composite cable. This cable integrates electrical units and multiple signal units, achieving unified power supply and transmission of multiple signals, reducing wiring complexity and improving space utilization. The central reinforcement in each unit enhances the overall mechanical strength and environmental adaptability of the cable. The cable is flexible and can extend and retract into a sealed cavity along with the probe, adapting to various working conditions. Furthermore, the metal shielding layer in each unit improves the anti-interference capability of the cable's signal transmission, effectively ensuring signal transmission stability and improving the accuracy and reliability of ultrasonic flaw detection. Attached Figure Description

[0016] To make the content of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings. Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 for Figure 1 A schematic diagram of the structure of the first signal unit; Figure 3 for Figure 2 A schematic diagram of the structure of a twisted pair cable; Figure 4 for Figure 1 A schematic diagram of the structure of the second signal unit; Figure 5 for Figure 1 A schematic diagram of the structure of the third signal unit; Figure 6 for Figure 1 Schematic diagram of the structure of the power supply unit; Explanation of reference numerals in the accompanying drawings: 1. First signal unit; 2. Second signal unit; 3. Third signal unit; 4. Electrical unit; 5. Oil pipe; 6. Wrapping layer; 7. Outer sheath; 8. Filler layer; 11. First central reinforcement; 12. Twisted pair; 13. First shielding layer; 14. First isolation layer; 15. Second isolation layer; 21. Second central reinforcement; 22. First signal line; 23. Second shielding layer; 24. Third isolation layer; 25. Fourth isolation layer; 31. Third central reinforcement; 32. Second signal line; 33, Third shielding layer; 34, Sheath layer; 35, Fifth isolation layer; 41, Fourth center reinforcement; 42, Power line; 43, Fourth shielding layer; 44, Sixth isolation layer; 45, Seventh isolation layer; 51, Eighth isolation layer; 121, Third signal line; 221, First conductor; 222, First insulation layer; 321, Second conductor; 322, Second insulation layer; 421, Third conductor; 422, Third insulation layer; 1211, Fourth conductor; 1212, Fourth insulation layer. Detailed Implementation

[0017] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments are not intended to limit the present invention.

[0018] Reference Figures 1-6 As shown, this utility model discloses a flexible ultrasonic flaw detection probe connecting composite cable, comprising: The first signal unit 1 includes a first central reinforcement 11, multiple twisted pairs 12, and a first shielding layer 13. The multiple twisted pairs 12 are twisted together on the outside of the first central reinforcement 11, and the first shielding layer 13 covers the outside of the multiple twisted pairs 12. The second signal unit 2 includes a second central reinforcement 21, multiple first signal lines 22 and a second shielding layer 23. The multiple first signal lines 22 are twisted together on the outside of the second central reinforcement 21, and the second shielding layer 23 covers the outside of the multiple first signal lines 22. The third signal unit 3 includes a third central reinforcement 31 and multiple second signal lines 32. Each second signal line 32 is covered with a third shielding layer 33 and a sheath layer 34 in sequence on its outer side. The multiple second signal lines 32 are coaxial on the outer side of the third central reinforcement 31. Electrical unit 4 includes a fourth central reinforcement 41, multiple power lines 42 and a fourth shielding layer 43. The multiple power lines 42 are twisted together on the outside of the fourth central reinforcement 41, and the fourth shielding layer 43 covers the outside of the multiple power lines 42. The wrapping layer 6 covers the outside of the first signal unit 1, the second signal unit 2, the third signal unit 3 and the electrical unit 4, and the outer side of the wrapping layer 6 is covered with an outer sheath 7.

[0019] The first signal unit 1 in this invention is used to connect to the rotary servo motor encoder. The encoder is mainly used to transmit pulse signals or analog signals generated by the encoder. These signals are used to accurately measure parameters such as rotational position, speed, and direction, so as to achieve precise control and monitoring of the rotary ultrasonic probe system. Specifically, the first central reinforcement 11 is used to improve the mechanical strength of the first signal unit 1. Twisted pair cables 12 are used as signal transmission cables. The twisted pair cables 12 consist of two wires twisted together. External electromagnetic interference will act on both wires simultaneously, and the resulting interference signals are similar in magnitude and opposite in direction. The interference signals will be canceled out, thereby ensuring the integrity of the original signal. The first shielding layer 13 is sleeved on the outside of the multiple twisted pair cables 12 to further ensure the stability of signal transmission.

[0020] The second signal unit 2 is used to connect to the Hall sensor of the rotary servo motor. The Hall sensor is used to detect information such as position or speed, and its main function is to transmit the electrical signals generated by the Hall sensor. These signals are used for feedback and control. Specifically, the second central reinforcement 21 is used to improve the mechanical strength of the entire second signal unit 2; multiple first signal wires 22 are twisted together on the outside of the second central reinforcement 21 for signal transmission; the second shielding layer 23 is sleeved on the outside of the multiple first signal wires 22 to shield external signal interference, ensure the stability of the Hall sensor signal transmission, and improve the reliability of the entire equipment operation.

[0021] The third signal unit 3 is connected to the ultrasonic probe, and its main function is to transmit the radio frequency echo signal of the ultrasonic wave (this signal is subsequently processed and displayed by relevant equipment). The radio frequency echo signal contains a wealth of information about the internal structure and defects of the object being tested. By analyzing these signals, the existence, location, size, and nature of defects can be determined more accurately. Specifically, the third signal unit 3 adopts a structure in which multiple second signal wires 32 are twisted together on the outside of the third central reinforcement 31. Each second signal wire 32 is covered with a third shielding layer 33 and a sheath layer 34. The third shielding layer 33 prevents external signals from interfering with the signal transmission of the second signal wire 32, and the sheath layer 34 is used to protect and isolate the third shielding layer 33.

[0022] Electrical unit 4 is used to connect to a rotary servo motor and to provide power to the servo motor. Specifically, the fourth central reinforcement 41 is used to improve the mechanical strength of electrical unit 4, multiple power lines 42 are used to transmit current, and the fourth shielding layer 43 is used to shield the electromagnetic interference of the power lines 42 transmitting current, preventing the electromagnetic signals generated by the power lines 42 during operation from interfering with the transmission of signals from other signal units.

[0023] The wrapping layer 6 secures multiple cable cores outside the first signal unit 1, the second signal unit 2, the third signal unit 3, and the electrical unit 4, facilitating the subsequent extrusion of the outer sheath 7. The outer sheath 7 is located on the outermost side of the entire cable, serving as a protective shell for the internal cable cores. Its function is to protect the internal structure of the cable from external environmental and mechanical damage, ensuring long-term stable operation of the cable.

[0024] As a preferred embodiment of this utility model, the first shielding layer 13, the second shielding layer 23, and the fourth shielding layer 43 in the above structure are all copper mesh braided layers, providing metallic shielding for the transmitted signal and ensuring the stability of signal transmission. The third shielding layer 33 is made of tin-plated copper alloy wire, which has a better signal shielding effect than traditional copper mesh shielding, and can also improve the tensile strength of the entire cable. The first central reinforcement 11, the second central reinforcement 21, the third central reinforcement 31, and the fourth central reinforcement 41 are all made of Kevlar. Utilizing the high strength and lightweight characteristics of Kevlar, while also possessing weather resistance and corrosion resistance, it can provide stable mechanical support for the cable. The outer sheath 7 is made of modified high-strength polyurethane elastomer material, which greatly improves the cable's wear resistance and oil resistance, and also has a certain degree of flexibility, making it convenient for use in confined spaces or mobile testing scenarios.

[0025] This invention integrates electrical unit 4 and multiple signal units into a single cable, achieving integrated power supply and transmission of various signals, reducing wiring complexity and improving space utilization. The central reinforcement in each unit enhances the overall mechanical strength and environmental adaptability of the cable. The cable is flexible and can extend and retract into the sealed cavity along with the probe, adapting to different working conditions. Furthermore, the metal shielding layer in each unit improves the anti-interference capability of the cable's signal transmission, effectively ensuring signal transmission stability and improving the accuracy and reliability of ultrasonic flaw detection.

[0026] Furthermore, the first signal unit 1 also includes a first isolation layer 14 and a second isolation layer 15. The first isolation layer 14 is disposed between the twisted pair 12 and the first shielding layer 13, and the second isolation layer 15 is disposed outside the first shielding layer 13.

[0027] Specifically, the first shielding layer 13 is used to isolate the twisted pair 12 from the first shielding layer 13. On the one hand, it wraps the multiple twisted pairs 12 into shape, and on the other hand, it prevents the twisted pairs 12 from directly contacting the first shielding layer 13 and damaging the twisted pairs 12. The second isolation layer 15 is set on the outermost side of the entire first signal unit 1 to prevent direct contact with other cable cores.

[0028] Furthermore, the second signal unit 2 also includes a third isolation layer 24 and a fourth isolation layer 25. The third isolation layer 24 is disposed between the first signal line 22 and the second shielding layer 23, and the fourth isolation layer 25 is disposed outside the second shielding layer 23.

[0029] Specifically, the third isolation layer 24 is used to wrap and shape multiple first signal lines 22 to prevent the first signal lines 22 from directly contacting the second shielding layer 23 and damaging the first signal lines 22; the fourth isolation layer 25 is to prevent friction between the second signal unit 2 and other cable cores.

[0030] Furthermore, the third signal unit 3 also includes a fifth isolation layer 35, which covers the outside of the plurality of second signal lines 32.

[0031] Similarly, the fifth isolation layer 35 is used to wrap and shape multiple second signal lines 32 to prevent the multiple second signal lines 32 from becoming loose, while also preventing the second signal unit 2 from rubbing against other cable cores.

[0032] Furthermore, the electrical unit 4 also includes a sixth isolation layer 44 and a seventh isolation layer 45. The sixth isolation layer 44 is disposed between the fourth shielding layer 43 and the multiple power lines 42, and the seventh isolation layer 45 is disposed outside the fourth shielding layer 43.

[0033] Specifically, the sixth isolation layer 44 is used to wrap the multiple power lines 42 to prevent them from loosening and also to prevent the power lines 42 from contacting the fourth shielding layer 43. The seventh isolation layer 45 is disposed outside the fourth shielding layer 43 to protect the cable core of the electrical unit 4 and prevent the fourth shielding layer 43 from contacting and rubbing against other cable cores.

[0034] Furthermore, it also includes an oil pipe 5, which, along with the first signal unit 1, the second signal unit 2, the third signal unit 3, and the electrical unit 4, is all encased within the wrapping layer 6.

[0035] Specifically, the composite cable core of this invention also includes an oil pipe 5. The oil pipe 5 is used to supply coupling oil to the ultrasonic probe. In ultrasonic flaw detection, the core function of the coupling oil supplied by the oil pipe 5 is to eliminate air between the probe and the surface of the workpiece being inspected, allowing ultrasonic waves to efficiently penetrate the workpiece and achieve defect detection. Preferably, the oil pipe 5 in this invention is made of PU tubing with an inner diameter of 3mm and an outer diameter of 4mm. The rated pressure of the oil pipe 5 is 0.7MPa, and the test pressure is 1.05MPa, ensuring smooth transmission of the coupling oil in the composite cable oil pipe 5.

[0036] Furthermore, a filling layer 8 is also provided inside the wrapping layer 6, and the filling layer 8 is disposed in the gap between the oil pipe 5, the first signal unit 1, the second signal unit 2, the third signal unit 3 and the electrical unit 4.

[0037] Specifically, the filling layer 8 fills the gaps between each unit (cable core), filling the voids and ensuring the cable structure is round. Secondly, it can also fix the cable core and prevent the internal cable core from shifting.

[0038] Furthermore, the outer side of the oil pipe 5 is covered with an eighth isolation layer 51.

[0039] Specifically, the eighth isolation layer 51 separates the oil pipe 5 from other cable cores. As a preferred embodiment of this utility model, the materials of the first isolation layer 14, the second isolation layer 15, the third isolation layer 24, the fourth isolation layer 25, the fifth isolation layer 35, the sixth isolation layer 44, the seventh isolation layer 45, the eighth isolation layer 51 and the wrapping layer 6 in the above structure are all non-woven fabrics, which have good wear resistance and insulation.

[0040] Further, the first signal line 22 includes a first conductor 221 and a first insulating layer 222, with the first insulating layer 222 covering the outside of the first conductor 221; the second signal line 32 includes a second conductor 321 and a second insulating layer 322, with the second insulating layer 322 covering the outside of the second conductor 321, and the third shielding layer 33 and sheath layer 34 sequentially covering the outside of the second insulating layer 322; the power line 42 includes a third conductor 421 and a third insulating layer 422, with the third insulating layer 422 covering the outside of the third conductor 421. The twisted pair cable 12 includes two intertwined third signal lines 121, each third signal line 121 including a fourth conductor 1211 and a fourth insulating layer 1212, with the fourth insulating layer 1212 covering the outside of the fourth conductor 1211.

[0041] In the above structure, the first conductor 221, the third conductor 421, and the fourth conductor 1211 are all made of metallic copper, which has good conductivity and signal transmission performance. The second conductor 321 is made of tin-plated copper alloy, which not only ensures stable signal transmission but also improves the tensile strength of the entire second signal line 32. The first insulation layer 222, the second insulation layer 322, the third insulation layer 422, and the fourth insulation layer 1212 are all made of FEP (perfluoroethylene propylene), which has excellent electrical insulation performance, reduces the outer diameter of the insulation, lowers the cable weight, and further ensures that the composite cable can operate in small spaces with the ultrasonic probe.

[0042] In summary, this utility model introduces a flexible ultrasonic flaw detection probe connecting composite cable. This cable integrates electrical unit 4 and multiple signal units into a single cable, achieving integrated power supply and transmission of multiple types of signals, reducing wiring complexity and improving space utilization. The central reinforcement in each unit enhances the overall mechanical strength and environmental adaptability of the cable. The cable is flexible and can extend and retract with the probe into the sealed cavity for operation, adapting to different working conditions. Furthermore, the metal shielding layer in each unit improves the anti-interference capability of the cable signal transmission, effectively ensuring signal transmission stability and improving the accuracy and reliability of ultrasonic flaw detection.

[0043] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the protection scope of this invention.

Claims

1. A flexible ultrasonic flaw detection probe connecting a composite cable, characterized in that, include: The first signal unit includes a first central reinforcement, multiple twisted pairs, and a first shielding layer. The multiple twisted pairs are twisted together on the outside of the first central reinforcement, and the first shielding layer covers the outside of the multiple twisted pairs. The second signal unit includes a second central reinforcement, multiple first signal lines, and a second shielding layer. The multiple first signal lines are twisted together on the outside of the second central reinforcement, and the second shielding layer covers the outside of the multiple first signal lines. The third signal unit includes a third central reinforcement and multiple second signal lines. Each second signal line is sequentially covered with a third shielding layer and a sheath layer. The multiple second signal lines are coaxial on the outside of the third central reinforcement. An electrical unit, comprising a fourth central reinforcement, multiple power lines, and a fourth shielding layer, wherein the multiple power lines are twisted together on the outside of the fourth central reinforcement, and the fourth shielding layer covers the outside of the multiple power lines. The wrapping layer covers the outside of the first signal unit, the second signal unit, the third signal unit, and the electrical unit, and the outside of the wrapping layer is covered with an outer sheath.

2. The flexible ultrasonic flaw detector probe connecting composite cable according to claim 1, characterized in that: The first signal unit further includes a first isolation layer and a second isolation layer. The first isolation layer is disposed between the twisted pair and the first shielding layer, and the second isolation layer is disposed outside the first shielding layer.

3. The flexible ultrasonic flaw detector probe connecting composite cable according to claim 1, characterized in that: The second signal unit further includes a third isolation layer and a fourth isolation layer. The third isolation layer is disposed between the first signal line and the second shielding layer, and the fourth isolation layer is disposed outside the second shielding layer.

4. The flexible ultrasonic flaw detector probe connecting composite cable according to claim 1, characterized in that: The third signal unit further includes a fifth isolation layer, which covers the outside of the plurality of second signal lines.

5. The flexible ultrasonic flaw detector probe connecting composite cable according to claim 1, characterized in that: The electrical unit also includes a sixth isolation layer and a seventh isolation layer. The sixth isolation layer is disposed between the fourth shielding layer and the multiple power lines, and the seventh isolation layer is disposed outside the fourth shielding layer.

6. The flexible ultrasonic flaw detector probe connecting composite cable according to claim 1, characterized in that: It also includes an oil pipe, which, along with the first signal unit, the second signal unit, the third signal unit, and the electrical unit, is encased within the wrapping layer.

7. The flexible ultrasonic flaw detector probe connecting composite cable according to claim 6, characterized in that: A filling layer is also provided inside the wrapping layer, and the filling layer is disposed in the gap between the oil pipe, the first signal unit, the second signal unit, the third signal unit and the electrical unit.

8. The flexible ultrasonic flaw detector probe connecting composite cable according to claim 6, characterized in that: The outer side of the oil pipe is covered with an eighth isolation layer.

9. The flexible ultrasonic flaw detector probe connecting composite cable according to claim 1, characterized in that: The first signal line includes a first conductor and a first insulating layer, with the first insulating layer covering the outside of the first conductor; the second signal line includes a second conductor and a second insulating layer, with the second insulating layer covering the outside of the second conductor, and the third shielding layer and the sheath layer sequentially covering the outside of the second insulating layer; the power line includes a third conductor and a third insulating layer, with the third insulating layer covering the outside of the third conductor.

10. The flexible ultrasonic flaw detector probe connecting composite cable according to claim 1, characterized in that: The twisted pair cable includes two twisted third signal lines, each third signal line including a fourth conductor and a fourth insulating layer, the fourth insulating layer covering the outside of the fourth conductor.

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