Ultrasonic testing device for cement rotary kiln cylinder structure

Abstract

The utility model relates to a kind of ultrasonic detection devices of cement rotary kiln cylinder structure, including cement rotary kiln body structure, is provided with a group of detection components in the outside of cement rotary kiln body structure Relative arrangement, the detection component includes adjustment connecting base structure, the horizontal adjustment structure of being arranged on the upper portion of adjustment connecting base structure and the kiln body ultrasonic detection structure of being arranged on the upper portion of horizontal adjustment structure, the utility model has the beneficial effect: detection precision: crack minimum detection size 0.3mm (depth is greater than or equal to 1mm), air hole detection diameter is greater than or equal to 0.5mm;Temperature adaptability: it can be stable work when cylinder surface temperature is less than or equal to 650 DEG C;Detection efficiency: single time full kiln detection time is less than or equal to 12 hours (traditional method needs greater than or equal to 48 hours).Detection efficiency is increased by more than 3 times, support online detection (downtime reduction 80%).Minimum defect size 0.3mm can be identified, false alarm rate is less than 5%.

Description

Technical Field

[0001] This utility model relates to the field of cement rotary kiln testing, and in particular to an ultrasonic testing device for the structure of a cement rotary kiln cylinder. Background Technology

[0002] Cement kilns are the core equipment in cement production. Their cylinders operate for extended periods under high temperatures (300-800℃), alternating mechanical stress, and chemical corrosion, which can easily lead to the following defects: Cylinder weld cracking: fatigue cracks occur in the circumferential / longitudinal welds due to thermal stress concentration; Internal casting defects: casting defects such as porosity and slag inclusions exist in the grate cooler castings; Local cylinder deformation: high-temperature creep causes deviations in the ellipticity of the cylinder, accelerating defect propagation.

[0003] Traditional ultrasonic testing requires manual hand-held probe inspection after the machine is stopped, which is inefficient and has blind spots, and cannot adapt to changes in the curvature of the cylinder; infrared thermal imaging technology can only detect surface temperature anomalies and has insufficient resolution for internal defects (>3mm); electromagnetic ultrasonic testing does not require coupling agent but the equipment cost is high, and it is highly sensitive to the casting material and has poor detection stability. Utility Model Content

[0004] The purpose of this invention is to provide an online detection system that integrates automated control, a high-temperature adaptive ultrasonic array, and multimodal data analysis.

[0005] The technical solution adopted by this utility model to solve its technical problem is: an ultrasonic testing device for a cement rotary kiln shell structure, including a cement rotary kiln shell structure, and a set of relatively arranged testing components on the outside of the cement rotary kiln shell structure. The testing components include an adjustment connecting base structure, a horizontal adjustment structure provided on the upper part of the adjustment connecting base structure, and a kiln body ultrasonic testing structure provided on the upper part of the horizontal adjustment structure. The adjustment connecting base structure includes a testing platform and a connecting adjustment rod structure provided in the testing platform. The horizontal adjustment structure includes a horizontal assembly rod seat connected to the adjustment connecting base structure, a horizontal adjustment platform structure provided on the upper part of the horizontal assembly rod seat, and a horizontal mounting set seat provided on the upper part of the horizontal adjustment platform structure. The kiln body ultrasonic testing structure includes a two-section vertical drive structure connected to the horizontal mounting set seat, a detection mounting arc seat connected to the two-section vertical drive structure, and a matrix ultrasonic testing structure provided in the detection mounting arc seat.

[0006] The matrix ultrasonic testing structure includes an automatic retraction control frame seat located in the arc-shaped mounting base for testing, and an ultrasonic testing structure and a cooling sealing plate structure located within the automatic retraction control frame seat.

[0007] The automatic retraction control frame includes a telescopic drive seat body located on the outer side of the detection mounting arc seat, a telescopic drive motor located on the outer side of the telescopic drive seat body, and a telescopic connecting inner seat located in the telescopic drive seat body. The telescopic connecting inner seat is connected to the ultrasonic detection structure.

[0008] The ultrasonic testing structure includes a testing equipment connecting plate connected to the inner seat of the retractable connector, a testing component mounting base located on the upper part of the testing equipment connecting plate, and multiple ultrasonic testing units located on the testing component mounting base.

[0009] The ultrasonic testing unit includes a horizontal testing connection platform mounted on a testing component mounting base, multiple ultrasonic testing heads arranged at intervals in the horizontal testing connection platform, and a testing camera assembly disposed in the horizontal testing connection platform above the ultrasonic testing heads.

[0010] The aforementioned connecting and adjusting rod structure includes a base and an adjusting connecting seat disposed on the base.

[0011] The aforementioned horizontal adjustment platform structure includes a horizontal drive connecting seat connected to a horizontal assembly rod seat, a horizontal adjustment screw seat located on the upper part of the horizontal drive connecting seat, and a horizontal adjustment drive motor located in the horizontal adjustment screw seat.

[0012] The two-stage vertical drive structure includes a lifting platform connected to a horizontal mounting base, a two-stage vertical drive screw base connected to the lifting platform, and a two-stage vertical lifting inner connecting seat provided in the two-stage vertical drive screw base. The two-stage vertical lifting inner connecting seat is connected to a detection and installation arc-shaped seat.

[0013] The cooling plate structure includes an air-cooled connecting frame, a cooling duct assembly structure disposed in the air-cooled connecting frame, a cooling fan disposed in the air-cooled connecting frame and connected to the cooling duct assembly structure, and a brush mounting bracket disposed in the air-cooled connecting frame surrounding the cooling duct assembly structure.

[0014] The beneficial effects of this utility model are: detection accuracy: minimum crack detection size is 0.3mm (depth ≥ 1mm), and pore detection diameter is ≥ 0.5mm;

[0015] Temperature adaptability: It can operate stably when the surface temperature of the cylinder is ≤650℃;

[0016] Detection efficiency: Single kiln inspection time ≤ 12 hours (traditional methods require ≥ 48 hours).

[0017] The detection efficiency is improved by more than 3 times, and online detection is supported (downtime is reduced by 80%).

[0018] It can identify defects as small as 0.3 mm with a false alarm rate of <5%.

[0019] Suitable for cement kiln shells with diameters of 3-8m and tires with thicknesses of 50-500mm.

[0020] The present invention will be described in more detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of this utility model.

[0022] Figure 2 This is a schematic diagram of the ultrasonic testing structure for the kiln body in this utility model.

[0023] Figure 3 for Figure 2 The split state diagram.

[0024] Figure 4 for Figure 2 A schematic diagram of the structure of the intermediate cooling plate.

[0025] Figure 5 This is a diagram showing the usage state of this utility model.

[0026] Figure 6 This is a schematic diagram illustrating the construction of another embodiment of the present invention.

[0027] In the diagram: 1. Cement rotary kiln body structure; 2. Testing platform; 3. Horizontal assembly rod seat; 4. Horizontal assembly set seat; 5. Testing installation arc seat; 6. Base; 7. Adjustment connecting seat; 8. Horizontal drive connecting seat; 9. Horizontal adjustment screw seat; 10. Horizontal adjustment drive motor; 11. Lifting platform; 12. Two-stage vertical drive screw seat; 13. Two-stage vertical lifting inner connecting seat; 14. Air-cooled connecting frame; 15. Cooling duct assembly structure; 16. Cooling fan; 17. Brush body mounting side seat; 18. Automatic retraction control frame seat; 19. Telescopic drive seat; 20. Telescopic drive motor; 21. Telescopic connecting inner seat; 22. Testing equipment connecting plate; 23. Testing component mounting seat; 24. Horizontal testing connecting platform; 25. Ultrasonic testing head; 26. Testing camera assembly; 27. Air-cooled connecting plate. Detailed Implementation

[0028] The terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end" used in the application text to indicate the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings. They are used solely for the convenience of describing the present invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0029] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," and "connected," etc., should be interpreted broadly. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0030] Example 1, such as Figure 1-5 As shown, an ultrasonic testing device for a cement rotary kiln structure includes a cement rotary kiln structure. A testing component, either unilaterally or in a group of oppositely arranged components, is provided on the exterior of the cement rotary kiln structure 1. The testing component includes an adjustment connecting base structure, a horizontal adjustment structure located on the upper part of the adjustment connecting base structure, and a kiln ultrasonic testing structure located on the upper part of the horizontal adjustment structure. The adjustment connecting base structure includes a testing platform 2 and a connecting adjustment rod structure located within the testing platform 2. The horizontal adjustment structure includes a horizontal assembly rod seat 3 connected to the adjustment connecting base structure, a horizontal adjustment platform structure located on the upper part of the horizontal assembly rod seat 3, and a horizontal mounting bracket 4 located on the upper part of the horizontal adjustment platform structure. The kiln ultrasonic testing structure includes a testing installation arc seat 5 and a matrix ultrasonic testing structure located within the testing installation arc seat.

[0031] The aforementioned connecting and adjusting rod structure includes a base 6 and an adjusting connecting seat 7 disposed on the base.

[0032] The aforementioned horizontal adjustment platform structure includes a horizontal drive connecting seat 8 connected to a horizontal assembly rod seat, a horizontal adjustment screw seat 9 located on the upper part of the horizontal drive connecting seat, and a horizontal adjustment drive motor 10 located in the horizontal adjustment screw seat.

[0033] The cooling plate structure includes a wind-cooled connecting plate 27 located between the detection mounting arc seat 5 and the automatic retraction control frame seat 18, a wind-cooled connecting frame body 14 located outside the wind-cooled connecting plate 27, a cooling air duct assembly structure 15 located in the wind-cooled connecting frame body, a cooling fan 16 located in the wind-cooled connecting frame body and connected to the cooling air duct assembly structure, and a brush mounting side seat 17 located in the wind-cooled connecting frame body surrounding the cooling air duct assembly structure.

[0034] The matrix ultrasonic testing structure includes an automatic retraction control frame 18 disposed in the arc-shaped mounting base for testing, an ultrasonic testing structure disposed within the automatic retraction control frame, and a cooling sealing plate structure.

[0035] The automatic retraction control frame includes a telescopic drive seat 19 located on the outer side of the detection mounting arc seat, a telescopic drive motor 20 located on the outer side of the telescopic drive seat, and a telescopic connecting inner seat 21 located in the telescopic drive seat. The telescopic connecting inner seat is connected to the ultrasonic detection structure.

[0036] The ultrasonic testing structure includes a testing equipment connecting plate 22 connected to the inner seat 21, a testing component mounting base 23 located on the upper part of the testing equipment connecting plate, and multiple ultrasonic testing units located on the testing component mounting base.

[0037] The ultrasonic testing unit includes a horizontal testing connection platform 24 mounted on a testing component mounting base, multiple ultrasonic testing heads 25 arranged at intervals in the horizontal testing connection platform, and a testing camera assembly 26 disposed in the upper part of the ultrasonic testing head in the horizontal testing connection platform.

[0038] The ultrasonic testing device for the cement rotary kiln structure moves along the kiln's axial direction at a speed of 0.5 m / s, and the probe array emits a dynamically focused sound beam (center frequency 5 MHz).

[0039] After acquiring the echo signal, feature frequency bands are extracted through wavelet packet decomposition and input into a pre-trained ResNet-18 model to determine the defect type.

[0040] The results are displayed on the terminal in real time, the defect location is marked (accuracy ±5mm) and an inspection report is generated.

[0041] Tire inspection:

[0042] Switch to TOFD mode and use a low-frequency probe (2MHz) to penetrate high-attenuation materials.

[0043] The adaptive filter adjusts the threshold according to the material grain size to suppress speckle noise.

[0044] By combining X-ray inspection results with data fusion, the detection rate of complex defects can be improved.

[0045] The ultrasonic testing device for the cement rotary kiln cylinder structure adopts a double-layer water-cooled phased array probe. The outer shell material is silicon carbide reinforced aluminum matrix composite material (SiC / Al), and the internal micro eddy tube cooling device is integrated to keep the probe operating temperature ≤80℃.

[0046] The automatic coupling agent spraying module uses boron nitride (BN) high-temperature coupling agent and achieves a uniform film thickness of 0.1-0.3mm through piezoelectric ceramic atomizing nozzles, with a spraying accuracy of ±5μm.

[0047] Adaptive scanning control method for curved surfaces

[0048] Based on the acquisition of 3D point cloud data (0.1mm resolution) of the cylinder surface by LiDAR, the radius of curvature R of the probe array is dynamically adjusted (satisfying R = κ). 1 ±2mm, κ is the local curvature);

[0049] Adopting a variable step size spiral scanning strategy ( Figure 1 The axial moving speed v = 0.2-1.0 m / s and the circumferential scanning angle step Δθ = 5°-15° are used to ensure that the sound beam coverage overlap rate is ≥30%.

[0050] Multimodal data fusion defect identification

[0051] Simultaneously acquire A-scan (time-domain waveform), B-scan (cross-sectional imaging), and C-scan (three-dimensional volume data) to construct defect feature vectors [amplitude, time delay, spectral centroid, scattering coefficient];

[0052] Design a lightweight convolutional neural network (CNN) model, consisting of 5 convolutional kernels (3×3) + 2 fully connected layers. The input is a 128×128 pixel TFM image, and the output is the defect type and confidence level.

[0053] The ultrasonic testing device for the structure of the cement rotary kiln shell is equipped with a high-precision servo motor or a lidar.

[0054] It features a water-cooled phased array probe array, an integrated boron nitride coupling agent spraying module and temperature sensor, a data processing unit, and a built-in defect classification algorithm based on a convolutional neural network and a 3D imaging module.

[0055] The ultrasonic detection head 25 has an adjustable operating frequency of 2-15MHz, and the array element spacing satisfies d≤λ / 2 (λ is the ultrasonic wavelength).

[0056] Example 2, as Figure 6 As shown, based on Embodiment 1, to adapt to kiln body structures of various diameters, the ultrasonic detection structure for the kiln body further includes a two-stage vertical drive structure connected to the horizontal mounting base, a detection mounting arc-shaped seat 5 connected to the two-stage vertical drive structure, and a matrix ultrasonic detection structure disposed in the detection mounting arc-shaped seat. The two-stage vertical drive structure includes a lifting platform 11 connected to the horizontal mounting base 3, a two-stage vertical drive screw seat 12 connected to the lifting platform, and a two-stage vertical lifting inner connecting seat 13 disposed in the two-stage vertical drive screw seat, which is connected to the detection mounting arc-shaped seat.

[0057] Detection accuracy: minimum crack detection size 0.3mm (depth ≥ 1mm), pore detection diameter ≥ 0.5mm;

[0058] Temperature adaptability: It can operate stably when the surface temperature of the cylinder is ≤650℃;

[0059] Detection efficiency: Single kiln inspection time ≤ 12 hours (traditional methods require ≥ 48 hours).

[0060] The detection efficiency is improved by more than 3 times, and online detection is supported (downtime is reduced by 80%).

[0061] It can identify defects as small as 0.3 mm with a false alarm rate of <5%.

[0062] Suitable for cement kiln shells with diameters of 3-8m and tires with thicknesses of 50-500mm.

[0063] The above embodiments are merely descriptions of preferred embodiments of the present utility model and are not intended to limit the scope of the present utility model. Various modifications and improvements made to the technical solutions of the present utility model by those skilled in the art without departing from the spirit of the present utility model should fall within the protection scope defined by the claims of the present utility model.

[0064] The parts not covered in this utility model are the same as or can be implemented using existing technologies.

Claims

1. An ultrasonic testing device for the structure of a cement rotary kiln, comprising the structure of a cement rotary kiln, characterized in that: A set of opposing detection components is installed on the outside of the cement rotary kiln structure. The detection components include an adjustment connecting base structure, a horizontal adjustment structure located on the upper part of the adjustment connecting base structure, and a kiln body ultrasonic detection structure located on the upper part of the horizontal adjustment structure. The adjustment connecting base structure includes a detection platform and a connecting adjustment rod structure located in the detection platform. The horizontal adjustment structure includes a horizontal assembly rod seat connected to the adjustment connecting base structure, a horizontal adjustment platform structure located on the upper part of the horizontal assembly rod seat, and a horizontal assembly set seat located on the upper part of the horizontal adjustment platform structure. The kiln body ultrasonic detection structure includes a two-stage vertical drive structure connected to the horizontal assembly set seat, a detection mounting arc seat connected to the two-stage vertical drive structure, and a matrix ultrasonic detection structure located in the detection mounting arc seat.

2. The ultrasonic testing device for the structure of a cement rotary kiln as described in claim 1, characterized in that: The matrix ultrasonic testing structure includes an automatic retraction control frame seat located in the arc-shaped mounting base for testing, and an ultrasonic testing structure and a cooling sealing plate structure located within the automatic retraction control frame seat.

3. The ultrasonic testing device for the structure of a cement rotary kiln as described in claim 2, characterized in that: The automatic retraction control frame includes a telescopic drive seat body located on the outer side of the detection mounting arc seat, a telescopic drive motor located on the outer side of the telescopic drive seat body, and a telescopic connecting inner seat located in the telescopic drive seat body. The telescopic connecting inner seat is connected to the ultrasonic detection structure.

4. The ultrasonic testing device for the structure of a cement rotary kiln as described in claim 3, characterized in that: The ultrasonic testing structure includes a testing equipment connecting plate connected to the inner seat of the retractable connector, a testing component mounting base located on the upper part of the testing equipment connecting plate, and multiple ultrasonic testing units located on the testing component mounting base.

5. The ultrasonic testing device for the structure of a cement rotary kiln as described in claim 4, characterized in that: The ultrasonic testing unit includes a horizontal testing connection platform mounted on a testing component mounting base, multiple ultrasonic testing heads arranged at intervals in the horizontal testing connection platform, and a testing camera assembly disposed in the horizontal testing connection platform above the ultrasonic testing heads.

6. The ultrasonic testing device for the structure of a cement rotary kiln as described in claim 1, characterized in that: The aforementioned connecting and adjusting rod structure includes a base and an adjusting connecting seat disposed on the base. The aforementioned horizontal adjustment platform structure includes a horizontal drive connecting seat connected to a horizontal assembly rod seat, a horizontal adjustment screw seat located on the upper part of the horizontal drive connecting seat, and a horizontal adjustment drive motor located in the horizontal adjustment screw seat. The two-stage vertical drive structure includes a lifting platform connected to a horizontal mounting base, a two-stage vertical drive screw base connected to the lifting platform, and a two-stage vertical lifting inner connecting seat provided in the two-stage vertical drive screw base. The two-stage vertical lifting inner connecting seat is connected to a detection and installation arc-shaped seat.

7. The ultrasonic testing device for the structure of a cement rotary kiln as described in claim 2, characterized in that: The cooling plate structure includes an air-cooled connecting frame, a cooling duct assembly structure disposed in the air-cooled connecting frame, a cooling fan disposed in the air-cooled connecting frame and connected to the cooling duct assembly structure, and a brush mounting bracket disposed in the air-cooled connecting frame surrounding the cooling duct assembly structure.

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