Ultrasonic Weld Seam Tracking for Oxide-Independent Pipe Inspection
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Solution Overview
Problem
Existing ultrasonic flaw detection methods for electric resistance welded pipes rely on reflected ultrasonic wave signals from minute oxides, which are not detectable when these oxides are absent, making it difficult to accurately detect seam positions and perform flaw detection.
Innovation Solution
An ultrasonic flaw detection apparatus that includes a seam detection unit for capturing thermal images, an ultrasonic probe for flaw detection, and a bead cutting band detection unit using illumination light sources to calculate seam and bead cutting positions, allowing the ultrasonic probe to track the welded seam without relying on reflected waves from minute oxides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reflected ultrasonic wave signals from minute oxides are used for seam position detection, then seam position can be detected, but the method becomes unreliable when minute oxides are absent
Solution Approach 1:
The patent introduces light sources and cameras as intermediary devices to detect the welded seam position through optical reflection characteristics. Instead of relying on minute oxides as intermediaries for ultrasonic detection, the system uses light reflection from the seam surface to identify position, providing a more universally applicable detection method that works regardless of oxide presence.
Solution Approach 2:
The patent replaces the ultrasonic-based detection method with an optical detection system using light sources and cameras. This substitution transitions from acoustic wave reflection detection to optical reflection detection, enabling seam position identification through luminance variations caused by different surface reflection characteristics of the welded seam versus the base material.
2Measurement precision
If focused ultrasonic wave signals are used for flaw detection, then detection precision is improved, but positioning accuracy requirements increase
Solution Approach 1:
The patent implements a feedback mechanism where the optical detection system continuously monitors the welded seam position and provides real-time position information to the ultrasonic detection system. This feedback loop enables dynamic adjustment of the sensor head position or focal point, maintaining high detection precision while compensating for positioning variations through active correction.
Solution Approach 2:
The patent performs preliminary detection of the welded seam position using the optical system before conducting ultrasonic flaw detection. By first identifying the exact seam location and characteristics, the system can pre-position the ultrasonic sensors and adjust focal parameters to match the detected geometry, thereby reducing the stringency of positioning requirements during the actual flaw detection process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate detection of seam positions and flaw detection on welded seam portions without relying on reflected ultrasonic waves from minute oxides, ensuring precise tracking and quality evaluation of the welded seams.
Implementation Method 1
a seam detection unit that captures a thermal image of a welded seam portion
Implementation Method 2
an ultrasonic probe configured to perform ultrasonic flaw detection on the welded seam portion
Implementation Method 3
reflected ultrasonic wave signals from a defect in a welded seam portion
Implementation Method 4
a first light source that is configured to emit illumination light to the vicinity of the welded seam portion
Implementation Method 5
emit illumination light to the vicinity of the welded seam portion from an upper left side direction
Data Source
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AI summary
An ultrasonic flaw detection apparatus 1 includes: a ultrasonic flaw detection sensor head 11 installed downstream from a seam detection unit 13; a seam position calculation unit 14a that calculates a seam position and a bead cutting position of an electric resistance welded pipe P by using a thermal image of a welded seam portion captured by the seam detection unit 13; a bead cutting band detection unit 15 that is installed immediately before or immediately after the ultrasonic flaw detection sensor head 11 and that detects a bead cutting band of the electric resistance welded pipe P; a bead cutting position calculation unit 14c that calculates, based on the bead cutting band detected by the bead cutting band detection unit 15, a bead cutting position of the electric resistance welded pipe P; and a tracking movement amount calculation unit 14d that calculates a tracking movement amount of the ultrasonic flaw detection sensor head 11 by using the seam position and bead cutting position calculated by the seam position calculation unit 14a and the bead cutting position calculated by the bead cutting position calculation unit 14c.