CN114965716A - Full-automatic ultrasonic detection system for pipeline circumferential weld - Google Patents

Abstract

The application discloses full-automatic ultrasonic detection system of pipeline girth weld belongs to pipeline inspection technical field. The system comprises an ultrasonic collector and computer equipment, wherein a plurality of groups of ultrasonic control circuits are arranged in the ultrasonic collector, and the computer equipment comprises a simulation calculation module and a signal display module. The system realizes simulation and calculation of an ultrasonic sound field through the simulation calculation module, can determine a target ultrasonic simulation result meeting a focusing condition, further determine an excitation time sequence of a plurality of groups of ultrasonic control circuits, then control the plurality of groups of ultrasonic control circuits to transmit ultrasonic signals according to the excitation time sequence through the ultrasonic collector, and receive echo signals reflected by a target pipeline girth weld, and realizes strip chart display of detection results and auxiliary interpretation of the detection results through the signal display module.

Description

Full-automatic ultrasonic detection system for pipeline circumferential weld

Technical Field

The application relates to the technical field of pipeline detection, in particular to a full-automatic ultrasonic detection system for a pipeline girth weld.

Background

With the rapid development of pipeline engineering construction industry in China, the long-distance oil and gas pipeline gradually develops rapidly in the directions of high steel grade, large caliber and large wall thickness, and the requirements on the quality of the circumferential weld of the pipeline and the welding construction technology are higher. In recent years, full-automatic welding has become the main mode of girth welding of long-distance oil and gas pipelines, and meanwhile, the full-automatic ultrasonic detection technology matched with the full-automatic welding is widely applied.

At present, when a pipeline girth weld is detected by using a full-automatic ultrasonic detection technology, an ultrasonic signal is generally transmitted to the pipeline girth weld by using an ultrasonic collector, the pipeline girth weld is scanned by using the ultrasonic signal, the propagation time and the propagation size of a reflected echo of the ultrasonic signal are measured based on various propagation characteristics of the ultrasonic signal in a medium, such as reflection and refraction, scattering and diffraction, sound velocity change and the like, and then a technician performs manual judgment according to the measured propagation time and the received amplitude to judge the size and the position of a defect in the pipeline girth weld.

However, in the above full-automatic ultrasonic detection technology, the judgment needs to be performed manually, and the judgment efficiency is low.

Disclosure of Invention

The embodiment of the application provides a full-automatic ultrasonic detection system for a pipeline girth weld, which can effectively realize auxiliary interpretation of a detection result and improve the evaluation efficiency of the detection result. The technical scheme is as follows:

in one aspect, a full-automatic ultrasonic detection system for a pipe girth weld is provided, which comprises an ultrasonic collector and a computer device, wherein,

the ultrasonic collector is electrically connected with the computer equipment;

a plurality of groups of ultrasonic control circuits are arranged in the ultrasonic collector and are used for transmitting and receiving ultrasonic signals;

the computer equipment comprises a simulation calculation module, wherein the simulation calculation module is used for constructing an ultrasonic sound field model, carrying out ultrasonic simulation on the ultrasonic sound field model under the conditions of different groove parameters, probe parameters, wedge block parameters and ultrasonic parameters to obtain the ultrasonic simulation result of multiple times of ultrasonic simulation, selecting a target ultrasonic simulation result meeting a focusing condition, and determining the excitation time sequence of the multiple groups of ultrasonic control circuits based on the groove parameters, the probe parameters, the wedge block parameters and the ultrasonic parameters corresponding to the target ultrasonic simulation result;

the ultrasonic collector is used for controlling the multiple groups of ultrasonic control circuits to transmit ultrasonic signals to the girth weld of the target pipeline and receive echo signals reflected by reflectors in the girth weld of the target pipeline based on the excitation time sequences of the multiple groups of ultrasonic control circuits;

the computer equipment further comprises a signal display module, wherein the signal display module is used for generating and displaying a strip chart of the reflector based on the echo signal, carrying out image recognition on the strip chart and outputting a detection result of the target pipeline girth weld.

In one possible implementation manner, a 128-channel ultrasound acquisition board card is arranged in the ultrasound acquisition unit, and the 128-channel ultrasound acquisition board card is provided with 128 sets of ultrasound control circuits.

In a possible implementation manner, the ultrasound collector includes a central processing unit, and the central processing unit is configured to trigger the multiple sets of ultrasound control circuits to transmit ultrasound signals, and to combine echo signals received by the multiple sets of ultrasound control circuits to obtain combined echo signals.

In one possible implementation, the central processing unit is formed based on a cascade of a plurality of Field Programmable Gate Array (FPGA) chips.

In a possible implementation manner, the ultrasound collector further includes a communication module, and the communication module is configured to receive the excitation timings of the multiple sets of ultrasound control circuits sent by the simulation computation module, and transmit the echo signal to the signal display module.

In a possible implementation manner, the signal display module is configured to perform image recognition on the strip chart to obtain amplitude data and time data in the strip chart, determine a defect size and a defect position of the target pipe girth weld based on the amplitude data and the time data, and use the defect size and the defect position as a detection result of the target pipe girth weld.

In a possible implementation manner, the simulation calculation module is further configured to divide a pipe wall of the target pipe circumferential weld along a vertical direction of the target pipe circumferential weld to obtain a plurality of partitions of the pipe wall, allocate an ultrasonic control circuit of a target group number to the plurality of partitions, and determine an excitation timing sequence of the ultrasonic control circuit corresponding to each partition based on a groove parameter, a probe parameter, a wedge parameter, and an ultrasonic parameter corresponding to a partition height of each partition and the target ultrasonic simulation result;

the ultrasonic collector is also used for controlling the ultrasonic control circuit corresponding to each partition to transmit ultrasonic signals to the corresponding partition based on the excitation time sequence of the ultrasonic control circuit corresponding to each partition.

In a possible implementation manner, the full-automatic ultrasonic detection system for the pipe circumferential weld further comprises a direct current motor, the ultrasonic collector is arranged on the direct current motor, and the direct current motor is used for driving the ultrasonic collector to move along the target pipe circumferential weld.

In a possible implementation manner, the dc motor is electrically connected to the computer device, and the computer device is further configured to control a movement speed of the dc motor.

In a possible implementation manner, the full-automatic ultrasonic detection system for the circumferential weld of the pipeline further comprises a circumferential track, wherein the circumferential track is used for being arranged on the outer wall of the pipeline where the circumferential weld of the target pipeline is located;

the direct current motor is arranged on the circumferential track.

The full-automatic ultrasonic detection system for the pipeline girth weld provided by the embodiment of the application realizes simulation and calculation of an ultrasonic sound field through the simulation calculation module, can determine a target ultrasonic simulation result meeting a focusing condition, further determine the excitation time sequence of a plurality of groups of ultrasonic control circuits, then control the plurality of groups of ultrasonic control circuits to transmit ultrasonic signals according to the excitation time sequence, and receive echo signals reflected by the target pipeline girth weld, and realize strip chart display of the detection result and auxiliary interpretation of the detection result through the signal display module.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present application and together with the description, serve to explain the principles of the application. In the drawings:

FIG. 1 is a schematic view of a fully automatic ultrasonic inspection system for a pipe girth weld according to an embodiment of the present disclosure;

fig. 2 is an electrical schematic diagram of a fully-automatic ultrasonic detection system for a pipe girth weld according to an embodiment of the present application.

Description of the figures

1: an ultrasonic collector, 2: computer device, 201: simulation calculation module, 202: signal display module, 3: direct current motor, 300: motor control line, 4: power supply control component, 401: first switching power supply, 402: second switching power supply, 403: third switching power supply, 501: motor signal interface, 502: power interface, 503: first 485 signal interface, 504: first high-speed network cable adapter, 505: reserved USB debug interface, 506: encoder signal transfer interface, 507: temperature probe signal transfer interface, 508: first TOFD signal transfer interface, 509: second TOFD signal transfer interface, 510: motor control signal switching interface, 511: cable quick connector, 512: second 485 signal interface, 513: second high-speed network cable adapter, 514: built-in adapter, 515: USB interface, 601: dc power supply cable, 602: 485 signal line, 603: first high-speed network line, 604: internal patch cord, 605: second high-speed network line, 606: a USB line.

With the above figures, there are shown specific embodiments of the present application, which will be described in more detail below. These drawings and written description are not intended to limit the scope of the inventive concepts in any manner, but rather to illustrate the inventive concepts to those skilled in the art by reference to specific embodiments.

Detailed Description

To make the objects, technical solutions and advantages of the present application more clear, embodiments of the present application will be described in further detail below with reference to the accompanying drawings.

The embodiment of the application provides a full-automatic ultrasonic detection system for a pipeline girth weld, which is shown in fig. 1 and comprises an ultrasonic collector 1 and computer equipment 2, wherein the ultrasonic collector 1 is electrically connected with the computer equipment 2; a plurality of groups of ultrasonic control circuits are arranged in the ultrasonic collector 1 and are used for transmitting and receiving ultrasonic signals; the computer device 2 comprises a simulation calculation module 201, wherein the simulation calculation module 201 is used for constructing an ultrasonic sound field model, performing ultrasonic simulation on the ultrasonic sound field model under the conditions of different groove parameters, probe parameters, wedge block parameters and ultrasonic parameters to obtain ultrasonic simulation results of multiple times of ultrasonic simulation, selecting a target ultrasonic simulation result meeting a focusing condition, and determining the excitation time sequence of the multiple groups of ultrasonic control circuits based on the groove parameters, the probe parameters, the wedge block parameters and the ultrasonic parameters corresponding to the target ultrasonic simulation result; the ultrasonic collector 1 is used for controlling the multiple groups of ultrasonic control circuits to transmit ultrasonic signals to the girth weld of the target pipeline and receive echo signals reflected by reflectors in the girth weld of the target pipeline based on the excitation time sequences of the multiple groups of ultrasonic control circuits; the computer device 2 further comprises a signal display module 202, wherein the signal display module 202 is configured to generate and display a strip chart of the reflector based on the echo signal, perform image recognition on the strip chart, and output a detection result of the target pipe girth weld.

In the embodiment of the present application, the ultrasound acquisition unit 1 is used for transmitting and receiving ultrasound signals. The ultrasound collector 1 is a device for transmitting ultrasound signals based on an internal ultrasound array transducer. Optionally, the ultrasound harvester 1 is mounted in an instrument box. The ultrasonic array transducer is used for converting electric energy into sound energy and consists of a plurality of groups of ultrasonic control circuits. A set of ultrasound control circuits may be a wafer, the ultrasound array transducer being composed of an array of wafers, each wafer corresponding to an ultrasound probe. It should be noted that the multiple sets of ultrasonic control circuits in the ultrasonic array transducer can not only transmit ultrasonic signals, but also receive ultrasonic signals. In implementation, the ultrasound acquisition unit 1 activates each set of ultrasound control circuits according to a certain activation timing sequence, so as to adjust the focusing position and the focusing direction of the emitted ultrasound signals. The ultrasonic signal is an ultrasonic signal, and refers to a sound wave signal with a vibration frequency greater than 20000 Hz. Because ultrasonic signal has better directionality, and can see through opaque material, consequently utilize ultrasonic signal's effective transmission, can portable information in the transmission course, can effectively realize the detection of pipeline circumferential weld.

The computer device 2 may be one of a desktop computer and a laptop computer. The computer device 2 includes a simulation calculation module 201 and a signal display module 202. The simulation calculation module 201 may be simulation software having a sound field simulation function and a simulation calculation function. The signal display module 202 may be data reproduction software, and the data reproduction software is configured to reproduce the received echo signal, implement strip chart display of the detection result, and implement image recognition of the strip chart and auxiliary interpretation of the detection result.

The following describes the contents involved in the ultrasound simulation performed by the simulation computation module 201: groove parameters may include groove size, groove angle, groove type, and the like. The groove is a groove with a certain geometric shape formed by machining and assembling the part to be welded. The probe parameters may include probe shape, probe size, probe sensitivity, etc. The probe is a wafer probe. Wedge parameters may include wedge type, wedge angle, etc. The wedge is used to deflect the ultrasound signal to a desired angle of incidence. The ultrasound parameters may include signal strength, signal frequency, etc. of the ultrasound signal. The target ultrasonic simulation result refers to an ultrasonic simulation result meeting a focusing condition. The focusing condition refers to a condition in which the ultrasonic signal is concentrated at the weld and the ultrasonic signal can cover the weld. The ultrasonic simulation result can intuitively display the propagation path of the ultrasonic signal and the energy condition of the sound field formed by the ultrasonic signal.

In implementation, the process of the simulation calculation module 201 performing sound field simulation is as follows: and constructing an ultrasonic sound field model according to the distribution characteristics of the ultrasonic sound field, and carrying out ultrasonic simulation on the ultrasonic sound field model under the conditions of different groove parameters, probe parameters, wedge block parameters and ultrasonic parameters by changing related parameters to obtain the ultrasonic simulation result of multiple times of ultrasonic simulation. The process of the simulation calculation performed by the simulation calculation module 201 is as follows: after the multiple times of ultrasonic simulation are completed, selecting a target ultrasonic simulation result meeting focusing conditions from ultrasonic simulation results of the multiple times of ultrasonic simulation, and performing focusing rule calculation based on groove parameters, probe parameters, wedge block parameters and ultrasonic parameters corresponding to the target ultrasonic simulation result to obtain excitation time sequences of multiple groups of ultrasonic control circuits, namely obtaining a focusing rule. In the full-automatic ultrasonic detection system, the simulation calculation module 201 is arranged, so that ultrasonic simulation can be performed before the focusing scheme is set, the optimal focusing scheme is determined, and the accuracy of the focusing scheme is ensured.

In implementation, when the full-automatic ultrasonic detection system for the circumferential weld of the pipeline is in a working state, the computer device 2 performs ultrasonic simulation through the simulation calculation module 201 based on the constructed ultrasonic field model and the set groove parameter, probe parameter, wedge parameter and ultrasonic parameter to obtain ultrasonic simulation results of multiple times of ultrasonic simulation, selects a target ultrasonic simulation result meeting a focusing condition, and determines the excitation time sequence of multiple groups of ultrasonic control circuits based on the groove parameter, probe parameter, wedge parameter and ultrasonic parameter corresponding to the target ultrasonic simulation result. The simulation calculation module 201 sends the excitation time sequences of the multiple groups of ultrasonic control circuits to the ultrasonic collector 1, and then the ultrasonic collector 1 controls the multiple groups of ultrasonic control circuits to transmit ultrasonic signals to the target pipeline girth weld based on the excitation time sequences of the multiple groups of ultrasonic control circuits, receives echo signals reflected by reflectors in the target pipeline girth weld, and sends the echo signals to the computer device 2. After receiving the echo signal, the computer device 2 generates and displays a strip chart of the reflector based on the echo signal through the signal display module 202, performs image recognition on the strip chart, and outputs a detection result of the target pipe girth weld.

The full-automatic ultrasonic detection system for the pipeline girth weld provided by the embodiment of the application realizes simulation and calculation of an ultrasonic sound field through the simulation calculation module 201, can determine a target ultrasonic simulation result meeting a focusing condition, further determine the excitation time sequence of a plurality of groups of ultrasonic control circuits, then control the plurality of groups of ultrasonic control circuits to transmit ultrasonic signals according to the excitation time sequence, and receive echo signals reflected by the target pipeline girth weld, and realize ribbon diagram display of detection results and judgment and identification of the detection results through the signal display module 202, the whole process is completely and automatically realized without manual participation, so that auxiliary judgment and reading of the detection results can be effectively realized, and the judgment efficiency of the detection results is improved.

In some possible implementations, a 128-channel ultrasound acquisition board card is provided in the ultrasound acquisition unit 1, and the 128-channel ultrasound acquisition board card is provided with 128 sets of ultrasound control circuits.

Optionally, the 128-channel ultrasound acquisition board card is formed based on 4 32-channel acquisition board cards, or the 128-channel ultrasound acquisition board card is formed based on 2 64-channel acquisition board cards.

In this full-automatic ultrasonic testing system, through setting up 128 passageway supersound collection integrated circuit boards, can realize 128 passageways simultaneous emission and receipt ultrasonic signal, make 128 ultrasonic control circuit probes of group detect the pipeline girth joint simultaneously, its effective area and efficiency that detects are 128 times of single channel, the focusing channel number and the detection dynamic range have been promoted, can realize more accurate focus and detection, adopt the collection integrated circuit board that the channel number is 32 passageways or 64 passageways among the correlation technique of comparison, when having improved detection efficiency, still greatly improved detectivity and detection precision.

In some possible implementation manners, the ultrasound collector 1 includes a central processing unit, and the central processing unit is configured to trigger multiple sets of ultrasound control circuits to emit ultrasound signals, and perform combination processing on echo signals received by the multiple sets of ultrasound control circuits to obtain combined echo signals.

The central processing unit is used for processing control commands and collecting data in a high-speed parallel mode. For example, the control command may be a command instructing the transmission of an ultrasound signal. The acquisition data may be received echo signals. Optionally, the echo signals received by the multiple groups of ultrasonic control circuits are combined to obtain callback a scan data, where the callback a scan data includes the combined echo signals.

Alternatively, the central processing unit may be disposed in a 128-channel ultrasound acquisition board card disposed in the ultrasound acquisition unit 1. Optionally, a plurality of acquisition boards arranged in the 128-channel ultrasound acquisition board are respectively connected to a PCIE (Peripheral Component Interconnect Express, high-speed serial computer expansion bus standard) bus, and communicate via the PCIE bus, so as to exchange a control command and acquire data, thereby implementing 128-channel independent parallelism.

In some possible implementations, the central processor is formed based on a cascade of multiple FPGA chips. In the ultrasonic collector 1, a multi-FPGA cascading mode is adopted for design, so that the transmission of ultrasonic signals can be synchronously triggered among a plurality of FPGA chips.

In some possible implementations, the ultrasound collector 1 further includes a communication module, which is configured to receive the excitation timings of the multiple sets of ultrasound control circuits sent by the simulation calculation module 201, and transmit the echo signals to the signal display module 202.

Wherein, the communication module can be a communication module with an upper computer. The upper computer is a computer capable of directly sending out a control command. In the embodiment of the present application, the computer device 2 is an upper computer. Alternatively, the communication module may be disposed in a 128-channel ultrasound acquisition board card disposed in the ultrasound acquisition unit 1.

In implementation, the computer device 2 sends a control command for instructing to transmit an ultrasonic signal to the ultrasonic collector 1, where the control command carries an excitation timing sequence of a plurality of groups of ultrasonic control circuits, and then the communication module of the ultrasonic collector 1 can receive the control command and further analyze the control command to obtain a corresponding timing sequence signal, and then controls the ultrasonic collector 1 to transmit the ultrasonic signal based on the corresponding timing sequence signal. In the process, the communication between the ultrasonic collector 1 and the computer device 2 is facilitated by arranging the communication module.

In some possible implementations, the ultrasound collector 1 further includes a signal transmitting module, a signal receiving module, an amplifying and filtering circuit, an ad (analog to digital) analog-to-digital conversion module, and a DDR (Double Data Rate) external storage module. The signal transmitting module is used for triggering and transmitting ultrasonic signals. Alternatively, the signal transmitting module may be a high voltage pulse transmitting module. The signal receiving module is used for receiving echo signals reflected by reflectors in the target pipeline circumferential weld. The amplifying and filtering circuit is used for carrying out signal amplifying processing and filtering processing on the generated ultrasonic signals. The AD conversion module is used for converting the analog signals into digital signals, so that the signals can be conveniently transmitted. The DDR external storage module is used for storing the collected data.

In some possible implementations, a temperature signal to 485 signal card is provided in the ultrasound collector 1. In implementation, the temperature signal of the target pipeline girth weld is detected through the ultrasonic collector 1, and then the temperature signal is converted into a 485 signal card, so that the measured temperature signal is converted into a 485 signal which is convenient to transmit, and the temperature sensitivity and other parameters of the target pipeline girth weld are convenient to measure.

In some possible implementations, an electric fan is provided in the ultrasound harvester 1, and the electric fan is used for dissipating heat, thereby reducing the temperature of the ultrasound harvester 1 and increasing the processing speed of the ultrasound harvester 1.

In some possible implementation manners, the signal display module 202 is configured to perform image recognition on the strip chart to obtain amplitude data and time data in the strip chart, determine the defect size and the defect position of the target pipe girth weld based on the amplitude data and the time data, and use the defect size and the defect position as the detection result of the target pipe girth weld.

Wherein the strip chart comprises a dual threshold strip chart channel comprising time gate data and amplitude gate data. It should be understood that the echo signal contains amplitude information and time information. The time gate is a time range for acquiring time information of the echo signal, and data of the time gate is used for judging the defect position of the target pipeline circumferential weld. The amplitude gate is a time range for acquiring amplitude information of the echo signal, and data of the amplitude gate is used for judging the defect size of the target pipeline circumferential weld.

Optionally, the dual-threshold strip chart channel displays the time-gate color blocks based on the time information in the received echo signal and the time-gate threshold, that is, different colors are set in different time value intervals in the dual-threshold strip chart channel. For example, the time threshold is set to be green at 20-40%, the time threshold is set to be red at 40-70%, the time threshold is set to be yellow at 70-99%, and the time threshold > 99% is set to be red, so that the time information can be embodied more intuitively and vividly. Moreover, the dual-threshold strip chart channel displays the amplitude envelope curve based on the amplitude information in the received echo signal and the amplitude gate threshold, that is, in the dual-threshold strip chart channel, the amplitude value greater than the amplitude gate threshold is displayed, and the amplitude value less than or equal to the amplitude gate threshold is not displayed. For example, if the amplitude is greater than 5%, the display is made, and if the amplitude is less than or equal to 5%, the display is not made.

In implementation, when the signal display module 202 performs image recognition, the time gate data and the amplitude gate data included in the strip chart can be recognized, calculation is performed according to the length of the color block in the recognized time gate data to obtain the defect position of the target pipeline girth weld, calculation is performed according to the recognized amplitude gate data to obtain the defect size of the target pipeline girth weld, and the defect position and the defect size are used as the detection result of the target pipeline girth weld.

Optionally, the strip chart display further includes a volume channel display, a TOFD (Time Of Flight Diffraction) channel display, and a coupling channel display. Wherein, the volume channel display is B-scan display based on the acquired echo A-scan data. The scanning A means displaying the corresponding relation between the amplitude of the ultrasonic signal and the propagation time in a rectangular coordinate mode. The B-scan is to display a section parallel to the propagation direction of the acoustic beam formed by the ultrasonic signal and perpendicular to the measurement surface of the target pipe girth weld. The TOFD channel display is a TOFD gray scale map display based on the acquired echo A scan data. Through volume channel display, TOFD channel display and coupling channel display, the three-dimensional section display of the detection result can be realized, and the defect condition in the target pipeline girth weld can be visually displayed.

In some possible implementation manners, the simulation calculation module 201 is further configured to divide the pipe wall of the target pipe circumferential weld along the vertical direction of the target pipe circumferential weld to obtain a plurality of partitions of the pipe wall, allocate the ultrasonic control circuits of the target group number to the plurality of partitions, and determine the excitation timing sequence of the ultrasonic control circuit corresponding to each partition based on the partition height of each partition and the groove parameter, the probe parameter, the wedge parameter, and the ultrasonic parameter corresponding to the target ultrasonic simulation result, and the ultrasonic collector 1 is further configured to control the ultrasonic control circuit corresponding to each partition to transmit the ultrasonic signal to the corresponding partition based on the excitation timing sequence of the ultrasonic control circuit corresponding to each partition.

Optionally, the simulation calculation module 201 divides the pipe wall of the target pipe girth weld according to the target partition height. The target partition height is a preset partition height. For example, the partition height may be 2-3 mm. It should be noted that each partition corresponds to a focusing rule, and there are as many focusing rules as there are partitions. Optionally, one partition corresponds to two sets of ultrasonic control circuits, wherein one set of ultrasonic control circuits transmits an ultrasonic signal from the left side of the weld, and the other set of ultrasonic control circuits transmits an ultrasonic signal from the right side of the weld.

In implementation, after the ultrasonic simulation is completed, the simulation calculation module 201 divides the circumferential weld of the target pipeline along the vertical direction according to the groove parameters set by the target ultrasonic simulation result, so as to obtain a plurality of partitions of the pipe wall. For any one of the plurality of subareas, the simulation calculation module 201 sets a subarea scanning angle according to the height of the subarea, and further calculates the excitation timing sequence of the ultrasonic control circuit corresponding to the subarea according to the subarea scanning angle, the focus point position and the groove parameter (such as the groove angle), the probe parameter and the wedge parameter set by the target ultrasonic simulation result, so as to form the focusing rule of the subarea. After the simulation calculation module 201 determines the excitation time sequence of the ultrasonic control circuit corresponding to each partition, the excitation time sequence of the ultrasonic control circuit corresponding to each partition is sent to the ultrasonic collector 1, and then the ultrasonic collector 1 excites the ultrasonic control circuit corresponding to each partition according to the excitation time sequence of the ultrasonic control circuit corresponding to each partition after receiving the excitation time sequence of the ultrasonic control circuit corresponding to each partition, so as to transmit an ultrasonic signal, and at the same time, the ultrasonic control circuit corresponding to each partition is controlled to receive an echo signal reflected by a girth weld of a target pipeline.

Before performing the weld joint detection on the pipeline girth weld, or after detecting 10 pipeline girth welds (also called 10 openings), the full-automatic ultrasonic detection system for the pipeline girth weld needs to be subjected to test block verification, that is, the full-automatic ultrasonic detection system for the pipeline girth weld is subjected to performance inspection, and after the pipeline girth weld is qualified through calibration, the on-site pipeline girth weld is detected, so as to ensure the accuracy of the on-site pipeline girth weld detection. In implementation, a calibration chart of the test block can be obtained through test block verification, validity identification is carried out on the calibration chart, amplitude information of a reflector in the test block can be obtained, and when the amplitude information of the reflector meets a target condition, the calibration is determined to be qualified. Wherein the target condition may be a wave amplitude greater than a certain threshold, for example, a wave amplitude greater than 70%.

In some possible implementation modes, the full-automatic ultrasonic detection system for the pipeline girth weld adjusts the distance between the ultrasonic control circuits according to the ultrasonic simulation result, so that an ultrasonic beam formed by an ultrasonic signal can cover the whole weld, and the detection accuracy of the pipeline girth weld is improved.

In some possible implementation manners, the full-automatic ultrasonic detection system for the pipeline girth weld further comprises a direct current motor 3, the ultrasonic collector 1 is arranged on the direct current motor 3, and the direct current motor 3 is used for driving the ultrasonic collector 1 to move along the target pipeline girth weld.

In some possible implementations, the full-automatic ultrasonic detection system for the pipe girth weld further includes a circumferential track, the circumferential track is disposed on the outer side of the pipe wall of the full-automatic ultrasonic detection system for the pipe girth weld, and the dc motor 3 is disposed on the circumferential track.

The dc motor 3 may be a 48V motor.

In implementation, a circumferential track is arranged in the circumferential direction of a weld of a target pipeline girth weld, the ultrasonic collector 1 and the direct current motor 3 are installed on the circumferential track, and the direct current motor 3 is started, so that the direct current motor 3 can move along the circumferential track, namely along the target pipeline girth weld, and further drives the ultrasonic collector 1 to move along the target pipeline girth weld. Through setting up direct current motor 3, be convenient for to the detection of pipeline girth weld, further realized full automated inspection.

In some possible implementations, the dc motor 3 is electrically connected to the computer device 2, and the computer device 2 is further configured to control the movement speed of the dc motor 3.

Wherein, the computer device 2 adopts the direct current motor motion control technology to control the direct current motor 3 to move. Optionally, the computer device 2 further comprises a motor driving module for controlling the movement speed of the dc motor 3.

Optionally, a speed reduction module is arranged in the dc motor 3, and the speed reduction module is used for reducing the movement speed of the dc motor 3. Through setting up the speed reduction module, control direct current motor 3's velocity of movement for reduce the velocity of movement when not receiving echo signal, ensure to receive all echo signals, ensure the integrality of data collection.

Alternatively, referring to fig. 2, a motor control line 300 for controlling the travel of the dc motor 3 is connected to the dc motor 3.

In some possible implementations, the fully automatic ultrasonic detection system for the pipe girth weld further comprises a power supply control assembly 4, and the power supply control assembly 4 is used for supplying power. Optionally, the power control assembly 4 is mounted within a power control box.

Optionally, the power control assembly 4 includes a first switched power supply 401, a second switched power supply 402 and a third switched power supply 403. The first switching power supply 401 may be a 24VDC150W power supply, and the 24VDC150W is used to indicate a rated voltage of 24V and a rated power of 150W. The second switching power supply 402 may be a 48VDC40W power supply, 48VDC40W to indicate 48V rated and 40W rated. The third switching power supply 403 may be a 12VDC120W power supply, 12VDC120W to indicate a nominal voltage of 12V and a nominal power of 120W.

The full-automatic ultrasonic detection system for the pipeline girth weld provided by the embodiment of the application further comprises a plurality of interfaces, and connection among a plurality of devices is convenient to realize. A number of interfaces are described in detail below based on fig. 2:

the ultrasonic collector 1 is provided with a motor signal interface 501, a power interface 502, a first 485 signal interface 503, a first high-speed network cable adapter 504, a reserved USB debugging adapter 505, an encoder signal adapter 506, a temperature probe signal adapter 507, a first TOFD signal adapter 508 and a second TOFD signal adapter 509; a motor control signal adapter 510 is arranged on the direct current motor 3; the power control component 4 is provided with a cable fast-plug interface 511, a second 485 signal interface 512, a second high-speed network cable adapter interface 513, a built-in adapter interface 514 and a USB adapter interface 515.

The motor signal interface 501 is used for connecting the ultrasound collector 1 with the dc motor 3. The GLAND connection of the motor signal interface 501. Optionally, the motor signal interface 501 has a diameter of 6 mm. Optionally, the aperture size of the motor signal interface 501 is M12X1.5, M12X1.5 being used to indicate an aperture diameter of 12mm and a pitch of 1.5 mm.

The power interface 502 is used for connecting the ultrasound collector 1 with the power control assembly 4. The power interface 502 may be an airline cable outlet. Alternatively, the power interface 502 may be a 7-core interface. Optionally, the opening of the power interface 502 has a diameter of 20mm and a pitch of 22 mm.

The first 485 signal interface 503 is used for connecting the ultrasound collector 1 with the power supply control component 4. The first 485 signal interface 503 is a 4-core aircraft plug. Optionally, the first 485 signal interface 503 has an opening with a diameter of 16mm and a pitch of 20 mm.

The first high-speed network cable adapter 504 is used to connect the ultrasound collector 1 with the power control unit 4. Alternatively, the first high-speed network wire interface 504 has an opening diameter of 25mm and a pitch of 30 mm.

The reserved USB debug interface 505 is a reserved USB3.0 debug interface. Optionally, the reserved USB debug interface 505 has an opening diameter of 24.6mm and a pitch of holes of 26 mm.

The encoder signal adapter 506 is a No. 1 5-core waterproof socket. Optionally, the aperture diameter of the encoder signal interface 506 is 8.3mm, and the pitch of the apertures is 9.0 mm. An encoder is a device that compiles, converts, and communicates signals or data into a form of signals that can be communicated, transmitted, and stored.

The temperature probe signal switching port 507 is a No. 02 core waterproof socket. Optionally, the opening size of the temperature probe signal adapter 507 is M8.3X9.0. M8.3X9 is used to indicate an opening diameter of 8.3mm and a pitch of 9.0 mm.

The first TOFD signal interface 508 and the second TOFD signal interface 509 are coaxial waterproof sockets. Optionally, the first TOFD signal interface 508 and the second TOFD signal interface 509 each have an outer opening dimension of M12X1.5 and an inner opening dimension of M7X0.5. Wherein M12X1.5 is used to indicate the outer diameter of the openings is 12mm and the outer pitch is 1.5mm, M7X0.5 is used to indicate the inner diameter of the openings is 7mm and the inner pitch is 0.5 mm.

The motor control signal adapter 510 is used to connect the dc motor 3 with the ultrasound acquisition unit 1. The motor control signal adapter 510 is a No. 0, 2-core waterproof socket. Optionally, the motor control signal adapter 510 has an opening size of M8.3X9.0. M8.3X9 is used to indicate an opening diameter of 8.3mm and a pitch of 9.0 mm.

The cable quick-connect interface 511 is a 7-pin cable quick-connect interface.

The second 485 signal interface 512 is a 4-pin aircraft plug.

In one possible implementation, a motor control line 300 is connected between the motor signal interface 501 and the motor control signal adapter 510. The full-automatic ultrasonic detection system of pipeline circumferential weld that this application embodiment provided still includes many detection cables, is convenient for provide DC power supply for the full-automatic ultrasonic detection system of pipeline circumferential weld. The following describes the plurality of detection cables in detail based on fig. 2:

in one possible implementation, a dc power cable 601 is connected between the power interface 502 and the cable quick-connect interface 511.

In one possible implementation, a 485 signal line 602 is connected between the first 485 signal interface 503 and the second 485 signal interface 512.

In one possible implementation, a high-speed network cable 603 is connected between the first high-speed network cable adapter 504 and the second high-speed network cable adapter 513.

In one possible implementation manner, inside the power control component 4, the second 485 signal interface 512 and the USB interface 515 are connected to an internal patch cable 604; an internal switching network cable 604 is connected between the second high-speed network cable switching port 513 and the built-in switching port 514; a second high-speed network cable 605 is connected between the internal adapter 514 and the computer device 2; a USB cable 606 is connected between the USB interface 515 and the computer device 2.

The working principle of the full-automatic ultrasonic detection system for the girth weld of the pipeline provided by the embodiment of the application is introduced as follows:

(1) a circumferential track is arranged in the circumferential direction of a welding seam of a target pipeline circumferential welding seam, and a direct current motor 3 provided with an ultrasonic collector 1 is arranged on the circumferential track. And starting the direct current motor 3, the direct current motor 3 can move along the circular orbit, namely along the girth weld of the target pipeline, and further drives the ultrasonic collector 1 to move along the girth weld of the target pipeline.

(2) The computer device 2 performs ultrasonic simulation based on the constructed ultrasonic field model and the set groove parameter, probe parameter, wedge parameter and ultrasonic parameter through the simulation calculation module 201 to obtain ultrasonic simulation results of multiple times of ultrasonic simulation, and selects a target ultrasonic simulation result meeting the focusing condition from the ultrasonic simulation results.

(3) After the ultrasonic simulation is completed, the simulation calculation module 201 divides the circumferential weld of the target pipeline along the vertical direction according to the groove parameters set by the target ultrasonic simulation result, so as to obtain a plurality of partitions of the pipe wall. And determining the excitation time sequence of the ultrasonic control circuit corresponding to each partition based on the partition height of each partition and the groove parameter, the probe parameter, the wedge block parameter and the ultrasonic parameter corresponding to the target ultrasonic simulation result, and sending the excitation time sequence of the ultrasonic control circuit corresponding to each partition to the ultrasonic collector 1.

(4) After the ultrasonic collector 1 receives the excitation time sequence of the ultrasonic control circuit corresponding to each partition, the ultrasonic control circuit corresponding to each partition is excited according to the excitation time sequence of the ultrasonic control circuit corresponding to each partition, so that an ultrasonic signal is emitted, meanwhile, the ultrasonic control circuit corresponding to each partition is controlled to receive an echo signal reflected by a girth weld of a target pipeline, and then the echo signal is sent to the computer device 2.

(5) After receiving the echo signal, the computer device 2 generates a strip chart of the target pipe circumferential weld based on the echo signal through the signal display module 202, performs image recognition on the strip chart to obtain amplitude data and time data in the strip chart, determines the defect size and defect position of the target pipe circumferential weld based on the amplitude data and the time data, and takes the defect size and defect position as the detection result of the target pipe circumferential weld.

The full-automatic ultrasonic detection system for the pipeline girth weld provided by the embodiment of the application realizes the simulation and calculation of an ultrasonic sound field through the simulation calculation module 201, can determine a target ultrasonic simulation result meeting a focusing condition, further determine the excitation time sequence of a plurality of groups of ultrasonic control circuits, then control the plurality of groups of ultrasonic control circuits to transmit ultrasonic signals according to the excitation time sequence through the ultrasonic collector 1, and receive echo signals reflected by the target pipeline girth weld, realizes the strip chart display of the detection result and the judgment and identification of the detection result through the signal display module 202, realizes the whole process completely and automatically without manual participation, can effectively realize the auxiliary judgment and reading of the detection result, improves the judgment efficiency and the judgment accuracy of the detection result, also improves the detection precision of the pipeline girth weld, and ensures the welding quality of long-distance pipeline engineering construction, the method has a promoting effect on the intelligent judgment of the AUT detection result, so that the construction quality of the long oil and gas pipeline project is guaranteed.

All the above optional technical solutions may be combined arbitrarily to form optional embodiments of the present application, and are not described herein again.

The present application is intended to cover various modifications, alternatives, and equivalents, which may be included within the spirit and scope of the present application.

Claims (10)

1. A full-automatic ultrasonic detection system for the circumferential weld of the pipeline is characterized by comprising an ultrasonic collector (1) and computer equipment (2),

the ultrasonic collector (1) is electrically connected with the computer equipment (2);

a plurality of groups of ultrasonic control circuits are arranged in the ultrasonic collector (1) and are used for transmitting and receiving ultrasonic signals;

the computer equipment (2) comprises a simulation calculation module (201), wherein the simulation calculation module (201) is used for constructing an ultrasonic sound field model, carrying out ultrasonic simulation on the ultrasonic sound field model under the conditions of different groove parameters, probe parameters, wedge block parameters and ultrasonic parameters to obtain the ultrasonic simulation results of multiple times of ultrasonic simulation, selecting a target ultrasonic simulation result meeting a focusing condition, and determining the excitation time sequence of the multiple groups of ultrasonic control circuits based on the groove parameters, the probe parameters, the wedge block parameters and the ultrasonic parameters corresponding to the target ultrasonic simulation result;

the ultrasonic collector (1) is used for controlling the multiple groups of ultrasonic control circuits to transmit ultrasonic signals to a target pipeline girth weld and receiving echo signals reflected by reflectors in the target pipeline girth weld based on the excitation time sequences of the multiple groups of ultrasonic control circuits;

the computer device (2) further comprises a signal display module (202), wherein the signal display module (202) is used for generating and displaying a strip chart of the reflector based on the echo signal, carrying out image recognition on the strip chart and outputting a detection result of the target pipeline girth weld.

2. The full-automatic ultrasonic detection system for the pipe girth weld according to claim 1, characterized in that a 128-channel ultrasonic acquisition board card is arranged in the ultrasonic acquisition unit (1), and the 128-channel ultrasonic acquisition board card is provided with 128 sets of ultrasonic control circuits.

3. The full-automatic ultrasonic detection system for the pipe girth weld according to claim 1, wherein the ultrasonic collector (1) comprises a central processing unit, and the central processing unit is used for triggering the multiple groups of ultrasonic control circuits to transmit ultrasonic signals and combining echo signals received by the multiple groups of ultrasonic control circuits to obtain combined echo signals.

4. The system of claim 3, wherein the central processor is formed based on a cascade of a plurality of FPGA chips.

5. The full-automatic ultrasonic detection system for the pipe girth weld according to claim 1, wherein the ultrasonic collector (1) further comprises a communication module, and the communication module is used for receiving the excitation time sequences of the multiple groups of ultrasonic control circuits sent by the simulation calculation module (201) and transmitting the echo signals to the signal display module (202).

6. The full-automatic ultrasonic detection system for the pipe girth weld according to claim 1, wherein the signal display module (202) is configured to perform image recognition on the strip chart, obtain amplitude data and time data in the strip chart, determine the defect size and the defect position of the target pipe girth weld based on the amplitude data and the time data, and use the defect size and the defect position as the detection result of the target pipe girth weld.

7. The full-automatic ultrasonic detection system for the pipe girth weld according to claim 1, wherein the simulation computation module (201) is further configured to divide a pipe wall of the target pipe girth weld along a vertical direction of the target pipe girth weld to obtain a plurality of partitions of the pipe wall, allocate an ultrasonic control circuit of a target group number to the plurality of partitions, and determine an excitation timing sequence of the ultrasonic control circuit corresponding to each partition based on a groove parameter, a probe parameter, a wedge parameter, and an ultrasonic parameter corresponding to a partition height of each partition and the target ultrasonic simulation result;

the ultrasonic collector (1) is also used for controlling the ultrasonic control circuits corresponding to the partitions to transmit ultrasonic signals to the corresponding partitions based on the excitation time sequences of the ultrasonic control circuits corresponding to the partitions.

8. The full-automatic ultrasonic detection system for the pipe girth weld according to claim 1, further comprising a direct current motor (3), wherein the ultrasonic collector (1) is arranged on the direct current motor (3), and the direct current motor (3) is used for driving the ultrasonic collector (1) to move along the target pipe girth weld.

9. The full-automatic ultrasonic detection system for the pipe girth weld according to claim 8, wherein the direct current motor (3) is electrically connected with the computer device (2), and the computer device (2) is further used for controlling the movement speed of the direct current motor (3).

10. The fully-automatic ultrasonic detection system for the pipe girth weld according to claim 8, further comprising a circumferential rail, wherein the circumferential rail is arranged on the outer wall of the pipe where the target pipe girth weld is located;

the direct current motor (3) is arranged on the circumferential track.

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