CN106442637B - Flange crack monitoring device and method - Google Patents
Flange crack monitoring device and method Download PDFInfo
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- CN106442637B CN106442637B CN201610696517.8A CN201610696517A CN106442637B CN 106442637 B CN106442637 B CN 106442637B CN 201610696517 A CN201610696517 A CN 201610696517A CN 106442637 B CN106442637 B CN 106442637B
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Abstract
The invention discloses a flange crack monitoring device and a method, wherein the device comprises: the crack detection piece is at least one piece and is adhered to the measurement position of the flange, and the crack detection pieces are mutually connected in series to form a crack detection piece group; and the data acquisition device is electrically connected with the crack detection sheet set so as to determine the crack state information of the flange according to the resistance change of the crack detection sheet set. The invention judges the broken resistance wire by using the change of the electric signal caused by the breakage of the resistance wire, further determines the crack state information such as the position, the propagation direction, the crack degree and the like of the flange crack, realizes the purpose of rapidly finding and determining the position and the crack direction of the flange crack of large equipment applying the flange in a non-stop state, ensures that the large equipment does not need to carry out stop detection on the flange crack, and ensures that the maintenance of the flange is more effective and rapid.
Description
Technical Field
The invention relates to the field of flange monitoring, in particular to a flange crack monitoring device and a flange crack monitoring method using the same.
Background
A flange, also known as a flange collar or flange. The flange is a part for connecting the shafts and is used for connecting pipe ends; there are also flanges on the inlet and outlet of the equipment for connecting two pieces of equipment, such as speed reducer flanges and the like.
The flange is a key part for connecting a power system and a load structure in a large structure and plays a role in fixing load equipment and transmitting torque.
In the operation process of a large-scale structure, load equipment is influenced by self weight, external environment and the like, a flange is subjected to fatigue damage, and cracks are generated after the damage reaches a certain degree. If the cracks are not found in time, the cracks are gradually deepened and lengthened, and finally the flange is broken, so that the safety of the large-scale structure is seriously threatened. Therefore, flange crack condition monitoring is very important.
At present, no on-line monitoring system for the crack state of the flange exists, and most of the systems are used for detecting the flange when a large-scale structure is shut down and overhauled manually and regularly.
Disclosure of Invention
In view of the above, the present invention provides a flange crack monitoring device and method, which are used for monitoring the crack state of a flange on line in real time, and determining the occurrence time, degree, position and crack direction of a crack, so as to perform timely maintenance on equipment.
The technical scheme of the invention is realized as follows:
a flange crack monitoring device comprising:
the crack detection piece is at least one piece and is adhered to the measurement position of the flange, and the crack detection pieces are mutually connected in series to form a crack detection piece group;
and the data acquisition device is electrically connected with the crack detection sheet set so as to determine the crack state information of the flange according to the resistance change of the crack detection sheet set.
Further, each crack detection piece comprises:
the resistance wires are connected in parallel; and the number of the first and second groups,
the two detection sheet pins are respectively and electrically connected to two ends of the resistance wires connected in parallel; wherein the content of the first and second substances,
in the crack detection sheet set, the resistance values of any two resistance wires are different.
Further, when the crack detection sheet is adhered to the measurement position of the flange, all resistance wires in the crack detection sheet are in a straightening state.
Further, the data acquisition device includes:
the measuring circuit is electrically connected with the crack detection sheet set so as to generate a voltage signal according to the resistance value of the crack detection sheet set;
a data processing unit electrically connected to the measurement circuit to convert the voltage signal generated by the measurement circuit into crack status information; and the number of the first and second groups,
and the power supply module is electrically connected with the measuring circuit and the data processing unit so as to supply power to the measuring circuit and the data processing unit.
Further, the measurement circuit includes:
the bridge resistor is electrically connected to the crack detection sheet set, and the bridge resistor and the crack detection sheet set jointly form a crack measurement bridge circuit;
an excitation power supply electrically connected to the crack measurement bridge to provide an excitation electrical signal to the crack measurement bridge;
the amplifying circuit is electrically connected to the crack measuring bridge circuit and is used for collecting and amplifying voltage signals of the crack detection sheet group in the crack measuring bridge circuit;
the filter circuit is electrically connected to the amplifying circuit to filter the voltage signal amplified by the amplifying circuit; and the number of the first and second groups,
the A/D conversion circuit is electrically connected with the filter circuit to perform A/D conversion on the voltage signal filtered by the filter circuit and send the voltage signal subjected to the A/D conversion to the data processing unit.
Further, the crack measurement bridge is excited by a constant voltage source;
the excitation power supply is a constant voltage power supply.
Further, the crack measuring bridge circuit is excited by a constant current source;
the excitation power supply is a constant current power supply.
Further, the data acquisition device further comprises:
the wireless communication module is electrically connected with the data processing unit so as to send the crack state information out in a wireless mode, receive a wireless control signal and forward the wireless control signal to the data processing unit so as to set the data processing unit;
the power module is electrically connected to the wireless communication module to supply power to the wireless communication module.
A flange crack monitoring method which adopts the flange crack monitoring device comprises the following steps:
determining the number of crack detection sheets adopted by a crack detection sheet set and the number of resistance wires in the crack detection sheets according to the size of the detected flange plate;
sequentially sticking the crack detection sheets on the tested flange disc in a clockwise or anticlockwise direction;
establishing a resistance wire information arrangement table according to the resistance values of all resistance wires in the crack detection sheet set;
when flange crack monitoring is carried out, according to the resistance change of the crack detection sheet set, a broken resistance wire is determined in the resistance wire information arrangement table;
and determining the crack state information of the flange according to the position of the broken resistance wire.
Further, the crack status information of the flange includes:
the location, propagation direction, extent of cracking, and repair recommendations for the flange.
According to the flange crack monitoring device and method, the crack detection sheets formed by the resistance wires are adhered to the measurement positions of the flange, the broken resistance wires are judged by using the change of electric signals caused by the breakage of the resistance wires, and the crack state information such as the position, the expansion direction, the crack degree and the like of the flange cracks is further determined, so that the purpose of rapidly finding and determining the position and the crack direction of the flange cracks of large equipment applying the flange in a non-stop state is achieved, the large equipment does not need to perform stop detection on the flange cracks, and the maintenance of the flange is more effective and rapid. The adoption of the wireless communication module enables the flange crack monitoring device to be free from the trouble of wire connection, the problem of wire connection does not need to be considered during the operation and the operation of the flange, meanwhile, the real-time remote transmission of the crack state information of the flange is realized, and the remote monitoring and the remote production are realized.
Drawings
FIG. 1 is a schematic diagram of a flange crack monitoring device according to an embodiment of the present invention;
FIG. 2 is a schematic diagram illustrating the effect of the crack detection sheet adhered to the flange according to the embodiment of the invention;
FIG. 3 is a schematic diagram of a data acquisition device according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a measurement circuit according to an embodiment of the present invention;
FIG. 5 is a schematic circuit diagram of a constant voltage source excited crack measurement bridge;
FIG. 6 is a circuit schematic of a constant current source energized crack measurement bridge;
fig. 7 is a schematic flow chart of a flange crack monitoring method according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and examples.
As shown in fig. 1, the flange crack monitoring device according to the embodiment of the present invention includes a crack detection sheet 1 and a data acquisition device 2. The crack detection sheet 1 is at least one, the crack detection sheet 1 is adhered to a measurement position of the flange, and the crack detection sheets 1 are connected in series to form a crack detection sheet group 10. The data acquisition device 2 is electrically connected to the crack detection sheet group 10 to determine the crack state information of the flange according to the resistance change of the crack detection sheet group 10. The data acquisition device 2 is electrically connected to the crack detection sheets 1 at two ends of the crack detection sheet group 10.
As for the structure of the crack detection sheet 1, as shown in fig. 2, each crack detection sheet 1 includes a plurality of resistance wires 101 having different resistance values and a detection sheet pin 102. The resistance wires 101 are connected in parallel, the number of the detection sheet pins 102 is two, for example, a first detection sheet pin a and a second detection sheet pin B, the two detection sheet pins 102 (the first detection sheet pin a and the second detection sheet pin B) are electrically connected to two ends of the resistance wires 101 connected in parallel, that is, one ends of the resistance wires 101 connected in parallel are electrically connected to the first detection sheet pin a, and the other ends of the resistance wires 101 connected in parallel are electrically connected to the second detection sheet pin B. It should be emphasized that, in the embodiment of the present invention, in the crack detection sheet set 10, the resistance values of any two resistance wires 101 are not equal. Furthermore, in each crack detection sheet 1, after any one resistance wire 101 is broken, the resistance values of the crack detection sheets 1 are different, for example, in one crack detection sheet: after the first resistance wire is broken, the resistance value of the crack detection sheet is the first resistance value, after the second resistance wire is broken, the resistance value of the crack detection sheet is … … after the nth resistance wire is broken, the resistance value of the crack detection sheet is the nth resistance value, and then the first resistance value and the second resistance value … … are unequal to each other. Further, in the crack detection sheet group 10 formed by connecting in series, the resistance value of the crack detection sheet group after any one resistance wire is broken is different from the resistance value of the crack detection sheet group after any other resistance wire is broken. And the method is convenient for determining which resistance wire is broken when being easily monitored.
Fig. 2 shows only one crack detection piece 1, and a plurality of crack detection pieces 1 are connected in series. In addition, as shown in fig. 2, when the crack detection sheet 1 is attached to the measurement position of the flange 3, each resistance wire 101 in the crack detection sheet 1 is in a straightened state, so that when a crack occurs on the surface of the flange 3 where the resistance wire 101 is located, the resistance wire 101 will break to indicate that the crack occurs on the surface of the flange 3, otherwise, the monitoring cannot be performed.
As shown in fig. 3, in the embodiment of the present invention, the data acquisition device 2 includes a measurement circuit 201, a data processing unit 202, and a power module 203. The measuring circuit 201 is electrically connected to the crack detection sheet assembly 10 to generate a voltage signal according to the resistance value of the crack detection sheet assembly 10. The data processing unit 202 is electrically connected to the measurement circuit 201 to convert the voltage signal generated by the measurement circuit 201 into crack status information. The power module 203 is electrically connected to the measurement circuit 201 and the data processing unit 202 to supply power to the measurement circuit 201 and the data processing unit 202. The data acquisition device 2 further includes a wireless communication module 204, and the wireless communication module 204 is electrically connected to the data processing unit 202 to send out the crack state information in a wireless manner, receive a wireless control signal, and forward the wireless control signal to the data processing unit 202 to set the data processing unit 202. The power module 203 is also electrically connected to the wireless communication module 204 to supply power to the wireless communication module 204.
As shown in fig. 4, in the embodiment of the present invention, the measurement circuit 201 includes a bridge resistor 2011, an excitation power source 2012, an amplification circuit 2013, a filter circuit 2014, and an a/D (analog/digital) conversion circuit 2015. The bridge resistor 2011 is electrically connected to the crack detection plate group 10, and the bridge resistor 2011 and the crack detection plate group 10 together form a crack measurement bridge. The excitation power supply 2012 is electrically connected to the crack measurement bridge to provide an excitation electrical signal to the crack measurement bridge. The amplifying circuit 2013 is electrically connected to the crack measurement bridge circuit to collect and amplify the voltage signals of the crack detection plate group 10 in the crack measurement bridge circuit, and the amplifying circuit 2013 is connected to two ends of the bridge circuit. The filter 2014 is electrically connected to the amplifier 2013 for filtering the voltage signal amplified by the amplifier 2013. The a/D conversion circuit 2015 is electrically connected to the filter circuit 2014, and the a/D conversion circuit 2015 is electrically connected to the data processing unit 202, so as to perform a/D conversion on the voltage signal filtered by the filter circuit 2014, and send the voltage signal after the a/D conversion to the data processing unit 202.
In an embodiment of the invention, the crack measurement bridge may be excited by a constant voltage source, and the schematic diagram is shown in fig. 5. The constant voltage source excited crack measurement bridge may include a first bridge resistor R1, a second bridge resistor R2, a third bridge resistor R3, and a crack detector sheet set resistor Rg. One end of the first bridge resistor R1 and one end of the second bridge resistor R2 are connected to the power supply voltage VEXC, the other end of the first bridge resistor R1 and one end of the third bridge resistor R3 are connected to the node Sx-, the other end of the second bridge resistor R2 and one end of the crack detection sheet group resistor Rg are connected to the node Sx +, the other end of the third bridge resistor R3 and the other end of the crack detection sheet group resistor Rg are grounded, and a constant voltage is kept between the power supply voltage VEXC and the ground. And an amplifying circuit 2013 is connected to the node Sx-and the node Sx + to measure the voltage between the node Sx-and the node Sx +. After a certain resistance wire in the crack detection sheet group 10 is broken, the crack detection sheet group resistor Rg changes, and further the voltage between the node Sx-and the node Sx + changes, so that the new voltage between the node Sx-and the node Sx + can be used for calculating and judging which resistance wire in the crack detection sheet group 10 is broken, further the flange position where the broken resistance wire is located can be known to have a crack, and the expansion direction and the crack degree of the crack can be further judged.
The crack measurement bridge may also be energized by a constant current source, the schematic diagram of which is shown in FIG. 6. The constant current source excited crack measurement bridge may include a first constant current source DC1, a second constant current source DC2, a fourth bridge resistor R4, and a crack detector sheet set resistor Rg. The output end of the first constant current source DC1 and one end of the fourth bridge resistor R4 are connected to the node a, the output end of the second constant current source DC2 and one end of the crack detection sheet group resistor Rg are connected to the node B, the other end of the fourth bridge resistor R4 and the other end of the crack detection sheet group resistor Rg are grounded, the input end of the first constant current source DC1 and the input end of the second constant current source DC2 are connected to form a common input end, and a power supply voltage Vcc is arranged between the common input end of the first constant current source DC1 and the second constant current source DC2 and the ground end. An amplifying circuit 2013 is connected to the node a and the node B to measure the voltage between the node a and the node B. After a certain resistance wire in the crack detection sheet group 10 is broken, the crack detection sheet group resistor Rg changes, and then the voltage between the node A and the node B changes, so that the new voltage between the node A and the node B can be used for calculating and judging which resistance wire in the crack detection sheet group 10 is broken, and further knowing that the position of a flange where the broken resistance wire is located has a crack, the expansion direction and the crack degree of the crack can be judged.
In general, when the resistance value of the crack detection sheet 1 is large, a constant voltage source is used for supplying power, that is, the excitation power source 2012 adopts a constant voltage source; when the resistance value of the crack detection sheet 1 is small, a double constant current source can be adopted for supplying power, that is, the excitation power source 2012 adopts a constant current source (double constant current source power source).
When the flange has cracks, the resistance wires of the crack detection sheet 1 are broken one by one, and then the resistance value of the crack measurement bridge circuit changes, which causes the voltage value collected by the amplifying circuit 2013 to change, that is, the voltage signal of the measurement circuit 201 changes, and then the data processing unit 202 collects and converts the voltage signal of the measurement circuit 201 into crack state information and sends the crack state information through the wireless communication module 204.
In the embodiment of the present invention, the wireless communication module 204 adopts an 802.15.4 wireless communication protocol, and supports a plurality of network topologies such as point-to-point, star, line, tree, and the like. The crack state information obtained by the data processing unit 202 and the serial number of the data acquisition device 2 are wirelessly transmitted, for example, to an upper computer monitoring system. To meet the communication distance requirement, the wireless communication module 204 may be configured with a power transceiver module to increase the communication distance. The power transceiving module may be subdivided into a power amplifier and a transmit antenna. To increase the communication distance, this can be solved by additional power amplifiers, including a radio frequency power amplifier HFA3925 on the transmit path and a low noise amplifier HFA3424 on the receive path. The radio frequency power amplifier HFA3925 realizes the power amplification function of the 2.4GHz transmission signal, and the maximum amplification gain can reach 28dB (the maximum output power can reach 250 mW). The low noise amplifier HFA3424 realizes the low noise amplification function of the 2.4GHz receiving signal, and the amplification gain can reach 14 dB.
In the embodiment of the present invention, the data processing unit 202 mainly functions to convert the voltage signal output by the front-end measurement circuit 201 into crack state information, set the device number of the data acquisition device 2, and send the crack state information and the device number out through the wireless communication module 204, or start acquisition, stop acquisition, instantaneous acquisition, group number, channel setting, sampling rate, channel number setting, channel zero clearing, and power inquiry according to the instruction and parameters issued by the host.
In the embodiment of the present invention, the system chip CC2430 integrating the data processing unit 202 and the wireless communication module 204 may be used to implement data processing and transmission. The solution can improve the performance and meet the requirements of ZigBee-based 2.4GHz ISM band application on low cost and low power consumption. It combines a high-performance 2.4GHz DSSS (direct sequence spread spectrum) radio frequency transceiver core and an industrial-scale small and high-efficiency 8051 controller.
The CC2430 contains an enhanced industry standard 8-bit 8051 microcontroller core for MCU processing power requirements for protocol stack, network and application software execution. The CC2430 enhanced 8051 core using the standard 8051 instruction set has 8 times the performance of the standard 8051 core due to faster execution times and by eliminating wasted bus state.
In the transmit mode, the bit mapping and modulation is done according to the IEEE 802.15.4 specification. Modulation (and spreading) is done digitally. The modulated baseband signal is passed through a D/a (digital/analog) converter and then low-pass filtered and directly up-converted by a single-sideband modulator into a radio frequency signal. Finally, the high frequency signal is amplified by an on-chip power amplifier to a programmable level.
In the embodiment of the present invention, the power module 203 is used to supply power to active devices in the apparatus, and also perform charging and discharging management on the battery. The power module 203 employs independent power management for each module in the device, and enters a sleep state or turns off its power when it is idle. Thereby greatly reducing the total power consumption of the system.
In the embodiment of the invention, the digital signal processor can be connected with the power module through the IIC or UART interface, thereby realizing the real-time monitoring of the voltage, current and temperature conditions of the power part, preventing the occurrence of the phenomena of over-charge and under-charge of the power and informing the network host to replace the battery in time.
The embodiment of the invention also provides a flange crack monitoring method, which adopts the flange crack monitoring device. As shown in fig. 7, the flange crack monitoring method includes:
step 1, determining the number of crack detection sheets adopted by a crack detection sheet set and the number of resistance wires in the crack detection sheets according to the size of a detected flange plate;
step 3, establishing a resistance wire information arrangement table according to the resistance values of all resistance wires in the crack detection sheet group;
step 4, determining a broken resistance wire in the resistance wire information arrangement table according to the resistance change of the crack detection sheet group during flange crack monitoring;
and 5, determining crack state information of the flange according to the position of the broken resistance wire.
Wherein the crack state information of the flange comprises the position, the propagation direction, the crack degree and the repair suggestion of the crack generated by the flange.
The following is a specific example of the method.
Design of crack detection sheet
Firstly, when the detection pieces are designed, the number M of the crack detection pieces which need to be adhered on one flange plate in total is calculated.
And then, according to experience, setting the grade of the crack to be monitored, and setting the number N of the resistance wires in each crack detection sheet.
Secondly, pasting of crack detection piece
When the crack detection pieces are pasted on the flange plate, the position of the first crack detection piece is marked, and then the other crack detection pieces are pasted in sequence in the clockwise or anticlockwise direction. In the resistance wire of each crack detection sheet, the longer one is positioned outside the flange, and the shorter one is positioned inside the flange. All crack detection plates were connected in series.
Thirdly, establishing a resistance wire information arrangement table
In the part, a resistance wire information arrangement table is established by taking an example that M is 6 crack detection sheets, and each crack detection sheet has N is 5 resistance wires, as shown in table 1.
Table 1: resistance wire information arrangement table
| Crack sheet 1 | |
Crack sheet 3 | Crack sheet 4 | Crack sheet 5 | Crack sheet 6 | |
| Resistance wire 1 | R11 | R12 | R13 | R14 | R15 | |
| Resistance wire | ||||||
| 2 | R21 | R22 | R23 | R24 | R25 | R26 |
| Resistance wire 3 | R31 | R32 | R33 | R34 | R35 | R36 |
| Resistance wire 4 | R41 | R42 | R43 | R44 | R45 | R46 |
| Resistance wire 5 | R51 | R52 | R53 | R54 | R55 | R56 |
Rxy represents the resistance value measured at the total output end after any resistance wire is broken in the whole series-connected crack detection sheet link (namely the crack detection sheet set) in table 1. Namely, R11 represents the crack detection sheet group, the resistance value measured at the main output end after the first resistance wire of the first crack detection sheet is broken, R12 represents the crack detection sheet group, the resistance value measured at the main output end after the first resistance wire of the second crack detection sheet is broken, R21 represents the crack detection sheet group, the resistance value measured at the main output end after the second resistance wire of the first crack detection sheet is broken, the resistance value measured at the main output end … … R56 represents the crack detection sheet group, and the resistance value measured at the main output end after the fifth resistance wire of the sixth crack detection sheet is broken.
Fourthly, judging the crack state information
In table 1, the resistance values of any Rxy are not equal to each other, and the sum of the resistance values of any plurality of Rxy is not equal to each other.
When the resistance value monitored by the crack monitoring device is a certain resistance value in the 1 st row in table 1:
when the resistance value monitored by the crack monitoring device is R11 resistance value, the crack state information is as follows: 1 grade of cracks, wherein the crack detection sheet is 1, the cracks are expanded inwards, and the cracks are slightly cracked;
when the resistance value monitored by the crack monitoring device is R12 resistance value, the crack state information is as follows: 1 grade of cracks, 2 grade of crack detection sheets, inward expansion of cracks and slight cracks;
……
when the resistance value monitored by the crack monitoring device is R16 resistance value, the crack state information is as follows: the crack is grade 1, the crack detection sheet is 6, the crack is expanded inwards, and the crack is slight.
When the resistance value monitored by the crack monitoring device is a certain resistance value in the 5 th row in table 1:
when the resistance value monitored by the crack monitoring device is R51 resistance value, the crack state information is as follows: 1 grade of cracks, wherein the crack detection sheet is 1, the cracks are expanded outwards, and the cracks are slightly cracked;
when the resistance value monitored by the crack monitoring device is R52 resistance value, the crack state information is as follows: 1 grade of cracks, 2 grade of crack detection sheets, outward expansion of cracks and slight cracks;
……
when the resistance value monitored by the crack monitoring device is R56 resistance value, the crack state information is as follows: the crack is grade 1, the crack detection piece is 6, and the crack expands outwards.
If the resistance value of the line 1 is monitored and the resistance wire 1 is stuck to the outer side of the flange, the crack state prompt information is that the crack expands inwards; if the resistance value of the 5 th line is monitored and the resistance wire 5 is stuck to the inner side of the flange, the crack state prompt message is that the crack expands outwards. Since the cracks monitored are located on the outermost resistance wire, it is presumed that cracks are just generated near the flange edge, the generated cracks are not serious, and the operation of the large structure is not affected, and only slight cracks can be indicated about the degree of the cracks. Crack level 1 may be indicated as a relatively mild crack when continued use of the flange is not affected.
When the crack monitoring device monitors that the resistance value is any one of the resistance values in the 1 st line or the 5 th line in the table 1, the crack state information is as follows: crack 2 grade, need to shut down the maintenance immediately. The monitored cracks are located on the resistance wire in the middle of the crack detection sheet, so that the cracks are presumed to be formed in the middle of the flange, the cracks formed in the middle extend towards the inner side and the outer side, and the middle of the flange is stressed greatly, so that the influence of the cracks generated at the position is judged to be large, the problem that the flange is broken and the like can be caused quickly, the operation of a large-scale structure can be influenced, and only slight cracks can be prompted about the crack degree at the moment. Crack level 2 may be characterized as a more severe crack that may propagate over time and affect continued use of the flange, requiring a shutdown for inspection.
According to the flange crack monitoring device and method, the plurality of crack detection sheets formed by the plurality of resistance wires are adhered to the measuring positions of the flange, the broken resistance wires are judged by utilizing the change of electric signals caused by the breakage of the resistance wires, and the crack state information such as the position, the expansion direction, the crack degree and the like of the flange cracks is further determined, so that the purpose that large equipment applying the flange can quickly find and determine the position and the crack direction of the flange cracks under the non-stop state is achieved, the large equipment does not need to perform stop detection on the flange cracks, and the maintenance of the flange is more effective and quick. The adoption of the wireless communication module enables the flange crack monitoring device to be free from the trouble of wire connection, the problem of wire connection does not need to be considered during the operation and the operation of the flange, meanwhile, the real-time remote transmission of the crack state information of the flange is realized, and the remote monitoring and the remote production are realized.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (9)
1. A flange crack monitoring device, comprising:
the crack detection piece is at least one piece and is adhered to the measurement position of the flange, and the crack detection pieces are mutually connected in series to form a crack detection piece group; each crack detection piece comprises: the resistance wires are connected in parallel; the two detection sheet pins are respectively and electrically connected to two ends of the resistance wires connected in parallel; in the crack detection sheet set, the resistance values of any two resistance wires are different;
the resistance wire information arrangement table records the resistance value of the crack detection sheet group after any one resistance wire in the crack detection sheet group is broken;
the data acquisition device is electrically connected with the crack detection sheet set so as to determine a broken resistance wire in the resistance wire information arrangement table according to the resistance change of the crack detection sheet set and determine the crack state information of the flange according to the position of the broken resistance wire;
wherein:
in the resistance wire information arrangement table, the resistance values of any Rxy are not equal to each other, and the resistance values of any multiple Rxy are not equal to each other when added together, wherein Rxy represents the resistance value measured at the total output end after any one resistance wire in the crack detection sheet group is broken in the resistance wire information arrangement table, x represents the serial number of the resistance wire in the crack detection sheet, and y represents the serial number of the crack detection sheet in the crack detection sheet group;
the resistance wire corresponding to the resistance value of the 1 st line in the resistance wire information arrangement table is pasted outside the flange, and when the resistance wire corresponding to the resistance value of the last 1 lines in the resistance wire information arrangement table is pasted inside the flange:
when the resistance value measured at the main output end is the resistance value of the 1 st line in the resistance wire information arrangement table after the fracture of a certain resistance wire in the crack detection sheet group is monitored, the crack state information comprises: crack propagation inward and mild cracking;
when it is monitored that a certain resistance wire in the crack detection sheet group is broken, the resistance value measured at the main output end is the resistance value of the last 1 line in the resistance wire information arrangement table, and the crack state information comprises: crack propagation outward and mild cracking;
when it is monitored that a certain resistance wire in the crack detection sheet group is broken, the resistance value measured at the main output end is the resistance value of the resistance wire information arrangement table except the resistance value of the 1 st line and the resistance value of the last 1 line, and the crack state information comprises: crack 2 grade, need to shut down the maintenance immediately.
2. The flange crack monitoring device of claim 1, wherein:
when the crack detection sheet is adhered to the measurement position of the flange, all resistance wires in the crack detection sheet are in a straightening state.
3. The flange crack monitoring device of claim 1, wherein the data acquisition device comprises:
the measuring circuit is electrically connected with the crack detection sheet set so as to generate a voltage signal according to the resistance value of the crack detection sheet set;
a data processing unit electrically connected to the measurement circuit to convert the voltage signal generated by the measurement circuit into crack status information; and the number of the first and second groups,
and the power supply module is electrically connected with the measuring circuit and the data processing unit so as to supply power to the measuring circuit and the data processing unit.
4. The flange crack monitoring device of claim 3, wherein the measurement circuit comprises:
the bridge resistor is electrically connected to the crack detection sheet set, and the bridge resistor and the crack detection sheet set jointly form a crack measurement bridge circuit;
an excitation power supply electrically connected to the crack measurement bridge to provide an excitation electrical signal to the crack measurement bridge;
the amplifying circuit is electrically connected to the crack measuring bridge circuit and is used for collecting and amplifying voltage signals of the crack detection sheet group in the crack measuring bridge circuit;
the filter circuit is electrically connected to the amplifying circuit to filter the voltage signal amplified by the amplifying circuit; and the number of the first and second groups,
the A/D conversion circuit is electrically connected with the filter circuit to perform A/D conversion on the voltage signal filtered by the filter circuit and send the voltage signal subjected to the A/D conversion to the data processing unit.
5. The flange crack monitoring device of claim 4, wherein:
the crack measuring bridge circuit is excited by a constant voltage source;
the excitation power supply is a constant voltage power supply.
6. The flange crack monitoring device of claim 4, wherein:
the crack measuring bridge circuit is excited by a constant current source;
the excitation power supply is a constant current power supply.
7. The flange crack monitoring device of claim 3, wherein the data acquisition device further comprises:
the wireless communication module is electrically connected with the data processing unit so as to send the crack state information out in a wireless mode, receive a wireless control signal and forward the wireless control signal to the data processing unit so as to set the data processing unit;
the power module is electrically connected to the wireless communication module to supply power to the wireless communication module.
8. A flange crack monitoring method using the flange crack monitoring apparatus according to any one of claims 1 to 7, the flange crack monitoring method comprising:
determining the number of crack detection sheets adopted by a crack detection sheet set and the number of resistance wires in the crack detection sheets according to the size of the detected flange plate;
sequentially sticking the crack detection sheets on the tested flange disc in a clockwise or anticlockwise direction;
establishing a resistance wire information arrangement table according to the resistance values of all resistance wires in the crack detection sheet set;
when flange crack monitoring is carried out, according to the resistance change of the crack detection sheet set, a broken resistance wire is determined in the resistance wire information arrangement table;
and determining the crack state information of the flange according to the position of the broken resistance wire.
9. The flange crack monitoring method of claim 8, wherein the crack status information of the flange comprises:
the location, propagation direction, extent of cracking, and repair recommendations for the flange.
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| CN107894445A (en) * | 2017-10-30 | 2018-04-10 | 江阴市恒润重工股份有限公司 | A kind of flange available for end face of flange crack monitoring |
| CN108020583B (en) * | 2017-10-30 | 2021-04-13 | 江阴市恒润环锻有限公司 | Flange for crack regional monitoring by adopting finite element meshing method |
| CN110567512A (en) * | 2019-08-19 | 2019-12-13 | 上海今旦机械制造有限公司 | metal product inspection tool |
| CN110487165B (en) * | 2019-08-23 | 2020-08-28 | 北京石墨烯技术研究院有限公司 | Metal crack detection sensor and system |
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