CN106645418B - Crawler-type magnetoacoustic composite detection robot and detection method and device - Google Patents

Crawler-type magnetoacoustic composite detection robot and detection method and device Download PDF

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Publication number
CN106645418B
CN106645418B CN201710061664.2A CN201710061664A CN106645418B CN 106645418 B CN106645418 B CN 106645418B CN 201710061664 A CN201710061664 A CN 201710061664A CN 106645418 B CN106645418 B CN 106645418B
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detection
electromagnetic ultrasonic
area
ultrasonic
sensor
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CN106645418A (en
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郑阳
沈功田
谭继东
张宗健
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China Special Equipment Inspection and Research Institute
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China Special Equipment Inspection and Research Institute
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/06—Visualisation of the interior, e.g. acoustic microscopy
    • G01N29/0654—Imaging
    • G01N29/069—Defect imaging, localisation and sizing using, e.g. time of flight diffraction [TOFD], synthetic aperture focusing technique [SAFT], Amplituden-Laufzeit-Ortskurven [ALOK] technique
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D55/00—Endless track vehicles
    • B62D55/08—Endless track units; Parts thereof
    • B62D55/18—Tracks
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B17/00—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations
    • G01B17/02—Measuring arrangements characterised by the use of infrasonic, sonic or ultrasonic vibrations for measuring thickness
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
    • G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
    • G01N27/83—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws by investigating stray magnetic fields
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/02—Indexing codes associated with the analysed material
    • G01N2291/023—Solids
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/02—Indexing codes associated with the analysed material
    • G01N2291/028—Material parameters
    • G01N2291/0289—Internal structure, e.g. defects, grain size, texture
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/26—Scanned objects
    • G01N2291/263—Surfaces
    • G01N2291/2634—Surfaces cylindrical from outside
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/26—Scanned objects
    • G01N2291/269—Various geometry objects
    • G01N2291/2695—Bottles, containers

Abstract

The invention discloses a crawler-type magnetoacoustic composite detection robot and a detection method and device. Wherein, this detection robot includes: the control unit is used for communicating with the external equipment, controlling the mechanical part of the detection robot and the detection system of the detection robot according to the instruction issued by the external equipment; the at least one crawler belt is connected with the control unit and used for detecting the detected area, and the detection at least comprises any one of the following steps: electromagnetic ultrasonic guided wave scanning imaging, electromagnetic ultrasonic guided wave tomography, electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection; wherein, every track is formed by a plurality of sensor track units connection, and sensor track unit includes: a magnetic flux leakage detection unit, and/or at least one electromagnetic ultrasonic unit. The invention solves the technical problems of low detection efficiency and high cost caused by the fact that the detection robot in the existing nondestructive detection adopts a plurality of technologies to separate and use and common C scanning detection.

Description

Crawler-type magnetoacoustic composite detection robot and detection method and device
Technical Field
The invention relates to the technical field of industrial nondestructive testing, in particular to a crawler-type magnetoacoustic composite testing robot and a testing method and device.
Background
At present, energy safety has become a focus of wide attention worldwide, and how to improve the service cycle of large-scale petroleum and petrochemical equipment and oil gas conveying pipelines, reduce production stopping loss and ensure safe operation of the large-scale petroleum and petrochemical equipment and the oil gas conveying pipelines is a hot spot for research of scientific workers in various countries. Thus, non-destructive testing of large atmospheric storage tanks (e.g., large numbers of storage tanks owned by national crude oil strategic reserves, millions of tons of oil refineries, million tons of ethylene engineering, etc.) is a very important project that will be needed by those skilled in the art.
China has more than 20 ten thousands of large-scale normal pressure storage tanks (oil storage tanks with the volume of more than or equal to 5000 cubic meters and the diameter of more than or equal to 12.5 meters), while crude oil strategic storage reservoirs have the diameter of more than 100 meters and the height of tens of meters, and in the detection of the wall surfaces of the storage tanks, the defects of wall thickness thinning, surface cracks and the like caused by corrosion are mainly concerned. The outer wall of a storage tank (generally a cylindrical storage tank) is not provided with any climbable attachment part except a crawling ladder, and for detecting defects of the outer wall of the storage tank, the traditional means is to adopt a manual detection mode, a sling is used for suspending detection personnel to the wall surface of the outer wall of the storage tank to be detected, and the detection mode needs to be used for high-altitude operation of the detection personnel, is dangerous and has low efficiency.
In order to ensure the personal safety of detection personnel, the wall climbing robot is used for detecting the large storage tank, so that the method is a good solution. Some designs have been made on wall climbing robots by researchers, and the wall climbing robots are studied as follows:
patent publication No. US4664212 discloses a vacuum wall crawler, patent publication No. EP2653864A1 discloses a climbing robot for corrosion monitoring and a sensor for potential mapping, patent publication No. US 919668 B2 discloses a structure evaluation, maintenance and repair apparatus and method, patent publication No. CN201210130261 discloses a climbing robot, and patent publication No. CN201410645993 discloses a magnetic adsorption climbing robot. The robots disclosed in these documents mainly rely on magnetic adsorption or negative pressure adsorption, are general robot structures, do not consider specific design aiming at different detection requirements, have no detection capability, and can only carry detection instruments or equipment if used for detection, so that the volume and weight of the whole machine are increased, and if multiple technical detection is realized, the weight of the whole machine is greatly increased, so that new requirements are put forward on the load capacity of the robot.
Aiming at the wall climbing detection robot designed for detection and application, the research situation is as follows: patent document publication No. US 8171809B2 discloses a wind turbine inspection system and method which is designed for a wind turbine inspection trolley, but is inconvenient to use due to the fact that the robot is pulled by a rope; the robot proposed in the article "development of climbing robot for negative pressure adhesion for inspection" adopts a vacuum chuck structure, so that the robot can only be applied to smooth surfaces and is difficult to adapt to wall surfaces with different curvature radiuses; patent document with application number of CN201210185203 discloses a composite magnetic adsorption type video detection wall climbing robot which only performs visual detection on a wall surface through video, so that the robot does not have functions of thickness measurement and the like; patent document with application number of CN201510173038 discloses a wall climbing robot for magnetic powder flaw detection, which is mainly designed and optimized for magnetic powder flaw detection and cannot automatically measure wall thickness; patent document with application number of CN2010101060800 discloses an automatic online detection device for welding lines of a tower drum of a fan, which can only detect the welding lines of the tower of the fan by phased array technology and does not realize thickness measurement of a wall surface and detection of non-welding areas.
In addition, the article "a compact wall-climbing and surface adaptation robot for non-destructive testing" discloses a robot for a magnet array, which can well adsorb and crawl ferromagnetic materials, can automatically adjust the current situation of an adaptation curved surface in a certain curvature range, carries a piezoelectric ultrasonic sensor of a Sonatest Ltd company, which uses rubber for coupling, can realize wall thickness measurement, but has an unsatisfactory detection effect on a wall plate with an uneven thicker paint layer, and takes a lot of time for complete all scanning detection on a wall plate of a large storage tank.
The product CROCELLS robot of London South Bank University can finish wall climbing detection by carrying Olympus piezoelectric phased array equipment, can not work for a wall plate with a paint layer, and can take a lot of time for finishing all scanning detection for a wall plate of a large storage tank.
As can be seen from the above, in the related art, no wall climbing robot is designed for detecting the wall surface of a large-scale petroleum storage tank, but only single-function detection can be realized in the existing storage tank detection scheme, for example, the patent with the authority number CN 102661995B discloses an electromagnetic ultrasonic and magnetic leakage composite detection method, and the provided detection method can only realize ultrasonic thickness measurement and magnetic leakage detection functions, but not ultrasonic guided wave defect detection functions; the detection method provided by the patent document with the authorization number of CN 103353479B, namely an electromagnetic ultrasonic longitudinal guided wave and magnetic leakage detection combined detection method, can only realize the ultrasonic longitudinal guided wave detection and magnetic leakage detection functions generated on the inner surface of the detected area. The typical corrosion wall thickness reduction for a tank cannot be measured.
Aiming at the problems of low detection efficiency and high cost caused by the fact that the detection robot in the existing nondestructive detection is separated and used by adopting various technologies, no effective solution is proposed at present.
Disclosure of Invention
The embodiment of the invention provides a crawler-type magnetoacoustic composite detection robot, a detection method and a detection device, which at least solve the technical problems of low detection efficiency and high cost caused by the separation and use of various technologies in the existing nondestructive detection.
According to an aspect of an embodiment of the present invention, there is provided a crawler-type magnetoacoustic composite inspection robot including: the control unit is used for communicating with the external equipment, controlling the mechanical part of the detection robot and the detection system of the detection robot according to the instruction issued by the external equipment; the at least one crawler belt is connected with the control unit and used for detecting the detected area, and the detection at least comprises any one of the following steps: electromagnetic ultrasonic guided wave scanning imaging, electromagnetic ultrasonic guided wave tomography, electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection; wherein, every track is formed by a plurality of sensor track units connection, and sensor track unit includes: a magnetic flux leakage detection unit, and/or at least one electromagnetic ultrasonic unit.
According to the embodiment of the invention, the detection equipment comprises the crawler-type magnetoacoustic composite detection robot.
According to an aspect of the embodiment of the present invention, there is also provided a crawler-type magnetoacoustic composite detection method, including: scanning and imaging a detected area by a detection robot, and determining one or more first defect areas with defects on the detected area according to imaging results, wherein the detection robot comprises at least one crawler, each crawler is formed by connecting at least one sensor crawler unit, and the sensor crawler unit comprises: a magnetic flux leakage detection unit, and/or at least one electromagnetic ultrasonic unit; performing tomography on the first defect area through at least one crawler belt, and determining the position and the size of the defect according to the imaging result; determining a second defect area of the defect according to the position and the size of the defect, and detecting the second defect area through a sensor track unit, wherein the detection at least comprises any one of the following steps: electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection; wherein the second defective area is an area defective to one or more of the first defective areas.
According to another aspect of the embodiment of the present invention, there is also provided a crawler-type magnetoacoustic composite detection apparatus, including: the first processing module is used for scanning and imaging the detected area through the detection robot and determining one or more first defect areas with defects on the detected area according to imaging results, wherein the detection robot comprises at least one crawler, each crawler is formed by connecting at least one sensor crawler unit, and the sensor crawler unit comprises: a magnetic flux leakage detection unit, and/or at least one electromagnetic ultrasonic unit; the second processing module is used for performing tomography on the first defect area through at least one crawler belt and determining a second defect area of the defect according to an imaging result, wherein the second defect area is an area where the defect exists in the first defect area; the first detection module is used for detecting the second defect area through the sensor track unit, and the detection at least comprises any one of the following steps: electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection; wherein the second defective area is an area defective to one or more of the first defective areas.
In the embodiment of the invention, based on the overall design concept of the robot and the detection system, the sensor for detecting the detected area and the moving part of the robot are integrated into a whole, the robot comprises a plurality of tracks, each track is formed by connecting a plurality of sensor track units, and the weight and the volume of the whole robot are reduced. Because the detection robot is always contacted with the detected area in the moving (e.g. crawling or sliding) process, the sensor for detecting the detected area is used as a unit component for forming the crawler, and the sensor and the detected wall are in rolling friction type, so that the abrasion caused by the contact or collision between the fixed scanning probe and the wall can be avoided, and the defects that the fixed scanning probe is difficult to cross a welding line and the like are avoided.
According to the technical scheme provided by the embodiment of the invention, the comprehensive detection modes of ultrasonic guided wave large-area imaging, ultrasonic guided wave tomography, ultrasonic scanning thickness measurement, magnetic leakage scanning detection and surface wave scanning detection are achieved, the detection process is from coarse detection to further fine detection to final fine detection, the technical effect of improving the detection speed while ensuring the detection precision is achieved, and the technical problems of low detection efficiency and high cost caused by separation and use of various technologies in the existing nondestructive detection are further solved.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the application and do not constitute a limitation on the application. In the drawings:
FIG. 1 is a schematic illustration of an alternative tracked magnetoacoustic composite inspection robot in accordance with an embodiment of the present application;
FIG. 2 (a) is a front view of an alternative tracked magnetoacoustic composite inspection robot according to an embodiment of the present application;
FIG. 2 (b) is a right side view of an alternative tracked magnetoacoustic composite inspection robot in accordance with an embodiment of the present application;
FIG. 3 is an alternative curved panel adaptation schematic according to an embodiment of the present application;
FIG. 4 is a schematic illustration of an alternative monopolar sensor track unit configuration according to an embodiment of the present application;
FIG. 5 is a coil schematic diagram of an alternative spiral coil configuration in accordance with an embodiment of the application;
FIG. 6 is a schematic illustration of an alternative bipolar sensor track unit configuration in accordance with an embodiment of the present application;
FIG. 7 is a schematic illustration of an alternative conductive sensor track unit configuration in accordance with an embodiment of the present application;
FIG. 8 is a schematic diagram of a control system of an alternative tracked magnetoacoustic composite inspection robot in accordance with an embodiment of the present application;
FIG. 9 is a schematic diagram of an alternative three-dimensional tracked magnetoacoustic composite inspection robot in accordance with an embodiment of the present invention; and
FIG. 10 is a schematic illustration of an alternative sensor track unit in accordance with an embodiment of the invention, shown disassembled;
FIG. 11 is a flowchart of a crawler-type magnetoacoustic composite detection method according to an embodiment of the present invention;
FIG. 12 is a schematic illustration of an alternative tracked magnetoacoustic composite inspection robot in accordance with an embodiment of the present invention;
FIG. 13 is a schematic illustration of an alternative tracked magnetoacoustic composite inspection robot in accordance with an embodiment of the present invention;
FIG. 14 is a schematic illustration of an alternative tracked magnetoacoustic composite inspection robot fine sweep in accordance with an embodiment of the present invention;
FIG. 15 is a schematic view of an alternative tracked magnetoacoustic composite inspection robot sensor array in accordance with an embodiment of the present invention;
FIG. 16 is a schematic illustration of an alternative robotic rough detection area according to an embodiment of the invention;
FIG. 17 is a schematic view of an alternative robotic fine inspection area in accordance with an embodiment of the invention;
FIG. 18 is a schematic view of an alternative robotic fine detection area according to an embodiment of the invention;
FIG. 19 is a flowchart of an alternative track-type magnetoacoustic composite detection method according to an embodiment of the present invention;
FIG. 20 is a flowchart of an alternative track-type magnetoacoustic composite detection method according to an embodiment of the present invention;
FIG. 21 is a flowchart of an alternative track-type magnetoacoustic composite detection method according to an embodiment of the present invention;
FIG. 22 is a flow chart of a preferred track-type magnetoacoustic composite sensing method in accordance with an embodiment of the present invention; and
FIG. 23 is a schematic diagram of a crawler-type magnetoacoustic composite detection device according to an embodiment of the present invention.
Detailed Description
In order that those skilled in the art will better understand the present invention, a technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in which it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present invention without making any inventive effort, shall fall within the scope of the present invention.
It should be noted that the terms "first," "second," and the like in the description and the claims of the present invention and the above figures are used for distinguishing between similar objects and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used may be interchanged where appropriate such that the embodiments of the invention described herein may be implemented in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
Example 1
According to an embodiment of the present invention, there is provided a crawler-type magnetoacoustic composite inspection robot, and fig. 1 is a schematic diagram of an alternative crawler-type magnetoacoustic composite inspection robot according to an embodiment of the present invention, as shown in fig. 1, the crawler-type magnetoacoustic composite inspection robot includes: a control unit 3 and at least one track 5.
The control unit 3 is used for communicating with external equipment and controlling the mechanical part of the detection robot and the detection system of the detection robot according to an instruction issued by the external equipment;
at least one crawler belt 5 is connected with the control unit and is used for detecting the detected area, and the detection at least comprises any one of the following steps: electromagnetic ultrasonic guided wave scanning imaging, electromagnetic ultrasonic guided wave tomography, electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection;
wherein, every track is formed by a plurality of sensor track units 2 connection, and sensor track unit 2 includes: a magnetic flux leakage detection unit, and/or at least one electromagnetic ultrasonic unit.
As a preferred embodiment, the crawler-type magneto-acoustic composite detection robot adopts the modes of primary detection, fine detection and fine detection, firstly carries out large-area rapid imaging (electromagnetic ultrasonic guided wave scanning imaging) coarse detection on a detected area, moves to the area after the primary detection obtains one or more areas with defects on the detected area, carries out small-area tomography (electromagnetic ultrasonic guided wave tomography) fine detection on the area, and further determines the size, the position and the type of the defects through electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection after the area where the defects are located is further fine detected.
Alternatively, the leakage magnetic detection unit may be a magnetic sensor.
In an alternative embodiment, FIG. 2 (a) is a front view of an alternative tracked magnetoacoustic composite inspection robot according to an embodiment of the present application; as shown in fig. 2 (a), the track 5 may include a driving wheel 1, a driven wheel 4, a plurality of sensor track units 2, a control unit 3, a wire connection unit seat 7, and a dynamic wire connection unit 8. Fig. 2 (b) is a right side view of an alternative crawler magnetoacoustic composite inspection robot according to an embodiment of the present application, and as shown in fig. 2 (b), the crawler magnetoacoustic composite inspection robot provided in the embodiment of the present application may include n (n is greater than or equal to 1) tracks (tracks 5-1, tracks 5-2, … tracks 5-n), where the tracks are connected by a rotational connection unit 6, and each track is formed by connecting a plurality of sensor track units 2.
It should be noted that, the sensor track unit 2 is used as a part of the track and is an important component for completing detection, the internal structure of the sensor track unit 2 mainly comprises an electromagnetic ultrasonic unit and a magnetic leakage detection unit, and the sensor track unit 2 can generate ultrasonic waves through the electromagnetic ultrasonic unit for thickness measurement and excitation of ultrasonic guided waves to detect surface defects; the surface defect or crack is judged to be an upper surface defect or a lower surface defect by receiving the leakage magnetic signal of the leakage magnetic by a leakage magnetic detection unit (for example, a magnetic sensor).
It should be further noted that, the single sensor track unit is a set of independent systems, so that multiple tracks can be connected in parallel for adapting to curved surfaces and controlling steering, and fig. 3 is an optional curved wall plate adaptive schematic diagram according to an embodiment of the present application; as shown in fig. 3, the track-type magnetoacoustic composite inspection robot includes n tracks (tracks 5-1, 5-2, 5-3, … tracks 5-n), and the steering of the tracks is controlled by differential rotation between the different tracks. The multiple tracks are connected through the track connecting unit 6, and the track connecting unit can rotate around the point O due to the magnetism of the track, so that the whole robot can adapt to surfaces with different curvatures, and can be well adsorbed on the wall surface, and meanwhile, the sensor can well contact with the surface 14 to be detected (curved wall surface) to achieve a good detection state, so that the wall climbing robot formed by connecting the multiple tracks in parallel can greatly improve the detection efficiency while adapting to the curved surface.
It can be seen from the above that, in the above embodiment of the present application, the overall design concept of the robot and the detection system is adopted, the sensor and the moving component (for example, the wall climbing mechanism) are integrated, the overall volume is reduced, the sensor and the detected wall are in rolling friction type, the abrasion caused by the contact or collision between the fixed scanning probe and the wall is avoided, and the defect that the fixed scanning probe is difficult to cross the welding seam is avoided. In addition, sensors on the track form an array, so that ultrasonic guided wave large-area imaging, ultrasonic guided wave tomography, ultrasonic scanning thickness measurement, magnetic leakage scanning detection and surface wave scanning detection can be realized, and the problems of low detection efficiency and high cost caused by separate use of various technologies in the existing detection are solved. In the process of detecting the detected area by using the crawler-type magnetoacoustic composite detection robot, the detection precision of the defects is gradually increased by adopting the modes of primary detection, fine detection and fine detection, and finally the positions, the sizes and the types of the defects are obtained. Based on the crawler-type magnetoacoustic composite detection robot provided by the embodiment, the detection speed is high, and meanwhile, the detection precision is also achieved. The method is a very superior detection method in engineering practical application.
Alternatively, the structure of the sensor track unit 2 may be any one of the following structures: monopolar, bipolar and conducting.
Wherein, in the case that the structure of the sensor track unit is a monopolar structure, the sensor track unit includes: a first electromagnetic ultrasound unit, and/or a magneto-sensitive element.
In the case where the structure of the sensor track unit is a bipolar structure, the sensor track unit includes: the electromagnetic ultrasonic device comprises a first electromagnetic ultrasonic unit, a second electromagnetic ultrasonic unit and a magneto-sensitive element, wherein the first electromagnetic ultrasonic unit and the second electromagnetic ultrasonic unit are symmetrically positioned on two sides of the magneto-sensitive element.
In an alternative embodiment, the first electromagnetic ultrasonic unit is composed of a first magnet and a first electromagnetic ultrasonic coil, and the second electromagnetic ultrasonic unit is composed of a second magnet and a second electromagnetic ultrasonic coil.
In the case where the structure of the sensor track unit is a conduction type structure, the sensor track unit includes: the magnetic induction device comprises a U-shaped magnet, a first electromagnetic ultrasonic coil, a second electromagnetic ultrasonic coil and a magnetic sensor, wherein the first electromagnetic ultrasonic coil is positioned below the N pole of the U-shaped magnet, and the second electromagnetic ultrasonic coil is positioned below the S pole of the U-shaped magnet.
Optionally, the shapes of the first electromagnetic ultrasonic coil and the second electromagnetic ultrasonic coil are any one of the following: spiral, reverse-turn, and racetrack.
As an alternative embodiment, fig. 4 is a schematic structural diagram of an alternative monopole type sensor track unit according to an embodiment of the present invention, and as shown in fig. 4, the monopole type sensor track unit mainly includes a housing 10, a coil 9, a magnet 11, a magneto-sensitive element 13, and a dynamic binding post 12, where the bottom of the monopole type sensor track unit contacts a measured component 14. In the monopole sensor caterpillar unit, a coil 9 and a magnet 11 form an electromagnetic ultrasonic unit, the electromagnetic ultrasonic unit is placed at one side of a magnetic sensor 1, the electromagnetic ultrasonic unit can be excited to generate and acquire ultrasonic signals when excited externally to measure the thickness of a measured part, the magnetic sensor 1 is used for receiving magnetic leakage signals and judging the surface cracks of the measured part, the wiring of the coil 9 and the magnetic sensor 1 is connected to a dynamic connecting column 12, and when a chain rotates, the dynamic connecting column 12 can be contacted with a dynamic contact unit 8 so that the sensor caterpillar unit is connected to a control unit 3 to be excited and acquire signals, and the magnetic sensor 13 is an optional part, if the magnetic sensor is not used, only ultrasonic related detection is completed.
The coil 9 may be a coil of various forms, for example, a spiral shape, a reverse-turn shape, a racetrack shape, etc. The coil 9 can cooperate with the magnet 11 to generate and acquire an ultrasonic signal, as shown in fig. 5, which is a schematic diagram of a coil of helical coil configuration.
In the process of detecting the region to be detected by the crawler-type magnetoacoustic composite detection robot, only the lower crawler of the robot is in contact with the wall surface, and the plurality of sensor crawler units in contact with the wall surface are continuously changed due to the movement of the crawler, so that the sensor crawler units are connected with the control unit 3 through the dynamic contact unit 8, and the plurality of sensor crawler units on the lower surface of the detection are connected with the dynamic contact unit to complete the detection.
As an alternative implementation manner, fig. 6 is a schematic structural diagram of an alternative bipolar sensor track unit according to an embodiment of the present invention, as shown in fig. 6, where identical coils 9 and magnets 11 are symmetrically disposed on two sides of a magnetic sensor in the bipolar sensor track unit, and is characterized in that by adjusting an excitation frequency of one of the coils, an ultrasonic guided wave signal is generated, and the ultrasonic guided wave propagates along a surface of a detected component, and the guided wave signal can be received by the identical coils and is symmetrically disposed to detect whether a defect exists on the surface of the side of the detected component, and since the guided wave can only complete initial detection of the defect, the magnetic leakage signal received by the magnetic sensor 13 determines whether the defect is a defect on the side of the detected component sensor or an opposite side, and therefore, combining the guided wave signal and the magnetic leakage signal can determine the surface defect more accurately, and distinguish whether the defect is the side of the detected component sensor or the opposite side. Simultaneously, the excitation frequency is adjusted, and two electromagnetic ultrasonic units consisting of two coils and two magnets can independently generate and receive ultrasonic body wave signals so as to measure the wall thickness.
As an alternative implementation, fig. 7 is a schematic structural diagram of an alternative conductive sensor track unit according to an embodiment of the present invention, and as shown in fig. 7, the conductive sensor track unit is different from the bipolar sensor track unit in that two magnets 9 on two sides of the magneto-sensitive element 13 are replaced by a U-shaped magnet 15 integrally, which has the same function as the bipolar sensor track unit, and is characterized in that the magnetic field strength of the U-shaped magnet 15 is larger than that of the columnar magnet 9, and the sensor track unit with such a structure can be adopted when the magnetism of the detected part is relatively weak.
In an alternative embodiment, fig. 8 is a schematic diagram of a control system of an alternative crawler magnetoacoustic composite inspection robot according to an embodiment of the present invention, as shown in fig. 8, the control unit 3 may include: a main controller 31, a signal generator 32, a power amplifier 33, a multi-channel switch 34, an ultrasonic signal amplifier 35, a magnetic flux leakage signal amplifier 36, a multi-channel data collector 37 and a motion control unit 38.
The main controller 31 is configured to communicate with an external device, and receive a detection instruction issued by the external device; a signal generator 32 for generating an excitation signal for exciting the sensor track unit to generate any one of the following signals: ultrasonic signals, ultrasonic guided wave signals, surface wave signals; a power amplifier 33 connected to the signal generator for amplifying the excitation signal from the signal generator; a multi-channel change-over switch 34 connected with the sensor track units on the track for receiving ultrasonic signals from the sensor track units and/or magnetic leakage signals; an ultrasonic signal amplifier 35 connected to the multi-channel switch for amplifying the ultrasonic signal from the multi-channel switch; a magnetic leakage signal amplifier 36 connected to the multi-channel switch for amplifying the magnetic leakage signal from the multi-channel switch; a multi-channel data collector 37 connected to the ultrasonic signal amplifier and the magnetic leakage signal amplifier for receiving signals from the ultrasonic signal amplifier and the magnetic leakage signal amplifier; a motion control unit 38 for controlling mechanical motion of the robot, comprising: a motor 38a and a position sensor 38b.
Alternatively, the power amplifier 33 may be a broadband power amplifier.
It should be noted that, the control unit 3 may complete control of the wall climbing mechanical portion of the whole robot, control of the detection system, and communication with the external device 30 (e.g., a computer), and information interaction between the computer 30 and the communication transmission control unit 39, mainly complete setting of a detection command and a detection parameter given to the wall climbing robot, and return a detection result. The main controller is used for completing the control of the wall climbing robot according to the information received by the communication transmission unit, and comprises a step of controlling the multichannel change-over switch to be switched to one or more specified sensor track units, a step of controlling the signal generator to generate specified excitation waveform signals, a step of amplifying the generated specified excitation waveform signals by the broadband power amplifier, a step of exciting the specified one or more sensor track units through the multichannel change-over switch, a step of amplifying ultrasonic signals after the one or more sensor track units pass through the multichannel change-over switch, a step of collecting the ultrasonic signals after the ultrasonic signals enter the ultrasonic signal amplifier, a step of collecting the ultrasonic signals through the multichannel data collector, a step of amplifying magnetic leakage signals after the magnetic leakage signals enter the magnetic leakage signal amplifier, a step of collecting the magnetic leakage signals through the multichannel data collector, a step of finally transmitting data to the main controller for processing, a step of transmitting the latest result to a computer through the communication transmission unit, a step of controlling mechanical parts of the wall climbing robot by the main controller, a step of controlling the rotation of a motor, a step of controlling the motor, a step of completing the movement of the wall climbing robot.
In an alternative embodiment, taking a robot with two tracks as an example, fig. 9 is a schematic diagram of an alternative three-dimensional track type magnetoacoustic composite detection robot according to an embodiment of the present invention, as shown in fig. 9, each track of the track type magnetoacoustic composite detection robot has a driving wheel and a driven wheel, the two tracks rotate at the same speed to enable the robot to advance or retract, and differential rotation of the two tracks can enable the robot to steer. Each caterpillar comprises 9 dynamic contact units, each two caterpillar comprises 18 dynamic contact units which are respectively contacted with 18 sensor caterpillar units, in the embodiment column, each dynamic contact unit is designed into a sheet metal structure, the dynamic contact unit can move up and down, and when a robot moves even if encountering an uneven area, the robot can be guaranteed to be in good contact with the sensor caterpillar units, and the normal detection function of the robot is guaranteed.
Preferably, the sensor track unit is designed to adopt a U-shaped magnetic yoke type sensor, fig. 10 is a schematic diagram showing an alternative sensor track unit disassembled according to an embodiment of the present invention, as shown in fig. 10, a shell of the sensor track unit 2 is provided with double teeth so as to be well meshed with a driving wheel and a driven wheel, the shell 10 further comprises a strip-shaped dynamic binding post, so that the robot can well connect an electric circuit of the sensor when moving, and the robot can realize a moving function, and the sensor track unit comprises a U-shaped magnet 15, two coils 9 and a magnetic sensor element 13 (which can be a hall element). Thus, the thickness can be measured under the external excitation, and the guided wave and the magnetic leakage can be detected.
According to the embodiment of the invention, the detection equipment is also provided, and the detection equipment comprises the optional or preferable crawler-type magnetoacoustic composite detection robot.
Example 2
In accordance with an embodiment of the present invention, there is provided a track-type magnetoacoustic composite detection method embodiment, it being noted that the steps illustrated in the flowchart of the figures may be performed in a computer system, such as a set of computer-executable instructions, and that, although a logical sequence is illustrated in the flowchart, in some cases, the steps illustrated or described may be performed in a different order than that illustrated herein.
FIG. 11 is a flowchart of a crawler-type magnetoacoustic composite detection method according to an embodiment of the present invention, as shown in FIG. 1, the method includes the steps of:
step S102, scanning and imaging a detected area by a detection robot, and determining one or more first defect areas with defects on the detected area according to imaging results, wherein the detection robot comprises at least one crawler, each crawler is formed by connecting at least one sensor crawler unit, and the sensor crawler unit comprises: a magnetic flux leakage detection unit, and/or at least one electromagnetic ultrasonic unit.
Specifically, in the above step, the detection robot may include at least one track, each track being formed by connecting at least one sensor track unit, wherein each sensor track unit includes at least one electromagnetic ultrasonic unit, and preferably, may further include a magnetic flux leakage detection unit. A portion to be detected (for example, an outer wall surface of a large-scale petroleum storage tank) on the object to be detected (for example, a steel plate, a storage tank, a pipeline, etc.) in the detected region; if the detected area is the outer wall surface of the large-scale petroleum storage tank, the detection robot can be used for climbing the wall, and the crawler belt of the detection robot is prevented from contacting with the wall in the process of climbing the wall. The first defect area may be one or more areas with defects found on the detected area after the detected area is initially detected, and after the detected area is initially detected, the areas with defects on the detected area may be further detected after the approximate distribution condition of the defect distribution is obtained.
In an alternative embodiment, fig. 12 is a schematic diagram of an alternative crawler-type magnetoacoustic composite inspection robot according to an embodiment of the present invention, where the inspection robot (wall climbing robot) first performs rapid crawling on an area to be inspected (for example, a wall panel area of a large-scale petroleum storage tank), and a large-area rapid imaging rough inspection method is adopted to obtain rough defect conditions of the entire area, and perform preliminary positioning and size assessment on the defect conditions of the entire wall panel area.
It should be noted that, in this embodiment, based on the overall design concept of the robot and the detection system, the sensor for detecting the detected area is integrated with the moving part of the robot, and the detection robot in the above step generally includes multiple tracks, and each track is formed by connecting multiple sensor track units. Because the detection robot is always contacted with the detected area in the moving (e.g. crawling or sliding) process, the sensor for detecting the detected area is used as a unit component for forming the crawler, and the sensor and the detected wall are in rolling friction type, so that the abrasion caused by the contact or collision between the fixed scanning probe and the wall is avoided, and the defects that the fixed scanning probe is difficult to cross a welding line and the like are avoided.
Preferably, the inspection robot in the implementation of the present application may be a crawler-type magnetoacoustic composite inspection robot in embodiment 1.
Step S104, performing tomography on the first defect area through at least one crawler belt, and determining a second defect area of the defect according to an imaging result, wherein the second defect area is an area with the defect in the first defect area.
Specifically, in the above step, the first defect area may be one or more areas where a defect exists on the detected area after the detected area is primarily detected (coarse detection), the defective areas on the detected area may be further detected, the second defect area is a defect area obtained by further detecting (fine detection by tomography) the first defect area after the detection robot moves to the first defect area, and the second defect area is one or more areas in the first defect area. Specifically, the crawler-type magnetoacoustic composite inspection robot can be controlled to move (e.g., slide or crawl) to a defect area with a defect on a detected area, perform tomography between the crawlers thereof, and further determine the position and size of the defect according to the image of the defect area.
In an alternative embodiment, FIG. 13 is a schematic illustration of an alternative tracked magnetoacoustic composite inspection robot in accordance with an embodiment of the present invention. After the large-area rapid imaging coarse inspection of the detected area, the defective areas (i.e., the first defective areas) on the detected area can be further detected, and the first defective areas can be subjected to tomography through the crawler of the robot.
Step S106, detecting the second defect area through the sensor track unit, wherein the detection at least comprises any one of the following steps: electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection.
Specifically, in the step, the second defect area is a defect area obtained by further detecting (fine detection by tomography) the first defect area after the detection robot moves to the first defect area, and the second defect area is smaller than the first defect area. After the detected area is finely detected, electromagnetic ultrasonic detection can be performed on the second defect area through an electromagnetic ultrasonic unit in a sensor track unit on the track of the crawler-type magnetoacoustic composite detection robot, or magnetic leakage detection can be performed on the second defect area through a magnetic leakage detection unit in the sensor track unit.
In an alternative embodiment, FIG. 14 is a schematic illustration of an alternative tracked magnetoacoustic composite inspection robot fine scan in accordance with an embodiment of the present invention. After the second defect area is determined, final fine defect detection is carried out on the defects of the areas, and electromagnetic ultrasonic thickness measurement, guided wave and magnetic leakage detection are carried out on the areas step by step to detect the crack condition.
As a preferred embodiment, the crawler-type magnetoacoustic composite inspection robot may include n tracks, each of which is formed by connecting m sensor track units. FIG. 15 is a schematic view of an alternative track-mounted magnetoacoustic composite inspection robot sensor array according to an embodiment of the present invention, wherein a plurality of sensor track units of the track-mounted magnetoacoustic composite inspection robot, as shown in FIG. 15, may form a sensor array, n tracks form n sensor linear arrays, each sensor linear array comprising m array elements (sensor track units 2-1, 2-2, … -m), so that according to acoustic theory, it may implement large-area fast imaging coarse inspection of a wide surrounding area of the robot, and FIG. 16 is a schematic view of an alternative robot coarse inspection area according to an embodiment of the present invention; FIG. 17 is a schematic view of an alternative robotic fine inspection area according to an embodiment of the invention; fig. 18 is a schematic diagram of an alternative robot refinement detection zone according to an embodiment of the present invention.
The large-area rapid imaging coarse detection is characterized by high speed and large detection area, but only coarse judgment of the positioning and the size of the coarse cloth can be carried out on the defects; the detection precision of the small-area tomography fine detection is further improved compared with that of the large-area rapid imaging coarse detection, the imaging area is in the bottom range of the wall climbing robot, the whole wallboard area is scanned, more time is consumed than that of the large-area rapid imaging coarse detection, and the detection can be used for further and more definite judgment of defects; the magnetic leakage and thickness measurement fine scanning has high detection precision, can accurately measure the crack and the corrosion wall thickness, and can take the longest time if the magnetic leakage and thickness measurement fine scanning is used for scanning the whole wallboard area. It can be seen that, in the above embodiment of the present application, in order to ensure the detection accuracy and achieve the efficient effect of detection, the crawler-type magnetoacoustic composite detection robot first performs large-area rapid imaging coarse detection on the detected area in a manner of combining primary detection, fine detection and fine detection, moves to the detected area after the primary detection obtains one or more areas (i.e., the first defect areas) with defects on the detected area, performs small-area tomography fine detection on the detected area, further determines the position and size of the defects, obtains the second defect area of the defects, and finally further determines the size, position and type of the defects through electromagnetic ultrasonic and magnetic leakage detection.
Through the technical scheme disclosed by the embodiment, the comprehensive detection modes of ultrasonic guided wave large-area imaging, ultrasonic guided wave tomography, ultrasonic scanning thickness measurement, magnetic leakage scanning detection and surface wave scanning detection are achieved, the technical effect of improving the detection speed while ensuring the detection precision is achieved, and the technical problems that the detection efficiency is low and the cost is high due to the fact that a detection robot in the existing nondestructive detection is separated and used by adopting various technologies in the existing nondestructive detection are solved.
In an alternative embodiment, as shown in fig. 19, the tracked magnetoacoustic composite inspection robot may include n tracks, each of which is formed by connecting m sensor track units. Forming an array of n multiplied by m array elements on a detected object, wherein the whole scanning imaging is carried out on a detected area by a crawler-type magnetoacoustic composite detection robot, one or more first defect areas with defects on the detected area are determined according to imaging results, and the method comprises the following steps:
step S902, generating ultrasonic signals by detecting any i array elements on the robot, wherein i is more than or equal to 1 and less than or equal to m is more than or equal to n, and m and n are positive integers more than or equal to 1;
step S904, receiving echo signals returned by the detected region to the ultrasonic signals through any j array elements on the detection robot, wherein j is more than or equal to 1 and less than or equal to m is more than or equal to n, and m and n are positive integers which are more than or equal to 1;
Step S906, determining the amplitude information of each pixel point in the image of the detected area according to the echo signals;
step S908, determining an image of the detected area according to the amplitude information, and determining one or more first defect areas with defects on the detected area according to the image of the detected area.
Specifically, in the above steps, the robot has n (n is greater than or equal to 1) tracks, each track and the detected surface have m (m is greater than or equal to 1) sensor track units, namely an n×m array element array is formed, and when the detected area is imaged, the excitation and receiving sequence of each array element in the n×m array element array is as follows:
(1) among n×m array elements, i (1 < i < m×n) array elements are excited, and any j (1 < j < m×n) array elements in n×m array elements are received; the i array elements are excited again, and any j (1 < j < m x n) array elements are received, and the operation is repeated until all n×m array elements are appointed to receive signals under the excitation of the i array elements.
(2) Reassigning other array elements in (1) as i (1 < i < m x n) array elements in (1), and repeating the step (1);
(3) until the expected multiple array elements k (1 < k < m x n) are obtained, the appointed array elements receive echo signals.
(4) And (3) imaging technology is carried out through all acquired echo signals, so that the rough position and rough size of the defect are obtained.
Through the embodiment, the rough detection of the detected area is realized, so that one or more areas with defects on the detected area are determined, and the detection range is reduced.
In an alternative embodiment, as shown in fig. 20, determining the amplitude of each pixel point in the image of the measured area according to the echo signal includes:
step S9061, receiving echo signals returned by the detected area to the ultrasonic signals according to the ultrasonic signals generated by each sensor track unit in the array and all the sensor tracks in the array, and obtaining N multiplied by N full matrix data;
step S9063, any coordinate point in the image of the detected area is obtained, and a plurality of amplitudes of all echo signals at the coordinate point are solved by utilizing full matrix data;
in step S9065, the plurality of magnitudes are summed, and the summed total magnitude is used as the magnitude of the coordinate point.
Specifically, in the above steps, each sensor of the array sensor is sequentially activated, and all sensors are controlled to receive after each activation, so as to obtain n×n full matrix data, where N is the number of array elements of the sensor array. On the basis of the full matrix data, the detected area is imaged by using a full focus imaging method (TFM, total Focus Method) to judge the position of the defect. The full focusing method is as follows:
For any point (x, z) of the imaging detection area, full matrix data P is utilized ij (i=1, 2, …, N; j=1, 2, …, N), solving the signal amplitude of all ultrasonic echo signals at the point according to the wave path relation from each array element to the point, and superposing the amplitudes to obtain the amplitude I (x, z) representing the information of the point. Repeating the above steps to obtain the final productAnd (3) obtaining a full-focus image by detecting the amplitude information of all pixel points in the area and restoring the amplitude information of each point to the whole detection area.
The amplitude I (x, z) of a particular focus point (x, z) can be expressed as:
wherein P is ij (t ij (x, z)) represents the amplitude at coordinate point (x, z) of a set of ultrasonic detection signals transmitted by the ith element and received by the jth element. t is t ij (x, z) is the delay time for extracting the amplitude of the focal point calculated by the law of focusing, which time includes the total time of the travel of the acoustic wave from the transmitting element i to the focal point (x, z) and from the focal point back to the receiving element j, and can be calculated by the following equation:
wherein x is t 、x r Respectively representing the abscissa of the transmitting array element and the receiving array element; c (C) L Is the velocity of sound of the longitudinal wave in the test block.
Through the embodiment, the aim of imaging the large area of the tested area and determining the defects on the tested area according to the imaging result is fulfilled.
In an alternative embodiment, as shown in fig. 21, the step of performing tomography on the first defect area by at least one crawler, and determining the position and size of the defect according to the imaging result may include the following steps:
step S112, controlling the detection robot to move to a first defect area;
step S114, forming a sensor array between the crawler of the inspection robot and the crawler, and performing tomographic imaging of the first defect region at the bottom of the inspection robot.
Specifically, in the above steps, after the large-area rapid imaging coarse inspection of the region to be detected, these defective regions (i.e., the first defective regions) on the region to be detected may be further detected, and the first defective regions may be tomographic imaged through the crawler of the robot.
Through the embodiment, the purpose of carrying out small-area tomography on the defect area on the detected area and further determining the position and the size of the defect according to the imaging result is realized.
Optionally, the structure of the sensor track unit is any one of the following structures: monopolar, bipolar and conducting.
In an alternative embodiment, in case the sensor track unit is of a monopolar structure, the sensor track unit comprises: a magnet and electromagnetic ultrasonic coil for detecting a second defect region through a sensor track unit, comprising:
In step S1061a, an ultrasonic signal is generated by the electromagnetic ultrasonic coil and the magnet, and an electromagnetic ultrasonic detection is performed on the defective region.
In another alternative embodiment, in the case that the sensor track unit is of a monopolar structure, the sensor track unit includes: magnet, electromagnetic ultrasonic coil and magnetosensitive element, detect the second defect area through the sensor track unit, include:
step S1061b, generating ultrasonic signals through a magnet and an electromagnetic ultrasonic coil, and performing electromagnetic ultrasonic detection on the second defect area;
in step S1063b, the second defect region is detected for magnetic leakage by detecting whether the magnetic leakage signal exists outside the magnetic sensor detection region.
Wherein, before the ultrasonic signal is generated by the electromagnetic ultrasonic coil and the magnet, an excitation signal for generating the ultrasonic signal can be also acquired and input to the electromagnetic ultrasonic coil.
In an alternative embodiment, in case the sensor track unit is of a bipolar structure, the sensor track unit comprises: the magnet and the electromagnetic ultrasonic coil of magnetic sensing element, the bilateral symmetry placed at the magnetic sensing element, wherein, detect the second defective area through the sensor track unit, include:
Step S1061c, generating ultrasonic signals through the magnet and the electromagnetic ultrasonic coil on any side of the magneto-sensitive element, and performing electromagnetic ultrasonic detection on the second defect area;
step S1063c, generating ultrasonic signals through the magnet and the electromagnetic ultrasonic coil on any side of the magneto-sensitive element, receiving the ultrasonic signals through the electromagnetic ultrasonic coil on the other side, and detecting electromagnetic ultrasonic guided waves of the second defect area;
in step S1065c, the magnetic sensor detects whether a leakage magnetic field signal exists outside the second defect area, and performs leakage magnetic detection on the second defect area.
Before the ultrasonic signal is generated by the magnet and the electromagnetic ultrasonic coil on any side of the magneto-sensitive element, an excitation signal for generating the ultrasonic signal can be acquired and input to the electromagnetic ultrasonic coil.
The electromagnetic ultrasonic coil and the magnet can be excited to generate signals such as ultrasonic waves, ultrasonic guided waves, surface waves and the like by excitation signals with different frequencies.
In an alternative embodiment, in the case that the sensor track unit is of a conductive type structure, the sensor track unit includes: the magnetic sensor, U type magnet and two electromagnetic ultrasonic coils, wherein, detect the second defective area through the sensor track unit, include:
Step S1061d, generating ultrasonic signals through any one magnetic pole of the U-shaped magnet and an electromagnetic ultrasonic coil below the magnetic pole, and performing electromagnetic ultrasonic detection on the second defect area;
step S1063d, generating ultrasonic signals through any one magnetic pole of the U-shaped magnet and an electromagnetic ultrasonic coil below the magnetic pole, receiving the ultrasonic signals through the electromagnetic ultrasonic coil below the other magnetic pole of the U-shaped magnet, and performing electromagnetic ultrasonic guided wave detection on the second defect area;
in step S1065d, the leakage magnetic field signal is detected in the second defect region by the presence or absence of the leakage magnetic field signal outside the detection region of the magnetic sensor.
As a preferred implementation manner, fig. 22 is a flowchart of a preferred crawler-type magnetoacoustic composite detection method according to an embodiment of the present invention, as shown in fig. 22, a wall climbing robot first performs rapid crawling on a wall plate area, and adopts a large-area rapid imaging rough detection method to obtain rough defect conditions of the whole area, and performs preliminary positioning and size assessment on the defect conditions of the whole wall plate area; and under the condition of determining the approximate position and the size of the defect, the wall climbing robot quickly crawls to the areas, and the areas are subjected to tomography, so that the size and the condition of the defect are further and more accurately obtained. And further detecting the final fine defects of the areas under the conditions of positions and sizes of the defects, and gradually detecting the conditions of cracks by performing electromagnetic ultrasonic thickness measurement, guided wave and magnetic leakage on the areas.
Through the embodiment, the detection precision of the defects is gradually increased, and finally the positions, the sizes and the types of the defects are obtained. The method has the advantages that the detection speed is high, and meanwhile, the detection precision is also achieved. The method is a very superior detection method in engineering practical application.
Example 3
According to an embodiment of the present invention, there is further provided an embodiment of a device for implementing the above-mentioned crawler-type magnetoacoustic composite detection method, and a schematic diagram of a crawler-type magnetoacoustic composite detection device according to an embodiment of the present invention shown in fig. 23, where the device includes: a first processing module 231, a second processing module 233, and a first detection module 235.
The first processing module 231 is configured to scan and image a detected area by using a detection robot, and determine, according to an imaging result, one or more first defect areas with defects on the detected area, where the detection robot includes at least one track, and each track is formed by connecting at least one sensor track unit, where the sensor track unit includes: a magnetic flux leakage detection unit, and/or at least one electromagnetic ultrasonic unit; a second processing module 233, configured to perform tomography on the first defect area through at least one crawler, and determine a second defect area of the defect according to the imaging result, where the second defect area is an area where the defect exists in the first defect area; the first detection module 235 is configured to detect the second defect area through the sensor track unit, where the detection includes at least any one of the following: electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection.
It should be noted that the large-area rapid imaging coarse inspection is characterized by high speed and large detection area, but only coarse judgment of the positioning and size of the coarse cloth can be performed on the defects; the detection precision of the small-area tomography fine detection is further improved compared with that of the large-area rapid imaging coarse detection, the imaging area is in the bottom range of the wall climbing robot, the whole wallboard area is scanned, more time is consumed than that of the large-area rapid imaging coarse detection, and the detection can be used for further and more definite judgment of defects; the magnetic leakage and thickness measurement fine scanning has high detection precision, can accurately measure the crack and the corrosion wall thickness, and can take the longest time if the magnetic leakage and thickness measurement fine scanning is used for scanning the whole wallboard area. In the above embodiment of the present application, in order to ensure the detection accuracy and achieve the high-efficiency effect of detection, a mode of combining primary detection, fine detection and fine detection is adopted, the detection robot first performs large-area rapid imaging coarse detection on the detected area, after one or more areas (i.e., first defect areas) with defects on the detected area are obtained through the primary detection, the detected area is moved to the area, small-area tomography fine detection is performed on the area, after the position and the size of the defects are further determined, a second defect area of the defects is obtained, and finally the size, the position and the type of the defects are further determined through electromagnetic ultrasonic and magnetic leakage detection.
Through the technical scheme disclosed by the embodiment, the comprehensive detection modes of ultrasonic guided wave large-area imaging, ultrasonic guided wave tomography, ultrasonic scanning thickness measurement, magnetic leakage scanning detection and surface wave scanning detection are achieved, the technical effect of improving the detection speed while ensuring the detection precision is achieved, and the technical problems of low detection efficiency and high cost caused by separating and using various technologies in the existing nondestructive detection are solved.
Preferably, the inspection robot in the implementation of the present application may be a crawler-type magnetoacoustic composite inspection robot in embodiment 1.
In an alternative embodiment, the tracked magnetoacoustic composite inspection robot includes n tracks, each track includes m sensor track units, and an array of n×m array elements is formed on the inspected object, where the first processing module 231 may include: the generation module is used for generating ultrasonic signals by detecting any i array elements on the robot, wherein i is more than or equal to 1 and less than or equal to m is more than or equal to n, and m and n are positive integers which are more than or equal to 1; the first receiving module is used for receiving echo signals returned by the ultrasonic signals of the detected region through any j array elements on the detecting robot, wherein j is more than or equal to 1 and less than or equal to m is more than or equal to n, and m and n are positive integers which are more than or equal to 1; the first determining module is used for determining the amplitude information of each pixel point in the image of the measured area according to the echo signals; and the second determining module is used for determining an image of the detected area according to the amplitude information and determining one or more first defect areas with defects on the detected area according to the image of the detected area.
In an alternative embodiment, the first determining module may include: the second receiving module is used for receiving echo signals returned by the detected area to the ultrasonic signals according to the ultrasonic signals generated by each sensor track unit in the array and all the sensor tracks in the array to obtain N multiplied by N full matrix data; the third processing module is used for acquiring any coordinate point in the image of the detected area and solving a plurality of amplitudes of all echo signals at the coordinate point by utilizing the full matrix data; and the fourth processing module is used for summing the plurality of amplitude values, and taking the summed total amplitude value as the amplitude value of the coordinate point.
In an alternative embodiment, the second processing module 233 may include: the control module is used for controlling the detection robot to move to the first defect area; and a fifth processing module for forming a sensor array between the tracks of the inspection robot and performing tomographic imaging of the first defect region at the bottom of the inspection robot.
In an alternative embodiment, the structure of the sensor track unit is any one of the following structures: monopolar, bipolar and conducting.
In an alternative embodiment, in case the sensor track unit is of a monopolar structure, the sensor track unit comprises: a magnet and an electromagnetic ultrasonic coil, the first detection module 235 may include: and the second detection module is used for generating ultrasonic signals through the electromagnetic ultrasonic coil and the magnet and carrying out electromagnetic ultrasonic detection on the defective area.
In an alternative embodiment, in case the sensor track unit is of a monopolar structure, the sensor track unit comprises: the first detection module 235 may include: the third detection module is used for generating ultrasonic signals through the magnet and the electromagnetic ultrasonic coil and carrying out electromagnetic ultrasonic detection on the second defect area; and the fourth detection module is used for detecting whether a leakage magnetic field signal exists outside the detection area of the magnetic sensitive element and detecting the leakage magnetic field of the second defect area.
In an alternative embodiment, the apparatus further comprises, prior to generating the ultrasonic signal by the electromagnetic ultrasonic coil and the magnet: an acquisition module for acquiring an excitation signal for generating an ultrasonic signal; and the input module is used for inputting the excitation signal to the electromagnetic ultrasonic coil.
In an alternative embodiment, in case the sensor track unit is of a bipolar structure, the sensor track unit comprises: the magnetic sensor, the magnets and the electromagnetic ultrasonic coils symmetrically disposed on two sides of the magnetic sensor, wherein the first detection module 235 may include: the fifth detection module is used for generating ultrasonic signals through the magnet and the electromagnetic ultrasonic coil at any side of the magnetic sensor and carrying out electromagnetic ultrasonic detection on the second defect area; the sixth detection module is used for generating ultrasonic signals through the magnet and the electromagnetic ultrasonic coil on any side of the magneto-sensitive element, receiving the ultrasonic signals through the electromagnetic ultrasonic coil on the other side, and detecting electromagnetic ultrasonic guided waves of the second defect area; and the seventh detection module is used for detecting whether a magnetic leakage signal exists outside the second defect area through the magnetic sensor, and detecting the magnetic leakage of the second defect area.
In an alternative embodiment, in the case that the sensor track unit is of a conductive type structure, the sensor track unit includes: the magnetic sensor, the U-shaped magnet and the two electromagnetic ultrasonic coils, wherein the first detection module 235 may include: the eighth detection module is used for generating ultrasonic signals through any one magnetic pole of the U-shaped magnet and an electromagnetic ultrasonic coil below the magnetic pole and carrying out electromagnetic ultrasonic detection on the second defect area; the ninth detection module is used for generating ultrasonic signals through any one magnetic pole of the U-shaped magnet and an electromagnetic ultrasonic coil below the magnetic pole, receiving the ultrasonic signals through the electromagnetic ultrasonic coil below the other magnetic pole of the U-shaped magnet, and carrying out electromagnetic ultrasonic guided wave detection on the second defect area; and the tenth detection module is used for detecting whether a leakage magnetic field signal exists outside the detection area of the magnetic sensitive element and detecting the leakage magnetic field of the second defect area.
The foregoing embodiment numbers of the present invention are merely for the purpose of description, and do not represent the advantages or disadvantages of the embodiments.
In the foregoing embodiments of the present invention, the descriptions of the embodiments are emphasized, and for a portion of this disclosure that is not described in detail in this embodiment, reference is made to the related descriptions of other embodiments.
In the several embodiments provided in the present application, it should be understood that the disclosed technology may be implemented in other manners. The above-described embodiments of the apparatus are merely exemplary, and the division of the units, for example, may be a logic function division, and may be implemented in another manner, for example, a plurality of units or components may be combined or may be integrated into another system, or some features may be omitted, or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be through some interfaces, units or modules, or may be in electrical or other forms.
The units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.
In addition, each functional unit in the embodiments of the present application may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit. The integrated units may be implemented in hardware or in software functional units.
The integrated units, if implemented in the form of software functional units and sold or used as stand-alone products, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present invention may be embodied essentially or in part or all of the technical solution or in part in the form of a software product stored in a storage medium, including instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the method according to the embodiments of the present invention. And the aforementioned storage medium includes: a U-disk, a Read-Only Memory (ROM), a random access Memory (RAM, random Access Memory), a removable hard disk, a magnetic disk, or an optical disk, or other various media capable of storing program codes.
The foregoing is merely a preferred embodiment of the present invention and it should be noted that modifications and adaptations to those skilled in the art may be made without departing from the principles of the present invention, which are intended to be comprehended within the scope of the present invention.

Claims (16)

1. Crawler-type magnetoacoustic composite detection robot, characterized by comprising:
the control unit is used for communicating with external equipment and controlling the mechanical part of the detection robot and the detection system of the detection robot according to the instruction issued by the external equipment;
the at least one crawler belt is connected with the control unit and used for detecting a detected area, and the detection at least comprises any one of the following steps: electromagnetic ultrasonic guided wave scanning imaging, electromagnetic ultrasonic guided wave tomography, electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection;
wherein, every track is formed by a plurality of sensor track units connection, sensor track unit includes: a magnetic flux leakage detection unit, and/or at least one electromagnetic ultrasonic unit; the magnetic leakage detection unit is a magnetic sensor;
the structure of the sensor track unit is any one of the following structures: monopolar, bipolar and conducting;
in the case where the structure of the sensor track unit is a monopolar structure, the sensor track unit includes: a first electromagnetic ultrasound unit, and/or a magneto-sensitive element;
in the case where the structure of the sensor track unit is a bipolar structure, the sensor track unit includes: the electromagnetic ultrasonic device comprises a first electromagnetic ultrasonic unit, a second electromagnetic ultrasonic unit and a magneto-sensitive element, wherein the first electromagnetic ultrasonic unit and the second electromagnetic ultrasonic unit are symmetrically positioned at two sides of the magneto-sensitive element;
In the case where the structure of the sensor track unit is a conductive structure, the sensor track unit includes: the electromagnetic ultrasonic device comprises a U-shaped magnet, a first electromagnetic ultrasonic coil, a second electromagnetic ultrasonic coil and a magnetic sensor, wherein the first electromagnetic ultrasonic coil is positioned below the N pole of the U-shaped magnet, and the second electromagnetic ultrasonic coil is positioned below the S pole of the U-shaped magnet.
2. The robot of claim 1, wherein the first electromagnetic ultrasonic unit is comprised of a first magnet and a first electromagnetic ultrasonic coil, and the second electromagnetic ultrasonic unit is comprised of a second magnet and a second electromagnetic ultrasonic coil.
3. The robot of claim 1 or 2, wherein the shape of the first electromagnetic ultrasonic coil and the second electromagnetic ultrasonic coil is any one of: spiral, reverse-turn, and racetrack.
4. The robot of claim 1, wherein the control unit comprises:
the main controller is used for communicating with the external equipment and receiving a detection instruction issued by the external equipment; the signal generator is used for generating an excitation signal, wherein the excitation signal is used for exciting the sensor track unit to generate any one of the following signals: ultrasonic signals, ultrasonic guided wave signals, surface wave signals;
A power amplifier connected to the signal generator for amplifying the excitation signal from the signal generator;
the multichannel change-over switch is connected with the sensor track unit on the track and is used for receiving ultrasonic signals and/or magnetic leakage signals from the sensor track unit;
the ultrasonic signal amplifier is connected with the multi-channel change-over switch and used for amplifying ultrasonic signals from the multi-channel change-over switch;
the magnetic leakage signal amplifier is connected with the multi-channel change-over switch and used for amplifying magnetic leakage signals from the multi-channel change-over switch;
the multichannel data acquisition device is connected with the ultrasonic signal amplifier and the magnetic leakage signal amplifier and is used for receiving signals from the ultrasonic signal amplifier and the magnetic leakage signal amplifier;
a motion control unit for controlling mechanical motion of the robot, comprising: a motor and a position sensor.
5. A detection apparatus comprising a tracked magnetoacoustic composite inspection robot according to any one of claims 1 to 4.
6. The crawler-type magnetoacoustic composite detection method is characterized by comprising the following steps of:
scanning and imaging a detected area by a detection robot, and determining one or more first defect areas with defects on the detected area according to imaging results, wherein the detection robot comprises at least one crawler, each crawler is formed by connecting at least one sensor crawler unit, and the sensor crawler unit comprises: a magnetic flux leakage detection unit, and/or at least one electromagnetic ultrasonic unit;
Performing tomography on the first defect area through the at least one crawler belt, and determining a second defect area of the defect according to an imaging result, wherein the second defect area is an area with the defect in the first defect area;
detecting the second defect area through the sensor track unit, wherein the detection at least comprises any one of the following steps: electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection.
7. The method of claim 6, wherein the inspection robot includes n tracks, each track including m sensor track units, forming an array of n x m array elements on the inspected object, wherein the overall scanning imaging of the inspected area by the inspection robot and determining one or more first defect areas on the inspected area where defects exist based on the imaging results, comprises:
generating ultrasonic signals through any i array elements on the detection robot, wherein i is more than or equal to 1 and less than or equal to m is more than or equal to n, and m and n are positive integers which are more than or equal to 1;
receiving echo signals returned by the detected area to the ultrasonic signals through any j array elements on the detection robot, wherein j is more than or equal to 1 and less than or equal to m is more than or equal to n, and m and n are positive integers which are more than or equal to 1;
Determining the amplitude information of each pixel point in the image of the detected area according to the echo signals;
and determining an image of the detected area according to the amplitude information, and determining one or more first defect areas with defects on the detected area according to the image of the detected area.
8. The method of claim 7, wherein determining the amplitude of each pixel in the image of the region under test from the echo signals comprises:
receiving echo signals returned by the detected area to the ultrasonic signals according to the ultrasonic signals generated by each sensor track unit in the array and all the sensor tracks in the array, so as to obtain N multiplied by N full matrix data;
any coordinate point in the image of the measured area is obtained, and a plurality of amplitudes of all echo signals at the coordinate point are solved by utilizing the full matrix data;
and summing the plurality of amplitude values, and taking the summed total amplitude value as the amplitude value of the coordinate point.
9. The method of claim 6, wherein tomography the first defect region through the at least one track and determining the location and size of the defect based on the imaging results comprises:
Controlling the detection robot to move to the first defect area;
and forming a sensor array between the caterpillar bands of the detection robot, and performing tomography on the first defect area at the bottom of the detection robot.
10. The method of claim 6, wherein the sensor track unit is configured as any one of: monopolar, bipolar and conducting.
11. The method of claim 10, wherein, in the case where the sensor track unit is of a monopolar configuration, the sensor track unit comprises: a magnet and an electromagnetic ultrasonic coil for detecting the defective area through the sensor track unit, comprising:
and generating ultrasonic signals through the electromagnetic ultrasonic coil and the magnet, and performing electromagnetic ultrasonic detection on the defective area.
12. The method of claim 10, wherein, in the case where the sensor track unit is of a monopolar configuration, the sensor track unit comprises: magnet, electromagnetic ultrasonic coil and magnetosensitive element, detect through the sensor track unit the second defect area includes:
Generating ultrasonic signals through the magnet and the electromagnetic ultrasonic coil, and performing electromagnetic ultrasonic detection on the second defect area;
and detecting whether a leakage magnetic field signal exists outside the area through the magnetic sensor, and performing leakage magnetic detection on the second defect area.
13. The method of claim 11 or 12, wherein prior to generating an ultrasonic signal with the magnet by the electromagnetic ultrasonic coil, the method further comprises:
acquiring an excitation signal for generating the ultrasonic signal;
the excitation signal is input to the electromagnetic ultrasonic coil.
14. The method of claim 10, wherein in the case where the sensor track unit is of a bipolar configuration, the sensor track unit comprises: the magneto-sensitive element, the magnet and the electromagnetic ultrasonic coil of symmetry place in the both sides of magneto-sensitive element, wherein, through the sensor track unit is to the second defect area detects, includes:
generating ultrasonic signals through the magnet and the electromagnetic ultrasonic coil at any side of the magneto-sensitive element, and performing electromagnetic ultrasonic detection on the second defect area;
Generating ultrasonic signals through a magnet and an electromagnetic ultrasonic coil on any side of the magneto-sensitive element, receiving the ultrasonic signals through an electromagnetic ultrasonic coil on the other side, and detecting electromagnetic ultrasonic guided waves of the second defect area;
and detecting whether a leakage magnetic field signal exists outside the second defect area through the magnetic sensor, and detecting the leakage magnetic field of the second defect area.
15. The method of claim 10, wherein in the case where the sensor track unit is of a conductive type structure, the sensor track unit includes: the magnetic sensor comprises a magnetic sensor element, a U-shaped magnet and two electromagnetic ultrasonic coils, wherein the second defect area is detected through the sensor track unit, and the magnetic sensor comprises:
generating ultrasonic signals through any one magnetic pole of the U-shaped magnet and an electromagnetic ultrasonic coil below the magnetic pole, and performing electromagnetic ultrasonic detection on the second defect area;
generating ultrasonic signals through any one magnetic pole of the U-shaped magnet and an electromagnetic ultrasonic coil below the magnetic pole, receiving the ultrasonic signals through the electromagnetic ultrasonic coil below the other magnetic pole of the U-shaped magnet, and carrying out electromagnetic ultrasonic guided wave detection on the second defect area;
And detecting whether a leakage magnetic field signal exists outside the area through the magnetic sensor, and performing leakage magnetic detection on the second defect area.
16. Crawler-type magnetoacoustic composite detection device, characterized by comprising:
the first processing module is used for scanning and imaging a detected area through the detection robot and determining one or more first defect areas with defects on the detected area according to imaging results, wherein the detection robot comprises at least one crawler, each crawler is formed by connecting at least one sensor crawler unit, and the sensor crawler unit comprises: a magnetic flux leakage detection unit, and/or at least one electromagnetic ultrasonic unit;
the second processing module is used for performing tomography on the first defect area through the at least one crawler belt, and determining a second defect area of the defect according to an imaging result, wherein the second defect area is an area where the defect exists in the first defect area;
the first detection module is used for determining a second defect area of the defect according to the position and the size of the defect, detecting the second defect area through the sensor track unit, and the detection at least comprises any one of the following steps: electromagnetic ultrasonic detection, electromagnetic ultrasonic guided wave detection, surface wave detection and magnetic leakage detection.
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