CN209878670U - Remote rotary eddy current nondestructive flaw detection system - Google Patents
Remote rotary eddy current nondestructive flaw detection system Download PDFInfo
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- CN209878670U CN209878670U CN201920638761.8U CN201920638761U CN209878670U CN 209878670 U CN209878670 U CN 209878670U CN 201920638761 U CN201920638761 U CN 201920638761U CN 209878670 U CN209878670 U CN 209878670U
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Abstract
The utility model provides a long-range rotatory eddy current nondestructive test detecting system, including supply the user to use at least one test terminal that detects and pass through wireless communication link realization data interaction's cloud server with at least one test terminal, the test terminal who detects the sensor as the front end is responsible for the damage detection of different users under different scenes and/or occasion, and itself does not do the processing to data, but discern and judge in the original data transmission that will detect reaches long-range cloud server, consequently reduce local test terminal's cost and convenient to use, and needn't all carry data processing equipment under any scene, can use a plurality of test terminals to carry out different positions simultaneously, different factories, the detection under the different processes, and needn't prepare many sets of test system, use cost is reduced, and the efficiency is improved.
Description
Technical Field
The utility model relates to an eddy current testing technical field particularly relates to long-range rotatory eddy current nondestructive test detecting system.
Background
The current rail detection method mainly comprises manual identification, ultrasonic flaw detection, a CCD scanning camera and point eddy current flaw detection, but the methods have advantages and disadvantages. The manual identification mode has the advantages of low detection speed, poor precision and extremely high requirement on the work literacy of detection personnel. The ultrasonic flaw detection is suitable for detecting the inside of a rail and is extremely easy to be influenced by environmental factors. The CCD line scanning camera has high detection precision, is suitable for rail surface detection and is easily influenced by impurities on the rail surface. The traditional eddy current flaw detection is suitable for detecting the surface and the subsurface of a rail, can accurately judge the position of a flaw, but still cannot realize the quantitative evaluation of the shape, the size and the damage degree of the rail flaw.
The eddy current generated by the probe design of the common eddy current rail flaw detection can only finish measuring the cracks of a certain type of defects, such as transverse cracks, and is difficult to measure for other types of cracks, such as longitudinal cracks. This directly leads to the possibility of missed detections and does not allow assessment of quantitative visualizations.
SUMMERY OF THE UTILITY MODEL
An object of the utility model is to provide a long-range rotatory eddy current nondestructive test detecting system, produce rotatory eddy current at the front end through exciting coil, realize the detection to the damage of multiple damage and equidirectional not through rotatory eddy current from this, detect data transmission and discern and judge the processing to cloud server, and return the result, and need not purchase complete equipment when using, the user only need purchase the front end sensing detect the testing terminal can, reduce cost and availability factor.
In order to achieve the above object, the utility model provides a long-range rotatory eddy current nondestructive inspection detecting system, including supplying the user to use at least one test terminal that detects and pass through wireless communication link realization data interaction's cloud ware with at least one test terminal, wherein:
the detection terminal comprises a shell, two orthogonal U-shaped iron cores positioned in the shell, two groups of coils wound on the iron cores, an electromagnetic sensor array, a first processor, a signal generation circuit and a first wireless data transceiver, wherein the electromagnetic sensor array, the signal generation circuit and the first wireless data transceiver are all connected with the first processor, the two groups of coils are used as eddy current generators, independent circuits are formed through coil wires respectively and are connected with the signal generation circuit, and the signal generation circuit excites the coils through two sine wave signals with the phase difference of 90 degrees to enable the coils to generate rotating eddy currents around the measured rail surface or sub-surface;
the electromagnetic sensor array is formed by arranging a plurality of magnetic sensors to form an M-N combination and is used for receiving a feedback signal of eddy current detection, wherein M and N are positive integers which are more than or equal to 1; the feedback signal is sent to a cloud server through the first wireless data transceiver;
the cloud server comprises a second processor, and a second wireless data transceiver, a signal conditioning circuit, an AD acquisition circuit and an image reconstruction circuit which are respectively connected with the second processor, wherein the signal conditioning circuit, the AD acquisition circuit and the image reconstruction circuit are sequentially and electrically connected, and the signal conditioning circuit receives a feedback signal output by the electromagnetic sensor array through the second wireless data transceiver, performs phase discrimination, amplification and shaping processing, and outputs the feedback signal to the AD acquisition circuit; the AD acquisition circuit converts the analog quantity into digital quantity; the image reconstruction circuit carries out image reconstruction based on digital quantity obtained by detecting the magnetic field detection signal at the relevant position by the array type magnetic sensor to obtain a defect pattern, and returns the defect pattern to the corresponding detection terminal.
Furthermore, the shell of the detection terminal comprises an upper shell and a lower shell, the lower shell is detachably clamped and fixed with the upper shell, and the iron core, the coil and the electromagnetic sensor array which are distributed orthogonally are all installed in the lower shell; the upper part of the shell is also provided with a holding part fixed through a sealing ring for a user to hold.
Furthermore, the first processor, the signal generating circuit and the first wireless data transceiver are all arranged inside the holding part.
Further, the winding of the coil adopts any one of the following modes:
1) respectively winding the slot parts of the two orthogonal iron cores at the mutually overlapped positions, and respectively forming a coil on each of the two iron cores;
2) and the coils are respectively wound at the opposite end positions of each iron core, and a pair of coils wound on each iron core form a group of coils.
Furthermore, a PCB is fixed in the lower shell and on one side far away from the upper shell, and the electromagnetic sensor array is arranged on the PCB.
Further, the signal generating circuit is configured to generate two sine wave signals with a phase difference of 90 degrees for exciting the coil by adjusting the type of output signal, the phase of the signal, the peak amplitude value of the signal and the frequency of the signal, wherein the peak amplitude value of the sine wave signals is 5V, and the frequency is 1 KHz.
Furthermore, the signal conditioning circuit comprises a phase discrimination circuit, an amplifying circuit and a shaping circuit, wherein the phase discrimination circuit is used for detecting the phase of a circuit signal and judging whether the phase changes; the amplifying circuit is used for amplifying the signal and outputting an amplified voltage signal; the shaping circuit is used for shaping the voltage signal output by the amplifying circuit, correcting the output waveform and outputting the corrected output waveform to the AD acquisition circuit.
Further, the magnetic sensor is a three-axis electromagnetic sensor of the AMI 306R.
Furthermore, the shell of the detection terminal is made of an iron material.
Further, the wireless data transceiver includes at least one of Wifi, 4G, and 5G wireless communication modules.
It should be understood that all combinations of the foregoing concepts and additional concepts described in greater detail below can be considered as part of the inventive subject matter of the present disclosure unless such concepts are mutually inconsistent. In addition, all combinations of claimed subject matter are considered a part of the inventive subject matter of this disclosure.
The foregoing and other aspects, embodiments and features of the present teachings can be more fully understood from the following description taken in conjunction with the accompanying drawings. Additional aspects of the present invention, such as features and/or advantages of exemplary embodiments, will be apparent from the description which follows, or may be learned by practice of the specific embodiments in accordance with the teachings of the present invention.
Drawings
The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. Embodiments of various aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
fig. 1 is a system architecture diagram of the remote rotary eddy current nondestructive inspection system of the present invention.
Fig. 2 is a schematic diagram of the detection terminal of the remote rotary eddy current nondestructive inspection system of the present invention.
Fig. 3 is the internal structure schematic diagram of the detection terminal of the remote rotary eddy current nondestructive inspection system of the present invention.
Fig. 4 is a schematic diagram of the internal circuit principle of the detection terminal of the present invention.
Figure 5 is a schematic circuit diagram of the cloud server of the present invention,
fig. 6 is a schematic diagram of the coil winding of the detection terminal of the present invention.
Fig. 7 is a schematic diagram of another embodiment of coil winding of the detection terminal of the present invention.
Detailed Description
For a better understanding of the technical content of the present invention, specific embodiments are described below in conjunction with the accompanying drawings.
In this disclosure, aspects of the present invention are described with reference to the accompanying drawings, in which a number of illustrative embodiments are shown. Embodiments of the present disclosure are not necessarily intended to include all aspects of the invention. It should be appreciated that the various concepts and embodiments described above, as well as those described in greater detail below, may be implemented in any of numerous ways, as the disclosed concepts and embodiments are not limited to any implementation. Additionally, some aspects of the present disclosure may be used alone or in any suitable combination with other aspects of the present disclosure.
Referring to fig. 1-6, the present invention provides a remote rotary eddy current nondestructive inspection system, which includes at least one inspection terminal for user to use inspection and a cloud server for data interaction with the at least one inspection terminal through a wireless communication link, wherein the inspection terminal as a front-end inspection sensor is responsible for the damage inspection of different users in different scenes and/or occasions, and does not process data, but transmits the original data to the remote cloud server for identification and judgment, so as to reduce the cost and convenience of use of the local inspection terminal without carrying data processing equipment in any scene, for example, in a factory or an inspection site, a plurality of inspection terminals can be used simultaneously to perform inspection in different positions, different factories and different processes, without preparing a plurality of sets of inspection systems (including inspection terminals and signal processing equipment), the use cost is reduced, and the efficiency is improved.
With reference to fig. 2 and 3, the detection terminal includes a housing 10, two orthogonal U-shaped iron cores (1a, 1b) disposed in the housing, two sets of coils (3a, 3b) wound around the iron cores, an electromagnetic sensor array, a first processor, a signal generating circuit, and a first wireless data transceiver.
The electromagnetic sensor array, the signal generating circuit and the first wireless data transceiver are all connected with the first processor.
A signal generating circuit for generating an excitation signal for exciting the coil. In the scheme of the embodiment, the adopted excitation signals are two sine wave signals with a phase difference of 90 degrees.
Two groups of coils (3a, 3b) are used as eddy current generating devices, form independent circuits through coil leads respectively and are connected with a signal generating circuit, and the signal generating circuit excites the coils through two sine wave signals with the phase difference of 90 degrees so as to generate rotating eddy current around the measured rail surface or subsurface.
Referring to fig. 3, 6 and 7, the electromagnetic sensor array is formed by arranging a plurality of magnetic sensors 2 to form M × N combinations for receiving feedback signals of eddy current detection, where M and N are positive integers greater than or equal to 1. The feedback signal is sent to the cloud server via the first wireless data transceiver.
With reference to fig. 1 and 4, the cloud server includes a second processor, and a second wireless data transceiver, a signal conditioning circuit, an AD acquisition circuit, and an image reconstruction circuit, which are respectively connected to the second processor. The signal conditioning circuit, the AD acquisition circuit and the image reconstruction circuit are electrically connected in sequence.
The second wireless data transceiver is used as a wireless signal access device and connects the cloud server with the wireless internet to realize data interaction with one or more detection terminals.
The signal conditioning circuit receives a feedback signal output by the electromagnetic sensor array through the second wireless data transceiver, performs phase discrimination, amplification and shaping processing, and outputs the feedback signal to the AD acquisition circuit; .
The AD acquisition circuit converts the analog quantity into a digital quantity.
The image reconstruction circuit carries out image reconstruction based on digital quantity obtained by detecting the magnetic field detection signal at the relevant position by the array type magnetic sensor to obtain a defect pattern, and returns the defect pattern to the corresponding detection terminal.
As shown in fig. 2, the housing 10 includes an upper case 10a and a lower case 10 b.
The upper portion of the housing 10 also secures a grip portion 20, preferably having an ergonomic configuration, such as the cylindrical shape illustrated to facilitate gripping, by a sealing ring 30. The top of the wireless data transceiver is provided with an antenna 40, which is connected with the first wireless data transceiver and used for transmitting data to an adjacent base station through electromagnetic waves so as to transmit the corresponding cloud server through a network.
The lower case 10b is detachably engaged with the upper case 10a, and is, for example, an engaging structure with a stopper in the drawing.
Referring to fig. 1, the orthogonally distributed cores include two identical U-shaped cores, a first core 1a and a second core 1b, which are orthogonally fixed in the housing, particularly, inside the lower case 10b, respectively.
The first core 1a and the second core 1b are distributed in an orthogonal position with a gap left therebetween.
A group of coils 3a and another group of coils 3b are correspondingly and respectively arranged on the first iron core 1a and the second iron core 1b, and corresponding coils (namely two groups of coils) on different iron cores are used as eddy current generating devices.
The two groups of coils form independent circuits through respective coil leads, are led out of the shell and are electrically connected with the signal generating circuit.
With reference to the coil winding method shown in fig. 6 and 7, the flaw detector of the present invention forms a wound coil using one of the following two types:
referring to fig. 6, the slot portions of the first iron core 1a and the second iron core 1b are respectively wound at the positions overlapped with each other, and a coil 3a and a coil 3b are respectively formed on the two iron cores and respectively excited;
referring to fig. 7, the coils are wound around opposite end portions of each of the irons 1a and 1b, a pair of coils wound around each iron core forms a group of coils, and 2 groups of coils are correspondingly formed on the two iron cores to apply excitation respectively.
With reference to fig. 1 and 3, the signal generating circuit has a signal generator for generating a 50-100KHz signal and a phase detector for phase-detecting two sine wave excitation signals with a phase difference of 90 degrees and outputting the two sine wave excitation signals to the two corresponding sets of coils.
Optionally, the signal generating circuit generates two sine wave signals with a phase difference of 90 degrees by adjusting the type of the output signal, the phase of the signal, the peak amplitude value of the signal and the frequency of the signal, wherein the peak amplitude value is 5V and the frequency is 1 KHz.
Preferably, a buffer is further provided between the phase detector and the coil.
Referring to fig. 3, a buffer memory in data connection with the first processor is further disposed in the detection terminal.
It will be appreciated that the test terminals are powered by a battery, particularly a rechargeable battery pack, for example to power the first processor, the cache, the sensor array and other components. Of course, in another embodiment, an external charging circuit and an external interface may be further provided to charge the storage battery pack or to charge the storage battery pack simultaneously.
Preferably, the storage battery pack is a nickel-metal hydride battery or a lithium battery and is disposed in the grip portion 20.
With reference to fig. 2, 3, 6 and 7, the electromagnetic sensor array is formed by arranging a plurality of magnetic sensors 2 to form M × N combinations, i.e., M rows and N columns, and receives feedback signals of eddy current detection. M and N are positive integers greater than or equal to 1. The lower surface of the electromagnetic sensor array and the free end of the side part of the U-shaped iron core which is orthogonally distributed are positioned on the same plane.
In the foregoing embodiment, the winding base of the coil is provided by the orthogonal U-shaped iron core, so as to perform a magnetic gathering function, prevent excessive leakage of the magnetic field, and reduce energy loss.
The utility model discloses the preferred triaxial electromagnetic sensor who adopts AMI306R detects out interfering signal as the magnetic sensor that the feedback detected to confirm the situation of defect.
With reference to fig. 2 and 3, the orthogonally distributed iron core, coil and magnetic sensor are lighter in weight, which is beneficial to the miniaturization design of the whole device. The core and the PCB board are both fixed to the housing using an adhesive.
Preferably, the shell is made of a ferrous material so as to carry out electromagnetic shielding and avoid the influence of an external magnetic field on the flaw detection equipment.
As shown in fig. 3, a PCB board 5 is further fixed inside the lower casing 10b on a side away from the upper casing, and the electromagnetic sensor array is disposed on the PCB board to realize fixed installation of the sensor array.
Preferably, the aforementioned signal generating circuit, the first wireless data transceiver and the first processor are all integrated on the PCB board.
With reference to fig. 4, the processing of the feedback data in the cloud server of the detection system of the present invention is shown.
Fig. 4 illustrates circuitry and data processing logic within a cloud server.
The signal conditioning circuit, the AD acquisition circuit and the image reconstruction circuit are electrically connected in sequence.
The signal conditioning circuit performs phase discrimination, amplification and shaping processing on a plurality of paths of output signals output by the electromagnetic sensor array and received through a wireless network, and outputs the signals to the AD acquisition circuit.
The AD acquisition circuit converts the analog quantity into a digital quantity.
The image reconstruction circuit carries out image reconstruction based on digital quantity obtained by detecting magnetic field detection signals of relevant positions by the array type magnetic sensor to obtain a defect graph.
With reference to fig. 1, when the coil is energized with a pulse signal, the winding coil will generate a magnetic field, and the present invention applies two sine wave excitations with a phase difference of 90 degrees, so that the coil generates an eddy current that is applied to the surface to be detected (e.g., rail) and the subsurface to form a rotation, and if the detected rail has a defect, the detection result of the probe will change (i.e., form an interference signal).
With reference to fig. 1, 3 and 4, two sinusoidal signals with a phase difference of 90 degrees generated by a signal generator are applied to the coil to form a rotating eddy current on the surface or subsurface to be detected, when a defect occurs, because the defect portion has a blocking effect on the rotating eddy current, a feedback magnetic field generated by the rotating eddy current will be different from a feedback signal generated when the defect does not occur, and the feedback signal is detected by using a three-axis electromagnetic sensor with the model of AMI 306R.
In a specific embodiment, the signal conditioning circuit includes a phase detection circuit, an amplification circuit, and a shaping circuit.
The phase detection circuit is used for detecting the phase of a circuit signal and judging whether the phase changes, the input of the phase detection circuit is from a signal generator and is input in a sine wave form, and the output signal is two paths of sine wave signals with the phase difference of 90 degrees.
The amplifying circuit is used for amplifying the signal and outputting an amplified voltage signal.
The shaping circuit is used for shaping the voltage signal output by the amplifying circuit, correcting the output waveform and outputting the corrected output waveform to the AD acquisition circuit.
It can be seen that the description of the detection system who combines above embodiment combines, the utility model discloses a detection device does benefit to and forms a rotatory eddy current on surveying the object, can detect the defect of the different grade type on rail surface to can avoid environmental variable to the influence of detection methods such as ultrasonic wave, CCD line scanning camera effectively. The device breaks through the problems that other rail flaw detection vehicles are single in function, low in detection speed, low in detection precision, greatly influenced by the environment and the like, innovatively applies a novel signal processing and damage reconstruction technology, and innovatively utilizes a rail surface and subsurface damage detection method (early detection) combining an eddy current flaw detection method and an MI sensor.
Simultaneously in order to realize low-cost and efficient use to different highway sections, under the different scenes, for example use simultaneously, data processing with front end and rear end separately, make the user of the detection terminal of front end can be convenient detect, with data transmission back to the cloud server carry out comprehensive treatment and differentiate can, need not to drag the volume, the detection system that weight is all great makes a round trip to move on the track, when detecting and multiple spot detects many times, also need not to use many sets of equipment simultaneous workings, so take trouble and hard and with high costs, adopt the utility model discloses an its scalability of scheme is good, and the availability factor is high, can reduce use cost moreover.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to limit the present invention. The present invention is intended to cover by those skilled in the art various modifications and adaptations of the invention without departing from the spirit and scope of the invention. Therefore, the protection scope of the present invention is subject to the claims.
Claims (10)
1. The remote rotary eddy current nondestructive inspection system is characterized by comprising at least one inspection terminal for a user to use for inspection and a cloud server for realizing data interaction with the at least one inspection terminal through a wireless communication link, wherein:
the detection terminal comprises a shell, two orthogonal U-shaped iron cores positioned in the shell, two groups of coils wound on the iron cores, an electromagnetic sensor array, a first processor, a signal generation circuit and a first wireless data transceiver, wherein the electromagnetic sensor array, the signal generation circuit and the first wireless data transceiver are all connected with the first processor, the two groups of coils are used as eddy current generators, independent circuits are formed through coil wires respectively and are connected with the signal generation circuit, and the signal generation circuit excites the coils through two sine wave signals with the phase difference of 90 degrees to enable the coils to generate rotating eddy currents around the measured rail surface or sub-surface;
the electromagnetic sensor array is formed by arranging a plurality of magnetic sensors to form an M-N combination and is used for receiving a feedback signal of eddy current detection, wherein M and N are positive integers which are more than or equal to 1; the feedback signal is sent to a cloud server through the first wireless data transceiver;
the cloud server comprises a second processor, and a second wireless data transceiver, a signal conditioning circuit, an AD acquisition circuit and an image reconstruction circuit which are respectively connected with the second processor, wherein the signal conditioning circuit, the AD acquisition circuit and the image reconstruction circuit are sequentially and electrically connected, and the signal conditioning circuit receives a feedback signal output by the electromagnetic sensor array through the second wireless data transceiver, performs phase discrimination, amplification and shaping processing, and outputs the feedback signal to the AD acquisition circuit; the AD acquisition circuit converts the analog quantity into digital quantity; the image reconstruction circuit carries out image reconstruction based on digital quantity obtained by detecting the magnetic field detection signal at the relevant position by the array type magnetic sensor to obtain a defect pattern, and returns the defect pattern to the corresponding detection terminal.
2. The remote rotary eddy current nondestructive inspection system of claim 1, wherein the housing of the inspection terminal comprises an upper housing and a lower housing, the lower housing is detachably fastened to the upper housing, and the orthogonally distributed iron core, coil and electromagnetic sensor array are mounted in the lower housing; the upper part of the shell is also provided with a holding part fixed through a sealing ring for a user to hold.
3. The remote rotary eddy current nondestructive inspection system of claim 2 wherein the first processor, the signal generating circuit, and the first wireless data transceiver are disposed within the interior of the gripping portion.
4. The remote rotary eddy current nondestructive inspection system of claim 1 wherein the coil is wound in any one of the following ways:
1) respectively winding the slot parts of the two orthogonal iron cores at the mutually overlapped positions, and respectively forming a coil on each of the two iron cores;
2) and the coils are respectively wound at the opposite end positions of each iron core, and a pair of coils wound on each iron core form a group of coils.
5. The remote rotary eddy current nondestructive inspection system of claim 2, wherein a PCB board is further fixed to the inside of the lower housing on a side away from the upper housing, and the electromagnetic sensor array is disposed on the PCB board.
6. The remote rotary eddy current nondestructive inspection system of any one of claims 1-5 wherein the signal generating circuit is configured to generate two sine wave signals having a phase difference of 90 degrees for exciting the coil by adjusting the type of output signal, the phase of the signal, the peak amplitude of the signal, and the frequency of the signal, the sine wave signals having an amplitude of 5V at a peak frequency of 1 KHz.
7. The remote rotary eddy current nondestructive inspection system of claim 6, wherein the signal conditioning circuit comprises a phase detection circuit, an amplification circuit and a shaping circuit, wherein the phase detection circuit is configured to detect a phase of a circuit signal and determine whether the phase is changed; the amplifying circuit is used for amplifying the signal and outputting an amplified voltage signal; the shaping circuit is used for shaping the voltage signal output by the amplifying circuit, correcting the output waveform and outputting the corrected output waveform to the AD acquisition circuit.
8. The remote rotary eddy current nondestructive inspection system of claim 1, wherein the magnetic sensor is a three-axis electromagnetic sensor of AMI 306R.
9. The remote rotary eddy current nondestructive inspection system of claim 1 wherein the housing of the inspection terminal is made of a ferrous material.
10. The remote rotary eddy current nondestructive inspection system of claim 1, wherein the wireless data transceiver device comprises at least one of Wifi, 4G, 5G wireless communication modules.
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| CN201920638761.8U CN209878670U (en) | 2019-05-07 | 2019-05-07 | Remote rotary eddy current nondestructive flaw detection system |
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| CN201920638761.8U CN209878670U (en) | 2019-05-07 | 2019-05-07 | Remote rotary eddy current nondestructive flaw detection system |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110031544A (en) * | 2019-05-07 | 2019-07-19 | 南京工业职业技术学院 | Long-range electric rotating vortex nondestructive flaw detection system |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110031544A (en) * | 2019-05-07 | 2019-07-19 | 南京工业职业技术学院 | Long-range electric rotating vortex nondestructive flaw detection system |
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