基于脉冲漏磁检测机理的缺陷检测研究
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摘要
漏磁检测技术作为电磁无损检测技术的重要分支之一,被广泛应用于导磁构件的检测。本文在分析国内外漏磁检测技术研究动态的基础上,针对目前该技术中所存在的一些不足,结合有限元仿真和实验研究,对铁磁性管道脉冲漏磁检测中的轴向缺陷如何识别、传感器结构参数对缺陷检测的影响以及内外壁缺陷的分类和识别技术等几个方面进行了深入研究。主要研究内容及创新如下:
以电磁场理论为基础,讨论了缺陷漏磁检测模型及脉冲漏磁检测原理,对不同走向缺陷进行了有限元仿真和实验研究。利用三维有限元仿真技术,分析了周向缺陷和轴向缺陷三维漏磁场分量分布情况,并对缺陷漏磁瞬态信号与缺陷宽度、深度之间的关系进行了仿真研究,发现两种不同走向缺陷漏磁场的三维分量均有不同程度的扰动,轴向缺陷在切向分量的扰动较周向缺陷明显,综合缺陷漏磁场的三维分量变化情况将能对不同走向管道表面缺陷进行有效识别,提出三维脉冲漏磁检测方法以提高轴向缺陷检测能力。
研究了改善传感器检测灵敏度的优化设计方法,提出了一种同时提取三维漏磁分量的新型脉冲漏磁传感器结构。对影响检测灵敏度的各种参量进行了分析,如励磁线圈的尺寸、励磁线圈形状、磁轭高度等;用有限元法分析了几种不同励磁结构的脉冲漏磁传感器,发现矩形励磁线圈漏磁传感器信噪比高于圆柱形励磁线圈漏磁传感器,但它对提离变化较圆柱形励磁传感器敏感;因为典型便携式磁轭中的实心铁氧体磁芯上的损耗将使励磁线圈电感增加,不利于检测信号特征量的提取,所以提出将脉冲漏磁检测传感器的励磁结构设计为矩形空心线圈。设计了用于场量测量的两两正交的三维漏磁检测传感器。
研究了不同走向缺陷三维脉冲漏磁瞬态信号的特点,提出了一种利用三维脉冲漏磁瞬态信号峰值扫描波形来识别周向缺陷和轴向缺陷的新方法。研究了缺陷定量估计的方法:根据三维峰值扫描电压变化定量估计缺陷长度和宽度,以三维分量差分信号的过零时间估计缺陷深度。采用有限元仿真和实验对所设计的新型脉冲漏磁传感器结构进行了验证。仿真和实验结果表明,采用新型脉冲漏磁传感器及综合三维脉冲漏磁瞬态信号能在提高轴向缺陷检测灵敏度的同时实现两种不同走向缺陷的分类识别。同时,围绕新型传感器结构,对系统各种参数如激励脉冲信号的频率、占空比等的选择问题进行了详细探讨,设计和实现了脉冲漏磁检测硬件系统。
对管道内外壁缺陷的分类识别技术进行了研究。由于脉冲磁化所产生的励磁场频率丰富,使得其对于内外壁缺陷都具有识别能力。利用有限元仿真技术,研究了脉冲磁化下的漏磁场三维分量分布特性。分别在时域和频域对三维脉冲漏磁瞬态信号进行了分析,在时域提取了缺陷信号过零时间、参考信号与缺陷信号的交叉点时间、缺陷瞬态信号积分峰值时间及下降点时间作为特征量,在频域提取了谱图峰度系数、谱图偏态系数、相位谱交叉点频率作为特征量。通过提取三维瞬态信号的上述时域和频域特征及轴向分量峰值电压相对变化量等22个特征量,用主成分分析法成功实现了周向内壁、周向外壁、轴向内壁、轴向外壁四种缺陷的分类。
As an important branch of electromagnetic nondestructive testing technology, magnetic flux leakage (MFL) testing technique is widely used in the detection of magnetic materials. The domestic and overseas research developments of magnetic flux leakage testing technique were analyzed in this paper. Aiming at the shortages currently existed in this technique, the research on the pulsed magnetic flux leakage (PMFL) testing of ferromagnetic pipeline was implemented combining the finite element simulation with experiments. The identification method of axial defects as well as the impact of sensor structure parameters on the flaw detection and the defect classification and recognition techniques on inner and outer walls of pipelines was studied in depth. The main research content and innovations are as follows:
The magnetic flux leakage detection model of defects and the principle of pulsed magnetic flux leakage testing were discussed based on the electromagnetic field theory. Different types of defects were researched with finite element simulation and experiments. The 3D magnetic leakage field component distributions of circumferential and axial defects as well as the relationship between the magnetic flux leakage transient signal and the width and depth of the defects were analyzed with 3D finite element simulation technique. It is found that the two defects have different disturbance to the 3D components of magnetic leakage field. Compared with the circumferential defects, the axial defects will cause more distinct disturbance to the tangential component. Thus different defects on the pipe surface can be identified according to the change of 3D components of magnetic leakage field, and the 3D pulsed magnetic flux leakage detection method was presented to improve the testing ability of axial defects.
The optimal design method to improve the detection sensitivity of the sensor was studied and a new pulsed magnetic flux leakage sensor structure was presented, which can be used to pick up the 3D magnetic flux leakage components at the same time. The influence of various parameters on detection sensitivity was analyzed, such as the size of the excitation coil, the magnetic yoke shape and the magnetic yoke height. Several different pulsed excitation magnetic flux leakage sensors were analyzed using the finite element method, and it was found that the rectangular excitation sensor has higher SNR than the cylindrical excitation sensor, but its lift-off changes is more sensitive than the cylindrical section. Because the losses of solid ferrite core in the typical portable yoke will increase inductance of the excitation coil, which is unfavorable to the feature extraction of detection signals, the excitation structure in the pulsed magnetic flux leakage sensor was proposed to be a rectangular hollow coil. The 3D magnetic flux leakage sensors was designed to obtain field measurements, which is orthogonal each other.
The transient signal characteristics of the 3D pulsed magnetic flux leakage with defects in different directions were studied, and a new method using 3D pulsed magnetic flux leakage transient signal peak scanning waveform to classify the circumferential defects and axial defects was presented. The method of quantitative defect assessment was studied. The length and width of the defects were evaluated quantitatively according to the change of 3D scanning peak voltage, and the defect depth was evaluated with the zero passage time of the 3D differential signal. The newly designed structure of pulsed magnetic flux leakage sensor was validated with finite element simulation and experiments. The simulation and experimental results show that the utilization of this new pulsed magnetic flux leakage sensor and the 3D pulsed magnetic flux leakage signals can improve the detection sensitivity of axial defects and realize the classification and identification of defects with two different directions at the same time. Meanwhile, the system parameters such as the excitation pulsed frequency and the choice of the duty cycle around the new sensor structure were discussed in details, and the 3D pulsed magnetic flux leakage testing system was designed and realized to pick up 3D pulsed magnetic flux leakage transient signal.
The classification and recognition techniques of the defects of the inside and outside walls of the pipeline were studied. Because of the rich frequencies of the excitation magnetic field generated by the pulsed magnetization, the defects on either the inside or the outside wall can be identified. The 3D component distribution characteristics of leakage magnetic field under pulsed magnetization were studied using finite element simulation. The 3D pulsed magnetic flux leakage transient signals were analyzed in time domain and frequency domain respectively. Time domain features such as zero-crossing time of defect signal, intersection-time of reference signal and defect signal, integration time of defect peak transient signal, arrival time of the descending point and frequency domain features such as spectrum kurtosis coefficient, skewness coefficient, phase spectral intersection frequency were extracted. After the 22 features (including the above mentioned features of 3D transient signals and peak voltage relative variation of the axial component) were extracted, four kinds of defects on the circumferential inner wall, circumferential outer wall, axial inner wall and axial outer wall were classified using principal component analysis.
以电磁场理论为基础,讨论了缺陷漏磁检测模型及脉冲漏磁检测原理,对不同走向缺陷进行了有限元仿真和实验研究。利用三维有限元仿真技术,分析了周向缺陷和轴向缺陷三维漏磁场分量分布情况,并对缺陷漏磁瞬态信号与缺陷宽度、深度之间的关系进行了仿真研究,发现两种不同走向缺陷漏磁场的三维分量均有不同程度的扰动,轴向缺陷在切向分量的扰动较周向缺陷明显,综合缺陷漏磁场的三维分量变化情况将能对不同走向管道表面缺陷进行有效识别,提出三维脉冲漏磁检测方法以提高轴向缺陷检测能力。
研究了改善传感器检测灵敏度的优化设计方法,提出了一种同时提取三维漏磁分量的新型脉冲漏磁传感器结构。对影响检测灵敏度的各种参量进行了分析,如励磁线圈的尺寸、励磁线圈形状、磁轭高度等;用有限元法分析了几种不同励磁结构的脉冲漏磁传感器,发现矩形励磁线圈漏磁传感器信噪比高于圆柱形励磁线圈漏磁传感器,但它对提离变化较圆柱形励磁传感器敏感;因为典型便携式磁轭中的实心铁氧体磁芯上的损耗将使励磁线圈电感增加,不利于检测信号特征量的提取,所以提出将脉冲漏磁检测传感器的励磁结构设计为矩形空心线圈。设计了用于场量测量的两两正交的三维漏磁检测传感器。
研究了不同走向缺陷三维脉冲漏磁瞬态信号的特点,提出了一种利用三维脉冲漏磁瞬态信号峰值扫描波形来识别周向缺陷和轴向缺陷的新方法。研究了缺陷定量估计的方法:根据三维峰值扫描电压变化定量估计缺陷长度和宽度,以三维分量差分信号的过零时间估计缺陷深度。采用有限元仿真和实验对所设计的新型脉冲漏磁传感器结构进行了验证。仿真和实验结果表明,采用新型脉冲漏磁传感器及综合三维脉冲漏磁瞬态信号能在提高轴向缺陷检测灵敏度的同时实现两种不同走向缺陷的分类识别。同时,围绕新型传感器结构,对系统各种参数如激励脉冲信号的频率、占空比等的选择问题进行了详细探讨,设计和实现了脉冲漏磁检测硬件系统。
对管道内外壁缺陷的分类识别技术进行了研究。由于脉冲磁化所产生的励磁场频率丰富,使得其对于内外壁缺陷都具有识别能力。利用有限元仿真技术,研究了脉冲磁化下的漏磁场三维分量分布特性。分别在时域和频域对三维脉冲漏磁瞬态信号进行了分析,在时域提取了缺陷信号过零时间、参考信号与缺陷信号的交叉点时间、缺陷瞬态信号积分峰值时间及下降点时间作为特征量,在频域提取了谱图峰度系数、谱图偏态系数、相位谱交叉点频率作为特征量。通过提取三维瞬态信号的上述时域和频域特征及轴向分量峰值电压相对变化量等22个特征量,用主成分分析法成功实现了周向内壁、周向外壁、轴向内壁、轴向外壁四种缺陷的分类。
As an important branch of electromagnetic nondestructive testing technology, magnetic flux leakage (MFL) testing technique is widely used in the detection of magnetic materials. The domestic and overseas research developments of magnetic flux leakage testing technique were analyzed in this paper. Aiming at the shortages currently existed in this technique, the research on the pulsed magnetic flux leakage (PMFL) testing of ferromagnetic pipeline was implemented combining the finite element simulation with experiments. The identification method of axial defects as well as the impact of sensor structure parameters on the flaw detection and the defect classification and recognition techniques on inner and outer walls of pipelines was studied in depth. The main research content and innovations are as follows:
The magnetic flux leakage detection model of defects and the principle of pulsed magnetic flux leakage testing were discussed based on the electromagnetic field theory. Different types of defects were researched with finite element simulation and experiments. The 3D magnetic leakage field component distributions of circumferential and axial defects as well as the relationship between the magnetic flux leakage transient signal and the width and depth of the defects were analyzed with 3D finite element simulation technique. It is found that the two defects have different disturbance to the 3D components of magnetic leakage field. Compared with the circumferential defects, the axial defects will cause more distinct disturbance to the tangential component. Thus different defects on the pipe surface can be identified according to the change of 3D components of magnetic leakage field, and the 3D pulsed magnetic flux leakage detection method was presented to improve the testing ability of axial defects.
The optimal design method to improve the detection sensitivity of the sensor was studied and a new pulsed magnetic flux leakage sensor structure was presented, which can be used to pick up the 3D magnetic flux leakage components at the same time. The influence of various parameters on detection sensitivity was analyzed, such as the size of the excitation coil, the magnetic yoke shape and the magnetic yoke height. Several different pulsed excitation magnetic flux leakage sensors were analyzed using the finite element method, and it was found that the rectangular excitation sensor has higher SNR than the cylindrical excitation sensor, but its lift-off changes is more sensitive than the cylindrical section. Because the losses of solid ferrite core in the typical portable yoke will increase inductance of the excitation coil, which is unfavorable to the feature extraction of detection signals, the excitation structure in the pulsed magnetic flux leakage sensor was proposed to be a rectangular hollow coil. The 3D magnetic flux leakage sensors was designed to obtain field measurements, which is orthogonal each other.
The transient signal characteristics of the 3D pulsed magnetic flux leakage with defects in different directions were studied, and a new method using 3D pulsed magnetic flux leakage transient signal peak scanning waveform to classify the circumferential defects and axial defects was presented. The method of quantitative defect assessment was studied. The length and width of the defects were evaluated quantitatively according to the change of 3D scanning peak voltage, and the defect depth was evaluated with the zero passage time of the 3D differential signal. The newly designed structure of pulsed magnetic flux leakage sensor was validated with finite element simulation and experiments. The simulation and experimental results show that the utilization of this new pulsed magnetic flux leakage sensor and the 3D pulsed magnetic flux leakage signals can improve the detection sensitivity of axial defects and realize the classification and identification of defects with two different directions at the same time. Meanwhile, the system parameters such as the excitation pulsed frequency and the choice of the duty cycle around the new sensor structure were discussed in details, and the 3D pulsed magnetic flux leakage testing system was designed and realized to pick up 3D pulsed magnetic flux leakage transient signal.
The classification and recognition techniques of the defects of the inside and outside walls of the pipeline were studied. Because of the rich frequencies of the excitation magnetic field generated by the pulsed magnetization, the defects on either the inside or the outside wall can be identified. The 3D component distribution characteristics of leakage magnetic field under pulsed magnetization were studied using finite element simulation. The 3D pulsed magnetic flux leakage transient signals were analyzed in time domain and frequency domain respectively. Time domain features such as zero-crossing time of defect signal, intersection-time of reference signal and defect signal, integration time of defect peak transient signal, arrival time of the descending point and frequency domain features such as spectrum kurtosis coefficient, skewness coefficient, phase spectral intersection frequency were extracted. After the 22 features (including the above mentioned features of 3D transient signals and peak voltage relative variation of the axial component) were extracted, four kinds of defects on the circumferential inner wall, circumferential outer wall, axial inner wall and axial outer wall were classified using principal component analysis.
引文
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