管道复杂焊缝扫查器的研究与设计
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摘要
目前,管道焊缝全自动超声检测系统技术在国内外业内得到公认,逐步取代传统人工检测技术,成为管道焊缝检测技术发展的趋势。随着我国管道结构应用量的增大,研制出具有自主知识产权的管道焊缝自动检测系统对管道工业的应用和发展具有十分重要的意义。本论文的开展基于国家“863”项目课题——“深水海管水下回接技术及AUT检验设备国产化技术研究”,针对环焊缝、螺旋焊缝和相贯焊缝这三种复杂焊缝具有不同的检测要求,进行相应的管道扫查器系统的研究,并进行机械装置的模块化设计。
论文根据不同的复杂焊缝几何特点及实际工作要求,设计出多种扫查器机械装置模块,以应用于不同工作路径的检测工作。扫查器主要由爬行机构和探头调整机构两部分组成,则模块化设计主要包括这两部分的具体设计方案。根据扫查器模块的不同工作特点,在模块间进行组装,得到可适用于不同的复杂焊缝检测的扫查器。其中,环行链式爬行机构模块和螺旋链式爬行机构模块采用链连接结构,分别适用于对中小型管道中的环焊缝和螺旋焊缝检测的装置中；可伸缩探头调整机构模块与环行链式爬行机构装配,组成相贯焊缝链式扫查器,适用于对相贯焊缝的跟踪检测。
本文重点对相贯焊缝链式扫查器进行具体结构设计和研究分析。该装置的静力学分析中,首先根据重力分量分析扫查器在环行工作中的各种失稳情况,然后建立箍紧力在克服各种失稳情况下随管道倾角和姿态角变化的函数模型,利用MATLAB进行结果分析。静力学分析对研究扫查器克服失稳情况,选材以及结构布置等方面起到指导作用。
在研究相贯焊缝链式扫查器的运动学问题时,采用D-H法建立扫查器末端执行机构的运动学方程,并采用递推法求出运动学逆解。利用MATLAB对正、逆运动学模型进行结果分析,求出末端执行器的仿真轨迹曲线,验证了运动学方程建立的正确性,并求出扫查器各关节变量变化曲线图,验证了逆解建立的正确性和逆解的唯一性。
本文以递阶式分层控制体系为指导思想,提出了相贯焊缝链式扫查器控制系统总体方案,并对以DSP为核心的控制系统硬件电路实施方案进行了简要的设计。
研制了弹性导轨式管道环焊缝扫查器系统,对样机做了爬行试验和超声探伤试验分析。其中爬行实验结果表明该扫查器运行稳定,速度误差在控制范围内,验证了该扫查器满足功能方案的要求。基于RcurDyn软件对相贯焊缝链式扫查器进行虚拟样机仿真分析,验证了该扫查器运动学模型建立的正确性以及该装置设计的合理性。
Use of mechanical ultrasonic inspection systems has now become a common occurrence in nondestructive testing, and gradually replaces the traditional manual inspection techniques. With the increase of pipeline structural applications in our country, the developing of automatic ultrasonic testing equipment for weld inspection with independent intellectual property rights is of great significance for the application and development of pipeline industry. This paper is based on the national "863" project- "Underwater reflow soldering technology for pipe in deep-sea and the localization technology research of AUT testing equipment", researching of the scanning of girth weld, spiral weld and intersected weld and designing the corresponding pipe scanner. The paper focus on the research of intersected weld scanner device, including concrete structure design, static analysis, forward and inverse kinematics analysis, control system design and simulation analysis.
Based on geometric features of different complex weld and actual working requirement, the design gives a variety of mechanical device modules adapted to working in different path. Modular design mainly includes the schemes of crawling institution and probe adjusting mechanism. According to the different working characteristics of the modules, it can get scanner devices through the assembly of those modules, which used in different complex weld detecting. Two of the crawling institution modules are circled chain crawling institution and spiral chain crawling institutions, which both use chain link, respectively applicable to the weld defects testing of small and medium-sized pipes' girth and spiral weld. Retractable probe adjusting mechanism, using synchronous belt, screw nut and worm and worm wheel, can be assembled with circled chain crawling mechanism for the composition of Intersected Weld Chain Scanner, which applicable to intersected weld's tracing testing.
This paper focuses on the analysis of the Intersected Weld Chain Scanner and the concrete structure design. The statics analysis on the scanner is carried out as the followed: first, researching on all kinds of instability of scanner in the circling, caused by gravity component; then, building up the function relation between the Elastic tightening force and the pipe inclination angle and driven car's attitude angle; using MATLAB analyze the change of the Elastic tightening force. The statics analysis has theoretical significance in the analysis of scanning device overcoming instability, the choice of the crawling institution's materials and the structural layout.
In order to research on the kinematical problem of the Intersected Weld Chain Scanner, the D-H method is applied in establishing the end actuator's kinematics model, and the recursion algorithm is used in finding the inverse kinematic resolution. Use MATLAB analyze the result of the positive and inverse kinematics model, and work out the end of actuator's tracing curve and each joint-variables'changing curves to proving the correctness of the kinematics model and the uniqueness of inverse kinematic resolution.
The paper using hierarchical layered control architecture as the guiding ideology, carries out the design of hardware and software implementation scheme of the control system, especially for the Intersected Weld Chain Scanner, and carries out the brief design of the DSP-based control system hardware circuit implementation programme.
The prototype experiments of Elastic Rail-type Pipeline Girth Weld Scanner includes the crawling test and ultrasonic flaw detection test. The crawling test proves that the auto-inspection scanner system works stable and velocity error is in the control range. Then, the system meets the function scheme's requirement. The virtual prototype simulation analysis of Intersected Weld Chain Scanner based on RecurDyn simulation analysis software, verifies the kinematics model is correct, and the design of the device is reasonable.
论文根据不同的复杂焊缝几何特点及实际工作要求,设计出多种扫查器机械装置模块,以应用于不同工作路径的检测工作。扫查器主要由爬行机构和探头调整机构两部分组成,则模块化设计主要包括这两部分的具体设计方案。根据扫查器模块的不同工作特点,在模块间进行组装,得到可适用于不同的复杂焊缝检测的扫查器。其中,环行链式爬行机构模块和螺旋链式爬行机构模块采用链连接结构,分别适用于对中小型管道中的环焊缝和螺旋焊缝检测的装置中；可伸缩探头调整机构模块与环行链式爬行机构装配,组成相贯焊缝链式扫查器,适用于对相贯焊缝的跟踪检测。
本文重点对相贯焊缝链式扫查器进行具体结构设计和研究分析。该装置的静力学分析中,首先根据重力分量分析扫查器在环行工作中的各种失稳情况,然后建立箍紧力在克服各种失稳情况下随管道倾角和姿态角变化的函数模型,利用MATLAB进行结果分析。静力学分析对研究扫查器克服失稳情况,选材以及结构布置等方面起到指导作用。
在研究相贯焊缝链式扫查器的运动学问题时,采用D-H法建立扫查器末端执行机构的运动学方程,并采用递推法求出运动学逆解。利用MATLAB对正、逆运动学模型进行结果分析,求出末端执行器的仿真轨迹曲线,验证了运动学方程建立的正确性,并求出扫查器各关节变量变化曲线图,验证了逆解建立的正确性和逆解的唯一性。
本文以递阶式分层控制体系为指导思想,提出了相贯焊缝链式扫查器控制系统总体方案,并对以DSP为核心的控制系统硬件电路实施方案进行了简要的设计。
研制了弹性导轨式管道环焊缝扫查器系统,对样机做了爬行试验和超声探伤试验分析。其中爬行实验结果表明该扫查器运行稳定,速度误差在控制范围内,验证了该扫查器满足功能方案的要求。基于RcurDyn软件对相贯焊缝链式扫查器进行虚拟样机仿真分析,验证了该扫查器运动学模型建立的正确性以及该装置设计的合理性。
Use of mechanical ultrasonic inspection systems has now become a common occurrence in nondestructive testing, and gradually replaces the traditional manual inspection techniques. With the increase of pipeline structural applications in our country, the developing of automatic ultrasonic testing equipment for weld inspection with independent intellectual property rights is of great significance for the application and development of pipeline industry. This paper is based on the national "863" project- "Underwater reflow soldering technology for pipe in deep-sea and the localization technology research of AUT testing equipment", researching of the scanning of girth weld, spiral weld and intersected weld and designing the corresponding pipe scanner. The paper focus on the research of intersected weld scanner device, including concrete structure design, static analysis, forward and inverse kinematics analysis, control system design and simulation analysis.
Based on geometric features of different complex weld and actual working requirement, the design gives a variety of mechanical device modules adapted to working in different path. Modular design mainly includes the schemes of crawling institution and probe adjusting mechanism. According to the different working characteristics of the modules, it can get scanner devices through the assembly of those modules, which used in different complex weld detecting. Two of the crawling institution modules are circled chain crawling institution and spiral chain crawling institutions, which both use chain link, respectively applicable to the weld defects testing of small and medium-sized pipes' girth and spiral weld. Retractable probe adjusting mechanism, using synchronous belt, screw nut and worm and worm wheel, can be assembled with circled chain crawling mechanism for the composition of Intersected Weld Chain Scanner, which applicable to intersected weld's tracing testing.
This paper focuses on the analysis of the Intersected Weld Chain Scanner and the concrete structure design. The statics analysis on the scanner is carried out as the followed: first, researching on all kinds of instability of scanner in the circling, caused by gravity component; then, building up the function relation between the Elastic tightening force and the pipe inclination angle and driven car's attitude angle; using MATLAB analyze the change of the Elastic tightening force. The statics analysis has theoretical significance in the analysis of scanning device overcoming instability, the choice of the crawling institution's materials and the structural layout.
In order to research on the kinematical problem of the Intersected Weld Chain Scanner, the D-H method is applied in establishing the end actuator's kinematics model, and the recursion algorithm is used in finding the inverse kinematic resolution. Use MATLAB analyze the result of the positive and inverse kinematics model, and work out the end of actuator's tracing curve and each joint-variables'changing curves to proving the correctness of the kinematics model and the uniqueness of inverse kinematic resolution.
The paper using hierarchical layered control architecture as the guiding ideology, carries out the design of hardware and software implementation scheme of the control system, especially for the Intersected Weld Chain Scanner, and carries out the brief design of the DSP-based control system hardware circuit implementation programme.
The prototype experiments of Elastic Rail-type Pipeline Girth Weld Scanner includes the crawling test and ultrasonic flaw detection test. The crawling test proves that the auto-inspection scanner system works stable and velocity error is in the control range. Then, the system meets the function scheme's requirement. The virtual prototype simulation analysis of Intersected Weld Chain Scanner based on RecurDyn simulation analysis software, verifies the kinematics model is correct, and the design of the device is reasonable.
引文
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[3]曹健.全自动相控阵超声检测技术在环焊缝检测中的应用[J].无损检测,2003,(04)：201-203页
[4]郑中兴.天然气长输管道对接环焊缝相控阵超声波全自动检测系统[J].无损探伤,2002,(04)：29-30页
[5]曹先伟.管道环焊缝扫查机器人研究[D].哈尔滨工程大学硕士学位论文,2009：3,61页
[6]E.A.Ginzel. Mechanised Ultrasonic Inspections of Pipeline Girth Welds. http://www.mri.on.ca
[7]肖雄.相控阵全自动超声波检测技术在西气东输工程中的应用[J].无损探伤,2004,(05)：5-8,14页
[8]薛振奎,白世武,詹华,等.国内长输管道对接环焊缝相控阵全自动超声检测装置的研制[J].焊管,2006,(04)：44-48,94页
[9]詹湘琳.超声相控阵油气管道环焊缝缺陷检测技术的研究[D].天津大学博士学位论文,2007：3,14页
[10]http://www.olympus-ims.com/zh/pipewizard/
[11]http://www.geinspectiontechnologies.cn/
[12]郭瑞.弹性导轨式管道环焊缝扫查器研究[D].哈尔滨工程大学硕士学位论文,2010：7,31页
[13]Murayama R., Makiyama S., Kodama M., et al. Development of an ultrasonic inspection robot using an electromagnetic acoustic transducer for a Lamb wave and SH-plate wave [J]. Ultrasonic.2004.42:825-829
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