CN105136910A - Tube plate stereostructure girth joint sound emission detecting and positioning method - Google Patents
Tube plate stereostructure girth joint sound emission detecting and positioning method Download PDFInfo
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Abstract
Description
技术领域 technical field
本发明涉及利用声发射动态监测技术对管板立体结构环焊缝进行实时监测和声发射源准确定位，是属于声学无损检测范围，具体为一种管板立体结构环焊缝声发射检测定位方法。 The invention relates to the real-time monitoring and accurate positioning of the acoustic emission source for the three-dimensional structure of the tube-plate girth weld using the dynamic monitoring technology of acoustic emission, which belongs to the scope of acoustic non-destructive testing, and is specifically an acoustic emission detection and positioning method for the three-dimensional structure of the tube-plate girth weld .
背景技术 Background technique
管板焊接结构在日常生活中是一种常见结构，如换热器、石油管道、压力容器、起重机械和列车转向架等结构，都出现了管板焊接结构。但是目前对这类结构检测仍然采用常规超声、射线、电磁检测等方法，需要在设备停机或静止条件下检测，不仅影响设备的正常工作和生产进度，而且需要花费大量人力、物力和时间，一旦出现漏检，将会带来灾难性后果。随着国家对质量检测要求的提高，不仅要在检测准确性、稳定性上提高，而且要求能在设备使用过程中动态的对可能发生的缺陷、故障进行预报，从而能在某一合适时间段内采取相应解决措施，保证结构安全使用。声发射技术的发展使动态无损检测技术成为了可能。 The tube-sheet welded structure is a common structure in daily life, such as heat exchangers, oil pipelines, pressure vessels, hoisting machinery, and train bogies, all of which have tube-sheet welded structures. However, at present, conventional ultrasonic, ray, and electromagnetic detection methods are still used for this type of structure detection, which need to be detected under equipment shutdown or static conditions, which not only affects the normal operation and production progress of the equipment, but also requires a lot of manpower, material resources and time. Failure to detect will have catastrophic consequences. With the improvement of national quality inspection requirements, it is not only necessary to improve the accuracy and stability of the inspection, but also to be able to dynamically predict possible defects and failures during the use of the equipment, so that the Take corresponding measures to ensure the safe use of the structure. The development of acoustic emission technology makes dynamic nondestructive testing technology possible.
声发射是指材料在外力或者内力的作用下，其中某一局部源会迅速释放出能量而产生瞬态弹性波的一种现象。这种弹性波会包含该局部源的一些性质并传播到材料表面，放置在材料表面的声发射传感器能够扑捉到这些信息。而且根据所采集到信号的一些特点以及施加的外部条件，不仅可以了解缺陷现状，还能够了解这个缺陷之前的形成状况，甚至判断在之后的使用中发展的趋势，这一点也是其它无损检测方法难以做到的，所以用声发射技术可以判断缺陷的活动性和严重性。 Acoustic emission refers to a phenomenon in which a local source of a material rapidly releases energy to generate transient elastic waves under the action of external or internal forces. This elastic wave will contain some properties of the local source and propagate to the material surface, where the acoustic emission sensor placed on the material surface can capture this information. Moreover, according to some characteristics of the collected signals and the external conditions imposed, not only the current status of the defect can be understood, but also the formation status of the defect before it can be understood, and even the development trend in the subsequent use can be judged, which is difficult for other non-destructive testing methods. It is done, so the activity and severity of defects can be judged with acoustic emission technology.
在材料或结构内部出现了位错和微裂纹，将会以弹性波形式发出能量，通常称为声发射源，因此对于声发射源的定位是声发射检测技术中一个重要内容，可以确定缺陷的发生部位。目前声发射源的定位方法主要有时差法和区域法，区域定位虽然处理速度快，但是定位效果却比较差，定位出来的是一片区域，准确性不够，而且一般是在要求不高或者时差法较难应用的情况下使用。时差定位相对复杂，且容易丢失很多比较低能量的信号，定位的效果也会被波速、波形、衰减以及构件的几何形状等因素影响，但是通常会采取一定的信号处理方法提高信噪比，目前该方法还是比区域定位法精确，应用更多。 Dislocations and microcracks appear in the material or structure, and energy will be emitted in the form of elastic waves, which is usually called the acoustic emission source. Therefore, the location of the acoustic emission source is an important content in the acoustic emission detection technology, which can determine the location of the defect. Occurrence site. At present, the positioning methods of acoustic emission sources are mainly time difference method and area method. Although the processing speed of area positioning is fast, the positioning effect is relatively poor. What is located is an area, the accuracy is not enough, and generally it is not demanding or the time difference method Use in difficult applications. Time difference positioning is relatively complicated, and it is easy to lose many relatively low-energy signals. The positioning effect will also be affected by factors such as wave velocity, waveform, attenuation, and geometric shape of components. However, certain signal processing methods are usually adopted to improve the signal-to-noise ratio. At present, This method is still more accurate than the regional positioning method and has more applications.
就目前的声发射检测仪器而言，主要还是以规则形状的检测定位为主，如板形、柱形、球形和锥形等，而由于管板结构较复杂，声发射检测在该类结构上的检测较少，对其定位更是鲜有报道，大都处于初步研究阶段。本发明结合了区域定位和时差定位两种方法的特点，实现了管板立体结构声发射源的准确定位。 As far as the current acoustic emission detection instruments are concerned, the detection and positioning of regular shapes are mainly used, such as plate shape, cylinder shape, spherical shape, and cone shape. There are few detections, and there are few reports on its location, most of which are in the preliminary research stage. The invention combines the characteristics of the two methods of regional positioning and time difference positioning, and realizes accurate positioning of the acoustic emission source of the three-dimensional structure of the tube plate.
发明内容 Contents of the invention
本发明的目的是针对管板立体结构声发射动态监测需要，提出一种管板立体结构环焊缝声发射检测定位方法，其结合管板结构特点和声发射动态监测方法对缺陷的敏感性，先后利用声发射区域定位和时差定位方法，达到对声发射源即缺陷准确定位的目的，为实现管板立体结构环焊缝声发射检测技术提供保障。 The purpose of the present invention is to propose a method for acoustic emission detection and positioning of the three-dimensional structure of the tube-sheet structure for the dynamic monitoring of acoustic emission, which combines the structural characteristics of the tube-sheet and the sensitivity of the acoustic emission dynamic monitoring method to defects. Acoustic emission area positioning and time difference positioning methods have been used successively to achieve the purpose of accurate positioning of the acoustic emission source, that is, the defect, and provide guarantee for the realization of the acoustic emission detection technology of the three-dimensional structure of the tube plate girth weld.
本发明的技术方案：一种管板立体结构环焊缝声发射检测定位方法，在管板立体结构上利用布置的传感器和现有声发射检测仪器平面定位功能，通过弧面转换方法将立体结构转化成平面结构，根据各传感器接收到的声发射信号到达时间，分析声发射信号在结构内的传播过程，判断出声发射源所在区域，最后采用时差定位法实现对管板立体结构环焊缝声发射源的准确定位；其特征在于具体方法是： The technical scheme of the present invention: a method for acoustic emission detection and positioning of the three-dimensional structure of the tube plate, using the sensors arranged on the three-dimensional structure of the tube plate and the plane positioning function of the existing acoustic emission detection instrument to transform the three-dimensional structure through the arc surface conversion method According to the arrival time of the acoustic emission signal received by each sensor, analyze the propagation process of the acoustic emission signal in the structure, judge the area where the acoustic emission source is located, and finally use the time difference positioning method to realize the sound detection of the three-dimensional structure of the tube sheet. Accurate positioning of the emission source; it is characterized in that the specific method is:
步骤一：使用声发射检测仪器进行测试，采集声发射源发出的声发射信号；对于管板立体结构特征，布置三个传感器，分布是在板上两端对称布置两个传感器S1、S2，在管上布置一个传感器S3，且三个传感器位置在空间上为等腰三角形状；如果以S3在环焊缝上的投影位置为中心点A（实际焊缝有一定宽度，那么A点是在焊道中心线上），则检测范围可达±90°的焊缝长度。 Step 1: Use the acoustic emission detection instrument for testing to collect the acoustic emission signal from the acoustic emission source; for the three-dimensional structural characteristics of the tube plate, arrange three sensors, and the distribution is to arrange two sensors S 1 and S 2 symmetrically at both ends of the plate , a sensor S 3 is arranged on the pipe, and the positions of the three sensors are in the shape of an isosceles triangle in space; if the projected position of S 3 on the girth weld is taken as the center point A (the actual weld has a certain width, then A point is on the centerline of the weld bead), the detection range can reach ±90° weld length.
步骤二：由于管板环焊缝声波路径比较复杂，与声发射源位置较远的传感器接收到的信号路径很难确定，使板上两个传感器不能确定声发射源准确位置，因此将管面以S3到A点的直线为对称轴展开成平面，然后再将该平面以展开后的焊缝线为轴线，向没有布置传感器的一侧转动，达到与板面重合在同一平面上。 Step 2: Since the acoustic path of the girth weld of the tube sheet is relatively complicated, it is difficult to determine the signal path received by the sensor far from the acoustic emission source, so that the two sensors on the board cannot determine the exact location of the acoustic emission source, so the pipe surface Take the straight line from S 3 to point A as the axis of symmetry to expand into a plane, and then take the expanded weld line as the axis to rotate the plane to the side where the sensor is not arranged, so as to coincide with the plate surface on the same plane.
步骤三：接下来先根据板上两个传感器S1和S2接收到的信号情况进行声发射源区域判别，确定声发射源离哪个传感器距离更近，根据声发射源B的位置，可能出现以下两种情况： Step 3: Next, judge the area of the acoustic emission source based on the signals received by the two sensors S 1 and S 2 on the board, and determine which sensor the acoustic emission source is closer to. According to the position of the acoustic emission source B, there may be The following two situations:
（1）声发射源B到达S1和S2的时间相同，那么只有一种可能，就是B在焊缝内过A点且与焊道中心线垂直的直线上，然后根据S3的到达时间计算出B的准确位置。 (1) The arrival time of the acoustic emission source B at S 1 and S 2 is the same, so there is only one possibility, that is, B passes through point A in the weld and is on a straight line perpendicular to the centerline of the weld bead, and then according to the arrival time of S 3 Calculate the exact position of B.
（2）声发射源B到达S1和S2的时间不同，那么B可能离S1近，也可能离S2近，但不管离哪个传感器更近，后续的计算方法相同。假设B离S1近，那么以S1为圆心，根据S1测量的到达时间作圆弧，在焊缝区域内与焊缝相交形成一条弧线，即声发射源B就在焊道区域的弧线上。然后再以S3为圆心，根据S3的到达时间作圆弧，与前面的弧线在焊缝区域内交叉处为声发射源B的准确位置。 (2) The arrival time of acoustic emission source B to S 1 and S 2 is different, so B may be closer to S 1 or S 2 , but no matter which sensor is closer, the subsequent calculation method is the same. Assuming that B is close to S1, then take S1 as the center of the circle, and make an arc according to the arrival time measured by S1, and intersect the weld in the weld area to form an arc, that is, the acoustic emission source B is in the weld bead area on the arc. Then take S3 as the center of the circle, and make a circular arc according to the arrival time of S3, and the intersection with the previous arc in the weld area is the exact position of the acoustic emission source B.
步骤四：还需根据几何关系，将获得的声发射源B平面位置还原到实际位置上，即声发射源B到A的水平距离应该与实际环焊缝上的声发射源S到A的弧长相同，然后根据弧长和管径的关系式，计算出声发射源S的实际位置坐标，实现对管板立体结构环焊缝的声发射检测定位方法。 Step 4: It is also necessary to restore the obtained plane position of the acoustic emission source B to the actual position according to the geometric relationship, that is, the horizontal distance from the acoustic emission source B to A should be the same as the arc from the acoustic emission source S to A on the actual girth weld The lengths are the same, and then according to the relationship between the arc length and the pipe diameter, the actual position coordinates of the acoustic emission source S are calculated to realize the acoustic emission detection and positioning method for the three-dimensional structural girth weld of the tube sheet.
本发明与现有技术相比具有的特点是：对管板立体结构进行了平面化处理，利用现有声发射检测仪器的平面定位功能对环焊缝进行声发射源定位监测，由于实际声波传播路径难确定，采用区域定位先确定声发射源所在区域；然后根据时差定位法确定声发射源实际位置；最后将直线环焊缝上声发射源经过几何校正，计算出声发射源在立体结构上的实际位置。此发明提出一种管板立体结构环焊缝声发射监测定位方法，可用于不同尺寸、不同领域内的管板结构声发射监测定位，为该类结构的检测提供了一个新的检测手段，也为声发射检测开辟了新的应用领域。 Compared with the prior art, the present invention has the following characteristics: the three-dimensional structure of the tube sheet is planarized, and the acoustic emission source location monitoring of the girth weld is carried out by using the plane positioning function of the existing acoustic emission detection instrument. If it is difficult to determine, use regional positioning to first determine the area where the acoustic emission source is located; then determine the actual location of the acoustic emission source according to the time difference positioning method; actual location. This invention proposes an acoustic emission monitoring and positioning method for the three-dimensional structure of the tube-sheet structure, which can be used for the acoustic emission monitoring and positioning of the tube-sheet structure in different sizes and in different fields, and provides a new detection method for the detection of this type of structure. It opens up a new application field for acoustic emission detection.
附图说明 Description of drawings
图1本发明的钢制管板立体结构与传感器分布示意图。 Fig. 1 is a schematic diagram of the three-dimensional structure of the steel tube sheet and the distribution of sensors of the present invention.
图2本发明的管弧面展开并转到板平面示意图。 Fig. 2 is a schematic diagram of the arc surface of the tube unfolded and transferred to the plate plane of the present invention.
图3本发明的声发射源实际位置转换示意图。 Fig. 3 is a schematic diagram of the actual position conversion of the acoustic emission source of the present invention.
具体实施方式 Detailed ways
对于此发明的有效性以及可行性采用以下实验方案进行验证。实验测试管板结构为钢制转向架部件试样，按照实际尺寸进行了缩小，结构中管材为外径168mm、壁厚12mm，板材为350mm长、230mm宽、10mm厚。实验采用美国PAC公司8通道PCI-2系统声发射检测设备。传感信号通过前置功率放大器放大后被输入计算机中进行处理，实际使用了三个R15SNAT68型传感器，其中心频率为150KHz。 For the validity and feasibility of this invention, the following experimental scheme is adopted to verify. The experimental test tubesheet structure is a steel bogie component sample, which is reduced according to the actual size. The tube in the structure is 168mm in outer diameter, 12mm in wall thickness, and the plate is 350mm long, 230mm wide, and 10mm thick. The experiment adopts the 8-channel PCI-2 system acoustic emission detection equipment of American PAC Company. The sensing signal is amplified by the pre-power amplifier and then input to the computer for processing. Three R15SNAT68 sensors are actually used, and the center frequency is 150KHz.
使用中对于管板立体结构特征，布置了三个传感器，分别是在板上两端对称布置两个传感器S1、S2，在管上布置1个传感器S3，且三个传感器位置在空间上为等腰三角形状，具体结构及传感器位置如图1所示。实验测试前，首先需要对声发射检测仪器按照平面定位方式进行设定定位参数，所以将该结构进行了平面化处理，即将管弧面以过S3和A点的直线为对称轴展开成平面，然后再将该平面以展开后的焊道中心线为轴线，向没未布置传感器的一侧转动，达到与板面重合在同一平面上，处理后的结果如图2所示，经过处理以后三个传感器就在同一平面内，将传感器位置坐标输入处理软件，就可以对焊缝区域进行声发射源定位。实验中以板面左下角为原点，三个传感器平面上坐标分别为S1（40,40）、S2（190,40）、S3（115,150），焊缝中心线中间点坐标为A（115,90），单位为mm。 For the three-dimensional structural characteristics of the tube sheet in use, three sensors are arranged, respectively, two sensors S 1 and S 2 are symmetrically arranged on both ends of the plate, and one sensor S 3 is arranged on the tube, and the positions of the three sensors are in the space The upper part is in the shape of an isosceles triangle, and the specific structure and sensor location are shown in Figure 1. Before the experimental test, it is first necessary to set the positioning parameters of the acoustic emission detection instrument according to the plane positioning method, so the structure is planarized, that is, the arc surface of the tube is unfolded into a plane with the straight line passing through S3 and point A as the symmetrical axis , and then turn the plane to the side where the sensor is not arranged with the center line of the developed weld bead as the axis, so as to coincide with the plate surface on the same plane. The processed result is shown in Figure 2. After processing The three sensors are in the same plane, and the position coordinates of the sensors are input into the processing software to locate the source of the acoustic emission in the weld area. In the experiment, the lower left corner of the panel is taken as the origin, the coordinates on the three sensor planes are S 1 (40,40), S 2 (190,40), S 3 (115,150), and the coordinates of the middle point of the weld centerline are A ( 115,90), the unit is mm.
接下来根据板面上两个传感器S1和S2接收到的信号情况进行声发射源区域判别，确定声发射源离哪个传感器距离更近。根据声发射源B的位置，可能出现以下两种情况： Next, according to the signals received by the two sensors S1 and S2 on the board, the area of the acoustic emission source is identified to determine which sensor the acoustic emission source is closer to. Depending on the location of the acoustic emission source B, the following two situations may occur:
（1）声发射源B到达S1和S2的时间相同，那么只有一种可能，就是B在焊缝内过A点且与焊道中心线垂直的直线上，然后根据S3的到达时间计算出B的准确位置； (1) The arrival time of the acoustic emission source B at S 1 and S 2 is the same, so there is only one possibility, that is, B passes through point A in the weld and is on a straight line perpendicular to the centerline of the weld bead, and then according to the arrival time of S 3 Calculate the exact position of B;
（2）声发射源B到达S1和S2的时间不同，那么B可能离S1近，也可能离S2近，图2中的声发射源B位置靠近S2，t1和t2分别为S1和S2接收到声发射信号的时间。但不管离哪个传感器更近，后续处理和计算方法相同。假设B离S1近，如图3所示，那么以S1为圆心，根据S1测量的到达时间作圆弧，在焊缝区域内与焊缝相交形成一条弧线，即声发射源B就在焊道区域的弧线上。然后再以S3为圆心，根据S3的到达时间作圆弧，与前面的弧线交叉处为声发射源B的准确位置。 (2) The arrival time of acoustic emission source B to S 1 and S 2 is different, so B may be close to S 1 or S 2. The position of acoustic emission source B in Figure 2 is close to S 2 , t 1 and t 2 are the times when S 1 and S 2 receive the acoustic emission signal, respectively. But no matter which sensor is closer, the subsequent processing and calculation methods are the same. Assuming that B is close to S1, as shown in Figure 3 , then take S1 as the center of the circle, and make an arc according to the arrival time measured by S1, and intersect the weld in the weld area to form an arc, that is, the acoustic emission source B Just on the arc of the weld bead area. Then take S3 as the center of the circle, make an arc according to the arrival time of S3, and the intersection with the previous arc is the exact position of the acoustic emission source B.
最后还需根据几何关系，将获得的声发射源B平面位置还原到实际位置上，即声发射源B到A的水平距离应该与实际环焊缝上的声发射源S到A的弧长相同，假设平面定位声发射源B的坐标为（x,y），那么其与焊道中心线的垂直距离为： Finally, it is necessary to restore the plane position of the acoustic emission source B to the actual position according to the geometric relationship, that is, the horizontal distance from the acoustic emission source B to A should be the same as the arc length from the acoustic emission source S to A on the actual girth weld , assuming that the coordinates of the plane positioning acoustic emission source B are ( x, y ), then its vertical distance from the centerline of the weld bead is:
Δy＝（90－y）（1） Δy = (90 - y ) (1)
而到A点的水平坐标差值为：l＝（115－x）（2） And the horizontal coordinate difference to point A is: l = (115- x ) (2)
那么根据弧长计算公式（3）可推导出公式（4），计算出实际声发射源与A点的弧度角θ： Then, according to the arc length calculation formula (3), the formula (4) can be deduced, and the arc angle θ between the actual sound emission source and point A can be calculated:
（3） (3)
（4） (4)
式中R是钢管的外半径。最后可以根据弧度角按照公式（5）和（6）计算出实际声发射源S（X s ,Y s ）坐标，实现对声发射源S的准确定位。 where R is the outer radius of the steel tube. Finally, the coordinates of the actual acoustic emission source S ( X s , Y s ) can be calculated according to formulas (5) and (6) according to the radian angle, so as to realize accurate positioning of the acoustic emission source S.
（5） (5)
（6）。 (6).
实验中采用铅笔断芯的方式模拟声发射信号，声发射源坐标为（178.5,121），单位为mm。然后声发射检测仪器通过传感器接收信号并且形成平面定位结果。从定位结果中发现声发射源离传感器S2更近，按照上述的方法计算出声发射源的位置为（174.7,118.1），与实际位置误差（3.8,2.9），按照S1和S2间的距离150mm计算，相对误差仅为3.19％，能够满足实际检测要求。 In the experiment, the acoustic emission signal was simulated by breaking the core of a pencil. The coordinates of the acoustic emission source are (178.5, 121), and the unit is mm. Then the acoustic emission detection instrument receives the signal through the sensor and forms a plane positioning result. From the positioning results, it is found that the acoustic emission source is closer to the sensor S 2. According to the above method, the position of the acoustic emission source is calculated as (174.7, 118.1), and the actual position error is (3.8, 2.9), according to the distance between S 1 and S 2 Calculated at a distance of 150mm, the relative error is only 3.19%, which can meet the actual detection requirements.
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