CN111537600A - Isometric layout three-dimensional magnetic flux leakage sensor and positioning and mounting method thereof - Google Patents
Isometric layout three-dimensional magnetic flux leakage sensor and positioning and mounting method thereof Download PDFInfo
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Abstract
The invention relates to a stereoscopic magnetic leakage sensor with equal-angle layout and a positioning and mounting method thereof, wherein the stereoscopic magnetic leakage sensor with equal-angle layout comprises a bottom plate with acquisition and transmission functions, an A-axis sensor plate, a C-axis sensor plate and an R-axis sensor plate which are sequentially mounted on the bottom plate, and an acquisition and transmission circuit is printed on the bottom plate; a plurality of A-axis sensors are arranged on the A-axis sensor plate; the C-axis sensor plate is provided with a plurality of C-axis sensors; and the R-axis sensor plate is provided with a plurality of R-axis sensors. According to the three-dimensional assembling method, the sensors are arranged on the sensor plates vertical to the inner wall of the pipeline, three plates are adopted, more sensors can be arranged, the positions and surface angles of the sensors can be controlled on the sensor plates, the assembling precision is greatly improved, and the assembling difficulty is reduced.
Description
Technical Field
The invention relates to the technical field of damage detection of oil and gas pipelines, in particular to a three-dimensional magnetic flux leakage sensor with an equiangular layout and a positioning and mounting method thereof.
Background
In the current oil and gas pipeline damage detection, the most common nondestructive detection method is magnetic flux leakage detection. The basic principle of magnetic flux leakage detection is that magnetic flux lines always go through a loop with the smallest magnetic resistance (the largest magnetic permeability). When the ferromagnetic oil and gas pipeline wall (the magnetic permeability is far larger than that of air) is magnetized locally, if the surface of the pipeline wall is smooth, the inside of the pipeline wall has no defects, magnetic lines of force almost completely pass through the pipeline wall, and a magnetic field is basically absent near the surface, as shown in fig. 1; if the surface or the inside of the pipeline is defective, the defect and the magnetic resistance near the defect are increased, and the magnetic field is distorted and leaked to the surface, as shown in figure 2. By measuring the magnetic induction intensity near the pipeline wall, whether the corresponding position has defects or not and the size of the defects can be judged.
The leakage flux detection adopts Hall sensors, a typical Hall sensor is an SOT23 package or a T0-92 package, as shown in FIG. 3, a one-dimensional magnetic field vertical to the surface of the sensor can be measured, and to measure a three-dimensional magnetic field at a certain point, three Hall sensors vertical to each other must be placed at the measuring point.
The existing scheme widely uses a TO-92 packaged sensor, the pin length and the surface direction of the sensor can be manually adjusted TO corresponding positions, and the measured value is corresponding TO the magnetic field component of a certain position and direction. In order TO measure the magnetic field near the pipeline wall, the pipeline is divided into N circular arc pipelines on average, a measuring board PCB is placed under each pipeline section, a plurality of hall sensors (TO-92 packages) are mounted on the measuring board PCB and extend TO the vicinity of the pipeline wall, as shown in fig. 4, the height and surface angle of each sensor are manually adjusted, so that the magnetic induction intensity near the pipeline wall is measured.
However, because the sensors have sizes, the number of the sensors mounted on the PCB is limited, so that the distance between each measuring point is correspondingly increased, and the measuring precision is limited; because the inner part of the pipeline is arc-shaped, in order to ensure the consistency of lift-off values (the distance between the sensors and the pipe wall), the mounting height of each sensor on the PCB needs to be manually adjusted, the mounting is complex, and the precision is difficult to ensure; because the sensors are all packaged by TO-92, the surface of the sensor needs TO be manually adjusted TO be vertical TO the radial direction and the circumferential direction simultaneously for the radial direction and the circumferential direction of the sensor, and the precision is difficult TO guarantee.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a three-dimensional magnetic flux leakage sensor with an equal-angle layout and a positioning and mounting method thereof.
In order to achieve the purpose, the invention adopts the following technical scheme:
a stereoscopic magnetic flux leakage sensor with an equal-angle layout comprises a bottom plate with acquisition and transmission functions, and an A-axis sensor plate, a C-axis sensor plate and an R-axis sensor plate which are sequentially arranged on the bottom plate, wherein an acquisition transmission circuit is printed on the bottom plate;
the A-axis sensor plate is provided with a plurality of A-axis sensors, the A-axis sensors are directly surface-mounted on the A-axis sensor plate by adopting surface mount technology (SOT) -packaged sensors, each A-axis sensor is vertical to an axial line A axis of the pipeline, and the minimum distance between each A-axis sensor and the inner wall of the pipeline is equal;
the C-axis sensor board is provided with a plurality of C-axis sensors, the C-axis sensors are arranged on the C-axis sensor board by adopting TO-packaged sensors, each C-axis sensor is perpendicular TO a C axis of a circumferential line of the pipeline, and the minimum distance between each C-axis sensor and the inner wall of the pipeline is equal;
the R-axis sensor board is provided with a plurality of R-axis sensors, the R-axis sensors are arranged on the R-axis sensor board by adopting TO-packaged sensors, each R-axis sensor is perpendicular TO the R axis of the radial line of the pipeline, and the minimum distance between each R-axis sensor and the inner wall of the pipeline is equal;
the A-axis sensor, the C-axis sensor and the R-axis sensor are electrically connected with the acquisition and transmission circuit on the bottom plate.
The tops of the A-axis sensor plate, the C-axis sensor plate and the R-axis sensor plate are all arc-shaped structures matched with the inner wall of the pipeline.
The number of the A-axis sensors, the number of the C-axis sensors and the number of the R-axis sensors are ten.
The A-axis sensor 5, the C-axis sensor 6 and the R-axis sensor 7 are all Hall sensors.
The positioning and mounting method of the isometric layout three-dimensional magnetic flux leakage sensor specifically comprises the following steps:
if the radius of the pipeline is R, the distance between the sensor and the inner wall of the pipeline is D, N three-dimensional magnetic flux leakage sensors are needed for surrounding the pipeline for a circle, and then one sensor is usedThe radian of the pipeline detected by the three-dimensional magnetic flux leakage sensor is
Each three-dimensional magnetic flux leakage sensor is provided with M sensors in three directions of an A axis, a C axis and an R axis;
the radius of the arc where the three-dimensional magnetic flux leakage sensor is located is (R-D), the angle of the first detector is set to be 0, and the angle of the ith detector is set to be
The A-axis sensor is packaged on the A-axis sensor board by adopting surface-mounted SOT-23, the surface of the A-axis sensor is always vertical to the axial direction of A, the position of the ith chip is radius (R-D), and the angle is
The C-axis sensor is inserted on a C-axis sensor board by adopting TO-92 packaging, the position of the ith chip is radius (R-D), and the angle is
The surface of the C-axis sensor is always vertical to the C axis; in actual calculation, the surface of the first C-axis sensor is firstly set to be parallel to the radius, and the packaging rotation angles of other C-axis sensors on the C-axis sensor plate are sequentially increased
The R-axis sensor is packaged and inserted on the R-axis sensor board by adopting TO-92, the position of the ith chip is radius (R-D), and the angle is
The surface of the R-axis sensor is always vertical to the R axis; in actual calculation, the surface of the first R-axis sensor is firstly set to be vertical to the radius, and then the other R-axis sensors are arrangedThe rotation angles of the packaging on the R-axis sensor board are sequentially increased
The invention has the beneficial effects that: according to the three-dimensional assembling method, the sensors are arranged on the sensor plates vertical to the inner wall of the pipeline, three plates are adopted, more sensors can be arranged, the positions and surface angles of the sensors can be controlled on the sensor plates, the assembling precision is greatly improved, and the assembling difficulty is reduced.
Drawings
FIG. 1 is a diagram illustrating the principle of magnetic flux leakage detection when the pipe is free of defects;
FIG. 2 is a schematic view showing the principle of the magnetic flux leakage test when the pipe is defective;
FIG. 3 is a schematic diagram of a packaging manner of a Hall sensor;
FIG. 4 is a layout diagram of Hall sensors in a prior art measurement scheme;
FIG. 5 is a schematic view of the pipe in various orientations;
fig. 6 is a schematic structural diagram of a three-dimensional magnetic flux leakage sensor;
FIG. 7 is a schematic view of angle calculation for positioning and mounting of sensors on a sensor board;
FIG. 8 is a processing circuit diagram in embodiment 1;
in the figure: 1-a bottom plate; 2-a axis sensor board; a 3-C axis sensor board; a 4-R axis sensor board; 5-a axis sensor; a 6-C axis sensor; 7-R axis sensors;
the following detailed description will be made in conjunction with embodiments of the present invention with reference to the accompanying drawings.
Detailed Description
The invention is further illustrated by the following examples in conjunction with the accompanying drawings:
as shown in fig. 5 and 6, the isometric magnetic flux leakage sensor comprises a bottom plate 1 with acquisition and transmission functions, and an a-axis sensor board 2, a C-axis sensor board 3 and an R-axis sensor board 4 which are sequentially mounted on the bottom plate 1, wherein an acquisition and transmission circuit is printed on the bottom plate 1;
the A-axis sensor plate 2 is provided with a plurality of A-axis sensors 5, the A-axis sensors 5 are directly surface-mounted on the A-axis sensor plate 2 by adopting sensors packaged by patch SOT-23, each A-axis sensor 5 is vertical to an axial line A axis of the pipeline, and the minimum distance between each A-axis sensor 5 and the inner wall of the pipeline is equal;
the C-axis sensor plate 3 is provided with a plurality of C-axis sensors 6, the C-axis sensors 6 are mounted on the C-axis sensor plate 3 by adopting TO-92 packaged sensors, each C-axis sensor 6 is perpendicular TO a C axis of a circumferential line of the pipeline, and the minimum distance between each C-axis sensor 6 and the inner wall of the pipeline is equal;
the R-axis sensor plate 4 is provided with a plurality of R-axis sensors 7, the R-axis sensors 7 are mounted on the R-axis sensor plate 4 by adopting TO-92 packaged sensors, each R-axis sensor 7 is perpendicular TO the R axis of a radial line of the pipeline, and the minimum distance between each R-axis sensor 7 and the inner wall of the pipeline is equal;
the A-axis sensor 5, the C-axis sensor 6 and the R-axis sensor 7 are electrically connected with the acquisition and transmission circuit on the bottom plate 1.
The tops of the A-axis sensor plate 2, the C-axis sensor plate 3 and the R-axis sensor plate 4 are all arc-shaped structures matched with the inner wall of the pipeline.
The number of the A-axis sensor 5, the C-axis sensor 6 and the R-axis sensor 7 is ten.
The A-axis sensor 5, the C-axis sensor 6 and the R-axis sensor 7 are all Hall sensors.
As shown in fig. 7, the method for positioning and mounting the flux leakage sensor in the isometric layout specifically includes:
if the radius of the pipeline is R, the distance between the sensor and the inner wall of the pipeline is D, N three-dimensional magnetic flux leakage sensors are needed for surrounding the pipeline for a circle, and the radian of the pipeline detected by one three-dimensional magnetic flux leakage sensor is R
Each three-dimensional magnetic flux leakage sensor is provided with M sensors in three directions of an A axis, a C axis and an R axis;
then stand immediatelyThe radius of the arc where the body type magnetic leakage sensor is located is (R-D), the angle of the first detector is set to be 0, and the angle of the ith detector is set to be
The A-axis sensor 5 is packaged on the A-axis sensor board 2 by adopting surface-mounted SOT-23, the surface of the A-axis sensor 5 is always vertical to the axial direction of A, the position of the ith chip is radius (R-D), and the angle is
The C-axis sensor 6 is packaged and inserted on the C-axis sensor board (3) by adopting TO-92, the position of the ith chip is the radius (R-D), and the angle is
The surface of the C-axis sensor 6 is always vertical to the C axis; in actual calculation, the surface of the first C-axis sensor 6 is firstly arranged to be parallel to the radius, and the packaging rotation angles of other C-axis sensors 6 on the C-axis sensor plate (3) are sequentially increased
The R-axis sensor 7 is packaged and inserted on the R-axis sensor board 4 by adopting TO-92, the position of the ith chip is the radius (R-D), and the angle is
The surface of the R-axis sensor 7 is always vertical to the R axis; in actual calculation, the surface of the first R-axis sensor 7 is set to be vertical to the radius, and the packaging rotation angles of the other R-axis sensors 7 on the R-axis sensor plate 4 are sequentially increased
According to the three-dimensional assembling method, the sensors are arranged on the sensor plates vertical to the inner wall of the pipeline, three plates are adopted, more sensors can be arranged, the positions and surface angles of the sensors can be controlled on the sensor plates, the assembling precision is greatly improved, and the assembling difficulty is reduced.
Specific example 1:
taking the most common 12-inch pipeline as an example, the circumference of the inner diameter of the pipeline wall is 960mm, if the distance between measuring points is 6mm, the magnetic field of 160 points needs to be measured, and the currently common hall sensor can only output the magnetic induction intensity analog quantity in one direction, and 480 sensors need to be arranged along the pipeline wall in total. Because the output of the sensor is analog quantity, 480 paths of signals are acquired and uploaded, and because the pipeline pig runs at a very high speed (5 m/s at the fastest speed), the sampling speed is required to be very high (5 kHz at the highest speed) in order to improve the measurement accuracy.
The pipeline can be divided into 16 circular arcs, and each circular arc corresponds to one three-dimensional magnetic flux leakage sensor. Each three-dimensional magnetic leakage sensor is internally provided with 30 Hall sensors, and a circuit acquisition module samples and uploads analog signals of the 30 Hall sensors, and the number of the modules is 16.
The diameter of the 12-inch pipeline is 12 inches, the circumference is about 36 inches, the magnetic flux leakage is measured by a magnetic field near the circumference, the whole circumference is divided into 16 sections, and each section is about 2.25 inches due to the inconvenience of one-time measurement and the requirement of certain flexibility of the whole measuring module. Here, just to give an example, there are many ways of segmenting for different sized pipes.
Analog signals output by the sensor array enter a high-speed multi-path switching analog switch so that the MCU can collect the analog signals in turn, and the multi-path switching switch is controlled by the MCU and then enters an AD sampling port of the MCU. Taking 30 paths of signals as an example, 4 analog switches with 8 paths are shared, during sampling, the MCU controls one path of the multi-path switches to be on, and after sampling 4 paths of signals, the multi-path switches are switched to another 4 paths of signals for sampling, as shown in fig. 8, the 30 paths of signals are a1-a10, R1-R10, C1-C10, ADR0/ADR1/ADR2 are switching control signals led from the MCU, and D1/D2/D3/D4 are sensor signals output from the 4 analog switches to the MCU.
For convenience of description, this is merely an example. Assuming that there are 30 analog signals (10 signals in each direction in 3 directions) to be collected in the module, according to normal practice, 30 ADCs are required to collect these signals, and if the number of signals is larger, more ADCs are required, so that the required ADCs are reduced by using the multi-way analog switch.
The multi-path analog switch selects one path of output by multi-path input, the output is connected to one ADC, only one input signal enters the ADC for sampling by MCU logic control each time, one path of sampling is finished, the MCU switches the other path of signal to the ADC by logic control, and thus, only one ADC can sample no input signal in turn.
In this example, 30 signals plus 2 backup signals (which can be directly grounded) and 32 signals (all signals are equivalent, and sampling rules have no special requirements) can be divided into 4 groups according to the spatial proximity principle, each group has 8 paths, each group of signals enters one 8-path analog switch, the output of each analog switch is connected with one ADC, the total number of the 4 analog switches and the 4 ADCs are, and the switching logics of the 4 analog switches are uniformly controlled by the MCU. The method comprises the following specific steps: firstly, the MCU controls the conduction of a first channel of 4 analog switches, the 4 ADCs respectively perform sampling to obtain a first analog signal value of each group, the MCU controls the conduction of a second channel of the 4 analog switches after the sampling is finished, the 4 ADCs respectively perform sampling to obtain a second analog signal value of each group, and the sampling of 32 analog signals is completed after the sampling is repeated for 8 times. Through the multichannel analog switch, greatly reduced the use number of ADC, reduced overall cost.
The above description is only a specific example to describe the method of collecting multiple signals with a multi-way switch and not just to protect this particular case.
The data acquisition and transmission are carried out by the mileage wheel pulse signals, and the synchronization of all the signals is ensured.
The mileage wheel is provided with a special encoder, a pulse signal is sent out every time the mileage wheel walks a fixed short distance, and the measuring position of the sensor can be calibrated by calculating the number of the pulse signals. This pulse signal is fed in parallel to the acquisition system of 16 sensor modules. The MCU of the sensor array module uses this signal as an interrupt signal and starts the acquisition of 32 channels of signals (as described above) when the MCU receives the interrupt signal. And when the next interrupt signal arrives, repeatedly acquiring and transmitting.
When hundreds or thousands of analog sensors need to be acquired, the sensors are grouped, and each group only needs to process dozens of sensor signals; each group of sensors adopts a method of sampling by high-speed analog switches in turn, so that the number of ADCs used is reduced; and starting to sample and transmit by adopting a mileage wheel pulse signal, and synchronizing the sensors.
The invention has been described in connection with the accompanying drawings, it is to be understood that the invention is not limited to the specific embodiments disclosed, but is intended to cover various modifications, adaptations or uses of the invention, and all such modifications and variations are within the scope of the invention.
Claims (5)
1. The isometric magnetic flux leakage sensor is characterized by comprising a bottom plate (1) with acquisition and transmission functions, an A-axis sensor plate (2), a C-axis sensor plate (3) and an R-axis sensor plate (4) which are sequentially arranged on the bottom plate (1), wherein an acquisition and transmission circuit is printed on the bottom plate (1);
the A-axis sensor plate (2) is provided with a plurality of A-axis sensors (5), the A-axis sensors (5) are directly surface-mounted on the A-axis sensor plate (2) by adopting sensors packaged by a patch SOT-23, each A-axis sensor (5) is vertical to an axis A of an axial line of the pipeline, and the minimum distance between each A-axis sensor (5) and the inner wall of the pipeline is equal;
the C-axis sensor plate (3) is provided with a plurality of C-axis sensors (6), the C-axis sensors (6) are mounted on the C-axis sensor plate (3) by adopting TO-92 packaged sensors, each C-axis sensor (6) is perpendicular TO a C axis of a circumferential line of the pipeline, and the minimum distance between each C-axis sensor (6) and the inner wall of the pipeline is equal;
a plurality of R-axis sensors (7) are mounted on the R-axis sensor board (4), the R-axis sensors (7) are mounted on the R-axis sensor board (4) by adopting TO-92 packaged sensors, each R-axis sensor (7) is perpendicular TO the R axis of a radial line of the pipeline, and the minimum distance between each R-axis sensor (7) and the inner wall of the pipeline is equal;
the A-axis sensor (5), the C-axis sensor (6) and the R-axis sensor (7) are electrically connected with the acquisition and transmission circuit on the bottom plate (1).
2. The isometric magnetic flux leakage sensor according to claim 1, wherein the tops of the A-axis sensor plate (2), the C-axis sensor plate (3) and the R-axis sensor plate (4) are arc structures matched with the inner wall of the pipeline.
3. The isometric layout magnetic flux leakage sensor according to claim 2, wherein the number of the A-axis sensors (5), the C-axis sensors (6) and the R-axis sensors (7) is ten.
4. The isometric layout magnetic flux leakage sensor according to claim 3, wherein the A-axis sensor (5), the C-axis sensor (6) and the R-axis sensor (7) are all Hall sensors.
5. The positioning and mounting method of the isometric layout three-dimensional magnetic flux leakage sensor according to claims 1 to 4, is characterized in that:
if the radius of the pipeline is R, the distance between the sensor and the inner wall of the pipeline is D, N three-dimensional magnetic flux leakage sensors are needed for surrounding the pipeline for a circle, and the radian of the pipeline detected by one three-dimensional magnetic flux leakage sensor is R
Each three-dimensional magnetic flux leakage sensor is provided with M sensors in three directions of an A axis, a C axis and an R axis;
the radius of the arc where the three-dimensional magnetic flux leakage sensor is located is (R-D), the angle of the first detector is set to be 0, and the angle of the ith detector is set to be
The A-axis sensor (5) is packaged on the A-axis sensor board (2) by adopting surface-mounted SOT-23, the surface of the A-axis sensor (5) is always vertical to the axial direction of A, the position of the ith chip is radius (R-D), and the angle is
The C-axis sensor (6) is inserted on the C-axis sensor board (3) by adopting TO-92 packaging, the position of the ith chip is radius (R-D), and the angle is
The surface of the C-axis sensor (6) is always vertical to the C axis; in actual calculation, the surface of the first C-axis sensor (6) is arranged to be parallel to the radius, and the packaging rotation angles of other C-axis sensors (6) on the C-axis sensor plate (3) are sequentially increased
The R-axis sensor (7) is inserted on the R-axis sensor board (4) by adopting TO-92 packaging, the position of the ith chip is radius (R-D), and the angle is
The surface of the R-axis sensor (7) is always vertical to the R axis; in actual calculation, the surface of the first R-axis sensor (7) is arranged to be vertical to the radius, and the packaging rotation angles of other R-axis sensors (7) on the R-axis sensor plate (4) are sequentially increased
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN111321058A (en) * | 2020-03-06 | 2020-06-23 | 成都博奥晶芯生物科技有限公司 | Optical positioning coded disc, device and method for microfluidic chip |
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| US20120038354A1 (en) * | 2006-12-21 | 2012-02-16 | Gies Paul D | Linear structure inspection apparatus and method |
| CN102159944A (en) * | 2008-06-27 | 2011-08-17 | Pii(加拿大)有限公司 | Integrated multi-sensor non-destructive testing |
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Application publication date: 20200814 |