KR102270635B1 - Ultrasound Real-time detection system for defect in a pipeline - Google Patents

Abstract

The present invention relates to an ultrasonic real-time pipe defect inspection system, and it is possible to easily and conveniently detect pipe defects in real time by detecting the thickness of the pipe by a relatively simple ultrasonic detection method, rather than a complicated magnetic field distribution detection method.

Description

Ultrasound Real-time detection system for defect in a pipeline

The present invention relates to a technique for detecting defects such as wear or breakage of pipes used in industrial facilities or ships, and more particularly, to an ultrasonic real-time pipe defect detection system.

A pipe is a circular structure mainly made of metal, and is basically used in various facilities, and in particular, in a facility such as a chemical industrial complex, a myriad of pipes are used to transport various substances.

These pipes not only have different abrasion rates and shapes depending on the type of liquid or gas flowing inside, but also have differences depending on their location, so it is very difficult to identify corrosion or cracks due to aging. In addition, it is very difficult to inspect because the installation location is very diverse from a place close to the ground to a place higher than 100m.

Therefore, in order to inspect the wear and cracks of the pipes, the inspection period is set and the inspection is performed periodically. Conducted regularly at least once a year. However, in this method, it is not easy to accurately inspect the worn area because the person directly inspects and intermittently inspects.

In addition, there is always a possibility that an accident may occur during the period between the inspection periods, and it has a disadvantage that it requires a lot of cost. If an accident occurs, there is a high possibility of a major accident, and the damage is inevitably large, such as a personnel accident, as well as a complete shutdown of the factory or its impact on the surrounding area.

The phenomenon that appears as a result of wear and corrosion of the pipe is that the thickness of the pipe gradually decreases with time. If the reduced pipe thickness exceeds the limit value, cracks occur, and if the crack becomes severe, it cannot withstand the pressure of the fluid flowing inside. It will leak or explode.

In Korean Patent Laid-Open No. 10-2013-0130529 (2013.12.02), the magnetic field distribution resulting from the defect in the pipe due to the AC power applied to the coil is detected through the sensor unit, and the defect in the pipe is detected in a short time with high spatial resolution. A small-diameter pipe defect detection device for flaw detection is proposed.

In this device, a plurality of magnetic sensors are arranged and a sensor unit formed in a cylindrical shape, a coil unit wound along the outer surface of the sensor unit, a power supply unit that applies DC power to the sensor unit and AC power to the coil unit, and a sensor unit applied from the sensor unit. It includes a signal receiver for quantitatively quantifying the signal.

The present inventor conducted a study on real-time pipe defect detection technology using an array-type ultrasonic transducer that can easily and conveniently detect pipe defects in real time by detecting the thickness of the pipe with a relatively simple ultrasonic detection method, rather than a complex magnetic field distribution detection method. did.

Republic of Korea Patent Publication No. 10-2013-0130529 (2013.12.02)

The present invention is not a complicated magnetic field distribution detection method, but a relatively simple ultrasonic detection method to detect the thickness of the pipe to provide an ultrasonic real-time pipe defect inspection system using an array type ultrasonic transducer that can easily and conveniently detect the defects in the pipe in real time. for that purpose

Another object of the present invention is to implement an array-type ultrasonic transducer by arranging a plurality of ultrasonic sensors on a flexible circuit board, so that the array-type ultrasonic transducer can be easily and conveniently attached to the outer curved surface of the pipe regardless of the diameter of the pipe to detect defects in the pipe It is to provide an ultrasonic real-time pipe fault detection system that can do this.

According to an aspect of the present invention for achieving the above object, an ultrasonic real-time pipe defect detection system includes an array-type ultrasonic transducer in which a plurality of ultrasonic sensors are arranged; Including a controller that receives an electrical pipe defect detection signal from an arrayed ultrasonic transducer in real time to detect a pipe defect in real time, and warns when a pipe defect is detected, wherein the arrayed ultrasonic transducer emits an ultrasonic signal to the pipe and is reflected from the pipe a plurality of ultrasonic sensors for receiving an ultrasonic signal and converting the received ultrasonic signal into an electrical pipe defect detection signal; It includes a flexible printed circuit board (FPCB) on which a plurality of ultrasonic sensors are arranged.

According to an additional aspect of the present invention, the array type ultrasonic transducer serves to attenuate the ultrasonic wave and at the same time a sound absorbing layer for bonding a plurality of ultrasonic sensors to the flexible circuit board; It further includes a matching layer for impedance matching of the ultrasonic signal emitted to the pipe, reflected from the pipe and received.

According to an additional aspect of the present invention, the array type ultrasonic transducer further includes a protective layer surrounding and protecting the exterior of the plurality of ultrasonic sensors.

According to an additional aspect of the present invention, a plurality of comb-tooth portions arranged in parallel with a specific interval in a direction in which the flexible circuit board is bent; At one end of the comb portions arranged in parallel, a support portion for connecting the comb portions to each other in a right angle direction is included.

According to an additional aspect of the present invention, a controller comprises: a driving unit for driving ultrasonic sensors arranged in an array-type ultrasonic transducer; a signal processing unit that processes electrical pipe defect detection signals received in real time from ultrasonic sensors to obtain pipe thickness information, and detects pipe defects in real time from the acquired pipe thickness information; When the signal processing unit detects a pipe defect, it includes a warning unit for warning it.

According to an additional aspect of the present invention, the controller further includes a MUX for sequentially driving the ultrasonic sensors arranged in the arrayed ultrasonic transducer.

According to an additional aspect of the present invention, the array type ultrasonic transducer further includes a temperature sensor for measuring the temperature of the pipe in real time, and the signal processing unit of the controller processes the electrical pipe defect detection signal received in real time from the ultrasonic sensors to process the pipe defect detection signal. When real-time flaw detection of pipe defects by acquiring thickness information, the ultrasonic transmission speed (speed of sound) is adjusted according to the temperature of the pipe 200 measured by the temperature sensor to reduce the thickness measurement error.

According to an additional aspect of the present invention, an ultrasonic real-time pipe defect inspection system includes: a contact medium (Couplant) disposed between the inspection surface of the array type ultrasonic transducer and the pipe; It further includes a fixing means for preventing separation of the array type ultrasonic transducer mounted on the pipe.

The present invention has the effect of being able to easily and conveniently detect defects in the pipe in real time by detecting the thickness of the pipe by a relatively simple ultrasonic detection method rather than a complicated magnetic field distribution detection method.

According to the present invention, an array-type ultrasonic transducer is implemented by arranging a plurality of ultrasonic sensors on a flexible circuit board, so that an array-type ultrasonic transducer can be easily and conveniently attached to a curved surface of a pipe regardless of the diameter of the pipe to detect defects in the pipe there is

1 is a diagram showing the configuration of an embodiment of the ultrasonic real-time pipe defect detection system according to the present invention.
2 is a diagram showing the configuration of an embodiment of the array type ultrasonic transducer of the ultrasonic real-time pipe defect detection system according to the present invention.
3 is a diagram illustrating an arrangement form of ultrasonic sensors arranged in an array-type ultrasonic transducer of an ultrasonic real-time pipe defect detection system according to the present invention.
4 is a view showing an embodiment of the flexible circuit board of the array type ultrasonic transducer of the ultrasonic real-time pipe defect detection system according to the present invention.
5 is a block diagram showing the configuration of an embodiment of the controller of the ultrasonic real-time pipe fault detection system according to the present invention.
6 is a view illustrating reception of an ultrasonic signal in a state in which there is no wear of a pipe.
7 is a view illustrating reception of an ultrasonic signal in a state in which a pipe is worn.

Hereinafter, the present invention will be described in detail so that those skilled in the art can easily understand and reproduce it through preferred embodiments described with reference to the accompanying drawings. While specific embodiments are illustrated in the drawings and the related detailed description is set forth, they are not intended to limit the various embodiments of the present invention to a specific form.

In describing the present invention, if it is determined that a detailed description of a related well-known function or configuration may unnecessarily obscure the gist of the embodiments of the present invention, the detailed description thereof will be omitted.

When a component is referred to as being “connected” or “connected” to another component, it is understood that the other component may be directly connected or connected to the other component, but other components may exist in between. it should be

On the other hand, when it is mentioned that a certain element is "directly connected" or "directly connected" to another element, it should be understood that the other element does not exist in the middle.

1 is a diagram showing the configuration of an embodiment of the ultrasonic real-time pipe defect detection system according to the present invention. As shown in FIG. 1 , the ultrasonic real-time pipe defect detection system 100 according to this embodiment includes an array-type ultrasonic transducer 110 and a controller 120 .

In the array type ultrasonic transducer 110 , a plurality of ultrasonic sensors 111 connected to each other through a controller 120 and a signal line (not shown) are arranged. In this case, the number of the ultrasonic sensors 111 arranged in the array-type ultrasonic transducer 110 may be determined according to the size and flaw detection accuracy (resolution) of the pipe.

On the other hand, the array type ultrasonic transducer 110 is implemented with a flexible material to be able to be attached to a pipe having a curved external shape, so that it can be universally used for various pipes having different diameters. At this time, the length of the curved surface of the array type ultrasonic transducer 110 should be less than or equal to the circumferential length of the pipe.

The controller 120 receives the electrical pipe defect detection signal from the array type ultrasonic transducer 110 in real time to detect the pipe defect in real time, and warns when the pipe defect is detected. In this case, the controller 120 may be connected through a signal line or a flexible printed circuit board (FPCB) between the array type ultrasonic transducers 110 .

When the controller 120 drives the plurality of ultrasonic sensors 111 of the array-type ultrasonic transducer 110 , the plurality of ultrasonic sensors 111 radiate an ultrasonic signal to the pipe and transmit the reflected ultrasonic signal from the pipe to the electrical pipe. It is converted into a defect detection signal and transmitted to the controller 120 in real time.

Then, the controller 120 receives the electrical pipe defect detection signal from the array type ultrasonic transducer 110 in real time to detect the pipe defect in real time, and when detecting the pipe defect, an audible warning through a buzzer, a visual warning through an LED, or , it notifies that a fault has occurred in the piping by remotely transmitting a warning message through the wireless network.

By implementing in this way, the present invention can detect the thickness of the pipe by a relatively simple ultrasonic detection method, rather than a complicated magnetic field distribution detection method, to easily and conveniently detect defects in the pipe in real time.

2 is a view showing the configuration of an embodiment of the array type ultrasonic transducer of the ultrasonic real-time pipe defect detection system according to the present invention. As shown in FIG. 2 , the array type ultrasonic transducer 110 according to this embodiment includes a plurality of ultrasonic sensors 111 and a flexible printed circuit board (FPCB) 112 .

The plurality of ultrasonic sensors 111 radiate an ultrasonic signal to the pipe 200 , receive an ultrasonic signal reflected from the pipe 200 , and convert the received ultrasonic signal into an electrical pipe defect detection signal.

For example, the ultrasonic sensor 111 may be an ultrasonic oscillation element including a piezoelectric ultrasonic ceramic, and the electrical pipe defect detection signal may be a signal including pipe thickness information calculated by detecting the return time of the ultrasonic wave.

Ultrasonic waves emitted from the ultrasonic sensor 111 pass through the metal part of the pipe 200 and reach the inner surface of the pipe, that is, the interface that comes into contact with the air in the pipe. Ultrasonic waves are not transmitted well in the air, but have a property of being transmitted well in metal or water, so they are reflected from the interface in contact with the air in the pipe and returned to the ultrasonic sensor 111 .

Since the ultrasonic propagation speed (velocity of sound) v in the medium is a known value, and the ultrasonic return time 2t can be measured by the ultrasonic sensor 111, the thickness S of the pipe 200 is the ultrasonic transfer speed and the ultrasonic return time 2t It becomes vt, which is half the value multiplied by .

6 is a diagram illustrating the reception of an ultrasonic signal in a state in which there is no wear of the pipe, and FIG. 7 is a diagram illustrating the reception of an ultrasonic signal in a state in which there is abrasion of the pipe. As shown in FIG. 6 , the thickness S = vt of the pipe 200 has a constant thickness value when the pipe is not worn or damaged.

However, if the pipe is worn or broken, it becomes smaller than the value of the pipe thickness that is not worn or broken, as shown in FIG. 7 . Therefore, when the ultrasonic wave returns time is detected using the ultrasonic sensor 111 to obtain the pipe thickness, defects in the pipe can be detected.

A plurality of ultrasonic sensors 111 are arranged on the flexible circuit board 120 . For example, N×M ultrasonic sensors 111 may be regularly or irregularly arranged on the flexible circuit board 120 .

3 is a diagram illustrating an arrangement form of ultrasonic sensors arranged in an array-type ultrasonic transducer of an ultrasonic real-time pipe defect detection system according to the present invention. 3 (a) shows that the ultrasonic sensors are uniformly arranged, and (b) shows that the ultrasonic sensors are alternately arranged.

By implementing in this way, in the present invention, since a plurality of ultrasonic sensors 111 are arranged on the flexible circuit board 120, the array-type ultrasonic transducer 110 can be easily and conveniently attached to the outer curved surface of the pipe regardless of the diameter of the pipe. It can detect defects in piping.

Meanwhile, according to an additional aspect of the present invention, the array type ultrasonic transducer 110 may further include a sound absorbing layer 113 and a matching layer 114 . For example, the sound absorbing layer 113 may be formed between the plurality of ultrasonic sensors 111 and the flexible circuit board 120 , and the matching layer 114 is formed between the ultrasonic sensor 111 and the pipe 200 . It can be an inspection surface.

The sound absorbing layer (Backing Layer) 113 serves to attenuate ultrasonic waves and at the same time serve to bond the plurality of ultrasonic sensors 111 to the flexible circuit board 112 . The matching layer 114 performs impedance matching of the ultrasonic signal radiated to the pipe 200 , reflected from the pipe 200 and received.

Meanwhile, according to an additional aspect of the present invention, the array type ultrasonic transducer 110 may further include a protective layer 115 . The protective layer 115 serves to surround and protect the exterior of the plurality of ultrasonic sensors 111 .

The protective layer 115 has excellent flexibility, has excellent bonding strength with ultrasonic sensors, and has to maintain strength while being bent, and is molded with an epoxy resin as the protective layer 115 . A flexible epoxy formed by doing so may be used, but is not limited thereto.

4 is a view showing an embodiment of the flexible circuit board of the array type ultrasonic transducer of the ultrasonic real-time pipe defect detection system according to the present invention. As shown in FIG. 4 , the flexible circuit board 112 may have a comb shape including comb portions 112a and a support portion 112b.

A plurality of comb portions 112a may be arranged in parallel with a specific interval in a bending direction. The support portion 112b connects the comb portions to each other in a right angle direction at one end of the comb portions 112a arranged in parallel.

When the flexible circuit board 112 is implemented in a comb shape, since the ultrasonic sensors 111 are arranged in the bending direction, it is possible to prevent the wiring of the ultrasonic sensors 111 from being cut when the flexible circuit board 112 is bent. .

5 is a block diagram showing the configuration of an embodiment of the controller of the ultrasonic real-time pipe fault detection system according to the present invention. 5 , the controller 120 includes a driving unit 121 , a signal processing unit 122 , and a warning unit 123 .

The driving unit 121 drives the ultrasonic sensors 111 arranged in the array-type ultrasonic transducer 110 . The driving unit 121 generates a pulse signal for generating ultrasonic waves from the ultrasonic sensors 111 arranged in the arrayed ultrasonic transducer 110 and applies it to the ultrasonic sensors 111 arranged in the arrayed ultrasonic transducer 110 . do.

The signal processing unit 122 obtains pipe thickness information by processing the electrical pipe defect detection signal received in real time from the ultrasonic sensors 111, and performs real-time detection of pipe defects from the acquired pipe thickness information.

For example, if the electrical pipe defect inspection signal received in real time from the ultrasonic sensors 111 is a signal including pipe thickness information calculated by detecting the return time of the ultrasonic wave, the signal processing unit 122 is an electrical pipe defect inspection signal Pipe thickness information is obtained from the pipe thickness information, and pipe defects are detected in real time from the acquired pipe thickness information.

The warning unit 123 warns this when a pipe defect is detected by the signal processing unit 122 . For example, when the warning by the warning unit 123 is an audible warning, the warning unit 123 may include a buzzer, and when the warning by the warning unit 123 is a visual warning, the warning unit 123 is LEDs may be included.

On the other hand, if the warning by the warning unit 123 notifies that a fault has occurred in the piping by remotely transmitting a warning message through the wireless network, the warning unit 123 may include a wireless network module such as Bluetooth. have.

In this case, when the warning unit 123 is implemented as a wireless network module, it may be implemented to transmit a control command to the control unit 120 from a monitoring part, such as an external server, through the wireless network module.

By implementing in this way, the present invention can detect the thickness of the pipe by a relatively simple ultrasonic detection method, rather than a complicated magnetic field distribution detection method, to easily and conveniently detect defects in the pipe in real time.

Meanwhile, according to an additional aspect of the invention, the controller 120 may further include a mux (MUX) (124). The mux 124 sequentially drives the ultrasonic sensors 111 arranged in the array-type ultrasonic transducer 110 .

While sequentially driving the ultrasonic sensors 111 arranged in the array-type ultrasonic transducer 110 through the mux 124, the signal processing unit 122 receives the electrical pipe defect detection signal sequentially transmitted from the ultrasonic sensors 111. process sequentially to obtain pipe thickness information, and real-time flaw detection for pipe defects from the acquired pipe thickness information.

Then, it is possible to know the ultrasonic sensor 111 where the pipe defect has occurred, and from this, it is possible to accurately determine the location of the pipe where the pipe defect has occurred.

Meanwhile, according to an additional aspect of the invention, the controller 120 may further include a power supply unit 125 . The power supply unit 125 supplies power to the controller 120 and the array type ultrasonic transducer 110 . In this case, the power supply unit 125 may be a built-in battery for supplying its own power, or a power circuit operated by receiving power from an external power source.

Meanwhile, according to an additional aspect of the invention, the array type ultrasonic transducer 110 may further include a temperature sensor 116 . The temperature sensor 116 measures the temperature of the pipe 200 in real time.

Since the ultrasonic transmission speed (speed of sound) slightly changes depending on the temperature, the signal processing unit 122 of the controller 120 processes the electrical pipe defect detection signal received in real time from the ultrasonic sensors to obtain pipe thickness information. When detecting pipe defects in real time, by adjusting the ultrasonic transmission speed (speed of sound) according to the temperature of the pipe 200 measured by the temperature sensor 116 to reduce the thickness measurement error, the pipe defects can be detected more precisely. .

Meanwhile, according to an additional aspect of the present invention, the ultrasonic real-time pipe defect detection system 100 according to the present invention may further include a contact medium (Couplant) 130 and a fixing means 140 .

The contact medium 130 is disposed between the flaw detection surface of the array type ultrasonic transducer and the pipe to facilitate ultrasonic transmission, has little ultrasonic attenuation, and is a liquid or solid gel or pad type that does not change in physical properties according to temperature change. is the substance of

The fixing means 140 prevents separation of the array type ultrasonic transducer 110 mounted on the pipe 200 , and a pressure band or an adhesive tape may be used as the fixing means 140 , but is not limited thereto.

A process of detecting a pipe defect using the ultrasonic real-time pipe defect detecting system 100 as described above will be described.

First, a contact medium is applied or positioned on the surface of the pipe 200 at a position where defects are to be detected, the arrayed ultrasonic transducer 110 is mounted thereon, and then the arrayed ultrasonic transducer 110 is fixed so as not to be separated from the pipe. .

Then, the ultrasonic transducer 110 is connected to the controller 120 and then sealed to protect it from being exposed to an external environment (rain, snow, direct sunlight, dust, etc.).

Next, after turning on the power of the controller 120 to drive the ultrasonic transducer 110 , the validity of the pipe defect detection signal is checked through test measurement and calibration is performed.

Then, the array-type ultrasonic transducer 110 emits an ultrasonic signal to the pipe 200 through the plurality of ultrasonic sensors 111, and converts the ultrasonic signal reflected from the pipe into an electrical pipe defect detection signal to the controller 120 ) is transmitted in real time.

Then, the controller 120 receives the electrical pipe defect detection signal from the array type ultrasonic transducer 110 in real time to detect the pipe defect in real time, and when detecting the pipe defect, an audible warning through a buzzer, a visual warning through an LED, or , it notifies that a fault has occurred in the piping by remotely transmitting a warning message through the wireless network.

By implementing in this way, the present invention can detect the thickness of the pipe by a relatively simple ultrasonic detection method, rather than a complicated magnetic field distribution detection method, to easily and conveniently detect defects in the pipe in real time.

In addition, the present invention implements an array-type ultrasonic transducer by arranging a plurality of ultrasonic sensors on a flexible circuit board, so that defects in the pipe can be detected by easily and conveniently attaching the array-type ultrasonic transducer on the curved outer surface of the pipe regardless of the diameter of the pipe. have.

The various embodiments disclosed in the present specification and drawings are merely presented as specific examples to aid understanding, and are not intended to limit the scope of various embodiments of the present invention.

Accordingly, the scope of various embodiments of the present invention, in addition to the embodiments described herein, all changes or modifications derived based on the technical idea of various embodiments of the present invention are included in the scope of various embodiments of the present invention. should be interpreted as being

INDUSTRIAL APPLICABILITY The present invention can be industrially used in the field of pipe defect detection technology and its application technology.

100: Ultrasonic real-time pipe fault detection system
110: array type ultrasonic transducer
111: ultrasonic sensor
112: flexible circuit board
112a: comb part
112b: support
113: sound absorption layer
114: matching layer
115: protective layer
116: temperature sensor
120: controller
121: drive unit
122: signal processing unit
123: warning part
124 : mux
125: power supply
130: contact medium
140: fixing means
200: piping

Claims (8)

A plurality of ultrasonic sensors that radiate an ultrasonic signal to a pipe, receive an ultrasonic signal reflected from the pipe, and convert the received ultrasonic signal into an electrical pipe defect detection signal, and a flexible circuit board on which a plurality of ultrasonic sensors are arranged ( FPCB: Flexible Printed Circuit Board) and an array type ultrasonic transducer including a temperature sensor that measures the temperature of the pipe in real time;
A driving unit for driving ultrasonic sensors arranged in an array type ultrasonic transducer, and processing an electrical pipe defect detection signal received in real time from the ultrasonic sensors to obtain pipe thickness information, and to detect pipe defects in real time from the acquired pipe thickness information a controller including a signal processing unit and a warning unit for warning this when a pipe defect is detected by the signal processing unit;
including,
Signal processing unit:
When detecting pipe defects in real time by processing electrical pipe defect detection signals received from ultrasonic sensors in real time to obtain pipe thickness information, the thickness measurement error is adjusted by adjusting the ultrasonic transmission speed according to the temperature of the pipe measured by the temperature sensor. Ultrasonic real-time pipe fault detection system to reduce The method of claim 1,
Arrayed ultrasonic transducer:
a sound absorbing layer that serves to attenuate ultrasonic waves and to bond a plurality of ultrasonic sensors to the flexible circuit board;
a matching layer for impedance matching of an ultrasonic signal radiated to the pipe, reflected from the pipe and received;
Ultrasonic real-time pipe fault detection system further comprising. 3. The method of claim 2,
Arrayed ultrasonic transducer:
a protective layer surrounding and protecting the exterior of a plurality of ultrasonic sensors;
Ultrasonic real-time pipe fault detection system further comprising. The method of claim 1,
Flexible circuit boards are:
A plurality of comb-tooth portions arranged parallel to each other at a specific interval in a bending direction;
a support for connecting the comb portions to each other in a right angle direction at one end of the comb portions arranged in parallel;
Comb-shaped ultrasonic real-time pipe fault detection system. delete The method of claim 1,
The controller:
a mux (MUX) for sequentially driving the ultrasonic sensors arranged in the array-type ultrasonic transducer;
Ultrasonic real-time pipe fault detection system further comprising. delete The method of claim 1,
Ultrasonic real-time pipe fault detection system:
a contact medium (Couplant) disposed between the flaw detection surface of the array type ultrasonic transducer and the pipe;
a fixing means for preventing separation of the array type ultrasonic transducer mounted on the pipe;
Ultrasonic real-time pipe fault detection system further comprising.

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