D1016 mm天然气管道环焊缝相控阵超声内检测机器人系统研制与应用

Development and application of D1016 mm phased array ultrasonic internal inspection robot system for natural gas pipeline circumferential welds

  • 摘要: 针对埋地天然气管道焊缝传统检测存在开挖量大、精度低、适应性差和可靠性不足等问题,开发了基于相控阵超声技术的D1016 mm管道自适应超声内检测机器人系统。基于相控阵超声检测原理,设计高精度自对齐模块化检测装置,并采用多重浮动结构确保探头与管壁紧密耦合,同时通过焊缝定位模块实现精确识别与定位;针对工况适用性问题,设计轮式管道机器人,采用自调节轮式结构,提升在复杂工况下的适应能力;针对控制与通信问题,设计无线控制系统,机器人采用以太网与控制器局域网(controller area network,CAN)总线的高效协作,实现模块化设计与分布式控制。专用环道测试与缺陷检测结果表明:该机器人可在管道内部稳定作业,常见缺陷检出率达100%,检测效率显著优于传统检测方法,为管道安全运行提供了高效、可靠的技术支持,具有重要的工程应用价值。

     

    Abstract: The traditional inspection methods for buried pipelines require extensive excavation and exhibit limitations in terms of precision, adaptability, and reliability. To address this issue, an adaptive ultrasonic internal inspection robotic system for D1016 mm pipelines based on phased array ultrasonic technology was developed in this study. Based on the principles of phased array ultrasonic inspection, a high-precision self-aligning modular detection device was designed, incorporating a multi-floating structure to ensure tight coupling between the probe and the pipe wall, simultaneously employing a weld seam positioning module to enable precise identification and localization. To improve adaptability under various working conditions, a wheeled pipeline robot with a self-adjusting wheel structure was designed to enhance operational performance in complex environments. In response to control and communication challenges, a wireless control system was established using the robot Ethernet and controller area network (CAN) bus for efficient coordination, enabling modular design and distributed control. Results from dedicated loop tests and defect detection experiments show that the robot can achieve stable operation within the pipeline, with a defect detection rate of 100%. The inspection efficiency significantly surpasses that of traditional methods, providing an efficient and reliable solution to substantial engineering application value and ensuring comprehensive technical and equipment support for the safe operation of pipelines.

     

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