系泊链自动超声检测机构设计问题研究
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摘要
系泊链是用于海洋结构物定位与系泊的重要部件,在生产过程中,其焊缝位置需要接受严格的超声探伤。人工方式探伤存在误判和漏判的问题,因此需要设计一套自动检测系统,能够可靠地实现对系泊链焊缝的超声扫查任务。
自动超声检测相关的系泊链特点,可以从三个方面各提炼为三点。链条是环环相扣的,可见:超声检测区域不连续,焊缝方位不确定,整体连接非刚性;链环是弯制成圆的,可见:环臂形状有变化,横档区域有限制,环冠套接有干涉;材料是锻造而成的,可见:表面粗糙度大,扫查区域可能存在凸台凹坑,链环面也不洁净。系泊链的这些特点给自动超声检测系统的研发带来一系列难题,需要深入分析解决。
在以上问题中,本文主要致力于解决系泊链自动超声检测系统研发的机构方面的问题。其中重点工作如下:
1.用塔架式超声检测工作台,解决系泊链链条柔性问题。通过各主功能和辅助功能模块的位置和运行的配合,可靠地实现系泊链自动超声检测的基本功能。
2.用大粘度耦合剂的接触式探伤方法,解决系泊链链条表面粗糙度大的问题。通过多种探伤方式的比较,结合工件实际情况,自动化探伤系统选择了与系泊链人工超声探伤相似的方法。
3.用转换工位机构,解决系泊链链条焊缝方位问题。链条送进、周转换位、升降找位和横进入位,这四个外围动作各自独立驱动,相互配合,使扫查器逐个对准链条上各链环的焊缝扫查区域。
4.用内部周转和轴进机构相配合实现横方形超声探头扫查路径,解决系泊链普通有档链环的横档干涉问题。通过多种机构的分析比较,证明半环轨道和拖板相配合的周转往复机构,能够可靠地引导探头周转扫查运动。
5.用探头杆的一个伸缩自由度和探头架的四个转动自由度来适应链环曲面,解决链环环形变化问题。这些相互配合的自由度,实现了探头对链环的良好贴合。
6.用静力分析模型,解答了扫查器结构的悬臂和偏载问题。通过实际参数的测量、约束定性分析和程序承递求解,用计算数据说明了关键结构件的受力情况,证明零部件可以满足结构受力要求。
本文通过技术方法比较、功能模块分析、机构方案选择和力学模型计算等方法,解答了系泊链自动超声检测系统的机构问题,给出了一套能够可靠实现探伤功能的系统机构方案。所得结论可以用于后续详细设计,所用方法可供相似系统的研发工作者参考。
Mooring chains are important components for offshore structures, and need to be well tested by ultrasonic in the production process. The manual ultrasonic testing cannot avoid the problem of missing or misjudging the fault, thus an automated ultrasonic testing system for mooring chains is calling, which can perform complete scanning and consistent gauging.
The development of this system must analyze and solve some special problems which emerge from the mooring chains’special characters. First, rings link to each other to make a CHAIN: the scanning sections are discontinuous, the welding orientations are irregular, and the series of links are flexible connector; Second, bars are bent to an oval shape, looped together and welded shut to make a RING: the arm shape is not cylinder, the stud is an interfere of scanning, and the link section of the two rings limits the space of scanning mechanisms; Third, forging metal are manufactured into mooring chains’SURFACE: roughness is significant, convex and concave units sometimes emerge, and the scanning face is not clean.
Among all the considerations in developing the automated ultrasonic testing system, this dissertation focuses on studying the mechanism problems corresponding to the mooring chains specifications. The major achievements are listed here:
1. Suspend the chains on tower platform with multi-layers for ultrasonic testing, resolving the problem of flexibility of chain connector. The major and auxiliary function modules operate in coordination on the platform, to implement the basic goal of automated ultrasonic testing work.
2. Touch the rings directly with angle beam ultrasonic probe, which is assisted by high viscosity couplant, resolving the problem of surface roughness. By comparing a variety of testing methods, and investigating the actual condition of the workpiece, it finally chooses similar methods with the artificial testing.
3. Change working post to access the mooring chains’each link, resolving the problem of weld orientation. The mechanism diagram of circumferential, axial and lateral direction movement illustrate the detection configuration’s possibility and effectiveness
4. Scan the welding section by square-cross track with half circumferential and step axial mechanisms, resolving the problems of space limitation of rings. By comparing various structure, choose half circle orbit and carriage to well perform the circumferential scanning action.
5. Adapt the camber with one slide and four rotate local degree of freedom, resolving the problem of ring’s shape changing. These freedom and the spring, achieved the good touching condition between the probe and ring’s surface.
6. Calculate the constraints of scanning device with its static mechanic model, resolving the anxiety about the scanning mechanism’s structure problems of cantilever and eccentric load. With customized parameters and communicated data, mechanical components and industry part can be design and chosen in detail.
This dissertation, by comparing various testing methods, analyzing function relativity, choosing mechanisms and building mechanic model, resolved the special problems of mooring chains, and presented a sound mechanism system for automated ultrasonic testing. The results here can be used in further development of this project, and the methods might do favor to researchers while studying similar problems.
自动超声检测相关的系泊链特点,可以从三个方面各提炼为三点。链条是环环相扣的,可见:超声检测区域不连续,焊缝方位不确定,整体连接非刚性;链环是弯制成圆的,可见:环臂形状有变化,横档区域有限制,环冠套接有干涉;材料是锻造而成的,可见:表面粗糙度大,扫查区域可能存在凸台凹坑,链环面也不洁净。系泊链的这些特点给自动超声检测系统的研发带来一系列难题,需要深入分析解决。
在以上问题中,本文主要致力于解决系泊链自动超声检测系统研发的机构方面的问题。其中重点工作如下:
1.用塔架式超声检测工作台,解决系泊链链条柔性问题。通过各主功能和辅助功能模块的位置和运行的配合,可靠地实现系泊链自动超声检测的基本功能。
2.用大粘度耦合剂的接触式探伤方法,解决系泊链链条表面粗糙度大的问题。通过多种探伤方式的比较,结合工件实际情况,自动化探伤系统选择了与系泊链人工超声探伤相似的方法。
3.用转换工位机构,解决系泊链链条焊缝方位问题。链条送进、周转换位、升降找位和横进入位,这四个外围动作各自独立驱动,相互配合,使扫查器逐个对准链条上各链环的焊缝扫查区域。
4.用内部周转和轴进机构相配合实现横方形超声探头扫查路径,解决系泊链普通有档链环的横档干涉问题。通过多种机构的分析比较,证明半环轨道和拖板相配合的周转往复机构,能够可靠地引导探头周转扫查运动。
5.用探头杆的一个伸缩自由度和探头架的四个转动自由度来适应链环曲面,解决链环环形变化问题。这些相互配合的自由度,实现了探头对链环的良好贴合。
6.用静力分析模型,解答了扫查器结构的悬臂和偏载问题。通过实际参数的测量、约束定性分析和程序承递求解,用计算数据说明了关键结构件的受力情况,证明零部件可以满足结构受力要求。
本文通过技术方法比较、功能模块分析、机构方案选择和力学模型计算等方法,解答了系泊链自动超声检测系统的机构问题,给出了一套能够可靠实现探伤功能的系统机构方案。所得结论可以用于后续详细设计,所用方法可供相似系统的研发工作者参考。
Mooring chains are important components for offshore structures, and need to be well tested by ultrasonic in the production process. The manual ultrasonic testing cannot avoid the problem of missing or misjudging the fault, thus an automated ultrasonic testing system for mooring chains is calling, which can perform complete scanning and consistent gauging.
The development of this system must analyze and solve some special problems which emerge from the mooring chains’special characters. First, rings link to each other to make a CHAIN: the scanning sections are discontinuous, the welding orientations are irregular, and the series of links are flexible connector; Second, bars are bent to an oval shape, looped together and welded shut to make a RING: the arm shape is not cylinder, the stud is an interfere of scanning, and the link section of the two rings limits the space of scanning mechanisms; Third, forging metal are manufactured into mooring chains’SURFACE: roughness is significant, convex and concave units sometimes emerge, and the scanning face is not clean.
Among all the considerations in developing the automated ultrasonic testing system, this dissertation focuses on studying the mechanism problems corresponding to the mooring chains specifications. The major achievements are listed here:
1. Suspend the chains on tower platform with multi-layers for ultrasonic testing, resolving the problem of flexibility of chain connector. The major and auxiliary function modules operate in coordination on the platform, to implement the basic goal of automated ultrasonic testing work.
2. Touch the rings directly with angle beam ultrasonic probe, which is assisted by high viscosity couplant, resolving the problem of surface roughness. By comparing a variety of testing methods, and investigating the actual condition of the workpiece, it finally chooses similar methods with the artificial testing.
3. Change working post to access the mooring chains’each link, resolving the problem of weld orientation. The mechanism diagram of circumferential, axial and lateral direction movement illustrate the detection configuration’s possibility and effectiveness
4. Scan the welding section by square-cross track with half circumferential and step axial mechanisms, resolving the problems of space limitation of rings. By comparing various structure, choose half circle orbit and carriage to well perform the circumferential scanning action.
5. Adapt the camber with one slide and four rotate local degree of freedom, resolving the problem of ring’s shape changing. These freedom and the spring, achieved the good touching condition between the probe and ring’s surface.
6. Calculate the constraints of scanning device with its static mechanic model, resolving the anxiety about the scanning mechanism’s structure problems of cantilever and eccentric load. With customized parameters and communicated data, mechanical components and industry part can be design and chosen in detail.
This dissertation, by comparing various testing methods, analyzing function relativity, choosing mechanisms and building mechanic model, resolved the special problems of mooring chains, and presented a sound mechanism system for automated ultrasonic testing. The results here can be used in further development of this project, and the methods might do favor to researchers while studying similar problems.
引文
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[20].朱根兴,周晓军,黄中原,伍建国棒材一体化超声检测系统研制组合机床与自动化加工技术, 2008{05} : 55-62.
[21].江健,吴瑞明,杜兴吉,等.曲面构件超声检测中的灵敏度自动补偿技术[J]机床与液压, 2004(09) : 167-178.
[22].江健,郭天太,吴思源,周晓军.曲面构件一体化超声自动检测方法研究传感技术学报2006(4) : 383-392.
[23].王艳颖,周晓军,车焕淼,李甫永.超声检测中的路径受控仿形测量和曲面重构技术[J].中国机械工程, 2003(06) : 490-494.
[24].杨辰龙,周晓军.复杂曲面工件的超声无损检测系统研制[J].中国机械工程, 2005,(18) : 1625-1622.
[25].高克全.水轮机不锈钢叶片超声波探伤试验研究[J].无损检测, 2003,(12) : 628-630.
[26].陈自强,陈立功,倪纯珍,王裕文.随机粗糙表面超声双透射研究[J].声学学报(中文版) , 2000,(06) : 542-546.
[27].刘贵民,张昭光.超声检测中表面粗糙度引起的声衰减补偿[J].无损检测, 2007,(04) : 206-208.
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[2].郎宏军,张美玲,余文娟. GB/T 20848-2007,系泊链[S].北京:中国标准出版社, 2008.
[3].石生文.镇江锚链厂产品结构优化研究[学位论文].南京:南京理工大学,2003:6-23.
[4]. Ramnas Bruk. Ramnas Anchor Chain is a promise– Facts about Ramnas Safety Anchor Chains and Accessories. 2006. 2009.3.10 http://www.ramnas.com/archive/files/index.php?folder=3&id=30
[5].张燕宏,李志远.焊接结构件焊缝缺陷的无损检测技术研究[J]机电产品开发与创新, 2003,(02) : 27-29.
[6].蒋志艳.镇江市2007年度技术需求信息表-系泊链自动探伤技术(正茂集团有限责任公司).南京:镇江市科学技术局,2008.4.28. http://cg.zjst.gov.cn/ReadNews.asp?NewsID=799
[7]. Passi G.S, Shoef Y,. Kritsky M.V. Reducing the influence of human factors on the reliability of manual ultrasonic weld inspection. Insight: Non-Destructive Testing and Condition Monitoring, 1995(10): 788-791.
[8].郭宁生.系泊链超声波检测作业指导书[Z].QC/ZG09-5.0.镇江:正茂集团有限责任公司C层文件, 2008.
[9]. Brian F. Larson. Basic Principles of Ultrasonic Testing http://www.ndt-ed.org/EducationResources/CommunityCollege/Ultrasonics/Introduction/description.htm, 2008.5.8.
[10].北京技术交流站.超声波探伤原理及其应用[M].北京:机械工业出版社, 1982: 364-371 : 398-401.
[11]. Brian F. Larson. Automated Scanning http://www.ndt-ed.org/EducationResources/CommunityCollege/Ultrasonics/MeasurementTech/automatedscanning.htm, 2008.5.20
[12]. K. Borum. Evaluation of the Quality of Thick Fibre Composites Using Immersion and Air-Coupled Ultrasonic Techniques. In ECNDT. Berlin(Germany): September 2006. We.1.6.4.
[13].余汪洋.超声水浸检测系统机械扫描装置的研制[J].无损探伤, 2002,(03) : 32-37.
[14].孙凯,杨青,郭广平.喷水穿透超声C扫描自动检测系统的研制[J].无损探伤, 2002,(03) : 21-23.
[15].施德恒,陈玉科,孙金锋,等.激光超声技术及其在无损检测中的应用概况[J]激光杂志, 2004,(05) .
[16]. Martin SCHICKERT, Ulrich TüMMLER. Rapid Scanning Approaches for Ultrasonic Imaging of Concrete. ECNDT 2006 - Poster 20.
[17].石增强,程洪杰,谢建,杜文正.大型圆筒件超声检测系统的设计[J]无损检测, 2005,(09) : 475-478.
[18].王三武,王清秀.管道焊缝检测扫查器设计研究[J]机械制造, 2007,(04) : 26-28.
[19].支正轩,孙振国,杜学刚,汪宏.机车车轴超声自动探伤系统[J]无损检测, 2005,(11) : 572-575.
[20].朱根兴,周晓军,黄中原,伍建国棒材一体化超声检测系统研制组合机床与自动化加工技术, 2008{05} : 55-62.
[21].江健,吴瑞明,杜兴吉,等.曲面构件超声检测中的灵敏度自动补偿技术[J]机床与液压, 2004(09) : 167-178.
[22].江健,郭天太,吴思源,周晓军.曲面构件一体化超声自动检测方法研究传感技术学报2006(4) : 383-392.
[23].王艳颖,周晓军,车焕淼,李甫永.超声检测中的路径受控仿形测量和曲面重构技术[J].中国机械工程, 2003(06) : 490-494.
[24].杨辰龙,周晓军.复杂曲面工件的超声无损检测系统研制[J].中国机械工程, 2005,(18) : 1625-1622.
[25].高克全.水轮机不锈钢叶片超声波探伤试验研究[J].无损检测, 2003,(12) : 628-630.
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