阅读说明：本技术 一种热气导管马鞍面焊缝检查装置控制系统及检查方法 (Control system and inspection method for saddle surface weld joint inspection device of hot gas conduit ) 是由 管朝鹏 王庆武 张益成 王俊涛 徐安 陈姝 徐华锋 贾晶晶 李铮 孙海漩 马刚 于 2020-12-30 设计创作，主要内容包括：本发明属于压力容器无损检测技术领域,具体涉及一种热气导管马鞍面焊缝检查装置控制系统及检查方法。该装置包括控制计算机、运动控制器和驱动组件；控制计算机通过Ethernet网络向运动控制器下发控制指令,接收其反馈的状态信息；运动控制器和驱动组件的驱动器之间采用EtherCAT总线通讯。该方法包括连接线路,参数配置,运动轨迹、指令生成和发送,目标位置信息解析和执行,实时位置结算和判断轨迹执行是否完毕等步骤。有益效果在于：热气导管的周向运动采用主从轴龙门控制方式,可实现在周向360度方向变负载检查过程中设备速度平稳、定位精确,探头贴合可靠；热气导管周向运动采用双闭环控制方式,可确保周向运动实际位置和超声仪接收的编码位置一致性。(The invention belongs to the technical field of nondestructive testing of pressure vessels, and particularly relates to a control system and a testing method of a saddle surface welding seam testing device of a hot gas conduit. The device comprises a control computer, a motion controller and a driving component; the control computer sends a control command to the motion controller through the Ethernet network and receives the feedback state information; the motion controller and the driver of the driving assembly are communicated by an EtherCAT bus. The method comprises the steps of connecting circuits, configuring parameters, generating and sending motion tracks and instructions, analyzing and executing target position information, settling positions in real time, judging whether track execution is finished or not and the like. Has the advantages that: the circumferential motion of the hot gas guide pipe adopts a master-slave axis gantry control mode, so that the equipment speed is stable, the positioning is accurate and the probe is reliably attached in the circumferential 360-degree direction variable load inspection process; the circumferential motion of the hot gas guide pipe adopts a double closed-loop control mode, so that the consistency of the actual position of the circumferential motion and the coding position received by the ultrasonic instrument can be ensured.)

1. The utility model provides a control system of hot gas conduit saddle face welding seam inspection device which characterized in that: comprises a control computer (1), a motion controller (2) and a driving component; the driving assembly is used for driving the inspection device to scan and step in different directions; the control computer (1) issues a control instruction to the motion controller (2) through an Ethernet network and receives state information fed back by the motion controller (2); and the motion controller (2) and a driver of the driving assembly are communicated by adopting an EtherCAT bus.

2. The control system for a hot gas duct saddle weld inspection device as claimed in claim 1, wherein: the drive assemblies are 4 groups, the main drive assembly X1 and the auxiliary drive assembly X2 can synchronously move along the circumferential direction of the hot gas guide pipe, the radial drive assembly Z can move along the radial direction of the hot gas guide pipe, and the deflection drive assembly Y can deflect and move along the axial direction of the hot gas guide pipe.

3. The control system for a hot gas duct saddle-seam weld inspection device of claim 2, wherein: the main drive assembly X1 comprises an X1 main drive (3), an X1 main motor (7), an X1 coaxial code (8) and an X1 terminal code (9); the slave drive assembly X2 comprises an X2 slave drive (4), an X2 slave motor (10) and an X2 coaxial coding (11); the Y driving component comprises a Y driver (5), a Y motor (12) and a Y coaxial code (13); the Z driving assembly comprises a Z driver (6), a Z motor (14) and a Z coaxial code (15).

4. A control system for a hot gas duct saddle weld inspection device as claimed in claim 3, wherein: the control command comprises enabling, inching, calibrating, PTP movement and PVT movement, and the state information comprises information of current position, real-time speed, real-time current, current movement state and error state.

5. A control system for a hot gas duct saddle weld inspection device as claimed in claim 3, wherein: the EtherCAT bus adopts a topology of a paired line type.

6. The control system of a hot gas duct saddle weld inspection device as claimed in claim 3, 4 or 5, wherein: the primary drive assembly X1 employs a double closed loop configuration.

7. The control system for a hot gas duct saddle weld inspection device of claim 6, wherein: in the X1 main driver (3), an X1 coaxial encoder (8) is used as a speed control loop feedback of a main driving assembly X1, and an X1 terminal encoder (9) is used as a position control loop feedback.

8. The control system for a hot gas duct saddle weld inspection device of claim 7, wherein: the output shaft of the X1 main motor (7) is connected with an X1 coaxial encoder (8), an X1 terminal encoder (9) is directly attached to the scanning surface of the ultrasonic probe through an elastic wheel set, the X1 coaxial encoder (8) is connected into a PortA port of the X1 main driver (3), and the X1 terminal encoder (9) is connected into a PortB port of the X1 main driver (3).

9. The control system for a hot gas duct saddle weld inspection device of claim 8, wherein: the X1 master driver (3) is set to be in a simulation mode, and coaxial encoder signals collected by a PortA port of the X1 master driver (3) are routed to a PortB port of the X2 slave driver (4); the X2 slave drive (4) is set to profile position mode, setting its encoder signal input at the PortB port as input information to the electronic gear.

10. A saddle-seam weld inspection method using the hot gas duct saddle-seam weld inspection device control system according to claim 9, comprising the following in order:

step 1, connecting Port C Port coding output interfaces of a Y driver (5) and a Z driver (6) to an ultrasonic instrument;

step 2, setting a Port B of an X1 main driver (3) as an incremental encoder signal input, configuring a Port C Port into a simulation output mode, and routing an encoder signal collected by a Port A Port to the Port C Port; setting an X2 Port B Port of a driver (4) as an electronic gear input interface;

step 3, generating and sending a motion track and an instruction;

s3.1, generating a motion track point and a control command in a control computer (1), setting an X1 master driver (3), a Y driver (5) and a Z driver (6) into a circulating position mode, and setting an X2 slave driver (4) into a contour position mode;

s3.2, the control command and the motion locus point generated in S3.1 are sent to the motion controller (2) through an Ethernet network;

step 4, the motion controller 4 reads the motion track points, analyzes the motion track points into target position information of each driver, and sends the target position information to each driver through an EtherCAT bus;

step 5, each driver reads the target position information sent by the motion controller 4 and executes the action, and each driver collects the feedback position information of each encoder and the state information of the driver in real time and uploads the feedback position information and the state information to the motion controller (2) through an EtherCAT bus;

step 6, the motion controller (2) reads position information fed back by the X1 main driver (3), the Y driver (5) and the Z driver (6), the real-time positions of the X1 main driver (3), the Y driver (5) and the Z driver (6) are resolved into ultrasonic scanning position codes and stepping position codes by adopting a coded signal inverse solution algorithm, and the ultrasonic scanning position codes and the stepping position codes are sent to Port C ports of the Y driver (5) and the Z driver (6) for simulation output;

step 7, judging whether the track execution is finished;

s7.1, when the track execution is detected to be finished, the check is finished;

s7.2, detecting that track points which are not executed exist, and jumping to the step 4 to be executed circularly.

Technical Field

The invention belongs to the technical field of nondestructive testing of pressure vessels, and particularly relates to a control system and a testing method of a saddle surface welding seam testing device of a hot gas conduit.

Background

The high-temperature gas cooled reactor nuclear power plant is one of the fourth generation advanced nuclear energy system technologies which are mainly developed in China due to the characteristics of high thermal efficiency, intrinsic safety and the like. Compared with the existing operating pressurized water reactor nuclear power plant, the high-temperature gas cooled reactor nuclear power plant has different requirements on in-service inspection compared with the pressurized water reactor nuclear power plant. Therefore, corresponding inspection technology needs to be developed for the new model to ensure safe and reliable operation of the nuclear power plant.

The pressure vessel and the pipeline connected with the pressure vessel are respectively processed and molded during production and manufacturing, the pressure vessel and the pipeline are connected on the intersecting surface through a welding mode during equipment installation, and the welding seam is a complex space curve distributed on the intersecting surface and is called saddle surface welding seam, as shown in figure 1. High-temperature and high-pressure gas generated by a nuclear reactor during the operation of the nuclear power plant needs to be conveyed into primary circuit equipment from a pressure vessel through a pipeline, and a saddle surface welding seam serving as a primary circuit sealing boundary needs to be periodically detected so as to implement aging management.

Because the high-temperature gas cooled reactor adopts a non-stop detection mode, the detection of saddle surface welding seams needs to be carried out from the outer wall of the pressure vessel cylinder. The diameter of the pressure vessel cylinder exceeds 5 meters, the diameter of the connecting pipe exceeds 2 meters, the requirement range of nondestructive testing is wide, manual testing cannot effectively cover the large-range testing area, and the testing quality cannot be guaranteed, so that a set of efficient control system and testing method of the automatic testing device needs to be developed to realize nondestructive testing of saddle surface welding seams.

Disclosure of Invention

The invention aims to provide a control system and a detection method of a saddle surface welding seam detection device of a hot gas guide pipe of a high-temperature gas cooled reactor, which are used for realizing stable, efficient and automatic nondestructive detection of saddle surface welding seams by methods such as double closed-loop control, master-slave synchronous control and the like.

The technical scheme of the invention is as follows:

a control system of a hot gas conduit saddle surface welding seam inspection device comprises a control computer, a motion controller and a driving assembly; the driving assembly is used for driving the inspection device to scan and step in different directions; the control computer sends a control command to the motion controller through the Ethernet network and receives state information fed back by the motion controller; and the motion controller and the driver of the driving assembly are communicated by adopting an EtherCAT bus.

Further, there are 4 sets of drive assemblies, the main drive assembly X1 and the auxiliary drive assembly X2 can move along the circumferential direction of the hot gas duct synchronously, the radial drive assembly Z can move along the radial direction of the hot gas duct, and the deflection drive assembly Y can deflect along the axis direction of the hot gas duct.

Further, the main drive assembly X1 includes an X1 main drive, an X1 main motor, an X1 coaxial encoding, and an X1 end encoding; the slave drive assembly X2 comprises an X2 slave drive, an X2 slave motor and an X2 coaxial coding; the Y driving component comprises a Y driver, a Y motor and a Y coaxial code; the Z drive assembly comprises a Z driver, a Z motor and a Z coaxial code.

Further, the control instruction comprises enabling, jog, calibrating, PTP moving and PVT moving, and the state information comprises information of current position, real-time speed, real-time current, current moving state and error state.

Further, the EtherCAT bus adopts a pair-line type topology structure.

Further, the primary drive assembly X1 employs a double closed loop configuration. In the X1 main drive, an X1 coaxial encoder is used as a speed control loop feedback of a main drive assembly X1, and an X1 terminal encoder is used as a position control loop feedback. The output shaft of the X1 main motor is connected with an X1 coaxial encoder, an X1 terminal encoder is directly attached to the scanning surface of the ultrasonic probe through an elastic wheel set, the X1 coaxial encoder is connected to a PortA port of an X1 main driver, and an X1 terminal encoder is connected to a PortB port of an X1 main driver.

Further, the X1 master driver is configured in an emulation mode to route the coaxial encoder signals collected by the portA port of the X1 master driver to the portB port of the X2 slave driver; the X2 slave drive is set to profile position mode with its PortB port encoder signal input set as the electronic gear input.

The invention also provides a saddle surface weld joint inspection method adopting the control system of the hot gas conduit saddle surface weld joint inspection device, which is characterized by sequentially comprising the following steps:

step 1, connecting Port C Port coding output interfaces of a Y driver and a Z driver to an ultrasonic instrument;

step 2, setting a Port B of an X1 main driver as an incremental encoder signal input, configuring a Port C Port into a simulation output mode, and routing an encoder signal collected by a Port A Port to the Port C Port; setting an X2 Port B interface of a driver as an electronic gear input interface;

step 3, generating and sending a motion track and an instruction;

s3.1, generating a motion track point and a control command at a control computer, setting an X1 master driver, a Y driver and a Z driver into a circulating position mode, and setting an X2 slave driver into a contour position mode;

s3.2, sending the control command and the motion trail points generated in the S3.1 to a motion controller through an Ethernet network;

step 4, the motion controller 4 reads the motion track points, analyzes the motion track points into target position information of each driver, and sends the target position information to each driver through an EtherCAT bus;

step 5, each driver reads the target position information sent by the motion controller 4 and executes the action, and each driver collects the feedback position information of each encoder and the state information of the driver in real time and uploads the feedback position information and the state information to the motion controller through an EtherCAT bus;

step 6, the motion controller reads position information fed back by the X1 main driver, the Y driver and the Z driver, real-time positions of the X1 main driver, the Y driver and the Z driver are resolved into ultrasonic scanning position codes and stepping position codes by adopting a coded signal inverse solution algorithm, and the ultrasonic scanning position codes and the stepping position codes are sent to Port C ports of the Y driver and the Z driver for simulation output;

step 7, judging whether the track execution is finished;

s7.1, when the track execution is detected to be finished, the check is finished;

s7.2, detecting that track points which are not executed exist, and jumping to the step 4 to be executed circularly.

The invention has the beneficial effects that: in the technical scheme of the invention, the circumferential motion of the hot gas guide pipe adopts a master-slave axis gantry control mode, so that the equipment speed is stable, the positioning is accurate and the probe is reliably attached in the circumferential 360-degree direction variable load inspection process; the circumferential motion of the hot gas guide pipe adopts a double closed-loop control mode, so that the consistency of the actual position of the circumferential motion and the coding position received by the ultrasonic instrument can be ensured.

Drawings

FIG. 1 is a schematic view of the movement direction of a hot gas duct saddle weld inspection device;

FIG. 2 is a schematic diagram of the components of the control system of the hot gas conduit saddle surface weld inspection device of the present invention.

In the figure: 1-control computer, 2-motion controller, 3-X1 main driver, 4-X2 slave driver, 5-Y driver, 6-Z driver, 7-X1 main motor, 8-X1 coaxial encoder, 9-X1 terminal encoder, 10-X2 slave motor, 11-X2 coaxial encoder, 12-Y motor, 13-Y coaxial encoder, 14-Z motor and 15-Z coaxial encoder.

Detailed Description

The invention is described in further detail below with reference to the figures and the embodiments.

The embodiment provides a control system of a hot gas conduit saddle surface welding seam inspection device, which is applicable to an automatic ultrasonic detection device with the application number of 202010473802.X or other similar inspection devices. The control system principle of the embodiment is shown in fig. 2, and the system mainly comprises a control computer 1, a motion controller 2 and 4 groups of driving components and is used for realizing scanning and stepping of a probe of the inspection device in different directions; the main driving assembly X1 and the auxiliary driving assembly X2 in the 4 groups of driving assemblies synchronously move along the circumferential direction of the hot gas guide pipe, the radial driving assembly Z moves along the radial direction of the hot gas guide pipe, and the deflection driving assembly Y moves along the deflection direction of the axis of the hot gas guide pipe so as to ensure that the probe can be stably attached to the pressure container body in real time.

The main drive assembly X1 comprises an X1 main drive 3, an X1 main motor 7, an X1 coaxial encoder 8, an X1 terminal encoder 9 and the like; the slave drive assembly X2 comprises an X2 slave drive 4, an X2 slave motor 10, an X2 coaxial encoder 11 and the like; the radial driving assembly Y comprises a Y driver 5, a Y motor 12, a Y coaxial encoder 13 and the like; the deflection driving assembly Z includes a Z driver 6, a Z motor 14, a Z coaxial encoder 15, and the like. The X1 master driver 3, the X2 slave driver 4, the Y driver 5 and the Z driver 6 are all provided with a PortA port, a PortB port and a PortC port; the Port C Port coding output interfaces of the Y driver 5 and the Z driver 6 are connected to the ultrasonic instrument.

The control computer 1 issues a control instruction to the motion controller 2 through an Ethernet network, and receives state information fed back by the motion controller 2; the control instruction mainly comprises enabling, Point moving, calibrating, PTP moving (Point to Point moving), PVT moving (Position Velocity and Time moving), and the like, and the state information mainly comprises information such as a current Position, a real-Time speed, a real-Time current, a current moving state, an error state, and the like.

The motion controller 2 and the drivers (X1 master driver 3, X2 slave driver 4, Y driver 5 and Z driver 6) of each drive assembly communicate by adopting an EtherCAT bus, and adopt a pair-line type topological structure. The X1 master driver 3, the X2 slave driver 4, the Y driver 5 and the Z driver 6 are all provided with a PortA port, a PortB port and a PortC port; the Port C Port coding output interfaces of the Y driver 5 and the Z driver 6 are connected to the ultrasonic instrument.

The inspection apparatus may slip between the master drive assembly X1 and the slave drive assembly X2 during circumferential movement along the hot gas duct, which may cause the actual position coordinates of the inspection apparatus to be inconsistent with the coordinates sent to the ultrasonic instrument, thus employing a double closed loop configuration in designing the master drive assembly X1. The output shaft of the X1 main motor 7 is connected with an X1 coaxial encoder 8, an X1 terminal encoder 9 is directly attached to the scanning surface of the ultrasonic probe through an elastic wheel set, the X1 coaxial encoder 8 is connected to a PortA port of the X1 main driver 3, and the X1 terminal encoder 9 is connected to a PortB port of the X1 main driver 3; in the X1 main driver 3, the X1 coaxial encoder 8 is used as the speed control loop feedback of the main driving assembly X1, and the X1 terminal encoder 9 is used as the position control loop feedback, so that the actual position information output by the main driving assembly X1 can be consistent with the coordinates of the ultrasonic probe.

The circumferential load of the inspection equipment in the circumferential 360-degree movement process along the hot gas guide pipe needs to change along with the change of the movement angle, in order to meet the stability and the accuracy of the circumferential movement under the condition of the changed load, the circumferential movement is realized by an X1 main driving assembly and an X2 auxiliary driving assembly, and the movement problem under the condition of the changed load can be solved by controlling the real-time synchronism of the X1 main driving assembly and the X2 auxiliary driving assembly.

The main drive assembly X1 still adopts a double closed loop structure, and by setting a simulation Mode (Emulation) in the X1 main drive 3, the signals of the X1 coaxial encoder 8 collected by a PortA port thereof are routed to a portab port of the X2 slave drive 4, and the X2 slave drive 4 is set to a Profile Position Mode (Profile Position Mode), and simultaneously, the encoder signal input of the PortA port thereof is set as the input information of the electronic gear. At this time, the target position information of the EtherCAT bus is not received by the X2 from the drive 4, and the real-time speed and position information of the X2 slave motor 10 are both from the pulse input speed and the pulse input number of the PortB port of the X2 slave drive 4, so that the synchronous stable motion of the master drive assembly X1 and the slave drive assembly X2 is realized.

The electronic gear belongs to a function in the driver, and under the same input condition, the displacement corresponding to the output can be changed by setting the electronic gear ratio in the driver. The electronic gear can realize the displacement of the motor corresponding to any input signal (such as a pulse) by means of soft parameter setting and the like, and the traditional method for changing the corresponding relation is to adjust the reduction ratio by means of mechanical gears and the like.

The embodiment also provides an inspection device adopting the control system, and a saddle surface welding seam ultrasonic inspection process is carried out, and the method specifically comprises the following steps:

step 1, connecting lines;

1.1, connecting the lines according to the principle shown in FIG. 2;

1.2, connecting Port C Port coding output interfaces of a Y driver 5 and a Z driver 6 to an ultrasonic instrument;

step 2, parameter configuration;

2.1, setting a Port B of an X1 main driver 3 as an incremental encoder signal input, configuring a Port C Port into a simulation output (Emulation) mode, and routing an encoder signal collected by a Port A Port to the Port C Port;

2.2, setting the Port B Port of the X2 from the driver 4 as an electronic gear input interface, wherein the electronic gear ratio is 1: 1 (in line with the gear ratios of the X1 master drive assembly and the X2 slave drive assembly);

step 3, generating and sending a motion track and an instruction;

3.1, generating a motion track point and a control command at the control computer 1, wherein in the work Mode command (the work Mode command belongs to a part of the control command)), the X1 master driver 3, the Y driver 5 and the Z driver 6 are set to a Cyclic Position Mode (Cyclic Position Mode), and the X2 slave driver 4 is set to a Profile Position Mode (Profile Position Mode);

3.2, sending the control command and the motion trail points generated in the S3.1 to the motion controller 2 through an Ethernet network;

step 4, the motion controller 4 reads the motion track points, analyzes the motion track points into target position information of the X1 master driver 3, the X2 slave driver 4, the Y driver 5 and the Z driver 6, and sends the target position information to each driver through an EtherCAT bus;

step 5, X1, the main driver 3 and the X2 read the target position information sent by the motion controller 4 from the driver 4, the Y driver 5 and the Z driver 6 and execute the motion, and each driver collects the feedback position information of each encoder and the state information of the driver in real time and uploads the feedback position information and the state information to the motion controller 2 through an EtherCAT bus;

step 6, the motion controller 2 reads the position information fed back by the X1 main driver 3, the Y driver 5 and the Z driver 6, the real-time positions of the X1 main driver 3, the Y driver 5 and the Z driver 6 are resolved into ultrasonic scanning position codes and stepping position codes by adopting a coded signal inverse solution algorithm, and the ultrasonic scanning position codes and the stepping position codes are sent to Port C ports of the Y driver 5 and the Z driver 6 for simulation output;

step 7, judging whether the track execution is finished;

7.1, when the track execution is detected to be finished, exiting the motion control program; specifically, there are many ways to detect whether the track is executed completely, for example, an index value may be added to each group of position points, that is, the second group of data represented by the index value, and when the index value of the current position point is detected to be equal to the total group number of the track data, it may be determined that the current position point is the last group of data, or other existing techniques known to those skilled in the art are used to determine whether the track is executed completely;

7.2, detecting that track points which are not executed exist, and jumping to the step 4 to execute circularly.

It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. It is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.