燃气管道内部缺陷智能检测器的设计.doc

哈尔滨工程大学本科生毕业论文摘要本课题来源于实际科研项目燃气管道内部缺陷智能检测器的设计，并为其子项目之一。管道内部缺陷检测机器人的设计涉及电子、计算机、信息处理、模式识别、探伤、管道等。目前，管道无损检测的方法很多，利用漏磁管道检测的方法通用性广，本课题因此应运而生。本课题利用实验室环境建立管道模型，进行运载体管道定位技术研究，完成运行体及检测电路设计。第一章绪论介绍课题的背景意义，国内外的发展现状。第二章说明管道检测的基本原理及对缺陷漏磁场分析出的三种理论模型，并列举漏磁场的三个影响因素。第三章说明了霍尔传感器功能及应用，并进行硬件电路的的设计。第四章简要说明了运载体管内定位方法，并进行运载体的外形设计。通过本课题的研究，自己对管道漏磁检测有了更为深入的理解，对管道定位技术有了新的认识，自己解决问题的能力也得到了提高。关键词：管道机器人；漏磁检测；霍尔传感器；定位技术；运载体设计哈尔滨工程大学本科生毕业论文ABSTRACTThepaperstemsfromoneofsub-projectsoftheactualscientificresearchproject-gaspipelineofinternaldefectsinthedesignofintelligentdetector.Thedesignofpipelineinternaldefectinspectionrobotisinvolvedinelectronics,computer,informationprocessing,patternrecognition,flawdetection,pipeandother.Atpresent,therearealotofpipelinenon-destructivetestingmethods.Magneticfluxleakagepipelineinspectionisusedwidely,thesubjectthuscomesintobeing.Thepipemodelwasestablishedbasedonlaboratoryenvironment,throughtheresearchofpipelinecarrierpositioningtechnology,thepapercompleteddetectioncircuitoperationanddesignofbody.InthispaperChapterIintroducesthebackgroundandsignificationoftheinspection,andthedevelopmentoftheprojectathomeandabroad.ChapterIIintroducestothebasicprinciplesofpipelineinspectionandthreetheoreticalmodelsofdetectionanalysisofleakagemagneticfield,andliststhethreemagneticfieldleakagefactor.ThethirdchapterdescribesthefunctionandapplicationofHallsensorandthedesignofhardwarecircuits.ChapterIVprovidesabriefdescriptionaboutthetransportertubepositioningmethods,anddesignmethodofthecarrierisgiven.Throughthestudyofthesubject,basicunderstandingtopipelinemagneticfluxleakagetestingtechniquecanbegiventome,andabilitytosolveactualproblemalsohasbeenimproved.Keywords:pipelinerobot；magneticfluxleakagetesting；hallsensor；positioningtechnology；carrierdesign哈尔滨工程大学本科生毕业论文目录第1章绪论·················································································11.1课题的背景及意义···································································11.2管道机器人的发展概况····························································31.2.1国外发展现状·································································41.2.2国内发展现状·································································61.3课题的主要工作······································································7第2章漏磁检测的理论分析·······················································82.1管道漏磁检测原理··································································82.1.1管道漏磁检测基本原理····················································82.1.2管道检测系统的结构······················································102.2缺陷漏磁场分析····································································122.2.1点偶极子模型·······························································132.2.2带偶极子模型·······························································142.2.3面偶极子模型·······························································172.3缺陷漏磁场的有限元分析·······················································172.4漏磁场的影响因素·································································192.4.1磁化场对漏磁场的影响···················································192.4.2缺陷方向、大小和位置对漏磁场的影响·····························192.4.3工件材质及工况对漏磁场的影响······································202.5本章小结·············································································20第3章基于霍尔传感器的数据采集模块设计···························213.1霍尔传感器及其应用·····························································213.1.1霍尔效应和霍尔元件······················································213.1.2霍尔传感器典型应用电路···············································253.2基于霍尔传感器的漏磁检测电路设计·······································283.2.1霍尔传感器的选择·························································28哈尔滨工程大学本科生毕业论文3.2.2硬件电路具体设计与调试···············································313.3本章小结·············································································32第4章运载体定位方法研究及外形设计··································334.1运载体定位方法研究·······························································334.1.1视觉传感器方法····························································334.1.2低频电磁波方法及应用··················································344.1.3计程轮方法··································································354.2计程轮的应用设计·································································354.2.1里程电路组成的部件霍尔开关·········································364.2.2里程电路的计数器原理··················································374.2.3位置误差校正方法·························································374.3运载体外形设计····································································384.3.1钢管选择······································································384.3.2磁铁选择······································································394.3.3导磁体选择··································································404.3.4运载体结构整体计算······················································414.4本章小结·············································································43结论·······················································································44参考文献·······················································································45致谢·······················································································48哈尔滨工程大学本科生毕业论文1第1章绪论1.1课题的背景及意义机器人是一种自动化的机器，具备一些与人或生物相似的能力，如感知、规划、运动及动作能力的协作等，机器人技术被视为20世纪人类最伟大的发明之一。自20世纪60年代工业机器人问世以来，随着社会的进步和科学技术的迅猛发展，特别是在信息技术、控制理论等学科迅速发展的支持下，机器人的种类日益繁多，性能不断地改进，工作领域也在不断地扩大。从深海到宇宙空间，在各种人类所不能承受的极限环境中都能找到机器人的应用。可以说，现代机器人技术已经突破了传统的工业机器人的范畴，逐步转向应用于各种特殊工况的特种机器人技术。特种机器人工作于非结构环境中，即工作无法在事先布置好的条件下进行，而且在工作进行过程中环境或工作的内容可能随时发生变化。开发非结构环境下工作的特种机器人，使人脱离危险作业的生产第一线，减轻人的劳动强度，是机器人发展的一个必然方向。目前国际上特种机器人技术的研究和开发非常活跃。在研究和开发的过程中，人们逐步认识到特种机器人技术的本质是感知、决策、行动和交互四大技术的结合。随着人们对特种机器人智能化本质认识的加深，特种机器人技术开始源源不断地向人类活动的各个领域渗透。特种机器人的新机构、新结构、新传感器和新型伺服驱动系统的开发和先进的控制算法、控制策略的研究已经成为机器人研究的一个重要领域。管道运输乃当今五大运输手段之一，在石油化工城市输水与供热核工业等部门都用到了大量金属和非金属管道。由于许多管道的工作环境非常恶劣容易发生腐蚀、疲劳破坏或使管道内部潜在缺陷发展成破损而引起泄漏事故等。为提高管道运输的可靠性和使用寿命，在重要的管道施工中都要求对管道进行管内防腐、喷漆、补口、检测、探伤、管内加工等作业。管道内部检测极其困难，用传统的开挖方法进行地下管道检测往往是一项巨大的工程。哈尔滨工程大学本科生毕业论文2而使用管道机器人检测管道可以消除由于管道泄漏而产生的不安全隐患，保障人民生活及财产安全并大量减少在役煤气管道的提前报废，延长在役管道的寿命，为国家节约了大量资金以及大幅度减少维护管道开挖面积及长度，大大降低了管道维护成本，减少城市污染保护城市环境卫生，减少了由于开挖而产生的城市道路交通的阻塞，为此世界各工业发达国家都竞相开展了管道检测机器人的研究。我国油气管道大多是在6070年代建设的迄今仅在役的长输管线已逾1.7万公里正面临管道进入中老龄期处于事故多发阶段油气管道的检测和评价的需求已日趋迫切，我国的天然气储量主要分布于中西部地区和近海海域，因此管道输送仍将是我国燃气传送的主要手段。管道检测机器人是针对油、气等输送管道的检测、喷涂、接口焊接、异物清理等维护检修作业所研制的一种特种机器人，它综合了智能移动载体技术和管道缺陷无损检测技术。这类机器人能进入人所不及、复杂多变的非结构管道环境中，通过携带的无损检测装置和作业装置，对工作中的油气管道进行在役检测、清理、维护，以保障管道的安全和畅通无阻地工作。由于管道检测机器人实施的是管道内检测技术，它还能够方便地获取、传输、存储管道内的视频影像数据，作为分析判断管道内壁腐蚀状况、几何形状异常、堵塞、断裂、泄漏的重要依据，并可利用机器人自身精确的定位系统对缺陷进行定位，通过携带的检测装置对关键部位实施进一步的定量检测。这一技术特点，使得在对穿越河流、铁路、道路的特殊管道或埋地管道的重要部位进行有选择的检测时，管道检测机器人具有独特的优势因此，与管外检测技术相比，管道检测机器人技术在管道安全管理工程中具有不可替代的作用，是管外检测技术的重要补充1。综上所述，管道检测机器人的研究为管道的检测、维护提供了新的技术手段，改变了传统管道开挖抽检的单一模式。这种检测技术提高了管道检侧的准确性，便于管道工程管理维护人员分析了解管道缺陷产生的原因，开展对缺陷的评估，制订管道维护方案，消除管道安全隐患，在事故发生前就有计划地维修或更换管段，从而节约大量的维修费用，降低管道维护成本，保哈尔滨工程大学本科生毕业论文3障人民生活及财产安全，减少有毒气体或液体泄漏造成的环境污染。因此，开展管道检测机器人的研究具有重要的科学意义和明显的社会经济效益。目前，管道检测机器人的研究得到了世界各国的高度重视，也得到了我们国家部委和相关行业的重视。大量的管道检测维护需求为管道检测机器人的研究开发和应用提供了广阔的市场空间，将逐渐成为一项十分巨大的产业工程。因此，管道机器人的研究具有现实意义。在我国国家高技术研究发展计划先进制造与自动化技术领域机器人技术主题中，就将管道作业机器人及应用作为发展重点。1.2管道机器人的发展概况20世纪70年代以来，石油、化工、天然气及核工业等产业迅速发展，各种管道作为一种重要的物料输送设施，得到了广泛应用。由于腐蚀、重压等作用，管道不可避免地会出现裂纹、漏孔等现象。而管道所处的环境往往是人们不易或不能直接接触的，因此，对于管道的检测和维护，成了工业生产中的一道难题。传统的管道检测方法有全面挖掘法、随机抽样法等，这些方法均存在工程量大、准确率低等缺点。目前，管道的检测和维护多采用管道机器人来进行。管道机器人是一种可沿管道内壁行走的机械，它可以携带一种或多种传感器及操作装置（如CCD摄像机、位置和姿态传感器、超声传感器、涡流传感器、管道清理装置、管道裂纹及管道接口焊接装置、防腐喷涂装置、简单的操作机械手等），在操作人员的控制下进行一系列的管道检测维修作业。一个完整的管道机器人系统，应由移动载体（行走机构）、管道内部环境识别检测系统、信号传递和动力传输系统及控制系统组成，其中移动载体是管道检测移动机器人的核心部分。管道检测机器人的工作空间是复杂、封闭的各种管道，包括水平直管、各角度弯管、斜坡管、垂直管以及变径管接口等，它的运行距离一般也较长。