【摘要】：許多工業(yè)容器由于長期運(yùn)行在高溫、高壓及化學(xué)侵蝕的惡劣環(huán)境下,設(shè)備的內(nèi)壁容易產(chǎn)生應(yīng)力和腐蝕,進(jìn)而會(huì)導(dǎo)致設(shè)備內(nèi)部出現(xiàn)缺陷或故障,給生產(chǎn)安全帶來隱患,因此對(duì)工業(yè)容器進(jìn)行高效的在線檢測(cè)就顯得十分重要。紅外熱像檢測(cè)技術(shù)是一種新的無損檢測(cè)方法,通過對(duì)獲得的紅外熱圖像進(jìn)行分析,來判斷容器內(nèi)部缺陷的情況。它適合外場(chǎng)、在線、在役檢測(cè),在電力、冶金、石油化工等眾多領(lǐng)域得到了廣泛的應(yīng)用。紅外熱像檢測(cè)技術(shù)也存在一些不足,目前在對(duì)設(shè)備狀況進(jìn)行診斷分析時(shí)主要依據(jù)的是獲取的紅外圖像,但是紅外圖像空間層次感較差,依據(jù)二維紅外圖像難以準(zhǔn)確判定缺陷幾何特征,也難以準(zhǔn)確確定缺陷位置,這會(huì)導(dǎo)致診斷的精度和實(shí)用性不足。針對(duì)這一問題,本文以高溫容器缺陷診斷為目標(biāo),開展了紅外三維診斷技術(shù)研究。采用三維激光掃描儀獲取容器的三維點(diǎn)云數(shù)據(jù),建立容器的精準(zhǔn)幾何場(chǎng),同時(shí)熱紅外相機(jī)獲取容器的溫度場(chǎng);將三維幾何場(chǎng)和溫度場(chǎng)疊加形成三維多源場(chǎng),并結(jié)合數(shù)值模擬技術(shù),在三維多源場(chǎng)上對(duì)缺陷進(jìn)行三維診斷分析,最終實(shí)現(xiàn)了容器缺陷的三維診斷分析技術(shù)在實(shí)際工程中的應(yīng)用。本文研究的主要內(nèi)容如下:首先,通過實(shí)驗(yàn)驗(yàn)證了利用紅外三維診斷技術(shù)對(duì)容器缺陷進(jìn)行診斷的可靠性,并與傳統(tǒng)紅外檢測(cè)技術(shù)進(jìn)行了對(duì)比分析。結(jié)果表明,在得到的三維點(diǎn)云上可以實(shí)現(xiàn)缺陷診斷的三維可視化,可以準(zhǔn)確定位缺陷位置,與傳統(tǒng)方法相比可以比較簡(jiǎn)便的測(cè)出缺陷尺寸。在此基礎(chǔ)上進(jìn)行了一系列實(shí)驗(yàn),研究了內(nèi)外溫差、檢測(cè)距離、缺陷參數(shù)對(duì)紅外三維診斷技術(shù)檢測(cè)效果的影響規(guī)律,得到了以下結(jié)論:(1)提高內(nèi)外溫差的數(shù)值可以提高該技術(shù)的檢測(cè)能力;(2)檢測(cè)距離對(duì)該技術(shù)的檢測(cè)效果有很大影響,減小檢測(cè)距離可以提高該技術(shù)的檢測(cè)效果;(3)該技術(shù)對(duì)缺陷的最大檢測(cè)距離隨缺陷的尺寸、深度的增大而增大,隨缺陷尺寸、深度的減小而減小;(4)該技術(shù)對(duì)缺陷的檢測(cè)能力受到缺陷本身屬性的限制,對(duì)大尺寸、大深度的缺陷檢測(cè)能力較強(qiáng)。在利用紅外三維診斷技術(shù)對(duì)容器進(jìn)行診斷時(shí),不能僅僅簡(jiǎn)單判斷一下缺陷是否存在,往往還需要依據(jù)獲取的容器表面溫度圖譜來分析容器內(nèi)部缺陷的情況。針對(duì)這一問題,本文以高爐爐缸為研究對(duì)象,在ANSYS軟件中建立了含有不同形狀腐蝕孔、裂紋的爐墻三維模型,開展了缺陷溫度場(chǎng)數(shù)值計(jì)算,得到了常見特征缺陷對(duì)應(yīng)的爐墻表面溫度圖譜,分析總結(jié)了不同缺陷對(duì)應(yīng)的爐墻表面溫度圖譜的特點(diǎn),從而為實(shí)際工程中分析容器內(nèi)部缺陷情況提供必要的依據(jù)。最后,在上述研究的基礎(chǔ)上利用紅外三維診斷技術(shù)對(duì)工廠中的容器進(jìn)行現(xiàn)場(chǎng)檢測(cè),建立了高溫容器的數(shù)字化實(shí)景模型,在三維點(diǎn)云上對(duì)缺陷進(jìn)行診斷分析,測(cè)出了缺陷尺寸、坐標(biāo)位置以及缺陷距地面距離等缺陷信息。同時(shí)與前面數(shù)值模擬得到的溫度圖譜進(jìn)行比較分析,推測(cè)出容器內(nèi)部缺陷可能的情況,從而為指導(dǎo)設(shè)備維護(hù)提供準(zhǔn)確依據(jù)。
[Abstract]:Many industrial containers are liable to produce stress and corrosion in the harsh environment of high temperature, high pressure and chemical erosion for a long time, which will lead to defects or failures inside the equipment and bring hidden dangers to the safety of production. Therefore, it is very important to carry out efficient line detection for industrial containers. It is a new nondestructive testing method to determine the internal defects in the container by analyzing the infrared thermal image obtained. It is suitable for external field, online, in service, and has been widely used in many fields, such as electric power, metallurgy, petrochemical and other fields. The infrared thermal image testing technology also has some shortcomings, and it is now in the condition of equipment. The infrared image obtained is mainly based on the infrared image obtained in the diagnosis and analysis, but the infrared image has a poor spatial level. It is difficult to accurately determine the geometric characteristics of the defect according to the two-dimensional infrared image, and it is difficult to accurately determine the position of the defect. This will lead to the lack of accuracy and practicability of the diagnosis. The three-dimensional point cloud data of the container is obtained by the three-dimensional laser scanner, the accurate geometric field of the container is established, and the temperature field of the container is obtained by the thermal infrared camera, and the three-dimensional multi-source field is formed by superimposing the three-dimensional geometric field and temperature field, and the defects in the three-dimensional multi source field are combined with the numerical simulation technology. Three dimensional diagnosis analysis is carried out. Finally, the application of three-dimensional diagnosis and analysis technology for container defects in practical engineering is realized. The main contents of this paper are as follows: first, the reliability of the diagnosis of container defects by using infrared 3D diagnosis technology is verified by experiments, and the results are compared with the traditional infrared detection technology. It shows that the 3D visualization of defect diagnosis can be realized on the 3D point cloud, and the defect location can be located accurately. Compared with the traditional method, the defect size can be easily detected. On this basis, a series of experiments are carried out to study the effect of internal and external temperature difference, detection distance and defect parameters on the infrared 3D diagnosis technology. The following conclusions are obtained: (1) increasing the value of the internal and external temperature difference can improve the detection ability of the technology; (2) the detection distance has a great influence on the detection effect of the technology, and the detection distance can be reduced to improve the detection effect of the technology. (3) the maximum detection distance of the technique increases with the size and depth of the defect. Large, decrease with the defect size and depth decrease; (4) the detection ability of the defect is limited by the property of the defect itself, and has a strong ability to detect the defects in large size and deep. In this paper, a three-dimensional model of the furnace wall with different shapes of corrosion holes and cracks is established in the ANSYS software, and the temperature field of the defect is calculated, and the temperature Atlas of the wall surface corresponding to the common characteristic defects is obtained. The characteristics of the temperature map of the furnace wall surface with different defects are analyzed and summarized, which provides the necessary basis for the analysis of the internal defects in the actual engineering. Finally, on the basis of the above research, the infrared three-dimensional diagnosis technology is used to test the container in the factory, and the digital real model of the high temperature container is set up. The defect is diagnosed and analyzed on the three dimensional point cloud. Defect information, such as defect size, coordinate position and distance from the defect to ground, is measured. At the same time, it is compared with the temperature map obtained from the previous numerical simulation, and the possibility of internal defects in the container is speculated, thus providing an accurate basis for the maintenance of the guide equipment.
【學(xué)位授予單位】：西南交通大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TG115.28;TF57

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