CN109932375B - Digital imaging detection method for calibrating DR long-focal-length transillumination sensitivity of thick weld seam of tube plate - Google Patents
Digital imaging detection method for calibrating DR long-focal-length transillumination sensitivity of thick weld seam of tube plate Download PDFInfo
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Abstract
The invention relates to the technical field of foundation construction, in particular to a digital imaging detection method for calibrating DR long-focal-length transillumination sensitivity of a thick weld joint of a tube plate. The detection method comprises the following steps: detecting a transillumination mode selection; the ray machine working training machine; setting detection information; calibrating the response sensitivity of the detector; installing a detection imaging system; setting a detection transillumination geometric parameter; arranging a detection mark and an image quality meter; setting detection process parameters; calibrating imaging sensitivity of the system; and acquiring and imaging weld joint data and evaluating the weld joint quality. The detection method provided by the invention improves the DR detection transillumination capability, detection sensitivity and imaging quality, realizes DR detection under the conditions of thick-wall weld joint of the tube plate and long focal length, improves the detection quality and work efficiency, and reduces the operation intensity and construction cost.
Description
Technical Field
The invention relates to the technical field of foundation construction, in particular to a digital imaging detection method for calibrating DR long-focal-length transillumination sensitivity of a thick weld joint of a tube plate.
Background
At present, a conventional welding seam DR detection process selects a transillumination mode according to workpiece characteristics and detection technical requirements, a radiation source is generally a variable-frequency X-ray machine, a detection focal length is generally smaller than 700mm, working voltage of the radiation machine, detection exposure and other process parameters are set, and a DR system is started to detect welding seams and evaluate quality. The detection method is only suitable for detecting the DR of the welding seam with the detection focal length smaller than 700mm and the transillumination thickness smaller than 25mm, and the image quality can only reach the technical grade of medium sensitivity. In engineering detection, the thick-wall weld joint of the tube plate is often detected, double-wall single-image external transillumination detection conditions exist for the thick-wall weld joint of the large-caliber pipeline, the detection focal length is far greater than 700mm, the transillumination thickness is in decreasing change along with the increase of the detection focal length, and the DR detection transillumination capability and the detection sensitivity are reduced because the attenuation change of the ray intensity along with the increase of the detection focal length and the transillumination thickness is large, so that the imaging quality cannot meet the technical requirements of detection standards, and therefore, the DR detection technology has limitations in engineering application and cannot realize DR detection of the long focal length of the weld joint of the thick-wall weld joint of the tube plate.
Disclosure of Invention
First, the technical problem to be solved
The invention provides a digital imaging detection method for calibrating DR long-focus transillumination sensitivity of a thick weld joint of a tube plate, which aims to overcome the defects that DR detection transillumination capability and detection sensitivity are reduced, imaging quality cannot meet the technical requirements of detection standards, DR detection technology has limitations in engineering application, DR detection of the long-focus weld joint of the thick weld joint of the tube plate and the wall cannot be realized, and the like.
(II) technical scheme
In order to solve the problems, the invention provides a digital imaging detection method for calibrating long-focus transillumination sensitivity of a thick weld DR of a tube plate, which comprises the following steps:
s1: detecting transillumination mode selection, comprising: selecting a transillumination detection mode according to the specification of a workpiece to be detected, wherein the plate welding seam adopts single-wall single-shadow transillumination detection, and the large-caliber pipeline joint mouth girth welding seam adopts double-wall single-shadow external transillumination detection; wherein the effective pixel size of the imaging detector for detection is not more than 200 μm; the high-frequency constant-voltage X-ray machine with the rated voltage of 300kv is selected as the ray source, and the effective focal spot size is not more than 3mm;
step S2: ray machine training machine includes: performing a working training machine on the selected X-ray machine according to the weld joint material and the maximum transillumination thickness of the detected workpiece;
step S3: setting detection information, including starting a DR digital detector and a system detector;
step S4: calibrating detector response sensitivity, comprising: under the condition of no workpiece, the digital detector and the X-ray machine are oppositely placed and fixed through a detection tool, and the distance between the digital detector and the X-ray machine is set according to the actual detection focal length; calibrating consistency of the pixel of the detector and the background gray level in a state of closing the X-ray machine; then, opening a ray combined control safety protection device and an X-ray machine, calibrating the radiation response sensitivity of the detector by setting the working voltage and the working current of the X-ray machine, adjusting the gray level histogram curve of the detector to be 80% -95% of the gray level full scale range, and then closing the X-ray machine;
setting a detection control program file according to parameters of pipeline specification, frame rate, integration times, overlap length, exposure times, movement step length and movement speed, and realizing movement control of a detection driving mechanism;
step S5: a mounting detection imaging system comprising: detecting the welding seam of the plate, mounting a detection imaging system on a detection tool, oppositely placing an imaging detector and a directional X-ray machine on two sides of the welding seam, enabling the center of a ray bundle to be vertical to the welding seam, and enabling the center of the detector to be aligned with the detection starting point position of the welding seam; detecting a pipeline joint mouth girth joint, firstly, fixedly installing a steel track on the surface of a pipeline at one side of the girth joint, then installing an imaging detector and an X-ray machine on the track, oppositely placing and fixedly connecting the two driving mechanisms, then installing the imaging detector and the directional X-ray machine on the respective driving mechanisms respectively, and forming an included angle between the center of a ray bundle and a vertical plane where the center line of the pipeline girth joint is locatedThe center of the detector is aligned with the detection starting point position of the welding line within 5 degrees.
Step S6: setting the detection transillumination geometry parameters, comprising: setting the distance from the imaging detector to the welding seam to be 20mm-30mm through a detection tool adjusting mechanism, and setting a detection focal length through the adjusting mechanism;
step S7: arranging a detection mark and an image quality meter, comprising: before detection, arranging a detection mark and an image quality meter on the surface of a detection workpiece;
step S8: setting detection process parameters, including: and (3) primarily setting working voltage and working current of the X-ray machine according to the detection focal length and the transillumination thickness, and setting imaging frame rate and integration times technological parameters.
Step S9: calibrating system imaging sensitivity, comprising: the imaging sensitivity and the gray level of a system are calibrated by adjusting and setting the working voltage of an X-ray machine and detecting the technological parameters of exposure, and the gray level histogram curve of the digital imaging of the welding seam is adjusted to be between 50 and 60 percent of the full range of gray level;
step S10: weld data acquisition imaging, comprising: the method comprises the steps of taking a welding seam detection imaging area, controlling two detection driving mechanisms to synchronously run along a track, carrying out welding seam data acquisition and digital imaging according to set technological parameters, acquiring a plurality of digital images according to the length of a welding seam and the exposure times, and storing the welding seam digital images into a computer in a DICOMDE format;
step S11: assessing weld quality, comprising: in a static imaging state, measuring the sensitivity, resolution, normalized signal-to-noise ratio and gray scale technical indexes of the digital image of the welding seam, calibrating the geometric dimension by adopting a double-line type image quality meter, enhancing the digital image of the welding seam, adjusting the contrast, and evaluating the quality of the welding seam according to a detection standard.
Preferably, the detection mark and the image quality meter should be arranged on the surface of the detection workpiece before detection:
arranging engineering numbers, pile numbers, weld specifications, position numbers and date identification marks on the marking tape, fixing the marking tape and the marking ruler on the surface of a workpiece by using a magnetic clamp, and detecting the marks to be at least 5mm away from the edge of the weld;
when single-wall single-shadow transillumination is performed, the linear imager is arranged on the radiation source side of the workpiece; when double-wall single-image transillumination is performed, the linear image quality meter is arranged on the detector side of the workpiece; the image quality meter is arranged at 1/4 of the length of the detected area at one end of the welding line, the metal wire vertically crosses the welding line, and the thin wire is arranged at the outer side;
the double-line image quality meter is arranged on the ray source side of the workpiece and is arranged on a base material at the 1/4 position of the length of a detected area of the plate weld joint, and the center position and the end point position of an effective transillumination area of the pipeline girth weld joint; the metal wire of the double-wire image quality meter forms an included angle of 2-5 degrees with the row or the column of the detector, and the filament is arranged outside.
(III) beneficial effects
The digital imaging detection method for calibrating the DR long-focal-length transillumination sensitivity of the thick weld joint of the tube plate improves the DR detection transillumination capability, detection sensitivity and imaging quality, realizes DR detection of the thick weld joint of the tube plate under the conditions of long focal length, improves the detection quality and work efficiency, and reduces the operation intensity and construction cost.
Drawings
FIG. 1 is a flow chart of a digital imaging detection method for calibrating the long-focus transillumination sensitivity of a thick tube plate weld DR according to an embodiment of the present invention;
fig. 2 is a diagram of a pipeline girth weld detection tool in a tube plate thick weld DR long-focus transillumination sensitivity calibration digital imaging detection method according to an embodiment of the present invention.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and examples.
As shown in fig. 1 and 2, the invention provides a tube plate thick weld DR long-focal-length transillumination sensitivity calibration digital imaging detection method, which specifically comprises the following steps:
step S1: the detection transillumination mode is selected, the detection transillumination mode is selected according to the specification of a workpiece to be detected, the plate welding seam is detected by single-wall single-shadow transillumination, and the large-caliber pipeline (phi 813 mm-phi 1422 mm) continuous head mouth girth joint is detected by double-wall single-shadow external transillumination. The effective pixel size of the imaging detector used for detection should not be larger than 200 μm. The high-frequency constant-voltage X-ray machine with the rated voltage of 300kv is selected as the ray source, and the effective focal spot size is not more than 3mm. Materials such as a type for detection, a marking tape, a marking ruler, a magnetic clamp, an image quality meter, and a marker pen are prepared. The surface quality (including the residual height) of the weld and the heat affected zone should be acceptable by visual inspection.
Step S2: ray machine training machine includes: and (3) according to the weld joint material and the maximum transillumination thickness of the detected workpiece, performing a working training machine on the selected X-ray machine, and setting the highest working voltage and the highest working current value of the X-ray machine, wherein the working voltage is not more than 90% of the rated voltage of the X-ray machine. And (3) turning on a power switch of the X-ray machine to adjust to a working gear for carrying out a training machine, gradually increasing the tube voltage and the tube current of the X-ray machine to the working voltage and the working current, and turning on the power switch of the X-ray machine to a safe gear after the training machine is completed to turn off the X-rays.
Step S3: setting detection information, starting a DR digital detector, and setting information steps such as a detection file name, a storage path, a detection program file and the like after the network connection of the detection system is successful.
S4: calibrating detector response sensitivity, comprising: under the condition of no workpiece, the digital detector and the X-ray machine are oppositely placed and fixed through a detection tool, and the distance between the digital detector and the X-ray machine is set according to the actual detection focal length; calibrating consistency of the pixel of the detector and the background gray level in a state of closing the X-ray machine; then, the ray combined control safety protection device and the X-ray machine are turned on, the radiation response sensitivity of the detector is calibrated by setting the working voltage and the working current of the X-ray machine, the gray level histogram curve of the detector is adjusted to be 80% -95% of the gray level full scale range, and then the X-ray machine is turned off.
And setting a detection control program file according to parameters of pipeline specification, frame rate, integration times, overlap length, exposure times, movement step length and movement speed, so as to realize movement control of a detection driving mechanism.
Step S5: a mounting detection imaging system comprising: detecting the welding line of the plate, mounting a detection imaging system on a detection tool, oppositely placing an imaging detector 3 and a directional X-ray machine 1 on two sides of the welding line, enabling the center of a ray bundle to be vertical to the welding line, and enabling the center of the detector 3 to be aligned with the detection starting point position of the welding line; detecting a pipeline joint mouth girth joint, firstly fixedly mounting a steel track 2 on the surface of a pipeline at one side of the girth joint, then mounting two driving mechanisms 4 of an imaging detector and an X-ray machine 1 on the track, oppositely placing and fixedly connecting the two driving mechanisms, and then respectively mounting the imaging detector 3 and the directional X-ray machine 1 on the respective driving mechanisms 4, wherein a clamp of the center of a ray bundle and a vertical plane where the center line of the pipeline girth joint is positionedCorner angleThe center of the detector is aligned with the detection starting point position of the welding line within 5 degrees.
Step S6: setting the detection transillumination geometry parameters, comprising: the distance from the imaging detector to the welding line is 20mm-30mm through the detection tool adjusting mechanism, and the detection focal length is set through the adjusting mechanism.
Step S7: arranging a detection mark and an image quality meter, comprising: before detection, detection marks and an image quality meter are arranged on the surface of the detection workpiece.
The method specifically comprises the following steps: arranging engineering numbers, pile numbers, weld specifications, position numbers and date identification marks on the marking tape, fixing the marking tape and the marking ruler on the surface of a workpiece by using a magnetic clamp, and detecting the marks to be at least 5mm away from the edge of the weld;
when single-wall single-shadow transillumination is performed, the linear imager is arranged on the radiation source side of the workpiece; when double-wall single-image transillumination is performed, the linear image quality meter is arranged on the detector side of the workpiece; the image quality meter is arranged at 1/4 of the length of the detected area at one end of the welding line, the metal wire vertically crosses the welding line, and the thin wire is arranged at the outer side;
the double-line image quality meter is arranged on the ray source side of the workpiece and is arranged on a base material at the 1/4 position of the length of a detected area of the plate weld joint, and the center position and the end point position of an effective transillumination area of the pipeline girth weld joint; the metal wire of the double-wire image quality meter forms an included angle of 2-5 degrees with the row or the column of the detector, and the filament is arranged outside.
Step S8: setting detection process parameters, including: and (3) primarily setting working voltage and working current of the X-ray machine according to the detection focal length and the transillumination thickness, and setting imaging frame rate and integration times technological parameters.
Step S9: calibrating system imaging sensitivity, comprising: and (3) adjusting the imaging sensitivity and gray scale of the calibration system by adjusting and setting the working voltage of the X-ray machine and detecting the technological parameters of exposure, and adjusting the gray scale histogram curve of the digital imaging of the welding seam to be between 50 and 60 percent of the gray scale full scale range.
In the step, the gray level histogram curve of the weld digital imaging is adjusted to be between 50 and 60 percent of the gray level full scale range, so that the definition of the image imaging can be ensured to the greatest extent.
Step S10: weld data acquisition imaging, comprising: the method comprises the steps of taking a welding seam detection imaging area, controlling two detection driving mechanisms to synchronously run along a track, carrying out welding seam data acquisition and digital imaging according to set technological parameters, acquiring a plurality of digital images according to the length of a welding seam and the exposure times, and storing the welding seam digital images into a computer in a DICOMDE format;
step S11: assessing weld quality, comprising: in a static imaging state, measuring the sensitivity, resolution, normalized signal-to-noise ratio and gray scale technical indexes of the digital image of the welding seam, calibrating the geometric dimension by adopting a double-line type image quality meter, enhancing the digital image of the welding seam, adjusting the contrast, and evaluating the quality of the welding seam according to a detection standard.
The two steps of weld data acquisition imaging and weld quality assessment adopted in the embodiment of the invention are directly realized by adopting mature technology in the prior art.
The invention provides a tube plate thick weld DR long-focus transillumination sensitivity calibration digital imaging detection method, which comprises the following steps:
(1) The DR system detection imaging sensitivity calibration process technology is adopted, so that the DR detection transillumination capability is greatly improved, the transillumination thickness reaches 65mm under the condition of 1600mm of detection focal length, the detection transillumination thickness is improved by more than 3 times under the condition of the same focal length, the important technical problem of DR detection is solved, and the long-focal-length DR detection of the thick-wall weld joint of the tube plate is realized;
(2) The DR imaging geometric deformation and the image unclear degree are reduced by adopting a high-frequency constant-pressure small-focus ray source technology and a detector near-distance imaging technology, and the image quality reaches the high-sensitivity technical grade of the detection standard;
(3) The detection process program and the control system are adopted to improve the precision of the process parameters such as the movement speed, the movement step length, the movement times, the lap joint length and the like of the detection driving mechanical device, realize the DR high-efficiency automatic control detection, improve the detection work efficiency of the welding seam DR of the joint of the large-caliber pipeline by more than 7 times on average, and reduce the detection operation intensity and the construction cost; (4) The ray protection combined control device is adopted to carry out ray operation safety protection, so that the detection operation safety is improved;
(5) The DR long-focus double-wall single-image external transillumination detection of the thick-wall welding seam of the large-caliber pipeline (phi 813-phi 1422 mm) is realized, and the engineering application range of the DR detection technology is expanded.
The invention provides a tube plate thick weld DR long-focus sensitivity calibration digital imaging detection method. And selecting a DR transillumination mode according to the type and specification of the welding seam. The gray response accuracy of the detector pixels is ensured by a response sensitivity calibration technology. Mounting detection tool, driving mechanism and imaging control system. The geometric parameters of the transillumination are set and detected, and the geometric deformation and the unclear definition of the image are reduced by adopting the near-range imaging technology of the detector. The detection mark and the image quality meter are arranged. The detection transillumination capability and the sensitivity are ensured by setting detection process parameters and calibrating the imaging sensitivity of the system, and the imaging quality of the system is improved. And acquiring weld data for imaging by automatic control of a detection process program and a control system and storing the acquired weld data into a computer. And (3) performing geometric dimension calibration, detail enhancement and contrast adjustment on the weld joint digital image, and evaluating the weld joint quality according to the detection standard.
The above embodiments are only for illustrating the present invention, not for limiting the present invention, and various changes and modifications may be made by one of ordinary skill in the relevant art without departing from the spirit and scope of the present invention, and therefore, all equivalent technical solutions are also within the scope of the present invention, and the scope of the present invention is defined by the claims.
Claims (2)
1. A tube plate thick weld DR long-focus transillumination sensitivity calibration digital imaging detection method comprises the following steps:
step S1: detecting transillumination mode selection, comprising: selecting a transillumination detection mode according to the specification of a workpiece to be detected, wherein the plate welding seam adopts single-wall single-shadow transillumination detection, and the large-caliber pipeline joint mouth girth welding seam adopts double-wall single-shadow external transillumination detection; wherein the effective pixel size of the imaging detector for detection is not more than 200 μm; the high-frequency constant-voltage X-ray machine with the rated voltage of 300kv is selected as the ray source, and the effective focal spot size is not more than 3mm;
step S2: ray machine training machine includes: performing a working training machine on the selected X-ray machine according to the weld joint material and the maximum transillumination thickness of the detected workpiece;
step S3: setting detection information, including starting a DR digital detector and a system detector;
step S4: calibrating detector response sensitivity, comprising: under the condition of no workpiece, the digital detector and the X-ray machine are oppositely placed and fixed through a detection tool, and the distance between the digital detector and the X-ray machine is set according to the actual detection focal length; calibrating consistency of the pixel of the detector and the background gray level in a state of closing the X-ray machine; then, opening a ray combined control safety protection device and an X-ray machine, calibrating the radiation response sensitivity of the detector by setting the working voltage and the working current of the X-ray machine, adjusting the gray level histogram curve of the detector to be 80% -95% of the gray level full scale range, and then closing the X-ray machine;
setting a detection control program file according to parameters of pipeline specification, frame rate, integration times, overlap length, exposure times, movement step length and movement speed, and realizing movement control of a detection driving mechanism;
step S5: a mounting detection imaging system comprising: detecting the welding seam of the plate, mounting a detection imaging system on a detection tool, oppositely placing an imaging detector and a directional X-ray machine on two sides of the welding seam, enabling the center of a ray bundle to be vertical to the welding seam, and enabling the center of the detector to be aligned with the detection starting point position of the welding seam; detecting a pipeline joint mouth girth joint, firstly, fixedly installing a steel track on the surface of a pipeline at one side of the girth joint, then installing an imaging detector and an X-ray machine on the track, oppositely placing and fixedly connecting the two driving mechanisms, then installing the imaging detector and the directional X-ray machine on the respective driving mechanisms respectively, and forming an included angle between the center of a ray bundle and a vertical plane where the center line of the pipeline girth joint is locatedThe center of the detector is aligned with the detection starting point position of the welding line within 5 degrees;
step S6: setting the detection transillumination geometry parameters, comprising: setting the distance from the imaging detector to the welding seam to be 20mm-30mm through a detection tool adjusting mechanism, and setting a detection focal length through the adjusting mechanism;
step S7: arranging a detection mark and an image quality meter, comprising: before detection, arranging a detection mark and an image quality meter on the surface of a detection workpiece;
step S8: setting detection process parameters, including: setting the working voltage and working current of an X-ray machine according to the detection focal length and the transillumination thickness, and setting the imaging frame rate and the integral frequency process parameters;
step S9: calibrating system imaging sensitivity, comprising: the imaging sensitivity and the gray level of a system are calibrated by adjusting and setting the working voltage of an X-ray machine and detecting the technological parameters of exposure, and the gray level histogram curve of the digital imaging of the welding seam is adjusted to be between 50 and 60 percent of the full range of gray level;
step S10: weld data acquisition imaging, comprising: the method comprises the steps of taking a welding seam detection imaging area, controlling two detection driving mechanisms to synchronously run along a track, carrying out welding seam data acquisition and digital imaging according to set technological parameters, acquiring a plurality of digital images according to the length of a welding seam and the exposure times, and storing the welding seam digital images into a computer in a DICOMDE format;
step S11: assessing weld quality, comprising: in a static imaging state, measuring the sensitivity, resolution, normalized signal-to-noise ratio and gray scale technical indexes of the digital image of the welding seam, calibrating the geometric dimension by adopting a double-line type image quality meter, enhancing the digital image of the welding seam, adjusting the contrast, and evaluating the quality of the welding seam according to a detection standard.
2. The method for calibrating digital imaging detection of long-focus transillumination sensitivity of thick weld seam DR of tube plate according to claim 1, wherein detection marks and an image quality meter are arranged on the surface of the detected workpiece before detection: arranging engineering numbers, pile numbers, weld specifications, position numbers and date identification marks on the marking tape, fixing the marking tape and the marking ruler on the surface of a workpiece by using a magnetic clamp, and detecting the marks to be at least 5mm away from the edge of the weld;
when single-wall single-shadow transillumination is performed, the linear imager is arranged on the radiation source side of the workpiece; when double-wall single-image transillumination is performed, the linear image quality meter is arranged on the detector side of the workpiece; the image quality meter is arranged at 1/4 of the length of the detected area at one end of the welding line, the metal wire vertically crosses the welding line, and the thin wire is arranged at the outer side; the double-line image quality meter is arranged on the ray source side of the workpiece and is arranged on a base material at the 1/4 position of the length of a detected area of the plate weld joint, and the center position and the end point position of an effective transillumination area of the pipeline girth weld joint; the metal wire of the double-wire image quality meter forms an included angle of 2-5 degrees with the row or the column of the detector, and the filament is arranged outside.
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| EP3764089A1 (en) * | 2019-07-11 | 2021-01-13 | Direct Conversion AB | X-ray weld inspection |
| CN110736758B (en) * | 2019-10-18 | 2022-04-19 | 西安航天动力机械有限公司 | Method for determining head welding seam transillumination arrangement parameters |
| CN113125473B (en) * | 2020-01-13 | 2022-08-30 | 中国石油天然气集团有限公司 | Pipeline X-ray digital imaging detection equipment calibration method |
| CN112557423B (en) * | 2020-09-15 | 2022-05-17 | 中国石油天然气集团有限公司 | Method for determining low exposure standard parameter in ray direct digital imaging detection |
| CN112630237A (en) * | 2020-10-23 | 2021-04-09 | 上海船舶工程质量检测有限公司 | Digital imaging method for thick-wall pipeline welding seam radiographic inspection |
| CN113447501A (en) * | 2021-06-28 | 2021-09-28 | 国网黑龙江省电力有限公司电力科学研究院 | Radiographic inspection method for power plant metal pipeline under operating condition |
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