CN111189861A - Automatic detection method and device for tube and tube plate radiographic digital imaging based on robot - Google Patents
Automatic detection method and device for tube and tube plate radiographic digital imaging based on robot Download PDFInfo
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- CN111189861A CN111189861A CN202010146573.0A CN202010146573A CN111189861A CN 111189861 A CN111189861 A CN 111189861A CN 202010146573 A CN202010146573 A CN 202010146573A CN 111189861 A CN111189861 A CN 111189861A
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- G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
- G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
- G01N23/04—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material and forming images of the material
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Abstract
A tube and tube plate ray digital imaging automatic detection method and device based on a robot comprises the robot, a digital imaging unit, a video positioning unit, a pre-detection unit and a remote control unit; the robot is controlled to move to a first pipe hole to be detected according to the detection path; the video positioning unit photographs a pipe hole to be detected and determines the central position of the pipe hole; the pre-detection unit realizes position correction by using a pre-detection rod; a rod anode in the digital imaging unit emits rays to perform transillumination imaging on the welding seam pipe hole, and the digital imaging detection of the rays of a fillet welding seam is completed; and the radiographic digital imaging detection of all fillet welds is completed in sequence. The invention combines the ray digital imaging technology with the automatic detection device, can realize high-precision and high-efficiency automatic detection, greatly improves the detection efficiency, reduces the labor intensity of personnel, and realizes high-image quality and high-efficiency ray detection.
Description
Technical Field
The invention relates to the field of detection of fillet welds of tube plates of heat exchangers, in particular to a method and a device for automatically detecting tube plates by X-ray digital imaging based on a robot.
Background
At present, nondestructive detection methods for fillet welds of tube plates of heat exchangers mainly comprise permeation, eddy current and ray methods; the penetration detection method can only detect the surface defect condition of the welding seam, the eddy current detection method can only detect the surface and near surface defects, and the defects in the welding seam cannot be detected by the penetration detection method and the eddy current detection method. The ray detection method can detect all defects of the welding line, and is the only effective means for detecting the defects inside and outside the fillet weld of the tube plate of the heat exchanger at present.
However, because the heat exchanger is formed by welding hundreds or even tens of thousands of tubes and tube plates, the fillet welds can be hundreds or thousands, and the conventional radiographic inspection for the fillet welds of the tube plates and the tube plates mainly adopts the film photographic technology based on X rays or gamma rays, the technology has environmental pollution, and the inspection of each fillet weld needs manual arrangement and manual control inspection, the inspection labor intensity is high, and the working efficiency is extremely low, so that only part of heat exchangers with special purposes carry out 20% of inspection at the present stage.
The development of the ray digital imaging Detection (DR) technology can not only eliminate the environmental pollution, but also have the image acquisition rate of high frame frequency, and can realize high-precision automatic detection. The problems of high labor intensity, high labor cost, low working efficiency and the like caused by the large number of the detection objects still cannot be solved.
Disclosure of Invention
The invention aims to provide a method and a device for automatically detecting a tube plate through radiographic digital imaging based on a robot, so as to solve the problems in the prior art.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a tube and tube plate ray digital imaging automatic detection method based on a robot comprises a digital imaging unit, a video positioning unit, a pre-detection unit, a robot and a remote control unit; the detection method comprises the following steps
S1, leading in a structural design drawing of a tube and tube plate to be tested in the remote control unit, and planning a detection path of the tube and tube plate; and setting detection settings and parameters;
s2, controlling the robot to move to a first pipe hole to be detected according to the planned detection path by the robot;
s3, the video positioning unit takes a picture of the pipe hole to be detected and transmits the picture to the remote control unit, the central position of the pipe hole is determined, and the digital imaging unit is controlled to carry out position correction;
s4, the pre-detection unit inserts a pre-detection rod into the pipe hole to be detected to realize position correction;
s5, emitting rays by a rod anode in the digital imaging unit to perform transillumination imaging on the weld pipe hole, and completing ray digital imaging detection of a fillet weld;
and S6, driving the digital imaging unit to move to the next fillet weld to be detected by the robot according to the detection path in the step S1, performing ray digital imaging detection, and completing the ray digital imaging detection of all the fillet welds in sequence.
Preferably, the radiographic digital imaging detection for one fillet weld in step S5 includes one or more transillumination imaging; when multiple transillumination imaging is carried out, the digital imaging unit rotates once every time transillumination imaging is completed.
A tube and tube plate ray digital imaging automatic detection device based on a robot comprises the robot, a digital imaging unit, a video positioning unit, a pre-detection unit and a remote control unit; the digital imaging unit, the video positioning unit and the pre-detection unit are arranged on the robot; the robot, the digital imaging unit, the video positioning unit and the pre-detection unit are respectively communicated with the remote control unit; the robot is provided with a crawling claw; the crawling claw moves on the tube plate.
Preferably, the digital imaging unit comprises a rod anode and a detector.
Preferably, the radiation emitted by the rod anode is cone beam X-rays.
Preferably, a detection system is arranged in the remote control unit, and the robot moves according to a path planned by a tube and tube plate design drawing led into the detection system.
Preferably, the rod anode is provided with an anti-collision structure and an elastic assembly for ensuring the combination of the detector and the plate surface of the tube plate.
Preferably, the video positioning unit photographs the pipe hole to be detected, and the central position of the pipe hole is determined through the remote control unit; and the pre-detection unit inserts a pre-detection rod according to the center position of the pipe hole to perform position correction.
The invention has the beneficial effects that: according to the method and the device for the automatic detection of the tube plate by the ray digital imaging based on the robot, the ray digital imaging technology and the automatic detection device are combined, so that the high-precision and high-efficiency automatic detection can be realized, the detection efficiency is greatly improved, the labor intensity of personnel is reduced, and the high-image quality and high-efficiency ray detection is realized; a video positioning unit is arranged in the automatic detection device to correct the rod anode, so that accurate positioning is realized, and the detection quality is improved; the heat exchange tube to be detected is detected by adding the pre-detection rod into the automatic detection device, whether a blocking foreign body exists or not is judged, and the anode of the rod is prevented from being damaged.
Drawings
FIG. 1 is a schematic structural view of a robot automatic detection device for fillet welds of tube and tube sheets;
FIG. 2 is a schematic structural view of a robot automatic detection device for fillet welds of tube and tube sheets;
in the figure, 1-robot, 2-digital imaging unit, 3-video positioning unit, 4-pre-detection unit, 5-crawling claw, 6-tube and tube plate.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
A tube and tube plate ray digital imaging automatic detection method based on a robot comprises a digital imaging unit 2, a video positioning unit 3, a pre-detection unit 4, a robot 1 and a remote control unit; the remote control unit communicates with the digital imaging unit 2, the video positioning unit 3, the pre-detection unit 4 and the robot 1 in a wired or wireless manner; the digital imaging unit 2 comprises a rod anode and a detector, and the digital imaging unit 2 forms transillumination imaging by emitting rays through the rod anode; the video positioning unit 3 photographs a to-be-detected pipe hole by adopting photographing equipment, transmits the photographed to the remote control unit, determines the central position of the pipe hole, and finely adjusts the position of the rod anode to realize position correction; the pre-detection unit is inserted into the pipe hole by using a pre-detection rod, and judges whether foreign matters exist in the pipe hole or not in advance; the robot 1 adjusts the relative position between the digital imaging unit 2 and the pipe hole, the rotation angle of the digital imaging unit 2, and the insertion and extraction of the rod anode in the digital imaging unit 2 according to the motion path planned in the remote control unit; the remote control unit controls the switch of the digital imaging unit 2 and controls various motion modes of the robot 1.
The working process of the digital imaging automatic detection system is as follows:
s1, leading in a structural design drawing of a tube and tube plate to be tested in the remote control unit, and planning a detection path of the tube and tube plate 6; and setting detection settings and parameters;
s2, controlling the robot 1 to move to a first pipe hole to be detected according to the planned detection path by the robot 1;
s3, the video positioning unit 3 photographs a pipe hole to be detected and transmits the photographed pipe hole to the remote control unit, the central position of the pipe hole is determined, and the digital imaging unit 2 is controlled to carry out position correction;
s4, inserting the pre-detection rod into the pipe hole to be detected by the pre-detection unit 4 to realize position correction;
s5, emitting rays by a rod anode in the digital imaging unit 2 to perform transillumination imaging on the pipe hole of the welding seam, and completing the ray digital imaging detection of the fillet welding seam;
and S6, driving the digital imaging unit to move to the next fillet weld to be detected by the robot 1 according to the detection path in the step S1, performing ray digital imaging detection, and completing the ray digital imaging detection of all the fillet welds in sequence.
In step S5, radiographic digital imaging detection for one fillet weld may also be performed for multiple transillumination imaging, including the following steps:
s501, inserting a rod anode in the digital imaging unit 2 into the pipe hole, starting switches of the rod anode and a detector through a detection device set in the remote control unit, and enabling a ray source in the rod anode to emit cone beam rays to perform transillumination imaging on the pipe hole of the welding seam;
s502, closing the switch in the step S501, driving the digital imaging unit 2 to rotate by the robot 1 according to detection setting, and carrying out second transillumination imaging on the welding seam pipe hole in the step S501;
s503, synchronizing the working process of the step S502, and carrying out next transillumination imaging on the welded seam pipe hole in the step S501; thus, the multi-time ray digital imaging detection of one fillet weld is completed.
The automatic radiographic imaging device for the tube and the tube plate based on the robot, which is formed based on the automatic radiographic imaging method, comprises a robot 1, a digital imaging unit 2, a video positioning unit 3, a pre-detection unit 4 and a remote control unit, as shown in fig. 1 and 2; the digital imaging unit 2, the video positioning unit 3 and the pre-detection unit 4 are integrally installed as a ray digital imaging detection system and are installed on the robot 1. The robot 1 is provided with a crawling claw 5, and the crawling claw 5 grabs on a tube and tube plate 6 and can move on the tube and tube plate 6. The digital imaging unit 2 comprises a rod anode and a detector.
The connection structure is as follows: the digital imaging unit 2, the video positioning unit 3 and the pre-detection unit 4 are fixedly arranged into a whole and are arranged on the robot 1; the digital imaging unit 2, the video positioning unit 3 and the pre-detection unit 4 are connected with a remote control unit in a wired or wireless connection mode; the crawling claw 5 of the robot 1 grabs on the tube sheet 6.
The robot 1 drives the ray digital imaging detection system to move on the tube plate 6 through the crawling claw 5 according to the control of the remote control unit, and adjusts the relative position between the digital imaging unit 2 and the tube hole to be detected; controlling the rotation of the digital imaging unit 2; insertion and extraction of the rod anode in the digital imaging unit 2; and completing transillumination imaging of the whole fillet weld according to the path planned in the remote control unit.
The digital imaging unit 2 comprises a rod anode and a detector, wherein the rod anode emits cone beam rays to perform transillumination imaging on the fillet weld, and the detector receives the rays, so that the fillet weld is detected.
The video positioning unit 3 shoots a to-be-detected tube hole by adopting shooting equipment and transmits the to-be-detected tube hole to the detection system in the remote control unit to determine the center position of the tube hole, and the robot 1 controls the digital imaging unit 2 to correct the position of the rod anode according to the center position of the tube hole.
The pre-detection unit 4 inserts a pre-detection rod into the pipe hole to be detected according to the determined center position of the pipe hole in the remote control unit, so as to realize position correction, detect whether foreign matters exist in the pipe hole and check the pipe hole to be detected.
The rod anode mounting assembly is provided with an anti-collision structure, and under the condition of controlling error or misalignment of the hole center to the center, if the rod anode collides with the plate surface, the rod anode can be protected, so that the rod anode is prevented from being damaged; and a distance sensor is arranged at the rear end of the mounting component of the rod anode, so that after the rod anode is inserted into the pipe hole, the detector is ensured to be attached to the surface of the pipe plate, and the rod anode emits cone beam X rays.
Example one
The working process of the automatic ray digital imaging detection device is as follows: running software of a detection system in the remote control unit, introducing a design drawing of a tube plate of a tube to be detected into the remote control unit, and setting detection parameters; the remote control unit transmits motion information to the robot 1 according to the design drawing, and the robot 1 receives the information and controls the crawling claw 5 to move to the position near the first welding line to be detected; when the robot 1 moves to a welding seam to be detected, the remote control unit controls the video positioning unit 3 to align to a pipe hole to be detected for photographing, and uploads the photographed image to the remote control unit to determine the central position of the pipe hole; the pre-detection unit inserts a pre-detection rod into the pipe hole according to the central position of the pipe hole determined by the remote control unit, so that position correction is realized, whether foreign matters exist in the pipe hole is detected, and the pipe hole to be detected is checked; then controlling the digital imaging unit 2 to align the rod anode and enter the pipe hole, starting the rod anode and the detector to perform transillumination imaging on the weld joint, and enabling the rod anode to emit cone beam rays to perform transillumination imaging on the diagonal weld joint; after the radiographic digital imaging detection of a fillet weld is finished, closing the switches of the rod anode and the detector, and pulling the rod anode out of the pipe hole; according to the path of the design drawing of the tube plate of the tube to be detected in the working process, the crawling claw 5 of the robot 1 moves to the position of the next fillet weld to be detected, and the radiographic digital imaging detection of all the fillet welds is completed accordingly.
Example two
In this embodiment, the process of transillumination imaging performed by the digital imaging unit 2 is as follows: the digital imaging unit 2 starts the diagonal weld of the rod anode and the detector to implement first transillumination imaging, and a ray source of the rod anode emits cone beam rays to perform transillumination imaging on the diagonal weld; after the first transillumination imaging is finished, the rod anode is closed, the digital imaging unit 2 is controlled to rotate by a certain angle, and the rod anode is opened to implement the second transillumination imaging; after the second transillumination imaging is finished, the rod anode is closed, the digital imaging unit 2 is controlled to rotate again, the rod anode is opened to implement the next transillumination imaging, a fillet weld is subjected to multiple transillumination imaging in the above mode, and finally the rod anode is controlled by the robot 1 to be pulled out of the pipe hole; the radiographic digital imaging detection of one fillet weld is completed through the multiple transillumination imaging; according to the path of the design drawing of the tube plate of the tube to be detected in the working process, the crawling claw 5 of the robot 1 moves to the position of the next fillet weld to be detected, and the radiographic digital imaging detection of all the fillet welds is completed accordingly.
By adopting the technical scheme disclosed by the invention, the following beneficial effects are obtained:
according to the method and the device for the automatic detection of the tube plate by the ray digital imaging based on the robot, the ray digital imaging technology and the automatic detection device are combined, so that the high-precision and high-efficiency automatic detection can be realized, the detection efficiency is greatly improved, the labor intensity of personnel is reduced, and the high-image quality and high-efficiency ray detection is realized; a video positioning unit is arranged in the automatic detection device to correct the rod anode, so that accurate positioning is realized, and the detection quality is improved; the automatic detection device is added with a pre-detection rod to detect a pipe hole to be detected, and whether a blocking foreign body exists or not is judged, so that the anode of the rod is prevented from being damaged.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and improvements can be made without departing from the principle of the present invention, and such modifications and improvements should also be considered within the scope of the present invention.
Claims (8)
1. A tube and tube plate ray digital imaging automatic detection method based on a robot is characterized by comprising a digital imaging unit, a video positioning unit, a pre-detection unit, a robot and a remote control unit; the detection method comprises the following steps
S1, leading in a structural design drawing of a tube and tube plate to be tested in the remote control unit, and planning a detection path of the tube and tube plate; and setting detection settings and parameters;
s2, controlling the robot to move to a first pipe hole to be detected according to the planned detection path by the robot;
s3, the video positioning unit takes a picture of the pipe hole to be detected and transmits the picture to the remote control unit, the central position of the pipe hole is determined, and the digital imaging unit is controlled to carry out position correction;
s4, the pre-detection unit inserts a pre-detection rod into the pipe hole to be detected to realize position correction;
s5, emitting rays by a rod anode in the digital imaging unit to perform transillumination imaging on the weld pipe hole, and completing ray digital imaging detection of a fillet weld;
and S6, driving the digital imaging unit to move to the next fillet weld to be detected by the robot according to the detection path in the step S1, performing ray digital imaging detection, and completing the ray digital imaging detection of all the fillet welds in sequence.
2. The robot-based tube-plate radiographic digital imaging automatic detection method of claim 1, wherein radiographic digital imaging detection for one fillet weld in step S5 includes one or more transillumination imaging; when multiple transillumination imaging is carried out, the digital imaging unit rotates once every time transillumination imaging is completed.
3. A tube and tube plate ray digital imaging automatic detection device based on a robot is characterized by comprising the robot, a digital imaging unit, a video positioning unit, a pre-detection unit and a remote control unit; the digital imaging unit, the video positioning unit and the pre-detection unit are arranged on the robot; the robot, the digital imaging unit, the video positioning unit and the pre-detection unit are respectively communicated with the remote control unit; the robot is provided with a crawling claw; the crawling claw moves on the tube plate.
4. The robot-based tube-sheet radiographic digital imaging automatic detection device of claim 3, wherein the digital imaging unit comprises a rod anode and a detector.
5. The robot-based tube-sheet radiographic digital imaging automatic detection device of claim 3, wherein the radiation emitted by the rod anode is cone beam X-rays.
6. The automated robot-based radiographic imaging inspection device for tube and tube sheets according to claim 3, wherein the remote control unit has an inspection system therein, and the robot moves according to a path planned by a tube and tube sheet design drawing introduced into the inspection system.
7. The robot-based automatic radiographic imaging detection device for tube and tube sheets according to claim 3, wherein the rod anode is provided with an anti-collision structure and is provided with an elastic component for ensuring the detector to be combined with the surface of the tube and tube sheet.
8. The robot-based automatic radiographic imaging detection device for the tube and the tube plate of the tube and the tube plate according to claim 3, wherein the video positioning unit photographs a tube hole to be detected and determines the center position of the tube hole through the remote control unit; and the pre-detection unit inserts a pre-detection rod according to the center position of the pipe hole to perform position correction.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010146573.0A CN111189861A (en) | 2020-03-05 | 2020-03-05 | Automatic detection method and device for tube and tube plate radiographic digital imaging based on robot |
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| CN202010146573.0A CN111189861A (en) | 2020-03-05 | 2020-03-05 | Automatic detection method and device for tube and tube plate radiographic digital imaging based on robot |
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| CN111189861A true CN111189861A (en) | 2020-05-22 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111982936A (en) * | 2020-08-25 | 2020-11-24 | 绍兴市特种设备检测院 | X-ray automatic detection device for heat exchanger tube-tube plate welding seam |
-
2020
- 2020-03-05 CN CN202010146573.0A patent/CN111189861A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111982936A (en) * | 2020-08-25 | 2020-11-24 | 绍兴市特种设备检测院 | X-ray automatic detection device for heat exchanger tube-tube plate welding seam |
| CN111982936B (en) * | 2020-08-25 | 2023-10-10 | 绍兴市特种设备检测院 | X-ray automatic detection device for heat exchanger tube-tube plate welding seam |
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