CN112986261A - Steel structure building quality supervision acceptance detection analysis method based on machine vision and image processing technology - Google Patents
Steel structure building quality supervision acceptance detection analysis method based on machine vision and image processing technology Download PDFInfo
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Abstract
The invention discloses a steel structure building quality supervision acceptance inspection analysis method based on machine vision and image processing technology, which is characterized in that the comprehensive supervision of the welding quality of a steel structure building is realized by counting the number of welding seam nodes of the steel structure building, performing joint misalignment detection, welding seam appearance detection, welding flux filling integrity detection and welding flux filling uniformity detection on each welding seam node and further combining the detection results to count the comprehensive welding quality coefficient of the welding seam of the steel structure building, the defect that the supervision index is too single in the current steel structure building welding quality supervision mode is overcome, the counted comprehensive welding quality coefficient of the welding seam can intuitively and comprehensively reflect the welding quality condition of the steel structure building, the reliability of the supervision result is improved, and reliable assessment basis is provided for a supervisor to assess whether the welding quality of the steel structure building meets the acceptance requirements or not, the comprehensive reliability supervision requirement of the welding quality of the steel structure building is met.
Description
Technical Field
The invention belongs to the technical field of steel structure building quality supervision, and particularly relates to a steel structure building quality supervision acceptance inspection analysis method based on machine vision and image processing technologies.
Background
Along with the development of science and technology in China, the building industry is gradually started, meanwhile, the requirements of people on buildings are higher and higher, compared with the traditional concrete building, the steel structure building replaces reinforced concrete with steel plates or section steel, the strength is higher, and the steel structure building is more and more widely applied to the building industry. However, the steel structure building is formed by welding a plurality of rigid members, the welding quality of the steel structure building directly affects the quality of the whole steel structure building, if the welding quality is poor, the stability of the whole steel structure building is poor, and a serious person causes the collapse of the steel structure building, thereby causing engineering accidents. Therefore, after the steel structure building is finished, the welding quality of the steel structure building needs to be supervised.
The existing supervision mode of the welding quality of the steel structure building is mainly used for detecting the welding flux filling integrity of a welding area, the supervision index is too single, the misalignment problem between joints of the welding area and the influence of the welding seam appearance quality and the welding flux filling uniformity on the welding quality of the welding area are not considered, the reliability of a detection result obtained by the existing supervision mode of the welding quality of the steel structure building is low, the welding quality condition of the steel structure building cannot be comprehensively reflected, and the comprehensive reliability supervision requirement of the welding quality of the steel structure building cannot be met.
Disclosure of Invention
In order to overcome the defects, the invention provides a steel structure building quality supervision acceptance inspection analysis method based on machine vision and image processing technology, joint misalignment detection, weld appearance detection, solder filling integrity detection and solder filling uniformity detection are carried out on the steel structure building weld joint, and then the comprehensive weld joint welding quality coefficient of the steel structure building is counted by combining the detection results, so that the defect that the supervision index is too single in the current steel structure building welding quality supervision mode is overcome.
The purpose of the invention can be realized by the following technical scheme:
the steel structure building quality supervision acceptance detection analysis method based on the machine vision and image processing technology comprises the following steps:
s1, counting and numbering weld joints: counting the number of welding seam nodes existing on a steel structure building to be managed and accepted, numbering the counted welding seam nodes according to a preset sequence, and respectively marking the counted welding seam nodes as 1,2.
S2, statistical marking of the joint joints of the welding seams: acquiring the number of joints of each welding joint node, numbering the joints corresponding to the acquired welding joint nodes, and marking the joints as 1,2.. j.. m respectively;
s3, performing node analysis on the misalignment welding line and constructing a misalignment length set of the misalignment joint: adopting a high-definition camera to acquire images of all welding seam nodes to obtain images of all welding seam nodes, carrying out image enhancement processing on the obtained images of all welding seam nodes to obtain enhanced images of all welding seam nodes, and then focusing the enhanced weld joint images at the weld joint to check whether the joints of the weld joints have wrong edges, if so, then the weld joint is marked as a misalignment weld joint, the number of the misalignment weld joint and the number of the misalignment joint corresponding to the misalignment weld joint are counted at the moment, the number of each misalignment weld joint can be marked as 1,2.. a.. k, the number of the misalignment joint corresponding to each misalignment weld joint can be marked as 1,2.. d.. z, and simultaneously acquiring the misalignment length of each misalignment joint corresponding to each misalignment welding joint node, and forming a misalignment joint misalignment length set L by the obtained misalignment welding joint node corresponding to the misalignment length of each misalignment joint.a(la1,la2,...,lad,...,laz)，lad represents the misalignment length of the d-th misalignment joint of the a-th misalignment weld joint;
s4, analyzing appearance abnormal weld joint: extracting a weld contour from each enhanced weld joint image, dividing each weld joint image into a weld zone image and other zone images by the extracted weld contour, comparing the weld zone image of each weld joint with a standard weld zone image in a database at the moment, checking whether abnormal points exist, marking the weld joint as an appearance abnormal weld joint if an abnormal zone exists, counting the number of the appearance abnormal weld joint at the moment, and counting the number of the abnormal zones corresponding to each appearance abnormal weld joint, wherein the number of each appearance abnormal weld joint can be marked as 1,2. Further extracting the characteristics of each abnormal area, and comparing the characteristics with the characteristics corresponding to various appearance abnormal weld types in the database, thereby obtaining the appearance abnormal weld types of each appearance abnormal weld node corresponding to each abnormal area;
s5, counting the quality coefficient of the filling integrity of the solder: carrying out X-ray irradiation on the welding seam area of each welding seam node by adopting an X-ray detector, developing the emitted rays penetrating through the surface of the welding seam of each welding seam node by using a radiographic film to obtain the welding seam area radiographic film of each welding seam node, carrying out darkroom treatment on the obtained welding seam area radiographic film of each welding seam node to obtain the welding seam area radiographic film of each welding seam node, further analyzing whether a gray value corresponding to an unfilled area exists in the gray value displayed in the welding seam area radiographic film of each welding seam node according to the difference between the gray values displayed in the radiographic film of the solder filled area and the unfilled area in each welding seam area radiographic film, if the gray value corresponding to the unfilled area exists, indicating that the welding seam area of the welding seam node is not filled with the solder, marking the welding seam node as the welding seam node which is not filled with the solder, and counting the number of the welding seam node which is not filled with the solder at this, the method can be recorded as 1,2.. c.. h, and the welding line region outline and the unfilled region outline are extracted from the welding line region ray negative of each welding material unfilled welding line node, so that the welding line region area and the unfilled region area corresponding to each welding material unfilled welding line node are obtained, and a welding material unfilled welding line node filling parameter set Q is formedw(qw1,qw2,...,qwc,...,qwh)，qwc represents a numerical value corresponding to the w-th filling parameter of the c-th solder joint which is not filled with the full solder, w represents the filling parameter, and w is s1, s2, s1 and s2 respectively represent the areas of the welding seam areas and the unfilled areas, so that the solder filling integrity quality coefficient of each solder joint which is not filled with the full solder is counted according to the filling parameter of the solder joint which is not filled with the full solder;
s6, obtaining the welding seam node welding flux filling uniformity coefficient: focusing the welding seam area ray negative of each welding seam node in the welding seam filling area according to the gray value displayed in the welding seam filling area, and further acquiring a filling uniformity coefficient corresponding to the welding seam filling area of each welding seam node;
s7, constructing a misalignment length comparison set of the misalignment joints and obtaining appearance quality coefficients of the welding seams: extracting the safe misalignment length corresponding to the welding seam joint of the steel structure building welding seam from the database, and comparing the misalignment length set of the misalignment joint with the safe misalignment length corresponding to the welding seam joint of the steel structure building welding seam in the database to obtain a misalignment joint misalignment length comparison set delta La(Δla1,Δla2,...,Δlad,...,Δlaz) simultaneously comparing the appearance abnormal weld joint types of the appearance abnormal weld joints corresponding to the abnormal areas with weld joint appearance quality coefficients corresponding to the appearance abnormal weld joints in the database to obtain the weld joint appearance quality coefficients of the appearance abnormal weld joints corresponding to the abnormal areas;
s8, comprehensive welding quality coefficient statistics of the welding seams: counting the comprehensive welding seam welding quality coefficient of the steel structure building according to the comparison set of the staggered length of the staggered joint, the welding seam appearance quality coefficient of each appearance abnormal welding seam node corresponding to each abnormal area, the welding flux filling integrity quality coefficient of each welding flux unfilled welding seam node and the filling uniformity coefficient of each welding seam node welding flux filling area corresponding to each welding seam node;
s9, abnormal display: and displaying the joint number of the misalignment welding seam, the corresponding joint number of the misalignment welding seam, the joint number of the welding seam with abnormal appearance and the joint number of the welding seam which is not filled with the welding flux.
Further, the database is used for storing standard welding seam area images, wherein the standard welding seam area images refer to welding seam area images without abnormality, and storing characteristics corresponding to various appearance abnormal welding seam types, wherein the various appearance abnormal welding seam types comprise air holes, slag inclusions and cracks, the safety misalignment length corresponding to the welding seam joint of the steel structure building welding seam is stored, and the welding seam appearance quality coefficients corresponding to the various appearance abnormal welding seam types are stored.
Further, the specific statistical method for counting the number of the misalignment joint corresponding to the misalignment weld node in S3 executes the following steps:
h1, if the number of joints corresponding to a certain misalignment welding seam node is two, one of the joints is taken as a reference joint, the other joint is taken as a misalignment joint, and the misalignment distance between the misalignment joint and the reference joint is taken as the misalignment length of the misalignment joint;
h2, if the number of joints corresponding to a certain misalignment welding seam node is more than two, taking one of the joints of the misalignment welding seam node as a reference joint, analyzing whether other joints corresponding to the misalignment welding seam node are aligned with the reference joint, and counting the number of the unaligned joints, wherein the unaligned joints are the misalignment joints of the misalignment welding seam node, and the staggered distance between each misalignment joint and the reference joint is the misalignment length of each misalignment joint.
Further, the calculation formula of the quality coefficient of the filling integrity of the solder of each solder unfilled full solder joint node is
ηcQuality factor of solder fill integrity expressed as c-th solder unfilled solder joint node, qs1c、qs2And c is respectively expressed as the weld joint area of the c-th solder unfilled full weld joint and the unfilled area.
Further, the specific obtaining method for obtaining the filling uniformity coefficient corresponding to the solder filling area of each weld joint in S6 includes the following steps:
w1, uniformly distributing each monitoring point in a solder filling area in the radiographic film of the corresponding welding area of each welding point, numbering each monitoring point, and marking each monitoring point as 1,2.. e.. x;
w2 detecting the gray value of each monitoring point distributed in the solder filling area of each welding joint by using a gray meter, and forming a monitoring point gray value set R by the obtained gray value of each monitoring point distributed in the solder filling area of each welding jointi(ri1,ri2,...,rie,...,rix)，rie represents the gray value of the e monitoring point corresponding to the ith welding seam node solder filling area;
w3, subtracting the gray values of two adjacent monitoring points from the gray value set of the monitoring points in the welding seam node welding material filling area to obtain the gray value comparison value corresponding to the two adjacent monitoring points in each welding seam node welding material filling area to form the gray value comparison set delta R of the two adjacent monitoring points in the welding seam node welding material filling areai[Δri1,Δri2,...,Δrie,...,Δri(x-1)]，Δrie is expressed as a contrast value between the gray value of the ith weld joint solder filling area corresponding to the ith monitoring point and the gray value of the (e + 1) th monitoring point:
and W4, counting the filling uniformity coefficient corresponding to the solder filling area of each weld joint according to the gray value comparison set of two adjacent monitoring points of the solder filling area of the weld joint.
Furthermore, the calculation formula of the filling uniformity coefficient corresponding to the solder filling area of each welding seam node is
σiAnd is expressed as a filling uniformity coefficient corresponding to the i-th weld joint solder filling area.
Further, the calculation formula of the comprehensive welding seam welding quality coefficient of the steel structure building is
Integrated weld seam welding for buildings represented as steel structuresIs connected to the mass coefficient,. DELTA.lad is the difference between the misalignment length of the d-th misalignment joint of the a-th misalignment weld joint and the safety misalignment length corresponding to the weld joint of the steel structure building weld joint, l0Expressed as the corresponding safe misalignment length, epsilon, of the welding seam joint of the welding seam node of the steel structure buildingbAnd I is expressed as the weld appearance quality coefficient of the b-th appearance abnormal weld joint corresponding to the I-th abnormal area.
The invention has the following beneficial effects:
(1) the invention counts the number of the welding seam nodes of the steel structure building, and carries out joint misalignment detection, welding seam appearance detection, welding flux filling integrity detection and welding flux filling uniformity detection on each welding seam node, further, the comprehensive welding quality coefficient of the welding seam of the steel structure building is counted by combining the detection results, the comprehensive supervision of the welding quality of the steel structure building is realized, the defect that the supervision index is too single in the current supervision mode of the welding quality of the steel structure building is overcome, the comprehensive weld joint welding quality coefficient of the statistics can intuitively and comprehensively reflect the welding quality condition of the steel structure building, the reliability of the supervision result is improved, a reliable assessment basis is provided for the supervision personnel to assess whether the welding quality of the steel structure building meets the acceptance requirements, and the comprehensive reliability supervision requirement of the welding quality of the steel structure building is met.
(2) In the process of performing joint misalignment detection and weld appearance detection on each weld joint, the invention acquires each weld joint image by adopting an image analysis method through image acquisition on each weld joint, focuses each weld joint image on the joint position and the welding area position respectively, performs misalignment detection on the weld joint and performs appearance detection on the weld joint welding area, thereby realizing joint misalignment detection on the weld joint, realizing weld appearance detection on the weld joint and improving the detection efficiency.
(3) The X-ray detection method is adopted in the process of detecting the welding flux filling integrity and the welding flux filling uniformity of each welding seam node, so that the detection precision is improved, the surface of the welding seam is not damaged in the detection process, and the integrity of the welding seam in the detection process is improved.
(4) The invention displays the node number of the misalignment welding seam and the corresponding misalignment joint number, the node number of the welding seam with abnormal appearance and the node number of the welding seam with unfilled solder, so that construction personnel can intuitively know various hidden danger types and corresponding positions of the welding quality of the steel structure building, and the invention provides a processing direction for the construction personnel to pertinently process various hidden dangers of the welding quality of the steel structure building.
Drawings
The invention is further illustrated by means of the attached drawings, but the embodiments in the drawings do not constitute any limitation to the invention, and for a person skilled in the art, other drawings can be obtained on the basis of the following drawings without inventive effort.
FIG. 1 is a flow chart of the method steps of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, the steel structure building quality supervision acceptance inspection and analysis method based on machine vision and image processing technology comprises the following steps:
s1, counting and numbering weld joints: counting the number of welding seam nodes existing on a steel structure building to be managed and accepted, numbering the counted welding seam nodes according to a preset sequence, and respectively marking the counted welding seam nodes as 1,2.
In the embodiment, the welding seam nodes of the steel structure building are counted, so that a foundation is laid for joint misalignment detection, welding seam appearance detection, welding flux filling integrity detection and welding flux filling uniformity detection of each welding seam node;
s2, statistical marking of the joint joints of the welding seams: acquiring the number of joints of each welding joint node, numbering the joints corresponding to the acquired welding joint nodes, and marking the joints as 1,2.. j.. m respectively;
in the embodiment, the joint quantity statistics is carried out on each welding joint, so that a basis is provided for the subsequent joint misalignment detection of the welding joint;
s3, performing node analysis on the misalignment welding line and constructing a misalignment length set of the misalignment joint: adopting a high-definition camera to acquire images of all welding seam nodes to obtain images of all welding seam nodes, carrying out image enhancement processing on the obtained images of all welding seam nodes to obtain images of all welding seam nodes after enhancement processing, further focusing the images of all welding seam nodes after enhancement processing at the welding seam joints, checking whether staggered edges exist in all joints of all welding seam nodes, marking the welding seam nodes as the staggered welding seam nodes if the staggered edges exist, counting the numbers of the staggered welding seam nodes and the numbers of the corresponding staggered joint nodes at the moment, and executing the following steps by using a specific counting method:
h1, if the number of joints corresponding to a certain misalignment welding seam node is two, one of the joints is taken as a reference joint, the other joint is taken as a misalignment joint, and the misalignment distance between the misalignment joint and the reference joint is taken as the misalignment length of the misalignment joint;
h2, if the number of joints corresponding to a certain misalignment welding seam node is more than two, taking one of the joints of the misalignment welding seam node as a reference joint, analyzing whether other joints corresponding to the misalignment welding seam node are aligned with the reference joint, and counting the number of the unaligned joints, wherein the unaligned joints are the misalignment joints of the misalignment welding seam node, and the staggered distance between each misalignment joint and the reference joint is the misalignment length of each misalignment joint;
the serial number of each misalignment welding seam node can be recorded as 1,2.. a.. k, the misalignment joint serial number corresponding to each misalignment welding seam node can be recorded as 1,2.. d.. z, the misalignment length of each misalignment joint corresponding to each misalignment welding seam node is obtained simultaneously, and the misalignment length of each misalignment joint corresponding to each misalignment joint obtained forms a misalignment joint misalignment length set La(la1,la2,...,lad,...,laz)，lad represents the misalignment length of the d-th misalignment joint of the a-th misalignment weld joint;
s4, analyzing appearance abnormal weld joint: extracting a weld contour from each enhanced weld joint image, dividing each weld joint image into a weld zone image and other zone images by the extracted weld contour, comparing the weld zone image of each weld joint with a standard weld zone image in a database at the moment, checking whether abnormal points exist, marking the weld joint as an appearance abnormal weld joint if an abnormal zone exists, wherein the database is used for storing the standard weld zone image, the standard weld zone image refers to the weld zone image without abnormal appearance, storing the characteristics corresponding to various appearance abnormal weld joint types, wherein various appearance abnormal weld joint types comprise air holes, slag inclusions and cracks, storing the safety wrong edge length corresponding to the weld joint of the steel structure building weld joint, storing the weld appearance quality coefficients corresponding to various appearance abnormal weld joint types, and counting the serial numbers of the appearance abnormal weld joint at the moment, counting the number of abnormal areas corresponding to each appearance abnormal welding seam node, wherein the number of each appearance abnormal welding seam node can be marked as 1,2.. b.. f, meanwhile, numbering the abnormal areas corresponding to each appearance abnormal welding seam node, and respectively marking the abnormal areas as A, B.. I.. N, so as to amplify each abnormal area in the welding seam area image corresponding to each appearance abnormal welding seam node, further extracting the characteristics of each abnormal area, and comparing the characteristics with the characteristics corresponding to each appearance abnormal welding seam type in a database, thereby obtaining the appearance abnormal welding seam type of each abnormal area corresponding to each appearance abnormal welding seam node;
in the process of performing joint misalignment detection and weld appearance detection on each weld joint, the embodiment acquires an image of each weld joint by adopting an image analysis method through image acquisition on each weld joint, focuses each weld joint image on a joint position and a welding area position respectively, performs misalignment detection on the joint of the weld joint, and performs appearance detection on the welding area of the weld joint, thereby not only realizing joint misalignment detection on the weld joint, but also realizing weld appearance detection on the weld joint and improving the detection efficiency;
s5, counting the quality coefficient of the filling integrity of the solder: carrying out X-ray irradiation on the welding seam area of each welding seam node by adopting an X-ray detector, developing the emitted rays penetrating through the surface of the welding seam of each welding seam node by using a radiographic film to obtain the welding seam area radiographic film of each welding seam node, carrying out darkroom treatment on the obtained welding seam area radiographic film of each welding seam node to obtain the welding seam area radiographic film of each welding seam node, further analyzing whether a gray value corresponding to an unfilled area exists in the gray value displayed in the welding seam area radiographic film of each welding seam node according to the difference between the gray values displayed in the radiographic film of the solder filled area and the unfilled area in each welding seam area radiographic film, if the gray value corresponding to the unfilled area exists, indicating that the welding seam area of the welding seam node is not filled with the solder, marking the welding seam node as the welding seam node which is not filled with the solder, and counting the number of the welding seam node which is not filled with the solder at this, the method can be recorded as 1,2.. c.. h, and the welding line region outline and the unfilled region outline are extracted from the welding line region ray negative of each welding material unfilled welding line node, so that the welding line region area and the unfilled region area corresponding to each welding material unfilled welding line node are obtained, and a welding material unfilled welding line node filling parameter set Q is formedw(qw1,qw2,...,qwc,...,qwh)，qwc represents the numerical value corresponding to the w filling parameter of the c-th solder joint which is not filled with the full solder, w represents the filling parameter, w is s1, s2, s1 and s2 respectively represent the area of the welding seam area and the area of the unfilled area, and therefore the solder filling integrity quality coefficient of each solder joint which is not filled with the full solder is counted according to the solder joint filling parameter
ηcQuality factor of solder fill integrity expressed as c-th solder unfilled solder joint node, qs1c、qs2c is respectively expressed as the area of a welding seam area of the c-th welding material unfilled welding seam node and the area of the unfilled area, wherein the larger the welding material filling integrity quality coefficient is, the more complete the welding material filling is;
s6, obtaining the welding seam node welding flux filling uniformity coefficient: according to the gray value displayed in the solder filling area, focusing the ray negative of the welding area of each welding joint in the solder filling area, and further acquiring the filling uniformity coefficient corresponding to the solder filling area of each welding joint, wherein the specific acquisition method comprises the following steps:
w1, uniformly distributing each monitoring point in a solder filling area in the radiographic film of the corresponding welding area of each welding point, numbering each monitoring point, and marking each monitoring point as 1,2.. e.. x;
w2 detecting the gray value of each monitoring point distributed in the solder filling area of each welding joint by using a gray meter, and forming a monitoring point gray value set R by the obtained gray value of each monitoring point distributed in the solder filling area of each welding jointi(ri1,ri2,...,rie,...,rix)，rie represents the gray value of the e monitoring point corresponding to the ith welding seam node solder filling area;
w3, subtracting the gray values of two adjacent monitoring points from the gray value set of the monitoring points in the welding seam node welding material filling area to obtain the gray value comparison value corresponding to the two adjacent monitoring points in each welding seam node welding material filling area to form the gray value comparison set delta R of the two adjacent monitoring points in the welding seam node welding material filling areai[Δri1,Δri2,...,Δrie,...,Δri(x-1)]，Δrie is expressed as a contrast value between the gray value of the ith weld joint solder filling area corresponding to the ith monitoring point and the gray value of the (e + 1) th monitoring point:
w4 calculating the filling uniformity coefficient corresponding to each welding seam node solder filling area according to the gray value comparison set of two adjacent monitoring points in the welding seam node solder filling area
σiThe filling uniformity coefficient corresponding to the solder filling area of the ith weld joint is shown, wherein the larger the filling uniformity coefficient is, the more uniform the solder filling is;
in the embodiment, the X-ray detection method is adopted in the process of detecting the welding flux filling integrity and the welding flux filling uniformity of each welding seam node, so that the detection precision is improved, the surface of the welding seam is not damaged in the detection process, and the integrity of the welding seam in the detection process is improved;
s7, constructing a misalignment length comparison set of the misalignment joints and obtaining appearance quality coefficients of the welding seams: extracting the safe misalignment length corresponding to the welding seam joint of the steel structure building welding seam from the database, and comparing the misalignment length set of the misalignment joint with the safe misalignment length corresponding to the welding seam joint of the steel structure building welding seam in the database to obtain a misalignment joint misalignment length comparison set delta La(Δla1,Δla2,...,Δlad,...,Δlaz) simultaneously comparing the appearance abnormal weld joint types of the appearance abnormal weld joints corresponding to the abnormal areas with weld joint appearance quality coefficients corresponding to the appearance abnormal weld joints in the database to obtain the weld joint appearance quality coefficients of the appearance abnormal weld joints corresponding to the abnormal areas;
s8, comprehensive welding quality coefficient statistics of the welding seams: according to the comparison set of the misalignment length of the misalignment joint, the weld appearance quality coefficient of each appearance abnormal weld joint corresponding to each abnormal area, the solder filling integrity quality coefficient of each solder unfilled weld joint and the filling uniformity coefficient of each weld joint corresponding to the solder filling area, the comprehensive weld quality coefficient of the steel structure building is counted
Expressed as the comprehensive weld quality coefficient, Deltal, of the steel structure buildingad is the difference between the misalignment length of the d-th misalignment joint of the a-th misalignment weld joint and the safety misalignment length corresponding to the weld joint of the steel structure building weld joint, l0Expressed as the corresponding safe misalignment length, epsilon, of the welding seam joint of the welding seam node of the steel structure buildingbI represents welding of the b-th appearance abnormal welding seam node to the I-th abnormal areaSeam appearance quality factor;
the comprehensive welding quality coefficient counted by the embodiment fuses the joint misalignment condition, the welding seam appearance quality condition, the welding flux filling integrity condition and the welding flux filling uniformity condition of the welding seam node of the steel structure building, comprehensive supervision of the welding quality of the steel structure building is realized, the defect that the supervision index is too single in the current supervision mode of the welding quality of the steel structure building is overcome, the counted comprehensive welding quality coefficient of the welding seam can intuitively and comprehensively reflect the welding quality condition of the steel structure building, the reliability of supervision results is improved, the larger the comprehensive welding quality coefficient of the welding seam is, the better the welding quality of the welding seam is, a reliable evaluation basis is provided for a supervisor to evaluate whether the welding quality of the steel structure building meets the acceptance requirements, and the comprehensive reliability supervision requirement of the welding quality of the steel structure building is met;
s9, abnormal display: the joint number of the misalignment welding line and the number of the misalignment joint, the number of the appearance abnormal welding line and the number of the welding line unfilled full welding line joint which correspond to the joint number are displayed, so that a constructor can conveniently and visually know various hidden danger types and corresponding positions of the welding quality of the steel structure building, and a processing direction is provided for the constructor to pertinently process various hidden dangers of the welding quality of the steel structure building.
The foregoing is merely exemplary and illustrative of the present invention and various modifications, additions and substitutions may be made by those skilled in the art to the specific embodiments described without departing from the scope of the invention as defined in the following claims.
Claims (7)
1. The steel structure building quality supervision acceptance detection analysis method based on the machine vision and image processing technology is characterized by comprising the following steps of: the method comprises the following steps:
s1, counting and numbering weld joints: counting the number of welding seam nodes existing on a steel structure building to be managed and accepted, numbering the counted welding seam nodes according to a preset sequence, and respectively marking the counted welding seam nodes as 1,2.
S2, statistical marking of the joint joints of the welding seams: acquiring the number of joints of each welding joint node, numbering the joints corresponding to the acquired welding joint nodes, and marking the joints as 1,2.. j.. m respectively;
s3, performing node analysis on the misalignment welding line and constructing a misalignment length set of the misalignment joint: adopting a high-definition camera to acquire images of all welding seam nodes to obtain images of all welding seam nodes, carrying out image enhancement processing on the obtained images of all welding seam nodes to obtain enhanced images of all welding seam nodes, and then focusing the enhanced weld joint images at the weld joint to check whether the joints of the weld joints have wrong edges, if so, then the weld joint is marked as a misalignment weld joint, the number of the misalignment weld joint and the number of the misalignment joint corresponding to the misalignment weld joint are counted at the moment, the number of each misalignment weld joint can be marked as 1,2.. a.. k, the number of the misalignment joint corresponding to each misalignment weld joint can be marked as 1,2.. d.. z, and simultaneously acquiring the misalignment length of each misalignment joint corresponding to each misalignment welding joint node, and forming a misalignment joint misalignment length set L by the obtained misalignment welding joint node corresponding to the misalignment length of each misalignment joint.a(la1,la2,...,lad,...,laz)，lad represents the misalignment length of the d-th misalignment joint of the a-th misalignment weld joint;
s4, analyzing appearance abnormal weld joint: extracting a weld contour from each enhanced weld joint image, dividing each weld joint image into a weld zone image and other zone images by the extracted weld contour, comparing the weld zone image of each weld joint with a standard weld zone image in a database at the moment, checking whether abnormal points exist, marking the weld joint as an appearance abnormal weld joint if an abnormal zone exists, counting the number of the appearance abnormal weld joint at the moment, and counting the number of the abnormal zones corresponding to each appearance abnormal weld joint, wherein the number of each appearance abnormal weld joint can be marked as 1,2. Further extracting the characteristics of each abnormal area, and comparing the characteristics with the characteristics corresponding to various appearance abnormal weld types in the database, thereby obtaining the appearance abnormal weld types of each appearance abnormal weld node corresponding to each abnormal area;
s5, counting the quality coefficient of the filling integrity of the solder: carrying out X-ray irradiation on the welding seam area of each welding seam node by adopting an X-ray detector, developing the emitted rays penetrating through the surface of the welding seam of each welding seam node by using a radiographic film to obtain the welding seam area radiographic film of each welding seam node, carrying out darkroom treatment on the obtained welding seam area radiographic film of each welding seam node to obtain the welding seam area radiographic film of each welding seam node, further analyzing whether a gray value corresponding to an unfilled area exists in the gray value displayed in the welding seam area radiographic film of each welding seam node according to the difference between the gray values displayed in the radiographic film of the solder filled area and the unfilled area in each welding seam area radiographic film, if the gray value corresponding to the unfilled area exists, indicating that the welding seam area of the welding seam node is not filled with the solder, marking the welding seam node as the welding seam node which is not filled with the solder, and counting the number of the welding seam node which is not filled with the solder at this, the method can be recorded as 1,2.. c.. h, and the welding line region outline and the unfilled region outline are extracted from the welding line region ray negative of each welding material unfilled welding line node, so that the welding line region area and the unfilled region area corresponding to each welding material unfilled welding line node are obtained, and a welding material unfilled welding line node filling parameter set Q is formedw(qw1,qw2,...,qwc,...,qwh)，qwc represents a numerical value corresponding to the w-th filling parameter of the c-th solder joint which is not filled with the full solder, w represents the filling parameter, and w is s1, s2, s1 and s2 respectively represent the areas of the welding seam areas and the unfilled areas, so that the solder filling integrity quality coefficient of each solder joint which is not filled with the full solder is counted according to the filling parameter of the solder joint which is not filled with the full solder;
s6, obtaining the welding seam node welding flux filling uniformity coefficient: focusing the welding seam area ray negative of each welding seam node in the welding seam filling area according to the gray value displayed in the welding seam filling area, and further acquiring a filling uniformity coefficient corresponding to the welding seam filling area of each welding seam node;
s7, constructing a misalignment length comparison set of the misalignment joints and obtaining appearance quality coefficients of the welding seams: extracting the safe misalignment length corresponding to the welding seam joint of the steel structure building welding seam from the database, and comparing the misalignment length set of the misalignment joint with the safe misalignment length corresponding to the welding seam joint of the steel structure building welding seam in the database to obtain a misalignment joint misalignment length comparison set delta La(Δla1,Δla2,...,Δlad,...,Δlaz) simultaneously comparing the appearance abnormal weld joint types of the appearance abnormal weld joints corresponding to the abnormal areas with weld joint appearance quality coefficients corresponding to the appearance abnormal weld joints in the database to obtain the weld joint appearance quality coefficients of the appearance abnormal weld joints corresponding to the abnormal areas;
s8, comprehensive welding quality coefficient statistics of the welding seams: counting the comprehensive welding seam welding quality coefficient of the steel structure building according to the comparison set of the staggered length of the staggered joint, the welding seam appearance quality coefficient of each appearance abnormal welding seam node corresponding to each abnormal area, the welding flux filling integrity quality coefficient of each welding flux unfilled welding seam node and the filling uniformity coefficient of each welding seam node welding flux filling area corresponding to each welding seam node;
s9, abnormal display: and displaying the joint number of the misalignment welding seam, the corresponding joint number of the misalignment welding seam, the joint number of the welding seam with abnormal appearance and the joint number of the welding seam which is not filled with the welding flux.
2. The steel structure building quality supervision acceptance detection analysis method based on the machine vision and image processing technology as claimed in claim 1, characterized in that: the database is used for storing standard welding seam area images, wherein the standard welding seam area images refer to welding seam area images without abnormity, and storing characteristics corresponding to various appearance abnormal welding seam types, wherein the various appearance abnormal welding seam types comprise air holes, slag inclusions and cracks, the safety misalignment length corresponding to the welding seam joint of the steel structure building welding seam is stored, and the welding seam appearance quality coefficients corresponding to the various appearance abnormal welding seam types are stored.
3. The steel structure building quality supervision acceptance detection analysis method based on the machine vision and image processing technology as claimed in claim 1, characterized in that: the specific statistical method for the misalignment joint numbers corresponding to the misalignment weld joints in the step S3 comprises the following steps:
h1, if the number of joints corresponding to a certain misalignment welding seam node is two, one of the joints is taken as a reference joint, the other joint is taken as a misalignment joint, and the misalignment distance between the misalignment joint and the reference joint is taken as the misalignment length of the misalignment joint;
h2, if the number of joints corresponding to a certain misalignment welding seam node is more than two, taking one of the joints of the misalignment welding seam node as a reference joint, analyzing whether other joints corresponding to the misalignment welding seam node are aligned with the reference joint, and counting the number of the unaligned joints, wherein the unaligned joints are the misalignment joints of the misalignment welding seam node, and the staggered distance between each misalignment joint and the reference joint is the misalignment length of each misalignment joint.
4. The steel structure building quality supervision acceptance detection analysis method based on the machine vision and image processing technology as claimed in claim 1, characterized in that: the calculation formula of the solder filling integrity quality coefficient of each solder unfilled full solder joint node is
ηcQuality factor of solder fill integrity expressed as c-th solder unfilled solder joint node, qs1c、qs2And c is respectively expressed as the weld joint area of the c-th solder unfilled full weld joint and the unfilled area.
5. The steel structure building quality supervision acceptance detection analysis method based on the machine vision and image processing technology as claimed in claim 1, characterized in that: the specific obtaining method for obtaining the filling uniformity coefficient corresponding to the solder filling area of each welding joint in the step S6 includes the following steps:
w1, uniformly distributing each monitoring point in a solder filling area in the radiographic film of the corresponding welding area of each welding point, numbering each monitoring point, and marking each monitoring point as 1,2.. e.. x;
w2 detecting the gray value of each monitoring point distributed in the solder filling area of each welding joint by using a gray meter, and forming a monitoring point gray value set R by the obtained gray value of each monitoring point distributed in the solder filling area of each welding jointi(ri1,ri2,...,rie,...,rix)，rie represents the gray value of the e monitoring point corresponding to the ith welding seam node solder filling area;
w3, subtracting the gray values of two adjacent monitoring points from the gray value set of the monitoring points in the welding seam node welding material filling area to obtain the gray value comparison value corresponding to the two adjacent monitoring points in each welding seam node welding material filling area to form the gray value comparison set delta R of the two adjacent monitoring points in the welding seam node welding material filling areai[Δri1,Δri2,...,Δrie,...,Δri(x-1)]，Δrie is expressed as a contrast value between the gray value of the ith weld joint solder filling area corresponding to the ith monitoring point and the gray value of the (e + 1) th monitoring point:
and W4, counting the filling uniformity coefficient corresponding to the solder filling area of each weld joint according to the gray value comparison set of two adjacent monitoring points of the solder filling area of the weld joint.
6. The steel structure building quality supervision acceptance detection analysis method based on the machine vision and image processing technology as claimed in claim 5, characterized in that: the calculation formula of the filling uniformity coefficient corresponding to the solder filling area of each welding seam node is
σiAnd is expressed as a filling uniformity coefficient corresponding to the i-th weld joint solder filling area.
7. According to the claimsSolving 1 the steel structure building quality supervision acceptance detection analysis method based on machine vision and image processing technology is characterized in that: the calculation formula of the comprehensive welding seam welding quality coefficient of the steel structure building is
Expressed as the comprehensive weld quality coefficient, Deltal, of the steel structure buildingad is the difference between the misalignment length of the d-th misalignment joint of the a-th misalignment weld joint and the safety misalignment length corresponding to the weld joint of the steel structure building weld joint, l0Expressed as the corresponding safe misalignment length, epsilon, of the welding seam joint of the welding seam node of the steel structure buildingbAnd I is expressed as the weld appearance quality coefficient of the b-th appearance abnormal weld joint corresponding to the I-th abnormal area.
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