CN114280083A - Detection method for realizing industrial X-ray nondestructive testing of large-size flat casting based on linear array camera automatic CNC programming - Google Patents
Detection method for realizing industrial X-ray nondestructive testing of large-size flat casting based on linear array camera automatic CNC programming Download PDFInfo
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Abstract
The invention discloses a detection method for realizing industrial X-ray nondestructive detection of a large-size flat casting based on automatic CNC programming of a linear array camera, which aims at the problem that the original CNC detection mode of the large-size flat casting in the industrial X-ray nondestructive detection process is low in efficiency by utilizing the high-speed refreshing and continuous shooting characteristics of the linear array camera. The invention saves the complex operation and the long time consumption of CNC programming by operators manually, can automatically and quickly finish the industrial X-ray nondestructive testing of large-size flat castings without manual intervention, and greatly improves the testing efficiency.
Description
Technical Field
The invention relates to the technical field of X-ray detection, in particular to a detection method for realizing industrial X-ray nondestructive detection of a large-size flat casting based on automatic CNC programming of a linear array camera.
Background
The detection of industrial castings by industrial X-ray nondestructive testing is more and more accepted by casting factories and upstream and downstream customers, and is an efficient method for improving the quality of products and perfecting quality control. The industrial X-ray nondestructive testing mainly applies the special penetrability of X-rays, and under the premise of not damaging the casting, an operator controls an X-ray detection mechanism to move and irradiate different parts of the casting to obtain a perspective X-ray image of the casting, and finally judges whether the casting has internal quality defects or not according to the X-ray image.
With the improvement of the product yield, the method for carrying out nondestructive testing by controlling the movement of the X-ray detection mechanism by an operator greatly limits the detection efficiency. Later, the CNC programming is adopted to detect the position, the motion control unit controls the X-ray detection mechanism to move and acquire an X-ray image, and the detection efficiency of detecting castings with the same model or model in batches is improved to a certain extent.
The X-ray nondestructive testing method based on CNC programming requires special CNC programs to be programmed in advance for castings with different shapes. The operator is required to control the X-ray detection mechanism to move to the detection position, then the detection position is recorded, and the operation is repeated to complete the CNC programming. With the increase of the models or models of castings, a large amount of personnel and time are required for compiling different CNC programs; the larger the casting size, the longer it takes to program a dedicated CNC program. For large-size flat castings, one manual CNC programming requires even more time up to tens of minutes.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides the detection method for realizing the industrial X-ray nondestructive detection of the large-size flat casting based on the automatic CNC programming of the linear array camera, and the detection efficiency of the large-size flat casting is greatly improved.
In order to achieve the purpose, the invention adopts the following technical scheme:
a detection method for realizing industrial X-ray nondestructive testing of large-size flat castings based on linear array camera automatic CNC programming is characterized by comprising the following steps: adopts a detection system consisting of a linear array camera, a linear array camera image processing unit, a motion control unit, an X-ray acquisition device, an X-ray detection platform and an X-ray image processing unit,
comprises the following steps of (a) carrying out,
s1, placing the large-size flat casting to be detected on an industrial X-ray detection platform, and controlling the linear array camera to move from one side of the large-size flat casting to the other side of the large-size flat casting to be detected according to a preset direction by the motion control unit;
s2, synchronously starting to shoot continuous and complete surface pictures of the large-size flat casting to be detected by the linear array camera;
s3, the linear array camera transmits the pictures to the image processing unit of the linear array camera to synthesize continuous and complete surface pictures of complete large-size flat castings;
s4, calculating the minimum detection grid of the single detection visual field by the image processing unit of the linear array camera according to the coordinate parameter information received from the motion control unit;
s5, automatically identifying all detection areas of the detected large-size flat casting in the complete surface picture by the linear array camera image processing unit, and dividing detection grids on the complete surface picture of the large-size flat casting, wherein each grid corresponds to the position of an X-ray image detection view field;
s6, the linear array camera image processing unit automatically programs CNC according to the divided detection grids and sends the generated CNC program to the motion control unit;
s7, after receiving the CNC program, the motion control unit controls the X-ray detection platform to move and informs the X-ray acquisition equipment to take X-ray images;
s8, the X-ray acquisition equipment sends the acquired X-ray image to the X-ray image processing unit in real time; and an X-ray detection image is presented on the image processing unit, so that an operator can judge whether the casting has quality defects or not, and the detection is finished.
Further, when repeatedly inspecting the castings of the same model lot, the procedure of production through steps S1-S6 may be directly invoked.
Further, in step S5, alternatively, all the detection grids to be inspected may be manually selected, and the line camera image processing unit may then perform automatic CNC programming according to the selection result and send the programmed program to the motion control unit.
Furthermore, the X-ray detection platform comprises a C-shaped arm for arranging the X-ray collection equipment, a horizontal sliding rail for controlling the C-shaped arm to lift and slide and bearing a workpiece, the symmetrical middle of the C-shaped arm is arranged on the lifting sliding rail, the horizontal sliding rail is arranged along the symmetrical central line of the C-shaped arm, and a rotary table is arranged on the horizontal sliding rail.
Furthermore, the X-ray acquisition equipment comprises an X-ray source generator arranged at one end of the C-shaped arm and a flat panel detector arranged at the other end of the C-shaped arm, the X-ray source generator and the flat panel detector are arranged oppositely, and the linear array camera and the X-ray source generator are coaxially arranged in an up-and-down overlapping mode.
Further, the automatic program conversion algorithm process of step S6 is as follows,
firstly, measuring and obtaining the distance from the surface side of a workpiece to the surface of the front end of an X-ray generator or a linear array camera in X-ray acquisition equipment, and recording the distance as an object distance f; moving the linear array camera in the vertical direction at a constant speed, scanning and shooting to obtain a large-size flat casting surface picture, wherein the picture pixel sizes are px and py; the focal length of the X-ray acquisition equipment is known and recorded as F;
secondly, calculating the side length (mm) of the large-size flat casting surface area corresponding to the effective acquisition imaging visual field of the X-ray acquisition equipment under the condition of the current object distance, and recording the side length as the horizontal length LxAnd a vertical length Ly：
Wherein: r is the tower connection area proportion required in X-ray multi-image detection; l0xAnd l0yThe horizontal size and the vertical size (mm) of the inductor of the X-ray acquisition equipment are respectively;
Lx、Lythe actual side length (mm) of a single detection area of the large-size flat casting corresponding to the single detection grid in CNC programming is obtained;
the effective (maximum) scanning imaging view angle alpha of the known linear array camera is determined by a linear array camera sensor and parameters, and once the linear array camera sensor parameters are fixed, the angle alpha is a known fixed value; effective scanning imaging window side length (mm) of linear array camera is recorded as horizontal length l1xAnd a vertical length l1y(phase of linear array)Travel l of machine in vertical direction1yDetermined by the dimension of the detection platform mechanism, known as a constant), the dimension of the picture of the surface of the large-size flat casting shot by the line camera is known as px、py(ii) a Calculating a pixel (pixel) -length (mm) conversion coefficient gammaxAnd gammay：
Fourthly, calculating the pixel size G of the minimum unit grid marked on the large-size flat casting picture scanned by the linear array camerax、Gy：
Gx＝Lx×γx
Gy＝Ly×γy
Fifthly, the upper left corner of the large-size flat casting surface picture shot by the linear array camera is taken as the origin (0, 0) of a pixel coordinate system, and the middle pixel coordinate (x) of the lower edge of the large-size flat casting surface pictureorg，yorg) Corresponding to the origin of a motion coordinate system of the actual detection platform; central point pixel coordinate (x) of single grid on large-size flat casting surface picturei，yi) Relative to origin pixel coordinate (x)org，yorg) The offset is the offset distance of the X-ray detection platform in the actual motion coordinate system; calculating motor motion parameter (horizontal motion parameter D) of motion position of single CNC point in CNC programming according to mapping relation between pixel coordinate system and actual motion coordinate systemx(i)Vertical direction motion parameter Dy(i))：
Wherein k isxConversion factor, k, for a motor moving in the horizontal directionyConversion factors of a motor moving in the vertical direction;
when CNC program is to detect all grids, CNC program is generated automatically and orderly, and motor motion parameter D of next adjacent grid is calculated rapidly according to actual visual field size of gridx(i+1)And Dy(i+1)：
Dx(i+1)＝Dx(i)+Lx×kx
Dy(i+1)＝Dy(i)+Ly×ky
The beneficial effects of the invention include: the complex operation and the long time consumption of CNC programming manually performed by operators are saved, the industrial X-ray nondestructive testing of large-size flat castings can be automatically and quickly completed without manual intervention, and the testing efficiency is greatly improved.
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FIG. 1 is a flow chart of the present invention;
FIG. 2 is a block diagram of the system architecture of the present invention;
fig. 3 is a schematic structural diagram of a detection apparatus according to an embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the following embodiments and the accompanying drawings.
As shown in FIGS. 1-3, the invention relates to a method for realizing industrial X-ray nondestructive testing of large-size flat castings based on automatic CNC programming of a linear array camera.
The line camera is a CCD or CMOS sensor camera which is linearly arranged by a single line or a plurality of lines, has the characteristics of continuously shooting objects with super-long length, high scanning frequency and high resolution, and can shoot continuous and complete surface pictures of objects with super-large size.
The machine vision technology is to capture a target image through a machine vision product (i.e., an image pickup device, which is classified into a CMOS, a CCD, etc.), transmit the image to a processing unit, perform discrimination such as size, shape, and color through digital analysis processing, pixel distribution, luminance conversion, etc., and further control the operation of a field device according to the discrimination result.
The CNC programming is to combine the computer with the numerical control directly, the computer completes the numerical calculation, and directly sends out the control command to participate in the control process, and a series of point location coordinates are compiled and stored to form the CNC program. By executing the programmed CNC program, the position can be accurately and quickly moved, and the control efficiency is improved.
The X-ray detection system structure is formed by connecting a linear array camera, a linear array camera image processing unit, a motion control unit, X-ray acquisition equipment, an X-ray detection platform (comprising a C-shaped arm) and an X-ray image processing unit.
The X-ray detection platform comprises a C-shaped arm used for arranging X-ray collection equipment, a horizontal sliding rail used for controlling a C-shaped arm lifting sliding rail and used for bearing a workpiece, wherein the symmetrical middle part of the C-shaped arm is arranged on the lifting sliding rail, the horizontal sliding rail is arranged along the symmetrical central line of the C-shaped arm, and a rotary table is arranged on the horizontal sliding rail.
The X-ray acquisition equipment comprises an X-ray source generator arranged at one end of the C-shaped arm and a flat panel detector arranged at the other end of the C-shaped arm, and the X-ray source generator and the flat panel detector are arranged just opposite to each other. The preferred embodiment of the present invention is shown in FIG. 3: the linear array camera 1 and an X-ray source generator of the X-ray acquisition equipment 2 are coaxially and vertically overlapped and fixedly arranged and are opposite to a flat panel detector of the X-ray acquisition equipment 2; the X-ray acquisition equipment is integrally fixed on the vertical movement detection C-shaped arm 3; the large-size flat casting to be detected is placed on the central X-ray detection platform 4.
After the detection is started, the X-ray detection platform moves at a constant speed from top to bottom under the instruction control of the motion control unit; meanwhile, the linear array camera starts to work, a complete surface image of the large-size flat casting to be detected in the center of the X-ray detection platform is shot, and the shot image is sent to the image processing unit of the linear array camera;
the linear array camera image processing unit receives the motion parameters and the X-ray detection platform coordinate information transmitted by the picture and motion control unit; the linear array camera image processing unit automatically identifies the surface area of the large-size flat casting to be detected from the picture, automatically calculates the detection grid of the minimum detection visual field of the X-ray acquisition equipment according to the motion parameters and the coordinate information, and marks and displays all the detection grids on the complete surface image of the large-size flat casting; the image processing unit of the linear array camera generates a CNC program according to the automatic CNC programming of the detection grid;
the linear array camera image processing unit sends the CNC program to the motion control unit, and the motion control unit controls the X-ray detection platform to move and the X-ray acquisition equipment to take an X-ray image according to the motion parameters recorded by the CNC program; the X-ray acquisition equipment transmits the X-ray image to the X-ray image processing unit, and an operator checks and judges the detection result of the X-ray image.
In an intelligent automatic mode, the linear array camera image processing system takes an automatic identification result of a large-size flat casting surface image as a detection area, and automatically carries out CNC programming to generate a CNC program;
in the manual intervention mode, an operator selects all detection grids to be detected according to the detection technical requirements and confirms submission, and the linear array camera image processing unit automatically programs CNC according to the selection result to generate a CNC program.
The CNC automatic programming conversion algorithm process is as follows,
firstly, measuring and obtaining the distance from the surface side of a workpiece to the surface of the front end of an X-ray generator or a linear array camera in X-ray acquisition equipment, and recording the distance as an object distance f; moving the linear array camera in the vertical direction at a constant speed, scanning and shooting to obtain a large-size flat casting surface picture, wherein the picture pixel sizes are px and py; the focal length of the X-ray acquisition equipment is known and recorded as F;
secondly, calculating the side length (mm) of the large-size flat casting surface area corresponding to the effective acquisition imaging visual field of the X-ray acquisition equipment under the condition of the current object distance, and recording the side length as the horizontal length LxAnd a vertical length Ly：
Wherein: r is the tower connection area proportion required in X-ray multi-image detection; l0xAnd l0yThe horizontal size and the vertical size (mm) of the inductor of the X-ray acquisition equipment are respectively;
Lx、Lythe actual side length (mm) of a single detection area of the large-size flat casting corresponding to the single detection grid in CNC programming is obtained;
the effective (maximum) scanning imaging view angle alpha of the known linear array camera is determined by a linear array camera sensor and parameters, and once the linear array camera sensor parameters are fixed, the angle alpha is a known fixed value; effective scanning imaging window side length (mm) of linear array camera is recorded as horizontal length l1xAnd a vertical length l1y(line camera vertical direction running stroke l1yDetermined by the dimension of the detection platform mechanism, known as a constant), the dimension of the picture of the surface of the large-size flat casting shot by the line camera is known as px、py(ii) a Calculating a pixel (pixel) -length (mm) conversion coefficient gammaxAnd gammay：
Fourthly, calculating the pixel size G of the minimum unit grid marked on the large-size flat casting picture scanned by the linear array camerax、Gy：
Gx＝Lx×γx
Gy＝Ly×γy
Fifthly, the upper left corner of the large-size flat casting surface picture shot by the linear array camera is taken as the origin (0, 0) of a pixel coordinate system, and the middle pixel coordinate (x) of the lower edge of the large-size flat casting surface pictureorg，yorg) Origin of motion coordinate system corresponding to actual detection platform(ii) a Central point pixel coordinate (x) of single grid on large-size flat casting surface picturei，yi) Relative to origin pixel coordinate (x)org，yorg) The offset is the offset distance of the X-ray detection platform in the actual motion coordinate system; calculating motor motion parameter (horizontal motion parameter D) of motion position of single CNC point in CNC programming according to mapping relation between pixel coordinate system and actual motion coordinate systemx(i)Vertical direction motion parameter Dy(i))：
Wherein k isxConversion factor, k, for a motor moving in the horizontal directionyConversion factors of a motor moving in the vertical direction;
when CNC program is to detect all grids, CNC program is generated automatically and orderly, and motor motion parameter D of next adjacent grid is calculated rapidly according to actual visual field size of gridx(i+1)And Dy(i+1)：
Dx(i+1)＝Dx(i)+Lx×kx
Dy(i+1)＝Dy(i)+Ly×ky
The invention has the advantages that:
1. dividing a detection area grid according to a large-size flat casting complete surface picture, and automatically programming by CNC; the whole CNC programming process is completed by the linear array camera image processing unit, only 1s is needed, and waiting of operators is not needed. When a large-size flat casting is detected, the whole CNC programming time is shortened to within 5s from dozens of minutes, and the detection efficiency is greatly improved.
2. The linear array camera efficiently takes pictures of the complete surface of a large-size flat casting; the 2m by 1.5m casting can be shot in 3s, and the obtained large-size flat casting complete surface picture is visual.
3. The complete surface picture of the large-size flat casting can prompt the grid on the picture corresponding to the current detection part in real time in the whole X-ray detection process, and is visual.
The technical solutions provided by the embodiments of the present invention are described in detail above, and the principles and embodiments of the present invention are explained herein by using specific examples, and the descriptions of the embodiments are only used to help understanding the principles of the embodiments of the present invention; meanwhile, for a person skilled in the art, according to the embodiments of the present invention, there may be variations in the specific implementation manners and application ranges, and in summary, the content of the present description should not be construed as a limitation to the present invention.
Claims (6)
1. A detection method for realizing industrial X-ray nondestructive testing of large-size flat castings based on linear array camera automatic CNC programming is characterized by comprising the following steps: adopts a detection system consisting of a linear array camera, a linear array camera image processing unit, a motion control unit, an X-ray acquisition device, an X-ray detection platform and an X-ray image processing unit,
comprises the following steps of (a) carrying out,
s1, placing the large-size flat casting to be detected on an industrial X-ray detection platform, and controlling the linear array camera to move from one side of the large-size flat casting to the other side of the large-size flat casting to be detected according to a preset direction by the motion control unit;
s2, synchronously starting to shoot continuous and complete surface pictures of the large-size flat casting to be detected by the linear array camera;
s3, the linear array camera transmits the pictures to the image processing unit of the linear array camera to synthesize continuous and complete surface pictures of complete large-size flat castings;
s4, calculating the minimum detection grid of the single detection visual field by the image processing unit of the linear array camera according to the coordinate parameter information received from the motion control unit;
s5, automatically identifying all detection areas of the detected large-size flat casting in the complete surface picture by the linear array camera image processing unit, and dividing detection grids on the complete surface picture of the large-size flat casting, wherein each grid corresponds to the position of an X-ray image detection view field;
s6, the linear array camera image processing unit automatically programs CNC according to the divided detection grids and sends the generated CNC program to the motion control unit;
s7, after receiving the CNC program, the motion control unit controls the X-ray detection platform to move and informs the X-ray acquisition equipment to take X-ray images;
s8, the X-ray acquisition equipment sends the acquired X-ray image to the X-ray image processing unit in real time; and an X-ray detection image is presented on the image processing unit, so that an operator can judge whether the casting has quality defects or not, and the detection is finished.
2. The detection method for realizing industrial X-ray nondestructive detection of the large-size flat casting based on the automatic CNC programming of the line camera as claimed in claim 1, is characterized in that: when the castings of the same model lot are repeatedly inspected, the procedure of production through steps S1-S6 can be directly called.
3. The detection method for realizing industrial X-ray nondestructive detection of the large-size flat casting based on the automatic CNC programming of the line camera as claimed in claim 1, is characterized in that: in step S5, all the detection grids to be inspected may be selected manually, and the line camera image processing unit may then perform CNC programming according to the selection result and send the programmed program to the motion control unit.
4. The detection method for realizing industrial X-ray nondestructive detection of the large-size flat casting based on the automatic CNC programming of the line camera as claimed in claim 1, is characterized in that: the X-ray detection platform comprises a C-shaped arm used for arranging X-ray collection equipment, a horizontal sliding rail used for controlling a C-shaped arm lifting sliding rail and used for bearing a workpiece, wherein the symmetrical middle of the C-shaped arm is arranged on the lifting sliding rail, the horizontal sliding rail is arranged along the symmetrical central line of the C-shaped arm, and a rotary table is arranged on the horizontal sliding rail.
5. The method for detecting the large-size flat casting based on the linear array camera automatic CNC programming and realizing industrial X-ray nondestructive testing is characterized by comprising the following steps of: the X-ray acquisition equipment comprises an X-ray source generator arranged at one end of the C-shaped arm and a flat panel detector arranged at the other end of the C-shaped arm, the X-ray source generator and the flat panel detector are arranged oppositely, and the linear array camera and the X-ray source generator are coaxially and vertically overlapped.
6. The detection method for realizing industrial X-ray nondestructive detection of the large-size flat casting based on the automatic CNC programming of the line camera as claimed in claim 1, is characterized in that: the automatic program conversion algorithm process of step S6 is as follows,
firstly, measuring and obtaining the distance from the surface side of a workpiece to the surface of the front end of an X-ray generator or a linear array camera in X-ray acquisition equipment, and recording the distance as an object distance f; moving the linear array camera in the vertical direction at a constant speed, scanning and shooting to obtain a large-size flat casting surface picture, wherein the picture pixel sizes are px and py; the focal length of the X-ray acquisition equipment is known and recorded as F;
secondly, calculating the side length (mm) of the large-size flat casting surface area corresponding to the effective acquisition imaging visual field of the X-ray acquisition equipment under the condition of the current object distance, and recording the side length as the horizontal length LxAnd a vertical length Ly：
Wherein: r is the tower connection area proportion required in X-ray multi-image detection; l0xAnd l0yThe horizontal size and the vertical size (mm) of the inductor of the X-ray acquisition equipment are respectively;
Lx、Lynamely the actual side length (m) of the single detection area of the large-size flat casting corresponding to the single detection grid in CNC programmingm)；
The effective (maximum) scanning imaging view angle alpha of the known linear array camera is determined by a linear array camera sensor and parameters, and once the linear array camera sensor parameters are fixed, the angle alpha is a known fixed value; effective scanning imaging window side length (mm) of linear array camera is recorded as horizontal length l1xAnd a vertical length l1y(line camera vertical direction running stroke l1yDetermined by the dimension of the detection platform mechanism, known as a constant), the dimension of the picture of the surface of the large-size flat casting shot by the line camera is known as px、py(ii) a Calculating a pixel (pixel) -length (mm) conversion coefficient gammaxAnd gammay：
Fourthly, calculating the pixel size G of the minimum unit grid marked on the large-size flat casting picture scanned by the linear array camerax、Gy：
Gx＝Lx×γx
Gy＝Ly×γy
Fifthly, the upper left corner of the large-size flat casting surface picture shot by the linear array camera is taken as the origin (0, 0) of a pixel coordinate system, and the middle pixel coordinate (x) of the lower edge of the large-size flat casting surface pictureorg，yorg) Corresponding to the origin of a motion coordinate system of the actual detection platform; central point pixel coordinate (x) of single grid on large-size flat casting surface picturei，yi) Relative to origin pixel coordinate (x)org，yorg) The offset is the offset distance of the X-ray detection platform in the actual motion coordinate system; calculating motor motion parameters (horizontal motion) of motion position of single CNC point in CNC programming according to mapping relation between pixel coordinate system and actual motion coordinate systemDynamic parameter Dx(i)Vertical direction motion parameter Dy(i))：
Wherein k isxConversion factor, k, for a motor moving in the horizontal directionyConversion factors of a motor moving in the vertical direction;
when CNC program is to detect all grids, CNC program is generated automatically and orderly, and motor motion parameter D of next adjacent grid is calculated rapidly according to actual visual field size of gridx(i+1)And Dy(i+1)：
Dx(i+1)＝Dx(i)+Lx×kx
Dy(i+1)＝Dy(i)+Ly×ky。
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