CN115326844A - Automatic ray detection system and method for welding seam - Google Patents
Automatic ray detection system and method for welding seam Download PDFInfo
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- CN115326844A CN115326844A CN202211033477.0A CN202211033477A CN115326844A CN 115326844 A CN115326844 A CN 115326844A CN 202211033477 A CN202211033477 A CN 202211033477A CN 115326844 A CN115326844 A CN 115326844A
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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
The invention discloses an automatic ray detection system and method for a welding seam, which comprises the following steps: the robot unit comprises a robot body, wherein a motion platform is arranged on the robot body, the ray machine is arranged on the motion platform, and the motion platform can drive the ray machine to perform X-axis, Y-axis and Z-axis motion, planar rotation motion and axial inclination motion; the radiographic film imaging unit comprises a laser scanning device, is used for reading an X-ray result into digital image information and feeding back the digital image information to the main control unit; the main control unit is used for respectively controlling the movement of the robot body, the movement of the motion platform and the shooting parameters of the ray machine; receiving the digitized image information transmitted by the radiographic film imaging unit and feeding the digitized image information back to the auxiliary detection unit; and the auxiliary detection unit is used for carrying out auxiliary identification on the weld defects based on the digitalized image information. The whole welding seam defect detection process is realized automatically, the working flow is simplified, and the ray working efficiency is improved.
Description
Technical Field
The invention relates to the technical field of welding seam detection, in particular to an automatic ray detection system and method for a welding seam.
Background
The statements in this section merely provide background information related to the present disclosure and may not necessarily constitute prior art.
The manual welding of welding seams is greatly influenced by human and environmental factors, welding defects are easy to occur in the welding process, X-ray detection is needed, at present, film type X-rays are generally used in the industry, the detection process generally comprises the steps of adjusting the angle and distance of an X-ray machine, shooting a film, developing the film, evaluating the film and the like, and the detection efficiency is low; the adjustment of the parameters of the ray machine needs manual operation, the precision is not high, the mode is complicated, consumables such as a film, developing solution, fixing solution and the like need to be used for the film type X-ray, the film storage cost is high, and a large amount of hazardous wastes can be generated in the developing solution and the fixing solution; the film evaluation depends on manual experience, and the requirement on the professional level of personnel is high.
In addition, when the weld joint at the bottom of the railway vehicle is detected, the rail at the bottom of the railway vehicle is often required to be crossed, the adjustment of the angle and the distance of the ray machine is very inconvenient, and the detection precision is difficult to ensure.
Disclosure of Invention
In order to solve the problems, the invention provides an automatic ray detection system and method for a welding line, which can realize automatic adjustment of shooting angle and distance of a ray machine, digital image display of film results and auxiliary judgment of ray results, simplify the working process and improve the working efficiency of rays.
According to a first aspect of an embodiment of the present invention, there is provided an automated radiographic inspection system for a weld, comprising:
the robot unit comprises a robot body, wherein a motion platform is arranged on the robot body, the ray machine is arranged on the motion platform, and the motion platform can drive the ray machine to perform X-axis, Y-axis and Z-axis motion, planar rotation motion and axial inclination motion; the robot unit drives the ray machine to move to the position of the welding line to be detected, and the shooting position and angle of the ray machine are controlled through the motion platform, so that an X-ray result of the welding line to be detected is obtained;
the radiographic film imaging unit comprises a laser scanning device and is used for reading the X-ray result into digital image information and feeding the digital image information back to the main control unit;
the main control unit is used for respectively controlling the movement of the robot body, the movement of the movement platform and the shooting parameters of the ray machine; receiving the digitized image information transmitted by the radiographic film imaging unit and feeding the digitized image information back to the auxiliary detection unit;
and the auxiliary detection unit is used for carrying out auxiliary identification on the weld defects based on the digitized image information.
As a further scheme, an image acquisition module is arranged on the ray machine; acquiring an RGB image of a welding line in real time through an image acquisition module, and converting the RGB image into an HSV image; screening out the color range of a welding line to be detected based on the HSV image, and processing the color with smaller correlation by adopting corrosion operation; determining a welding seam contour to be detected, and obtaining a corresponding three-dimensional coordinate from a center coordinate to a depth coordinate based on the welding seam contour; feeding the three-dimensional coordinates back to the main control unit;
and the main control unit controls the position relation between the ray machine and the weld joint to be detected based on the three-dimensional coordinates so as to detect the weld joint.
According to the technical scheme, the robot body is provided with a magnetic stripe line patrol sensor and a laser distance measuring sensor, the magnetic stripe line patrol sensor senses the motion path of the robot body, and the laser distance measuring sensor detects the distance between the robot body and a space object so as to determine the position of the robot body.
As a further scheme, the robot body is a tracked robot.
As a further scheme, the motion platform comprises an X-axis motion module, a Y-axis motion module and a Z-axis motion module, wherein the X-axis motion module or the Y-axis motion module comprises a first stepping motor and a lead screw transmission mechanism connected with the first stepping motor, and the lead screw transmission mechanism is connected with the ray machine fixing platform; the Z-axis motion module comprises a second stepping motor and a screw rod lifting mechanism connected with the second stepping motor, and the screw rod lifting mechanism is connected with the ray machine fixing platform.
As a further scheme, the motion platform comprises a planar rotary motion module, the planar rotary motion module comprises a brushless speed reduction motor and a 1.
As a further scheme, the motion platform comprises an axial tilt motion module, the axial tilt motion module is arranged on the ray machine fixing platform and comprises a tube head mounting frame and a tilt rotating motor, the tube head mounting frame is connected with the ray machine, the tilt rotating motor drives the tube head mounting frame to realize that the ray machine rotates along the axial direction of the ray machine, and therefore the radiation window is aligned to a detected part when the directional ray machine takes a picture.
As a further aspect, the radiographic imaging unit further includes: and the results shot by the ray machine are stored by the ray result storage board, and the laser scanning device reads the results on the ray result storage board and converts the results into digital image information.
According to a second aspect of the embodiments of the present invention, there is provided an automated radiographic inspection method for a weld, including:
the robot body moves to a position to be detected according to a set moving path;
acquiring welding seam image information, determining a central three-dimensional coordinate of a welding seam outline, and determining the position, plane rotation angle and axial rotation angle of an X-axis, a Y-axis and a Z-axis of an X-ray machine based on the three-dimensional coordinate in combination with the detection requirement of the X-ray machine; adjusting the ray machine to move to a set position;
controlling a ray machine to carry out exposure, storing a detection result of the ray machine into a ray result storage board, reading the result on the ray result storage board by a laser scanning device, and converting the result into digital image information;
and performing auxiliary identification of weld defects based on the digitized image information.
As a further scheme, the auxiliary identification of the weld defects is carried out based on the digitized image information, and the specific process is as follows:
carrying out image enhancement on the brightness, the gray scale and the contrast of the digital image information;
inputting the enhanced image into a defect identification model to obtain a weld defect identification result;
the defect identification model adopts an image identification algorithm based on a YOLO model.
Compared with the prior art, the invention has the beneficial effects that:
(1) The automatic ray detection system for the welding seam carries an ray machine to carry out automatic welding seam detection based on the crawler-type robot, and the crawler-type robot can well run at the bottom of a rail vehicle and cannot be limited by a bottom rail; storing the detection result of the ray machine into a ray result storage board, and converting the detection result into a digital image through a laser scanning device; the film can replace the traditional ray film, the film result is displayed in the form of a digital image, and the auxiliary detection unit can conveniently and automatically identify the defects.
(2) The robot body automatically moves to a position to be detected, the position of a welding seam is automatically identified, the position and the angle of the ray machine are automatically adjusted, the welding seam ray detection is automatically realized, the detection result is automatically converted into a digital image, the defect identification is automatically carried out, the whole welding seam defect detection process is automatically realized, the intervention of operators is not needed, the work flow is simplified, and the ray work efficiency is improved.
Advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
Drawings
FIG. 1 is a schematic structural diagram of an automated radiographic inspection system for a weld joint according to an embodiment of the present invention;
FIG. 2 is an axial view of a robotic cell in an embodiment of the invention;
FIG. 3 is a top view of a robotic cell in an embodiment of the invention;
FIG. 4 is a schematic diagram of X-axis, Y-axis and Z-axis motion modules of a fixed platform of a radiographic machine according to an embodiment of the present invention;
FIG. 5 is a schematic view of a flat rotary motion module and an axial tilt motion module of a fixed platform of a ray machine according to an embodiment of the present invention;
FIG. 6 is a schematic diagram illustrating a positional relationship between a robot unit and a workpiece to be measured according to an embodiment of the present invention;
FIG. 7 is a schematic view of an automated radiographic inspection process of a weld joint in an embodiment of the present invention;
the robot comprises a robot body 1 and a crawler belt module 2, wherein the robot body is provided with a crawler belt module; 3. a camera module; 4. a motion platform; 5. a laser ranging sensor; 6. an ray machine; 7. a stepping motor; 8. a lead screw transmission mechanism; 9. a screw rod lifting mechanism; 10. a gear set; 11. a brushless gear motor; 12. a tilt rotating motor; 13. a tube head mounting frame.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise, and it should be understood that the terms "comprises" and "comprising", and any variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
Example one
In one or more embodiments, an automated radiation detection system for a weld is disclosed, which, with reference to fig. 1, specifically includes:
(1) The robot unit comprises a robot body 1, wherein a motion platform 4 is arranged on the robot body 1, a ray machine 6 is fixed on a ray machine fixing platform, and the ray machine fixing platform is arranged on the motion platform 4; the motion platform 4 can drive the ray machine 6 to perform X, Y and Z three-axis motion, plane rotation motion and axial tilt motion; the robot unit drives the ray machine 6 to move to the position of the weld joint to be detected, the shooting position and the shooting angle of the ray machine 6 are controlled through the moving platform 4, and the X-ray result of the weld joint to be detected is obtained.
Specifically, with reference to fig. 2, 3 and 6, the robot body 1 of the embodiment includes a crawler module 2, and is driven by a brushless speed reduction motor by using a crawler robot; when the welding seam at the bottom of the rail vehicle is detected, the robot body 1 needs to enter the bottom of the rail vehicle for detection, a track inevitably exists at the bottom of the rail vehicle, and the tracked robot can smoothly pass through the track to reach a set position without receiving the motion limitation of the track.
A magnetic stripe line patrol sensor, a laser distance measurement sensor 5 and a camera module 3 are respectively carried on the robot body 1; in the embodiment, a plurality of magnetic stripe line patrol sensors (four in the embodiment) are positioned at the bottom of the robot body, the track type robot is ensured to move stably by detecting the magnetic stripes on the ground, a plurality of laser ranging sensors 5 (six in the embodiment) are arranged on a shell of the robot body, and the position of the track type robot at the moment is confirmed by detecting the distance between the laser ranging sensors and a space object; the camera module 3 is located at the front end of the robot body 1 and used for implementing feedback environment conditions.
In addition, in this embodiment, an image acquisition module is also equipped at the front end of the ray machine 6, the image acquisition module adopts a depth camera, and an RGB image of the weld joint is acquired in real time by the depth camera and converted into an HSV image; screening out the color range of a welding line to be detected based on the HSV image, and processing the color with smaller correlation by adopting corrosion operation; determining a welding seam contour to be detected, and obtaining a corresponding three-dimensional coordinate from a center coordinate to a depth coordinate based on the welding seam contour; feeding back the three-dimensional coordinates to the main control unit; and the main control unit adjusts the distance between the ray machine 6 and the three-dimensional coordinate based on the three-dimensional coordinate until the distance meets the shooting requirement of the ray machine, so as to detect the welding seam.
In this embodiment, the motion platform 4 includes an X, Y, and Z three-axis motion module, a planar rotation motion module, and an axial tilt motion module.
With reference to fig. 4, the x-axis or Y-axis movement module includes a first stepping motor 7 and a lead screw transmission mechanism 8 connected to the first stepping motor 7, and the lead screw transmission mechanism 8 is connected to the ray machine fixing platform; the first stepping motor 7 drives the lead screw transmission mechanism 8 to move in the X-axis (left-right) or Y-axis (front-back) direction, and then drives the ray machine fixing platform to move correspondingly.
The Z-axis motion module comprises a second stepping motor and a screw rod lifting mechanism 9 connected with the second stepping motor, and the screw rod lifting mechanism 9 is connected with the ray machine fixing platform; the second stepping motor screw lifting mechanism 9 runs in the Z-axis (up-down) direction, and further drives the ray machine fixing platform to move in the Z-axis direction.
Referring to fig. 5, the planar rotational motion module includes: brushless gear motor 11 and the 1 n (for example 1 50) gear train 10 that is connected with brushless gear motor 11, gear train 10 is connected with ray machine fixed platform, and brushless gear motor 11 passes through drive gear train 10 and moves, drives motion platform 4 and carries out the plane rotation.
The axial tilt motion module sets up on ray apparatus fixed platform, includes: the tube head mounting frame 13 and the inclined rotating motor 12 are connected with the ray machine 6, and the inclined rotating motor 12 drives the tube head mounting frame 13 to realize that the ray machine 6 rotates along the self axial direction, so that the radiation window is aligned to the detected part when the directional ray machine 6 takes a picture.
The X-axis, Y-axis and Z-axis motion modules, the plane rotation motion module and the axial tilt motion module of the motion platform 4 can realize the motion of the ray machine in the X-axis, Y-axis and Z-axis directions, the plane direction and the axial tilt direction, so that the shooting position of the ray machine meets the shooting requirement, and the optimal shooting effect is achieved.
In the embodiment, the robot unit automatically drives the ray machine 6 to enter the set detection position at the bottom of the rail vehicle, and the position and the angle of the ray machine 6 are automatically adjusted, so that the purpose of automatically detecting the welding seam ray image is realized.
(2) A radiographic film imaging unit, which mainly comprises a laser scanning device and an X-ray result storage plate, in combination with FIG. 1;
inputting required tube voltage, tube current and exposure time in a main control unit according to field detection requirements, controlling a ray machine 6 to shoot by a ray controller according to input parameters, storing a shooting result on an X-ray result storage board, recording a detection result by the X-ray result storage board instead of a traditional radiographic film, reading by a laser scanner, converting imaging data in the X-ray result storage board in a form of a digitized image, and finally feeding back information of the digitized image to the main control unit; the X-ray result storage plate can be used repeatedly.
(3) The main control unit can receive data returned by the magnetic stripe line patrol sensor, the laser ranging sensor 5 and the image acquisition module on the robot body 1, control the moving path and the stopping position of the robot body 1, and control the movement of the movement platform 4 by acquiring the position of a welding line, so that the ray machine 6 is adjusted to a proper shooting position; sending a parameter control instruction to a controller of the ray machine 6 to control the parameters of the ray machine 6; and simultaneously, receiving the digital image information transmitted by the radiographic film imaging unit and feeding the digital image information back to the auxiliary detection unit.
In this embodiment, the main control unit may select an industrial personal computer, and certainly, other control devices may be selected according to needs.
(4) And the auxiliary detection unit is used for carrying out auxiliary identification on the weld defects based on the digitized image information.
In this embodiment, the auxiliary detection unit first performs image enhancement processing on the brightness, gray scale and contrast of the digitized image information to achieve the purpose of clearly observing the fine defects; and then inputting the enhanced image into a defect identification model to obtain a weld defect identification result.
The defect identification model adopts an image identification algorithm based on a YOLO model; firstly, digital pictures which are subjected to ray exposure and converted through a laser scanner are collected, the original pictures are classified and labeled according to the types of welding seams, the pictures are adjusted in multiple aspects such as definition, gray scale, outline, brightness, direction and the like, then the pictures are amplified, the number of small sample data is increased, and a basic training database is obtained. And then, applying a target recognition algorithm based on YOLO to finish the training of the defect recognition model.
According to the embodiment, the robot body 1 is automatically moved to a position to be detected, the position of a welding seam is automatically identified, the position and the angle of the ray machine 6 are automatically adjusted, the welding seam ray detection is automatically realized, the detection result is automatically converted into a digital image, the defect identification is automatically carried out, the whole welding seam defect detection process is automatically realized, the intervention of an operator is not needed, the work flow is simplified, and the ray work efficiency is improved.
Example two
In one or more embodiments, an automatic ray detection method for a weld is disclosed, which specifically comprises the following processes:
(1) The robot body 1 moves to a position to be detected according to a set moving path;
(2) Acquiring welding seam image information, determining a central three-dimensional coordinate of a welding seam outline, and determining the position of X, Y and Z three axes, a plane rotation angle and an axis rotation angle of the ray machine 6 based on the three-dimensional coordinate and in combination with the detection requirement of the ray machine 6; adjusting the ray machine 6 to move to a set position;
(3) Controlling the ray machine 6 to carry out exposure, storing a result detected by the ray machine 6 into a ray result storage board, reading the result on the ray result storage board by a laser scanning device, and converting the result into digital image information;
(4) And performing auxiliary identification of weld defects based on the digitized image information.
Specifically, with reference to fig. 7, the specific detection method of this embodiment is as follows: before the ray detection, an operator finishes training the machine firstly, parameters are selected according to an object to be detected, an X-ray result storage plate and other objects are placed, a protection door is closed, the operator inputs relevant parameters of the ray on a main control unit, a crawler-type robot is started, the robot carries a ray machine 6 to reach a first position, then the angle and the focal length of the ray machine 6 are automatically adjusted through an XYZ-axis moving platform, exposure shooting is carried out after the angle and the focal length are adjusted to a specified position, after exposure is finished, the crawler-type robot carries the ray machine 6 to drive to a second position for exposure shooting, after exposure is finished, the crawler-type robot automatically returns to an initial position, the protection door is opened to take out the X-ray result storage plate, data of the X-ray result storage plate are transmitted to an auxiliary detection unit through a laser scanner, a welding seam defect identification result is obtained, and a flaw detection report is generated.
The auxiliary detection unit has the following auxiliary identification process on the weld defects:
carrying out image enhancement on the brightness, the gray scale and the contrast of the digital image information;
inputting the enhanced image into a defect identification model to obtain a weld defect identification result;
the defect recognition model adopts an image recognition algorithm based on a YOLO model.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solutions of the present invention and not for limiting the same, and although the present invention is described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that: modifications and equivalents may be made to the embodiments of the invention without departing from the spirit and scope of the invention, which is to be covered by the claims.
Claims (10)
1. An automated radiographic inspection system for a weld, comprising:
the robot unit comprises a robot body, wherein a motion platform is arranged on the robot body, the ray machine is arranged on the motion platform, and the motion platform can drive the ray machine to perform X, Y and Z three-axis motion, plane rotation motion and axial inclination motion; the robot unit drives the ray machine to move to the position of the welding line to be detected, and the shooting position and angle of the ray machine are controlled through the motion platform to obtain an X-ray result of the welding line to be detected;
the radiographic film imaging unit comprises a laser scanning device and is used for reading the X-ray result into digital image information and feeding the digital image information back to the main control unit;
the main control unit is used for respectively controlling the movement of the robot body, the movement of the motion platform and the shooting parameters of the ray machine; receiving the digitized image information transmitted by the radiographic film imaging unit and feeding the digitized image information back to the auxiliary detection unit;
and the auxiliary detection unit is used for carrying out auxiliary identification on the weld defects based on the digitalized image information.
2. An automated radiographic inspection system for a weld according to claim 1, wherein the radiographic machine is provided with an image acquisition module; acquiring an RGB (red, green and blue) image of the welding line in real time through an image acquisition module, and converting the RGB image into an HSV (hue, saturation and value) image; screening out the color range of the welding line to be detected based on the HSV image, and processing the color with smaller correlation by adopting corrosion operation; determining a welding seam contour to be detected, and obtaining a corresponding three-dimensional coordinate from a center coordinate to a depth coordinate based on the welding seam contour; feeding the three-dimensional coordinates back to the main control unit;
and the main control unit controls the position relation between the ray machine and the weld joint to be detected based on the three-dimensional coordinate so as to detect the weld joint.
3. The automatic ray detection system for the welding line according to claim 1, wherein a magnetic strip line patrol sensor and a laser distance measuring sensor are mounted on the robot body, the magnetic strip line patrol sensor senses the movement path of the robot body, and the laser distance measuring sensor detects the distance between the robot body and a space object so as to determine the position of the robot body.
4. An automated radiation detection system for a weld according to claim 1, 2 or 3 wherein the robot body is a tracked robot.
5. The automated radiographic testing system for the weld according to claim 1, wherein the motion platform comprises an X, Y and Z three-axis motion module, wherein the X-axis or Y-axis motion module comprises a first stepping motor and a lead screw transmission mechanism connected with the first stepping motor, and the lead screw transmission mechanism is connected with the ray machine fixing platform; the Z-axis motion module comprises a second stepping motor and a screw rod lifting mechanism connected with the second stepping motor, and the screw rod lifting mechanism is connected with the ray machine fixing platform.
6. The automated radiographic inspection system for a weld according to claim 1, wherein the motion stage comprises a planar rotary motion module comprising a brushless gear motor and a 1 n gear set coupled to the brushless gear motor, the gear set coupled to the radiographic machine mounting stage.
7. The automated radiographic testing system for weld seams according to claim 1, wherein the motion platform includes an axial tilt motion module, the axial tilt motion module is disposed on the fixed platform of the radiographic machine and includes a tube head mounting bracket connected to the radiographic machine and a tilt rotation motor, and the tilt rotation motor drives the tube head mounting bracket to rotate the radiographic machine in the axial direction.
8. The automated radiographic inspection system for welded seams of claim 1, wherein the radiographic imaging unit further comprises: and the results shot by the ray machine are stored by the ray result storage board, and the laser scanning device reads the results on the ray result storage board and converts the results into digital image information.
9. An automated radiographic inspection method for a weld, comprising:
the robot body moves to a position to be detected according to a set moving path;
acquiring welding seam image information, determining a central three-dimensional coordinate of a welding seam outline, and determining the position, plane rotation angle and axial rotation angle of an X-axis, a Y-axis and a Z-axis of an X-ray machine based on the three-dimensional coordinate in combination with the detection requirement of the X-ray machine; adjusting the ray machine to move to a set position;
controlling the ray machine to carry out exposure, storing a detection result of the ray machine into a ray result storage board, reading the result on the ray result storage board by a laser scanning device, and converting the result into digital image information;
and performing auxiliary identification of weld defects based on the digitized image information.
10. The method for automatically detecting the rays of the welding seam according to claim 9, wherein the auxiliary identification of the welding seam defect is carried out based on the digital image information, and the specific process is as follows:
carrying out image enhancement on the brightness, the gray scale and the contrast of the digital image information;
inputting the enhanced image into a defect identification model to obtain a weld defect identification result;
the defect identification model adopts an image identification algorithm based on a YOLO model.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115980092A (en) * | 2023-03-20 | 2023-04-18 | 宁波吉宁汽车零部件有限公司 | Weld piece check out test set |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115980092A (en) * | 2023-03-20 | 2023-04-18 | 宁波吉宁汽车零部件有限公司 | Weld piece check out test set |
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