JP4576988B2 - Inspection processing method and inspection processing apparatus - Google Patents

Description

  The present invention relates to an inspection processing method and an inspection processing apparatus, and more particularly to an image processing technique for an inspection image obtained by a destructive inspection suitable for a corrosion state of a pipe or the like or a defect inspection of a welded portion.

  Conventionally, inspection of a welded portion of a pipe is often performed by an X-ray transmission test. In this X-ray transmission test, a film is placed on a part to be inspected, and X-rays that pass through the X-rays that are transmitted by irradiating the part to be inspected from the opposite direction through the part to be inspected are photographed. is there. This X-ray transmission test is an inspection method using a film with high recordability and has long been adopted as an official inspection. However, this conventional X-ray transmission test has a problem in rapidity and storage stability. Therefore, a method in which the detected X-ray is digitally processed as an image, displayed on a monitor, and stored in a medium as image data is being adopted in public inspection. On the other hand, as another non-destructive inspection method widely used among contractors, there is an ultrasonic flaw inspection using an ultrasonic echo. This ultrasonic flaw detection inspection is an inspection in which ultrasonic waves are incident on a part to be inspected, and ultrasonic echoes reflected on the part to be inspected are detected by a sensor to determine the presence or absence of a defect. Also in this ultrasonic flaw detection inspection, it is displayed on the echo image monitor of the acquired ultrasonic wave and can be stored as data.

Patent Document 1 discloses a method for improving the reliability of defect determination by displaying nondestructive inspection results of a part to be inspected by such two inspection methods on one monitor.
JP 2004-301723 A

  However, according to the above-mentioned Patent Document 1, in order to solve the fact that the display position at the time of displaying on the same monitor is shifted because the start position of the non-destructive inspection by the two inspection methods is different, It has only been disclosed to shift the phases of the image data to match each other. Therefore, even if the inspection positions are simply matched, the X-ray flaw detection image contains at least a geometric error because the mounting position of the X-ray sensor is separated from the part to be inspected. Detects the travel error due to the moving mechanism when scanning to inspect the part to be inspected, and the inspection scan length slightly overlaps instead of checking from the inspection start position to the inspection start position again. Therefore, there is a limit to matching the dimensional position of each inspection of the X-ray flaw detection image and the ultrasonic flaw detection image at the outer perimeter of the inspection object with high accuracy. It was.

  The present invention is for solving such problems, and a pre-process for removing an overlap image from an X-ray flaw detection image and correcting an error associated with an X-ray sensor mounting position. It is an object of the present invention to provide an inspection processing method and an inspection processing apparatus that can perform defect determination with high accuracy by matching the dimensional positions of ultrasonic flaw detection images.

In order to solve the above problems, according to the inspection processing method of the present invention, X-rays are irradiated while scanning in the circumferential direction with respect to the inner peripheral surface of the inspected portion along the circumferential direction of the cylindrical member. In order to detect an X-ray transmitted through the inspected part on the outer peripheral surface side of the inspected part and obtain an X-ray flaw detection image , the inspection start position arbitrarily set in the inspected part is scanned and detected. For an X-ray flaw detection image including an image that has passed through the inspection start position, an end start position set with an error portion from the start end of the X-ray flaw detection image, and an inspection scanned with respect to the inspected portion The temporary end end position is determined from the scanning length, and the image between the positions before and after the predetermined length with reference to the end start position, and the position between the positions before and after the predetermined length with reference to the temporary end end position. Cut out each image. Then, the two images cut out so that the images of the passages included in the two cut out images coincide with each other. Further, separation is performed at the end start position on the joined images. Next, each separated end image is connected to each end of the X-ray flaw detection image between a predetermined length position after the end start position and a predetermined length position before the temporary end position. Therefore, an overlap image can be removed from the X-ray flaw detection image, and a seamless X-ray flaw detection image can be obtained.

  In addition, by having a phase contraction process that contracts the entire phase length of the connected X-ray flaw detection image to the entire phase length of the ultrasonic flaw detection image, the dimensional position of the ultrasonic flaw detection image is matched and the defect has high accuracy. Judgment can be made.

  Furthermore, the contraction rate in the phase contraction step is determined by the relationship between the separation length between the X-ray sensor that detects X-rays and the inspected part and the inspection length on the outer peripheral surface of the inspected part. In addition, the provisional termination end position is a position that is provisionally determined based on the scanning movement distance of the drive mechanism that can be driven to scan the portion to be inspected.

An inspection processing apparatus as another invention is configured to irradiate an X-ray while passing through the inspected portion while scanning the inner peripheral surface of the inspected portion along the circumferential direction of the cylindrical member in the circumferential direction. An X-ray flaw detection image obtained by detecting the coming X-rays on the outer peripheral surface side of the inspected part and an ultrasonic wave incident on the outer peripheral surface of the inspected part while scanning in the circumferential direction from the inspected part It is an inspection processing apparatus that performs image processing on an ultrasonic flaw detection image obtained based on reflected echo waves. And the inspection processing apparatus of this invention has comprised the termination | terminus connection processing apparatus mainly. This terminal connection processing apparatus scans and detects an arbitrarily set inspection start position of the inspected part when obtaining an X-ray flaw detection image, so that an X-ray flaw detection image including an image corresponding to the passage through the inspection start position is detected. On the other hand, a provisional termination end position is determined from the termination start position set with an error portion from the start end of the X-ray flaw detection image and the inspection scan length scanned with respect to the inspected portion, and the termination start position is determined. An image between each position before and after a predetermined length with respect to the reference and an image between each position before and after the predetermined length with respect to the provisional termination end position are cut out. Then, the two images cut out so that the passage images included in the two cut out images coincide with each other, and are separated at the end start position on the pasted images. Further, a process is performed in which each separated end image is connected to each end of the X-ray flaw detection image between a predetermined length position after the end start position and a predetermined length position before the temporary end position. It is. Furthermore, the inspection processing apparatus of the present invention includes a phase contraction processing unit that contracts the entire phase length of the X-ray flaw detection images connected by the terminal connection processing unit to the entire phase length of the ultrasonic flaw detection image. Therefore, it is possible to perform a high-accuracy defect determination by removing the overlap image and applying a pre-process for correcting an error associated with the X-ray sensor mounting position so as to match the dimensional position of the ultrasonic flaw detection image. It becomes like this.

  According to the inspection processing method of the present invention, the X-ray flaw detection image is subjected to preprocessing for removing an overlap image and correcting an error associated with the X-ray sensor mounting position. Can be determined with high accuracy.

  FIG. 1 is a schematic diagram showing the configuration of an inspection system to which an inspection processing apparatus of the present invention is applied. In the inspection system shown in the figure, the length of the pipeline 1 to be inspected is several kilometers. The pipeline 1 is formed by welding a plurality of single pipes 1a to each other in the axial direction. Hereinafter, an example in which the inspection processing apparatus of the present invention is used when determining whether or not the welded portion 2 between the single pipes 1a in the pipeline 1 is defective will be described.

As shown in FIG. 1, a self-propelled X-ray apparatus that has been loaded from the end of a pipe into a pipeline 1 to be inspected and has moved to the position of a welded portion 2 that is an inspected portion. 3 is loaded. Here, the self-propelled X-ray apparatus 3 shown in FIG. 2 extends in a radial manner from the center of the apparatus so as to be capable of self-propelling in the pipeline 1, and includes a support arm 31 provided before and after the apparatus, and a support arm. A tire 32 that is attached to the tip end of 31 and is grounded to the inner peripheral surface of the pipeline 1 and rotationally driven by a drive motor (not shown), and attached to the apparatus main body 33, and X-rays are connected to the inner peripheral surface of the pipeline 1. And an X-ray irradiation device 34 for irradiating the laser beam. In addition to the above configuration, the self-propelled X-ray apparatus 3 can also be equipped with a camera that captures the state of the back bead of the welded portion 2 of the pipeline 1 and an illumination that illuminates the inside. The self-propelled X-ray apparatus 3 having such a configuration is remotely operated from an inspection processing apparatus 4 provided outside the pipeline 1.

  On the other hand, as shown in FIG. 1, a ring-shaped welding guide rail 7 disposed along the outer peripheral surface of the pipeline 1 is installed on the outer peripheral side of the pipeline 1. An inspection device 10 having an X-ray sensor 8 and an ultrasonic flaw detector 9 as shown in FIG. 3 is attached to the welding guide rail 7 by an operator. Further, the inspection apparatus 10 has a drive unit (not shown) including a drive mechanism unit such as a drive motor and a drive gear for driving along the welding guide rail 7. Furthermore, the X-ray sensor 8 is a sensor that receives X-rays irradiated from the X-ray irradiation device 34 of the inspection device 3 arranged inside the pipeline 1 and reads an image of the internal state of the welded portion 2. It is attached to the inspection apparatus 10 so as to oppose the welded part 2 that is the part to be inspected. The ultrasonic flaw detection apparatus 9 is a flaw detection apparatus based on the pulse reflection method, which includes two contacts 11 and 12 that detect the echo waves while entering a pulse ultrasonic wave into the welded portion 2 that is a part to be inspected. . The two contacts 11 and 12 are attached to the inspection apparatus 10 so as to be disposed on both sides of the welded portion 2 with the welded portion 2 serving as the portion to be inspected in between. Thus, the inspection apparatus 10 equipped with the ultrasonic flaw detector 9 including the X-ray sensor 8 and the contacts 11, 12 moves along the welding guide rail 7, so that the X-ray flaw of the entire circumference of the welded portion 2 is detected. Inspection and ultrasonic flaw detection are performed. The X-ray flaw detection image and the ultrasonic flaw detection image obtained by these inspections are sent to the inspection processing device 4 by wire or wirelessly, and the inspection processing device 4 transmits the defect determination device 6 such as a base via the network 5. . Note that the inspection processing apparatus 4 may have a function of performing the image processing of the present invention on the obtained inspection image and further performing a primary defect determination process at the site of flaw detection inspection. Further, the defect determination device 6 for performing the secondary defect determination processing directly operates the self-propelled X-ray device 3 remotely without the inspection processing device 4, and the X-ray flaw detection image and the ultrasonic flaw detection image are transmitted from the inspection device 10. It is also possible to obtain directly.

  Next, the configuration of the inspection processing apparatus according to an embodiment of the present invention will be described using the block configuration diagram shown in FIG. In the figure, an inspection processing apparatus 4 according to the present embodiment includes a CPU 41 that controls all of the components that will be described later, a receiving unit 42 that receives an ultrasonic flaw detection image and an X-ray flaw detection image obtained by inspection, and a reception. An image storage unit 43 for storing the ultrasonic flaw detection image and the X-ray flaw detection image received by the unit 42, a RAM 44 for storing each processing program, and the X-ray flaw detection image and the ultrasonic flaw detection image subjected to the end connection processing on the same monitor From the display unit 45 to be displayed (not shown), the operation input unit 46 for inputting various instructions such as the setting of the end start position of the X-ray flaw detection image obtained by the inspection, and the X-ray flaw detection image including the error image X-ray flaw detection of seamless images connected by the end connection processing unit 47 and a terminal connection processing unit 47 that performs processing to be described later on the end of the detected image to obtain a seamless image from which the error image is cut Is configured to include a phase erosion processor 48 to contract the entire phase length of an image on the entire phase length of the ultrasonic flaw detection image, the components are connected to each other via an internal bus 49. The display unit 45 need not be included in the inspection processing apparatus 4 and may be provided in the defect determination apparatus 6 of FIG.

  Next, the inspection method of the present invention for performing image processing on the X-ray flaw detection image and the ultrasonic flaw detection image detected by the inspection system shown in FIG. 1 using the inspection processing apparatus of the present embodiment will be described.

  FIG. 5 is a diagram for explaining the basic principle of the inspection processing method according to an embodiment of the present invention. (A) of the figure is, for example, each flaw detection image when flaw detection is performed on the welded portion 2 of the pipeline 1 of FIG. 1, and a solid line indicates all ultrasonic flaw detection images 51 from the start of detection to the end of detection. Indicates an X-ray flaw detection image 52. Among such inspection images, the X-ray flaw detection image 52 has an overlap from the inspection start position of the inspection apparatus 10 around the inspection start position to the arbitrary inspection end position. Minute image 53 and the geometric error due to the X-ray sensor 8 being mounted at a predetermined position from the outer peripheral surface of the pipeline 1 and the drive mechanism of the drive unit when the inspection apparatus 10 travels the welding guide rail 7 Part, for example, a driving error caused mainly by slipping of a gear or the like. On the other hand, since the ultrasonic flaw detection image 51 is an ultrasonic image obtained when the contacts 11 and 12 of the ultrasonic flaw detection apparatus 9 are in contact with the outer peripheral surface of the pipeline 1, the ultrasonic flaw detection image 51 contains almost no error. . As described above, the X-ray flaw detection image 52 includes the overlap image 53, the geometric error, and the running error as described above, and the X-ray flaw detection image 52 as it is, that is, the X-ray flaw detection image including the error image. Even if 52 and the ultrasonic flaw detection image 51 are displayed on the same monitor and are compared and referred to, it is impossible to accurately specify the position and size of the defective portion. Therefore, in order to cut this error image, it is necessary to perform a terminal connection process, which is an image process described later, to create a seamless X-ray flaw detection image 54 as shown in FIG. Then, as shown in FIG. 5C, with respect to the phase width of the created seamless X-ray flaw detection image 54, the separation length between the outer peripheral surface of the pipeline 1 of the object to be inspected and the X-ray sensor mounting position The phase length of the X-ray flaw detection image 54 can be approximated to the phase length of the ultrasonic flaw detection image 51 by contracting at a contraction rate determined by the diameter of the pipeline 1. Therefore, by displaying the ultrasonic flaw detection image 51 and the X-ray flaw detection image 54 on the same monitor and comparing and referring to both, it is possible to identify the position of the defective portion in distinction from noise and the like, and to accurately determine the size of the defective portion. Sizing can be performed, and reliability in determining a defective portion can be improved.

Next, FIG. 6 and FIG. 7 for explaining the outline of the inspection processing method of the present invention and FIG. 8 showing the inspection processing flow will be described in detail.
First, the operator inserts the self-propelled X-ray apparatus 3 from the pipe end of the pipeline 1 and operates the input operation section 46 of the inspection processing apparatus 4 in FIG. (Step S101). Further, the operator sets the inspection device 10 on the welding guide rail 7 (step S102). Then, in conjunction with the X-ray irradiation by the X-ray irradiation device 34 of the self-propelled X-ray device 3, the inspection apparatus 10 is moved and scanned along the welded portion 2 that is the inspected portion, and the X-ray flaw detection image is converted into an X-ray sensor. 8 (step S103). Further, the ultrasonic flaw detector 9 of the inspection apparatus 10 detects an ultrasonic flaw detection image by the two contacts 11 and 12 (step S104). Such an inspection is performed to detect an X-ray flaw detection image and an ultrasonic flaw detection image. The two detected images are stored in the image storage unit 43 via the reception unit 42 of the inspection processing device 4 by wire or wireless. Here, the X-ray flaw detection image data displayed in a strip shape as shown in FIG. 6A includes error image data as described above in addition to true image data, as shown in FIG. Contains. First, the end connection processing unit 47 of the inspection processing apparatus 4 reads the X-ray flaw detection image from the image storage unit 43, and arbitrarily sets the end start position (0 °) with respect to the read X-ray flaw detection image of FIG. Set as shown in (a). Then, the number of pulses of the drive mechanism of the inspection apparatus 10 of FIG. 1 and FIG. 3, for example, the drive motor, is counted, and the counted number of pulses is calculated from the diameter of the predetermined pipeline 1 or a predetermined outer peripheral length. Based on this, the provisional termination end position (360 °) is set as shown in FIG. 6A (step S105). Then, with the two end positions set in this way as references, the connecting positions of a predetermined length (−a, + a shown in FIG. 6B) and | a | <| b | The image position (+ b, −b shown in FIG. 6B) is set (step 106). Next, as shown in FIG. 7A, each of the connected images existing between the alignment position at each terminal position and the connected image position, that is, between −a to + b and + a to −b is cut (step). S107). Next, in order to match each end position in each connected image, as shown in FIG. 7B, the pasted images 71 are pasted so as to overlap each other (step S108). Then, as shown in FIG. 7C, the joined images are cut at the 0 ° position, which is the end start position, and a start end image and an end end image are created (step 109). Then, as shown in FIG. 7D, the created start end image and end end image are connected to each end image of the remaining image data cut out in step 107 (step S110). By the above processing, seamless X in which the overlapped image 53 from the inspection start position, passing through the inspection start position to the arbitrary inspection end position, as shown in FIG. A line flaw image is obtained. Thereafter, the seamless X-ray flaw detection image formed by connecting the phase contraction processing unit 48 in FIG. 4 is contracted at a contraction rate corresponding to the outer peripheral length of the object to be inspected and the separation length of the X-ray sensor mounting position. Thus, as shown in FIG. 5C, an X-ray flaw detection image 52 having image data approximate to the ultrasonic flaw detection image 51 is formed (step S111). Then, a phase matching process is performed to match the phases of the contracted X-ray flaw detection image and the ultrasonic flaw detection image with reference to the reading position and the defect position (step S112). Finally, an X-ray flaw detection image (image display area 92 in FIG. 9) and an ultrasonic flaw detection image (FIG. 9) processed by the inspection processing method for performing the end connection processing on the monitor 91 in FIG. 9 in the display unit 45 in FIG. 9 image display areas 93) are displayed in a phase-matched state (step S113).

  The present invention is not limited to the above-described embodiments, and it goes without saying that various modifications and substitutions are possible as long as they are described within the scope of the claims.

It is the schematic which shows the structure of the test | inspection system to which the test | inspection processing apparatus of this invention is applied. It is a front view which shows schematic structure of the self-propelled X-ray apparatus of FIG. It is a top view which shows schematic structure of the inspection apparatus of FIG. It is a block block diagram which shows the structure of the test | inspection processing apparatus which concerns on the example of 1 embodiment of this invention. It is a figure explaining the basic principle of the inspection processing method concerning one embodiment of the present invention. It is the schematic which shows a X-ray flaw detection image in order to demonstrate the outline | summary of the inspection processing method of this invention. It is the schematic which shows a X-ray flaw detection image in order to demonstrate the outline | summary of the inspection processing method of this invention. It is a flowchart which shows the test | inspection process by the test | inspection processing method which concerns on one embodiment of another invention. It is a figure which shows the example of a display of the test | inspection image processed by the test | inspection processing method of this invention.

Explanation of symbols

1; Pipeline, 1a; Single pipe, 2; Welded part, 3; X-ray irradiation device,
4; inspection processing device, 5; network, 6; defect determination device,
7; welding guideline, 8; X-ray sensor, 9; ultrasonic flaw detector,
10; inspection device, 11, 12; contact, 41; CPU, 42;
43; Image storage unit, 44; RAM, 45; Display unit, 46; Operation input unit,
47; terminal connection processing unit, 48; phase contraction processing unit, 49; internal bus.

Claims (6)

The outer peripheral surface of the inspected portion is irradiated with X-rays while scanning in the circumferential direction with respect to the inner peripheral surface of the inspected portion along the circumferential direction of the cylindrical member. Obtained based on the X-ray flaw detection image obtained by detection on the side and the echo wave that is reflected from the inspected part by entering ultrasonic waves while scanning the outer peripheral surface of the inspected part in the circumferential direction In the inspection processing method of performing image processing on the obtained ultrasonic flaw detection image,
For obtaining the X-ray flaw detection image, the X-ray flaw detection image including an image corresponding to the passage through the inspection start position in order to detect and pass through the inspection start position arbitrarily set in the inspected portion with respect to the X-ray inspection image. A provisional termination end position is determined from the termination start position set with an error portion from the start end of the X-ray flaw detection image and the inspection scan length scanned with respect to the inspected portion, and a predetermined length based on the termination start position Cutting the image between each position before and after the image and the image between each position before and after a predetermined length based on the provisional end position, respectively,
Pasting the two images cut out so that the passage images included in the two cut-out images match;
Separating the two end images at the end start positions on the pasted images;
Connecting each separated end image to each end of the X-ray flaw detection image between a predetermined length position after the end start position and a predetermined length position before the temporary end position. An inspection processing method characterized by the above.   The inspection processing method according to claim 1, further comprising a phase contraction step of contracting an entire phase length of the connected X-ray flaw detection image to an entire phase length of the ultrasonic inspection image.   3. The inspection processing method according to claim 2, wherein the contraction rate in the phase contraction step is determined by a relationship between a separation length between an X-ray sensor that detects X-rays and an inspected part and an inspection length on an outer peripheral surface of the inspected part.   The inspection processing method according to claim 1, wherein the temporary end position is a position temporarily determined based on a scanning movement distance of a drive mechanism that can be driven to scan a portion to be inspected. The outer peripheral surface of the inspected portion is irradiated with X-rays while scanning in the circumferential direction with respect to the inner peripheral surface of the inspected portion along the circumferential direction of the cylindrical member. Obtained based on the X-ray flaw detection image obtained by detection on the side and the echo wave that is reflected from the inspected part by entering ultrasonic waves while scanning the outer peripheral surface of the inspected part in the circumferential direction In the inspection processing apparatus that performs image processing on the obtained ultrasonic flaw detection image,
For obtaining the X-ray flaw detection image, the X-ray flaw detection image including an image corresponding to the passage through the inspection start position in order to detect and pass through the inspection start position arbitrarily set in the inspected portion with respect to the X-ray inspection image. A provisional termination end position is determined from the termination start position set with an error portion from the start end of the X-ray flaw detection image and the inspection scan length scanned with respect to the inspected portion, and a predetermined length based on the termination start position The images between the respective positions before and after the image and the images between the respective positions before and after the predetermined length based on the provisional terminal end position are cut out, and the passage images included in the two cut out images coincide with each other. The two images thus cut out are pasted together, separated into two end images at the end start position on the pasted images, and each separated end image is moved to a predetermined length position after the end start position and a temporary end end position. Position of the predetermined length before Inspection processing apparatus characterized by comprising a terminating connection processing unit that performs a process of connecting to each end of the X-ray flaw detection image between.   The inspection processing apparatus according to claim 5, further comprising a phase contraction processing unit that contracts an entire phase length of the X-ray flaw detection images connected by the terminal connection processing unit to an entire phase length of the ultrasonic inspection image.

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