WO2021003907A1 - 一种主动激励的焊缝缺陷红外智能检测系统及方法 - Google Patents
一种主动激励的焊缝缺陷红外智能检测系统及方法 Download PDFInfo
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- weld
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N25/00—Investigating or analyzing materials by the use of thermal means
- G01N25/72—Investigating presence of flaws
Definitions
- the present application relates to the technical field of non-destructive testing of weld defects, and specifically, to an active excitation infrared intelligent detection system and method for weld defects.
- Weld defects refer to the defects formed during the welding process of the welded joints, which mainly include pores, slag inclusions, incomplete penetration, incomplete fusion, etc. Because metal materials are affected by factors such as materials and welding processes during the welding process, it is difficult Avoid weld defects, and weld defects will reduce the cross-sectional area of the weld, produce stress concentration, reduce the structural load-bearing capacity and fatigue strength, and bury hidden dangers for structural safety. Therefore, efficient and accurate detection of weld defects is the key to ensuring welding quality.
- non-destructive testing technologies for weld defects mainly include ultrasonic testing, radiographic testing, magnetic particle testing, penetrant testing, etc.; among them, ultrasonic testing uses the properties of attenuation when ultrasonic waves propagate in the medium and reflection on cross-sections. Detecting internal defects has a wide range of applications, but it is not high for some small cracks and unfused reflected waves, which may easily lead to missed inspections; radiographic inspection uses various rays to pass through the inspected workpiece. Due to structural discontinuities, The rays produce attenuation, absorption or scattering, and then form an image on the recording medium. Real-time imaging can be used to intuitively measure the weld defects of thin-walled workpieces.
- radiographic inspection is harmful to the human body and expensive.
- the protection cost is high; magnetic particle detection uses ferromagnetic After the material is magnetized, due to the existence of discontinuities, the magnetic lines of force on the surface of the workpiece will be locally distorted. The application of magnetic powder on the surface of the workpiece will form visible magnetic marks, thereby showing the position, size, shape and severity of the discontinuity.
- magnetic powder Detection is not suitable for non-ferromagnetic materials, nor can it detect defects deep inside the surface; penetration detection means that after penetrating liquid is applied to the surface of the part, the penetrating liquid can penetrate into the surface under the action of capillary phenomenon for a certain period of time In the open defect, after removing the excess penetrant and drying, the developer is applied on the surface of the workpiece. Under the action of a certain light source, the traces of the penetrating liquid at the defect are displayed, thereby detecting the morphology and distribution of the defect. The sensitivity of penetrant detection is low, the surface finish requirements are high, and the depth cannot be detected.
- the above-mentioned welding seam detection technology has limitations and cannot effectively detect all welding seam defects; in addition, the welding seam detection method in the prior art requires manual operation and interpretation, which increases the subjectivity of welding seam defect detection; and the detection process It is mostly intermittent detection, low detection efficiency, and cumbersome detection process.
- the technical problem to be solved by this application is to provide an active-active infrared intelligent detection system and method for weld defects, which is suitable for a variety of weld defects.
- an actively excited infrared intelligent detection system for weld defects which includes a laser pulser, an infrared thermal imager, a host computer and a signal generator;
- the laser pulser is connected to the signal generator, and is used to emit laser pulses to thermally excite the weld area;
- the signal generator is connected to the host computer and is used to control the output characteristics of the laser pulser;
- the infrared thermal imager is connected to the host computer, and is used to obtain an infrared thermal image of the weld area after thermal excitation, and transmit the infrared thermal image to the host computer;
- the host computer controls the signal waveform characteristics of the signal generator and processes the infrared thermal image to identify weld defects.
- the system further includes a code spraying and marking device, which is connected to the upper computer, and when the upper computer recognizes a weld defect, the code spraying and marking device automatically marks the location of the weld defect .
- the system also includes a driving device, the laser pulser, infrared thermal imager, host computer and signal generator or the laser pulser, infrared thermal imager, host computer, signal generator, and coding marking
- the device is arranged on the driving device, and the driving device further includes a chassis, wheels, a driving member, a steering controller and a box body for driving the movement and steering of the detection system.
- the chassis is a reinforced steel plate with a hole in the middle, the box is placed on the upper part of the hole, and the wheels are supported at the four corners of the chassis;
- the driving part is placed at the rear of the chassis and consists of a motor, a transmission shaft and a gear, and the gear and transmission shaft are driven by a chain Transmit power and drive the overall structure forward through the rear wheel drive;
- the steering controller is arranged on both sides of the front wheel, and the front wheel steering is controlled by the servo motor and the eccentric pull rod;
- the box body is also provided with a high-definition camera, the high-definition camera is connected with the upper computer, and is used to implement the image of the conveying welding seam; the steering controller is connected with the upper computer, and the welding is obtained according to the high-definition camera.
- the seam direction picture automatically adjust the travel path of the detection device to ensure that the detection device is always located directly above the weld.
- the coding and marking device further includes: a spray head, a hydraulic pump and fluorescent paint;
- the nozzle is connected with a host computer, and the host computer performs real-time image processing on the infrared thermal image.
- the host computer controls the nozzle to spray fluorescent paint to mark the location of the weld defect .
- the driving device is connected with an adjusting device
- the mechanical adjusting device further includes: a lifting device, a transverse connecting rod and an angle rotating device;
- angle rotation devices There are three angle rotation devices, all of which are fixed on the transverse connecting rod, the laser pulser, the infrared thermal imager and the code spray marking device are fixed on the angle rotation device, and the angle rotation device is used for Adjusting the angles of the laser pulser, the infrared thermal imager and the coding and marking device;
- Both ends of the transverse connecting rod are fixed on the lifting device, and the height of the transverse connecting rod is adjusted by the movement of the lifting device;
- Both the lifting device and the angle rotating device are connected with the upper computer.
- the present application provides an actively excited infrared intelligent detection method for weld defects, which includes the following steps:
- the upper computer controls the driving device to move forward along the weld.
- the upper computer controls the steering controller to adjust the travel path of the detection device according to the weld direction image transmitted by the high-definition camera.
- the upper computer system controls the signal generator, and the signal generator controls the laser pulser. Transmit laser pulses to thermally excite the weld area, and the upper computer system signal controls the infrared thermal imager to obtain the infrared thermal image and transmit it to the upper computer system;
- the host computer system performs image processing on the infrared thermal image, real-time identification of weld defects, and signal control of the coding and marking device to automatically mark the location of weld defects.
- this application uses an active excitation laser pulser to emit laser pulses to thermally excite the weld area
- an infrared thermal imager acquires an infrared thermal image
- the upper computer system performs image processing on the infrared thermal image for real-time identification
- the weld defect detection system of the present application can not only identify the surface of the weld, but also the interior of the weld, regardless of whether it is ferromagnetic or non-ferromagnetic, and is suitable for Various weld defects;
- this application is safer and more reliable than other detection technologies, and workers do not need to directly touch related equipment during detection, which improves detection safety.
- this application can automatically follow the position of the welding seam, adjust the running direction and path of the system, and is completely automatically operated by the equipment, which reduces the tedious work flow and reduces the workload of the inspectors.
- Figure 1 is a schematic structural diagram of an infrared intelligent detection system for weld defects in an embodiment of the application
- FIG. 2 is a schematic diagram of the structure of the driving device in an embodiment of the application.
- Fig. 3 is a schematic structural diagram of an adjusting device in an embodiment of the application.
- Figure 4 is a schematic structural diagram of a steering controller in an embodiment of the application.
- connection should be interpreted broadly unless otherwise clearly specified and limited.
- it can be a fixed connection or a detachable connection. , Or one-piece connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, and it can be the internal communication between two components.
- connection should be interpreted broadly unless otherwise clearly specified and limited.
- it can be a fixed connection or a detachable connection. , Or one-piece connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, and it can be the internal communication between two components.
- the active-inspired infrared intelligent detection system for weld defects includes: a laser pulser 1, an infrared thermal imager 2, a host computer 3, and a signal generator 6;
- the laser pulser 1 is connected with the signal generator 6 and is used to emit laser pulses to thermally excite the weld area;
- the signal generator 6 is connected with the host computer 3 for controlling the output characteristics of the laser pulse meter 1;
- the infrared thermal imager 2 is connected with the host computer 3 to obtain the infrared thermal image of the weld area after thermal excitation, and transmit the infrared thermal image to the host computer 3;
- the upper computer 3 controls the signal waveform characteristics of the signal generator 6 and processes the infrared thermal image to identify weld defects.
- the signal generator 6 controls the laser pulser 1 to emit laser pulses to the weld position to thermally excite the weld area, and the infrared thermal imager 2 acquires thermal images of the weld position and transmits the signal to the upper position Computer 3, through the host computer 3 to process the image, identify weld defects, compared with the prior art, realizes the intelligent detection of welds, and reasonably set the amplitude and frequency of the signal generator 6, which can be realized For non-destructive testing of metals, alloys, plastics, ceramics, and composite materials, thermal imaging images can observe both the surface and internal conditions, thus realizing the detection of a variety of weld defects.
- the system also includes a code spraying and marking device 4, which is connected to the upper computer 3.
- the spraying code marks Device 4 automatically identifies the location of weld defects.
- the coding and marking device 4 further includes: a spray head, a hydraulic pump, and fluorescent paint; the spray head is connected to the upper computer 3, and the upper computer 3 performs real-time image processing on the infrared thermal image.
- the upper computer 3 controls The nozzle sprays fluorescent paint to mark the defect location of the weld.
- Fluorescent paint is colored paint, which can be yellow, green, red, blue and other colors that can be distinguished from welding materials.
- the arrangement of the coding and marking device 4 reduces manual labor in the prior art, and does not cause missed detection or missing labels due to human reasons, thereby improving the accuracy of detection.
- the system also includes a driving device, laser pulser 1, infrared thermal imager 2, host computer 3, signal generator 6, high-definition camera 17, and jet
- the code marking device 4 is arranged on the driving device, and the driving device further includes a driving member for driving the driving device to move.
- the setting of the driving device allows the entire system to move along the weld seam, and detect while moving, while the code spraying and marking device 4 performs labeling operations.
- the driving device moves from the weld area, it leaves a mark on the defect location of the weld.
- there is no need to manually hold the relevant instrument and there is no need to manually judge the weld position, reducing the tedious work process , Which reduces the workload of inspectors and improves the work efficiency of weld inspection.
- the driving device further includes an adjusting device, and the adjusting device further includes: a lifting device 10, a transverse connecting rod 11 and an angle rotating device 12;
- angle rotation devices 12 which are all fixed on the transverse connecting rod 11.
- the laser pulser 1, the infrared thermal imager 2 and the code spray marking device 4 are fixed on the angle rotation device 12, and the angle rotation device 12 is used to adjust the laser pulse
- Both ends of the horizontal connecting rod 11 are fixed on the lifting device 10, and the height of the horizontal connecting rod 11 is adjusted by the movement of the lifting device 10;
- the angle rotation device 12 can be a servo motor or a rotating cylinder.
- the laser pulser 1, the infrared thermal imager 2 and the coding and marking device 4 are fixed by a suitable workpiece, and then the angle is adjusted.
- the lifting device 10 may be a lifting cylinder, and the height of the transverse connecting rod 11 can be adjusted by the lifting of the lifting cylinder, thereby realizing the detection of welds of different heights and different angles, and improving the applicability of weld detection.
- the upper computer 3 adjusts the angle of the rotation device 12 for each angle, so as to adapt to welds of various structures.
- the driving device of the present application includes a beam 19, a chassis 13, a motor 8, a transmission shaft 14, a gear 9, a non-steer wheel 18, a steering wheel 15, a box body 5 and Steering controller 16;
- the non-steer wheel 18 is fixed at the rear end of the chassis, the center of the two wheels is connected by the drive shaft 14, the steering wheel 15 is fixed at the front end of the chassis, the box body 5 is fixed on the chassis 13, and the gear 9 is connected to the drive shaft 14 through a chain drive, and through a motor 8.
- the rotation drives the gear to rotate, drives the chain to drive, and drives the non-steer wheels to rotate.
- the driving device is arranged on the upper part of the weld and moves forward along the weld.
- the chassis 13 has a hole in the range of the box body 5, and a base 7 is provided on the inner side for supporting the lifting device 10.
- the box 5 is also provided with a high-definition camera 17, which is connected to the upper computer 3.
- the high-definition camera 17 can transmit the image of the welding seam to the upper computer 3 in real time.
- the upper computer 3 according to the weld
- the automatic control steering controller 16 adjusts the traveling direction of the detection device so that the detection device is always directly above the weld seam, which is suitable for automatic intelligent detection of various weld seam directions.
- the steering controller 16 is connected to the host computer 3, is installed at the steering wheel 15, and fixed on the cross beam 19 at the front of the chassis, and is composed of a servo motor and an eccentric pull rod.
- the host computer 3 controls the servo motor to drive the eccentric pull rod according to the welding seam direction image transmitted by the high-definition camera 17, adjusts the deflection angle of the steering wheel, so that the detection device advances along the welding seam direction.
- this application firstly realizes the intelligent detection of weld seams, can carry out uninterrupted automatic detection of weld seams of different directions and automatic coding and marking of defect positions; second, it improves defects Recognition accuracy, this application uses the active excitation laser pulse meter to apply laser excitation to the weld, combined with infrared thermal imaging technology, which can be applied to weld detection of various welding forms; third, the work flow is reduced, and this application is completely equipment Automatic operation reduces the cumbersome work process and reduces the workload of inspectors; fourth is to improve the accuracy of defect marking, which can realize accurate marking of defect positions, and provides strong support for the later repair of welds; fifth is to improve Detection safety: Compared with other detection technologies, this application is safer and more reliable, and workers do not need to directly touch related equipment during detection; this application has the characteristics of energy saving and environmental protection, high efficiency and accuracy, intelligent continuous, safe and reliable.
- the upper computer controls the driving device to move forward along the weld.
- the upper computer controls the steering controller to adjust the travel path of the detection device according to the weld direction image transmitted by the high-definition camera.
- the upper computer system controls the signal generator, and the signal generator controls the laser pulser. Transmit laser pulses to thermally excite the weld area, and the upper computer system signal controls the infrared thermal imager to obtain the infrared thermal image and transmit it to the upper computer system;
- the host computer system performs image processing on the infrared thermal image, real-time identification of weld defects, and signal control of the coding and marking device to automatically mark the location of weld defects.
- the above-mentioned embodiment is composed of driving device, adjusting device, high-definition camera, steering controller, host computer system, signal generator, laser pulser, infrared thermal imager and coding and marking device for infrared intelligent detection of welding defects
- the system can detect different types of welds.
- the infrared intelligent detection system and method for weld defects uses the high-definition camera to obtain the weld direction, uses the steering controller to automatically adjust the travel path of the detection device, and uses the active excitation laser pulse meter to emit laser pulse pairs.
- the weld area is thermally excited, the infrared thermal imager obtains the infrared thermal image, and the host computer system processes the infrared thermal image to identify weld defects in real time, and control the coding and marking device to automatically mark the location of weld defects.
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Abstract
本申请涉及焊缝缺陷无损检测技术领域，尤其涉及一种主动激励的焊缝缺陷红外智能检测系统及方法。由驱动装置、调节装置、高清摄像头、上位机、信号发生器、激光脉冲仪、红外热像仪和喷码标记装置组成的用于焊接缺陷红外智能检测系统，能够对不同种类焊缝缺陷进行检测，焊缝缺陷的红外智能检测系统通过高清摄像头获取焊缝走向，采用激光脉冲仪发射主动激光脉冲对焊缝区域进行热激励，红外热像仪获取红外热像图，上位机系统对红外热像图进行图像处理，实时辨识焊缝缺陷，控制喷码标记装置进行焊缝缺陷位置的自动标识。
Description
本申请要求于2019年7月9日提交至中国国家知识产权局、申请号为201910616290.5、发明名称为“一种主动激励的焊缝缺陷红外智能检测系统及方法”的专利申请的优先权，其全部内容通过引用结合在本公开中。
本申请涉及焊缝缺陷无损检测技术领域，具体而言，涉及一种主动激励的焊缝缺陷红外智能检测系统及方法。
焊缝缺陷是指焊接接头部位在焊接过程中形成的缺陷，主要包括气孔、夹渣、未焊透、未熔合等，由于金属材料在焊接过程中受材料和焊接工艺等因素的影响，很难避免焊缝缺陷的出现，而焊缝缺陷会导致减少焊缝截面面积，产生应力集中，降低了结构承载能力和疲劳强度，为结构安全埋下了隐患。因此，高效、准确地检测焊缝缺陷是保证焊接质量的关键。
现有技术中，焊缝缺陷的无损检测技术主要包括超声波检测、射线探伤、磁粉检测和渗透检测等；其中，超声波检测是利用超声波在介质中传播时产生衰减、遇到截面产生反射的性质来检测内部缺陷，其应用范围广，但是对一些细小裂纹和未熔合的反射波并不高，容易导致漏检；射线探伤是利用各种射线穿过被检测工件，由于结构上的不连续，使射线产生衰减吸收或散射，然后在记录介质上形成影像，可以通过实时成像，直观的测量薄壁工件的焊缝缺陷，然而射线探伤对人体有害且价格昂贵防护成本高；磁粉检测是利用铁磁材料被磁化后，由于不连续性的存在，会使工件表面的磁力线发生局部畸变，在工件表面施加磁粉会形成可见磁痕，从而显示不连续性的位置、大小、形状和严重程度，然而磁粉检测不适用于非铁磁性材料，也不能检测内部距离表面较深的缺陷；渗透检测是指在零件表面施加渗透液后，在毛细现象作用下，经过一定时间的渗透，渗透液可以渗透到表面开口缺陷中，经去除多余的渗透液和干燥后，再在工件表面施加显像剂，在一定的光源作用下，缺陷处的渗透液痕迹被显示，从而检测出缺陷的形貌及分布状态，而渗透检测的灵敏度低，对表面光洁度要求较高，也无法探测深度。
上述焊缝检测技术均存在局限性，无法对所有焊缝缺陷进行有效检测；此外，现 有技术中的焊缝检测方法需要人为操作和判读，增加了焊缝缺陷检测的主观性；而且检测过程多为断续检测，检测效率低，检测流程繁琐。
进行鉴于上述问题的存在，本设计人基于从事此类产品工程应用多年丰富的实务经验及专业知识，并配合学理的运用，积极加以研究创新，以期创设一种焊缝缺陷红外智能检测系统及方法，使其更具有实用性。
发明内容
本申请所要解决的技术问题是:提供一种主动激励的焊缝缺陷红外智能检测系统及方法，适用于多种焊缝缺陷。
为了达到上述目的，本申请一方面提供一种主动激励的焊缝缺陷红外智能检测系统，该系统包括：激光脉冲仪、红外热像仪、上位机和信号发生器；
所述激光脉冲仪与所述信号发生器连接，用于发射激光脉冲对焊缝区域进行热激励；
所述信号发生器与所述上位机连接，用于控制所述激光脉冲仪的输出特性；
所述红外热像仪与所述上位机连接，用于获取经热激励后焊缝区域的红外热像图，并将红外热像图传输至所述上位机；
所述上位机控制所述信号发生器的信号波形特征并对所述红外热图像进行处理，辨识焊缝缺陷。
可选地，该系统还包括喷码标记装置，所述喷码标记装置与所述上位机连接，当所述上位机识别到焊缝缺陷时，所述喷码标记装置自动标识焊缝缺陷位置。
可选地，该系统还包括驱动装置，所述激光脉冲仪、红外热像仪、上位机和信号发生器或所述激光脉冲仪、红外热像仪、上位机、信号发生器和喷码标记装置设置在所述驱动装置上，驱动装置还包括底盘、轮子、驱动件、转向控制器和箱体，用于驱动检测系统移动和转向。
所述底盘为加强钢板，中部开孔，箱体置于开孔位置上部，轮子支撑在底盘四角位置；驱动件置于底盘尾部，由电机、传动轴和齿轮组成，齿轮与传动轴由链传动传输动力，通过后轮驱动带动整体结构前行；转向控制器布置在前轮两侧，通过伺服电机和偏心拉杆控制前轮转向；
所述箱体上还设置有高清摄像头，所述高清摄像头与所述上位机连接，用于实施输送焊缝走向的图像；所述转向控制器与所述上位机连接，根据高清摄像头获取的焊 缝走向图片，自动调整检测装置的行进路径，保证检测装置时刻位于焊缝正上方。
可选地，所述喷码标记装置进一步包括：喷头、液压泵和荧光漆；
所述喷头与上位机连接，所述上位机对红外热图像进行实时图像处理，当识别到焊缝缺陷时，所述上位机控制所述喷头喷出荧光漆，对焊缝缺陷位置处进行标记。
可选地，所述驱动装置连接有调节装置，所述机械调节装置进一步包括：升降装置、横向连接杆和角度旋转装置；
所述角度旋转装置设置有三个，均固定于所述横向连接杆上，所述激光脉冲仪、红外热像仪和喷码标记装置固定于所述角度旋转装置上，所述角度旋转装置用于调整所述激光脉冲仪、红外热像仪和喷码标记装置的角度；
所述横向连接杆两端固定在所述升降装置上，通过所述升降装置的移动，调节所述横向连接杆的高度；
所述升降装置和所述角度旋转装置均与所述上位机连接。
本申请另一方面提供主动激励的焊缝缺陷红外智能检测方法，包括以下步骤：
设置焊缝缺陷红外智能检测系统于焊缝正上方，使之朝向焊缝长度方向移动；
通过机械调节装置调节激光脉冲仪、红外热像仪和喷码标记装置距离焊缝的高度以及角度，使三者处于最佳工作位置；
启动驱动装置、高清摄像头、上位机、信号发生器、激光脉冲仪、红外热像仪和喷码标记装置；
上位机控制驱动装置沿着焊缝前行，上位机根据高清摄像头传输的焊缝走向图像，控制转向控制器调整检测装置的行进路径，上位机系统控制信号发生器，信号发生器控制激光脉冲仪发射激光脉冲对焊缝区域进行热激励，上位机系统信号控制红外热像仪获取红外热像图并传输至上位机系统；
上位机系统对红外热像图进行图像处理，实时辨识焊缝缺陷，信号控制喷码标记装置进行焊缝缺陷位置的自动标识。
本申请的有益效果为：本申请采用主动激励激光脉冲仪发射激光脉冲对焊缝区域进行热激励，红外热像仪获取红外热像图，上位机系统对红外热像图进行图像处理，实时辨识焊缝缺陷，与现有技术相比，本申请的焊缝缺陷检测系统不仅能对焊缝表面进行识别、还可以对焊缝内部进行识别，不论铁磁性或非铁磁性均可识别，适用于多种焊缝缺陷；
而且，通过对焊缝进行不间断自动检测并对缺陷位置进行自动喷码标记，实现了对焊缝的智能化检测，提高了缺陷识别准确性。
此外，本申请相对其他检测技术更加安全可靠，检测时工作人员无需直接接触相关设备，提高了检测安全性。
最后，本申请能够自动追随焊缝位置，调整系统运行方向和路径，完全由设备自动操作，减少了繁琐的工作流程，降低了检测人员工作量。
为了更清楚地说明本申请实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本申请中记载的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本申请实施例中焊缝缺陷红外智能检测系统的结构示意图；
图2为本申请实施例中驱动装置的结构示意图；
图3为本申请实施例中调节装置的结构示意图。
图4为本申请实施例中转向控制器的结构示意图。
附图标记：1-激光脉冲仪、2-红外热像仪、3-上位机、4-喷码标记装置、5-箱体、6-信号发生器、7-底座、8-电机、9-齿轮、10-升降装置、11-横向连接杆、12-角度旋转装置、13-底盘、14-传动轴、15-转向轮、16-转向控制器、17-高清摄像头、18-非转向轮、19-横梁。
下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本申请一部分实施例，而不是全部的实施例。
在本申请的描述中，需要说明的是，属于“中心”、“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或者位置关系为基于附图所示的方位或者位置关系，仅是为了便于描述本申请和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本申请的限制。
在本申请的描述中，需要说明的是，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”应做广义理解，例如可以是固定连接，也可以是可拆卸连接，或一体式连 接；可以是机械连接，也可以是电连接；可以是直接连接，也可以是通过中间媒介间接连接，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以具体情况理解上述术语在本申请中的具体含义。
如图1所示的主动激励的焊缝缺陷红外智能检测系统，该系统包括：激光脉冲仪1、红外热像仪2、上位机3和信号发生器6；
激光脉冲仪1与信号发生器6连接，用于发射激光脉冲对焊缝区域进行热激励；
信号发生器6与上位机3连接，用于控制激光脉冲仪1的输出特性；
红外热像仪2与上位机3连接，用于获取经热激励后焊缝区域的红外热像图，并将红外热像图传输至上位机3；
上位机3控制信号发生器6的信号波形特征并对红外热图像进行处理，辨识焊缝缺陷。
在上述实施例中，信号发生器6控制激光脉冲仪1对焊缝位置发射激光脉冲对焊缝区域进行热激励，红外热像仪2对焊缝位置进行热图像获取，并将信号传输至上位机3，通过上位机3对图像进行处理，辨识焊缝缺陷，与现有技术相比，实现了对焊缝的智能化检测，且合理设置信号发生器6的振幅、频率等特性，可以实现对金属、合金、塑料、陶瓷以及复合材料的无损检测，由于热成像图既可以观测到表面，又可以观察到内部情况，因此实现了对多种焊缝缺陷的检测。
为了提高焊缝缺陷检测的准确性，继续参照图1，该系统还包括喷码标记装置4，喷码标记装置4与上位机3连接，当上位机3识别到焊缝缺陷时，喷码标记装置4自动标识焊缝缺陷位置。
具体的，喷码标记装置4进一步包括：喷头、液压泵和荧光漆；喷头与上位机3连接，上位机3对红外热图像进行实时图像处理，当识别到焊缝缺陷时，上位机3控制喷头喷出荧光漆，对焊缝缺陷位置处进行标记。荧光漆为有色漆，可以为黄色、绿色、红色、蓝色等其他能与焊接材料区分开的颜色。
在上述实施例中，通过喷码标记装置4的设置，减轻了现有技术中人工的劳动，而且不会因为人的原因导致漏检、漏标的情况发生，提高了检测的准确性。
为了提高焊缝检测的效率，如图1和图2所示，该系统还包括驱动装置，激光脉冲仪1、红外热像仪2、上位机3、信号发生器6、高清摄像头17、和喷码标记装置4设置在驱动装置上，驱动装置还包括驱动件，用于驱动驱动装置移动。在上述实施例中，驱动装置的设置，使得整个系统可以沿焊缝移动，边移动边检测，同时喷码标记 装置4进行标号作业。当驱动装置从焊缝区域移动过后，即留下了焊缝缺陷位置处的标记，与现有技术相比，无需人工手持相关仪器，也无需人工去判断焊缝位置，减少了繁琐的工作流程，降低了检测人员工作量，提高了焊缝检测的工作效率。
进一步的，为了提高该系统的适用性，如图3所示，驱动装置还包括调节装置，调节装置进一步包括：升降装置10、横向连接杆11和角度旋转装置12；
角度旋转装置12设置有三个，均固定于横向连接杆11上，激光脉冲仪1、红外热像仪2和喷码标记装置4固定于角度旋转装置12上，角度旋转装置12用于调整激光脉冲仪1、红外热像仪2和喷码标记装置4的角度；
横向连接杆11两端固定在升降装置10上，通过升降装置10的移动，调节横向连接杆11的高度；
升降装置10和角度旋转装置12均与上位机3连接。这里需要指出的是，角度旋转装置12可以是伺服电机，也可以是旋转气缸，通过相适应的工件将激光脉冲仪1、红外热像仪2和喷码标记装置4进行固定，然后调整角度。而升降装置10可以是升降气缸，通过升降气缸的升降实现对横向连接杆11高度的调节，从而实现对不同高度，不同角度焊缝的检测，提高了焊缝检测的适用性。并且通过上位机3分别调整各角度旋转装置12的角度，从而适应各种结构的焊缝。
作为上述实施例的优选，如图2所示，本申请的驱动装置包括一根横梁19、底盘13、电机8、传动轴14、齿轮9、非转向轮18、转向轮15、箱体5和转向控制器16；
非转向轮18固定在底盘后端，两轮中心通过传动轴14连接，转向轮15固定在底盘前端，箱体5固定在底盘13上，齿轮9通过链条传动与传动轴14连接，通过电机8旋转带动齿轮旋转，带动链条传动，带动非转向轮旋转，驱动装置设置在焊缝上部，沿着焊缝前行。其中底盘13在箱体5范围内开孔，内侧设置有底座7，用于支撑升降装置10。
请参照图1和图2，箱体5上还设置有高清摄像头17，高清摄像头17与上位机3连接，高清摄像头17可实时传输焊缝的走向图像至上位机3，上位机3根据焊缝的走向，自动调控转向控制器16对检测装置的行进方向进行调整，使得检测装置时刻处于焊缝的正上方，可适用于各类焊缝走向的全自动智能检测。
如图4，转向控制器16与上位机3连接，安装于转向轮15处，固定于底盘前部的横梁19上，由伺服电机和偏心拉杆组成。上位机3根据高清摄像头17传输的焊缝走向图像，控制伺服电机带动偏心拉杆，调整转向轮偏转角度，使检测装置沿着焊缝走向前进。
本申请相比于现有的检测技术，一是实现了对焊缝的智能化检测，可对不同走向的焊缝进行不间断自动检测并对缺陷位置进行自动喷码标记；二是提高了缺陷识别准确性，本申请通过主动激励激光脉冲仪对焊缝施加激光激励与红外热像技术相结合，可适用于各种焊接形式的焊缝检测；三是减少了工作流程，本申请完全由设备自动操作，减少了繁琐的工作流程，降低了检测人员工作量；四是提高了缺陷标记精确度，可实现对缺陷位置的精确标记，为后期焊缝的返修提供了有力支持；五是提高了检测安全性，本申请相对其他检测技术更加安全可靠，检测时工作人员无需直接接触相关设备；本申请具有节能环保、高效准确、智能连续、安全可靠的特点。
本申请实施例的主动激励的焊缝缺陷红外智能检测方法，包括以下步骤：
设置焊缝缺陷红外智能检测系统于焊缝正上方，使之朝向焊缝长度方向移动；
调节激光脉冲仪、红外热像仪和喷码标记装置距离焊缝的高度以及角度，使三者处于最佳工作位置；
启动驱动装置、高清摄像头、转向控制器、上位机、信号发生器、激光脉冲仪、红外热像仪和喷码标记装置；
上位机控制驱动装置沿着焊缝前行，上位机根据高清摄像头传输的焊缝走向图像，控制转向控制器调整检测装置的行进路径，上位机系统控制信号发生器，信号发生器控制激光脉冲仪发射激光脉冲对焊缝区域进行热激励，上位机系统信号控制红外热像仪获取红外热像图并传输至上位机系统；
上位机系统对红外热像图进行图像处理，实时辨识焊缝缺陷，信号控制喷码标记装置进行焊缝缺陷位置的自动标识。
在上述实施例中，由驱动装置、调节装置、高清摄像头、转向控制器、上位机系统、信号发生器、激光脉冲仪、红外热像仪和喷码标记装置组成的用于焊接缺陷红外智能检测系统，能够对不同种类焊缝进行检测，焊缝缺陷的红外智能检测系统及方法通过高清摄像头获取焊缝走向，利用转向控制器自动调整检测装置行进路径，采用主动激励激光脉冲仪发射激光脉冲对焊缝区域进行热激励，红外热像仪获取红外热像图，上位机系统对红外热像图进行图像处理，实时辨识焊缝缺陷，控制喷码标记装置进行焊缝缺陷位置的自动标识。
本行业的技术人员应该了解，本申请不受上述实施例的限制，上述实施例和说明书中描述的只是说明本申请的原理，在不脱离本申请精神和范围的前提下，本申请还会有各种变化和改进，这些变化和改进都落入要求保护的本申请范围内。本申请要求保护范围由所附的权利要求书及其等效物界定。
Claims (6)
- 一种主动激励的焊缝缺陷红外智能检测系统，包括：激光脉冲仪、红外热像仪、上位机和信号发生器；所述激光脉冲仪与所述信号发生器连接，用于发射激光脉冲对焊缝区域进行热激励；所述信号发生器与所述上位机连接，用于控制所述激光脉冲仪的输出特性；所述红外热像仪与所述上位机连接，用于获取经热激励后焊缝区域的红外热像图，并将红外热像图传输至所述上位机；所述上位机控制所述信号发生器的信号波形特征并对所述红外热图像进行处理，辨识焊缝缺陷。
- 根据权利要求1所述的主动激励的焊缝缺陷红外智能检测系统，其中，该系统还包括喷码标记装置，所述喷码标记装置与所述上位机连接，当所述上位机识别到焊缝缺陷时，所述喷码标记装置自动标识焊缝缺陷位置。
- 根据权利要求1或2所述的主动激励的焊缝缺陷红外智能检测系统，其中，该系统还包括驱动装置，所述激光脉冲仪、红外热像仪、上位机和信号发生器或所述激光脉冲仪、红外热像仪、上位机、信号发生器和喷码标记装置设置在所述驱动装置上，驱动装置还包括底盘、轮子、驱动件、转向控制器和箱体，用于驱动检测系统移动和转向。所述底盘为加强钢板，中部开孔，箱体置于开孔位置上部，轮子支撑在底盘四角位置；驱动件置于底盘尾部，由电机、传动轴和齿轮组成，齿轮与传动轴由链传动传输动力，通过后轮驱动带动整体结构前行；转向控制器布置在前轮两侧，通过伺服电机和偏心拉杆控制前轮转向；所述箱体上还设置有高清摄像头，所述高清摄像头与所述上位机连接，用于实施输送焊缝走向的图像；所述转向控制器与所述上位机连接，根据高清摄像头获取的焊缝走向图片，自动调整检测装置的行进路径，保证检测装置时刻位于焊缝正上方。
- 根据权利要求2所述的主动激励的焊缝缺陷红外智能检测系统，其中，所述喷码标记装置进一步包括：喷头、液压泵和荧光漆；所述喷头与上位机连接，所述上位机对红外热图像进行实时图像处理，当识别到焊缝缺陷时，所述上位机控制所述喷头喷出荧光漆，对焊缝缺陷位置处进行标记。
- 根据权利要求1所述的主动激励的焊缝缺陷红外智能检测系统，其中，所述该系统还包括调节装置，所述调节装置进一步包括：升降装置、横向连接杆和角度旋转装置；所述角度旋转装置设置有三个，均固定于所述横向连接杆上，所述激光脉冲仪、红外热像仪和喷码标记装置固定于所述角度旋转装置上，所述角度旋转装置用于调整所述激光脉冲仪、红外热像仪和喷码标记装置的角度；所述横向连接杆两端固定在所述升降装置上，通过所述升降装置的移动，调节所述横向连接杆的高度；所述升降装置和所述角度旋转装置均与所述上位机连接。
- 一种主动激励的焊缝缺陷红外智能检测方法，包括以下步骤：设置焊缝缺陷红外智能检测系统于焊缝正上方，使之朝向焊缝长度方向移动；通过调节装置调节激光脉冲仪、红外热像仪和喷码标记装置距离焊缝的高度以及角度，使三者处于最佳工作位置；启动驱动装置、高清摄像头、上位机、信号发生器、激光脉冲仪、红外热像仪和喷码标记装置；上位机控制驱动装置沿着焊缝前行，上位机系统控制信号发生器，信号发生器控制激光脉冲仪发射激光脉冲对焊缝区域进行热激励，上位机系统信号控制红外热像仪获取红外热像图并传输至上位机系统；上位机系统对红外热像图进行图像处理，实时辨识焊缝缺陷，信号控制喷码标记装置进行焊缝缺陷位置的自动标识。
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