Steel pipe welding seam flaw detection system and method

Abstract

The invention relates to a steel pipe weld flaw detection system and method, and the system comprises a laser tracking module which is used for carrying out the data collection of a walking process of a first group of detection frames of a flaw detection vehicle on a steel pipe according to a sampling walking gap parameter set on a communication module, obtaining offset data of the first group of probe frames at different positions when the first group of probe frames operate in the transverse axis and longitudinal coordinate directions of the steel pipe; the industrial personal computer is used for receiving the deviation data and the current positions of other groups of detection frames of the flaw detection car in the transverse axis direction, setting a walking distance in the transverse axis direction, and screening out target deviation data from the deviation data according to the walking distance in the transverse axis direction and the current positions; the controller is used for controlling the operation of the corresponding probe frame according to the received target offset data so as to carry out weld flaw detection; the laser tracking module controls the first group of probe frames to walk and collects offset data, the industrial personal computer cooperates with the controller to realize independent tracking of the multiple probe frames, and the problem that a traditional synchronous tracking mode is difficult to adapt to differential control of the multiple probe frames is solved.

Description

Technical Field

[0001] This invention relates to the field of weld seam tracking technology, and in particular to a steel pipe weld seam flaw detection system and method. Background Technology

[0002] In the steel pipe manufacturing process, weld quality inspection is a crucial step. Traditional weld tracking methods mainly employ a simple one-to-one control approach, where a laser tracking system controls a single servo motor, which in turn drives all probes to synchronously track the weld.

[0003] Currently, ultrasonic automatic flaw detection is a very economical and effective means of inspecting and controlling the quality of welded pipe welds. However, with the increase in the demand for steel pipes and the increase in the requirements of flaw detection processes and procedures, the number and length of the entire flaw detection vehicle will also increase. This makes it impossible to detect and process according to different situations when multiple probes are detected separately, resulting in problems such as low accuracy and poor adaptability.

[0004] Therefore, there is an urgent need to propose a steel pipe weld flaw detection system and method to solve the technical problems of low accuracy and poor adaptability in the existing technology, which are caused by the increasing demand for steel pipes and the increasing requirements of flaw detection processes and procedures, which also lead to an increase in the number and length of the entire flaw detection vehicle probes. This results in the inability to detect and process according to different situations when multiple probes are detected separately. Summary of the Invention

[0005] In view of this, it is necessary to provide a steel pipe weld flaw detection system and method to solve the technical problems of low accuracy and poor adaptability in the existing technology, which arises from the increasing demand for steel pipes and the increasing requirements of flaw detection processes and procedures, leading to an increase in the number and length of the entire flaw detection vehicle's probes. This makes it impossible to perform detection and processing according to different situations when detecting multiple probes separately. To solve the above problems, in a first aspect, the present invention provides a steel pipe weld flaw detection system, the system comprising a laser tracking module, a communication module, a flaw detection vehicle, a controller, and an industrial control computer; The laser tracking module is used to collect data on the walking process of the first set of probes of the flaw detection vehicle on the steel pipe according to the sampling walking gap parameter set on the communication module, to obtain the offset data of the first set of probes at different positions when running in the horizontal and vertical coordinate directions of the steel pipe, and to store the offset data corresponding to each position to the industrial control computer. The industrial control computer is used to receive the offset data and the current position of other groups of probes of the flaw detection vehicle in the horizontal axis direction, set the horizontal axis direction travel distance, filter the target offset data in the offset data according to the horizontal axis direction travel distance and the current position, and send the target offset data to the controller. The controller is used to control the operation of the corresponding probe according to the received target offset data, thereby performing weld flaw detection.

[0006] In one possible implementation, the laser tracking module is further configured to combine multiple sets of probes on the flaw detection vehicle according to a preset flaw detection process to obtain a combined probe to be activated; the combined probe to be activated includes a first set of probes and at least one other set of probes. The laser tracking module is also used to start the probe frame in the combined probe frame to be started, and to control the movement of the first set of probe frames of the flaw detection vehicle on the steel pipe, so that the controller controls the other sets of probe frames in the combined probe frame to be started to move on the steel pipe according to the corresponding target offset data.

[0007] In one possible implementation, a laser tracking camera is installed on the first set of probes. The laser tracking module is also used to collect image data of the weld seam of the steel pipe through the laser tracking camera during the movement of the first set of probes of the flaw detection vehicle on the steel pipe, and to determine the offset data of the weld seam center per millimeter at different positions based on the field of view of the laser tracking camera and the image data.

[0008] In one possible implementation, the offset data includes offset amount, travel position, and offset speed. The laser tracking module is also used to determine the offset amount and offset speed of the weld center per millimeter in the longitudinal axis direction and the travel position of the first set of probes in the transverse axis direction at different positions based on the field of view of the laser tracking camera and the image data, and to send the offset amount, the travel position, and the offset speed to the industrial control computer through the communication module.

[0009] In one possible implementation, each probe frame of the flaw detection vehicle is equipped with a tracking servo motor, which is used to monitor the position of the corresponding probe frame in real time; the controller is also used to send the target offset data to the tracking servo motor on the corresponding probe frame, so that the tracking servo motor runs to the designated position in absolute positioning mode according to the target offset data to perform weld flaw detection.

[0010] In one possible implementation, the industrial control computer is further used to calculate the distance from the other groups of probe positions to the position of the laser tracking camera, to obtain the actual tracking position of each group of probes; and to store the target offset data that is consistent with the actual tracking position of each group of probes in different stored positions to the controller.

[0011] In one possible implementation, the calculation process for the actual tracking position of each set of probes is as follows: the current position of the probe minus all distances between the current position of the probe and the position of the laser tracking camera.

[0012] In one possible implementation, the system further includes a flaw detection module, which is used to acquire the offset data of each set of probes in real time through the controller during the weld flaw detection process of the flaw detection vehicle, and to draw a longitudinal axis tracking curve of each set of probes based on the offset data.

[0013] In one possible implementation, the laser tracking module is also used to set other groups of probes on the flaw detection vehicle, except for the probes in the combined probe frame to be started, to not start, and to disable the probe frame lifting device and tracking function.

[0014] Secondly, the present invention also provides a method for inspecting weld seams of steel pipes, comprising: The first set of probes of the flaw detection vehicle is used to collect data on the movement of the first set of probes on the steel pipe according to the set sampling walking gap parameters, so as to obtain the offset data of the first set of probes at different positions when running in the horizontal and vertical coordinate directions of the steel pipe. Receive the offset data and the current position of other groups of probes on the flaw detection vehicle in the horizontal axis direction, set the horizontal axis direction travel distance, and filter the target offset data from the offset data according to the horizontal axis direction travel distance and the current position; The corresponding probe is controlled to operate based on the received target offset data, thereby performing weld flaw detection.

[0015] The beneficial effects of this invention are as follows: The laser tracking module is used to collect data on the movement of the first set of probes on the steel pipe according to the sampling walking gap parameters set on the communication module, obtaining the offset data of the first set of probes at different positions in the horizontal and vertical coordinate directions of the steel pipe, and sending the offset data corresponding to each position to the industrial control computer; the industrial control computer is used to receive the offset data and the current position of the other sets of probes on the horizontal axis of the flaw detection vehicle, and set the walking gap in the horizontal axis direction, filter out the target offset data in the offset data according to the walking gap in the horizontal axis direction and the current position, and send the target offset data to the controller; the controller is used to control the operation of the corresponding probes according to the received target offset data, thereby performing weld flaw detection; by controlling the movement of the first set of probes and collecting offset data through the laser tracking module, the industrial control computer and the controller work together to realize independent tracking of multiple probes, solving the problem that the traditional synchronous tracking mode is difficult to adapt to the differentiated control of multiple probes, and has the advantages of improving the accuracy of independent control of multiple probes and enhancing the adaptability of the system. Attached Figure Description

[0016] Figure 1A schematic diagram of an embodiment of the steel pipe weld flaw detection system provided by the present invention; Figure 2 A schematic diagram of an embodiment of the basic structural diagram of weld flaw detection provided by the present invention; Figure 3 A schematic diagram of an embodiment of the component relationship structure diagram provided by the present invention; Figure 4 This is a schematic diagram of one embodiment of the installation diagram of multiple probe frames on the flaw detection vehicle provided by the present invention; Figure 5 This is a schematic flowchart of an embodiment of the steel pipe weld flaw detection method provided by the present invention. Detailed Implementation

[0017] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which form part of this application and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not intended to limit the scope of the present invention.

[0018] like Figure 1 As shown in the figure, a specific embodiment of the present invention discloses a steel pipe weld flaw detection system. The system 100 includes a laser tracking module 101, a communication module 102, a flaw detection vehicle 103, a controller 104, and an industrial control computer 105.

[0019] The laser tracking module 101 is used to collect data on the walking process of the first set of probes of the flaw detection vehicle 103 on the steel pipe according to the sampling walking gap parameters set on the communication module 102, obtain the offset data of the first set of probes at different positions when running in the horizontal and vertical coordinate directions of the steel pipe, and store the offset data corresponding to each position to the industrial control computer 105.

[0020] The laser tracking module 101 is a device that acquires the positional offset of the probe frame through laser ranging and image processing technology. Specifically, it can be implemented in hardware integrating a laser sensor and a vision analysis unit, used to capture the probe frame's trajectory deviation in real time. The communication module 102 is an interactive unit for transmitting control commands and data, such as an industrial Ethernet protocol interface, responsible for parameter distribution and data feedback. The flaw detection vehicle is a mobile platform equipped with multiple independently adjustable probe frames. The probe frames can be configured with detection elements such as ultrasonic sensors, and their walking mechanism can be driven by servo motors.

[0021] The industrial control computer 105 is used to receive offset data and the current position of other groups of probes on the flaw detection vehicle in the horizontal direction, and to set the horizontal direction travel distance. Based on the horizontal direction travel distance and the current position, it filters the target offset data in the offset data and sends the target offset data to the controller 104. This set of offset data reflects the longitudinal offset of the weld at different horizontal positions (and the curve of the weld).

[0022] Among them, the industrial control computer 105 refers to the central processing unit that coordinates the work of multiple modules, such as an industrial computer, which realizes collaborative control of the probe through position detection and data retrieval.

[0023] The controller 104 is used to control the operation of the corresponding probe based on the received target offset data, thereby performing weld flaw detection.

[0024] The controller refers to the computing unit that stores and processes location data, such as a programmable logic controller, which is used to match the real-time position with the pre-stored offset.

[0025] In specific embodiments, such as Figure 2 As shown, Figure 2 This is a basic structural diagram of weld flaw detection, which may include a flaw detection vehicle, a steel pipe, and rotating rollers. There may be multiple rotating rollers. Figure 2 The image shows two rotating rollers that can fix the steel pipes separately. A flaw detection vehicle can be positioned above the steel pipes. The flaw detection vehicle, steel pipes, and rotating rollers are aligned horizontally by the dotted line in the middle of the steel pipe. The movement of the flaw detection vehicle performs weld flaw detection on the steel pipes. Figure 3 As shown, Figure 3 A relational structure diagram is set for the components. The flaw detection vehicle, steel pipe, and rotating roller are aligned by the central dotted line. The rotating roller can be used to rotate the weld center of the standard sample steel pipe to the 12 o'clock position (based on the unblocking hole on the sample pipe weld). Combined with the mechanical mechanism of the probe frame, the initial positions (origin) of all tracking servos are set to ensure that the center of the probe frame and the center of the rotating roller (steel pipe) are consistent. When the first set of probe frames moves along the horizontal axis of the steel pipe, the laser tracking module records its position offset data at a preset sampling interval, for example, collecting the offset every 5 mm. The offset data includes the horizontal and vertical coordinates, the vertical offset, and speed parameters, and is stored in the register of the industrial control computer. When the remaining probe frames move to a specific position, the industrial control computer obtains its coordinates through the encoder and sends them to the controller. The controller retrieves the offset that matches the coordinates from the stored data, generates a control signal accordingly, and drives the servo motor of the corresponding probe frame to adjust its vertical position, so that its ultrasonic sensor is accurately aligned with the weld centerline. For example, when a probe travels to 1200 mm on the horizontal axis, the corresponding longitudinal offset of -0.3 mm is called, and the servo motor compensates for this deviation value in the opposite direction.

[0026] Compared with existing technologies, the laser tracking module provided in this embodiment controls the movement of the first set of probes on the steel pipe according to the sampling walking gap parameters set on the communication module. This obtains offset data of the first set of probes at different positions along the horizontal axis of the steel pipe, and stores the offset data corresponding to each position in the industrial control computer. The industrial control computer filters some longitudinal offset data of the weld seam based on the lateral walking gap of the flaw detection vehicle and sends it to the controller. The controller sends the offset data from different stored positions that are consistent with the positions of other sets of probes to the probe servo motor, so that the servo motor controls the corresponding probe to run according to the offset data, thereby performing weld flaw detection. By controlling the movement of the first set of probes and collecting offset data through the laser tracking module, and with the industrial control computer and controller working together to achieve independent tracking of multiple probes, the problem of traditional synchronous tracking mode being difficult to adapt to the differentiated control of multiple probes is solved. This has the advantages of improving the accuracy of independent control of multiple probes and enhancing system adaptability.

[0027] Through the above technical solutions, this application solves the problem of independent control of multiple probe frames and improves weld seam tracking accuracy. For example, when switching probe frame combinations, the system can quickly call up the corresponding offset dataset to adapt to the needs of different flaw detection processes for probe frame grouping. At the same time, through the real-time position data matching mechanism, the detection blind zone caused by the accumulation of mechanical errors of the probe frames is reduced, improving adaptability in complex weld seam scenarios.

[0028] In some embodiments of the present invention, the laser tracking module 101 is further configured to combine multiple sets of probes on the flaw detection vehicle 103 according to a preset flaw detection process to obtain a combined probe to be activated; the combined probe to be activated includes a first set of probes and at least one other set of probes. The preset flaw detection process refers to the flaw detection process parameters pre-set according to the material, weld type, or inspection accuracy requirements of different steel pipes. This can be implemented using a process database or parameter configuration interface, dynamically adjusting the probe combination method by matching the steel pipe parameters. The probe combination to be activated refers to a dynamic set formed by selecting probes that match the current flaw detection process. This includes a first group of probes and at least one other group of probes. This can be implemented using probe number grouping or a logical mapping table, allowing the probe combination to flexibly adapt to different inspection needs.

[0029] The laser tracking module 101 is also used to start the probe in the combined probe frame to be started, and to control the movement of the first set of probes of the flaw detection vehicle on the steel pipe, so that the controller 104 controls the other sets of probes in the combined probe frame to be started to move on the steel pipe according to the corresponding target offset data.

[0030] Specifically, when the flaw detection vehicle performs an inspection task, the communication module selects the probe sets to be activated based on preset process parameters. For example, for large-diameter steel pipes, multiple probe sets need to simultaneously cover the weld area; in this case, only the probe sets matching the process are activated. The laser tracking module activates the tracking function of the corresponding probes according to the selection results. After receiving the start command, the controller controls the activated probes to move along the axial direction of the steel pipe, while the remaining unactivated probes remain stationary or disengage from tracking. Thus, the probe sets can be dynamically adjusted according to actual inspection needs, avoiding redundant probes from interfering with the inspection process.

[0031] Compared to existing technologies, traditional methods use fixed probe combinations that require all probes to operate synchronously, leading to mutual interference between probes and an inability to adapt to different process requirements. This solution uses dynamic probe combinations, activating only the necessary probe groups, reducing the negative impact of redundant probes on detection accuracy, and improving the system's adaptability to different steel pipe specifications.

[0032] Through the above technical solution, this application solves the problem that the probe combination cannot be flexibly adjusted in multi-probe inspection scenarios, effectively reduces motion interference between probes, improves weld tracking accuracy, and adapts to the dynamic requirements of different flaw detection processes on the number and layout of probes.

[0033] In some embodiments of the present invention, a laser tracking camera is installed on the first set of probes. The laser tracking module 101 is also used to collect image data of the weld seam of the steel pipe through the laser tracking camera during the process of the first set of probes of the flaw detection vehicle 103 moving on the steel pipe, and to determine the offset data of the weld seam center per millimeter at different positions based on the field of view and image data of the laser tracking camera.

[0034] The laser tracking camera refers to an optical device used to acquire real-time images of the weld surface of steel pipes. Specifically, it can be implemented using a high-resolution industrial camera, such as a META camera. Its function is to capture changes in weld morphology and generate continuous image data. The field of view refers to the size of the weld area that the camera can cover in a single frame image. This can be controlled by adjusting the lens focal length or installation angle to limit the effective range of image analysis. The offset data per millimeter corresponding to the weld center refers to the dynamic deviation between the probe position and the weld centerline calculated based on the image data. This can be achieved through a pixel coordinate transformation algorithm to quantify the actual degree of probe offset in the longitudinal direction.

[0035] Specifically, before using the laser tracking camera, it needs to be adjusted to keep the actual weld center in the center position, preventing it from going out of range when tracking deviates. After confirming the adjustment is correct, pressing the teach button will create a reference point. To the left of the reference point is a negative deviation, and vice versa. During the movement of the flaw detection vehicle, the laser tracking module drives the first set of probes to move along the transverse axis of the steel pipe, while simultaneously acquiring images of the weld area through the laser tracking camera. The acquired image data is transmitted to the laser tracking module, where it is combined with preset field-of-view parameters to identify the weld centerline position in real time. For example, when the probe moves in the transverse direction, the pixel coordinate change of the weld centerline in the image is converted into an actual physical offset, and then the longitudinal axis offset data corresponding to each millimeter of transverse displacement is calculated. This data is stored in the industrial control computer, providing a reference for the subsequent tracking and adjustment of other sets of probes.

[0036] Compared to existing technologies, traditional methods use a single servo motor to synchronously control all probes, making it impossible to independently adjust tracking parameters based on the actual position of each probe. This solution, however, introduces a laser tracking camera to acquire weld images in real time and calculate dynamic offset data, enabling each probe to independently compensate for weld offset based on its own position. This adapts to the accuracy requirements of different flaw detection processes for multi-probe collaborative operations.

[0037] Through the above technical solution, this application achieves precise data support for independent tracking control of multiple probes, solving the problem of decreased tracking accuracy caused by the increase in the number of probes in traditional methods. Real-time image analysis and offset calculation ensure that each probe dynamically conforms to the weld centerline in the longitudinal direction, improving the adaptability and stability of flaw detection.

[0038] In some embodiments of the present invention, the laser tracking module 101 is also used to disable the probe lifting and lowering device and tracking function when setting other probe frames on the flaw detection vehicle 103, except for the probe frames in the probe frame to be started, to not be started.

[0039] The shielding function refers to blocking the flaw detection signal and isolating the tracking command for the unselected probe. Specifically, this can be achieved by cutting off the enable of the probe servo motor or shutting down the probe communication port to shield the probe lifting device, or by setting it to not start, so that the unselected probe remains stationary during the detection process.

[0040] Specifically, before the flaw detection vehicle begins its inspection task, the industrial control computer generates probe combination instructions based on preset flaw detection process parameters. The communication module transmits these instructions to the laser tracking module. After parsing the instructions, the laser tracking module activates only the control channel of the probe corresponding to the probe combination to be started via the probe activation button, while simultaneously sending a shielding signal to the remaining probes. The shielding signal triggers an internal relay in the probe to disconnect the power supply to the flaw detection sensor and shut down the communication link between the probe and the controller. Therefore, probes not selected cannot receive position adjustment instructions during the inspection process, thus preventing unnecessary probes from interfering with the inspection process. Furthermore, the first group of probes cannot be shielded during automatic operation because the laser tracking camera on the first group of probes needs to collect data on the steel pipe welds.

[0041] Compared to existing technologies, which employ a one-to-one control method that requires all probes to operate synchronously and cannot dynamically adjust their working status according to inspection needs, this solution selectively disables unnecessary probes. This allows the system to flexibly match different inspection processes. For example, when inspecting narrow welds, only some probes can be activated to reduce energy consumption, or when inspecting complex welds, probe combinations can be quickly switched to improve inspection coverage.

[0042] In some embodiments of the present invention, the offset data includes offset amount, walking position and offset speed. The laser tracking module 101 is also used to determine the offset amount and offset speed of the weld center in the longitudinal direction and the walking position of the first set of probes in the transverse direction per millimeter at different positions according to the field of view and image data of the laser tracking camera, and to send the offset amount, walking position and offset speed to the industrial control computer 105 through the communication module.

[0043] The offset refers to the deviation of the probe frame from the weld center in the longitudinal direction. This is achieved through image processing algorithms that perform edge recognition and coordinate calculation on the weld image captured by the laser tracking camera, reflecting the actual degree of vertical offset of the probe frame. The travel position refers to the real-time position of the first set of probe frames in the transverse direction. This is continuously monitored by an encoder or displacement sensor mounted on the probe frame vehicle, determining the probe frame's trajectory along the length of the steel pipe. The offset speed refers to the rate of change of the probe frame's movement in the transverse direction. This is dynamically acquired through feedback signals from the servo motor or a speed sensor, used to adjust the probe frame's motion to adapt to the weld's curvature or undulations. The field of view is determined by the laser tracking camera model.

[0044] Specifically, as the first set of probes on the flaw detection vehicle moves along the transverse axis of the steel pipe, the laser tracking camera continuously collects image data of the weld area. The laser tracking module analyzes the image based on preset field-of-view parameters and calculates the longitudinal axis offset per millimeter. Simultaneously, the laser camera acquires the transverse axis position and offset speed of the first set of probes in real time, and integrates this data with the offset before transmitting it to the industrial control computer 105. An array (e.g., 1000 arrays) is created in the PLC controller to record the tracking data sent by the META laser tracking communication software. Each array includes the walking servo position and the offset and offset speed in the Y-axis direction at that position. The controller generates control commands based on multi-dimensional data (i.e., offset, walking position, and offset speed), enabling subsequent probes to dynamically adjust the longitudinal and transverse axis motion parameters during synchronous movement, thereby ensuring that each probe is always aligned with the weld centerline. The tracking and communication software, based on its set writing interval parameters, synchronously collects real-time tracking offset, offset speed, and current position of the travel servo from the laser tracking module every 15mm traveled along the X-axis by the first set of probes on the flaw detection vehicle. These three parameters are then sequentially written into array 1-1000 in the above diagram. Thus, the data in this array reflects the complete offset data (i.e., offset amount, travel position, and offset speed) of the first set of probes (controlled by the META laser tracking system) at different positions as it travels along the entire X-axis of the steel pipe.

[0045] Compared to existing technologies, traditional methods rely solely on single-dimensional position feedback for probe control, such as monitoring only the horizontal axis coordinate or the vertical axis offset. This leads to tracking errors in complex weld morphologies. This application achieves multi-parameter coordinated control by simultaneously acquiring the vertical axis offset, horizontal axis travel position, and offset speed. This allows the probe to dynamically correct its trajectory based on real-time data during travel, effectively addressing irregularities such as weld bending and misalignment.

[0046] Through the above technical solution, this application solves the problem of decreased accuracy caused by insufficient data dimensions when multiple probes are tracked together. By integrating the vertical axis offset, horizontal axis position and speed information, the adaptive capability of the probes under complex working conditions is improved, ensuring that different probes can accurately align with the weld center during the movement, thereby improving the stability and reliability of flaw detection.

[0047] In some embodiments of the present invention, each probe frame of the flaw detection vehicle 103 is equipped with a tracking servo motor. The tracking servo motor is used to monitor and absolutely position the corresponding probe frame in real time. The controller 104 is also used to send offset data to the tracking servo motor on the corresponding probe frame so that the tracking servo motor can run to the specified position in the absolute positioning mode according to the offset data to perform weld flaw detection.

[0048] The absolute positioning mode refers to a positioning control method based on a preset coordinate system. This can be implemented using the absolute position control algorithm built into the servo driver, ensuring the probe can move directly to the target coordinate point without relying on relative displacement accumulation. The tracking servo motor is an actuator that drives the probe movement through closed-loop control. This can be implemented using a servo motor with a rotary encoder, which receives pulse signals from the controller to drive the probe movement and transmits real-time position feedback signals to the controller. Real-time monitoring refers to the continuous acquisition of the probe's displacement on the steel pipe surface at millisecond levels. This can be achieved by using a Hall sensor or photoelectric encoder linked with the servo motor, combined with the controller's built-in sampling algorithm to dynamically process the probe position data.

[0049] Specifically, each probe frame is independently configured with a tracking servo motor that generates pulse signals via an encoder. These signals are converted into the actual displacement of the probe frame along the longitudinal axis of the steel pipe surface. As the probe frame moves along the steel pipe surface, the encoder of the servo motor continuously collects the position data of the probe frame and transmits the data to the controller in real time through the controller's communication interface. The controller matches the position data with the offset data generated by the laser tracking module according to the preset flaw detection process parameters, and then sends compensation commands to the servo motors to dynamically adjust the position deviation of the probe frame during movement. When the real-time tracking position of the other groups of probe frames matches the flaw detection movement positioning position value in a certain array, the controller sends the probe frame offset position and offset speed in that array to the corresponding tracking servo, and then the tracking servo moves to the designated position in absolute positioning mode.

[0050] The controller transmits the offset data collected by the laser tracking module to the tracking servo motor of the corresponding probe via the communication module. The servo motor switches to absolute positioning mode according to the received target coordinate parameters, driving the probe to move directly to the designated position corresponding to the weld center. During this process, the tracking servo motor of each probe independently receives offset data matching its current position, without relying on the motion state of other probes, thus achieving parallel control of multiple probes.

[0051] Compared to existing technologies, traditional methods use a single servo motor to synchronously drive all probes, resulting in the inability to independently adjust the probes based on weld offset differences. This solution, by configuring an independent tracking servo motor for each probe and employing an absolute positioning mode, enables each probe to autonomously correct its position based on real-time offset data, avoiding the decrease in control accuracy caused by an increase in the number of probes.

[0052] In some embodiments of the present invention, the industrial control computer 105 is also used to calculate the position of other groups of probes to the position of the laser tracking camera, so as to obtain the actual tracking position of each group of probes; and to store the target offset data in the stored offset data that are consistent with the actual tracking position of each group of probes in the DB block of the controller 104.

[0053] The positions of the other probe groups refer to the coordinate positions of all probes except the first group along the transverse axis of the steel pipe. This can be monitored in real-time using an encoder or servo motor mounted on the flaw detection vehicle, representing the movement trajectory of the probes on the steel pipe surface. The actual tracking position of each probe relative to the laser camera can be calculated using the distance between the laser camera and each probe, and the current position of the walking servo. The calculation process for the actual tracking position of each group of probes is as follows: the current probe position minus all distances between the current probe position and the position of the laser tracking camera, for example: Figure 4 As shown, Figure 4 This is a schematic diagram of the installation of multiple probe frames on the flaw detection vehicle. The actual tracking position of probe frame 2 is IN1-IN2-IN3, the actual tracking position of probe frame 3 is IN1-IN2-IN3-IN4, the actual tracking position of probe frame 4 is IN1-IN2-IN3-IN4-IN5, the actual tracking position of probe frame 5 is IN1-IN2-IN3-IN4-IN5-IN6, and the actual tracking position of probe frame 6 is IN1-IN2-IN3-IN4-IN5-IN6-IN7. IN1 is the current position of the travel servo, IN2 is the distance from the laser tracking camera to the center of the first group of probe frames, IN3 is the distance from the center of the first group of probe frames to the center of the second group of probe frames, IN4 is the distance from the center of the second group of probe frames to the center of the third group of probe frames, IN5 is the distance from the center of the third group of probe frames to the center of the fourth group of probe frames, IN6 is the distance from the center of the fourth group of probe frames to the center of the fifth group of probe frames, and IN7 is the distance from the center of the fifth group of probe frames to the center of the sixth group of probe frames. The above process confirms that tracking the actual position can eliminate mechanical installation errors between multiple probes.

[0054] Specifically, the controller receives the first set of real-time probe position data sent by the industrial computer, maps it to the coordinate system of the laser tracking camera using a coordinate transformation algorithm, and calculates the actual offset of each probe relative to the weld center. This calculation process considers factors such as probe spacing, steel pipe curvature, and mechanical installation errors to establish a correspondence between the probe position and the laser tracking camera's field of view. Subsequently, the controller retrieves the offset parameters matching the current tracking position from the pre-stored offset database and sends a complete data packet containing the longitudinal axis compensation and velocity correction values ​​to the industrial computer. This data transmission mechanism based on spatial position matching allows subsequent probes to directly call the verified offset parameters for motion control.

[0055] Compared to existing technologies, traditional methods can only synchronously copy the offset data of the first set of probes, failing to address spatial position differences caused by probe spacing. This solution establishes a spatial position mapping relationship between probes, enabling each probe to call corresponding compensation parameters based on its actual position, effectively solving the problem of accumulated tracking errors caused by mechanical installation deviations in multiple probes on long flaw detection vehicles.

[0056] In some embodiments of the present invention, the system further includes a flaw detection module, which is used to acquire the offset data of each set of probes in real time through the controller 104 during the weld flaw detection process of the flaw detection vehicle 103, and to draw a longitudinal axis tracking curve of each set of probes based on the offset data.

[0057] The flaw detection module refers to the hardware or software unit used to acquire and process probe offset data in real time during weld inspection. Specifically, it can be implemented using a data acquisition card combined with graphics processing software. It obtains the dynamic offset of the probe during operation through a controller, providing the basic data for subsequent tracking curve generation. The longitudinal tracking curve is a two-dimensional chart generated with the probe's travel position as the abscissa and the offset as the ordinate. It can be implemented using Matplotlib or LabVIEW graphics libraries and can intuitively reflect the tracking accuracy fluctuation of the probe along the longitudinal axis of the steel pipe. After flaw detection is completed, all tracking servos return to their origin position, awaiting the next run.

[0058] Specifically, the flaw detection module periodically reads the offset data of each probe frame through the controller's real-time communication interface, for example, acquiring the offset and corresponding travel position coordinates every 50 milliseconds. After the data is filtered, a graphics rendering algorithm is used to generate a continuous curve of the longitudinal axis offset of each probe frame according to the time series. This curve can be stored as a log file or displayed in real time on the industrial control computer's human-machine interface. After the flaw detection vehicle completes a single inspection stroke, the operator can evaluate the consistency of multi-probe collaborative tracking by analyzing the curve overlap of different probe frames.

[0059] Compared to existing technologies, traditional weld seam tracking systems only record the current position of the probe and lack the ability to visualize historical offset data. This solution generates a tracking curve along the vertical axis, allowing operators to trace the dynamic offset trend of the probe throughout the inspection process, facilitating rapid location and tracking of anomalies. For example, if the curve of a probe continuously deviates from the baseline, it can be determined that its servo drive system has a mechanical lag problem.

[0060] To better implement the steel pipe weld flaw detection system in this embodiment of the invention, based on the steel pipe weld flaw detection system, this embodiment of the invention also provides a steel pipe weld flaw detection method, such as... Figure 5 As shown, it includes: S501. Based on the set sampling travel gap parameters, the first set of probes of the flaw detection vehicle is used to collect data on the travel process of the first set of probes on the steel pipe, and the offset data of the first set of probes at different positions when running in the horizontal and vertical coordinate directions of the steel pipe are obtained. S502: Receive offset data and the current position of other groups of probes on the flaw detection vehicle in the horizontal axis direction, set the horizontal axis direction travel distance, and filter the target offset data from the offset data according to the horizontal axis direction travel distance and the current position; S503. Control the operation of the corresponding probe frame according to the received target offset data, so as to perform weld flaw detection.

[0061] The steel pipe weld flaw detection method provided in the above embodiments can realize the technical solutions described in the above steel pipe weld flaw detection system embodiments. The specific implementation principles of each module or unit can be found in the corresponding content of the above steel pipe weld flaw detection system embodiments, which will not be repeated here.

[0062] The above provides a detailed description of the steel pipe weld flaw detection system and method provided by the present invention. Specific examples have been used to illustrate the principle and implementation of the present invention. The description of the above embodiments is only for the purpose of helping to understand the method and core idea of ​​the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation and application scope based on the idea of ​​the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A flaw detection system for steel pipe welds, characterized in that, Includes laser tracking module, communication module, flaw detection vehicle, controller and industrial control computer; The laser tracking module is used to collect data on the walking process of the first set of probes of the flaw detection vehicle on the steel pipe according to the sampling walking gap parameter set by the communication module, to obtain the offset data of the first set of probes at different positions when running in the horizontal and vertical coordinate directions of the steel pipe, and to store the offset data corresponding to each position to the industrial control computer. The industrial control computer is used to receive the offset data and the current position of other groups of probes of the flaw detection vehicle in the horizontal axis direction, set the horizontal axis direction travel distance, filter the target offset data in the offset data according to the horizontal axis direction travel distance and the current position, and send the target offset data to the controller. The controller is used to control the operation of the corresponding probe frame according to the received target offset data, so as to perform weld flaw detection.

2. The steel pipe weld flaw detection system according to claim 1, characterized in that, The laser tracking module is also used to combine multiple sets of probes on the flaw detection vehicle according to a preset flaw detection process to obtain a combined probe to be activated; the combined probe to be activated includes a first set of probes and at least one other set of probes. The laser tracking module is also used to start the probe frame in the combined probe frame to be started, and to control the movement of the first set of probe frames of the flaw detection vehicle on the steel pipe, so that the controller controls the other sets of probe frames in the combined probe frame to be started to move on the steel pipe according to the corresponding target offset data.

3. The steel pipe weld flaw detection system according to claim 1, characterized in that, The first set of probes is equipped with a laser tracking camera. The laser tracking module is also used to collect image data of the weld seam of the steel pipe through the laser tracking camera during the movement of the first set of probes of the flaw detection vehicle on the steel pipe, and to determine the offset data of the weld seam center per millimeter at different positions based on the field of view of the laser tracking camera and the image data.

4. The steel pipe weld flaw detection system according to claim 3, characterized in that, The offset data includes offset amount, travel position and offset speed. The laser tracking module is also used to determine the offset amount and offset speed of the weld center per millimeter in the longitudinal axis direction and the travel position of the first set of probes in the transverse axis direction at different positions based on the field of view of the laser tracking camera and the image data, and to send the offset amount, the travel position and the offset speed to the industrial control computer through the communication module.

5. The steel pipe weld flaw detection system according to claim 1, characterized in that, Each probe frame of the flaw detection vehicle is equipped with a tracking servo motor, which is used to monitor the position of the corresponding probe frame in real time. The controller is also used to send the target offset data to the tracking servo motor on the corresponding probe frame, so that the tracking servo motor can run to the designated position in absolute positioning mode according to the target offset data to perform weld flaw detection.

6. The steel pipe weld flaw detection system according to claim 3, characterized in that, The industrial control computer is also used to calculate the distance from the other groups of probe positions to the position of the laser tracking camera, so as to obtain the actual tracking position of each group of probes; and to store the target offset data in the stored offset data that is consistent with the actual tracking position of each group of probes to the controller.

7. The steel pipe weld flaw detection system according to claim 6, characterized in that, The calculation process for the actual tracking position of each set of probes is as follows: the current position of the probe minus all distances between the current position of the probe and the position of the laser tracking camera.

8. The steel pipe weld flaw detection system according to claim 1, characterized in that, The system also includes a flaw detection module, which is used to acquire the offset data of each set of probes in real time through the controller during the weld flaw detection process of the flaw detection vehicle, and to draw a longitudinal axis tracking curve of each set of probes based on the offset data.

9. The steel pipe weld flaw detection system according to claim 2, characterized in that, The laser tracking module is also used to set other groups of probes on the flaw detection vehicle, except for the probes in the combined probe frame to be started, to not start, and to disable the probe frame lifting device and tracking function.

10. A method for inspecting flaws in steel pipe welds, characterized in that, include: The first set of probes of the flaw detection vehicle is used to collect data on the movement of the first set of probes on the steel pipe according to the set sampling walking gap parameters, so as to obtain the offset data of the first set of probes at different positions when running in the horizontal and vertical coordinate directions of the steel pipe. Receive the offset data and the current position of other groups of probes on the flaw detection vehicle in the horizontal axis direction, set the horizontal axis direction travel distance, and filter the target offset data from the offset data according to the horizontal axis direction travel distance and the current position; The corresponding probe is controlled to operate based on the received target offset data, thereby performing weld flaw detection.

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