A mobile scanning device for weld defects based on machine vision
By designing a machine vision-based mobile scanning device for weld defects, which incorporates wheels and a pusher, along with a closed housing and an adjustable light source module, the high labor intensity and unstable image acquisition issues of existing weld inspection equipment are resolved, achieving efficient and stable weld defect detection.
Patent Information
- Application Number
- CN202610719622.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-05-25
- Publication Date
- 2026-08-25
AI Technical Summary
Existing weld defect detection equipment suffers from problems such as high labor intensity, low detection efficiency, reliance on human experience for detection results and susceptibility to missed or false detections, and image acquisition equipment is difficult to operate stably in complex industrial environments.
A machine vision-based mobile scanning device for weld defects was designed, comprising a mobile scanning device and a vision scanning unit. It adopts a design with wheels and a pusher, combined with a closed box structure and an adjustable light source module, to achieve continuous scanning and stable imaging, adapting to complex industrial environments.
It significantly reduces manual labor intensity, improves detection efficiency and image quality, enhances the adaptability and stability of the equipment in complex environments, and ensures the automatic identification and classification of weld defects.
Smart Images
Figure CN122631641A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of inspection technology, and in particular to a machine vision-based mobile scanning device for weld defects. Background Technology
[0002] As crucial facilities in key sectors of the national economy such as petrochemicals and energy, pressure-bearing special equipment's weld quality directly impacts its safe operation. Weld surface defect detection is a vital step in ensuring the safety of pressure-bearing equipment, currently relying primarily on manual visual inspection combined with traditional methods such as magnetic particle testing and penetrant analysis. During the inspection process, operators must manually inspect the weld section by section using testing equipment, or perform fixed-point inspections using a fixed testing platform. This process is labor-intensive, inefficient, and the results are highly dependent on the inspector's subjective experience, posing a significant risk of missed or false detections.
[0003] With the development of machine vision and artificial intelligence technologies, automatic detection methods for weld defects based on image recognition have attracted widespread attention. However, existing research mostly focuses on defect recognition algorithms and image processing techniques, while the development of supporting image acquisition hardware equipment lags behind. Fixed inspection stands are bulky and difficult to relocate, making it difficult to perform continuous scanning inspections of long welds; portable handheld acquisition devices, while offering better flexibility, struggle to maintain the stable relative position of the camera and weld during deployment, resulting in insufficient image consistency. Furthermore, the complex industrial environment, with boiler and pressure vessel inspection sites typically experiencing strong surface reflections, variable lighting conditions, and high dust concentrations, further exacerbates the difficulty of image acquisition and restricts the practical application of machine vision technology in on-site weld defect detection. Therefore, a machine vision-based mobile scanning device for weld defects is proposed. Summary of the Invention
[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing a machine vision-based mobile scanning device for weld defects.
[0005] To achieve the above objectives, the present invention adopts the following technical solution: a machine vision-based mobile scanning device for weld defects, comprising a mobile scanning device and a vision scanning unit, wherein the vision scanning unit is installed on the rear end face of the mobile scanning device, the mobile scanning device comprises a main frame and traveling wheels installed at the bottom of both sides of the front end face of the main frame, and pushers are installed on the side end face of the main frame.
[0006] Preferably, the main frame includes a box body and bottom support feet installed at the bottom corners on both sides of the front end face of the box body. An inclined operating surface is opened on the upper end face of the box body, and a display screen is installed on both sides of the upper end face of the inclined operating surface.
[0007] The main frame serves as the load-bearing base of the entire machine, forming a closed cavity inside to accommodate the image processing unit, power supply, and control module. The bottom of both sides of its front face are equipped with walking wheels, and the side faces are equipped with push handles, which together form a human-machine collaborative platform that can be pushed and moved. This allows the device to move continuously along the weld seam trajectory, realizing push-sweep inspection of weld seams on site, replacing the traditional fixed-station inspection mode, and significantly improving the flexibility of on-site operations.
[0008] The main body of the enclosure is the core supporting structure of the overall frame, providing an installation benchmark and protecting the internal electrical components from dust, splashes, and humid environments in the industrial field, ensuring the stable operation of the machine vision system.
[0009] The bottom support feet are located at the bottom corners on both sides of the front face of the main body of the box. They provide multi-point support to the ground during the device's parking or scanning process. In conjunction with the rear vision scanning unit, they prevent the machine from shaking due to uneven ground or operating force, ensuring the spatial stability of the industrial camera during imaging.
[0010] The inclined operating surface is located on the upper surface of the main body of the box, with its inclination angle facing the operator's line of sight; the display screen installed on it is thus at an ergonomic viewing angle, allowing the operator to observe the defect identification results and equipment status in real time without having to look down or up while pushing the device, reducing neck fatigue from long-term outdoor or high-altitude work.
[0011] Preferably, the main frame further includes heat dissipation holes that are inclined outwardly opened at the two edges of the front face of the main body of the box; The heat dissipation holes are angled outwards and located on both sides of the front face of the main body of the box. They utilize the principle of natural convection of hot air to dissipate heat from inside the box. The angled outward opening structure can block dust and foreign objects falling from above while dissipating heat, thus balancing heat dissipation efficiency and overall protection level, and adapting to the complex working conditions of high dust levels at boiler and pressure vessel sites.
[0012] Preferably, the mobile scanning device further includes an interface panel module installed in the inner cavity of the pusher. The interface panel module includes a panel substrate and an edge buffer pad installed at the edge of the panel substrate. The other end of the edge buffer pad is connected to the interface of the inner cavity wall of the pusher. Bottom heat dissipation holes are opened on both sides of the bottom end face of the panel substrate. The traveling wheels are installed on both sides of the bottom of the front face of the main frame, forming a multi-point rolling support together with the traveling mechanism at the rear of the vision scanning unit. This disperses the weight of the whole machine and converts it into rolling friction, allowing the operator to easily push the device to move on the weld surface by pushing the handle, thus achieving continuous scanning and reducing the labor intensity of manual handling.
[0013] The push handle is installed on the side end face of the main frame as a force application point for human-machine interaction; its installation height and lateral span are ergonomic, making it easy for operators to hold and push the device in complex scenarios such as narrow spaces, pipelines, or high-altitude platforms, thus improving on-site accessibility.
[0014] The interface panel module is embedded in the inner cavity of the pusher, making full use of the hollow space inside the pusher to achieve a compact structure. The power interface, data communication port and trigger interface are centrally arranged on the panel substrate to realize the electrical interconnection between the main unit and the vision scanning unit; the edge buffer pad is connected to the inner wall of the pusher to absorb vibration and impact when the device passes over weld seam excess or uneven ground, preventing interface solder joints from loosening or connectors from becoming loose, and ensuring data transmission reliability; the bottom heat dissipation holes are opened on both sides of the bottom of the panel, which not only facilitates heat dissipation in the interface area, but also allows water to be drained in time during outdoor rain or washing scenarios, improving the environmental adaptability of the whole machine.
[0015] Preferably, the visual scanning unit includes a scanning bracket and an industrial camera mounted on the top of the scanning bracket. A transverse sliding groove is opened on the outer end face of the scanning bracket, and bottom guide grooves are opened on both sides of the bottom position of the scanning bracket. The two sets of bottom guide grooves are movably connected by an adjusting beam. The scanning bracket serves as the skeleton of the vision scanning unit. Its rear end is connected to the side face of the main frame via a quick-release connector. The upper end supports the industrial camera, and the light source module is installed horizontally in its inner cavity. The bottom is connected to the walking mechanism via a bottom guide groove, forming a gantry-type inspection frame spanning above the weld. Its overall structure provides a stable installation reference for the camera and light source, ensuring that the relative position of the imaging optical axis and the weld surface remains constant during the scanning process.
[0016] An industrial camera is mounted on top of the scanning bracket, with its lens pointing downwards at the weld area, undertaking the task of high-resolution acquisition of weld surface images. The acquired image data is transmitted in real time to the processing unit in the mobile scanning device, where machine vision algorithms are used to automatically identify and classify defects such as cracks, porosity, and incomplete penetration. It is the core sensing component for realizing intelligent detection of weld defects.
[0017] The transverse groove is located on the outer end face of the scanning bracket, providing lateral adjustment freedom for industrial cameras or light source modules; by changing the installation position, it can adapt to the scanning needs of welds of different widths or multi-pass welds, without replacing the whole machine or recalibrating, thus enhancing the versatility of the device in diverse industrial scenarios.
[0018] The bottom guide grooves are horizontally opened on both sides of the bottom of the scanning bracket, which, together with the adjusting crossbeam, form an adjustable wheel track chassis; this allows the scanning unit to straddle the weld seams of pipes or flat plates of different specifications and slide smoothly along the weld seam direction, ensuring the straightness of the scanning trajectory.
[0019] Preferably, the adjusting beam includes a beam body and an adjusting hole group arranged laterally on the surface of the beam body, and a bottom connecting hole is provided at the bottom position of the adjusting hole group.
[0020] Preferably, the visual scanning unit further includes a light source module horizontally installed in the inner cavity of the scanning bracket. The light source module includes a light source bracket and strip light sources installed on both sides of the light source bracket. An adjustment shaft is horizontally inserted into the upper end face of the light source bracket. Shaft end fixing seats are installed at both ends of the adjustment shaft. A top light source is installed on the upper end face of the light source bracket. The adjusting beam connects two sets of bottom guide grooves laterally, forming the bottom travel reference for the scanning unit. The main body of the beam maintains the parallelism and spacing stability of the bottom guide grooves on both sides, transmits the pushing force, and bears the static load of the upper camera and light source. The adjusting hole group is arranged laterally, and the wheel track can be adjusted in stages by matching different hole positions of the bottom guide grooves with pins or fasteners, so that the device can adapt to changes in pipe diameter or space constraints on both sides of the weld. The bottom connecting hole is used to fix the traveling wheel or guide slider, so as to achieve rolling contact between the scanning unit and the weld surface and reduce the pushing resistance.
[0021] The light source module is horizontally mounted inside the scanning bracket, located between the camera and the weld seam. It provides a controllable lighting environment for machine vision imaging and is a key structure for solving interference such as surface reflection and uneven lighting in the weld seam.
[0022] The light source bracket, serving as the base of the light source module, is connected to the inner wall of the scanning bracket via an adjustable rotating shaft, maintaining a constant distance between the light source and the weld surface. Strip light sources are installed on both sides of the bracket, illuminating the weld surface with low-angle side light. The difference in texture between the defects and the base material highlights the contrast between cracks, undercuts, and other defects, enhancing image edge clarity. The adjustable rotating shaft is horizontally inserted into the upper end of the light source bracket and is rotatably connected to the inner wall of the scanning bracket via a shaft-end fixing seat, allowing the light source bracket to swing around the shaft, thereby adjusting the illumination angle to adapt to welds with different bevel shapes or surface roughness. The shaft-end fixing seats are installed at both ends of the rotating shaft, providing rotational support and locking after angle adjustment to ensure the light source posture does not shift due to vibration during scanning. The top light source is installed on the upper surface of the light source bracket, providing highly uniform diffuse illumination or coaxial directional illumination. This effectively suppresses specular reflection and glare on the metal weld surface, preventing high-brightness areas from overshadowing defect features, significantly improving the image signal-to-noise ratio, and meeting the front-end optical requirements of the task description: "exploring robust preprocessing technologies that adapt to changes in illumination and interference factors such as surface reflection."
[0023] Preferably, the adjusting shaft is connected to both sides of the inner cavity wall of the scanning bracket via a shaft end fixing seat, so that the scanning bracket and the light source module are combined into a whole.
[0024] Preferably, the visual scanning unit further includes a top window opened on the upper surface of the scanning bracket, and the two sides of the side edge of the scanning bracket are connected to the side surface of the main frame through quick-release connectors. The top viewing window is located on the upper surface of the scanning bracket, providing an unobstructed shooting channel for the industrial camera lens, avoiding obstruction of the field of view by the scanning bracket itself, and ensuring that the camera can fully capture the image of the weld area.
[0025] Quick-release connectors are located on both sides of the edge of the scanning bracket side face and connected to the side face of the main frame, enabling quick assembly and disassembly of the visual scanning unit and the mobile scanning device; during transportation or relocation, the detection unit can be separated from the main unit, reducing the weight of a single item during handling; during on-site assembly, it can be hooked and locked without tools, shortening deployment time.
[0026] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This device combines the main unit and the vision scanning unit with quick-release connectors. The front of the machine is equipped with wheels and the side has a pusher, allowing for continuous image acquisition by pushing it along the weld seam. This eliminates the need for repeated equipment handling or fixed-point positioning, significantly reducing manual labor intensity when inspecting long weld seams. The scanning bracket forms a gantry-like frame across the weld seam, fixing the relative positions of the camera and light source. This prevents the optical axis from shifting during movement, resulting in better imaging stability than handheld devices. The bottom guide groove, along with multiple adjustment holes on the adjusting beam, allows for quick adjustment of the wheel track according to the pipe diameter or weld width. The transverse sliding groove allows for left and right adjustment of the camera and light source positions. One device can cover various working conditions such as flat plate welding, pipe welding, and multi-pass welding, demonstrating good equipment versatility.
[0027] 2. The light source module employs a combination of strip light sources and top light sources. The strip light sources provide low-angle side lighting, highlighting cracks and undercut contours by utilizing the texture difference between defects and the base material. The top light source provides highly uniform diffused illumination, suppressing specular reflections and glare on the metal surface. Adjusting the rotating shaft causes the light source bracket to swing, allowing for adjustments to the lighting direction based on different bevel angles and surface roughness. Once locked in place by the shaft-end fixing seat, it will not shift during scanning. The coordinated use of multiple light sources improves the image signal-to-noise ratio and makes defect edges clearer, providing a high-quality image source for the backend machine vision algorithm to identify defects such as cracks, porosity, and incomplete penetration.
[0028] 3. The main body of the enclosure is a closed structure, protecting internal electrical components from dust, splashes, and humid air. The front sides feature outward-sloping ventilation holes, utilizing natural convection for heat dissipation and preventing falling debris. The push handle's inner cavity houses the interface panel module, with edge buffer pads absorbing vibrations and impacts from weld seam height, preventing connectors from loosening. Ventilation holes at the bottom of the panel allow for timely drainage of rainwater or during washing. The entire machine is designed with dustproofing, heat dissipation, waterproofing, and vibration resistance in mind, enabling it to withstand the harsh conditions of boiler and pressure vessel inspection sites, including high dust levels, complex lighting, and uneven ground. It offers high reliability for continuous operation. Attached Figure Description
[0029] Figure 1 This is a three-dimensional structural schematic diagram of a machine vision-based mobile scanning device for weld defects proposed in this invention. Figure 2 This is a schematic diagram of the moving scanning device structure of a machine vision-based moving scanning device for weld defects proposed in this invention. Figure 3 This is a schematic diagram of the main frame structure of a machine vision-based mobile scanning device for weld defects proposed in this invention. Figure 4 This is a schematic diagram of the interface panel module structure of a machine vision-based mobile scanning device for weld defects proposed in this invention. Figure 5 This is a schematic diagram of the visual scanning unit structure of a machine vision-based mobile scanning device for weld defects proposed in this invention. Figure 6 This is a schematic diagram of the adjusting beam structure of a machine vision-based weld defect moving scanning device proposed in this invention. Figure 7 This is a schematic diagram of the light source module structure of a machine vision-based mobile scanning device for weld defects proposed in this invention.
[0030] In the diagram: 1. Mobile scanning device; 11. Main frame; 111. Main body of the housing; 112. Bottom support; 113. Inclined operating surface; 114. Display screen; 115. Heat dissipation holes; 12. Traveling wheels; 13. Push handle; 14. Interface panel module; 141. Panel substrate; 142. Edge buffer pad; 143. Bottom heat dissipation holes; 2. Vision scanning unit; 21. Scanning bracket; 22. Industrial camera; 23. Horizontal slide; 24. Bottom guide groove; 25. Adjustable crossbeam; 251. Crossbeam body; 252. Adjustment hole group; 253. Bottom connection hole; 26. Light source module; 261. Light source bracket; 262. Strip light source; 263. Adjustment shaft; 264. Shaft end fixing seat; 265. Top light source; 27. Top viewing window; 28. Quick-release connector. Detailed Implementation
[0031] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.
[0032] Reference Figures 1-7 Example 1: A mobile scanning device for weld defects based on machine vision includes a mobile scanning device 1 and a vision scanning unit 2. The vision scanning unit 2 is installed on the rear end face of the mobile scanning device 1. The mobile scanning device 1 includes a main frame 11 and walking wheels 12 installed at the bottom of both sides of the front end face of the main frame 11. Pushers 13 are installed on the side end face of the main frame 11.
[0033] The main frame 11 includes a cabinet body 111 and bottom support legs 112 installed at the bottom corners of both sides of the front end face of the cabinet body 111. An inclined operating surface 113 is opened on the upper end face of the cabinet body 111, and display screens 114 are installed on both sides of the upper end face of the inclined operating surface 113.
[0034] The main frame 11 serves as the load-bearing base of the whole machine, and forms a closed cavity inside to accommodate the image processing unit, power supply and control module. The bottom of both sides of its front face is equipped with walking wheels 12, and the side face is equipped with push handles 13, which together form a human-machine collaborative platform that can be pushed and moved, enabling the device to move continuously along the weld seam trajectory, realize the push-sweep inspection of the weld seam on site, replace the traditional fixed-station inspection mode, and significantly improve the flexibility of on-site operation.
[0035] The main body 111 is the core support structure of the overall frame, providing an installation benchmark and protecting the internal electrical components from dust, splashes and humid environments in the industrial field, ensuring the stable operation of the machine vision system.
[0036] The bottom support feet 112 are located at the bottom corners of both sides of the front face of the main body 111. They provide multi-point support to the ground during device parking or scanning. In conjunction with the rear vision scanning unit 2, they prevent the machine from shaking due to uneven ground or operating force, ensuring spatial stability when the industrial camera is imaging.
[0037] The inclined operating surface 113 is located on the upper surface of the main body 111 of the box, with its inclination angle facing the operator's line of sight; the display screen 114 installed on it is thus at an ergonomic viewing angle, so that the operator can observe the defect identification results and equipment status in real time without looking down or up while pushing the device, reducing neck fatigue from long-term outdoor or high-altitude work.
[0038] In embodiment 2, the main frame 11 also includes heat dissipation holes 115 that are inclined outwardly opened at the two edges of the front face of the main body 111; The heat dissipation holes 115 are inclined outward and opened on both sides of the front face of the main body 111 of the box. They utilize the principle of natural convection of hot air to dissipate the heat inside the box. The inclined outward opening structure can block dust and foreign objects falling from above while dissipating heat, taking into account both heat dissipation efficiency and overall protection level, and adapting to the complex working conditions of high dust in boiler and pressure vessel sites.
[0039] In embodiment 3, the mobile scanning device 1 further includes an interface panel module 14 installed in the inner cavity of the pusher 13. The interface panel module 14 includes a panel substrate 141 and an edge buffer pad 142 installed at the edge of the panel substrate 141. The other end of the edge buffer pad 142 is connected to the interface of the inner cavity wall of the pusher 13. Bottom heat dissipation holes 143 are opened on both sides of the bottom end surface of the panel substrate 141. The walking wheels 12 are installed on both sides of the bottom of the front face of the main frame 11, forming a multi-point rolling support together with the walking mechanism at the rear of the vision scanning unit 2. This disperses the weight of the whole machine and converts it into rolling friction, allowing the operator to easily push the device to move on the weld surface by pushing the handle 13, thereby achieving continuous scanning and reducing the labor intensity of manual handling.
[0040] The pusher 13 is installed on the side end face of the main frame 11 as a force application point for human-machine interaction; its installation height and lateral span are ergonomic, making it easy for operators to hold and push the device in complex scenarios such as narrow spaces, pipeline circumference or high-altitude platforms, improving on-site accessibility.
[0041] The interface panel module 14 is embedded in the inner cavity of the pusher 13, making full use of the hollow space inside the pusher to achieve a compact structure. The panel substrate 141 centrally arranges the power interface, data communication port and trigger interface to realize the electrical interconnection between the main unit and the vision scanning unit 2; the edge buffer pad 142 is connected to the inner wall of the pusher 13 to absorb vibration and impact when the device passes through the weld excess or uneven ground, preventing the interface solder joints from loosening or the connector from being loose, and ensuring the reliability of data transmission; the bottom heat dissipation holes 143 are opened on both sides of the bottom end of the panel, which not only facilitates the dissipation of heat in the interface area, but also allows water to be drained in time in outdoor rainy days or washing scenarios, improving the environmental adaptability of the whole machine.
[0042] Example 4: The visual scanning unit 2 includes a scanning bracket 21 and an industrial camera 22 mounted on the top of the scanning bracket 21. A transverse sliding groove 23 is opened on the outer end face of the scanning bracket 21, and bottom guide grooves 24 are opened on both sides of the bottom position of the scanning bracket 21. The two sets of bottom guide grooves 24 are movably connected by an adjusting beam 25. The scanning bracket 21 serves as the skeleton of the vision scanning unit 2. Its rear end is connected to the side face of the main frame 11 via a quick-release connector 28. The upper end supports the industrial camera 22, and the light source module 26 is installed horizontally in its inner cavity. The bottom is connected to the walking mechanism via a bottom guide groove 24, forming a gantry-type inspection frame spanning above the weld. Its overall structure provides a stable installation reference for the camera and the light source, ensuring that the relative position of the imaging optical axis and the weld surface remains constant during the scanning process.
[0043] The industrial camera 22 is mounted on top of the scanning bracket 21 with its lens facing downwards towards the weld area, undertaking the task of high-resolution acquisition of weld surface images; the acquired image data is transmitted in real time to the processing unit in the mobile scanning device 1, and the machine vision algorithm is used to automatically identify and classify defects such as cracks, pores, and incomplete penetration, which is the core sensing component for realizing intelligent detection of weld defects.
[0044] A transverse groove 23 is provided on the outer end face of the scanning bracket 21, providing a transverse degree of freedom for the industrial camera 22 or the light source module 26; by changing the installation position, it can adapt to the scanning needs of welds of different widths or multi-pass welds, without the need to replace the whole machine or recalibrate, thus enhancing the versatility of the device in diverse industrial scenarios.
[0045] Bottom guide grooves 24 are horizontally opened on both sides of the bottom of the scanning bracket 21, and cooperate with the adjusting beam 25 to form a walking chassis with adjustable wheel track; so that the scanning unit can ride on top of weld seams of pipes or flat plates of different specifications and slide smoothly along the weld seam direction to ensure the straightness of the scanning trajectory.
[0046] Example 5: The adjusting beam 25 includes a beam body 251 and an adjusting hole group 252 arranged laterally on the surface of the beam body 251. A bottom connecting hole 253 is provided at the bottom position of the adjusting hole group 252.
[0047] The visual scanning unit 2 also includes a light source module 26 that is horizontally installed in the inner cavity of the scanning bracket 21. The light source module 26 includes a light source bracket 261 and strip light sources 262 installed on both sides of the light source bracket 261. An adjustment shaft 263 is horizontally inserted into the upper end face of the light source bracket 261. Shaft end fixing seats 264 are installed at both ends of the adjustment shaft 263. A top light source 265 is installed on the upper end face of the light source bracket 261. The adjusting beam 25 connects two sets of bottom guide grooves 24 laterally, forming the bottom travel reference of the scanning unit. The main body of the beam 251 maintains the parallelism and spacing stability of the bottom guide grooves 24 on both sides, transmits the pushing force, and bears the static load of the upper camera and light source. The adjusting hole group 252 is arranged laterally and, through the cooperation of pins or fasteners with different hole positions of the bottom guide grooves 24, realizes the stepped adjustment of the wheel track, so that the device can adapt to changes in pipe diameter or space constraints on both sides of the weld. The bottom connecting hole 253 is used to fix the traveling wheel or guide slider, realize the rolling contact between the scanning unit and the weld surface, and reduce the pushing resistance.
[0048] The light source module 26 is horizontally mounted in the inner cavity of the scanning bracket 21, located between the camera and the weld seam. It provides a controllable lighting environment for machine vision imaging and is a key structure for solving interference such as surface reflection and uneven lighting of the weld seam.
[0049] The light source bracket 261 serves as the base of the light source module 26. It is connected to the inner wall of the scanning bracket 21 via an adjusting shaft 263, maintaining a constant distance between the light source and the weld surface. Strip light sources 262 are installed on both sides of the bracket, illuminating the weld surface with low-angle side light. The difference in texture between the defects and the base material highlights the contrast between cracks, undercuts, and other defects, enhancing image edge clarity. The adjusting shaft 263 is horizontally inserted into the upper end of the light source bracket 261 and is rotatably connected to the inner wall of the scanning bracket 21 via a shaft end fixing seat 264, allowing the light source bracket to swing around the shaft, thereby adjusting the illumination angle to adapt to different lighting conditions. Welds with different bevel shapes or surface roughness; shaft end fixing seat 264 is installed at both ends of the rotating shaft, providing rotational support and locking after angle adjustment, ensuring that the light source posture does not shift due to vibration during scanning; top light source 265 is installed on the upper end face of light source bracket 261, providing highly uniform diffuse illumination or coaxial directional illumination, effectively suppressing specular reflection and glare on the surface of metal welds, avoiding the high-light area from overshadowing defect features, significantly improving the image signal-to-noise ratio, and meeting the front-end optical requirements of "exploring robust preprocessing technology that adapts to interference factors such as changes in illumination and surface reflection" in the task statement.
[0050] In Example 6, the adjusting shaft 263 is connected to both sides of the inner cavity wall of the scanning bracket 21 through the shaft end fixing seat 264, so that the scanning bracket 21 and the light source module 26 are combined into a whole.
[0051] The visual scanning unit 2 also includes a top window 27 opened on the upper end face of the scanning bracket 21, and the two sides of the side end face edge of the scanning bracket 21 are connected to the side end face of the main frame 11 through quick-release connectors 28. The top window 27 is located on the upper surface of the scanning bracket 21, providing an unobstructed shooting channel for the lens of the industrial camera 22, avoiding obstruction of the field of view by the structure of the scanning bracket itself, and ensuring that the camera can completely capture the image of the weld area.
[0052] Quick-release connectors 28 are located on both sides of the edge of the side end face of the scanning bracket 21 and are connected to the side end face of the main frame 11, enabling quick assembly and disassembly of the visual scanning unit 2 and the mobile scanning device 1; during transportation or relocation, the detection unit can be separated from the main unit, reducing the weight of a single item; during on-site assembly, it can be hooked and locked without tools, shortening deployment time.
[0053] In summary: The main frame 11 serves as the load-bearing base of the entire machine, forming a closed cavity inside to accommodate the image processing unit, power supply, and control module; the bottom of both sides of its front face are equipped with walking wheels 12, and the side faces are equipped with push handles 13, which together constitute a human-machine collaborative platform that can be pushed and moved, enabling the device to move continuously along the weld seam trajectory, realize push-sweep inspection of weld seams on site, replace the traditional fixed-station inspection mode, and significantly improve the flexibility of on-site operations.
[0054] The main body 111 is the core support structure of the overall frame, providing an installation benchmark and protecting the internal electrical components from dust, splashes and humid environments in the industrial field, ensuring the stable operation of the machine vision system.
[0055] The bottom support feet 112 are located at the bottom corners of both sides of the front face of the main body 111. They provide multi-point support to the ground during device parking or scanning. In conjunction with the rear vision scanning unit 2, they prevent the machine from shaking due to uneven ground or operating force, ensuring spatial stability when the industrial camera is imaging.
[0056] The inclined operating surface 113 is located on the upper surface of the main body 111 of the box, with its inclination angle facing the operator's line of sight; the display screen 114 installed on it is thus at an ergonomic viewing angle, so that the operator can observe the defect identification results and equipment status in real time without looking down or up while pushing the device, reducing neck fatigue from long-term outdoor or high-altitude work.
[0057] The heat dissipation holes 115 are inclined outward and opened on both sides of the front face of the main body 111 of the box. They utilize the principle of natural convection of hot air to dissipate the heat inside the box. The inclined outward opening structure can block dust and foreign objects falling from above while dissipating heat, taking into account both heat dissipation efficiency and overall protection level, and adapting to the complex working conditions of high dust in boiler and pressure vessel sites.
[0058] The walking wheels 12 are installed on both sides of the bottom of the front face of the main frame 11, forming a multi-point rolling support together with the walking mechanism at the rear of the vision scanning unit 2. This disperses the weight of the whole machine and converts it into rolling friction, allowing the operator to easily push the device to move on the weld surface by pushing the handle 13, thereby achieving continuous scanning and reducing the labor intensity of manual handling.
[0059] The pusher 13 is installed on the side end face of the main frame 11 as a force application point for human-machine interaction; its installation height and lateral span are ergonomic, making it easy for operators to hold and push the device in complex scenarios such as narrow spaces, pipeline circumference or high-altitude platforms, improving on-site accessibility.
[0060] The interface panel module 14 is embedded in the inner cavity of the pusher 13, making full use of the hollow space inside the pusher to achieve a compact structure. The panel substrate 141 centrally arranges the power interface, data communication port and trigger interface to realize the electrical interconnection between the main unit and the vision scanning unit 2; the edge buffer pad 142 is connected to the inner wall of the pusher 13 to absorb vibration and impact when the device passes through the weld excess or uneven ground, preventing the interface solder joints from loosening or the connector from being loose, and ensuring the reliability of data transmission; the bottom heat dissipation holes 143 are opened on both sides of the bottom end of the panel, which not only facilitates the dissipation of heat in the interface area, but also allows water to be drained in time in outdoor rainy days or washing scenarios, improving the environmental adaptability of the whole machine.
[0061] The scanning bracket 21 serves as the skeleton of the vision scanning unit 2. Its rear end is connected to the side face of the main frame 11 via a quick-release connector 28. The upper end supports the industrial camera 22, and the light source module 26 is installed horizontally in its inner cavity. The bottom is connected to the walking mechanism via a bottom guide groove 24, forming a gantry-type inspection frame spanning above the weld. Its overall structure provides a stable installation reference for the camera and the light source, ensuring that the relative position of the imaging optical axis and the weld surface remains constant during the scanning process.
[0062] The industrial camera 22 is mounted on top of the scanning bracket 21 with its lens facing downwards towards the weld area, undertaking the task of high-resolution acquisition of weld surface images; the acquired image data is transmitted in real time to the processing unit in the mobile scanning device 1, and the machine vision algorithm is used to automatically identify and classify defects such as cracks, pores, and incomplete penetration, which is the core sensing component for realizing intelligent detection of weld defects.
[0063] A transverse groove 23 is provided on the outer end face of the scanning bracket 21, providing a transverse degree of freedom for the industrial camera 22 or the light source module 26; by changing the installation position, it can adapt to the scanning needs of welds of different widths or multi-pass welds, without the need to replace the whole machine or recalibrate, thus enhancing the versatility of the device in diverse industrial scenarios.
[0064] Bottom guide grooves 24 are horizontally opened on both sides of the bottom of the scanning bracket 21, and cooperate with the adjusting beam 25 to form a walking chassis with adjustable wheel track; so that the scanning unit can ride on top of weld seams of pipes or flat plates of different specifications and slide smoothly along the weld seam direction to ensure the straightness of the scanning trajectory.
[0065] The adjusting beam 25 connects two sets of bottom guide grooves 24 laterally, forming the bottom travel reference of the scanning unit. The main body of the beam 251 maintains the parallelism and spacing stability of the bottom guide grooves 24 on both sides, transmits the pushing force, and bears the static load of the upper camera and light source. The adjusting hole group 252 is arranged laterally and, through the cooperation of pins or fasteners with different hole positions of the bottom guide grooves 24, realizes the stepped adjustment of the wheel track, so that the device can adapt to changes in pipe diameter or space constraints on both sides of the weld. The bottom connecting hole 253 is used to fix the traveling wheel or guide slider, realize the rolling contact between the scanning unit and the weld surface, and reduce the pushing resistance.
[0066] The light source module 26 is horizontally mounted in the inner cavity of the scanning bracket 21, located between the camera and the weld seam. It provides a controllable lighting environment for machine vision imaging and is a key structure for solving interference such as surface reflection and uneven lighting of the weld seam.
[0067] The light source bracket 261 serves as the base of the light source module 26. It is connected to the inner wall of the scanning bracket 21 via an adjusting shaft 263, maintaining a constant distance between the light source and the weld surface. Strip light sources 262 are installed on both sides of the bracket, illuminating the weld surface with low-angle side light. The difference in texture between the defects and the base material highlights the contrast between cracks, undercuts, and other defects, enhancing image edge clarity. The adjusting shaft 263 is horizontally inserted into the upper end of the light source bracket 261 and is rotatably connected to the inner wall of the scanning bracket 21 via a shaft end fixing seat 264, allowing the light source bracket to swing around the shaft, thereby adjusting the illumination angle to adapt to different lighting conditions. Welds with different bevel shapes or surface roughness; shaft end fixing seat 264 is installed at both ends of the rotating shaft, providing rotational support and locking after angle adjustment, ensuring that the light source posture does not shift due to vibration during scanning; top light source 265 is installed on the upper end face of light source bracket 261, providing highly uniform diffuse illumination or coaxial directional illumination, effectively suppressing specular reflection and glare on the surface of metal welds, avoiding the high-light area from overshadowing defect features, significantly improving the image signal-to-noise ratio, and meeting the front-end optical requirements of "exploring robust preprocessing technology that adapts to interference factors such as changes in illumination and surface reflection" in the task statement.
[0068] The top window 27 is located on the upper surface of the scanning bracket 21, providing an unobstructed shooting channel for the lens of the industrial camera 22, avoiding obstruction of the field of view by the structure of the scanning bracket itself, and ensuring that the camera can completely capture the image of the weld area.
[0069] Quick-release connectors 28 are located on both sides of the edge of the side end face of the scanning bracket 21 and are connected to the side end face of the main frame 11, enabling quick assembly and disassembly of the visual scanning unit 2 and the mobile scanning device 1; during transportation or relocation, the detection unit can be separated from the main unit, reducing the weight of a single item; during on-site assembly, it can be hooked and locked without tools, shortening deployment time.
[0070] The above describes the entire working principle of this invention.
[0071] In this invention, the installation, connection or setting methods of all the components mentioned above are common mechanical methods, and the specific structure, model and coefficient index of all the components are their own technologies. As long as they can achieve their beneficial effects, they can be implemented, so they will not be described in detail.
[0072] The above embodiments are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the spirit and principle of the present invention shall be considered equivalent substitutions and shall be included within the protection scope of the present invention.
[0073] In this invention, unless otherwise stated, directional terms such as "up, down, left, right, front, back, inside, outside, and vertical and horizontal" in the terminology only represent the orientation of the term in its conventional use or are common terms understood by those skilled in the art, and should not be regarded as limitations on the term. At the same time, numerals such as "first," "second," and "third" do not represent specific quantities or orders, but are merely used to distinguish names. Moreover, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a series of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.
Claims
1. A machine vision-based mobile scanning device for weld defects, comprising a mobile scanning device (1) and a vision scanning unit (2), characterized in that, The rear end face of the mobile scanning device (1) is equipped with a visual scanning unit (2). The mobile scanning device (1) includes a main frame (11) and walking wheels (12) installed at the bottom of both sides of the front end face of the main frame (11). Pushers (13) are installed on the side end face of the main frame (11).
2. The machine vision-based weld defect moving scanning device according to claim 1, characterized in that, The main frame (11) includes a box body (111) and bottom support feet (112) installed at the bottom corners of both sides of the front end face of the box body (111). An inclined operating surface (113) is opened on the upper end face of the box body (111), and a display screen (114) is installed on both sides of the upper end face of the inclined operating surface (113).
3. The machine vision-based weld defect moving scanning device according to claim 2, characterized in that, The main frame (11) also includes heat dissipation holes (115) that are inclined outwardly opened at the two sides of the front end face of the main body (111).
4. The machine vision-based weld defect moving scanning device according to claim 3, characterized in that, The mobile scanning device (1) further includes an interface panel module (14) installed in the inner cavity of the pusher (13). The interface panel module (14) includes a panel substrate (141) and an edge buffer pad (142) installed at the edge of the panel substrate (141). The other end of the edge buffer pad (142) is connected to the interface of the inner cavity wall of the pusher (13). Bottom heat dissipation holes (143) are opened on both sides of the bottom end face of the panel substrate (141).
5. The machine vision-based weld defect moving scanning device according to claim 1, characterized in that, The visual scanning unit (2) includes a scanning bracket (21) and an industrial camera (22) installed at the top of the scanning bracket (21). A transverse sliding groove (23) is opened on the outer end face of the scanning bracket (21), and bottom guide grooves (24) are opened on both sides of the bottom position of the scanning bracket (21). The two sets of bottom guide grooves (24) are movably connected by an adjusting beam (25).
6. The machine vision-based weld defect moving scanning device according to claim 5, characterized in that, The adjusting beam (25) includes a beam body (251) and an adjusting hole group (252) arranged laterally on the surface of the beam body (251). A bottom connecting hole (253) is provided at the bottom position of the adjusting hole group (252).
7. The machine vision-based weld defect moving scanning device according to claim 6, characterized in that, The visual scanning unit (2) further includes a light source module (26) that is horizontally installed in the inner cavity of the scanning bracket (21). The light source module (26) includes a light source bracket (261) and strip light sources (262) installed on both sides of the light source bracket (261). An adjustment shaft (263) is horizontally inserted on the upper end face of the light source bracket (261). Shaft end fixing seats (264) are installed at both ends of the adjustment shaft (263). A top light source (265) is installed on the upper end face of the light source bracket (261).
8. The machine vision-based weld defect moving scanning device according to claim 7, characterized in that, The adjustment shaft (263) is connected to both sides of the inner cavity wall of the scanning bracket (21) through the shaft end fixing seat (264), so that the scanning bracket (21) and the light source module (26) are combined into a whole.
9. A machine vision-based moving scanning device for weld defects according to claim 8, characterized in that, The visual scanning unit (2) also includes a top window (27) opened on the upper surface of the scanning bracket (21), and the two sides of the side edge of the scanning bracket (21) are connected to the side surface of the main frame (11) through quick-release connectors (28).