An industrial detection CT device and its control system

Abstract

The present invention discloses a long-range and short-range scanning motion control system based on an outdoor online rapid detection CT device. The outdoor online rapid detection device is a portable and movable CT scanning system device. The main purpose is to realize the rapid task of non-destructive detection of workpieces by the device through remote operation. The functions are mainly concentrated on the design concepts of high precision of the motion axis of the device, high image quality, and high automation integration. The system is mainly composed of a ring track component and a motion control component, wherein the ring track component serves as the main mechanical device. It includes a supporting device, a ring base, a driving device, a motion slide, etc. The track of the ring track component is designed to be assembleable and detachable, the component can be clamped on the detection object, and a ray source and a detector can be installed, and the ray source and the detector can rotate synchronously. The remote control system is mainly composed of a remote control console, a remote emergency stop button box, a cable reel, a remote control box, and remote communication equipment.

Description

Technical Field

[0001] The present invention relates to the field of portable mobile industrial CT devices, and in particular to an industrial detection CT device and a control system thereof. Background Art

[0002] With the development of mobile industrial CT devices, such as motorization, lightness, diversified operation sites, fast detection and simple operation, there are problems such as the environmental limitations of the detection site and the professional requirements of personnel for various working conditions. Therefore, the scanning control of mobile industrial CT devices is required to be faster, more humane and more automated. When there is a need to detect multiple tasks of workpieces in the field, a portable and movable industrial detection CT device is required to achieve rapid disassembly and assembly of components, rapid detection of workpieces and rapid workpiece image processing and analysis. Since the detection of workpieces in harsh field environments involves radiation damage to the human body caused by the radiation dose emitted by the radiation source, and the immovable multi-workpieces in the field can only rely on distance protection, the operator must perform remote control at a safe distance. Summary of the invention

[0003] In view of the deficiencies in the prior art, the present invention provides an industrial inspection CT device and a control system thereof. The system can simultaneously meet the requirements of DR scanning imaging and cone beam CT scanning imaging. The system control is mainly achieved through the human-computer interaction unit and the emergency stop control unit in the remote control area. The operator directly controls the on-site mechanical motion mechanism and performs tasks such as system beam output image acquisition through the software.

[0004] In a first aspect of the present invention, an industrial inspection CT system is provided, comprising a remote control module and an on-site inspection module electrically connected to the remote control module, wherein the on-site inspection module comprises an on-site inspection element and a motion component, and the remote control module comprises a power supply and a controller, a driver, a router and a switch connected to the controller for communication, and also comprises a human-computer interaction unit; the remote control module performs the following functions:

[0005] Provide energy for the field detection module;

[0006] Set the scanning parameters required for detection gain correction through the human-computer interaction unit, control the movement of on-site detection elements and motion components, and collect data;

[0007] Accept data collected by the on-site detection unit;

[0008] Process the collected data.

[0009] In another aspect of the present invention, an industrial detection CT device is proposed, comprising an on-site detection area and a remote control area, wherein the on-site detection area is detachably provided with an assembled annular track assembly, on which a radiation source and a detector are detachably provided, and the radiation source and the detector rotate synchronously; an electric cabinet is arranged in the remote control area, in which a power supply, a driver, a controller, a router and a switch are integrated, and the electric cabinet is connected to the on-site detection area via cables; the outside of the electric cabinet is also communicatively connected to a human-computer interaction unit via cables.

[0010] The present invention has the following advantages:

[0011] 1) Take into account both remote control and short-range control, with remote control as the main method to avoid the radiation dose from the radiation source causing harm to the human body;

[0012] 2) It has a portable and mobile disassembly component to effectively improve the detection efficiency;

[0013] 3) The detection equipment and the motion unit are controlled by the controller to achieve accurate semi-enclosed positioning of the motion axis. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a simplified distribution diagram of an industrial inspection CT device in an embodiment of the present invention.

[0015] Figure 2 This is a flow chart of software control equipment for an industrial inspection CT system in an embodiment of the present invention.

[0016] Figure 3 It is a schematic side view of the structure of the annular track assembly in a preferred embodiment of the present invention.

[0017] Figure 4 The figure is a schematic top view of the structure of the annular track assembly in a preferred embodiment of the present invention.

[0018] The reference numerals are as follows:

[0019] 1. On-site detection area; 2. Remote control area; 3. Radiation source; 4. Camera; 5. Detector; 6. Cable; 7. Power supply; 8. Driver; 9. Controller; 10. Electric cabinet; 11. Switch; 12. Router; 13. Human-computer interaction unit; 14. Emergency stop control box; 15. Annular track assembly; 16. Support device; 17. Annular base; 18. Drive device; 19. Sports skateboard; 20. Support leg; 21. Anti-slip pad; 22. Guide rod; 23. Lifting device; 24. Lifting platform; 25. Lifting motor; 26. Lifting rod; 27. Synchronous rod; 28. Drive motor; 29. ​​Drive gear; 30. Track wheel; 31. Outer guide rail; 32. Outer gear ring; 33. Support guide device; 34. Roller. DETAILED DESCRIPTION

[0020] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0021] The design principles of this embodiment are as follows

[0022] Modular design: The functional modules are divided according to the functions of system functional components, which effectively reduces the coupling between components and modules, makes the modules independent and complete, facilitates manufacturing and inspection, and improves the quality of the whole machine.

[0023] Standardized design: From the whole machine to each sub-item, including mechanical, electrical, data and other interfaces, they follow consistent, standardized and complete protocols or specifications. The mechanical, electrical, software and appearance aspects comply with relevant national standards and enterprise specifications. Unified standards are stipulated in material selection, process equipment, process methods, test methods, etc. The components used in the equipment and parts should use reliable standard components as much as possible, so that the instrument has the characteristics of rapid replication, cost reduction and quality improvement.

[0024] Reliability design: component selection and control, thermal design, derating design, electromagnetic compatibility design, environmental protection design

[0025] Full life cycle design: The system takes into account the machinability, reliability, maintainability, assemblability, aesthetics and durability of components and instruments to achieve one-time success in manufacturing and debugging.

[0026] Rapid detection technology: In the optimization of component and equipment structure and instrument appearance design, digital simulation design (such as three-dimensional structure design) is used to optimize and beautify the instrument structure.

[0027] According to the above principles, an industrial detection CT system is designed, including a remote control module and a field detection module electrically connected to the remote control module, the field detection module includes a field detection element and a motion component, the remote control module includes a power supply 7 and a controller 9, a driver 8 connected to the controller 9, a router 12 and a switch 11, and also includes a human-computer interaction unit 13; the router 12 and the switch 11 are connected to the field detection module through a wireless module; the remote control module also includes an emergency stop control switch for controlling the field detection module through the controller 9; the remote control module completes the following functions:

[0028] Provide energy for the field detection module;

[0029] The scanning parameters required for detection gain correction are set through the human-computer interaction unit 13, and the movement of the on-site detection element and the motion component is controlled and data is collected;

[0030] Accept data collected by the on-site detection unit;

[0031] Process the collected data.

[0032] In view of the above system and its functions, the present invention proposes an embodiment, an industrial detection CT device, such as Figure 1 As shown, it includes a field detection area 1 and a remote control area 2, the field detection area 1 is detachably provided with an assembled annular track component 15, the annular track component 15 is detachably provided with a ray source 3 and a detector 5, and the ray source 3 and the detector 5 rotate synchronously; an electric cabinet 10 is arranged in the remote control area 2, and a power supply 7, a driver 8, a controller 9, a router 12 and a switch 11 are integrated in the electric cabinet 10, and the electric cabinet 10 is connected with the field detection area 1 through a cable 6; wherein the power supply 7 and the driver 8 are used to supply energy to each component of the field detection area 1, and the two are coordinated and controlled by the controller 9, the switch 11 is connected to the detector 5 through a wireless module for communication, and is used to receive the data collected by the detector 5, and then transmit it to the controller 9 through the router 12, and the outside of the electric cabinet 10 is also connected to the human-computer interaction unit 13 through a cable 6 for communication, and the human-computer interaction unit 13 generally adopts a PC or a portable notebook computer, which is used to adjust the detection parameters, issue instructions to the controller 9 and process the received data.

[0033] In a preferred embodiment of the present invention, Figure 3 , Figure 4As shown, the annular track assembly 15 includes a supporting device 16, an annular base 17, a driving device 18, and a moving slide 19. The supporting device 16 includes a group of symmetrically arranged supporting frames, and two are generally arranged in a group. Three supporting legs 20 distributed in a triangle are arranged at the bottom of the supporting frame. The triangular structure supports the middle part of the supporting legs 20 to be hinged on the supporting platform, so that the angle of the supporting legs 20 can be adjusted. The bottom of the supporting legs 20 is provided with anti-skid pads 21 to prevent the supporting legs 20 from moving; a guide rod 22 is arranged on the supporting platform, and a lifting device 23 is arranged on the guide rod 22. The lifting device 23 can slide up and down on the guide rod 22, and the lifting device 23 generally adopts a lifting mechanism. Cylinder, the lifting cylinder is driven by a lifting motor 25 arranged on the support platform; the lifting device 23 is provided with a lifting platform 24 facing the detection object, and the lifting platform 24 is provided with a lifting rod 26, the top of the lifting rod 26 is connected to the annular base 17, and the annular base 17 is slidingly provided with the mutually symmetrical moving slides 19, and the ray source 3 and the detector 5 are respectively arranged on the moving slides 19 to ensure that the ray source 3 and the detector 5 are arranged relative to each other, and the moving slides 19 are fixedly connected by a synchronization rod 27, and the synchronization rod 27 is semicircular, and the driving device 18 for driving the moving slide 19 to rotate around the annular base 17 is arranged on the outer side of one of the moving slides 19. A raised outer guide rail 31 is provided on one side of the top of the annular base 17, an inner guide rail is provided on the inner side of the annular base 17 at a position corresponding to the outer guide rail 31, and a group of track wheels 30 are provided at the bottom of the moving skateboard 19 and are respectively engaged with the inner guide rail and the outer guide rail 31; the driving device 18 includes a driving motor 28 fixed to the outside of the moving skateboard 19, the output shaft of the driving motor 28 extends vertically downward and is fixedly connected to the driving gear 29 at the bottom of the moving skateboard 19, and an annular outer gear ring 32 is provided on the outside of the annular base 17 below the outer guide rail 31, and the annular outer gear ring 32 is meshed with the driving gear 29. When the driving motor 28 is started, it drives the driving gear 29 to rotate, and under the action of the track wheel 30, the moving slide 19 makes a circular motion around the annular base 17; the synchronization rod 27 adopts an arc-shaped structure coaxial with the annular base 17, ensuring that all the moving slides 19 rotate synchronously around the annular base 17 under the drive of the driving device 18, so that the radiation source 3 and the detector 5 make a synchronous circular motion around the detected element.

[0034] In a preferred embodiment of the present invention, Figure 3The bottom of the moving slide 19 is hingedly provided with a support guide device 33, and the support guide device 33 includes a guide seat fixedly provided at the bottom of the moving slide 19, and a telescopic push rod is hingedly provided on the guide seat, and a roller 34 is provided at the end of the telescopic push rod; the support guide device 33 is distributed in an annular array. The support guide device 33 is used to cooperate with the lifting device 23 to adjust the position of the annular base 17 on the workpiece to be detected, that is, to adjust the detection position.

[0035] In a preferred embodiment of the present invention, Figure 1 The remote control area 2 is also provided with a remote operation console, on which the human-machine interaction unit 13 and an emergency stop control switch are provided, and the emergency stop control switch is connected to the electric cabinet 10 through a cable 6. The remote operation console is used to integrate the computer and the emergency stop control switch, which is convenient for manual control and avoids being unable to react in time in an emergency.

[0036] In a preferred embodiment of the present invention, an infrared sensor probe is arranged outside the field detection area 1, and the infrared sensor probe is interlocked with the ray source 3; the field detection area 1 is also provided with a camera 4, and the remote control area 2 is provided with a display device associated with the camera 4, such as a liquid crystal display screen. Under short-range working conditions, the ray interlocking detects intruders (people or other living things) within a diameter of 15m around by using the infrared sensor probe to ensure that the ray beam is emitted under the premise of safety; under long-range working conditions, when an emergency working condition is detected through monitoring by the camera 4, the emergency stop button on the remote emergency stop control box 14 can be pressed to stop the motion control axis in the system and stop the ray source 3.

[0037] When the above embodiment is used, the supporting CTScan software is used for control. The specific interface and operation method can refer to the existing technology, such as Figure 2 :

[0038] 1. Equipment Pre-setting

[0039] Place all components at the inspection site and install them in place. When the working state is ready, press the start momentary button on the control cabinet to power on the equipment. After confirming that the on-site equipment is in normal condition, personnel evacuate to the small remote control console and close the power switch on the reel. Turn on the laptop and start the "CTScan" software to initialize the equipment. Confirm that the control software communicates successfully with the lower controller (the "Communication" indicator light is on), and select "Run->Initialize" from the menu to start the initialization operation. The initialization process takes about 1 minute. Call up the power supply 7 control panel to power the detector 5 and the radiation source 3.

[0040] 2. Adjust geometric parameters

[0041] Select "Diagnosis->Geometric Parameter Adjustment" from the menu to start the geometric parameter adjustment interface and adjust to the starting position of the workpiece scan; set the scanning parameters required for the detector 5 gain correction (must be consistent with the background correction); turn on the beam of the radiation source 3 and stabilize it, and the detector 5 collects data for a period of time (a few seconds) until the data is basically stable, and perform background correction and air correction. Select "Calibration->Background Correction" and "Calibration->Air Correction" from the menu.

[0042] 3. Start DR imaging

[0043] Set the detector 5 merge mode, detection gain and other parameters. After background and air correction, the detector 5 parameters should not be changed, otherwise the image will be abnormal; select the "filming" mode in the detection control panel, set the appropriate acquisition frame number, click the "start acquisition" button to start the detector 5 acquisition, and view the acquired image.

[0044] 4. Start cone beam CT scanning

[0045] In the "Scan Control" panel on the left side of the software, set the scanning mode (cone beam scanning) and the number of scanning divisions, then click the "Start Scan" button to start the cone beam CT scan, control the lifting device 23 and the drive motor 28 to control the movement path of the ray source 3 and the detector 5, so as to achieve cone beam scanning. The collected images can be viewed through the image processing software, and the collected images can also be processed, such as grayscale stretching, as well as measurement, marking and other operations; refer to the instructions for use of the image processing software for details.

[0046] 5. Device shutdown

[0047] After scanning, the workpiece can be removed only after the ray source 3 stops emitting beams. Press and hold the "power 7" button for 3 seconds and release it, and the device will automatically power off.

[0048] The main goal of this system is to coordinate and control the X-ray source 3, flat panel detector 5, precision mechanical platform and image reconstruction and processing system to complete CT scanning in an orderly manner. It also includes auxiliary controls such as power supply 7 control of each unit, emergency safety device, alarm display, human-computer interaction and status diagnosis. The functions of the controller 9 include: high-precision motion control; control of the ray source 3; acquisition synchronization control of the detector 5; system power supply 7 control; system self-test, fault diagnosis and safety interlock protection; system status monitoring and status indication; data communication.

[0049] In order to achieve the functional goals of the system, the structural design of electrical components is mainly divided into main types such as power system, motion control system, control cabinet, safety system, etc.

[0050] Motion control design mainly includes the following aspects:

[0051] Power supply: The power distribution design of the control system power system ensures that all electrical components of the equipment can operate reliably, stably and safely and that the cables can be easily disassembled and carried. The power supply adopts a mobile power supply of a trolley box, with an AC 220V output and a peak value of 6kw to ensure that the power supply capacity of the distribution box is above 3kva. The detector 5 and the ray source 3 are powered by their own batteries. The controller 9 adopts the controller 9 commonly used in the prior art.

[0052] Power supply protection design: The power supply environment of the whole system meets the requirements for outdoor use; the control cabinet is equipped with short circuit, overload, overcurrent and other protectors to protect the safe operation of the equipment and personal safety; the power supply level and protection of the motion system meet the IP65 level; the power supply of auxiliary equipment requires voltage level and protection IP65 level. Three-level protection is adopted, and the specific details can be referred to the existing technology.

[0053] Motion control design: Motion control mainly controls the precise position of the motor shaft on the machine tool to achieve accurate semi-closed loop positioning of the motion control shaft.

[0054] The functional control mainly realizes the system's power distribution control, system fault corresponding display, system communication and other functions.

[0055] Safety control design mainly includes the following aspects:

[0056] When there is a potential safety hazard in the machine tool movement, the system has self-check and alarm functions;

[0057] When there is a safety hazard in the movement of the machine tool, the system has a manual emergency stop hardware device;

[0058] When a potential safety hazard occurs in the beam-emitting state of the radiation source 3, the system is equipped with a manual emergency stop hardware device.

[0059] The advantages of the above embodiment are:

[0060] (1) The equipment is equipped with a small remote control console, a remote control laptop and an emergency stop operation box, which can meet the requirements for rapid control of remote DR scanning imaging and cone beam CT scanning imaging.

[0061] (2) All equipment uses portable power supplies and batteries to supply energy and can be used in outdoor environments without power supply or wired connections.

[0062] (3) The main components use wireless modules for control and data collection, eliminating the need for wired connections.

[0063] (4) Under short-range working conditions, the ray interlocking detects intruders (people or moving animals) within a 15m diameter range through infrared sensing probes to ensure that the ray beam is emitted under safe conditions;

[0064] (5) Under remote working conditions, when an emergency condition is detected through monitoring by the camera 4, the emergency stop button on the remote emergency stop control box 14 can be pressed to perform an emergency stop on the motion control axis in the system and to stop the beam of the radiation source 3.

[0065] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution of the present invention, which should be included in the scope of the claims of the present invention.

Claims

1. An industrial inspection CT device, characterized in that: It includes an on-site detection area and a remote control area, the on-site detection area is detachably provided with an assembled annular track component, the annular track component is detachably provided with a radiation source and a detector, and the radiation source and the detector rotate synchronously; an electric cabinet is arranged in the remote control area, the electric cabinet is integrated with a power supply, a driver, a controller, a router and a switch, the electric cabinet is connected with the on-site detection area through a cable; the outside of the electric cabinet is also communicatively connected with a human-computer interaction unit through a cable; the annular track component includes a supporting device, an annular base, a driving device, and a moving skateboard, the supporting device includes a group of symmetrically arranged supporting frames, the bottom of the supporting frame is provided with three supporting legs distributed in a triangular shape, the middle part of the supporting legs is hinged on the supporting platform, the supporting platform is provided with a guide rod, and the guide rod is provided with a lifting device; the lifting device is provided with a lifting platform facing the detection object, the lifting platform is provided with a lifting rod, the top of the lifting rod is connected to the annular base, and the moving skateboards symmetrically arranged on the annular base are slidably provided , a ray source and a detector are respectively arranged on the moving slide, and the moving slides are fixedly connected by a synchronization rod, and the synchronization rod is in a semicircular arc shape, and the driving device that drives the moving slide to rotate around the annular base is arranged on the outer side of one moving slide; a raised outer guide rail is arranged on one side of the top of the annular base, and an inner guide rail is arranged at a position corresponding to the outer guide rail on the inner side of the annular base, and a group of track wheels are respectively buckled on the inner guide rail and the outer guide rail at the bottom of the moving slide; the driving device includes a driving motor fixed to the outer side of the moving slide, and the output shaft of the driving motor extends vertically downward and is fixedly connected to the driving gear at the bottom of the moving slide, and an annular outer gear ring is arranged on the outside of the annular base below the outer guide rail, and the annular outer gear ring is meshed with the driving gear; a supporting guide device is hingedly arranged at the bottom of the moving slide, and the supporting guide device includes a guide seat fixedly arranged at the bottom of the moving slide, and a telescopic top rod is hingedly arranged on the guide seat, and a roller is arranged at the end of the telescopic top rod; the supporting guide devices are distributed in an annular array.

2. An industrial inspection CT device as claimed in claim 1, characterized in that: The remote control area is also provided with a remote operation console and a cable reel. The remote operation console is provided with the human-machine interaction unit and an emergency stop control switch. The emergency stop control switch is connected to the electric cabinet through a cable.

3. An industrial inspection CT device as claimed in claim 1, characterized in that: An infrared sensing probe is arranged at the periphery of the on-site detection area, and the infrared sensing probe is interlocked with the ray source.

4. An industrial inspection CT device as claimed in claim 1, characterized in that: The on-site detection area is also provided with a camera, and the remote control area is provided with a display device associated with the camera.

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