Image processing system and method for girth weld DR detection data

Abstract

The present invention discloses an image processing system and method for DR detection data of a girth weld, belonging to the technical field of image processing systems. The system comprises an image reprocessing system for reprocessing images, defect identification and data analysis, a ray source for emitting rays to irradiate a pipeline, a ray detection module for receiving rays after the emission source irradiates the pipeline, an ultrasonic detection module for collecting point cloud data of the pipeline using ultrasonic detection and transmitting the data to a weld geometry modeling module, a three-dimensional scanner for collecting point cloud data of the pipeline shape and transmitting the data to the weld geometry modeling module, and a weld geometry modeling module for acquiring the point cloud data collected by the ultrasonic detection module, the three-dimensional scanner and the ray detection module to jointly establish a three-dimensional image of the pipeline.

Description

Technical Field

[0001] The present invention relates to an image processing system, in particular to an image processing system and method for girth weld DR detection data, belonging to the technical field of image processing systems. Background Art

[0002] The existing technology always uses only girth weld DR detection in the image processing system for girth weld DR detection data, and does not use other detections as auxiliary. This leads to certain problems as to what type of radiation source can achieve the optimal technical effect and how to improve the accuracy of girth weld DR detection. Therefore, an image processing system and method for girth weld DR detection data are designed to solve the above problems. Summary of the Invention

[0003] The main purpose of the present invention is to provide an image processing system and method for girth weld DR detection data.

[0004] The purpose of the present invention can be achieved by adopting the following technical solutions:

[0005] An image processing system for girth weld DR inspection data, including an image reprocessing system for reprocessing images, defect identification and data analysis;

[0006] A ray source, used for emitting rays to irradiate the pipeline;

[0007] A ray detection module, used for receiving rays emitted from the emission source after irradiating the pipeline;

[0008] Ultrasonic detection module, used to collect point cloud data from pipelines using ultrasonic detection and transmit it to the weld geometry modeling module;

[0009] 3D scanner, used to collect point cloud data of pipeline shape and transmit it to the weld geometry modeling module;

[0010] The weld geometry modeling module is used to obtain the point cloud data collected by the ultrasonic detection module, 3D scanner, and X-ray detection module to jointly build a 3D image of the pipeline;

[0011] The weld geometry modeling module transmits the pipeline three-dimensional image created by the ultrasonic detection module and the point cloud data collected by the three-dimensional scanner to the weld standard comparison module;

[0012] A weld standard comparison module is used to measure the size of the weld in the three-dimensional image input into the weld standard comparison module and transmit the measurement to the radiation source selection module;

[0013] The ray source selection module is used to select which ray to use and start the corresponding ray source.

[0014] Preferably, the weld geometry modeling module creates a three-dimensional image of the pipeline using point cloud data collected by a three-dimensional scanner, specifically including:

[0015] The reference point a is the coordinate origin a(x0, y0, z0) of the rectangular coordinate system, and the scanning head of the mobile 3D scanner is b(x i 、y i 、z i );

[0016] The shape of the pipeline is scanned by moving the 3D scanner to collect pipeline data, and the scanning head c of the 3D scanner is used as the initial orientation c (θ, α) of the polar coordinates;

[0017] The polar coordinates of the point cloud data scanned by the scanning head of the 3D scanner are c(θ i , α i d i );

[0018] The formula for converting polar coordinates to a three-dimensional rectangular coordinate system is:

[0019] x=d cosθcosα;

[0020] y=d cosθsinα;

[0021] z = d sinθ;

[0022] The polar coordinates of the point cloud data scanned by the scanning head of the 3D scanner are converted into point cloud data of a rectangular coordinate system, thereby obtaining point cloud data of different positions of the scanned pipeline;

[0023] Create an EXCE table and input the point cloud data of the rectangular coordinate system into the EXCE table to form EXCE coordinate data;

[0024] Then copy the EXCE coordinate data into the CAD drawing software and select the line or point command to create a three-dimensional pipeline graphic scanned by a three-dimensional scanner. For unclear positions, the three-dimensional scanner is used to perform repeated scans to collect data and establish a three-dimensional pipeline shape.

[0025] Preferably, the weld geometry modeling module establishes a three-dimensional image of the pipeline using the point cloud data collected by the ultrasonic detection module and the three-dimensional scanner, specifically including:

[0026] The weld geometry modeling module obtains the point cloud data transmitted by the ultrasonic detection module and imports the point cloud data into the CAD software, taking the reference point a as the coordinate origin a (x0, y0, z0) of the rectangular coordinate system;

[0027] The specific X, Y, and Z axis directions in the three-dimensional pipeline graphic are used as the X, Y, and Z axis directions of the three-dimensional geometric graphic established by the point cloud data collected by the ultrasonic detection module;

[0028] The coordinate value uses the unit size of the three-dimensional pipeline graphics as the unit value;

[0029] The unit vectors of the X, Y, and Z axes are the same as the specific unit vectors of the X, Y, and Z axes in the three-dimensional pipeline graphics;

[0030] According to the established coordinate origin a (x0, y0, z0) and direction, all points in the point cloud data are converted to a coordinate system. The coordinate conversion function in the CAD software is used to convert the coordinate value of each point in the point cloud data to the newly established rectangular coordinate system. The ultrasonic detection module is used to further realize ultrasonic scanning of the detailed weld positions in the pipeline that cannot be scanned by the three-dimensional scanner.

[0031] Preferably, the ray source includes an X-ray source and a Y-ray source.

[0032] Preferably, the weld geometry modeling module acquires the point cloud data collected by the ultrasonic detection module, the three-dimensional scanner, and the radiographic detection module to jointly establish a three-dimensional image of the pipeline, specifically including:

[0033] Import the point cloud data into the CAD software, and use the reference point a as the coordinate origin a (x0, y0, z0) of the rectangular coordinate system;

[0034] The specific X, Y, and Z axis directions in the pipeline 3D graphics are used as the X, Y, and Z axis directions of the 3D geometric graphics established by the point cloud data collected by the ray detection module;

[0035] The coordinate value uses the unit size of the three-dimensional pipeline graphics as the unit value;

[0036] The unit vectors of the X, Y, and Z axes are the same as the specific unit vectors of the X, Y, and Z axes in the three-dimensional pipeline graphics;

[0037] Based on the origin and direction of the established coordinate system, all points in the point cloud data are converted to a coordinate system. The coordinate conversion function in the CAD software is used to convert the coordinate value of each point in the point cloud data to the newly established rectangular coordinate system. The X-ray detection module is used to further implement X-ray scanning of detailed weld locations in the pipeline that cannot be scanned by the 3D scanner and ultrasonic detection module, further supplementing the established 3D pipeline model.

[0038] Preferably, measuring the size of the weld in the three-dimensional image input into the weld standard comparison module specifically includes:

[0039] Place measurement points on the 3D pipeline model. Use the Dimension tool in CAD to select the location where you want to place the measurement point using the mouse or touch screen. This can be the joint of the pipeline. Place the measurement point at the selected location and enter the corresponding dimension value to measure the specific weld size.

[0040] At the same time, the thickness of the 3D pipeline model and the specific values ​​of the detected weld size are obtained;

[0041] And input the specific type of material used for the pipeline to be inspected, and use the above three variables to determine whether to use an X-ray source or a Y-ray source.

[0042] Preferably, the specific determination is as follows:

[0043] The material is steel;

[0044] Thickness within the range of 2mm-20mm is detected using X-rays;

[0045] The material is aluminum;

[0046] Thickness within the range of 1mm-15mm is detected using X-rays;

[0047] The material is stainless steel;

[0048] Thickness within the range of 1mm-10mm is detected using X-rays;

[0049] The above judgment is valid when the weld size is less than 30mm;

[0050] When the weld size is greater than 30mm, Y-ray detection is directly used.

[0051] The material is steel;

[0052] If the thickness is greater than 20mm, use Y-ray for detection;

[0053] The material is aluminum;

[0054] Thickness greater than 15mm is detected by Y-ray;

[0055] The material is stainless steel;

[0056] Thickness greater than 10mm is detected using Y-ray.

[0057] Preferably, the image reprocessing system includes an image preprocessing module, an image segmentation module, a feature extraction module, a defect recognition module and a data analysis module;

[0058] The weld geometry modeling module is coupled with the image preprocessing module;

[0059] The image preprocessing module is coupled with the image segmentation module;

[0060] The image segmentation module is coupled with the feature extraction module;

[0061] The feature extraction module is coupled with the defect identification module;

[0062] The defect identification module is coupled with the data analysis module.

[0063] Preferably, the image preprocessing module performs preprocessing on the acquired image data, including denoising, contrast enhancement, and smoothing, to improve image quality and clarity;

[0064] Image segmentation module: Segments the weld and other areas in the image and identifies the position and shape of the weld using edge detection algorithms;

[0065] Feature extraction module: extracts key features of welds from images, such as width, length, depth, and defect type and location;

[0066] Defect recognition module: Identifies defects in welds, such as cracks, pores, and slag inclusions, through image processing algorithms, and distinguishes between normal and defective parts;

[0067] Data analysis module: Analyzes the processed image data, evaluates the quality of welds, detects and identifies defects, and outputs inspection reports.

[0068] Beneficial technical effects of the present invention:

[0069] The present invention provides an image processing system and method for DR detection data of girth welds. The radiographic detection module receives the detected information point cloud data. Similarly, the point cloud data is imported into the CAD software, with the reference point a as the coordinate origin a (x0, y0, z0) of the rectangular coordinate system;

[0070] The specific X, Y, and Z axis directions in the pipeline 3D graphics are used as the X, Y, and Z axis directions of the 3D geometric graphics established by the point cloud data collected by the ray detection module;

[0071] The coordinate value uses the unit size of the three-dimensional pipeline graphics as the unit value;

[0072] The unit vectors of the X, Y, and Z axes are the same as the specific unit vectors of the X, Y, and Z axes in the three-dimensional pipeline graphics;

[0073] According to the origin and direction of the established coordinate system, all points in the point cloud data are converted to the coordinate system. The coordinate conversion function in the CAD software is used to convert the coordinate value of each point in the point cloud data to the newly established rectangular coordinate system. In this way, the radiographic detection module can further realize radiographic scanning of detailed welds and other locations in the pipeline that cannot be scanned by the 3D scanner, and further supplement the established 3D pipeline model to present more complete and sufficient data with mutual verification, thereby realizing the function of image enhancement processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0074] Figure 1 It is a system diagram of a preferred embodiment of an image processing system and method for girth weld DR detection data according to the present invention. DETAILED DESCRIPTION

[0075] In order to make the technical solution of the present invention more clear and specific to those skilled in the art, the present invention is further described in detail below with reference to embodiments and drawings, but the embodiments of the present invention are not limited thereto.

[0076] like Figure 1 As shown, in the DR detection of girth welds, the present invention first detects the pipeline through an ultrasonic detection module, wherein the detection method adopts internal and external overall detection, and transmits the data collected by the detection to the weld geometry modeling module;

[0077] When ultrasonic testing is performed on pipelines, multiple inspections are performed on weld locations visible to the naked eye to improve accuracy.

[0078] When the weld geometry modeling module obtains the data collected by the ultrasonic detection module, it performs geometric modeling on the collected data;

[0079] Geometric modeling specifically includes the following:

[0080] The reference point a is the coordinate origin a(x0, y0, z0) of the rectangular coordinate system, and the scanning head of the mobile 3D scanner is b(x i 、y i 、z i );

[0081] The shape of the pipeline is scanned by moving the 3D scanner to collect pipeline data, and the scanning head c of the 3D scanner is used as the initial orientation c (θ, α) of the polar coordinates;

[0082] The polar coordinates of the point cloud data scanned by the scanning head of the 3D scanner are c(θ i , α i d i );

[0083] The formula for converting polar coordinates to a three-dimensional rectangular coordinate system is:

[0084] x=d cosθcosα;

[0085] y=d cosθsinα;

[0086] z = d sinθ;

[0087] The polar coordinates of the point cloud data scanned by the scanning head of the 3D scanner are converted into point cloud data of a rectangular coordinate system, thereby obtaining point cloud data of different positions of the scanned pipeline;

[0088] Create an EXCE table and input the point cloud data of the rectangular coordinate system into the EXCE table to form EXCE coordinate data;

[0089] Then copy the EXCE coordinate data into the CAD drawing software and select the line or point command to create a three-dimensional pipeline graphic scanned by a three-dimensional scanner. For unclear positions, the three-dimensional scanner is used to perform repeated scans to collect data and establish the three-dimensional pipeline shape function.

[0090] After the three-dimensional pipeline shape is established, the data collected by the ultrasonic detection module is transmitted to the weld geometry modeling module. The weld geometry modeling module obtains the point cloud data transmitted by the ultrasonic detection module and imports the point cloud data into the CAD software, with the reference point a as the coordinate origin a (x0, y0, z0) of the rectangular coordinate system;

[0091] The specific X, Y, and Z axis directions in the three-dimensional pipeline graphic are used as the X, Y, and Z axis directions of the three-dimensional geometric graphic established by the point cloud data collected by the ultrasonic detection module;

[0092] The coordinate value uses the unit size of the three-dimensional pipeline graphics as the unit value;

[0093] The unit vectors of the X, Y, and Z axes are the same as the specific unit vectors of the X, Y, and Z axes in the three-dimensional pipeline graphics;

[0094] According to the origin and direction of the established coordinate system, all points in the point cloud data are converted to the coordinate system. The coordinate conversion function in the CAD software is used to convert the coordinate value of each point in the point cloud data into the newly established rectangular coordinate system. In this way, the ultrasonic detection module can further realize ultrasonic scanning of detailed welds and other locations in the pipeline that cannot be scanned by the three-dimensional scanner, thereby supplementing the established three-dimensional pipeline model, thereby achieving the function of improving the accuracy of the supplemented three-dimensional pipeline model.

[0095] The established 3D pipeline model is transferred to the weld standard comparison module through the weld geometry modeling module to measure and analyze the weld dimensions;

[0096] Specifically, place measurement points on the 3D pipeline model. Use the Dimension tool in CAD and use the mouse or touch screen to select the location where you want to place the measurement point. This can be the joint of the pipeline. Place the measurement point at the selected location and enter the corresponding dimension value to measure the specific weld size.

[0097] At the same time, the thickness of the 3D pipeline model and the specific values ​​of the detected weld size are obtained;

[0098] And input the specific type of material used for the pipeline to be inspected, and the above three variables to determine whether to use an X-ray source or a Y-ray source;

[0099] The specific determination is as follows:

[0100] The material is steel;

[0101] Thickness within the range of 2mm-20mm is detected using X-rays;

[0102] The material is aluminum;

[0103] Thickness within the range of 1mm-15mm is detected using X-rays;

[0104] The material is stainless steel;

[0105] Thickness within the range of 1mm-10mm is detected using X-rays;

[0106] The above judgment is valid when the weld size is less than 30mm;

[0107] When the weld size is greater than 30mm, Y-ray detection is directly used.

[0108] The material is steel;

[0109] When the thickness is greater than 20mm, use Y-ray to detect;

[0110] The material is aluminum;

[0111] When the thickness is greater than 15mm, use Y-ray to detect;

[0112] The material is stainless steel;

[0113] When the thickness is greater than 10mm, use Y-ray to detect;

[0114] The reason for selectively using different radiation sources is that X-rays have higher detection accuracy but poorer penetration in small-size cases, while Y-rays are more suitable for large-size detection and have stronger penetration.

[0115] The data processed by the weld standard comparison module is sent to the radiation source selection module to select whether to use X-rays or Y-rays. The selected result is sent to start the corresponding radiation source, and the pipeline is inspected by the corresponding radiation source. After the inspection, the inspection information data is received by the radiation detection module;

[0116] The ray detection module receives the detected information point cloud data. Similarly, the point cloud data is imported into the CAD software, with the reference point a as the coordinate origin a (x0, y0, z0) of the rectangular coordinate system;

[0117] The specific X, Y, and Z axis directions in the pipeline 3D graphics are used as the X, Y, and Z axis directions of the 3D geometric graphics established by the point cloud data collected by the ray detection module;

[0118] The coordinate value uses the unit size of the three-dimensional pipeline graphics as the unit value;

[0119] The unit vectors of the X, Y, and Z axes are the same as the specific unit vectors of the X, Y, and Z axes in the three-dimensional pipeline graphics;

[0120] Based on the origin and direction of the established coordinate system, all points in the point cloud data are converted to a coordinate system. Using the coordinate conversion function in the CAD software, the coordinate value of each point in the point cloud data is converted to the newly established rectangular coordinate system. This allows the X-ray detection module to further implement X-ray scanning of detailed welds and other locations in the pipeline that cannot be scanned by the 3D scanner, thereby further supplementing the established 3D pipeline model to present more complete and mutually verified data.

[0121] Image preprocessing module: preprocesses the acquired image data, including denoising, contrast enhancement, smoothing, etc., to improve image quality and clarity;

[0122] Image segmentation module: Segments the weld and other areas in the image, and identifies the position and shape of the weld through edge detection and other algorithms;

[0123] Feature extraction module: extracts key features of welds from images, such as width, length, depth, and defect type and location;

[0124] Defect recognition module: Identifies defects in welds, such as cracks, pores, and slag inclusions, through image processing algorithms, and distinguishes between normal and defective parts.

[0125] Data analysis module: Analyzes the processed image data, evaluates the quality of welds, detects and identifies defects, and outputs inspection reports.

[0126] The above is only a further embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes based on the technical solutions and concepts of the present invention within the scope disclosed by the present invention, which fall within the scope of protection of the present invention.

Claims

1. An image processing system for girth weld DR inspection data, including an image reprocessing system for image reprocessing, defect identification, and data analysis; A ray source, used for emitting rays to irradiate the pipeline; A ray detection module, used for receiving rays after the ray source irradiates the pipeline; Its characteristics are: Ultrasonic detection module, used to collect point cloud data from pipelines using ultrasonic detection and transmit it to the weld geometry modeling module; 3D scanner, used to collect point cloud data of pipeline shape and transmit it to the weld geometry modeling module; The weld geometry modeling module is used to obtain the point cloud data collected by the ultrasonic detection module, 3D scanner, and X-ray detection module to jointly build a 3D image of the pipeline; The weld geometry modeling module transmits the pipeline three-dimensional image created by the ultrasonic detection module and the point cloud data collected by the three-dimensional scanner to the weld standard comparison module; A weld standard comparison module is used to measure the size of the weld in the three-dimensional image input into the weld standard comparison module and transmit the measurement to the radiation source selection module; A ray source selection module is used to select which ray to use and start the corresponding ray source; The weld geometry modeling module uses point cloud data collected by a 3D scanner to create a 3D image of the pipeline, which specifically includes: The reference point a is the origin of the rectangular coordinate system , taking the scanning head of the mobile 3D scanner as b ; The shape of the pipeline is scanned by moving the 3D scanner to collect pipeline data. At the same time, the scanning head of the 3D scanner is used as the initial orientation c1 of the polar coordinates. ; The polar coordinates of the point cloud data scanned by the scanning head of the 3D scanner are c2 ; The formula for converting polar coordinates to a three-dimensional rectangular coordinate system is: ； ； ； The polar coordinates of the point cloud data scanned by the scanning head of the 3D scanner are converted into point cloud data of a rectangular coordinate system, thereby obtaining point cloud data of different positions of the scanned pipeline; Create an EXCE table and input the point cloud data of the rectangular coordinate system into the EXCE table to form EXCE coordinate data; Then copy the EXCE coordinate data into the CAD drawing software and select the line or point command to create a 3D pipeline graphic scanned by a 3D scanner. For unclear positions, the 3D scanner is used to perform repeated scans to collect data and establish a 3D pipeline shape. The weld geometry modeling module uses the point cloud data collected by the ultrasonic detection module and the 3D scanner to create a 3D image of the pipeline, which specifically includes: The weld geometry modeling module obtains the point cloud data transmitted by the ultrasonic detection module, imports the point cloud data into the CAD software, and uses the reference point a as the coordinate origin of the rectangular coordinate system. ; The specific X, Y, and Z axis directions in the three-dimensional pipeline graphic are used as the X, Y, and Z axis directions of the three-dimensional geometric graphic established by the point cloud data collected by the ultrasonic detection module; The coordinate value uses the unit size of the three-dimensional pipeline graphics as the unit value; The unit vectors of the X, Y, and Z axes are the same as the specific unit vectors of the X, Y, and Z axes in the three-dimensional pipeline graphics; According to the established coordinate origin The coordinate system of all points in the point cloud data is converted into a newly established rectangular coordinate system using the coordinate conversion function in the CAD software. The ultrasonic detection module is used to further realize ultrasonic scanning of the detailed weld locations in the pipeline that cannot be scanned by the 3D scanner. The radiation source includes an X-ray source and a Y-ray source; The weld geometry modeling module obtains the point cloud data collected by the ultrasonic detection module, 3D scanner, and X-ray detection module to jointly build a 3D image of the pipeline. Specifically, it includes: Import point cloud data into CAD software and use reference point a as the origin of the rectangular coordinate system ; The specific X, Y, and Z axis directions in the pipeline 3D graphics are used as the X, Y, and Z axis directions of the 3D geometric graphics established by the point cloud data collected by the ray detection module; The coordinate value uses the unit size of the three-dimensional pipeline graphics as the unit value; The unit vectors of the X, Y, and Z axes are the same as the specific unit vectors of the X, Y, and Z axes in the three-dimensional pipeline graphics; Based on the origin and direction of the established coordinate system, all points in the point cloud data are converted to a coordinate system. The coordinate conversion function in the CAD software is used to convert the coordinate value of each point in the point cloud data to the newly established rectangular coordinate system. The X-ray detection module is used to further implement X-ray scanning of detailed weld locations in the pipeline that cannot be scanned by the 3D scanner and ultrasonic detection module, further supplementing the established 3D pipeline model.

2. The image processing system for girth weld DR inspection data according to claim 1, characterized in that: The dimensional measurement of the weld in the 3D image input into the weld standard comparison module specifically includes: Place measurement points on the 3D pipeline model. Use the Dimension tool in CAD to select the location where you want to place the measurement point using the mouse or touch screen. Place the measurement point at the selected location and enter the corresponding dimension value to measure the specific weld size. At the same time, the thickness of the 3D pipeline model and the specific values ​​of the detected weld size are obtained; And input the specific type of material used for the pipeline to be inspected, and determine whether to use an X-ray source or a Y-ray source based on the above three variables.

3. The image processing system for girth weld DR inspection data according to claim 2, characterized in that: The specific determination is as follows: The material is steel; Thickness within the range of 2mm-20mm is detected using X-rays; The material is aluminum; Thickness within the range of 1mm-15mm is detected using X-rays; The material is stainless steel; Thickness within the range of 1mm-10mm is detected using X-rays; The above judgment is valid when the weld size is less than 30mm; When the weld size is greater than 30mm, Y-ray detection is used directly; The material is steel; If the thickness is greater than 20mm, use Y-ray for detection; The material is aluminum; Thickness greater than 15mm is detected by Y-ray; The material is stainless steel; Thickness greater than 10mm is detected using Y-ray.

4. The image processing system for girth weld DR inspection data according to claim 1, characterized in that: The image reprocessing system includes an image preprocessing module, an image segmentation module, a feature extraction module, a defect recognition module, and a data analysis module; The weld geometry modeling module is coupled with the image preprocessing module; The image preprocessing module is coupled with the image segmentation module; The image segmentation module is coupled with the feature extraction module; The feature extraction module is coupled with the defect identification module; Defect identification module coupled with data analysis module; Image preprocessing module: preprocesses the acquired image data, including denoising, contrast enhancement, and smoothing, to improve image quality and clarity; Image segmentation module: Segments the weld and other areas in the image and identifies the position and shape of the weld using edge detection algorithms; Feature extraction module: extracts key features of welds from images, such as width, length, depth, and defect type and location; Defect recognition module: Identifies defects in welds through image processing algorithms, including cracks, pores, and slag inclusions, and distinguishes between normal and defective parts. Data analysis module: Analyzes the processed image data, evaluates the quality of welds, detects and identifies defects, and outputs inspection reports.

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