Full-automatic small-diameter tube DR detection system

Abstract

The invention discloses a full-automatic small-diameter tube DR detection system, relates to the technical field of automatic nondestructive testing, and automatically performs grating opening and closing, image acquisition, image quality indicator placement and defect identification, realizes full automation of small-diameter tube flaw detection operation, greatly reduces the workload of workers, and improves the production efficiency. And the flaw detection data are stored and traced by utilizing information such as a manufacturing operation management platform and a quality database, so that the data are effectively protected, and quick query and recheck are facilitated. Automatic double-filament and single-filament placement is achieved, and the image quality measurement efficiency is improved. The image quality indicator comprises a double-wire image quality indicator and a single-wire image quality indicator, the double-wire image quality indicator assists in measuring the DR image resolution of the small-diameter tube, and the single-wire image quality indicator assists in measuring the DR image sensitivity of the small-diameter tube, so that the quality of an image acquired in full-automatic DR detection of the small-diameter tube is confirmed, and subsequent defect evaluation on the DR image is facilitated. The monofilament image quality indicator has a plurality of different specifications so as to carry out image quality confirmation corresponding to different pipe diameter wall thicknesses of small-diameter pipes.

Description

Technical Field

[0001] The present invention relates to the technical field of automated nondestructive testing, and more specifically to a fully automated small-diameter pipe DR testing system. Background Art

[0002] Welding is a key process in the manufacturing of major power generation equipment, and its quality determines the safety and reliability of power generation equipment. According to external quality feedback over the years, more than 80% of the quality problems of power plant boilers are caused by weld quality. Therefore, effectively improving the welding quality of power plant boiler enterprises is very important to ensure production safety and help enterprises improve quality and efficiency.

[0003] In the petrochemical, energy and power, aerospace and other industries, small-diameter pipes (specifically pipes with a diameter of 100mm or less) are important parts of related equipment. The serpentine pipe is a small-diameter pipe and is a core component of power station boilers. The operating temperature is as high as 677℃ and the working pressure is 40MPa.

[0004] In the existing technology, when X-ray imaging defect detection is performed on the serpentine and straight pipe welds of boiler high-temperature components, a DR imaging detection system (industrial television RTV for short) is required. Currently, the industry's RTV systems are all semi-automatic systems, which require manual control to transport the small-diameter pipe welds to a fixed position, manually control the clamping and rotation of the small-diameter pipes, manually control the opening and closing of the grating, image acquisition, manually control the placement of the image quality meter, and manually mark defects, resulting in low flaw detection efficiency. Summary of the invention

[0005] In order to overcome the defects in the above-mentioned prior art, the present invention discloses a fully automated DR inspection system for small-diameter pipes. The purpose of the present invention is to solve the problem of low efficiency of flaw detection in the manual control of the semi-automatic system in the prior art. The present invention integrates the weld joint identification and positioning system, the grating opening and closing system, the image quality meter automatic placement system, the automatic marking system, etc., and can realize fully automated DR flaw detection of small-diameter pipe welds. Workers only need to confirm whether the flaw detection results are correct, which greatly improves the flaw detection efficiency of the production line.

[0006] In order to achieve the above objectives, the technical solution adopted by the present invention is: A fully automated small diameter pipe DR detection system, comprising: Manufacturing operations management platform and quality database; An information management system that communicates with the manufacturing operation management platform and the quality database; A controller in communication with the information management system; A weld traceability scanning system that communicates with the information management system and is used to scan codes for small-diameter pipes; A safety monitoring system that communicates with the information management system and is used to monitor the DR detection of small-diameter pipes; A weld joint identification and positioning system connected to the controller for positioning the weld joint on the small-diameter pipe; A pipe conveying system in communication with the controller and used for conveying small-diameter pipes; A pipe clamping and rotating system, which is in communication with the controller and is used to clamp and rotate the small-diameter pipe; A flaw detection system connected to the controller for DR inspection of small-diameter pipes, the flaw detection system is located in the lead room and automatically performs grating opening and closing, image acquisition, image quality meter placement and defect identification; Defect detection alarm system connected to the controller for defect alarm after DR detection; A tube sorting system that communicates with a controller and is used to sort defective and normal small diameter tubes after DR inspection.

[0007] In the present invention, the above-mentioned systems are specifically as follows: 1. Manufacturing Operation Management Platform and Quality Database In the present invention, the manufacturing operation management platform (MOM) and the quality database interact with the edge-end review information management system to query the weld information and upload the review results for traceability.

[0008] 2. Information Management System In the present invention, the information management system is specifically an X-ray image acquisition and evaluation software in a computer, namely, R-PCE software, which is used to control the DR detection of small-diameter pipes.

[0009] 3. Controller In the present invention, the controller is a programmable logic controller (PLC) for controlling the DR detection of small-diameter pipes.

[0010] 4. Weld traceability scanning system Preferably, the weld traceability scanning system includes a scanning gun.

[0011] In the present invention, the weld traceability scanning system mainly uses a barcode scanner to scan the pipe QR code and returns it to the R-PCE software through serial port communication.

[0012] 5. Security Monitoring System Preferably, the security monitoring system includes outdoor security monitoring cameras and indoor security monitoring cameras located outdoors and indoors of the lead room.

[0013] In the present invention, the main function of the security monitoring system is to perform security monitoring indoors and outdoors.

[0014] 6. Welding joint identification and positioning system Preferably, the weld identification and positioning system includes outdoor weld monitoring cameras and indoor weld monitoring cameras located outdoors and indoors of the lead room.

[0015] In the present invention, the weld joint identification and positioning system mainly functions to visually identify the weld joint position and feed back to the PLC via TCP / IP communication.

[0016] 7. Pipe conveying system Preferably, the pipe conveying system includes a conveying roller and a conveying motor, small-diameter pipes are placed on the conveying roller, and the conveying motor is drivingly connected to the conveying roller.

[0017] In the present invention, the main function of the pipe conveying system is that the PLC controls the forward / reverse rotation and speed reduction of the conveying motor so that the pipe is conveyed on the roller table for DR detection of small-diameter pipes.

[0018] 8. Pipe clamping and rotating system Preferably, the pipe clamping and rotating system comprises a clamping mechanism, a clamping cylinder and a pipe rotating motor, the clamping mechanism is used to clamp small-diameter pipes, and the clamping cylinder and the pipe rotating motor are both drivingly connected to the clamping mechanism.

[0019] In the present invention, the main function of the pipe clamping and rotating system is that the PLC controls the clamping cylinder and the pipe rotating motor to clamp and rotate the pipe.

[0020] 9. Flaw detection system In the present invention, the flaw detection system mainly includes an X-ray system located in a protective lead room, a ray machine motion system, a grating opening and closing system, a digital imaging system, an image quality meter automatic placement system, and an automatic marking system. X-ray imaging and image quality measurement of the weld are performed through R-PCE and PLC control.

[0021] Preferably, the flaw detection system comprises: An X-ray system, the output end of which is directed downward toward the weld of the small-diameter pipe transported into the lead room; A ray machine motion system drivingly connected to the X-ray system; The grating opening and closing system located below the weld of the small diameter pipe transported in the lead room; A digital imaging system located below the grating opening and closing system; An automatic placement system for the image quality meter located next to the grating opening and closing system, used to place the image quality meter above the small-diameter tube to measure the image quality; Automatic marking system located behind the transmission of the grating opening and closing system; Lead room protection system located in the lead room.

[0022] 1. X-ray system Preferably, the X-ray system comprises a ray machine, a high voltage generator and a cooler, and the high voltage generator and the cooler are both connected to the ray machine.

[0023] 2. X-ray machine motion system Preferably, the X-ray machine motion system includes a X-ray machine lifting cylinder and a X-ray machine swing motor, and both the X-ray machine lifting cylinder and the X-ray machine swing motor are connected to the X-ray machine drive of the X-ray system.

[0024] 3. Grating opening and closing system Preferably, the grating opening and closing system includes a grating for shading, and a grating opening and closing motor connected to the grating and used to drive the grating to open and close; The grating includes two filter plates that can be opened and closed, and the two filter plates that can be opened and closed are respectively mounted on two grating adjustment mechanisms, and the two grating adjustment mechanisms are both connected to the grating opening and closing motor drive; The grating adjustment mechanism includes a linear module and a grating slide rail which are parallel to each other. The grating opening and closing motor is drivingly connected to the linear module. One end of the filter plate is mounted on the output slider of the linear module, and the other end is slidably mounted on the grating slide rail.

[0025] 4. Digital imaging system Preferably, the digital imaging system comprises a flat-panel detector, and the linear module and the grating slide rail are both mounted on the flat-panel detector.

[0026] 5. Image quality meter automatic placement system Preferably, the automatic placement system of the image quality meter includes a dual-wire image quality meter for assisting in measuring the resolution of small-diameter tube DR images and several single-wire image quality meters of different specifications for assisting in measuring the sensitivity of small-diameter tube DR images, as well as a dual-wire placement mechanism and a single-wire placement mechanism for respectively driving the dual-wire image quality meter and the single-wire image quality meter to move between the small-diameter tube and the X-ray system for placement.

[0027] Preferably, the double-wire placing mechanism comprises a double-wire vertical moving structure, a double-wire horizontal moving structure and a double-wire fixing plate; The double-wire vertical moving structure is fixed on a fixing seat, the double-wire horizontal moving structure is mounted on the output end of the double-wire vertical moving structure, the double-wire fixing plate is mounted on the output end of the double-wire horizontal moving structure, and the double-wire image quality meter is mounted on the double-wire fixing plate; When the dual-wire image quality meter is placed, the dual-wire vertical moving structure and the dual-wire lateral moving structure drive the dual-wire image quality meter to move vertically and horizontally to the top of the small-diameter tube to assist in measuring the resolution of the small-diameter tube DR image.

[0028] Preferably, the monofilament placing mechanism comprises a monofilament vertical moving structure, a monofilament horizontal moving structure, a monofilament fixing plate, a rotating structure and a turntable structure; The single-wire vertical moving structure is fixed on a fixing seat, the single-wire transverse moving structure is mounted on the output end of the single-wire vertical moving structure, the single-wire fixing plate is mounted on the output end of the single-wire transverse moving structure, the rotating structure is mounted on the single-wire fixing plate, the turntable structure is mounted on the output end of the rotating structure, and the single-wire image quality meters of different specifications are mounted on the turntable structure; When the single-wire image quality meter is placed, the single-wire vertical moving structure, the single-wire horizontal moving structure and the rotating structure drive the turntable structure to move vertically, horizontally and rotate, and the turntable structure is moved above the small-diameter tube. The turntable structure drives the single-wire image quality meters of different specifications to rotate, and the single-wire image quality meters of corresponding specifications are selected and placed above the small-diameter tube to assist in measuring the DR image sensitivity of the small-diameter tube; Wherein, the rotating structure comprises a first rotating motor and a rotating plate, the first rotating motor is mounted on the monofilament fixing plate, and the rotating plate is mounted on the output end of the first rotating motor; The turntable structure includes a second rotating motor and a monofilament turntable, wherein the second rotating motor is mounted on the rotating plate, the monofilament turntable is mounted on the output end of the second rotating motor, and the monofilament image quality meters of different specifications are evenly arranged on the monofilament turntable in a circumferential manner.

[0029] 6. Automatic marking system Preferably, the automatic marking system comprises a marking motor, a marking frame, a motor fixing box, a lead screw, a lead screw slider, a connecting plate, a marking head and an ink storage box; The lead screw is assembled at the front end of the marking frame, and the motor fixing box is assembled at the top end. The marking motor is assembled in the motor fixing box and connected to the lead screw. The lead screw slider is assembled on the lead screw. One end of the connecting plate is connected to the lead screw slider, and the other end is connected to the marking head. The ink storage box is assembled on the marking head. The marking motor drives the lead screw to rotate, drives the lead screw slider to move up and down, and drives the marking head to move up and down through the connecting plate to mark the vicinity of the small-diameter pipe weld.

[0030] 7. Lead room protection system Preferably, the lead room protection system includes a door opening and closing motor, an interlocking sensor and a radiation meter.

[0031] 10. Defect detection alarm system Preferably, the defect detection alarm system includes a buzzer.

[0032] In the present invention, the defect detection alarm system mainly functions to control the buzzer to give an alarm prompt when a defect occurs.

[0033] 11. Tube sorting system Preferably, the tube sorting system comprises a sorting cylinder and a material rack, and the sorting cylinder drives the small-diameter tubes to the material rack for sorting.

[0034] In the present invention, the main function of the pipe sorting system is to sort the repaired pipes and normal pipes by controlling the extension and contraction of the cylinder by PLC.

[0035] Beneficial effects of the present invention: The fully automated small-diameter tube DR detection system provided by the present invention automatically performs grating opening and closing, image acquisition, image quality meter placement and defect marking, thereby realizing full automation of small-diameter tube flaw detection operations, greatly reducing the workload of workers and improving production efficiency.

[0036] The fully automated small-diameter pipe DR inspection system provided by the present invention utilizes information review such as a manufacturing operation management platform and a quality database to store and trace flaw detection data, thereby effectively protecting the data and facilitating rapid query and review.

[0037] The fully automated small-diameter tube DR detection system provided by the present invention automatically places double wires and single wires to improve the efficiency of image quality measurement. The image quality meter includes a double-wire image quality meter and a single-wire image quality meter. The double-wire image quality meter assists in measuring the resolution of small-diameter tube DR images, and the single-wire image quality meter assists in measuring the sensitivity of small-diameter tube DR images to confirm the quality of the images collected in the fully automated small-diameter tube DR detection, which is convenient for subsequent defect evaluation of DR images. The single-wire image quality meter has several different specifications to confirm the image quality corresponding to the different diameter wall thicknesses of small-diameter tubes. It avoids frequent manual entry into the lead room to manually place the image quality meter, which effectively avoids the workers from being exposed to X-ray radiation in the lead room while improving the detection efficiency, thereby reducing the risk of occupational health of the workers.

[0038] The fully automated small-diameter tube DR detection system provided by the present invention realizes automatic adjustment of the grating opening and closing of tubes with different diameters to obtain a DR image with a normal transmission dose. The grating opening and closing is automatically adjusted with high and accurate adjustment efficiency, avoiding the problems of low efficiency and low adjustment accuracy in manual adjustment. Visual fatigue caused by long-term manual adjustment is avoided, which is beneficial to the occupational health of professionals.

[0039] The fully automated small-diameter pipe DR detection system provided by the present invention utilizes a marking device for automatic marking, thereby avoiding frequent manual entry into the lead room to mark defects, thereby effectively avoiding X-ray radiation to personnel and reducing occupational health risks to personnel while improving detection efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 This is a schematic diagram of the fully automated small-diameter pipe DR detection system of the present invention; Figure 2 It is a schematic diagram of a grating opening and closing system, a digital imaging system, an image quality meter automatic placement system and an automatic marking system in the flaw detection system of the present invention; Figure 3 A schematic diagram of another perspective of the grating opening and closing system, the digital imaging system, the image quality meter automatic placement system and the automatic marking system in the flaw detection system of the present invention; Figure 4 It is a schematic diagram of the grating opening and closing system and the digital imaging system of the present invention; Figure 5 A schematic diagram of an automatic placement system for an image quality meter according to the present invention; Figure 6 A schematic diagram of an automatic marking system according to the present invention; Figure 7 It is a cross-sectional view of the fully automated small-diameter pipe DR detection system of the present invention; Figure 8 is a schematic diagram of a flaw detection system of the present invention; Fig. 9 It is the software interface of the information management system of the present invention.

[0041] Reference numerals: 1. Flaw detection system; 11. X-ray system; 12. X-ray machine motion system; 13. Grating opening and closing system; 131. Grating; 132. Grating opening and closing motor; 133. Linear module; 134. Grating slide rail; 14. Digital imaging system; 15. Image quality meter automatic placement system; 151. Double-wire image quality meter; 152. Single-wire image quality meter; 153. Double-wire placement mechanism; 1531. Double-wire vertical moving structure; 1532. Double-wire horizontal moving structure; 1533. Double-wire fixing plate; 154. Single-wire placement mechanism; 1541. Single-wire vertical moving structure; 1542. Single-wire horizontal moving structure; 154 3. Monofilament fixing plate; 1544. First rotating motor; 1545. Rotating plate; 1546. Second rotating motor; 1547. Monofilament turntable; 155. Fixed seat; 16. Automatic marking system; 161. Marking rack; 162. Motor fixing box; 163. Screw rod; 164. Screw rod slider; 165. Connecting plate; 166. Marking head; 167. Ink storage box; 17. Lead room protection system; 2. Weld joint traceability scanning system; 3. Safety monitoring system; 4. Weld joint identification and positioning system; 5. Pipe conveying system; 6. Pipe clamping and rotating system; 7. Defect detection alarm system; 8. Pipe sorting system. DETAILED DESCRIPTION

[0042] The concept, specific structure and technical effects of the present invention will be clearly and completely described below in conjunction with the embodiments and drawings to fully understand the purpose, characteristics and effects of the present invention.

[0043] Example 1 A fully automated small diameter pipe DR detection system, such as Figure 1 and 7 As shown, including: Manufacturing operations management platform and quality database; An information management system that communicates with the manufacturing operation management platform and the quality database; A controller in communication with the information management system; A weld joint traceability scanning system 2 that is connected to the information management system and is used to scan the small diameter pipe; A safety monitoring system 3 which is connected to the information management system and is used to monitor the DR detection of small diameter pipes; A weld joint identification and positioning system 4 is connected to the controller for positioning the weld joint on the small diameter pipe; A pipe conveying system 5, which is in communication with the controller and is used for conveying the small-diameter pipe; A pipe clamping and rotating system 6, which is in communication with the controller and is used to clamp and rotate the small-diameter pipe; A flaw detection system 1, which is connected to the controller for DR detection of small-diameter pipes, is located in the lead room and automatically performs grating opening and closing, image acquisition, image quality meter placement and defect identification; A defect detection alarm system 7 connected to the controller for alarming defects after DR detection; A tube sorting system 8 is connected in communication with the controller and is used for sorting defective and normal small-diameter tubes after DR inspection.

[0044] In this embodiment, the flaw detection system 1 automatically performs grating opening and closing, image acquisition, image quality meter placement and defect marking, thereby achieving full automation of small-diameter pipe flaw detection operations, greatly reducing the workload of workers and improving production efficiency.

[0045] Example 2 This embodiment is further described on the basis of embodiment 1. Figure 1 As shown, in this embodiment: The manufacturing operation management platform (MOM) and quality database interact with the edge review information management system to query weld information and upload review results for traceability.

[0046] The information management system is specifically the R-PCE software in the computer, and its main functions are as follows: a) Control pipe rotation, automatic weld identification, image acquisition, image correction processing, image measurement (signal-to-noise ratio and double wire), AI image review, result feedback, result storage and retrieval, and complete the entire flaw detection operation with the same software; b) Automatically trace the associated weld information and align and upload the files; c) Real-time presentation of the actual status of detection parameters and equipment operation status; d) Image storage includes workpiece information, personnel information, detection parameter information, etc.

[0047] The main interface of the software is as follows Fig. 9 shown.

[0048] The controller is a programmable logic controller (PLC) used to control the DR detection of small diameter pipes.

[0049] The main function of the weld traceability scanning system 2 is to use a barcode scanner to scan the pipe QR code and return it to the R-PCE review software through serial port communication.

[0050] The main function of the security monitoring system 3 is to monitor indoor and outdoor security.

[0051] The main function of the weld joint identification and positioning system 4 is to visually identify the weld joint position and feed it back to the PLC through TCP / IP communication.

[0052] The main function of the pipe conveying system 5 is to control the forward / reverse rotation and speed reduction of the conveying motor by PLC so that the pipe can be transported on the roller table for DR detection of small-diameter pipes.

[0053] The main function of the pipe clamping and rotating system 6 is that the PLC controls the clamping cylinder and the pipe rotating motor to clamp and rotate the pipe. The pipe clamping and rotating system 6 includes a clamping mechanism, a clamping cylinder and a pipe rotating motor, wherein the clamping mechanism is used to clamp the small-diameter pipe. The clamping cylinder is used to drive the clamping mechanism to clamp the small-diameter pipe, thereby causing the small-diameter pipe to leave the transmission roller and be fixed on the clamping mechanism. The pipe rotating motor is used to drive the clamping mechanism to rotate the small-diameter pipe, thereby causing the small-diameter pipe to rotate 72 degrees each time and rotate 4 times, thereby performing DR imaging detection.

[0054] The flaw detection system 1 mainly includes an X-ray system located in the protective lead room, a X-ray machine motion system, a grating opening and closing system, a digital imaging system, an image quality meter automatic placement system, and an automatic marking system. The X-ray imaging and image quality measurement of the weld are performed through R-PCE and PLC control.

[0055] The main function of the defect detection alarm system 7 is to control the buzzer to alarm when a defect occurs.

[0056] The main function of the pipe sorting system 8 is to sort the repaired pipes and normal pipes by PLC controlling the expansion and contraction of the sorting cylinder. The sorting cylinder is used to sort the qualified and unqualified small-diameter pipes to different racks. The specific workpiece sorting method is: the cylinder is extended to both sides, and the qualified and unqualified small-diameter pipes are sorted from the transmission roller to the racks on both sides.

[0057] Example 3 This embodiment is further described on the basis of embodiment 2. Figure 1 and 8 As shown, the flaw detection system 1 comprises: An X-ray system 11, wherein the output end of the X-ray system 11 is downwardly directed toward the weld of the small-diameter pipe transported into the lead room; A ray machine motion system 12 drivingly connected to the X-ray system 11; The grating opening and closing system 13 located below the weld of the small diameter pipe transported in the lead room; A digital imaging system 14 located below the grating opening and closing system 13; An automatic placement system 15 for placing an image quality meter on the small-diameter tube to measure the image quality is located next to the grating opening and closing system 13; An automatic marking system 16 located behind the transmission of the grating opening and closing system 13; Lead room protection system 17 located in the lead room.

[0058] The X-ray system 11 is used to generate X-rays at high voltage to illuminate the small-diameter pipe welds.

[0059] The X-ray machine motion system 12 is used to control the X-ray machine head to swing to form a certain penetration angle for the small-diameter pipe weld.

[0060] The grating opening and closing system 13 is used to control the opening and closing of the grating to control the transmission dose of X-rays to the small-diameter pipe weld.

[0061] The digital imaging system 14 is used for X-ray imaging of the small-diameter pipe weld and generating a digital radiographic (DR) image of the weld.

[0062] The image quality meter automatic placement system 15 is used to control the single-wire image quality meter and the double-wire image quality meter to be automatically placed on the small-diameter tube to collect images and measure the imaging quality.

[0063] The automatic marking system 16 is used to mark the base material near the weld where defects are detected.

[0064] The lead room protection system 17 is used to shield X-ray radiation.

[0065] Example 4 This embodiment is further described on the basis of embodiment 3. Figure 1 As shown, the X-ray system 11 includes a ray machine, a high voltage generator and a cooler, and the high voltage generator and the cooler are both connected to the ray machine. The ray machine is used to emit X-rays to irradiate the small diameter pipe weld. The high voltage generator is used to generate the high voltage required for X-ray generation. The cooler is used to cool the X-ray tube.

[0066] The X-ray machine motion system 12 includes a X-ray machine lifting cylinder and a X-ray machine swing motor, both of which are connected to the X-ray machine drive of the X-ray system 11. The X-ray machine lifting cylinder is used to drive the X-ray machine to lift and lower, so that the distance between the X-ray machine and the weld of the small-diameter pipe to be inspected can be adjusted. The X-ray machine swing motor is used to drive the X-ray machine to swing, so that the X-ray machine and the small-diameter pipe to be inspected form an inclined transillumination mode, and perform elliptical imaging of the weld.

[0067] The lead room protection system 17 includes a door opening and closing motor, an interlocking sensor and a radiation meter. The door opening and closing motor is used to drive the opening and closing of the lead door of the lead room. The interlocking sensor is used to sense the opening and closing of the lead room door. The radiation meter is used to detect whether the radiation exceeds the standard.

[0068] Example 5 This embodiment is further described on the basis of embodiment 4. Figure 2 , 3 As shown in FIG. 4 , the grating opening and closing system 13 includes a grating 131 for shading, and a grating opening and closing motor 132 connected to the grating 131 and used to drive the grating 131 to open and close; The grating 131 includes two openable and closable filter plates, which are respectively mounted on two grating adjustment mechanisms, and the two grating adjustment mechanisms are both driven and connected to the grating opening and closing motor 132; the grating opening and closing motor 132 drives the grating adjustment mechanism to move, driving the filter plates to open and close.

[0069] The grating adjustment mechanism includes a linear module 133 and a grating slide rail 134 which are parallel to each other. The grating opening and closing motor 132 is connected to the linear module 133 for driving. One end of the filter plate is mounted on the output slider of the linear module 133, and the other end is slidably mounted on the grating slide rail 134. When adjusting the grating 131, the grating opening and closing motor 132 drives the linear module 133 to move, and the linear module 133 drives the filter plate to slide on the grating slide rail 134 to achieve the adjustment of the grating 131.

[0070] The digital imaging system 14 includes a flat panel detector, and the linear module 133 and the grating slide rail 134 are both mounted on the flat panel detector.

[0071] Example 6 This embodiment is further described on the basis of embodiment 5. Figure 2 , 3As shown in Figure 5, the automatic image quality meter placement system 15 includes a double-wire image quality meter 151 for assisting in measuring the resolution of small-diameter tube DR images and a plurality of single-wire image quality meters 152 of different specifications for assisting in measuring the sensitivity of small-diameter tube DR images, as well as a double-wire placement mechanism 153 and a single-wire placement mechanism 154 for respectively driving the double-wire image quality meter 151 and the single-wire image quality meter 152 to move between the small-diameter tube and the X-ray system 11 for placement.

[0072] In this embodiment, when image quality measurement is required, the R-PCE software communicates with the PLC and sends an image quality meter placement signal. The PLC controls the image quality meter automatic placement system 15 to operate through the I / O output according to the different signals received. Specifically, the double-wire placement mechanism 153 drives the double-wire image quality meter 151 to move between the small-diameter tube and the X-ray system 11 for placement; the single-wire placement mechanism 154 drives the single-wire image quality meter 152 to move between the small-diameter tube and the X-ray system 11 for placement. After the image quality meter is placed in place, the X-ray system 11 operates, and the flat-panel detector obtains the DR image with the wire diameter and sends it to the information management system. The information management system then confirms the quality of the acquired image, such as sensitivity and resolution, based on the DR image with the wire diameter.

[0073] In this embodiment, the image quality meter is automatically placed by controlling the image quality meter automatic placement system 15 through the information management system and the controller, thereby improving the efficiency of image quality meter placement. The image quality meter includes a double-wire image quality meter 151 and a single-wire image quality meter 152. The double-wire image quality meter 151 assists in measuring the resolution of the DR image of the small-diameter tube, and the single-wire image quality meter 152 assists in measuring the sensitivity of the DR image of the small-diameter tube, so as to confirm the quality of the image collected in the fully automated small-diameter tube DR detection, and facilitate the subsequent defect evaluation of the DR image. The single-wire image quality meter 152 has several different specifications to confirm the image quality corresponding to the different diameter wall thickness of the small-diameter tube. At the same time, it avoids frequent manual entry into the lead room to manually place the image quality meter, avoids the staff from being exposed to X-ray radiation in the lead room, and reduces the risk of occupational health of the staff.

[0074] like Figure 2 , 3 As shown in FIG. 5 , the double-wire placing mechanism 153 includes a double-wire vertical moving structure 1531 , a double-wire horizontal moving structure 1532 and a double-wire fixing plate 1533 ; The double-wire vertical moving structure 1531 is fixed on the fixing seat 155, the double-wire lateral moving structure 1532 is mounted on the output end of the double-wire vertical moving structure 1531, the double-wire fixing plate 1533 is mounted on the output end of the double-wire lateral moving structure 1532, and the double-wire image quality meter 151 is mounted on the double-wire fixing plate 1533; When the dual-wire image quality meter 151 is placed, the dual-wire vertical moving structure 1531 and the dual-wire horizontal moving structure 1532 drive the dual-wire image quality meter 151 to move vertically and horizontally to the top of the small-diameter tube to assist in measuring the resolution of the small-diameter tube DR image.

[0075] In this embodiment, the above-mentioned double-wire vertical moving structure 1531 and double-wire horizontal moving structure 1532 can both be linear modules. For the placement of the double-wire image quality meter 151, the R-PCE software sends a signal to the PLC, and the PLC controls the movement of the double-wire vertical moving structure 1531 and the double-wire horizontal moving structure 1532, thereby driving the double-wire fixing plate 1533 to move up and down and left and right. The double-wire image quality meter 151 is fixed on the double-wire fixing plate 1533, and drives the double-wire image quality meter 151 to move to a distance less than 3mm from the small-diameter tube and stop, and the placement of the double-wire image quality meter 151 is completed.

[0076] like Figure 2 , 3 As shown in FIG. 5 , the monofilament placing mechanism 154 includes a monofilament vertical moving structure 1541, a monofilament horizontal moving structure 1542, a monofilament fixing plate 1543, a rotating structure and a turntable structure; The single-wire vertical moving structure 1541 is fixed on the fixing seat 155, the single-wire transverse moving structure 1542 is mounted on the output end of the single-wire vertical moving structure 1541, the single-wire fixing plate 1543 is mounted on the output end of the single-wire transverse moving structure 1542, the rotating structure is mounted on the single-wire fixing plate 1543, the turntable structure is mounted on the output end of the rotating structure, and the single-wire image quality meters 152 of different specifications are mounted on the turntable structure; When the single-wire image quality meter 152 is placed, the single-wire vertical moving structure 1541, the single-wire horizontal moving structure 1542 and the rotating structure drive the turntable structure to move vertically, horizontally and rotate, and move the turntable structure to above the small-diameter tube. The turntable structure drives the single-wire image quality meters 152 of different specifications to rotate, and the single-wire image quality meters 152 of corresponding specifications are selected and placed above the small-diameter tube to assist in measuring the DR image sensitivity of the small-diameter tube. The rotating structure includes a first rotating motor 1544 and a rotating plate 1545 . The first rotating motor 1544 is mounted on the monofilament fixing plate 1543 , and the rotating plate 1545 is mounted on the output end of the first rotating motor 1544 . The turntable structure includes a second rotating motor 1546 and a single-filament turntable 1547. The second rotating motor 1546 is mounted on the rotating plate 1545. The single-filament turntable 1547 is mounted on the output end of the second rotating motor 1546. The single-filament image quality meters 152 of different specifications are evenly arranged on the single-filament turntable 1547 in a circular shape.

[0077] In this embodiment, the above-mentioned single-wire vertical moving structure 1541 and single-wire horizontal moving structure 1542 can both be linear modules. For the placement of the single-wire image quality meter 152, the R-PCE software sends a signal to the PLC, and the PLC controls the movement of the single-wire vertical moving structure 1541 and the single-wire horizontal moving structure 1542 to control the rotation structure to move up, down, left, and right. When it moves to a distance less than 3mm from the small-diameter tube, it stops. At this time, the first rotating motor 1544 drives the turntable structure to rotate counterclockwise, so that the single-wire turntable 1547 reaches a suitable position and stops. At this time, the second rotating motor 1546 drives the single-wire turntable 1547 to rotate and select a single-wire image quality meter 152 of suitable specifications to be placed above the small-diameter tube, that is, the automatic placement of the single-wire image quality meter 152 is completed. In this embodiment, four types of single-wire image quality meters 152 are fixed on the single-wire turntable 1547, and different specifications of single-wire image quality meters 152 need to be selected according to the different diameters and wall thicknesses of the small-diameter tubes.

[0078] In this embodiment, the working principle of placing the image quality meter in the automatic placement system 15 of the image quality meter is: when performing single-wire measurement or double-wire measurement, it is necessary to place a single-wire image quality meter 152 or a double-wire image quality meter 151 above the small-diameter tube, and then perform imaging to obtain a DR image with a wire diameter. For the placement of the double-wire image quality meter 151, the R-PCE software sends a signal to the PLC, and the PLC directly controls the double-wire image quality meter 151 to move up and down and left and right for placement by controlling the double-wire vertical moving structure 1531 and the double-wire horizontal moving structure 1532. For the single-wire image quality meter 152, since there are 4 specifications, the R-PCE software needs to send different signals to the PLC according to the diameter and wall thickness of the small-diameter tube. The PLC controls the mechanical structure to rise and fall so that the single-wire image quality meter 152 reaches a suitable height, and then drives the turntable structure to rotate to select and place the single-wire image quality meter 152.

[0079] In this embodiment, during the DR flaw detection process of small-diameter pipes, it is necessary to measure the quality of the DR images taken, mainly including sensitivity and resolution, which requires the placement of a single-wire image quality meter 152 and a double-wire image quality meter 151. Among them, four types of single-wire image quality meters 152 are placed on the single-wire turntable 1547, and one specification of double-wire image quality meter 151 is placed on the double-wire fixing plate 1533.

[0080] In this embodiment, the image quality meter is provided with a single wire and a double wire because the single wire image quality meter 152 is used to measure image sensitivity, and the double wire image quality meter 151 is used to measure image resolution. For small-diameter pipes, each welded joint needs to be verified for DR image sensitivity during the first transillumination; each welded joint needs to be verified for DR image resolution during the first transillumination.

[0081] In this embodiment, the single-wire turntable 1547 fixes 4 types of single-wire image quality meters 152, which are less than 2 mm thick and have no image residue after transillumination. Each type of single-wire image quality meter 152 corresponds to the DR image sensitivity measurement requirements of small-diameter pipe welds with different wall thicknesses. At present, there are four types of small-diameter pipes with four wall thicknesses according to actual needs, so 4 types of single-wire image quality meters 152 need to be placed.

[0082] Example 7 This embodiment is further described on the basis of embodiment 6. Figure 2 , 3 As shown in 6 , the automatic marking system 16 includes a marking motor, a marking frame 161 , a motor fixing box 162 , a screw rod 163 , a screw rod slider 164 , a connecting plate 165 , a marking head 166 and an ink storage box 167 ; The lead screw 163 is assembled at the front end of the marking frame 161, and the motor fixing box 162 is assembled at the top end. The marking motor is assembled in the motor fixing box 162 and connected to the lead screw 163. The lead screw slider 164 is assembled on the lead screw 163. One end of the connecting plate 165 is connected to the lead screw slider 164, and the other end is connected to the marking head 166. The ink storage box 167 is assembled on the marking head 166. The marking motor drives the lead screw 163 to rotate, drives the lead screw slider 164 to move up and down, and drives the marking head 166 to move up and down through the connecting plate 165 to mark the vicinity of the small-diameter pipe weld.

[0083] In this embodiment, when the software detects that there is a defect in the weld, the information is sent to the PLC, the PLC drives the marking motor to rotate, the marking motor drives the marking device to slide up and down on the screw rod 163, and drives the marking head 166 with ink to move up and down near the weld of the small-diameter pipe to complete the marking action. At this time, the ink is present near the weld as a mark.

[0084] In order to better understand the present invention, the working principle of the present invention is described in detail below: a) After the small diameter pipe is welded, it is transported by the conveyor roller of the pipe conveying system. A weld joint identification and positioning system is installed at the front end of the lead room. After the weld is identified, the conveyor roller speed is reduced from 40 m / min to 10 m / min, and then it is transmitted to the flaw detection system; b) The weld traceability scanning system scans the straight pipe QR code and transmits the QR code information to the information management system to extract the weld information covered by the straight pipe; c) A weld identification and positioning system is installed inside the lead room. After the weld is identified, the flaw detection system locks the workpiece to be inspected and keeps the weld to be inspected in the inspection area; d) According to the acquired workpiece size specifications, the grating opening and closing system automatically adjusts the grating opening and closing size, and fine-tunes the grating according to the imaging effect after clamping the tube; e) Referring to the workpiece specifications, preset different specifications of acquisition process parameter packages, and automatically set the flaw detection acquisition parameters and X-ray process parameters; f) When quality confirmation is required, manually click the quality confirmation button, and the image quality meter automatic placement system will rotate the single-wire image quality meter to select the appropriate single wire according to the acquired size specifications, and post the double wire by moving and lifting. Then, combined with the built-in acquisition parameter package, the corresponding radiation process is automatically called, thereby realizing automatic single-wire and double-wire quality confirmation; g) Confirm the single-wire, double-wire and signal-to-noise ratio. If qualified, perform normal acquisition operation. If not qualified, adjust the acquisition parameters and re-confirm; h) The pipe clamping and rotating system automatically clamps the straight pipe, and automatically rotates the straight pipe according to the workpiece pipe diameter transmitted by the weld traceability to complete 5-angle flaw detection and perform automatic evaluation in real time; i) After the flaw detection is completed, the pipe clamping and rotating system automatically releases the straight pipe and automatically triggers the pipe sending operation. After the next weld is identified, it will be positioned for detection. The quality evaluation results are uploaded to the quality database for storage; j) After the whole pipe is completed, it is stored in the qualified and repair areas according to the evaluation results; k) The pipe is returned from the original conveyor roller for repair. After the repair is completed, the pipe is transported to the flaw detection roller for secondary automatic flaw detection.

[0085] The above is a specific description of the implementation mode of the present invention, but the present invention is not limited to the described embodiments. Those skilled in the art may make various equivalent modifications or substitutions without violating the spirit of the present invention, and these equivalents or substitutions are all included in the scope defined by the claims of the present invention.

Claims

1. A fully automated small-diameter pipe DR detection system, characterized in that: include: Manufacturing operations management platform and quality database; An information management system that communicates with the manufacturing operation management platform and the quality database; A controller in communication with the information management system; A weld traceability scanning system that communicates with the information management system and is used to scan codes for small-diameter pipes; A safety monitoring system that communicates with the information management system and is used to monitor the DR detection of small-diameter pipes; A weld joint identification and positioning system connected to the controller for positioning the weld joint on the small-diameter pipe; A pipe conveying system in communication with the controller and used for conveying small-diameter pipes; A pipe clamping and rotating system, which is in communication with the controller and is used to clamp and rotate the small-diameter pipe; A flaw detection system connected to the controller for DR inspection of small-diameter pipes, the flaw detection system is located in the lead room and automatically performs grating opening and closing, image acquisition, image quality meter placement and defect identification; Defect detection alarm system connected to the controller for defect alarm after DR detection; A tube sorting system that communicates with a controller and is used to sort defective and normal small diameter tubes after DR inspection.

2. The fully automated small-diameter pipe DR detection system according to claim 1, characterized in that: The weld traceability scanning system includes a scanning gun; The security monitoring system includes outdoor security monitoring cameras and indoor security monitoring cameras located outdoors and indoors in the lead room; The weld identification and positioning system includes outdoor weld monitoring cameras and indoor weld monitoring cameras located outdoors and indoors in the lead room; The pipe conveying system comprises a conveying roller and a conveying motor, a small-diameter pipe is placed on the conveying roller, and the conveying motor is drivingly connected to the conveying roller; The pipe clamping and rotating system comprises a clamping mechanism, a clamping cylinder and a pipe rotating motor. The clamping mechanism is used for clamping small-diameter pipes. The clamping cylinder and the pipe rotating motor are both drivingly connected to the clamping mechanism.

3. The fully automated small-diameter pipe DR detection system according to claim 1, characterized in that: The flaw detection system comprises: An X-ray system, the output end of which is directed downward toward the weld of the small-diameter pipe transported into the lead room; A ray machine motion system drivingly connected to the X-ray system; The grating opening and closing system located below the weld of the small diameter pipe transported in the lead room; A digital imaging system located below the grating opening and closing system; An automatic placement system for the image quality meter located next to the grating opening and closing system, used to place the image quality meter above the small-diameter tube to measure the image quality; Automatic marking system located behind the transmission of the grating opening and closing system; Lead room protection system located in the lead room.

4. The fully automated small-diameter pipe DR detection system according to claim 3, characterized in that: The X-ray system includes a ray machine, a high voltage generator and a cooler, and the high voltage generator and the cooler are both connected to the ray machine; The X-ray machine motion system includes a X-ray machine lifting cylinder and a X-ray machine swing motor, and the X-ray machine lifting cylinder and the X-ray machine swing motor are both connected to the X-ray machine drive of the X-ray system; The lead room protection system comprises a door opening and closing motor, an interlocking sensor and a radiation meter.

5. The fully automated small-diameter pipe DR detection system according to claim 3, characterized in that: The grating opening and closing system includes a grating for shading, and a grating opening and closing motor connected to the grating and used to drive the grating to open and close; The grating includes two filter plates that can be opened and closed, and the two filter plates that can be opened and closed are respectively mounted on two grating adjustment mechanisms, and the two grating adjustment mechanisms are both connected to the grating opening and closing motor drive; The grating adjustment mechanism includes a linear module and a grating slide rail which are parallel to each other, the grating opening and closing motor is drivingly connected to the linear module, one end of the filter plate is mounted on the output slider of the linear module, and the other end is slidably mounted on the grating slide rail; The digital imaging system comprises a flat panel detector, and the linear module and the grating slide rail are both assembled on the flat panel detector.

6. The fully automated small-diameter pipe DR detection system according to claim 3, characterized in that: The automatic placement system of the image quality meter includes a double-wire image quality meter for assisting in measuring the resolution of the small-diameter tube DR image and a plurality of single-wire image quality meters of different specifications for assisting in measuring the sensitivity of the small-diameter tube DR image, as well as a double-wire placement mechanism and a single-wire placement mechanism for respectively driving the double-wire image quality meter and the single-wire image quality meter to move to between the small-diameter tube and the X-ray system for placement.

7. The fully automated small-diameter pipe DR detection system according to claim 6, characterized in that: The double-wire placing mechanism comprises a double-wire vertical moving structure, a double-wire horizontal moving structure and a double-wire fixing plate; The double-wire vertical moving structure is fixed on a fixing seat, the double-wire horizontal moving structure is mounted on the output end of the double-wire vertical moving structure, the double-wire fixing plate is mounted on the output end of the double-wire horizontal moving structure, and the double-wire image quality meter is mounted on the double-wire fixing plate; When the dual-wire image quality meter is placed, the dual-wire vertical moving structure and the dual-wire lateral moving structure drive the dual-wire image quality meter to move vertically and horizontally to the top of the small-diameter tube to assist in measuring the resolution of the small-diameter tube DR image.

8. The fully automated small-diameter pipe DR detection system according to claim 6, characterized in that: The monofilament placing mechanism comprises a monofilament vertical moving structure, a monofilament horizontal moving structure, a monofilament fixing plate, a rotating structure and a turntable structure; The single-wire vertical moving structure is fixed on a fixing seat, the single-wire transverse moving structure is mounted on the output end of the single-wire vertical moving structure, the single-wire fixing plate is mounted on the output end of the single-wire transverse moving structure, the rotating structure is mounted on the single-wire fixing plate, the turntable structure is mounted on the output end of the rotating structure, and the single-wire image quality meters of different specifications are mounted on the turntable structure; When the single-wire image quality meter is placed, the single-wire vertical moving structure, the single-wire horizontal moving structure and the rotating structure drive the turntable structure to move vertically, horizontally and rotate, and the turntable structure is moved above the small-diameter tube. The turntable structure drives the single-wire image quality meters of different specifications to rotate, and the single-wire image quality meters of corresponding specifications are selected and placed above the small-diameter tube to assist in measuring the DR image sensitivity of the small-diameter tube; Wherein, the rotating structure comprises a first rotating motor and a rotating plate, the first rotating motor is mounted on the monofilament fixing plate, and the rotating plate is mounted on the output end of the first rotating motor; The turntable structure includes a second rotating motor and a monofilament turntable, wherein the second rotating motor is mounted on the rotating plate, the monofilament turntable is mounted on the output end of the second rotating motor, and the monofilament image quality meters of different specifications are evenly arranged on the monofilament turntable in a circumferential manner.

9. The fully automated small-diameter pipe DR detection system according to claim 3, characterized in that: The automatic marking system comprises a marking motor, a marking frame, a motor fixing box, a lead screw, a lead screw slider, a connecting plate, a marking head and an ink storage box; The lead screw is assembled at the front end of the marking frame, and the motor fixing box is assembled at the top end. The marking motor is assembled in the motor fixing box and connected to the lead screw. The lead screw slider is assembled on the lead screw. One end of the connecting plate is connected to the lead screw slider, and the other end is connected to the marking head. The ink storage box is assembled on the marking head. The marking motor drives the lead screw to rotate, drives the lead screw slider to move up and down, and drives the marking head to move up and down through the connecting plate to mark the vicinity of the small-diameter pipe weld.

10. The fully automated small-diameter pipe DR detection system according to claim 1, characterized in that: The defect detection alarm system includes a buzzer; The pipe sorting system comprises a sorting cylinder and a material rack, and the sorting cylinder drives the small-diameter pipes to the material rack for sorting.

Images