Weld joint nondestructive testing system

Abstract

The invention relates to a nondestructive testing system for a welding seam. The nondestructive testing system comprises a movement module, a penetrating fluid brushing module, a penetrating fluid removing module, an acquisition module, a lighting module and a control module, the movement module, the penetrating fluid brushing module, the penetrating fluid removing module, the collecting module and the lighting module are in signal connection with the control module, and the control module controls the movement module, the penetrating fluid brushing module, the penetrating fluid removing module and the lighting module according to a preset control strategy so as to complete nondestructive testing of a welding seam; the control strategy comprises the following steps: acquiring theoretical penetration time of penetrating fluid and a corresponding periodic detection area; executing a first detection operation according to the periodic detection area; through cooperation of all the modules, nondestructive testing of welding seams in the pipeline is achieved. The brushing stability of the penetrating fluid is ensured, so that the accuracy of welding seam detection is ensured; and meanwhile, through the acquisition module and the illumination module, the accuracy of data acquisition is ensured.

Description

Technical Field

[0001] This application relates to the technical field of weld detection, and particularly to a non-destructive weld detection system. Background Art

[0002] Welding is an essential manufacturing technology for large bridges, pressure vessels, oil and gas pipelines, etc. The number of welds formed by welding these large components is numerous and the length is huge, even counted in kilometers. All welds, including those hidden inside the structure, need to be non-destructively detected to verify the welding quality. The manual detection method can complete the non-destructive detection tasks of some external welds, but the workload is still extremely heavy. There are a large number of internal welds in large bridges, pressure vessels, and oil and gas pipelines. These internal welds can hardly be non-destructively detected by manpower and can only be completed by an automated non-destructive detection mobile platform. Penetrant testing is a non-destructive testing method that uses capillary action to detect crack defects on the surface of materials. This method is relatively effective for detecting internal weld cracks. However, at present, there are still few weld non-destructive detection systems with penetrant testing functions put into actual production, and no weld non-destructive detection system that can solve the non-destructive detection of internal pipeline welds has emerged. Summary of the Invention

[0003] In order to solve the problems existing in the above-mentioned prior art, the purpose of this application is to provide a weld non-destructive detection system to solve the technical problem that there is no weld non-destructive detection system in the prior art that can solve the non-destructive detection of internal welds.

[0004] A weld non-destructive detection system described in this application includes a motion module, a penetrant brushing module, a penetrant cleaning module, a collection module, an illumination module, and a control module; the motion module, the penetrant brushing module, the penetrant cleaning module, the collection module, and the illumination module are respectively signal-connected to the control module; the control module controls the motion module, the penetrant brushing module, the penetrant cleaning module, and the illumination module according to a preset control strategy to complete the non-destructive detection of welds; the control strategy includes: obtaining the theoretical penetrant penetration time and the corresponding periodic detection area; performing a first detection operation according to the periodic detection area.

[0005] Preferably, the obtaining of the theoretical penetrant time and the corresponding periodic detection area includes:

[0006] Establishing a pipeline coordinate system; according to when the motion module stops, mapping the brushing range of the penetrant brushing module onto the pipeline coordinate system, and dividing the pipeline into several brushing areas;

[0007] Mapping the motion path of the motion module onto the pipeline coordinate system;

[0008] Obtain the single brushing time of the penetrant brushing module, the theoretical penetration time of the penetrant, the theoretical removal time of the penetrant, the maximum movement speed and acceleration of the movement module;

[0009] Obtain the number of brushing areas that can be completed within a range of the theoretical penetration time of the penetrant according to the theoretical penetration time of the penetrant, the single brushing time, the movement speed and the acceleration, and define the brushing areas that need to be brushed within a period of the predicted penetration time of the penetrant as the periodic detection area.

[0010] Preferably, the number of brushing areas that can be brushed within a period of the theoretical penetration time of the penetrant is obtained by the following formula:

[0011] n=(T b -T c -T d ) / T a ;

[0012] wherein, n is the number of brushing areas that can be brushed, T a is the single brushing time, T b is the theoretical penetration time of the penetrant, T c is the theoretical removal time of the penetrant, T d is the return time.

[0013] Preferably, the first detection operation includes the following steps:

[0014] S1. Define the brushing area closest to the origin of the pipeline coordinate system as the initial brushing area, and brush the penetrant on the initial brushing area;

[0015] S2. After completing the brushing of the penetrant on the initial brushing area, sequentially brush the penetrant on other brushing areas within the periodic detection area;

[0016] S3. After completing the brushing of the penetrant on other brushing areas within the periodic detection area, return to the initial brushing area, and sequentially perform penetrant removal and image data collection on each of the brushing areas;

[0017] S4. According to the image data, judge the penetrant removal effect, classify the brushing areas according to the penetrant removal effect to obtain a classification result, and screen the brushing areas that meet the weld non-destructive testing;

[0018] S5. Perform weld non-destructive testing on the brushing areas that meet the weld non-destructive testing.

[0019] Preferably, the step S4 includes:

[0020] S401. Establish a penetrant removal effect model, and perform removal on each of the painting areas based on the theoretical penetrant removal time.

[0021] S402. Obtain the image data of each of the painting areas after removal according to the theoretical penetrant removal time, classify the removal conditions of the painting areas through the penetrant removal effect model, and obtain a classification result.

[0022] S403. According to the classification result, screen out the painting areas that meet the requirements of weld nondestructive testing; perform corresponding operations on each of the painting areas that do not meet the requirements of weld nondestructive testing.

[0023] Preferably, the classification result includes: excessive removal, proper removal, and insufficient removal.

[0024] Preferably, the performing corresponding operations on each of the painting areas that do not meet the requirements of weld nondestructive testing includes:

[0025] If the classification result corresponding to the painting area is excessive removal, mark the painting area as a re-inspection painting area; and correct the theoretical penetrant removal time of the painting area to obtain the corrected penetrant removal time.

[0026] If the classification result corresponding to the painting area is insufficient removal, perform a supplementary removal operation on the painting area until the classification result corresponding to the painting area is proper removal.

[0027] Preferably, the supplementary removal operation includes:

[0028] Obtain the supplementary removal time, and perform removal on the painting area based on the supplementary removal time;

[0029] Obtain the image data of the painting area after removal according to the supplementary removal time, classify the removal conditions of the painting area through the penetrant removal effect model, and obtain a classification result;

[0030] Execute the step S403.

[0031] Preferably, the control strategy further includes:

[0032] Obtain the distance data between the two closest re-inspection painting areas, and judge the time T 往返 for the motion module to travel back and forth between the two re-inspection painting areas according to the distance data, the theoretical penetrant penetration time, the single painting time, the moving speed, and the acceleration, 渗透 and the relationship with the theoretical penetrant penetration time T 往返 According to the relationship between T 渗透 and T, select the corresponding re-inspection operation.

[0033] Preferably, the corresponding reinspection operation selected according to T 往返 and T 渗透 is as follows:

[0034] If T 渗透 ≤ T 循环 , reinspect a single said reinspection painting area;

[0035] If T 渗透 > T 循环 , reinspect two said reinspection painting areas.

[0036] The non-destructive weld detection system described in this application has the following advantages:

[0037] Through the cooperation between modules, non-destructive detection of internal pipeline welds is achieved; and through the penetrant painting module and penetrant removal module, it is ensured that the penetrant is evenly painted on the inner wall of the workpiece, ensuring the painting stability of the penetrant, and further ensuring the accuracy of weld detection; at the same time, through the acquisition module and lighting module, the accuracy of data acquisition is ensured;

[0038] Furthermore, through the setting of the control module and detection strategy, the non-destructive weld detection system described in this application can perform non-destructive weld detection more efficiently. At the same time, for the detection results with deviations, the accuracy of the detection results is ensured through reinspection. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 is a schematic diagram of the specific structure of the non-destructive weld detection system described in this application;

[0040] Figure 2 is a front view of the specific structure of the non-destructive weld detection system described in this application;

[0041] Figure 3 is a schematic flowchart of the control strategy described in this application.

[0042] Description of the reference numerals:

[0043] 1 - Chassis structure, 11 - Chassis body, 12 - Towing member, 13 - Top plate;

[0044] 2 - Traveling assembly, 21 - Axle, 22 - Hub, 23 - Tire;

[0045] 3 - Guidance structure, 31 - Guide wheel assembly, 311 - Guide wheel body, 312 - Guide wheel arm;

[0046] 4 - Penetrant painting module, 41 - Penetrant storage tank, 42 - Penetrant painting pipe;

[0047] 5 - First connection structure, 51 - First connecting arm, 52 - First connecting hoop;

[0048] 6 - Penetrant removal module, 61 - Penetrant recovery tank, 62 - Penetrant removal pipe

[0049] 7 - Second connection structure, 71 - Second connecting arm, 72 - Second connecting hoop;

[0050] 8 - Acquisition module, 81 - Industrial camera;

[0051] 9 - Third connection structure, 91 - Third connecting arm, 92 - Third connecting hoop. Detailed implementation mode

[0052] As Figure 1 shown, a weld non - destructive testing system of the present application includes a motion module, a penetrant brushing module 4, a penetrant removal module 6, an acquisition module 8, an illumination module and a control module;

[0053] The motion module, the penetrant brushing module 4, the penetrant removal module 6, the acquisition module 8 and the illumination module are respectively connected to the control module by signal;

[0054] The control module controls the motion module, the penetrant brushing module 4, the penetrant removal module 6 and the illumination module according to a preset control strategy to complete the weld non - destructive testing.

[0055] The control strategy includes: obtaining the theoretical penetrant penetration time and the corresponding periodic detection area; performing a first detection operation according to the periodic detection area.

[0056] Specifically, in one embodiment of the present application, regarding the specific structures of each module, the following is an example description:

[0057] The penetrant brushing module 4, the penetrant removal module 6, the acquisition module 8 and the illumination module are all arranged on the motion module and are respectively connected to the motion module;

[0058] The motion module is used to drive the penetrant brushing module 4, the penetrant removal module 6, the acquisition module 8 and the cleaning module to move along a path;

[0059] The penetrant brushing module 4 is used to brush penetrant at the weld on the path;

[0060] The penetrant removal module 6 is used to remove the excess penetrant at the weld on the path;

[0061] The acquisition module 8 is used to collect image data on the path and input it into the control module;

[0062] The illumination module is used to provide illumination for the acquisition module 8.

[0063] The motion module includes a chassis structure 1, a traveling assembly 2, and a guiding structure 3.

[0064] Exemplarily, the chassis structure 1 includes a chassis body 11, a traction member 12, and a top plate 13;

[0065] The traction member 12 is disposed between the chassis body 11 and the top plate 13 and is connected to the chassis body 11; a traction hole is formed at an end in the length direction of the traction member 12; the top plate 13 is connected to the chassis body 11;

[0066] A slider is disposed at the bottom of the traction member 12, and a chute or slideway adapted to the slider is disposed on the chassis body 11 at a position corresponding to the slider; the chute or slideway extends along the length direction of the chassis body 11, the length of the chute or slideway is greater than the length of the slider and less than the length of the chassis body 11; the traction member 12 is slidably connected to the chassis body 11;

[0067] The traveling assembly 2 includes two wheel axles 21, four hubs 22, and four tires 23. The hubs 22 and the tires 23 are in one-to-one correspondence. The tire 23 is sleeved on the outer periphery of the hub 22. The hub 22 is rotatably connected to the end of the wheel axle 21. The axial direction of the wheel axle 21 extends along the width direction of the chassis structure 1 and is disposed at the bottom of the chassis structure 1 and connected to the chassis structure 1; in one embodiment of the present application, the two wheel axles 21 are disposed along the length direction of the chassis structure 1; both ends of the wheel axle 21 are respectively connected to a hub 22, and the length of the wheel axle 21 is greater than the width of the chassis structure 1. Preferably, the length of the wheel axle 21 can be the sum of the width of the chassis structure 1 and the widths of the two hubs 22. The traveling assembly 2 travels along the axial direction of the pipeline.

[0068] The guiding structure 3 includes at least two sets of guiding wheel assemblies 31. The guiding wheel assembly 31 includes a guiding wheel body 311 and a guiding wheel arm 312; at least two sets of guiding wheel assemblies 31 are disposed on both sides in the length direction of the chassis structure 1; the guiding wheel assembly 31 is connected to the chassis structure 1 through a limiting structure. The guiding wheel assembly 31 is disposed on both sides in the length direction of the chassis structure 1, that is, the guiding wheel assembly 31 comes into contact with the inner wall of the workpiece faster than the chassis structure If the guiding wheel assembly 31 comes into contact with the inner wall of the workpiece, the self-positioning weld non-destructive testing mobile device of the present application can be kept in the middle of the inside of the workpiece, that is, it is ensured that a self-positioning weld non-destructive testing mobile device of the present application can be timely positioned when performing non-destructive testing inside large workpieces such as pipelines.

[0069] The penetrant brushing module 4 is connected to the chassis structure 1 through the first connection structure 5. The penetrant brushing module 4 includes a penetrant storage tank 41 and a penetrant brushing pipe 42, and the penetrant storage tank 41 is communicated with the penetrant brushing pipe 42. A first pump member is arranged in the penetrant storage tank 41. The first connection assembly includes a first connection arm 51 and a first connection hoop 52. One end of the first connection arm 51 is connected to the chassis structure 1, and the other end extends in a direction away from the chassis structure 1 and is connected to the first connection hoop 52. One end of the penetrant brushing pipe 42 close to the chassis structure 1 is connected to the first connection hoop 52.

[0070] The penetrant removal module 6 is connected to the chassis structure 1 through the second connection structure 7. The penetrant removal module 6 includes a penetrant recovery tank 61 and a penetrant removal pipe 62, and the penetrant recovery tank 61 is communicated with the penetrant removal pipe 62. A second pump member is arranged in the penetrant recovery tank 61, and the second pump member is electrically connected to the control module. The second connection assembly includes a second connection arm 71 and a second connection hoop 72. One end of the second connection arm 71 is connected to the chassis structure 1, and the other end extends in a direction away from the chassis structure 1 and is connected to the second connection hoop 72. One end of the penetrant removal pipe 62 close to the chassis structure 1 is connected to the second connection hoop 72.

[0071] The acquisition module 8 is connected to the chassis structure 1 through the third connection structure 9. The acquisition module 8 includes an industrial camera 81, and the camera of the industrial camera 81 is arranged facing away from the chassis structure 1. The third connection assembly includes a third connection arm 91 and a third connection hoop 92. One end of the third connection arm 91 is connected to the chassis structure 1, and the other end extends in a direction away from the chassis structure 1 and is connected to the third connection hoop 92. One end of the industrial camera 81 away from the camera is connected to the third connection hoop 92.

[0072] The lighting module (not shown in the figure) includes a plurality of LED lamp groups, which are arranged around the acquisition module 8 and are used to provide light for the acquisition module 8 to ensure that the information collected by the acquisition module 8 is more accurate and improve the accuracy of weld non-destructive testing.

[0073] The control module is not necessarily arranged on the motion module. It can be an operation platform, as long as it is ensured to be signal-connected to the motion module, the penetrant brushing module 4, the penetrant removal module 6, the acquisition module 8 and the lighting module, so that the control module can control the motion module, the penetrant brushing module 4, the penetrant removal module 6, the acquisition module 8 and the lighting module.

[0074] Through the cooperation among various modules, non-destructive testing of the internal welds of the pipeline is achieved; and through the penetrant brushing module 4 and the penetrant removal module 6, it is ensured that the penetrant is evenly brushed on the inner wall of the workpiece, the brushing stability of the penetrant is ensured, and thus the accuracy of weld detection is ensured; at the same time, through the acquisition module 8 and the lighting module, the accuracy of data acquisition is ensured.

[0075] Furthermore, based on the application scenario of the weld non-destructive testing system of the present application, obtaining the theoretical penetrant time and the corresponding periodic detection area includes:

[0076] Establish a pipeline coordinate system; when the motion module stops, map the brushing range of the penetrant brushing module 4 onto the pipeline coordinate system, and divide the pipeline into several brushing areas;

[0077] Map the motion path of the motion module onto the pipeline coordinate system;

[0078] Obtain the single-time brushing time of the penetrant brushing module 4, the theoretical penetrant time of the penetrant, the maximum motion speed and acceleration of the motion module;

[0079] According to the theoretical penetrant time, the single-time brushing time, the motion speed and acceleration, obtain the number of brushing areas that can be completed within a period of the theoretical penetrant time, and define the brushing areas that need to be brushed within a period of the predicted penetrant time as the periodic detection area.

[0080] Specifically, the purpose of establishing the pipeline coordinate system is to provide a clear coordinate for the weld non-destructive testing system of the present application, and moreover, the motion data of the motion module, the specific range of the brushing module or the removal module can be quantified according to the coordinates mapped onto the coordinate system, so as to precisely control the weld non-destructive testing system of the present application to perform weld non-destructive testing.

[0081] Exemplarily, during a weld non-destructive testing process, in order to comprehensively inspect the pipe wall, it is necessary to rotate the weld non-destructive testing system so that the penetrant brushing module 4 etc. face the area to be detected (here, the area to be detected refers to the part of the entire pipeline to be detected); therefore, a pipeline coordinate system can be established each time facing the periodic detection area. The pipeline coordinate system can be established with the axial direction of the pipeline as the x-axis and the radial direction as the y-axis to establish a rectangular coordinate system. Map the single-time brushing range of the penetrant brushing module 4 onto the coordinate system, and set the length mapped onto the x-axis as the unit length of the x-axis; set the length mapped onto the y-axis as the unit length of the y-axis. Since the motion module moves along the axial direction of the pipeline, that is, the motion module moves along the x-axis direction, when calculating the motion distance, only the x coordinate needs to be considered.

[0082] The single brushing time of the penetrant brushing module 4 can be obtained through direct testing; the theoretical penetration time of the penetrant is the time when the penetrant theoretically reaches saturated adsorption in the defect and the penetration depth is sufficient to form an effective indication in subsequent inspection steps; the theoretical penetration time of the penetrant can be obtained according to existing standards and can also be adjusted according to temperature, etc. in actual operation; the maximum movement speed and acceleration of the movement module can be obtained through direct testing.

[0083] The following is an example:

[0084] Taking the unit length of the x-axis as 6m and the single brushing time T a as 5s, the theoretical penetration time T b of the penetrant as 100s, the theoretical removal time T d of the penetrant as 30s, the maximum movement speed of the movement module is V max as 1.2m / s, the acceleration a is 3m / s 2 , and taking the total length of the pipeline as 1200m as an example,

[0085] During the brushing process, it is calculated that the movement module moves at a constant speed at the maximum movement speed. Within the theoretical penetration time of the penetrant, the length L1 that the movement module can travel is 120m. Since it is necessary to return to the initial area, that is, a round trip is required. At the same time, in order to avoid excessive penetration of the penetrant at the end of the initial brushing area when returning to the starting point of the initial brushing area, which affects subsequent non-destructive testing, the time for removing the penetrant needs to be taken into account. Therefore, the length L2 of the area that can be covered within a cycle of the theoretical penetration time of the penetrant should be 57m.

[0086] Therefore, based on the above explanation, the formula for calculating the number of brushing areas that can be brushed within a cycle of the theoretical penetration time of the penetrant can be obtained, and the formula is as follows:

[0087] n = (T b - T c - T d ) / T a ;

[0088] In the above formula, n is the number of brushing areas that can be brushed, T a is the single brushing time, T b is the theoretical penetration time of the penetrant, T c is the theoretical removal time of the penetrant, and T d is the return time.

[0089] Specifically, the above formula is obtained by converting the following formula:

[0090] T b = nT a + T c + Td ;

[0091] The meaning of this formula is that in the optimal case, the theoretical penetration time of the penetrant should include the brushing time of n brushing areas, the theoretical removal time of the penetrant, and the return time; according to the formula obtained after conversion, the number of brushing areas that can be brushed within a cycle of calculating the theoretical penetration time of a penetrant. When calculating, if the value of n has a decimal point, to ensure the integrity of brushing, the value of n should be rounded down.

[0092] More specifically, the return time refers to the time taken for the motion module to move from the end point of the last brushing area to the starting point of the initial brushing area, that is, the time consumed for the motion module to travel L2.

[0093] T d It is calculated by the following formula:

[0094] T d = T d1 + 2T d2 ;

[0095] In the above formula, T d1 is the time consumed for the uniform motion of the motion module, T d2 is the time consumed for the motion module to accelerate to the maximum speed or decelerate from the maximum speed to a speed of 0. When returning, since there is no need to perform operations such as brushing and cleaning, the motion module travels L2 and satisfies the following formula:

[0096] L2 = V max ·T d1 +(a·T d2 2 ) / 2;

[0097] Through the above formula, T d1 can be obtained; furthermore, T d can be obtained.

[0098] Among them, T d2 is calculated by the following formula:

[0099] T d2 = V max / a;

[0100] Next, based on the example data provided above, an example of this calculation is given:

[0101] T d2 = V max / a = 1.2 / 3 = 0.4s;

[0102] T d1 = [L2 - (a·T d2 2 ) / 2] / Vmax = [57 - (3×0.4 2 ) / 2] / 1.2 = 47.3 s;

[0103] T d = T d1 + 2T d2 = 47.3 + 2×0.4 = 48.1 s;

[0104] n = (T b - T c - T d ) / T a = (100 - 30 - 48.1) / 5 = 4.38, rounded down, to get n = 4.

[0105] That is, within one cycle of the theoretical penetration time of the penetrant, the number of painting areas that can be painted is 4.

[0106] Furthermore, the first detection operation includes the following steps:

[0107] S1. Define the painting area closest to the origin of the pipeline coordinate system as the initial painting area, and apply penetrant to the initial painting area;

[0108] S2. After applying penetrant to the initial painting area, sequentially apply penetrant to the other painting areas within the periodic detection area;

[0109] S3. After applying penetrant to the other painting areas within the periodic detection area, return to the initial painting area, and sequentially perform penetrant removal and image data acquisition on each painting area;

[0110] S4. Based on the image data, judge the penetrant removal effect, classify the painting areas according to the penetrant removal effect to obtain a classification result, and screen the painting areas that meet the requirements for weld non-destructive testing;

[0111] S5. Perform weld non-destructive testing on the painting areas that meet the requirements for weld non-destructive testing.

[0112] More specifically, step S4 includes:

[0113] S401. Establish a penetrant removal effect model, and perform removal on each painting area based on the theoretical penetrant removal time;

[0114] S402. Obtain the image data of each painting area after removal according to the theoretical penetrant removal time, classify the removal situation of the painting areas through the penetrant removal effect model to obtain a classification result;

[0115] S403. According to the classification results, screen the painting areas that meet the requirements for weld non-destructive testing; perform corresponding operations on each painting area that does not meet the requirements for weld non-destructive testing.

[0116] Specifically, the classification results include: excessive cleaning, appropriate cleaning, and insufficient cleaning.

[0117] The following is an exemplary description of step S4:

[0118] Establishment of the penetrant removal effect model:

[0119] Use a convolutional neural network (CNN) with the structure: input layer → 2 convolutional layers (3×3 kernel, ReLU activation) → max pooling → fully connected layer → Softmax output (3 classifications: excessive cleaning, appropriate cleaning, insufficient cleaning); train with 10,000 images labeled with historical cleaning samples until the accuracy ≥ 95%.

[0120] For the processing of image data, conventional processing methods such as gray-level co-occurrence matrix can be used to improve the judgment ability of the model.

[0121] Taking the color intensity of the defect area as the quantization standard as an example:

[0122] Taking the range standard of the RGB single-channel value C in the range of 80 to 200 (including the endpoint values) as appropriate cleaning as an example, if C < 80, it is insufficient cleaning, and if C > 200, it is excessive cleaning.

[0123] According to the classification results, screen the painting areas that meet the requirements for weld non-destructive testing. The screened painting areas are subjected to step S5, and corresponding operations are performed on the painting areas that do not meet the requirements for weld non-destructive testing.

[0124] Specifically, the weld non-destructive testing for the painting areas that meet the requirements for weld non-destructive testing includes the following steps:

[0125] S501. Establish a weld non-destructive testing model;

[0126] S502. Obtain the image data of the painting areas that meet the requirements for weld non-destructive testing, and input the image data into the weld non-destructive testing model;

[0127] S503. The weld non-destructive testing model outputs the test results.

[0128] Exemplarily, the weld non-destructive testing model can be similar to the penetrant removal effect model, using a convolutional neural network (CNN) with the structure: input layer → 2 convolutional layers (3×3 kernel, ReLU activation) → max pooling → fully connected layer → Softmax output (2 classifications: presence of weld, absence of weld); train with 10,000 images labeled with historical cleaning samples until the accuracy ≥ 95%.

[0129] Perform corresponding operations on each painting area that does not meet the weld non-destructive testing, including:

[0130] If the classification result corresponding to the painting area is excessive cleaning, mark the painting area as a re-inspection painting area; and correct the theoretical removal time of the penetrant for this painting area to obtain the corrected removal time of the penetrant;

[0131] If the classification result corresponding to the painting area is insufficient cleaning, perform supplementary cleaning operations on this painting area until the classification result corresponding to this painting area is moderate cleaning.

[0132] Exemplarily, the theoretical removal time of the penetrant for the painting area can be corrected using PID control. The following is an example for illustration:

[0133] Obtain the real-time adjustment amount ΔT, and obtain ΔT through the following formula:

[0134] ΔT = -(K p E(T) + K i ∑E(T) + K d ΔE(T) / ΔT)

[0135] K p is the proportionality coefficient, which can be calibrated through process tests; K i is the integral coefficient; K d is the differential coefficient.

[0136] Taking the range standard of the RGB single-channel value C in the range of 80 to 200 (including the endpoint values) as moderate cleaning, T c being 30s, K p being 0.5, K i being 0.1, K d being 0.2, the lower limit of the cleaning time T min being 10s, and the minimum absolute value of the adjustment step |ΔT| ≥ 1 as an example, the detection data is shown in the following table as an example;

[0137] Table 1

[0138] Time T RGB value Deviation E(T) = RGB value - 200 Deviation change rate ΔE(T) / ΔT The first second 210 E(1)＝10 - The second second 215 E(2)＝15 (15-10) / 1＝5 The third second 220 E(3)＝20 (20-15) / 1＝5

[0139] The PID calculation process is as follows:

[0140] P(T) = Kp × E(T) = 0.5 × 20 = 10 seconds;

[0141] The cumulative deviation ∑E(T) = E(1) + E(2) + E(3) = 10 + 15 + 20 = 45

[0142] I(T) = K i × ∑E(T) × t = 0.1 × 45 × 1 = 4.5 seconds;

[0143] The deviation change rate ΔE(T) / Δt = 5

[0144] D(T) = K d ×ΔE(T) / Δt = 0.2×5 = 1 second.

[0145] ΔT = -(P(T) + I(T) + D(T)) = -(10 + 4.5 + 1) = -15.5 seconds;

[0146] The adjusted time is as follows:

[0147] T 修正 = T c + ΔT = 30 - 15.5 = 14.5 seconds > T min . Therefore, T correction = 14.5; if the calculated T 修正 < T min , then take T min as T 修正 .

[0148] Furthermore, the supplementary cleaning operation includes:

[0149] Obtain the supplementary cleaning time, and clean the painting area based on the supplementary cleaning time;

[0150] Obtain the image data of the painting area after cleaning according to the supplementary cleaning time, classify the cleaning situation of the painting area through the penetrant cleaning effect model, and obtain the classification result;

[0151] Execute step S403.

[0152] Exemplarily, the acquisition of the supplementary cleaning time can be similar to the acquisition of the penetrant correction cleaning time, and is obtained through PID control; taking the obtained supplementary cleaning time T supplement as 5s as an example, the painting area is cleaned for 5s. After the cleaning is completed, obtain the image data of the painting area, input the image data into the penetrant cleaning effect model for classification of the cleaning effect. After obtaining the classification result, since there is still a situation of insufficient cleaning in the painting area after the first supplementary cleaning, after obtaining the classification result, execute step S403, that is, according to the classification result, screen the painting areas that meet the requirements of weld non-destructive testing; perform corresponding operations on each of the painting areas that do not meet the requirements of weld non-destructive testing. The specific process of step S403 has been mentioned in this application and will not be elaborated here.

[0153] Furthermore, the control strategy also includes:

[0154] Obtain the distance data of the two closest re-inspection painting areas, and judge the time T for the movement module to travel back and forth between the two re-inspection painting areas according to the distance data, the theoretical penetration time of the penetrant, the single painting time, the movement speed, and the acceleration. 循环 And the theoretical penetration time T of the penetrant b Relationship, and select the corresponding re-inspection operation according to the relationship between T 循环 And T b Relationship.

[0155] Furthermore, selecting the corresponding re-inspection operation according to the relationship between T 往返 And T b Relationship includes:

[0156] If T b ≤T 循环 , then re-inspect a single re-inspection painting area;

[0157] If T b >T 循环 , then re-inspect two re-inspection painting areas.

[0158] Specifically, the distance data of the two re-inspection painting areas can be calculated according to the x-axis coordinates of the two re-inspection painting areas. For example: the x-axis coordinates of the endpoints of the first re-inspection painting area are x1 and x2, and the x-axis coordinates of the endpoints of the second re-inspection painting area are x3 and x4. Exemplarily, x1 is 6, x2 is 12, x3 is 30, and x4 is 36. Calculate the distance between the first re-inspection painting area and the second re-inspection painting area as x4 - x1 = 30. The theoretical penetration time of the penetrant for a single re-inspection painting area is calculated according to T b = 100s, calculate whether T b is greater than T 循环 , and the calculation of T 循环 is carried out according to (2T a +T c +T d ’ ), T d ’ = [30 - (3×0.4 2 ) / 2] / 1.2 + 0.8 = 25.6s;

[0159] T 循环 = 2×5 + 14.5 + 25.6 = 50.1 < 100. Therefore, when conducting re-inspection, after finishing the painting in the first re-inspection painting area, the painting in the second re-inspection painting area can be carried out, and then return to the first re-inspection painting area for cleaning and other operations, that is, re-inspect two re-inspection painting areas.

[0160] The operation of the re-inspection is similar to steps S3 to S5 in the first detection operation. The difference is that there is only one re-inspection painting area or two re-inspection painting areas in the "periodic detection area" of the re-inspection operation, and other operations are the same as steps S3 to S5 in the first detection operation, so they will not be elaborated here.

[0161] In the description of the present application, it should be understood that the orientation or positional relationship indicated by orientation words such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal" and "top, bottom", etc. is usually based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present application and simplifying the description. Without contrary explanation, these orientation words do not indicate and imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation on the protection scope of the present application.

[0162] For those skilled in the art, various corresponding changes and deformations can be made according to the technical solutions and concepts described above, and all these changes and deformations should fall within the protection scope of the claims of the present application.

Claims

1. A weld non-destructive testing system, comprising a motion module, a penetrant coating module, a penetrant removal module, a collection module, an illumination module and a control module; the motion module, the penetrant coating module, the penetrant removal module, the collection module and the illumination module are respectively in signal connection with the control module; characterized in that, The control module controls the motion module, the penetrant brushing module, the penetrant removal module, and the lighting module according to a preset control strategy to complete the non-destructive testing of the weld seam; the control strategy includes: obtaining the theoretical penetrant penetration time and the corresponding periodic detection area; performing a first detection operation according to the periodic detection area.

2. The weld non-destructive testing system according to claim 1, wherein The obtaining the theoretical penetrant time and the corresponding periodic detection area includes: Establishing a pipeline coordinate system; when the motion module stops, mapping the brushing range of the penetrant brushing module onto the pipeline coordinate system, and dividing the pipeline into several brushing areas; Mapping the motion path of the motion module onto the pipeline coordinate system; Obtaining the single brushing time of the penetrant brushing module, the theoretical penetrant penetration time, the theoretical penetrant removal time, the maximum motion speed and acceleration of the motion module; Obtaining the number of brushing areas that can be completed within a range of the theoretical penetrant penetration time according to the theoretical penetrant penetration time, the single brushing time, the motion speed, and the acceleration, and defining the brushing areas that need to be brushed within a period of the predicted penetrant penetration time as the periodic detection area.

3. The weld non-destructive testing system according to claim 2, wherein The obtaining the number of brushing areas that can be brushed within a period of the theoretical penetrant penetration time is obtained by the following formula: n=(T b -T c -T d ) / T a ; where n is the number of coating areas that can be coated, T a is the single coating time, T b is the theoretical penetration time of the penetrant, T c is the theoretical removal time of the penetrant, T d is the return time.

4. The weld non-destructive testing system according to claim 2, wherein The first detection operation includes the following steps: S1. Defining the brushing area closest to the origin of the pipeline coordinate system as the initial brushing area, and brushing penetrant on the initial brushing area; S2. After completing the penetrant brushing on the initial brushing area, sequentially brush penetrant on other brushing areas within the periodic detection area; S3. After completing the penetrant brushing on other brushing areas within the periodic detection area, return to the initial brushing area, and sequentially perform penetrant removal and image data acquisition on each of the brushing areas; S4. Judging the penetrant removal effect according to the image data, classifying the brushing areas according to the penetrant removal effect to obtain a classification result, and screening the brushing areas that meet the non-destructive testing of the weld seam; S5. Performing non-destructive testing of the weld seam on the brushing areas that meet the non-destructive testing of the weld seam.

5. The weld non-destructive testing system according to claim 4, wherein, The step S4 includes: S401. Establishing a penetrant removal effect model, and removing penetrant from each of the brushing areas based on the theoretical penetrant removal time; S402. Obtaining the image data of each of the brushing areas after being removed according to the theoretical penetrant removal time, and classifying the removal situation of the brushing areas through the penetrant removal effect model to obtain a classification result; S403. According to the classification result, screening the brushing areas that meet the non-destructive testing of the weld seam; performing corresponding operations on each of the brushing areas that do not meet the non-destructive testing of the weld seam.

6. The weld non-destructive testing system according to claim 5, wherein The classification result includes: over-removal, proper removal, and under-removal.

7. The weld non-destructive testing system according to claim 6, wherein The performing corresponding operations on each of the brushing areas that do not meet the non-destructive testing of the weld seam includes: If the classification result corresponding to the painted area is excessive removal, mark the painted area as a re-inspection painted area; and correct the theoretical removal time of the penetrant for the painted area to obtain the corrected removal time of the penetrant. If the classification result corresponding to the painted area is insufficient removal, perform a supplementary removal operation on the painted area until the classification result corresponding to the painted area is moderate removal.

8. The weld non-destructive testing system according to claim 7, wherein, The supplementary removal operation includes: Obtain the supplementary removal time, and perform removal on the painted area based on the supplementary removal time; Obtain the image data of the painted area after removal according to the supplementary removal time, classify the removal situation of the painted area through the penetrant removal effect model, and obtain the classification result; Execute step S403.

9. The weld non-destructive testing system according to claim 7, characterized in that, The control strategy further includes: Obtain the distance data between the two closest retest brushing areas, and determine the time T for the movement module to travel back and forth between the two retest brushing areas according to the distance data, the theoretical penetration time of the penetrant, the single brushing time, the movement speed, and the acceleration 驯悍 and the theoretical penetration time T of the penetrant 渗透 relationship, and select the corresponding retest operation according to the relationship between T 循环 and T 渗透 relationship 10. The weld non-destructive testing system according to claim 9, characterized in that, The selection of the corresponding re-inspection operation according to T 循环 and T b includes: If T b ≤ T 循环 , then reinspect a single said reinspection painting area; If T b > T 循环 , then reinspect the two reinspection painting areas.

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