A weld seam non-destructive testing system

Abstract

The application relates to a weld nondestructive testing system, comprising a motion module, a penetrating liquid brushing module, a penetrating liquid removing module, an acquisition module, an illumination module and a control module; the motion module, the penetrating liquid brushing module, the penetrating liquid removing module, the acquisition module and the illumination module are respectively connected with the control module in signal connection; the control module controls the motion module, the penetrating liquid brushing module, the penetrating liquid removing module and the illumination module according to a preset control strategy to complete weld nondestructive testing; the control strategy comprises the following steps: acquiring a penetrating liquid theoretical penetration time and a corresponding periodic detection area; performing a first detection operation according to the periodic detection area; realizing pipeline internal weld nondestructive testing through cooperation between the modules; ensuring the brushing stability of the penetrating liquid, thereby ensuring the accuracy of weld detection; meanwhile, the accuracy of data acquisition is ensured through the acquisition module and the illumination module.

Description

Technical Field

[0001] This application relates to the field of weld inspection technology, specifically to a non-destructive testing system for welds. Background Technology

[0002] Welding is an essential manufacturing technology for large bridges, pressure vessels, and oil and gas pipelines. The welds formed by welding these large components are numerous and extremely long, sometimes measured in kilometers. These welds, including those hidden within the structure, require non-destructive testing (NDT) to verify their quality. While manual inspection can perform some NDT on external welds, the workload remains extremely heavy. Large bridges, pressure vessels, and oil and gas pipelines contain numerous internal welds, which are almost impossible to inspect manually and require automated mobile NDT platforms. Penetrant testing is a NDT method that uses capillary action to inspect surface cracks and defects in materials. This method is relatively effective for detecting internal weld cracks; however, currently, few weld NDT systems with penetrant testing capabilities are in practical production, and no system has yet been developed that can effectively detect internal welds in pipelines. Summary of the Invention

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

[0004] This application discloses a non-destructive testing system for welds, comprising a motion module, a penetrant application module, a penetrant removal module, a data acquisition module, an illumination module, and a control module. The motion module, penetrant application module, penetrant removal module, data acquisition module, and illumination module are each signal-connected to the control module. The control module controls the motion module, penetrant application module, penetrant removal module, and illumination module according to a preset control strategy to complete the non-destructive testing of the weld. The control strategy includes: acquiring the theoretical penetrant penetration time and the corresponding periodic detection area; and performing a first detection operation based on the periodic detection area.

[0005] Preferably, the method for obtaining the theoretical permeation time of the permeate and the corresponding periodic detection area includes:

[0006] Establish a pipeline coordinate system; based on the fact that the permeate coating module stops, the coating range of the permeate coating module is mapped onto the pipeline coordinate system, dividing the pipeline into several coating areas;

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

[0008] The single-brush time of the penetrant coating module, the theoretical penetration time of the penetrant, the theoretical removal time of the penetrant, and the maximum speed and acceleration of the motion module are obtained.

[0009] Based on the theoretical penetration time of the penetrant, the single application time, the movement speed, and the acceleration, the number of application areas that can be completed within the theoretical penetration time of the penetrant is obtained, and the application area that needs to be applied within a cycle of the predicted penetration time of the penetrant is defined as the cycle detection area.

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

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

[0012] Where n is the number of areas that can be painted, and T a T is the time for a single coat. b T is the theoretical permeation time of the permeate. c T is the theoretical removal time of the permeate. d This refers to the return trip time.

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

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

[0015] S2. After completing the penetrant application in the initial coating area, the penetrant is applied to the other coating areas in the periodic detection area in sequence.

[0016] S3. After completing the permeate application in other coating areas within the periodic detection area, return to the initial coating area and sequentially perform permeate removal and image data acquisition in each coating area.

[0017] S4. Based on the image data, determine the penetrant removal effect, classify the coating area according to the penetrant removal effect, obtain the classification result, and select the coating area that meets the requirements for non-destructive testing of welds.

[0018] S5. Perform non-destructive testing on the coated area that meets the requirements for weld non-destructive testing.

[0019] Preferably, step S4 includes:

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

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

[0022] S403. Based on the classification results, select the coating areas that meet the requirements for non-destructive testing of welds; perform corresponding operations on each coating area that does not meet the requirements for non-destructive testing of welds.

[0023] Preferably, the classification results include: over-cleaning, moderate-cleaning, and under-cleaning.

[0024] Preferably, performing the corresponding operations on each of the coated areas that do not meet the requirements for non-destructive testing of the weld includes:

[0025] If the classification result corresponding to the coating area is excessive cleaning, then the coating area is marked as a re-inspection coating area; and the theoretical cleaning time of the penetrant in the coating area is corrected to obtain the corrected cleaning time of the penetrant.

[0026] If the classification result corresponding to the painted area is insufficiently cleared, then a supplementary clearing operation is performed on the painted area until the classification result corresponding to the painted area is moderately cleared.

[0027] Preferably, the replenishment and clearing operation includes:

[0028] Obtain the supplementary cleaning time, and clean the painted area based on the supplementary cleaning time;

[0029] Obtain image data of the coated area after it has been cleaned according to the replenishment cleaning time, classify the cleaning status of the coated area using the penetrant cleaning effect model, and obtain the classification result;

[0030] Perform step S403.

[0031] Preferably, the control strategy further includes:

[0032] Obtain the distance data between the two closest re-inspection coating areas, and determine the time T for the motion module to travel back and forth between the two re-inspection coating areas based on the distance data, the theoretical penetration time of the penetrant, the single coating time, the movement speed, and the acceleration. 往返 With respect to the theoretical permeation time T of the permeate 渗透 The relationship, according to T 往返 With T 渗透 Choose the appropriate re-inspection operation based on the relationship.

[0033] Preferably, the method according to T 往返 With T 渗透 The corresponding re-inspection operation for the relationship selection includes:

[0034] If T 渗透 ≤T 循环 Then, a re-inspection is performed on each of the aforementioned re-inspection areas;

[0035] If T 渗透 >T 循环 Then, the two re-inspection areas will be re-inspected.

[0036] The advantages of the non-destructive testing system for welds described in this application are as follows:

[0037] Through the cooperation of various modules, non-destructive testing of weld seams inside pipelines is achieved; and through the penetrant application module and penetrant removal module, the penetrant is evenly applied to the inner wall of the workpiece, ensuring the stability of the penetrant application and thus ensuring the accuracy of weld seam testing; at the same time, the data acquisition module and lighting module ensure the accuracy of data acquisition.

[0038] Furthermore, by setting up the control module and detection strategy, the weld non-destructive testing system described in this application can perform weld non-destructive testing more efficiently. At the same time, for test results with deviations, the accuracy of the test results can be ensured through re-inspection. Attached Figure Description

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

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

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

[0042] Explanation of reference numerals in the attached figures:

[0043] 1-Chassis structure, 11-Chassis body, 12-Traction component, 13-Top plate;

[0044] 2-Travel assembly, 21-Axle, 22-Wheel hub, 23-Tire;

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

[0046] 4-Permeate coating module, 41-Permeate container, 42-Permeate coating pipe;

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

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

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

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

[0051] 9-Third connecting structure, 91-Third connecting arm, 92-Third connecting hoop. Detailed Implementation

[0052] like Figure 1 As shown, a non-destructive testing system for welds according to this application includes a motion module, a penetrant application module 4, a penetrant removal module 6, a data acquisition module 8, an illumination module, and a control module.

[0053] The motion module, permeate coating module 4, permeate removal module 6, acquisition module 8, and lighting module are respectively connected to the control module for signal transmission.

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

[0055] The control strategy includes: obtaining the theoretical permeation time of the permeate and the corresponding periodic detection area; and performing a first detection operation based on the periodic detection area.

[0056] Specifically, in one embodiment of this application, the specific structure of each module is illustrated below:

[0057] The permeate coating module 4, permeate removal module 6, acquisition module 8, and lighting module are all mounted on the motion module and connected to it respectively.

[0058] The motion module is used to drive the permeate coating module 4, the permeate removal module 6, the collection module 8, and the cleaning module to move along the path;

[0059] Penetrant application module 4 is used to apply penetrant to the weld seams along the path;

[0060] Penetrant Removal Module 6 is used to remove excess penetrant from weld seams along the path;

[0061] Acquisition module 8 is used to acquire image data along the path and input it into the control module;

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

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

[0064] For example, the chassis structure 1 includes a chassis body 11, a traction component 12, and a roof 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 the end of the traction member 12 in the longitudinal direction; the top plate 13 is connected to the chassis body 11.

[0066] The bottom of the traction component 12 is provided with a slider, and the chassis body 11 is provided with a groove or track that matches the slider at the corresponding position; the groove or track extends along the length direction of the chassis body 11, and the length of the groove or track is greater than the length of the slider and less than the length of the chassis body 11; the traction component 12 is slidably connected to the chassis body 11.

[0067] The traveling assembly 2 includes two axles 21, four hubs 22, and four tires 23. Each hub 22 and tire 23 corresponds to one another. Each tire 23 is fitted around the outer circumference of a hub 22. The hubs 22 are rotatably connected to the ends of the axles 21. The axles 21 extend axially along the width direction of the chassis structure 1 and are located at the bottom of the chassis structure 1, connected to it. In one embodiment of this application, the two axles 21 are arranged along the length direction of the chassis structure 1. Hubs 22 are connected to both ends of each axle 21. The length of the axle 21 is greater than the width of the chassis structure 1. Preferably, the length of the axle 21 can be the sum of the width of the chassis structure 1 and the width of the two hubs 22. The traveling assembly 2 travels axially along the pipeline.

[0068] The guide structure 3 includes at least two sets of guide wheel assemblies 31. Each guide wheel assembly 31 includes a guide wheel body 311 and a guide wheel arm 312. The at least two sets of guide wheel assemblies 31 are arranged on both sides of the chassis structure 1 along its length. The guide wheel assemblies 31 are connected to the chassis structure 1 through a limiting structure. The guide wheel assemblies 31 are arranged on both sides of the chassis structure 1 along its length, meaning that the guide wheel assemblies 31 contact the inner wall of the workpiece faster than the chassis structure 1. When the guide wheel assemblies 31 contact the inner wall of the workpiece, the self-positioning weld non-destructive testing moving device of this application can be kept in the middle of the workpiece, thus ensuring that the self-positioning weld non-destructive testing moving device of this application can be positioned in a timely manner when performing non-destructive testing inside large workpieces such as pipes.

[0069] The permeate coating module 4 is connected to the chassis structure 1 via the first connecting structure 5. The permeate coating module 4 includes a permeate storage tank 41 and a permeate coating pipe 42. The permeate storage tank 41 and the permeate coating pipe 42 are connected. A first pump is installed inside the permeate storage tank 41. The first connecting assembly includes a first connecting arm 51 and a first connecting clamp 52. One end of the first connecting 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 connecting clamp 52. The end of the permeate coating pipe 42 near the chassis structure 1 is connected to the first connecting clamp 52.

[0070] The permeate removal module 6 is connected to the chassis structure 1 via the second connecting structure 7. The permeate removal module 6 includes a permeate recovery tank 61 and a permeate removal pipe 62, which are connected to each other. A second pump is installed inside the permeate recovery tank 61, and the second pump is electrically connected to the control module. The second connecting assembly includes a second connecting arm 71 and a second connecting clamp 72. One end of the second connecting arm 71 is connected to the chassis structure 1, and the other end extends away from the chassis structure 1 and is connected to the second connecting clamp 72. The end of the permeate removal pipe 62 near the chassis structure 1 is connected to the second connecting clamp 72.

[0071] The acquisition module 8 is connected to the chassis structure 1 via the third connection structure 9. The acquisition module 8 includes an industrial camera 81, with the camera of the industrial camera 81 facing away from the chassis structure 1. The third connection component includes a third connection arm 91 and a third connection clamp 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 clamp 92. The end of the industrial camera 81 away from the camera is connected to the third connection clamp 92.

[0072] The lighting module (not shown in the figure) includes several LED light groups, which are arranged around the acquisition module 8 to provide illumination for the acquisition module 8, ensuring that the information acquired by the acquisition module 8 is more accurate and improving the accuracy of non-destructive testing of welds.

[0073] The control module does not necessarily have to be located on the motion module; it can be an operating platform. It only needs to ensure that it is connected to the motion module, the permeate coating module 4, the permeate removal module 6, the acquisition module 8, and the lighting module so that the control module can control the motion module, the permeate coating module 4, the permeate removal module 6, the acquisition module 8, and the lighting module.

[0074] Through the cooperation of various modules, non-destructive testing of weld seams inside pipelines is achieved; and through the penetrant application module 4 and penetrant removal module 6, the penetrant is evenly applied to the inner wall of the workpiece, ensuring the stability of the penetrant application and thus ensuring the accuracy of weld seam testing; 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 scenarios of the weld non-destructive testing system of this application, the theoretical penetration time of the penetrant and the corresponding periodic testing area are obtained, including:

[0076] Establish a pipeline coordinate system; based on the coating range of the permeate coating module 4 when the motion module stops, map it onto the pipeline coordinate system to divide the pipeline into several coating areas;

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

[0078] The single-pass coating time of the penetrant coating module 4, the theoretical penetration time of the penetrant, and the maximum speed and acceleration of the motion module are obtained.

[0079] Based on the theoretical penetration time of the penetrant, the single-brush time, the movement speed, and the acceleration, the number of areas that can be coated within a cycle of the theoretical penetration time of the penetrant is obtained, and the area to be coated within a cycle of the predicted penetration time of the penetrant is defined as the cycle detection area.

[0080] Specifically, the purpose of establishing the pipeline coordinate system is to provide a clear coordinate system for the weld non-destructive testing system of this application, and to quantify the motion data of the motion module, the specific range of the coating module or the cleaning module based on the coordinates mapped onto the coordinate system, thereby accurately controlling the weld non-destructive testing system of this application to perform weld non-destructive testing.

[0081] For example, during a non-destructive testing (NDT) process of a weld, in order to comprehensively inspect the pipe wall, the NDT system needs to be rotated so that the penetrant coating module 4 faces the area to be inspected (the area to be inspected refers to the entire pipe section to be inspected). Therefore, a pipe coordinate system can be established each time the system faces the area to be inspected. The pipe coordinate system can be established with the pipe's axial direction as the x-axis and the radial direction as the y-axis, creating a rectangular coordinate system. The range of a single application of the penetrant coating module 4 is mapped onto the coordinate system. The length of the single application range mapped to the x-axis is set as the unit length of the x-axis, and the length mapped to the y-axis is set as the unit length of the y-axis. Since the motion module moves along the pipe's axial direction, that is, along the x-axis, the x-coordinate can be considered when calculating the distance moved.

[0082] The single-pass coating time of penetrant coating module 4 can be obtained through direct testing; the theoretical penetration time of penetrant is the time when the penetrant theoretically reaches saturation adsorption in the defect and the penetration depth is sufficient to form an effective display in subsequent detection steps; the theoretical penetration time of penetrant can be obtained according to existing standards, and can also be adjusted according to temperature and other factors in actual operation; the maximum movement speed and acceleration of the motion module can be obtained through direct testing.

[0083] The following is an example:

[0084] With a unit length of 6m on the x-axis and a single coat time T a The theoretical permeation time T of the permeate is 5s. b The theoretical removal time T of the permeate is 100s. d The maximum speed of the motion module is V, which is 30 seconds. max The velocity is 1.2 m / s², and the acceleration a is 3 m / s². 2 Taking a total pipeline length of 1200m as an example,

[0085] The coating process is calculated based on the motion module moving at a constant speed at its maximum speed. Within the theoretical penetration time of the penetrant, the length L1 that the motion module can travel is 120m. Since it needs to return to the initial area, that is, it needs to go back and forth. At the same time, in order to avoid excessive penetration of penetrant at the end of the initial coating area when returning to the starting point of the initial coating area, which would affect subsequent non-destructive testing, the time for removing penetrant needs to be taken into account. Therefore, the length of the area that can be covered within one cycle of the theoretical penetration time of the penetrant should be L2, which is 57m.

[0086] Therefore, based on the above explanation, a formula can be obtained to calculate the number of areas that can be coated within a theoretical permeation time cycle of the penetrant, as shown in the following formula:

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

[0088] In the above formula, n is the number of areas that can be painted, and T a T is the time for a single coat. b T is the theoretical permeation time of the permeate. c T is the theoretical removal time of the permeate. d This refers to the return trip time.

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

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

[0091] This formula means that, under optimal conditions, the theoretical penetration time of the penetrant should include the sum of the application time for n coated areas, the theoretical rinsing time of the penetrant, and the return time. Based on this, a formula is obtained to calculate the number of coated areas that can be coated within a cycle of one theoretical penetration time. When calculating, if the value of n has a decimal point, it should be rounded down to the nearest integer to ensure the completeness of the coating.

[0092] More specifically, the return time refers to the time it takes for the motion module to move from the end of the last painted area to the beginning of the initial painted area, which is the time consumed by the motion module to travel L2.

[0093] T d The calculation is performed using the following formula:

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

[0095] In the above formula, T d1 T is the time consumed by the motion module to move at a constant speed. d2 The time consumed by the motion module to accelerate to its maximum speed or decelerate from its maximum speed to zero speed is given by the following formula for the return trip, since no painting or cleaning operations are required:

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

[0097] T can be obtained using the above formula. d1 ; and thus be able to obtain T d .

[0098] Among them, T d2 Calculated using the following formula:

[0099] T d2 =V max / a;

[0100] The following example calculation is illustrated based on the aforementioned sample data:

[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=47.3s;

[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, round down to get n = 4.

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

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

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

[0108] S2. After completing the penetrant application in the initial coating area, apply penetrant to the other coating areas in the periodic testing area in sequence.

[0109] S3. After completing the permeate application in other areas within the periodic detection area, return to the initial application area and sequentially remove permeate and acquire image data for each application area.

[0110] S4. Based on the image data, determine the penetrant removal effect, classify the coating area according to the penetrant removal effect, obtain the classification results, and screen the coating areas that meet the requirements for non-destructive testing of welds.

[0111] S5. Perform non-destructive testing on the painted 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 remove each coated area based on the theoretical removal time of the penetrant;

[0114] S402. Obtain image data of each coated area after removal according to the theoretical removal time of penetrant, classify the removal status of the coated area through the penetrant removal effect model, and obtain the classification results;

[0115] S403. Based on the classification results, select the coating areas that meet the requirements for non-destructive testing of welds; perform the corresponding operations on each coating area that does not meet the requirements for non-destructive testing of welds.

[0116] Specifically, the classification results include: over-cleaning, moderate-cleaning, and under-cleaning.

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

[0118] Establishment of a model for the effectiveness of permeate removal:

[0119] A convolutional neural network (CNN) was used, with the following structure: input layer → 2 convolutional layers (3×3 kernels, ReLU activation) → max pooling → fully connected layer → softmax output (3 classifications: over-purge, moderate, under-purge); it was trained on 10,000 images labeled with historical purge samples until the accuracy was ≥95%.

[0120] Image data processing can employ conventional methods such as gray-level co-occurrence matrix to improve the model's judgment ability.

[0121] Using the color intensity of the defective area as a quantification standard as an example:

[0122] Taking an RGB single-channel value C of 80 to 200 (inclusive) as a standard for a moderate cleanup range, if C < 80, the cleanup is insufficient, and if C > 200, the cleanup is excessive.

[0123] Based on the classification results, the coating areas that meet the requirements for non-destructive testing of welds are selected, and the selected coating areas proceed to step S5. For the coating areas that do not meet the requirements for non-destructive testing of welds, the corresponding operations are performed.

[0124] Specifically, performing non-destructive testing (NDT) on coated areas that meet the requirements for NDT includes the following steps:

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

[0126] S502. Obtain image data of the painted area that meets the requirements for non-destructive testing of welds, and input the image data into the non-destructive testing model of welds.

[0127] S503, the non-destructive testing model for welds outputs the test results.

[0128] For example, the weld non-destructive testing model can be similar to the penetrant removal effect model, using a convolutional neural network (CNN) with the following structure: input layer → 2 convolutional layers (3×3 kernels, ReLU activation) → max pooling → fully connected layer → softmax output (2-class classification: weld present, weld absent); trained with 10,000 images labeled with historical removal samples until the accuracy is ≥95%.

[0129] For each coated area that does not meet the requirements for non-destructive testing of welds, the following corresponding operations should be performed:

[0130] If the classification result corresponding to the coated area is over-cleaned, the coated area is marked as a re-inspection coated area; and the theoretical removal time of the penetrant in the coated area is corrected to obtain the corrected removal time of the penetrant.

[0131] If the classification result for the painted area is insufficient, then perform supplementary cleaning operations on the painted area until the classification result for the painted area is moderately cleared.

[0132] For example, the theoretical removal time of penetrating liquid in the corrected coating area can be corrected using PID control. The following example illustrates this:

[0133] The real-time adjustment amount ΔT is obtained using the following formula:

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

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

[0136] Using an RGB single-channel value C of 80–200 (inclusive) as the standard for appropriate clearing range, T c For 30s, K p 0.5, K i For 0.1, K d =0.2, lower limit of clearing time T min Taking a time interval of 10 seconds and adjusting the minimum absolute value of the step size |ΔT|≥1 as an example, the detection data is shown in the table below.

[0137] Table 1

[0138] The PID calculation process is as follows:

[0139] P(T) = Kp × E(T) = 0.5 × 20 = 10 seconds;

[0140] Cumulative deviation ∑E(T)=E(1)+E(2)+E(3)=10+15+20=45

[0141] I(T)=K i ×∑E(T)×t=0.1×45×1=4.5 seconds;

[0142] Deviation change rate ΔE(T) / Δt=5

[0143] D(T) = K d ×ΔE(T) / Δt=0.2×5=1 second.

[0144] ΔT=-(P(T)+I(T)+D(T))=-(10+4.5+1)=-15.5 seconds;

[0145] The adjusted time is shown below:

[0146] 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 .

[0147] Further, supplementary cleanup operations include:

[0148] Obtain the supplementary cleaning time, and clean the painted area based on the supplementary cleaning time;

[0149] Obtain image data of the coated area after it has been cleaned according to the replenishment cleaning time, classify the cleaning status of the coated area using the penetrant cleaning effect model, and obtain the classification results;

[0150] Perform step S403.

[0151] For example, the acquisition of the supplementary cleaning time can be similar to the acquisition of the penetrant correction cleaning time, and can be obtained through PID control; taking a supplementary cleaning time T of 5 seconds as an example, the coated area is cleaned for 5 seconds. After cleaning, the image data of the coated area is acquired, and the image data is input into the penetrant cleaning effect model for cleaning effect classification. After obtaining the classification result, since there may still be insufficient cleaning in the coated area after the first supplementary cleaning, after obtaining the classification result, step S403 is executed, that is, according to the classification result, the coated areas that meet the requirements for weld non-destructive testing are selected; and the corresponding operations are performed on each coated area that does not meet the requirements for weld non-destructive testing. The specific process of step S403 has been mentioned in this application and will not be elaborated here.

[0152] Furthermore, control strategies also include:

[0153] Obtain the distance data between the two closest re-inspection coating areas. Based on the distance data, the theoretical penetration time of the penetrant, the single coating time, the movement speed, and the acceleration, determine the time T for the motion module to travel back and forth between the two re-inspection coating areas. 循环 Compared with the theoretical permeation time T of the permeate b The relationship, according to T 循环 With T b Choose the appropriate re-inspection operation based on the relationship.

[0154] Furthermore, according to T 往返 With T b The corresponding re-inspection operation for the relationship selection includes:

[0155] If T b ≤T 循环 Then, a re-inspection will be carried out on a single re-inspection area;

[0156] If T b >T 循环 Then, the two re-inspection areas will be re-inspected.

[0157] Specifically, the distance between the two re-inspection coating areas can be calculated based on their x-axis coordinates. For example, the x-axis coordinates of the endpoints of the first re-inspection coating area are x1 and x2, and the x-axis coordinates of the endpoints of the second re-inspection coating area are x3 and x4. For instance, x1 is 6, x2 is 12, x3 is 30, and x4 is 36. The distance between the first and second re-inspection coating areas is calculated as x4 - x1 = 30. The theoretical permeation time of the penetrant in a single re-inspection coating area is calculated according to T... b =100s calculation, calculate T b Is it greater than T? 循环 T 循环 The calculation is based on (2T) a +T c +T d ’ ) to perform the calculation, T d ’ =[30-(3×0.4 2 ) / 2] / 1.2+0.8=25.6s;

[0158] T 循环 =2×5+14.5+25.6=50.1<100, therefore, during the re-inspection, after the first re-inspection area is painted, the second re-inspection area can be painted, and then the first re-inspection area can be returned to perform cleaning and other operations, that is, the two re-inspection areas are re-inspected.

[0159] The re-inspection operation is similar to steps S3 to S5 in the first inspection operation. The difference is that the "periodic inspection area" in the re-inspection operation only has one or two re-inspection coating areas. The other operations are the same as steps S3 to S5 in the first inspection operation, and will not be elaborated on here.

[0160] In the description of this application, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this application.

[0161] For those skilled in the art, various other corresponding changes and modifications can be made based on the technical solutions and concepts described above, and all such changes and modifications should fall within the protection scope of the claims of this application.

Claims

1. A non-destructive testing system for welds, comprising a motion module, a penetrant application module, a penetrant removal module, a data acquisition module, an illumination module, and a control module; wherein the motion module, the penetrant application module, the penetrant removal module, the data acquisition module, and the illumination module are respectively signal-connected to the control module; characterized in that, The control module controls the motion module, the penetrant application module, the penetrant removal module, and the lighting module according to a preset control strategy to complete the non-destructive testing of the weld; the control strategy includes: obtaining the theoretical penetrant penetration time and the corresponding periodic detection area; and performing a first detection operation according to the periodic detection area; The method for obtaining the theoretical permeation time of the permeate and the corresponding periodic detection area includes: Establish a pipeline coordinate system; based on the fact that the permeate coating module stops, the coating range of the permeate coating module is mapped onto the pipeline coordinate system, dividing the pipeline into several coating areas; Map the motion path of the motion module onto the pipeline coordinate system; The single-brush time of the penetrant coating module, the theoretical penetration time of the penetrant, the theoretical removal time of the penetrant, and the maximum speed and acceleration of the motion module are obtained. Based on the theoretical penetration time of the penetrant, the single application time, the movement speed, and the acceleration, the number of application areas that can be completed within the theoretical penetration time of the penetrant is obtained, and the application area that needs to be applied within a cycle of the predicted penetration time of the penetrant is defined as the cycle detection area. The first detection operation includes the following steps: S1. Define the coating area closest to the origin of the pipeline coordinate system as the initial coating area, and apply penetrant to the initial coating area; S2. After completing the penetrant application in the initial coating area, the penetrant is applied to the other coating areas in the periodic detection area in sequence. S3. After completing the permeate application in other coating areas within the periodic detection area, return to the initial coating area and sequentially perform permeate removal and image data acquisition in each coating area. S4. Based on the image data, determine the penetrant removal effect, classify the coating area according to the penetrant removal effect, obtain the classification result, and select the coating area that meets the requirements for non-destructive testing of welds. S5. Perform non-destructive testing on the coated area that meets the requirements for weld non-destructive testing.

2. The weld non-destructive testing system according to claim 1, characterized in that, The number of areas that can be coated within a theoretical penetration time of the penetrant is obtained by the following formula: n=(T b -T c -T d ) / T a ; Where n is the number of areas that can be painted, and T a T is the time for a single coat. b T is the theoretical permeation time of the permeate. c T is the theoretical removal time of the permeate. d This refers to the return trip time.

3. The weld non-destructive testing system according to claim 1, characterized in that, Step S4 includes: S401. Establish a penetrant removal effect model, and remove each of the coating areas based on the theoretical removal time of the penetrant; S402. Obtain image data of each of the coating areas after removal according to the theoretical removal time of the penetrant, classify the removal status of the coating areas through the penetrant removal effect model, and obtain the classification result; S403. Based on the classification results, select the coating areas that meet the requirements for non-destructive testing of welds; perform corresponding operations on each coating area that does not meet the requirements for non-destructive testing of welds.

4. The weld non-destructive testing system according to claim 3, characterized in that, The classification results include: over-cleaning, moderate-cleaning, and under-cleaning.

5. The weld non-destructive testing system according to claim 4, characterized in that, The steps for performing corresponding operations on each of the coated areas that do not meet the requirements for non-destructive testing of welds include: If the classification result corresponding to the coating area is excessive cleaning, then the coating area is marked as a re-inspection coating area; and the theoretical cleaning time of the penetrant in the coating area is corrected to obtain the corrected cleaning time of the penetrant. If the classification result corresponding to the painted area is insufficiently cleared, then a supplementary clearing operation is performed on the painted area until the classification result corresponding to the painted area is moderately cleared.

6. The weld non-destructive testing system according to claim 5, characterized in that, The supplementary clearing operation includes: Obtain the supplementary cleaning time, and clean the painted area based on the supplementary cleaning time; Obtain image data of the coated area after it has been cleaned according to the replenishment cleaning time, classify the cleaning status of the coated area using the penetrant cleaning effect model, and obtain the classification result; Perform step S403.

7. The weld non-destructive testing system according to claim 5, characterized in that, The control strategy also includes: Obtain the distance data between the two closest re-inspection coating areas, and based on the distance data, the theoretical penetration time of the penetrant, the single coating time, the movement speed, and the acceleration, determine the time T for the motion module to travel back and forth between the two re-inspection coating areas. 循环 With respect to the theoretical permeation time T of the permeate 渗透 The relationship, according to T 循环 With T 渗透 Choose the appropriate re-inspection operation based on the relationship.

8. The weld non-destructive testing system according to claim 7, characterized in that, According to T 循环 With T b The corresponding re-inspection operation for the relationship selection includes: If T b ≤T 循环 Then, a re-inspection is performed on each of the aforementioned re-inspection areas; If T b >T 循环 Then, the two re-inspection areas will be re-inspected.

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