Digital ray detection angle centering device and method

Abstract

The invention belongs to the field of pipeline circumferential weld X-ray digital imaging nondestructive testing, particularly relates to a digital ray detection angle centering device and method, and aims to solve the problem that the existing double-vehicle centering device and control method cannot meet the requirements of high precision, high automation and low manual labor. The system is characterized in that a radiation source trolley and a detector trolley are respectively driven by a driving device, a radiation source angle detection module is mounted on the radiation source trolley, a detector detection module and an image acquisition module are mounted on the detector trolley, and the image acquisition module is used for acquiring image data; the driving device, the ray source angle detection module, the detector detection module and the image acquisition module are connected with a pre-constructed local area network through the wireless transceiver module. According to the invention, remote monitoring and automatic adjustment are realized, the requirement of manual intervention is reduced, the working efficiency is improved, and meanwhile, errors caused by human factors are also avoided.

Description

Technical Field

[0001] This invention belongs to the field of X-ray digital imaging nondestructive testing of pipeline circumferential welds, and specifically relates to a digital X-ray inspection angle alignment device and method. Background Technology

[0002] Double-wall single-image radiography is a commonly used X-ray digital imaging inspection technique for inspecting welds and joint welds in small- and medium-diameter pipes. The apparatus for this technique includes a radiation source carriage, a detector carriage, and carriage tracks. The key technical point is that the radiation source carriage and the detector carriage must be symmetrical about the pipe center to ensure that the radiation energy is maximized and accumulated on the detector, thereby improving the inspection sensitivity and defect detection rate of digital X-ray inspection.

[0003] Currently, there are several methods for controlling the alignment of dual-carriage system: ① Measure the actual straight-line distance between the two carriages on the pipeline based on the outer diameter, and then manually move them to align them. The measurement accuracy of this method is limited by the roundness of the pipeline itself and the measurement error of the workers, and the labor intensity is high. ② Patent application number CN201911128684.2 discloses a measuring device for locating a radiation source, which determines the position of the radiation source by the intersection of multiple laser pointers on an angle ruler. This method has high measurement accuracy, but requires a high level of worker skill and has a low degree of automation. ③ Fix the detector carriage at point 0 on the pipeline and the radiation source carriage at point 6. The travel distance of the detector carriage is determined by the encoder of its motor, and the radiation source carriage travels the same distance. This method has a high degree of automation, but is limited by the encoder triggering method. If the carriage slips or the wheels wear out, the travel distance of the two carriages will deviate, resulting in misalignment.

[0004] Based on this, the present invention proposes a digital ray detection angle alignment device and method. Summary of the Invention

[0005] To address the aforementioned problems in the prior art, namely the inability of existing dual-vehicle alignment devices and control methods to achieve high precision, high automation, and low manual labor requirements, this invention provides a digital X-ray detection angle alignment device and method.

[0006] In a first aspect, the present invention provides a digital X-ray detection angle alignment device, comprising a X-ray source carriage, a detector carriage, and a carriage track. A X-ray source is mounted on the X-ray source carriage, and a detector is mounted on the detector carriage. The carriage track is coaxially fixed with the pipeline. The X-ray source carriage and the detector carriage are each driven by a driving device. A X-ray source angle detection module is mounted on the X-ray source carriage for acquiring angle data of the X-ray source. A detector detection module and an image acquisition module are mounted on the detector carriage. The detector detection module acquires angle data of the detector, and the image acquisition module acquires electrical signals received by the detector and converts them into image data.

[0007] The drive device, the X-ray source angle detection module, the detector detection module, and the image acquisition module are all connected to a pre-built local area network via a wireless transceiver module. The local area network controls the position of the X-ray source trolley and the detector trolley by using the angle data of the X-ray source and the angle data of the detector, thereby achieving centering.

[0008] In some preferred embodiments, both the X-ray source angle detection module and the detector detection module include an angle sensor and a virtual serial port unit. The angle sensor is used to detect angle data, and the virtual serial port unit is connected to a pre-built local area network via a wireless transceiver module to upload the angle data.

[0009] In some preferred embodiments, the drive module includes a motor driver, a motor, a reducer, and a travel unit;

[0010] The output end of the motor is connected to the input end of the reducer, the output end of the reducer is connected to the drive of the travel unit, the motor is connected to the motor driver, and the motor driver is connected to a pre-built local area network through a wireless transceiver module.

[0011] In some preferred embodiments, at least two radiation source angle detection modules are symmetrically installed along the center of the radiation source vehicle, and at least two detector angle detection modules are symmetrically installed along the center of the detector vehicle.

[0012] In another aspect, the present invention proposes a digital ray detection angle alignment method, based on a digital ray detection angle alignment device, the method comprising:

[0013] Obtain the target angle data mapped onto the trolley track of the target detection position, and control the X-ray source trolley and detector trolley to move to the target position based on the target angle data;

[0014] Once the target location is reached, the angle data of the radiation source is obtained through the radiation source angle detection module, and the angle data of the detection detector is obtained through the detector detection module.

[0015] Determine whether the absolute value of the difference between the angle data of the X-ray source and the angle data of the detector is within a preset range; if yes, then use the image acquisition module to acquire the X-ray source; if no, adjust the position of the X-ray source carriage based on the difference and through the drive device until the difference is within the preset range and then stop.

[0016] In some preferred embodiments, before acquiring the target angle data mapped onto the trolley track by the target detection position, each X-ray source angle detection module and detector angle detection module is placed at a preset point position on the pipeline and the angle is set to zero, so that the readings of each X-ray source angle detection module and detector angle detection module are the same at the same position.

[0017] In some preferred embodiments, the X-ray source trolley and detector trolley are controlled to move to the target position based on the target angle data, and the method is as follows:

[0018] The target angle data is sent to the encoder of the drive device. The encoder sends the current angle data and the target angle data to the motor driver. The motor driver drives the motor to rotate, moving the X-ray source carriage and the detector carriage to the target position.

[0019] In some preferred embodiments, the method for determining whether the absolute value of the difference between the angle data of the radiation source and the angle data of the detector is within a preset range is as follows:

[0020] |α-β|=180°±0.1°;

[0021] Where α is the detector's angle data and β is the X-ray source's angle data, with a preset range of 180°±0.1°.

[0022] In some preferred embodiments, the angle data of the detector is the average of the angles of multiple detector angle detection modules, and the angle data of the radiation source is the average of the angles of multiple radiation source angle detection modules.

[0023] In some preferred embodiments, the position of the X-ray source carriage is adjusted based on the difference and via a driving device until the difference falls within a preset range. The method is as follows:

[0024] First, the X-ray source trolley runs at a preset first speed and a preset first boundary angle, while reading the current angle data. When the difference between the current angle data and the target angle data is within a preset threshold, it runs at a preset second speed and a preset second boundary angle until it reaches the target position. The second speed is less than the first speed, and the second boundary angle is less than the first boundary angle.

[0025] The beneficial effects of this invention are:

[0026] High-precision alignment: The X-ray source angle detection module and detector detection module monitor and adjust the positions of the X-ray source carriage and detector carriage in real time to ensure that they are always in a symmetrical position at the center of the pipeline, thus improving the accuracy of detection.

[0027] Automated operation: By connecting to a pre-built local area network via a wireless transceiver module, remote monitoring and automatic adjustment are achieved, reducing the need for manual intervention and improving work efficiency.

[0028] Reduced labor intensity: Automated control reduces manual operation by staff, thus reducing labor intensity and avoiding errors caused by human factors.

[0029] Improved detection efficiency: The drive module, consisting of a motor driver, motor, reducer, and travel unit, enables the trolley to move more quickly and accurately, shortening the detection preparation time.

[0030] Enhanced system stability: The design employs a multi-angle detection module (at least two), which reduces the error that may be caused by a single sensor by averaging multiple data points, thereby enhancing the stability and reliability of the system.

[0031] Highly adaptable: It supports the testing needs of pipes of different diameters and can be adapted to pipes of different sizes with simple adjustments, enhancing the versatility of the device.

[0032] Easy to maintain and upgrade: The modular design makes it easier to maintain and upgrade the equipment, such as replacing or updating components like angle sensors.

[0033] Optimize detection quality: By precisely controlling the relative position between the X-ray source and the detector, consistency and repeatability of each detection can be ensured, thereby improving the accuracy of defect detection. Attached Figure Description

[0034] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0035] Figure 1 This is a schematic diagram of the structure of a digital X-ray detection angle alignment device according to the present invention;

[0036] Figure 2 This is a schematic diagram of the trolley movement position during the double-wall single-image detection process in a digital X-ray detection angle alignment device of the present invention;

[0037] Figure 3 This is a schematic diagram of the electrical connections between the various structures of a digital X-ray detection angle alignment device according to the present invention. Detailed Implementation

[0038] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0039] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0040] The first embodiment of the present invention, as follows: Figures 1-3 As shown, see Figure 1 A digital X-ray detection angle alignment device is provided, comprising a X-ray source carriage 1, a detector carriage 2, and a carriage track 3. A X-ray source 4 is mounted on the X-ray source carriage 1, and a detector 5 is mounted on the detector carriage 2. The carriage track 3 is coaxially fixed to the pipeline. The device is characterized in that the X-ray source carriage 1 and the detector carriage 2 are driven by driving devices. The X-ray source carriage 1 is equipped with a X-ray source angle detection module for acquiring the angle data of the X-ray source. The detector carriage 2 is equipped with a detector detection module and an image acquisition module. The detector detection module acquires the angle data of the detector, and the image acquisition module acquires the electrical signals received by the detector 5 and converts them into image data.

[0041] The drive device, the X-ray source angle detection module, the detector detection module, and the image acquisition module are all connected to a pre-built local area network via a wireless transceiver module. The local area network controls the position of the X-ray source trolley 1 and the detector trolley 2 through the angle data of the X-ray source and the angle data of the detector, thereby achieving centering.

[0042] In this invention, see Figure 2 The trolley track 3 is fixed to the pipe. Both the X-ray source trolley 1 and the detector trolley 2 run on track 3, and the two trolleys are symmetrically positioned along the center of the pipe. During actual image acquisition, both the X-ray source 4 and the detector 5 remain stationary. Because the length of the weld seam covered by detector 5 is limited, detector 5 needs to move to the next position after acquiring images from the current location. This process continues until detector 5 covers the entire weld seam.

[0043] For further explanation of the present invention, see [link to relevant documentation]. Figure 3 The X-ray source angle detection module and detector detection module in this invention both include an angle sensor and a virtual serial port unit. The angle sensor is used to detect angle data, and the virtual serial port unit is connected to a pre-built local area network through a wireless transceiver module to upload the angle data.

[0044] The local area network is connected to a mobile terminal, which controls the swimsuits to automate the process and reduce worker labor. The mobile terminal includes at least a computer, a mobile smart device, or a mobile phone.

[0045] The detector trolley 2's travel distance is triggered by an encoder, and the angle data of the detector after stopping is returned to the computer. The X-ray source trolley 2's movement is triggered by an encoder distance, and the angle data of the X-ray source after stopping is returned to the computer.

[0046] As a further explanation of the present invention, the drive module includes a motor driver, a motor, a reducer, and a travel unit;

[0047] The output end of the motor is connected to the input end of the reducer, the output end of the reducer is connected to the drive of the travel unit, the motor is connected to the motor driver, and the motor driver is connected to a pre-built local area network through a wireless transceiver module.

[0048] The drive module further includes an encoder, which triggers the operation of the drive module.

[0049] In this invention, at least two radiation source angle detection modules are symmetrically installed along the center of the radiation source cart 1, and at least two detector angle detection modules are symmetrically installed along the center of the detector cart 2. Preferably, this invention uses two radiation source angle detection modules and two detector angle detection modules; in other words, each cart is equipped with two angle sensors to measure two angle data points, establishing an angle cross-compensation method to achieve accurate reading and error correction of angle information under multiple operating conditions.

[0050] A second embodiment of the present invention proposes a digital ray detection angle alignment method, based on a digital ray detection angle alignment device of the first embodiment, the method comprising:

[0051] Obtain the target angle data mapped onto the trolley track 3, and control the X-ray source trolley 1 and detector trolley 2 to move to the target position based on the target angle data;

[0052] Once the target location is reached, the angle data of the radiation source is obtained through the radiation source angle detection module, and the angle data of the detection detector is obtained through the detector detection module.

[0053] Determine whether the absolute value of the difference between the angle data of the X-ray source and the angle data of the detector is within a preset range; if yes, then use the image acquisition module to acquire the X-ray source; if no, adjust the position of the X-ray source carriage 1 based on the difference and through the drive device until the difference is within the preset range.

[0054] In this invention, the X-ray source cart 1 and the detector cart 2 are first triggered by the encoder to move to the target position. However, the position that the two carts move to may not be the exact target position. Therefore, it is necessary to obtain the angle data of the X-ray source and the angle data of the detector for secondary judgment. If the angle difference is within the preset range in the secondary judgment, it is determined that the target position has been reached. If the angle difference is not within the preset range, it means that there is an error in the movement of the two carts and they have not actually reached the specified target position. At this time, only the position of the X-ray source cart 1 is moved. At this time, the triggering is not carried out by the encoder, but by the angle difference.

[0055] When the position of the X-ray source trolley 1 is adjusted based on the difference and through the drive device, the X-ray source trolley 1 first runs at a preset first speed and a preset first boundary angle, while reading the current angle data. When the difference between the current angle data and the target angle data is within a preset threshold, it runs at a preset second speed and a preset second boundary angle until it reaches the target position. The second speed is less than the first speed and the second boundary angle is less than the first boundary angle.

[0056] The method for controlling the X-ray source vehicle 1 and the detector vehicle 2 to move to the target position based on the target angle data is as follows:

[0057] The target angle data is sent to the encoder of the drive device. The encoder sends the current angle data and the target angle data to the motor driver. The motor driver drives the motor to rotate, moving the X-ray source carriage 1 and the detector carriage 2 to the target position.

[0058] As a further explanation of the present invention, before obtaining the target angle data mapped on the trolley track 3, each X-ray source angle detection module and detector angle detection module are respectively placed at a preset point position in the pipeline and the angle is set to zero, so that the readings of each X-ray source angle detection module and detector angle detection module are the same at the same position.

[0059] The method for determining whether the absolute value of the difference between the angle data of the X-ray source and the angle data of the detector is within a preset range is as follows:

[0060] |α-β|=180°±0.1°;

[0061] Where α is the detector's angle data and β is the X-ray source's angle data, with a preset range of 180°±0.1°.

[0062] In this invention, an angle difference of 180° indicates that the alignment has been achieved, but this invention takes into account the existence of errors and therefore allows for a difference of ±0.1°.

[0063] The angle data of the detector is the average of the angles of multiple detector angle detection modules, and the angle data of the radiation source is the average of the angles of multiple radiation source angle detection modules.

[0064] The X-ray source carriage 1 and the detector carriage 2 need to be precisely aligned with the weld seam to ensure that the X-rays emitted by the X-ray source 4 can accurately pass through the weld seam and be received by the detector 5.

[0065] Two angle sensors were installed on the X-ray source carriage 1. These two sensors were symmetrically distributed about the center of the carriage and measured angles β1 and β2 respectively.

[0066] Normal operating conditions

[0067] When the trolley is not operating near the specific zero point on the pipeline, the data from the two angle sensors should be relatively consistent. The accurate angle information of the trolley can be obtained by averaging the two angle readings: Trolley angle = (β1 + β2) / 2

[0068] Special operating conditions

[0069] When the trolley approaches the zero point of the pipeline, the angle sensor readings may become discontinuous as they cross the boundary between 360° and 0°.

[0070] To address this problem, a logic control algorithm was designed, including the following steps:

[0071] Calculate the average values: For each sensor, calculate its average reading over the range closest to zero. For example, the reading range for β1 is 350° to 360°, while the reading range for β2 is 0° to 10°. These average values ​​are labeled A and B, respectively.

[0072] Remove outliers: Check whether the actual sensor readings deviate from the calculated average values ​​A and B. If the deviation is large, it is considered an outlier and needs to be removed.

[0073] Determine the position of the trolley: Determine whether the trolley is to the left or right of the 0 point by calculating the standard deviation.

[0074] Adjust the angle reading: If the trolley is to the left of 0, adjust the angle reading of β2 to 360-β2; if it is to the right, adjust the angle reading of β1 to 360-β1.

[0075] Calculate the final angle: The final angle reading β is the average of the adjusted β1 and β2: β = (β1 + β2) / 2;

[0076] Inaccurate angle sensor readings

[0077] If the angle sensor readings are inconsistent when the car is in different positions, for example, the reading is β at position 1. 11 and β 12 The reading at position 2 is β. 21 and β 22 .

[0078] The actual change in angle can be estimated by comparing the changes in these readings, and errors caused by inaccurate readings can be compensated for.

[0079] This technology ensures that accurate angle information can be obtained even in special locations or when sensor readings are inaccurate, thus guaranteeing the accuracy of the X-ray inspection system.

[0080] The angle calculation for detector car 2 is the same as described above, and will not be repeated here.

[0081] In the description of this invention, terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," which indicate direction or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. These are used merely for ease of description and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0082] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0083] The term "comprising" or any other similar term is intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus / device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent in such process, method, article, or apparatus / device.

[0084] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A digital radiography detection angle centering device, comprising a ray source trolley (1), a detector trolley (2) and a trolley track (3), a ray source (4) is installed on the ray source trolley (1), a detector (5) is installed on the detector trolley (2), and the trolley track (3) is fixed coaxially with the pipeline, characterized in that, The ray source trolley (1) and the detector trolley (2) are driven by driving devices, the ray source trolley (1) is provided with a ray source angle detection module and is used for acquiring angle data of the ray source, the detector trolley (2) is provided with a detector detection module and an image acquisition module, the detector detection module is used for acquiring angle data of the detector, and the image acquisition module is used for acquiring electrical signals received by the detector (5) and converting the electrical signals into image data; The driving devices, the ray source angle detection module, the detector detection module and the image acquisition module are connected with a pre-constructed local area network through wireless transceiving modules, the local area network controls positions of the ray source trolley (1) and the detector trolley (2) to move and realizes centering through the angle data of the ray source and the angle data of the detector.

2. A digital radiographic detection angle centering device according to claim 1, wherein, The ray source angle detection module and the detector detection module each include an angle sensor and a virtual serial port unit, the angle sensor is used for detecting angle data, and the virtual serial port unit is connected with the pre-constructed local area network through a wireless transceiving module and is used for uploading the angle data.

3. The digital radiographic detection angle centering device of claim 1, wherein, The driving module includes a motor driver, a motor, a speed reducer and a traveling unit; An output end of the motor is connected with an input end of the speed reducer, an output end of the speed reducer is drivingly connected with the traveling unit, the motor is connected with the motor driver, and the motor driver is connected with the pre-constructed local area network through a wireless transceiving module.

4. The digital radiographic detection angle centering device of claim 1, wherein, On the ray source trolley (1), at least two ray source angle detection modules are symmetrically installed along a center thereof, and on the detector trolley (2), at least two detector angle detection modules are symmetrically installed along a center thereof.

5. A method of digital radiographic angle collimation based on the digital radiographic angle collimation device according to any one of claims 1 to 4, characterized in that, The method includes: Acquiring target angle data of a target detection position mapped on a trolley track (3) and controlling the ray source trolley (1) and the detector trolley (2) to move to a target position based on the target angle data; After moving to the target position, acquiring angle data of the ray source through the ray source angle detection module and acquiring angle data of the detector through the detector detection module; Judging whether an absolute value of a difference between the angle data of the ray source and the angle data of the detector is within a preset range, if yes, acquiring the ray source based on the image acquisition module, and if no, adjusting the position of the ray source trolley (1) based on the difference through the driving device until the difference is within the preset range.

6. A method of digital radiographic angle collimation according to claim 5, wherein, Before acquiring the target angle data of the target detection position mapped on the trolley track (3), each ray source angle detection module and each detector angle detection module is respectively placed at a preset point position of a pipeline, angle zeroing is performed, and the indication of each ray source angle detection module and each detector angle detection module at the same position is the same.

7. A method of digital radiographic angle collimation according to claim 5, wherein, The method for controlling the ray source trolley (1) and the detector trolley (2) to move to the target position based on the target angle data is as follows: The target angle data is sent to an encoder of the driving device, the encoder sends current angle data and the target angle data to a motor driver, the motor driver drives the motor to rotate, and the ray source trolley (1) and the detector trolley (2) are moved to the target position.

8. The method of claim 5, wherein, The application relates to a method for judging whether the absolute value of the difference between the angle data of a ray source and the angle data of a detector is within a preset range, which comprises the following steps: |α-β|＝180°±0.1°； Wherein, alpha is the angle data of the detector, beta is the angle data of the ray source, and the preset range is 180 DEG+ / -0.1 DEG.

9. The method of claim 5, wherein, The angle data of the detector is the average of the angles of a plurality of detector angle detection modules, and the angle data of the ray source is the average of the angles of a plurality of ray source angle detection modules.

10. The method of claim 5, wherein, The position of the ray source trolley (1) is adjusted based on the difference and through a driving device until the difference is within the preset range, and the method comprises the following steps: Firstly, the ray source trolley (1) runs at a preset first speed and a preset first boundary angle, and the current angle data is read at the same time; when the difference between the current angle data and the target angle data is within a preset threshold, the ray source trolley (1) runs at a preset second speed and a preset second boundary angle until the target position is reached; wherein the second speed is smaller than the first speed, and the second boundary angle is smaller than the first boundary angle.

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