A digital radiographic x-ray detection system with an imaging plate ranging device and a ranging method thereof

Abstract

The application discloses a kind of digital ray X detection system imaging plate ranging device and its ranging method, including the imaging plate of being set, flat car and pair of light rays, the imaging plate is installed on flat car, the flat car is provided with pair of light rays and PC end processing unit, two groups of pair of light rays are symmetrically fixed to imaging plate two sides and form the detection light path of traversing photosensitive area.This digital ray X detection system imaging plate ranging device and its ranging method, rely on pair of light rays infrared light curtain to be matched with triangulation module to realize non-contact accurate measurement and take the distance between pipe wall and imaging plate, automatically aligns the center of exposure of ray projection and photosensitive, eliminates artificial measurement alignment error, stabilizes imaging geometric precision, improves the detection rate of small defect, reduces the amount of film shooting, and the multiple interlocking protection is formed by the light path, spacing signal of electric control linkage unit, which can prevent empty exposure and prevent collision to protect the imaging plate. Non-contact light path has no mechanical wear, and the equipment operation and maintenance cost is lower.

Description

Technical Field

[0001] This invention relates to the technical field of DR inspection of long-distance pipelines, specifically to an imaging plate ranging device and its ranging method for a digital X-ray inspection system. Background Technology

[0002] In DR digital radiographic testing of boiler water-cooled walls and pressure pipeline circumferential welds, the distance between the outer wall of the pipe fitting and the imaging plate directly determines the imaging resolution, geometric deformation, and signal-to-noise ratio, which are key parameters for quality control of the testing.

[0003] Currently, on-site spacing is determined solely by manual measurement with a ruler, resulting in an error of up to 15mm. The temporarily fixed imaging plate is prone to shaking and drifting, leading to poor consistency in multiple images. The equipment lacks dedicated calibration and anti-collision interlocking structures, making it susceptible to misexposure due to imaging plate misalignment and overtravel. The thermal expansion of high-temperature pipelines and uneven insulation layer thickness continuously alter the actual gap. Existing equipment lacks temperature compensation and automatic distance adjustment mechanisms, making it impossible to correct cold and hot spacing deviations in real time. The entire process relies on repeated manual fine-tuning for alignment. Furthermore, traditional inspection lacks automated control processes, requiring repeated manual adjustments of spacing, focal length, and X-ray parameters. There is no closed-loop automatic distance adjustment function, and images can only be scaled and corrected as a whole, failing to compensate for magnification distortion pixel by pixel for curved weld seams. Defect size measurement errors are significant, and inspection records only record focal length, lacking automatic storage channels for key data such as spacing and temperature. Traditional mechanical positioning fixtures are prone to wear and failure, occupy equipment space, and lack supporting automatic distance measurement and correction processes, making it difficult to simultaneously achieve accurate distance measurement, hardware protection, automatic distance adjustment, and digital quality control.

[0004] To address the aforementioned issues, there is an urgent need for innovative design based on the existing imaging plate ranging device and ranging method used in digital X-ray X-ray detection systems. Therefore, we propose an imaging plate ranging device and ranging method for digital X-ray X-ray detection systems that can effectively solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide an imaging plate ranging device and its ranging method for a digital X-ray inspection system, to solve the problems mentioned in the background art. Currently, on-site distance determination relies solely on manual measurement with a ruler, resulting in an error of up to 15mm. The imaging plate is temporarily fixed and prone to shaking and drift, leading to poor consistency in multiple images. The equipment lacks dedicated calibration and anti-collision interlocking structures, making it prone to misexposure due to imaging plate misalignment and overtravel. The thermal expansion of high-temperature pipelines and uneven insulation layer thickness continuously change the actual gap. Existing equipment lacks temperature compensation and automatic distance adjustment mechanisms, making it impossible to correct cold and hot distance deviations in real time. The entire process relies on repeated manual fine-tuning for alignment. Furthermore, traditional inspection lacks automated control processes, requiring repeated manual adjustments of distance, focal length, and X-ray parameters. There is no closed-loop automatic distance adjustment function, and the image can only be scaled and corrected as a whole, failing to compensate for magnification distortion pixel by pixel for curved weld seams. The defect size measurement error is large, and the inspection file only records the focal length, lacking an automatic storage channel for key data such as distance and temperature. Traditional mechanical positioning fixtures are prone to wear and failure, occupy equipment space, and lack a matching automatic distance measurement and correction process, making it difficult to simultaneously achieve accurate distance measurement, hardware protection, automatic distance adjustment, and digital quality control.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a ranging device and method for an imaging plate in a digital X-ray X-ray detection system, comprising an imaging plate, a flatbed cart, and a beam counter. The imaging plate is mounted on the flatbed cart, which is equipped with beam counters and a PC-based processing unit. Two sets of beam counters are symmetrically fixed on both sides of the imaging plate to form a detection optical path that traverses the photosensitive area. The PC integrates a spot imaging module, a distance calculation module, and an electronic control linkage unit. The beams from the beam counters irradiate the outer wall of the tube to generate a reflected spot. The module collects the spot data and calculates the distance between the tube wall and the imaging plate in real time. The electronic control unit realizes exposure interlocking, flatbed cart anti-collision stop, and distance deviation indication based on the optical path on / off and distance signals.

[0007] Preferably, the beam emitter adopts an infrared laser emitting structure, and the emitted beam is a parallel beam light curtain.

[0008] Preferably, the beam emitter is externally mounted on the side of the imaging plate, without occupying the space of the internal mounting slot of the imaging plate.

[0009] Preferably, the distance calculation module has built-in triangulation calculation logic to calculate the real-time distance b between the tube wall and the imaging plate by converting the light spot offset.

[0010] Preferably, the electronic control linkage unit is configured to output a locking signal to cut off the X-ray tube exposure triggering authority when the optical path is completely blocked.

[0011] Preferably, the electronic control linkage unit is connected to the flatbed truck conveying mechanism, and when the light spot calculation interval exceeds the set threshold, it controls the flatbed truck to pause pushing and sounds an alarm.

[0012] Preferably, the light spot imaging module uses the light curtain formed by the through-beam ray generator as a reference to calibrate the X-ray projection center to coincide with the photosensitive center of the imaging plate.

[0013] Preferably, the PC-side processing unit synchronously stores the real-time spacing, optical path occlusion duration, and imaging plate positioning status in the system operation log.

[0014] Preferably, S1: preset the target spacing and matching flaw detection process parameters for the pipeline; S2: calculate the real-time spacing by collecting the light spot of the pipe fitting through the through-beam detector; S3: compensate for the spacing deviation caused by thermal expansion according to the pipeline temperature; S4: the electronic control unit drives the flatbed cart to automatically adjust to the standard spacing; S5: correct the geometric deformation of the flaw detection image pixel by pixel according to the real-time spacing; S6: after the optical path is normal and the spacing meets the standard, unlock the X-ray tube to complete the exposure and archive all inspection data.

[0015] Compared with existing technologies, the advantages of this invention are as follows: This digital X-ray X-ray detection system uses an imaging plate ranging device and its ranging method, which relies on an infrared light curtain from a through-beam transducer combined with a triangulation ranging module to achieve non-contact and accurate measurement of the distance between the tube wall and the imaging plate. It automatically aligns the X-ray projection with the photosensitive center, eliminating manual measurement alignment errors, stabilizing imaging geometric accuracy, improving the detection rate of small defects, reducing the number of retakes, and the electronic control linkage unit, combined with the optical path and distance signals, forms multiple interlocking protections, preventing empty exposure and protecting the imaging plate from collisions. The non-contact optical path has no mechanical wear, resulting in lower equipment maintenance costs. The specific details are as follows: This device relies on symmetrically arranged through-beam emitters to emit parallel infrared light curtains. Combined with the triangulation logic built into the distance calculation module on the PC, it accurately calculates the distance b between the pipe wall and the imaging plate by measuring the offset of the reflected light spot. This completely replaces the traditional method of manual ruler measurement and visual estimation, eliminating measurement errors caused by human operation.

[0016] The light spot imaging module uses the light curtain as a unified reference to automatically align the X-ray projection center with the photosensitive center of the imaging plate, avoiding problems such as underexposure of images, weld deformation and missed edge shots caused by the tilt of the imaging plate. This effectively reduces the retake rate and solves the problems of inconsistent clarity and large fluctuations in defect detection rate caused by multiple imaging in traditional inspection.

[0017] The electronic control linkage unit synchronously connects with the optical path signal of the beam detector and the flatbed transport mechanism to form a dual protection mechanism. When the optical path is completely blocked, it means that there is no imaging plate or the imaging plate is tilted or offset. The system directly cuts off the X-ray tube exposure permission to avoid empty exposure damage to the X-ray tube and the generation of invalid radiation. If the measured distance exceeds the process threshold, the electronic control unit immediately controls the flatbed to stop and alarm to prevent the imaging plate from overtraveling and hitting the frame and beam limiter, which greatly reduces the cost of repairing and replacing high-priced imaging plate damage.

[0018] The device hardware consists of an imaging plate, a flatbed cart, and two sets of beam counters. The two sets of beam counters are externally mounted on the side of the imaging plate, without occupying the internal mounting slot of the imaging plate, and will not interfere with the pulling and moving of the imaging plate. No modification to the internal space of the equipment is required. It can be directly installed on various racks of fixed DR, flatbed DR, and industrial flaw detection DR. It is easy to modify and has a wide range of compatibility.

[0019] The PC-based processing unit collects and continuously stores all detection information in real time, including real-time spacing, optical path obstruction duration, imaging plate positioning status, pipeline temperature, and flaw detection process parameters. Furthermore, through the electronic control linkage unit, combined with the difference between the measured spacing and the standard threshold, it automatically drives the flatbed cart to complete precise translation and fine-tuning, forming a closed-loop control logic of distance measurement, compensation, comparison, and distance adjustment. This eliminates the need for repeated manual alignment and debugging, greatly shortening on-site setup time and improving detection efficiency and process consistency. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0021] In the diagram: 1. Imaging plate; 2. Flatbed vehicle; 3. Optical beam receiver. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Example: In this embodiment, parallel infrared light curtains are emitted by symmetrically arranged through-beam emitters 3. Combined with the triangulation logic built into the PC-side distance calculation module, the distance b between the pipe wall and the imaging plate 1 is accurately calculated using the offset of the reflected light spot. This completely replaces the traditional method of manual ruler measurement and visual estimation, eliminating the 5-15mm measurement error caused by human operation. Figure 1The technical solution shown includes an imaging plate 1, a flatbed cart 2, and a beam transducer 3. The imaging plate 1 is mounted on the flatbed cart 2, which is equipped with the beam transducer 3 and a PC processing unit. Two sets of beam transducers 3 are symmetrically fixed on both sides of the imaging plate 1 to form a detection optical path that traverses the photosensitive area. The PC integrates a spot imaging module, a distance calculation module, and an electronic control linkage unit. The beam from the beam transducer 3 illuminates the outer wall of the tube to generate a reflected spot. The module collects the spot data and calculates the distance from the tube wall to the imaging plate 1 in real time. The electronic control unit uses the optical path on / off and distance signals to implement exposure interlocking, anti-collision stop of the flatbed cart 2, and distance deviation indication. The beam transducer 3 adopts an infrared laser emitting structure, and the emitted beam is a parallel line-aligned light curtain. The through-beam ray unit 3 is externally mounted on the side of the imaging plate 1, without occupying the internal mounting slot space of the imaging plate 1. The distance calculation module has built-in triangulation calculation logic, which calculates the real-time distance b between the tube wall and the imaging plate 1 by converting the light spot offset. The electronic control linkage unit is configured to output a locking signal to cut off the X-ray tube exposure trigger permission when the light path is completely blocked. The electronic control linkage unit is connected to the flatbed trolley 2 conveying mechanism. When the light spot calculation distance exceeds the set threshold, the flatbed trolley 2 is controlled to stop pushing and alarm. The light spot imaging module uses the light curtain formed by the through-beam ray unit 3 as a reference to calibrate the X-ray projection center to coincide with the photosensitive center of the imaging plate 1. The PC processing unit synchronously stores the real-time distance, light path occlusion duration, and imaging plate 1 positioning status in the system operation log.

[0024] The specific distance measurement and adjustment steps are as follows: S1: Preset the target distance and matching flaw detection process parameters for the pipeline, and simultaneously input the thermal expansion coefficient and temperature deviation threshold of the corresponding pipe material to establish a standardized parameter library suitable for different working conditions; S2: Collect the light spot of the pipe fitting through the through-beam detector, and calculate the original real-time distance between the pipe wall and the imaging plate in real time by combining the triangulation distance measurement logic; S3: Collect the real-time operating temperature of the pipeline through an external temperature sensor, and accurately calculate the distance deviation caused by pipeline deformation under high temperature conditions by combining the preset thermal expansion coefficient of the pipe material, and perform temperature correction on the original distance measurement data to eliminate the distance error caused by switching between hot and cold working conditions, thermal expansion and contraction of the pipeline, and uneven insulation layer thickness; S4: The electrical control linkage unit compares the temperature. The compensated precise spacing and the system's preset standard spacing automatically output displacement adjustment commands, driving the flatbed cart conveying mechanism to move forward / backward, and finely adjusting the placement of the imaging plate in real time. This precisely calibrates the distance between the pipe wall and the imaging plate to the process standard value, achieving closed-loop automatic spacing adjustment without the need for manual measurement or repeated alignment adjustments throughout the process. S5: The system retrieves the compensated and calibrated precise real-time spacing b data, performs pixel-by-pixel geometric deformation correction on the flaw detection image, and accurately corrects the magnified distortion of the weld seam of the curved pipe fitting. S6: After the system detects that the optical path is unobstructed, the imaging plate is accurately aligned, and the spacing parameters meet the standards, it automatically unlocks the X-ray tube to complete the exposure operation and completely archives all detection data, including spacing, temperature, spacing parameters, and optical path status.

[0025] The main hardware components of this device include an imaging plate 1, a flatbed cart 2, two sets of beam detectors 3, and a PC-based processing unit. The imaging plate 1 is fixedly mounted on the flatbed cart 2, which carries two sets of beam detectors 3 and the entire PC-based processing unit. The two sets of beam detectors 3 are externally mounted on the side of the imaging plate 1, without occupying the internal mounting slot space. This external structure does not interfere with the sliding and repositioning of the imaging plate 1, offering strong compatibility for modification and adaptability to various industrial DR racks. Furthermore, there is no mechanical contact friction, preventing wear and jamming issues during long-term use. The beam detectors 3 utilize an infrared laser emission structure, capable of outputting a parallel alignment light curtain. The beam is resistant to environmental stray light, X-ray radiation, dust, and moisture interference, allowing stable operation even in low-light lead rooms and high-temperature flaw detection environments. The two sets of beam detectors 3 are symmetrically arranged on both sides of the imaging plate 1, constructing a continuous detection light path traversing the photosensitive area of ​​the imaging plate 1, eliminating visual errors caused by manual alignment. The PC-based processing unit... The processing unit integrates a spot imaging module, a distance calculation module, and an electronic control linkage unit. When the device is running, the through-beam laser 3 emits a parallel infrared laser beam to irradiate the outer wall of the pipe under test. The reflection from the pipe wall forms a clear spot. The spot imaging module collects the position and shape data of the spot in real time. This module uses the light curtain formed by the through-beam laser 3 as a unified reference to automatically calibrate the X-ray projection center to coincide with the photosensitive center of the imaging plate 1, avoiding local underexposure of the image, geometric deformation of the weld, and missed edge shots caused by the tilt of the imaging plate 1, effectively reducing the reshoot rate. The collected spot data is synchronously transmitted to the distance calculation module. The module has built-in triangulation distance calculation logic and accurately calculates the real-time distance b between the pipe wall and the imaging plate 1 based on the spot offset, replacing the traditional manual measurement and visual estimation method, greatly reducing the distance measurement error, and making the core geometric parameters of the imaging quantifiable and controllable, solving the problems of poor image consistency and defect detection rate fluctuations in multiple inspections.

[0026] This device is equipped with a high-precision patch-type temperature sensor, which is attached to the outer wall of the pipe being measured to collect the pipe surface temperature in real time. The sampling frequency is synchronized with the ranging frequency to ensure that each spacing calculation matches the real-time temperature data. The system has a pre-stored database of thermal expansion coefficients for various carbon steel and alloy steel pipes. Based on the real-time temperature difference, it dynamically calculates the thermal deformation compensation to correct the original ranging data. The system has a preset allowable spacing deviation threshold. When there is a deviation between the compensated measured spacing and the standard spacing, the electronic control unit outputs a graded speed adjustment command: small deviations trigger low-speed fine-tuning, large deviations trigger fast speed adjustment. The system rapidly approaches and precisely locks in place, preventing overshoot of the flatbed cart and achieving millimeter-level precise alignment. It uses a temperature sensor to collect pipe temperature in real time, dynamically correcting the distance measurement results based on the pipe's expansion coefficient to eliminate detection deviations caused by environmental and operational conditions. Then, an electronic control linkage unit drives the flatbed cart to precisely move, constantly correcting the relative position of the imaging plate and the pipe wall. This ensures the detection distance remains within the process standard range, completely eliminating problems such as repeated manual fine-tuning, large alignment errors, and inconsistent imaging parameters in hot and cold states. It achieves a fully closed-loop automated operation encompassing distance detection, deviation compensation, automatic distance adjustment, and precise imaging.

[0027] The electronic control linkage unit synchronously receives the optical path on / off signal and the distance calculation module outputting the distance value, realizing multiple safety and control linkages. First, when the optical path is completely blocked, the electronic control linkage unit outputs a locking signal to cut off the X-ray tube exposure authority. It can identify the absence of imaging plate 1 or the tilting and offset of imaging plate 1, preventing empty exposure from damaging the X-ray tube and wasting radiation by ineffective filming. Second, the electronic control linkage unit is directly connected to the flatbed trolley 2 conveying mechanism. If the actual distance calculated by the distance calculation module exceeds the process setting threshold, it will immediately control the flatbed trolley 2 to stop pushing and issue an audible and visual alarm to prevent imaging plate 1 from overtraveling and hitting the frame and limiter, protecting the high-value imaging plate 1 and significantly reducing equipment maintenance and replacement costs. Third, the electronic control unit compares the measured distance with the preset standard value in real time and actively pops up a distance deviation prompt, providing an intuitive reference for manual adjustment. Meanwhile, the PC processing unit continuously stores the real-time spacing, optical path obstruction duration, and imaging plate 1's arrival status in the system operation log, completely preserving the geometric data of each inspection. This ensures traceability of the entire flaw detection process, facilitates fault diagnosis, and meets the quantitative quality control standards for non-destructive testing such as ISO17636 and ASMEV. The imaging plate ranging method relies on the aforementioned imaging plate 1, flatbed trolley 2, through-beam transducer 3, and PC processing unit. The complete process is as follows: S1: Input the target spacing matching the corresponding pipe model and the corresponding flaw detection process parameters such as focal length, pipe voltage, and current into the system in advance to establish a standardized parameter library, eliminating the inefficient mode of trial and error based on experience; S2: After starting the inspection, rely on the through-beam transducer 3 to emit a beam to collect the reflected light spot of the pipe, and calculate the real-time spacing from the pipe wall to the imaging plate 1 through the distance calculation module; S3: Collect the real-time temperature of the pipe, and combine the pipe expansion coefficient to compensate for the spacing deviation caused by the thermal expansion of the pipe under high-temperature conditions, thus solving the problem. The system addresses the pain points of large distance differences between hot and cold states and decreased imaging clarity at high temperatures. The S4 electronic control linkage unit automatically drives the flatbed trolley 2 to adjust the distance based on the compensated distance difference, accurately calibrating the distance between the imaging plate 1 and the pipe wall to the preset standard value. This eliminates the need for repeated manual fine-tuning, resulting in a high degree of automation and significantly reducing on-site setup time. The S5 system retrieves real-time distance data (b) and performs pixel-by-pixel geometric deformation correction on the captured images of circumferential welds and water-cooled wall pipe arrays. Unlike traditional overall scaling correction, this system can compensate for the magnification distortion at the edges of curved pipe components, improve the accuracy of defect size measurement, and reduce the missed detection and misjudgment of small defects such as cracks and incomplete penetration. The S6 system automatically determines that the optical path of the through-beam ray generator 3 is unobstructed, the imaging plate 1 is properly positioned, and the distance meets the process standards. It then unlocks the X-ray tube to perform exposure testing. After exposure, the PC automatically archives all detection data, including distance, temperature, optical path status, and imaging parameters, forming a complete digital inspection archive. The entire process requires no manual recording, and the quality control process is standardized.

[0028] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An imaging plate ranging device for a digital X-ray X-ray detection system, comprising an imaging plate (1), a flatbed cart (2), and a beam transmitter (3), characterized in that, The imaging plate (1) is mounted on the flatbed (2). The flatbed (2) is equipped with a beam reflector (3) and a PC processing unit. Two beam reflectors (3) are symmetrically fixed on both sides of the imaging plate (1) to form a detection optical path that crosses the photosensitive area. The PC integrates a spot imaging module, a distance calculation module and an electronic control linkage unit. The beam of the beam reflector (3) illuminates the outer wall of the tube to generate a reflected spot. The module collects the spot data and calculates the distance from the tube wall to the imaging plate (1) in real time. The electronic control unit realizes exposure interlock, anti-collision stop of the flatbed (2) and distance deviation prompt based on the optical path on / off and distance signal.

2. The imaging plate ranging device for a digital X-ray X-ray detection system according to claim 1, characterized in that, The beam emitter (3) adopts an infrared laser emission structure, and the emitted beam is a parallel beam light curtain.

3. The imaging plate ranging device for a digital X-ray X-ray detection system according to claim 2, characterized in that, The beam transmitter (3) is externally mounted on the side of the imaging plate (1) and does not occupy the internal mounting slot space of the imaging plate (1).

4. The imaging plate ranging device for a digital X-ray X-ray detection system according to claim 3, characterized in that, The distance calculation module has built-in triangulation calculation logic, which calculates the real-time distance b between the tube wall and the imaging plate (1) by the light spot offset.

5. The imaging plate ranging device for a digital X-ray X-ray detection system according to claim 4, characterized in that, The electronic control linkage unit is configured to output a locking signal to cut off the X-ray tube exposure triggering authority when the optical path is completely blocked.

6. The imaging plate ranging device for a digital X-ray X-ray detection system according to claim 5, characterized in that, The electronic control linkage unit is connected to the conveying mechanism of the flatbed vehicle (2). When the light spot calculation distance exceeds the set threshold, the flatbed vehicle (2) is controlled to stop pushing and an alarm is triggered.

7. The imaging plate ranging device for a digital X-ray X-ray detection system according to claim 6, characterized in that, The light spot imaging module uses the light curtain formed by the through-beam (3) as a reference to calibrate the X-ray projection center to coincide with the photosensitive center of the imaging plate (1).

8. The imaging plate ranging device for a digital X-ray X-ray detection system according to claim 7, characterized in that, The PC-side processing unit synchronously stores the real-time spacing, optical path occlusion duration, and imaging plate (1) positioning status in the system operation log.

9. A ranging method for an imaging plate ranging device in a digital X-ray X-ray detection system, characterized in that, The implementation is carried out using the imaging plate ranging device of the digital X-ray X-ray detection system according to any one of claims 1 to 8. Includes the following steps: S1: Preset target spacing for pipeline matching and corresponding flaw detection process parameters; S2: Calculate real-time spacing by collecting light spots on pipe fittings using a through-beam detector; S3: Compensate for spacing deviations caused by thermal expansion based on pipeline temperature. S4: The electronic control unit drives the flatbed cart to automatically adjust to the standard spacing; S5: The geometric deformation of the flaw detection image is corrected pixel by pixel according to the real-time spacing. S6: After the optical path is normal and the spacing meets the standard, unlock the X-ray tube to complete the exposure and archive all test data.

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