Portable all-in-one machine for industrial defect detection

Abstract

The utility model discloses a portable all-in-one machine for industrial nondestructive defect detection, and belongs to the field of industrial radiography nondestructive detection. The portable all-in-one machine comprises a processing host module, an imaging module, a backlight module, a touch display module, a storage module and a wireless communication module, the imaging module, the backlight module, the touch display module, the storage module and the wireless communication module are connected with the processing host module, a power module is arranged to supply power to the modules, and all the modules are installed and fixed in a portable case. The imaging module is used for shooting the industrial film on the backlight module to obtain a multi-exposure image sequence and synthesizing a high-dynamic image, so that high-resolution, high-dynamic and high-quality digital imaging of the industrial film is realized. The portable all-in-one machine is small in size and convenient to operate and carry, an acceleration coprocessor is arranged in the portable all-in-one machine to assist in detection, defect prompts can be rapidly given out without networking, the multi-mode film viewing function of simulating film viewing, digital picture viewing and virtual reality viewing is provided for engineers on site, and therefore rapid and efficient detection of industrial welding quality is achieved.

Description

Technical Field

[0001] The utility model belongs to the field of industrial radiographic nondestructive testing, and in particular relates to a portable all-in-one device integrating industrial nondestructive testing film digital imaging and multi-mode film viewing. Background Art

[0002] Industrial non-destructive testing generally uses engineers to manually observe industrial non-destructive testing films taken by X-ray radiography to perform defect detection, which has the disadvantages of low efficiency, high labor intensity, complex system and low accuracy. With the development of electronic technology, computer technology and artificial intelligence technology, the digitization of industrial films has provided conditions for the information management and intelligent processing of defect detection, and has received increasing attention.

[0003] At present, the main means of digitizing industrial films is to use CCD scanners to scan the films line by line to obtain high-definition film images. The scanners for industrial X-ray films mainly include NDT Pro from Vidar of the United States, FS50B from Waygate, and 2905 / HD from Array of Japan. These scanners need to be scanned with desktop computers. They have the characteristics of high resolution, good image quality, and high dynamic range. However, it usually takes tens of seconds to complete the scanning of a single film. The imaging speed is slow and the equipment cost is high. Although some companies use area array imaging sensors to shoot films, the speed can reach less than 1 second, but this method usually has low resolution and is limited by the sensor. The image dynamic range is low and cannot meet the image quality requirements of defect detection.

[0004] CN216956532U, "An LED industrial radiographic film viewer with an adjustable clamping structure", discloses an LED industrial radiographic film viewer with an adjustable clamping structure, which can be used for manual observation of industrial non-destructive testing films and has a simulated film viewing function. However, there are defects such as strong light leakage and glare during film viewing, and it cannot perform digital imaging of films, making it inconvenient for information management. CN218157633U, "An integrated film digital evaluation machine", discloses a scanning film digitalization system. CN117714838A, "An industrial X-ray film digital imaging device", discloses a device and method for batch scanning of films using a motor. However, they only support film digitalization, have a slow scanning speed, or the imaging quality is limited by the sensor performance. Generally, they need to be combined with other devices such as computers and other terminals for digital film viewing to realize the display and intelligent processing of film digital images. At the same time, the system does not support on-site manual simulated film viewing function, cannot quickly give defect results, and is also inconvenient for defect review. CN108665452B, "Method and system for scanning and warehousing pipeline weld radiographic films and identifying weld defects", discloses a system that first scans and warehouses and then performs intelligent processing. CN115661057A, "An industrial non-destructive testing system and method based on cloud-edge collaboration and deep learning", discloses an industrial defect detection system that combines on-site terminals and cloud data processing centers. The systems disclosed in the above patent documents also do not support on-site manual film viewing function, and the systems are relatively complex.

[0005] In summary, the technologies involved in the current patent documents have defects such as low imaging quality, separation of imaging and film viewing, incomplete functions, relatively complex and bulky systems, and the need to be used online. They do not support portable movement, and there is no integrated portable device that combines film viewing and digital imaging into one, and cannot well adapt to scenarios that require quick response, such as applications in small industrial welding projects, narrow construction space projects, and local repair projects. Summary of the Invention

[0006] The purpose of the present invention is to provide a portable integrated device that integrates industrial non-destructive testing film digital imaging and multi-mode film viewing functions. Using this device, the operation processes of industrial film viewing and digitalization can be simplified, and the efficiency and portability can be improved.

[0007] To achieve the above object, the present utility model provides a portable all-in-one machine. The portable all-in-one machine uses an imaging module to photograph a film, and by means of multiple exposure methods, a high-dynamic image processing synthesis algorithm is used to improve the dynamic range and signal-to-noise ratio of the image, realizing high-resolution, high-dynamic and high-quality digital imaging of industrial films. At the same time, the portable all-in-one machine is smaller in size, easy to operate and carry, and is built-in with an acceleration coprocessor, which can quickly realize the auxiliary detection of defects, quickly give defect prompts of the current film without networking, and provide engineers with multi-mode film viewing functions such as simulated film viewing, digital picture viewing and virtual reality viewing on-site, so as to realize the rapid detection of industrial welding quality and improve the efficiency and performance of industrial non-destructive testing.

[0008] The technical solutions adopted in the utility model are specifically as follows:

[0009] A portable all-in-one machine for industrial non-destructive defect detection, which integrates the functions of digital imaging of industrial non-destructive testing films and multi-mode film viewing, includes a processing host module, an imaging module, a backlight module, a touch display module, a storage module, a wireless communication module and a power module. Among them, the processing host module is connected to the imaging module, the backlight module, the touch display module, the storage module and the wireless communication module, and the power module supplies power to the above modules. All modules are installed and fixed in a portable chassis; the backlight module includes a programmable controlled LED array, and each LED in the LED array can be individually controlled for switching and light-emitting brightness. The industrial non-destructive testing film is placed on the backlight module; the imaging module includes a camera with programmable controlled focal length, aperture and imaging angle, which is used to photograph the industrial non-destructive testing film on the backlight module, obtain film images, and measure the ambient light intensity; the processing host module is built-in with a high-performance processor, an acceleration coprocessor and a peripheral expansion interface, which is used to control the illumination range and brightness of the backlight module, and synthesize multiple film images taken by the imaging module under different backlights into a high-dynamic image; the touch display module includes a touch display screen, which is used to display the high-dynamic image and obtain the touch input of the user, and mark the defect information on the high-dynamic image; the storage module is used to store the high-dynamic image and defect information data; the wireless communication module is used to communicate with a remote server to realize image data upload and remote verification.

[0010] In addition, the portable all-in-one machine can also externally connect a mouse and a keyboard through the interfaces provided on the processing host module.

[0011] Furthermore, the above portable all-in-one machine further includes an audio input module and an audio output module connected to the processing host module. Among them, the audio input module is used to collect the voice input of the operator, realize voice text input and voice control of the all-in-one machine; the audio output module is used to play the audio output of the all-in-one machine and provide a voice prompt function.

[0012] Furthermore, the processing host module is built with a high-performance processor, an acceleration coprocessor, and a peripheral expansion interface, and is used for: determining the illumination brightness range of the backlight module according to user input and ambient light intensity, controlling the backlight module for multi-level backlight control, and simultaneously sending a shooting instruction and parameters to the imaging module to shoot an industrial non-destructive testing film placed on the backlight module, obtaining multiple film images under different backlights, executing high-dynamic image processing and synthesis algorithm software to complete high-dynamic imaging of the industrial film, and storing the high-dynamic image photos into the storage module; displaying the high-dynamic image photos on the touch display module; obtaining the touch input of the user from the touch display module, marking defect information such as defect positions and types on the high-dynamic image, and storing them together with the high-dynamic image, and supporting transmitting the high-dynamic image and defect information to a remote server through the wireless communication module for data backup and remote verification.

[0013] Furthermore, the imaging module includes a camera with programmable control functions for focal length, aperture, and imaging angle, and is used for: implementing shooting of the industrial non-destructive testing film to obtain a film image, measuring the intensity of ambient light according to the film image for determining the illumination brightness range of the backlight module, determining the position of the film on the backlight module according to the film image for determining the light-emitting range of the backlight module to avoid backlight leakage and glare; obtaining multiple images under different backlight intensities for high-dynamic image synthesis. The focal length of the imaging module can be adjusted to achieve automatic focusing of the film and image shooting at different focal lengths. Preferably, the imaging module is built with a rotatable mirror, and by controlling the rotation angle of the mirror, shooting of different parts of the industrial film can be achieved to expand the shooting orientation.

[0014] Furthermore, in the backlight module, a high-brightness LED array is formed (see Figure 4 ), each LED can be individually controlled for switch and light-emitting intensity, and at the same time, the backlight module is covered with a light homogenizing layer on the LED array, which can provide uniform backlight illumination for the industrial film placed on the backlight module. The backlight module is used for: providing backlight for the industrial film, and the backlight range can be adjusted according to the size and position of the film to prevent the backlight from directly shining into the eyes of the film viewing operator. At the same time, the backlight intensity can vary to provide lighting conditions for collecting images under different backlights.

[0015] Furthermore, the touch display module includes a high-resolution touch display screen, which supports high-resolution and high-dynamic image display and also supports multi-touch function, and is used for: displaying high-dynamic image photos of the industrial film, supporting the film viewing operator to mark defect information such as defect positions, types, and grades on the screen, supporting digital film viewing, and at the same time supporting operations such as data saving, data retrieval, and system setting.

[0016] Further, the wireless communication module is built with a WiFi module and / or a mobile communication module, and communicates with a remote server through a WiFi local area network or a mobile communication network to achieve image data uploading and remote verification.

[0017] Further, the power supply module is built with an AC-DC conversion circuit, a DC-DC conversion circuit, and a battery charge and discharge circuit, which is used to provide power for the entire portable all-in-one machine, support an external 220V AC power input, an external (12V to 28V) DC power supply, and an internal battery (12V to 28V) for three power supply modes to provide power for each of the above modules.

[0018] Further, the storage module is built with a large-capacity solid-state drive, which is used to store the high-dynamic image data synthesized by the imaging module, digital film viewing defect information data, device work logs, etc.

[0019] Further, the above-mentioned portable all-in-one machine further includes an audio input module and an audio output module, both of which are connected to the processing host module. The audio input module is used to collect the voice input of the operator to achieve voice-to-text input and voice control of the all-in-one machine system. The audio output module is used to play the audio output of the all-in-one machine system to provide a system voice prompt function.

[0020] Further, the imaging module is located at the upper part of the portable chassis, and the backlight module is located at the lower part of the portable chassis. The imaging module can have three imaging structures:

[0021] One is Figure 6 As shown in the vertical imaging structure, the camera lens directly faces downwards towards the backlight module, and can perform planar imaging on the entire film on the backlight module.

[0022] The second is Figure 7 As shown in the horizontal imaging structure with left-right horizontal placement, that is, the camera is located on the left or right side of the upper part of the chassis, horizontally facing right or left, and a rotatable mirror is arranged on the right or left side of the lens for reflective imaging. By rotating the mirror, the left-right range of film imaging can be expanded, and overlapping imaging of the same area can also be achieved. If a linear camera is used, left-right scanning imaging of the film can be achieved. This structure also has the advantage of reducing the vertical height of the chassis.

[0023] The third is Figure 7The front-to-back horizontally placed imaging structure shown, that is, the camera is located at the rear end or the front end of the upper part of the chassis, the camera lens faces forward or backward horizontally, and a rotatable mirror is arranged on the front side or the rear side of the lens for reflective imaging. By rotating the mirror, the front-to-back range of film imaging can be expanded, and overlapping imaging of the same area can also be achieved. If a linear camera is used, front-to-back scanning imaging of the film can be realized. This structure also has the advantage of reducing the vertical height of the chassis.

[0024] Using the above-mentioned portable all-in-one machine integrating industrial non-destructive testing film digital imaging and multi-mode film viewing, industrial defect detection is carried out by the following method:

[0025] Step 1: The processing host module controls the imaging module to continuously take pictures of the film placement area on the backlight module and perform object detection on the obtained images. At the same time, by measuring the brightness of the images, the ambient light intensity is obtained.

[0026] Step 2: Place an industrial non-destructive testing film to be detected on the backlight module. The processing host module obtains the placement coordinates of the film on the backlight module through the film image and controls the backlight module to turn on the LEDs below the film for illumination, providing backlight for film viewing and imaging, while the LEDs located outside the film remain off. As Figure 5 shown.

[0027] Step 3: The processing host module controls the backlight module to provide backlights of different intensities in the backlight area and simultaneously controls the camera module to take pictures of the film to obtain a multi-exposure image sequence under different backlight intensities.

[0028] Step 4: The processing host module, with the help of the acceleration coprocessor in the processing host module, synthesizes a high-dynamic-range image photo based on the multi-exposure image sequence and stores the high-dynamic-range image photo in the storage module.

[0029] Step 5: The processing host module obtains the backlight intensity suitable for manual viewing based on the high-dynamic-range image photo and the multi-exposure image sequence and sets the backlight module to this backlight intensity.

[0030] Step 6: The processing host module corrects the synthesized high-dynamic-range image photo using the previously obtained ambient light intensity to obtain a corrected high-dynamic-range image photo and displays it on the touch display screen.

[0031] Step 7: The user performs multi-mode film viewing to achieve defect location and defect detection of industrial films.

[0032] Artificial simulation film viewing mode: The engineer directly observes the film on the backlight module and uses touch to mark the defect location, type, and level on the touch display module.

[0033] Manual digital viewing mode: Engineers directly observe the high-dynamic image photos displayed on the touch screen. At the same time, they can use the image magnification, filtering, grayscale adjustment and other tools provided by the processing host module to observe the details, and mark the defect location, type and level by touch on the touch screen.

[0034] Intelligent assisted digital viewing mode: The processing host module inputs the high-dynamic image photos into an intelligent defect detection algorithm (such as the Mask RCNN defect detection algorithm that has been fine-tuned and trained with defect samples). The algorithm outputs prompt information on the defect location, type and level, and superimposes it on the high-dynamic image photos on the touch screen to assist engineers in defect location and defect detection.

[0035] Intelligent assisted virtual reality viewing mode: A laser projection device is placed next to the camera in the imaging module. The device can project the defect location information output by the intelligent defect detection algorithm directly onto the film, guiding engineers to further observe the defects and achieve rapid defect location and detection.

[0036] When viewing films, engineers can use a combination of the above modes to quickly locate and detect defects.

[0037] Step 8: The processing host module generates a film viewing record together with the defect detection results of the multi-mode viewing, including the defect location, defect type and defect level, the engineering management information (engineer information, location information, equipment information, time information, etc.), the multi-exposure image sequence, and the high-dynamic image photos, and stores them in the local storage module.

[0038] Step 9: The processing host module uploads the film viewing record to the remote server via the wireless communication module.

[0039] Step 10: At this point, the digital imaging and multi-mode viewing of the industrial film are completed. The engineer replaces the new industrial non-destructive testing film on the backlight module, returns to the aforementioned step 2, and repeats the operation.

[0040] Specifically, the processing host module in the aforementioned steps 1 and 2 uses an object detection algorithm to perform object detection on the image. A calibrated Yolo object detection algorithm, such as yoloV5, can be used to detect and locate the industrial film, and output the four-corner coordinates of the industrial film on the backlight module.

[0041] Specifically, the ambient light intensity in the aforementioned step 1 is obtained by averaging pixel values outside the industrial film area.

[0042] Specifically, in the aforementioned step 4, the processing host module infers the camera response function by using a high-dynamic-range image processing synthesis algorithm and the image sequence of multiple exposures, so as to synthesize an HDR image. The specific steps are as follows:

[0043] The first step: Define the camera response function:

[0044] That is, a function of pixel value, exposure time, and corresponding scene irradiance, which is defined as follows:

[0045] z ij = f(E i t j )

[0046] Among them, z ij represents the pixel value of the i-th pixel in the j-th image, E i is the irradiance received at this point (Radiance), representing the real image information at this point, and t j is the exposure time of the j-th image.

[0047] The second step: After taking the inverse function of the left and right of the camera response function and then taking the logarithm, we have:

[0048] log2f -1 (z ij ) = log2E i + log2t j

[0049] Denote this part on the left as g, then we have:

[0050] g(z ij ) = log2E i + log2t j

[0051] As long as the function g is obtained, the original camera response function can be obtained.

[0052] The third step: Establish an optimization objective function.

[0053] First, fix g(128) = 0, and convert the solution of the camera response function into a constrained extreme value problem. That is, it is required to find the irradiance E i of each point, so that the value of the following error function is the smallest:

[0054]

[0055] Among them, w is the weight function. We believe that the pixels near 128 have the best imaging quality, while the pixels near 0 and 255 have relatively poor imaging quality. Therefore, different weights are set for different pixels:

[0056]

[0057]

[0058] The λ in the second item is used as a parameter to multiply the second-order smoothing term, making the fitted function relatively smooth.

[0059] Step 4: Obtain g(z) using the singular value decomposition method

[0060] Since the pixel value z ij is discrete, for the 8-bit case, there are only 256 possible values. Therefore, the singular value decomposition method can be used to obtain the values of g(z) in these 256 cases, that is, the camera response function is obtained.

[0061] Step 5: Reconstruct the high dynamic range illumination map {Ei}

[0062] After obtaining the function g, we can calculate the corresponding illumination value E of each point according to the following formula i :

[0063] log2E i = g(z ij ) - log2t j

[0064] To be more robust and effectively utilize the information of all image sequences, we should use the pixel values at the same point of all images and calculate the illumination at this point by weighted mean:

[0065]

[0066] In this way, we can obtain the illumination map {Ei} at all pixel positions. Since E i represents the true illumination information of the image at this point, including the information of multiple images at this point, {Ei} is also the synthesized high dynamic range image data.

[0067] Specifically, in the aforementioned step 5, the processing host module obtains the backlight intensity suitable for manual film viewing through the manual film viewing backlight calculation algorithm. The specific method is to perform one-by-one correlation comparison between the multi-exposure image sequence and the synthesized high dynamic range image, select the exposure image with the highest correlation, and output the corresponding backlight intensity as the backlight intensity for manual film viewing.

[0068] Specifically, in the aforementioned step 6, the processing host module corrects the high-dynamic-range (HDR) image photo synthesized in step 4 using the high-dynamic-range image display ambient light correction algorithm. The specific method is as follows: Map the HDR image data to the pixel value range of [0, 255] through tone mapping, and then perform adaptive contrast enhancement; when performing adaptive contrast enhancement, add an ambient light intensity factor h to the enhancement factor P. When the ambient light is strong, increase the degree of adaptive contrast enhancement to make the image contrast stronger and facilitate observing details. Finally, display the image after the above contrast enhancement on the display screen of the touch display module for engineers to perform multi-mode film viewing processing. The specific steps of the above adaptive contrast enhancement are as follows:

[0069] The first step: Calculate the global brightness mean square deviation σ of the entire image, and determine the contrast enhancement factor P0 according to the following method:

[0070] If σ ≤ 3, P0 = 3,

[0071] If σ ≥ 10, P0 = 1,

[0072] If 3 < σ < 10, then P0 takes linear interpolation, P0 = (27 - 2σ) / 7;

[0073] The second step: Normalize the ambient light intensity to [0, 1] to obtain the ambient light intensity factor h, and take P = P0 + K*h, where K is the ambient light intensity amplification parameter, and the value of K is taken between 1 and 3, with a default value of 1.5;

[0074] The third step: For each pixel I(X, Y), calculate the Gaussian convolution G(X, Y) of this pixel, and calculate its exponent E(X, Y) = (G(X, Y) / I(X, Y)) P ;

[0075] The fourth step: Calculate the pixel value S(X, Y) of each pixel after adaptive enhancement, S(X, Y) = 255*In(X, Y) E(X，Y) , where In(X, Y) is the normalized value of the original image pixel I(X, Y): In(X, Y) = I(X, Y) / 255.

[0076] Compared with the prior art, the portable all-in-one machine for integrated industrial non-destructive testing film digital imaging and multi-mode film viewing and the corresponding industrial defect detection method of the present invention mainly have the following advantages:

[0077] 1. Good portability, and can perform film viewing and digital operations anytime and anywhere. Existing film digitalization instruments usually need to be used in conjunction with a desktop computer, with a large volume and inconvenient to carry. The all-in-one machine device of the present invention is smaller in volume, convenient to operate and carry.

[0078] 2. Fast speed. Without sacrificing image quality compared to existing film digitizing instruments, it can complete film viewing and digitizing operations faster. This is because existing instruments usually use the method of scanning imaging, which is slower. When the imaging module in this utility model uses a matrix imaging sensor, it can complete shooting faster. At the same time, it adopts a high-dynamic image synthesis algorithm and is accelerated by a built-in acceleration coprocessor to provide fast imaging ability while ensuring image quality.

[0079] 3. High imaging quality. Compared with existing film digitizing instruments that use shooting imaging, the multiple exposure synthesis method used in this utility model can improve the dynamic range and signal-to-noise ratio of the image, thereby improving the imaging quality. The quality reaches or exceeds that of film digitizing instruments using scanning imaging. When the imaging module adopts a mirror configuration, it can increase the imaging range, and more details can also be obtained through the overlap of the imaging range to generate high-quality high-dynamic images.

[0080] 4. High detection efficiency. This utility model combines multi-mode viewing means such as manual simulated film viewing, digital film viewing, intelligent assisted film viewing, and virtual reality film viewing, which can reduce the labor intensity of engineers and improve the detection accuracy and efficiency. Description of the Drawings

[0081] Figure 1 It is a three-dimensional schematic diagram of the internal composition of the portable industrial film digitizing imaging and viewing integrated machine device described in the embodiment.

[0082] Figure 2 is Figure 1 The right view of the interior of the portable industrial film digitizing imaging and viewing integrated machine device shown.

[0083] Figure 3 It is a block diagram of the portable industrial film digitizing imaging and viewing integrated machine device described in the embodiment.

[0084] Figure 4 It is a schematic diagram of the structure of the programmable backlight module described in the embodiment (the top light homogenizing layer is removed).

[0085] Figure 5 It is a schematic diagram of the operation of the programmable backlight module when placing an industrial film in the embodiment (the backlight under the film is turned on, and the backlight LEDs outside the film are turned off, and the top light homogenizing layer is removed).

[0086] Figure 6 It is a schematic diagram of the internal vertical imaging structure of the programmable imaging module.

[0087] Figure 7 It is a schematic diagram of the internal left-right horizontal imaging structure of the programmable imaging module.

[0088] In the figure: 1 - Processing host module, 2 - Programmable imaging module, 3 - Programmable backlight module, 4 - Touch display module, 5 - Power module, 21 - Camera, 22 - Lens, 23 - Mirror, 24 - Rotatable support rod. Detailed implementation mode

[0089] The technical solution of the present utility model will be clearly and completely described below with reference to the accompanying drawings through embodiments, but this does not limit the scope of the present utility model.

[0090] As Figure 1 、 Figure 2 and Figure 3 shown, the portable industrial film digital imaging and film viewing all-in-one device of this embodiment includes: a processing host module 1, a programmable imaging module 2, a programmable backlight module 3, a touch display module 4, a large-capacity storage module, an audio input module, an audio output module, a wireless communication module, and a power module 5. Among them, the processor host module 1 is connected to the programmable imaging module 2, the programmable backlight module 3, the touch display module 4, the storage module, the audio input module, the audio output module, and the wireless communication module. The power module 5 supplies power to the above modules, and all modules are installed and fixed in a portable chassis. In addition, the all-in-one device can also be externally connected to a mouse and a keyboard.

[0091] The processing host module 1 is arranged at the top of the all-in-one device ( Figure 1 ), and is built with a processor, an acceleration co-processor, and a peripheral expansion interface. The processing host module adopts an RK3588 embedded host, with an acceleration co-processor built in, providing HDMI interface, USB interface, and M.2 PCIe expansion interface. The functions of the processing host module 1 include: determining the illumination brightness range of the programmable backlight module 3 according to user input and ambient light intensity, controlling the programmable backlight module 3 for multi-level backlight control, and at the same time sending a shooting instruction and parameters to the programmable imaging module 2 to shoot the industrial film on the programmable backlight module 3, obtaining multiple film images under different backlights, executing high-dynamic image processing and synthesis algorithms, completing the high-dynamic imaging of the industrial film, and storing the high-dynamic image photos in the storage module; displaying the high-dynamic image photos on the touch display module 4; obtaining the touch input of the user from the touch display module 4, marking defect information such as defect positions and types on the image, and storing them together with the high-dynamic image photos, and supporting the transmission of the high-dynamic image photos and defect information to a remote server through the wireless communication module for backup and remote verification.

[0092] The programmable imaging module 2 is arranged at the top of the all-in-one device ( Figure 1), including a camera with programmable control of focal length, aperture, and imaging angle. The camera uses IMX586 as the image sensor and is connected to the processing host module through a USB interface or an MIPI-CSI interface. The functions of the programmable imaging module 2 include: taking pictures of industrial films, obtaining film images, measuring the intensity of ambient light based on the film images to determine the illumination brightness range of the programmable backlight module 3, determining the position of the film on the backlight based on the film images to determine the light-emitting range of the programmable backlight module 3, and avoiding backlight leakage and glare; obtaining multiple images under different backlight intensities for high-dynamic-range image synthesis. The focal length of the programmable imaging module 2 can be adjusted to achieve automatic focusing of the film and image capture at different focal lengths; the programmable imaging module 2 is built-in with a rotatable mirror ( Figure 7 ), by controlling the rotation angle of the mirror 23, different parts of the industrial film can be photographed to expand the shooting orientation.

[0093] The programmable backlight module 3 is arranged at the bottom of the all-in-one device ( Figure 1 ), as shown in Figure 4 . It is composed of a high-brightness LED array. Each LED can be individually controlled for on / off and light-emitting intensity. At the same time, the top layer of the programmable backlight module 3 is covered with a light homogenizing layer, which can provide uniform backlight illumination for the industrial film placed on the programmable backlight module 3. The programmable backlight module 3 is connected to the USB-RS485 interface provided by the processing host module through an RS485 interface. The functions of the programmable backlight module 3 include: providing backlight for the industrial film, and the backlight range can be adjusted according to the size and position of the film, as shown in Figure 5 . It prevents the backlight from directly shining into the eyes of the film viewers. At the same time, the backlight intensity can change to provide lighting conditions for image acquisition under different backlights.

[0094] The touch display module 4 is arranged on the side wall of the all-in-one device ( Figure 1 ). It includes a high-resolution 15.6-inch touch display screen and its controller. The display resolution is 3840×2160. The display screen is connected to the interface of the processing host module 1 through an HDMI interface, supporting high-resolution and high-dynamic-range image display. The touch display screen controller is connected to the processing host module 1 through a USB interface, supporting multi-touch function. The functions of the touch display module include: displaying high-dynamic-range image photos of industrial films, supporting film viewers to mark defect information such as defect positions, types, and grades on the screen, supporting digital film viewing, and at the same time supporting operations such as data saving, data retrieval, and system settings.

[0095] The audio input module is connected to the processing host module 1 through an SPI interface, used to collect the voice input of the operator, and realize voice text information input and system sound control.

[0096] The audio output module is connected to the HDMI interface of the processing host module 1 and is used for playing the audio output of the system and providing the system voice prompt function.

[0097] The wireless communication module communicates with the remote server through the built-in WiFi module or the mobile communication network connected by the 4G mobile communication module extended by USB, so as to realize image data uploading and remote verification.

[0098] The power module 5 is arranged on the top of the all-in-one device ( Figure 1 ), and is built with an AC-DC conversion circuit, a DC-DC conversion circuit and a battery charge and discharge circuit, which is used to provide power supply for the whole device, support the input of 220V AC power supply, and three power supply modes of external (12V-28V) DC power supply and internal battery (12V-28V), so as to provide power for each of the above modules.

[0099] The storage module installs a large-capacity NVMe SSD solid-state hard disk of 2242 specification through the M.2 PCIe interface of the processing host module 1, and is used to store the high-dynamic image data synthesized by the programmable imaging module 2, the digital film viewing defect information data, the device work log, etc.

[0100] The whole device uses an aluminum alloy frame to assemble each module together to form a portable industrial film digital imaging and multi-mode film viewing all-in-one device, as Figure 1 shown.

[0101] The operation method of the above portable industrial film digital imaging and multi-mode film viewing all-in-one device includes:

[0102] Step 1: After the device is powered on, after the all-in-one device shown in Figure 1 completes the system self-check, the processing host module 1 controls the programmable imaging module 2 to continuously take pictures of the film placement area on the programmable backlight module 3, and performs object detection on the obtained images. At the same time, by measuring the brightness of the images, the ambient light intensity of the all-in-one device is obtained.

[0103] Step 2: When an engineer places an industrial non-destructive testing film to be detected on the programmable backlight module 3, the processing host module 1 runs the object detection algorithm, obtains the placement coordinates of the film on the programmable backlight module 3, and controls the programmable backlight module 3 to turn on the LEDs under the film to emit light, so as to provide backlight for film viewing and imaging, while the LEDs located outside the film remain off, as Figure 5 shown.

[0104] Step 3: The processing host module 1 controls the backlight areas of the programmable backlight module 3 to provide backlights of different intensities, and simultaneously controls the programmable imaging module 2 to take pictures of the film, obtaining a multi-exposure image sequence under different backlight intensities.

[0105] Step 4: The processing host module 1 inputs the multi-exposure image sequence into a high-dynamic range image processing and synthesis algorithm software. With the help of the acceleration coprocessor in the processing host module 1, a high-dynamic range image is synthesized and stored in the storage module.

[0106] Step 5: The processing host module 1 inputs the high-dynamic range image and the multi-exposure image sequence into the artificial film viewing backlight calculation algorithm software, outputs a backlight intensity suitable for artificial viewing, and sets the programmable backlight module 3 to this backlight intensity.

[0107] Step 6: The processing host module 1 inputs the synthesized high-dynamic range image and the previously obtained ambient light intensity into a high-dynamic range image display ambient light correction algorithm software, outputs a corrected high-dynamic range image photo, and displays it on the touch display module 4.

[0108] Step 7: The user performs multi-mode film viewing to achieve defect location and defect detection of industrial films.

[0109] Artificial simulation film viewing mode: The engineer directly observes the film on the programmable backlight module 3 and uses touch on the touch display module 4 to mark the defect location, type, and level.

[0110] Artificial digital film viewing mode: The engineer directly observes the high-dynamic range image photo displayed on the touch display screen. At the same time, tools such as image magnification, filtering, and grayscale adjustment provided by the processing host module 1 can be used for detailed observation, and the defect location, type, and level are marked by touch on the touch display screen.

[0111] Intelligent assisted digital film viewing mode: The processing host module 1 inputs the high-dynamic range image photo into an intelligent defect detection algorithm software. This software outputs prompt information on the defect location, type, and level and superimposes it on the high-dynamic range image photo on the touch display screen to assist the engineer in further defect location and defect detection.

[0112] Intelligent assisted virtual reality film viewing mode: A laser projection device is set beside the camera in the programmable imaging module 2. This device can directly project the defect location information output by the intelligent defect detection algorithm software onto the film, guiding the engineer to further observe the defect and achieving rapid defect location and defect detection.

[0113] During film viewing, the engineer can use the above modes in combination to achieve rapid defect location and defect detection.

[0114] Step 8: The processing host module 1 generates a film viewing record together with the defect detection results of the multi-mode viewing, including the defect location, defect type and defect level, the engineering management information (engineer information, location information, equipment information, time information, etc.), the multi-exposure image sequence, and the high-dynamic image photos, and stores them in the local storage module.

[0115] Step 9: The processing host module 1 uploads the film viewing record to the remote server via the wireless communication module.

[0116] Step 10: At this point, the digital imaging and multi-mode viewing operation of the industrial film is completed. The engineer replaces the new industrial film onto the programmable backlight module 3, returns to the aforementioned step 2, and repeats the operation.

[0117] The description of the above embodiments is only used to help understand the method and core idea of the utility model, and its purpose is to enable those skilled in the art to understand the content of the utility model and implement it accordingly, and it cannot be used to limit the protection scope of the utility model. Various equivalent modifications or substitutions made without violating the spirit of the utility model are included in the scope defined by the claims of the utility model.

Claims

1. A portable all-in-one machine for industrial defect detection, characterized in that, It includes a processing host module, an imaging module, a backlight module, a touch display module, a storage module, a wireless communication module and a power module. Among them, the processing host module is connected to the imaging module, the backlight module, the touch display module, the storage module and the wireless communication module, and the power module supplies power to the above modules. All modules are installed and fixed in a portable chassis; the backlight module includes a programmable controlled LED array, and each LED therein can be individually controlled for switching and luminous brightness. The industrial non-destructive testing film is placed on the backlight module; the imaging module includes a camera with programmable controlled focal length, aperture and imaging angle, which is used to photograph the industrial non-destructive testing film on the backlight module, obtain the film image and measure the ambient light intensity; the processing host module is built-in with a high-performance processor, an acceleration coprocessor and a peripheral expansion interface, which is used to control the illumination range and brightness of the backlight module, and synthesize multiple film images under different backlights captured by the imaging module into a high-dynamic image; the touch display module includes a touch display screen, which is used to display the high-dynamic image and obtain the user's touch input, and mark the defect information on the high-dynamic image; the storage module is used to store the high-dynamic image and defect information data; the wireless communication module is used to communicate with a remote server to realize image data upload and remote verification.

2. The portable all-in-one machine according to claim 1, characterized in that, This portable all-in-one machine includes an audio input module and an audio output module connected to the processing host module. Among them, the audio input module is used to collect the voice input of the operator to realize voice-to-text input and voice control of the all-in-one machine; the audio output module is used to play the audio output of the all-in-one machine to provide a voice prompt function.

3. The portable all-in-one machine according to claim 1, wherein The processing host module is provided with interfaces for an external mouse and keyboard.

4. The portable all-in-one machine according to claim 1, wherein, The imaging module is located at the upper part of the chassis, and the backlight module is located at the lower part of the chassis. The imaging module is one of the following imaging structures: one is a vertical imaging structure, that is, the camera lens faces downwards and aligns with the backlight module to perform planar imaging on the entire film on the backlight module; the second is a horizontal imaging structure with left-right horizontal placement, that is, the camera is located on the left or right side of the upper part of the chassis, the camera lens faces horizontally to the right or left, and a rotatable mirror is arranged on the right or left side of the lens for reflective imaging; the third is a horizontal imaging structure with front-back horizontal placement, that is, the camera is located at the rear or front end of the upper part of the chassis, the camera lens faces horizontally forward or backward, and a rotatable mirror is arranged on the front or rear side of the lens for reflective imaging.

5. The portable all-in-one machine according to claim 1, characterized in that, The camera in the imaging module is a linear camera.

6. The portable all-in-one machine according to claim 1, characterized in that, The wireless communication module is built-in with a WiFi module and / or a mobile communication module.

7. The portable all-in-one machine according to claim 1, characterized in that, The backlight module is covered with a light homogenizing layer on the LED array.

8. The portable all-in-one machine according to claim 1, wherein, The power module is built-in with an AC-DC conversion circuit, a DC-DC conversion circuit and a battery charge and discharge circuit.

9. The portable all-in-one machine according to claim 1, characterized in that, The storage module is built-in with a large-capacity solid-state drive.

10. The portable all-in-one machine according to claim 1, characterized in that The processing host module, the power module and the imaging module are arranged on the top of the portable chassis, and the backlight module is arranged at the bottom of the portable chassis; the touch display module is arranged on the side wall of the portable chassis.

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