Digital Radiation Inspection for Pipe Welds
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Solution Overview
Problem
Current radiation transmission tests for inspecting welded portions of pipes are inefficient, requiring manual handling of films, limited by worker safety, and resulting in high burdens on workers and environmental concerns, with low inspection accuracy due to visual evaluation of developed films.
Innovation Solution
An inspection system that acquires digital imaging data of radiation transmission through welded portions using a radiation irradiation unit and detector, with a movement mechanism for circumferential scanning, and an automatic determination unit using machine learning to identify defects, eliminating the need for film-based evaluation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If film-based radiation transmission test is used, then defect detection can be performed, but worker safety is compromised and work efficiency is reduced due to manual film handling
Solution Approach 1:
The patent replaces the mechanical film-based imaging system with a digital detector system that directly captures radiation transmission images. The detector (e.g., flat panel detector) converts radiation signals into digital images electronically, eliminating the need for physical film handling, chemical processing, and manual evaluation. This substitution maintains defect detection capability while significantly reducing worker burden and improving safety.
Solution Approach 2:
The patent creates a digital copy of the radiation transmission image using a detector instead of a physical film copy. The digital image can be stored, transmitted, and evaluated without requiring physical film processing. This allows multiple evaluations and archiving without consuming additional materials, reducing waste and improving workflow efficiency.
2Productivity
If multiple imaging tasks are performed simultaneously in limited construction area, then inspection coverage increases, but worker safety distance requirements limit the number of simultaneous tasks
Solution Approach 1:
The digital detector system allows for remote operation and digital image transmission, enabling inspectors to evaluate images from a safe distance. Multiple imaging tasks can be performed simultaneously in different locations without increasing radiation exposure risk to inspectors, as the digital images can be reviewed remotely without requiring inspectors to be present at each imaging site.
Solution Approach 2:
The digital detector acts as an intermediary between the radiation source and the inspector. It captures the radiation transmission images and transmits them digitally, allowing inspectors to evaluate defects from a safe distance without direct exposure to radiation. This intermediary enables multiple simultaneous imaging tasks without compromising inspector safety.
3Reliability
If visual evaluation of developed films is used, then defect determination can be made, but inspection accuracy is limited
Solution Approach 1:
The patent replaces visual evaluation of film with digital image processing and analysis. The digital detector produces high-resolution images that can be enhanced, magnified, and analyzed using software tools. This allows for more precise measurement of defect characteristics such as size, shape, and location, improving inspection accuracy while maintaining the ability to determine defects reliably.
Solution Approach 2:
The digital imaging system allows for adjustment of image parameters such as contrast, brightness, and magnification to optimize defect visibility. Digital processing enables enhancement of subtle defects that may be difficult to detect in film images. These parameter adjustments improve measurement precision without compromising the reliability of defect determination.
4Productivity
If large quantity of films are used for numerous welded portions, then all welded portions can be inspected, but environmental impact increases due to film and chemical disposal
Solution Approach 1:
The digital detector system replaces the film and chemical processing system entirely. Digital images can be stored electronically without requiring physical film storage or chemical disposal. This eliminates the environmental pollution associated with film development chemicals and film waste, while maintaining the capacity to inspect large numbers of welded portions through efficient digital image management and processing.
Solution Approach 2:
The digital imaging system eliminates the need to discard physical films and chemical materials. Digital images can be stored, archived, and reused indefinitely without degradation. This recovering of the imaging medium (digital storage) eliminates the continuous consumption and disposal cycle of film and chemicals, significantly reducing environmental impact while maintaining high inspection capacity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Improves work efficiency and inspection accuracy by reducing worker burden, eliminating film handling, and enabling remote operation, with enhanced defect detection and reduced environmental impact.
Implementation Method 1
imaging data obtained by transmitting radiation through the welded portion of the pipe or pipe member to be inspected
Data Source
AI summary
In a nondestructive inspection of a defect of a welded portion of a pipe or a pipe member, work efficiency of a radiation transmission test is improved by reducing a burden on a worker, and an inspection accuracy is improved. Imaging data is acquired by transmitting radiation through a welded portion of the pipe to be inspected. Processing of associating determination data indicating a result of determining a defect of the welded portion of the pipe to be inspected based on a distribution of a transmission intensity of the radiation obtained from the imaging data with image data showing the distribution of the transmission intensity of the radiation is performed. As a result, through use of the imaging data, image data and determination data associated with the image data can be obtained, and the burden on the worker can be reduced.