Iterative 3D Model Correction for Radiographic Inspection
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Solution Overview
Problem
Current industrial inspection methods, including optical scanners and Computed Tomography (CT), face limitations such as long inspection times, inability to detect subsurface defects, and high costs, making them unsuitable for high-volume production and comprehensive non-destructive testing (NDT).
Innovation Solution
A method and system utilizing a detailed three-dimensional model, where radiographic images are acquired and compared to simulated images generated from a theoretical 3D mesh, allowing for precise 3D measurements and subsurface defect detection, enabling fast and cost-effective inspection of complex articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional CT methods are used to perform industrial inspection, then measurement precision and subsurface defect detection are improved, but inspection time and device complexity increase significantly
Solution Approach 1:
The system performs preliminary action by acquiring surface profile data before the radiographic imaging step. This surface information is used to generate an updated 3D model that serves as a starting point for the iterative reconstruction process, reducing the computational burden and time required compared to conventional CT methods that start from scratch
Solution Approach 2:
The system creates a digital copy of the object's surface geometry through the 3D mesh model. This digital replica is then used to generate simulated radiographic images that are compared with actual images during iterative reconstruction, eliminating the need for physical manipulation or rotation of the actual object
2Measurement precision
If conventional CT methods are used to perform industrial inspection, then measurement precision and subsurface defect detection are improved, but device complexity and cost increase
Solution Approach 1:
The system integrates multiple functions into a unified workflow: surface scanning, radiographic imaging, 3D model generation, simulated image creation, and iterative reconstruction all work together in a coordinated manner. This multi-functional approach reduces the need for separate specialized equipment and simplifies the overall inspection system
Solution Approach 2:
The system introduces simulated radiographic images as an intermediary element. These simulated images, generated from the 3D model, serve as a reference for comparing with actual radiographic images during the iterative reconstruction process, enabling precise defect detection without requiring complex physical manipulation of the object
3Measurement precision
If optical scanners are used to perform industrial metrology, then surface measurement capability is improved, but ability to detect subsurface defects and inspect inaccessible features deteriorates
Solution Approach 1:
The system merges the strengths of optical scanning (surface geometry capture) with radiographic imaging (subsurface defect detection). The surface profile data from optical scanning is integrated with the radiographic images through the iterative reconstruction process, creating a comprehensive inspection solution that delivers both surface measurement precision and subsurface defect detection capability
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
The system enables rapid, precise 3D measurements and subsurface defect detection, allowing for high-speed inspection of complex articles, exceeding 100 articles per minute, and is cost-efficient, suitable for high-volume production and NDT applications.
Implementation Method 1
acquiring a sequence of radiographic images of the article using a radiographic image acquisition device
Data Source
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AI summary
A method for performing inspection of a manufactured article. The method comprises acquiring a sequence of radiographic images of the article; determining a position of the article for each one of the acquired radiographic images; and performing a three- dimensional model correction loop which comprises, iteratively: generating a simulated radiographic image for each determined position of the article; and comparing the simulated radiographic images and the acquired radiographic images and generating a match result. If the match result is indicative of a mismatch, the method includes identifying and characterizing differences between the simulated radiographic images and the acquired radiographic images; correcting one of a geometry and a material density of a region of interest of the detailed three- dimensional model of the article based on each one of the identified and characterized differences; and performing a new iteration. A system for performing inspection is also provided.