Continuous Radiographic Weld Inspection With Time-Delayed Imaging
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Solution Overview
Problem
Existing methods for inspecting large structure welds, such as large bore pipe welds, are time-consuming due to the need for multiple radiographic images and film development, especially when using digital detectors or film.
Innovation Solution
An inspection system utilizing photon counting detectors and time delayed imaging techniques, combined with a motion control system and control logic to automate the inspection process, allowing for faster data collection and image generation by moving the radiation source and detector relative to the object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional radiographic inspection methods using film or digital detectors are used, then image quality can be achieved, but inspection time becomes excessively long (hours for large bore pipes)
Solution Approach 1:
The patent implements continuous scanning inspection where the radiation source and detector move continuously along the weld joint without stopping, acquiring multiple images in sequence. This continuous action eliminates the need for multiple separate positioning and exposure operations, reducing inspection time from hours to minutes while maintaining image quality through accumulated data from multiple frames
Solution Approach 2:
The system performs preliminary actions by pre-positioning the radiation source and detector in a configured geometry relative to the weld, then executing a single continuous scan. The motion control system pre-coordinates the movement of multiple components simultaneously, and the computer automatically prepares to acquire and process multiple images in sequence, eliminating setup time between exposures
2Reliability
If multiple radiographic images are acquired for large structures, then complete coverage is achieved, but the number of images required increases inspection complexity and time
Solution Approach 1:
The patent merges multiple separate radiographic exposure operations into a single continuous scanning operation. The radiation source and detector move continuously while acquiring multiple images in sequence, combining what would have been multiple discrete inspection steps into one unified process. The computer then merges the data from multiple frames into a complete inspection record, reducing process complexity
Solution Approach 2:
The system replaces manual positioning and multiple separate exposure operations with an automated motion control system that coordinates the movement of the radiation source and detector. The computer automatically acquires, stores, and processes multiple images in sequence, substituting manual mechanical operations with automated control to reduce inspection complexity
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
Significantly reduces inspection time by enabling continuous imaging and automated defect recognition, achieving desired image quality at speeds up to 2 inches per second, thereby reducing the overall inspection duration from hours to minutes.
Implementation Method 1
The radiation source 110 may include an x-ray source (such as a 150 kilovolt (kV) x-ray tube)
Implementation Method 2
The radiation detector 112 includes an imaging array 140. In some embodiments, the radiation detector 112 may include a include direct conversion sensors, including cadmium telluride (CdTe), cadmium zinc telluride (CdZnTe or CZT), selenium, or the like, configured to directly convert the radiation 111 into a signal
Implementation Method 3
In some embodiments, the radiation detector 112 includes a conversion screen, scintillator, or the like to convert the radiation 111 into wavelengths detectable by the imaging array 140 of the detector 102
Data Source
AI summary
Some embodiments include an inspection system, comprising: a radiation source; a radiation detector including an imaging array; a support structure configured to maintain a spatial relationship between the radiation source and the radiation detector; a motion control system configured to move an object relative to the radiation detector; control logic configured to: control the motion control system to move the object relative to the radiation detector; and combine data from multiple frames from the radiation detector as the object moves relative to the radiation detector into a single image.