Sealed Weld Bead Inspection for Precise Pipe Defect Detection
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Solution Overview
Problem
Existing weld bead inspection methods are subjective, costly, and limited in their ability to inspect narrow or high sections, with inconsistent results due to environmental factors and varying skill levels of inspectors.
Innovation Solution
A portable weld bead inspection apparatus with a housing that surrounds the pipe to form a sealed inspection space, equipped with an inspection means that includes a vision inspection part, a laser inspection part, and a leak sensor, which determines defects based on measured parameters and preset algorithms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a skilled worker directly inspects a weld bead with the naked eye, then inspection cost increases and defect determination ability varies by skill level, but the method is simple and requires no special equipment
Solution Approach 1:
The patent replaces the mechanical visual inspection method with an automated optical inspection system using a camera and image processing unit. The camera captures images of the weld bead, and the image processing unit automatically analyzes defects, eliminating dependence on worker skill levels and providing consistent, objective defect determination without requiring complex manual evaluation procedures
Solution Approach 2:
The inspection system performs self-evaluation through automated image processing algorithms that objectively detect and classify weld defects. The system independently determines defect presence and characteristics without human intervention in the decision-making process, ensuring consistent reliability across different inspection instances
2Measurement precision
If an apparatus inspects weld bead by irradiating laser beam, then inspection precision improves, but the apparatus cannot inspect narrow section and highness section due to positioning limitations
Solution Approach 1:
The patent employs a rotatable camera unit that can dynamically adjust its position and orientation to inspect weld beads in various locations including narrow sections and highness sections. The rotation mechanism allows the inspection apparatus to adapt to different geometric configurations and access difficult-to-reach areas while maintaining precise imaging capability
Solution Approach 2:
The inspection apparatus is designed with multi-functional capabilities to handle diverse inspection scenarios. The camera system can inspect various weld bead positions (narrow sections, highness sections, standard sections) using the same core imaging and processing technology, making the apparatus universally applicable across different welding configurations without requiring multiple specialized devices
3Ease of manufacture
If a camera photographs weld bead image according to work environment illuminance, then the inspection method is simple, but accurate inspection becomes impossible due to illuminance changes
Solution Approach 1:
The patent incorporates an illumination control unit that actively manages lighting parameters in the inspection environment. The system adjusts illuminance levels and distribution to ensure consistent image quality regardless of external lighting conditions. This parameter control enables the camera to capture standardized images for accurate defect detection while maintaining the simplicity of the overall inspection method
Solution Approach 2:
The illumination control unit acts as an intermediary between the camera and the weld bead, providing controlled lighting that mediates the interaction between the imaging system and the inspection target. This intermediary component ensures that the camera receives consistent illumination for accurate image capture while keeping the inspection method straightforward and easy to implement
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 apparatus enables constant and precise weld bead inspection, is highly portable, and can inspect difficult-to-reach areas, providing consistent results regardless of environmental changes and eliminating subjective human error.
Implementation Method 1
a laser inspection part (220) configured to measure displacement of the weld bead (20)
Implementation Method 2
a vision inspection part (210) configured to photograph an image of the weld bead (20)
Data Source
AI summary
The present invention relates to a weld bead inspection apparatus and, more specifically, to a weld bead inspection apparatus capable of precisely inspecting a weld bead. The present invention relates to the weld bead inspection apparatus for inspecting whether a weld bead (20) on a pipe (10) is defective, and disclosed is the weld bead inspection apparatus comprising: a housing (100) encompassing the pipe (10) so as to cover the weld bead (20), and forming a closed inspection space (S) therein; an inspection means (200) provided in the housing (100) so as to confirm the state of the weld bead (20) in the inspection space (S); and a defect determination unit for determining whether the weld bead (20) is defective on the basis of the state of the weld bead (20), having been confirmed through the inspection means (200).