Automated X-Ray Pipe Scanner for Corrosion Detection
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Solution Overview
Problem
Current x-ray inspection methods for insulated pipes are time-consuming and inefficient, particularly when scanning long lengths, and struggle to detect corrosion under insulation due to the need for manual operation and the complexity of aligning x-ray beams with large pipe diameters.
Innovation Solution
A scanning system comprising a translating structure and a controller that moves axially and rotationally along the pipe, using an x-ray scanner to perform axial and rotational scans with adjustable beam orientations, allowing for automated data collection and image generation of inconsistencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual x-ray inspection methods are used with insulated pipes, then inspection can be performed from the exterior of the pipe, but the inspection process becomes time-consuming and inefficient
Solution Approach 1:
The patent replaces manual mechanical inspection operations with an automated robotic system that includes a robot arm, x-ray source, and detector assembly. The system automatically positions and moves the x-ray equipment along the pipe, eliminating the need for manual handling while maintaining exterior inspection capability.
Solution Approach 2:
The system incorporates automated image processing and analysis capabilities that enable the inspection system to evaluate pipe conditions autonomously. The processor automatically generates images from detector signals and identifies inconsistencies without requiring constant human intervention, thereby improving inspection efficiency.
2Area of stationary object
If x-ray beams are aligned with large pipe diameters using manual methods, then inspection coverage can be achieved, but the alignment process becomes complex and time-consuming
Solution Approach 1:
The patent replaces manual beam alignment operations with an automated robotic positioning system. The robot arm precisely positions the x-ray source and detector assembly relative to the pipe, while sensors and control systems automatically adjust beam orientation to match pipe geometry, eliminating complex manual alignment procedures.
Solution Approach 2:
The system employs dynamic positioning and orientation adjustment capabilities that allow the x-ray beam to adapt to varying pipe diameters and positions. The robotic system can dynamically adjust the beam angle and position in real-time, simplifying the inspection of pipes with different dimensions.
3Productivity
If automated scanning systems are implemented, then inspection efficiency improves, but the system complexity and initial cost increase
Solution Approach 1:
The patent designs a multi-functional inspection system that can handle various pipe types, sizes, and inspection requirements using a single integrated platform. The robotic system incorporates multiple sensors, adjustable x-ray sources, and versatile positioning capabilities that enable it to perform different inspection tasks, thereby justifying the complexity through enhanced productivity and flexibility.
Solution Approach 2:
The system merges the x-ray source, detector assembly, positioning mechanisms, and image processing capabilities into an integrated robotic inspection system. This consolidation reduces the number of separate components and interfaces that would otherwise be needed, managing system complexity while maintaining high inspection efficiency.
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
This approach enables efficient, automated scanning of elongate structures like pipes, reducing inspection time and cost by combining axial and rotational scan data to accurately characterize inconsistencies without the need for manual operation or external guides.
Implementation Method 1
The scanner is configured to scan the elongate structure utilizing an x-ray beam in the form of a fan beam
Implementation Method 2
x-rays are directed through the pipe from a source on one side of the pipe and detected by a detector on the opposite side of the pipe
Data Source
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AI summary
A method, apparatus, and system for scanning an elongate structure. A scanner (112) in a scanning system (106) is moved axially along the elongate structure (102) using a translating structure (110) in the scanning system (106). The elongate structure (102) is scanned axially using an x-ray beam emitted by the scanner (112) as the scanner moves axially along the elongate structure (102) to perform an axial scan. The x-ray beam has a first orientation. A location on the elongate structure having an inconsistency is detected while scanning the elongate structure axially. The elongate structure (102) is scanned at the location with the x-ray beam in a second orientation.