Multi-Path X-Ray Inspection for High-Pressure Tank Joint Defects
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Solution Overview
Problem
High pressure tanks used in fuel cell vehicles often suffer from deformation due to impurities and voids in the joint portions of structural members, which existing inspection methods, such as X-ray transmission imaging, struggle to accurately detect, leading to reliability issues.
Innovation Solution
An inspection method and apparatus that emit X-ray beams through multiple paths, use multiple position distance measurement and image processing to differentiate between defects in the joint and fin portions, and identify defects with high accuracy by setting inspection regions based on structural member thickness and surface profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If general type X-ray transmission imaging is used to inspect structural members, then the inspection process is simple and fast, but the measurement precision is insufficient to accurately distinguish defects in joint portions from normal fin portions
Solution Approach 1:
The patent divides the inspection process into multiple stages: first capturing an overall X-ray image to identify potential defect regions, then performing localized high-resolution imaging only on those specific regions. This segmentation approach maintains simplicity for routine inspection while enabling high precision when needed, resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The patent introduces a new dimension of inspection by using multiple X-ray sources positioned at different angles and distances. This multi-dimensional approach allows the system to differentiate between fin portions and joint portions with defects, achieving high measurement precision without requiring excessively complex single-point imaging systems.
2Measurement precision
If multiple X-ray emission paths are used to improve defect detection accuracy, then the measurement precision increases, but the loss of time increases due to multiple measurements
Solution Approach 1:
The patent implements a two-stage inspection process where a quick initial X-ray scan identifies potential defect regions, followed by targeted high-resolution imaging only of those specific regions. This segmentation eliminates the need to perform multiple comprehensive measurements on the entire structural member, thereby maintaining high detection accuracy while significantly reducing total inspection time.
Solution Approach 2:
The patent applies partial action by performing complete multi-path X-ray measurements only on regions suspected of containing defects, rather than on the entire structural member. This approach achieves sufficient measurement precision for defect detection while minimizing the time loss associated with exhaustive inspection of all areas.
3Reliability
If thorough inspection of the entire structural member is performed, then the reliability of defect detection improves, but the productivity decreases due to extended inspection time
Solution Approach 1:
The patent segments the inspection process into a rapid initial survey followed by detailed examination only of regions identified as potentially defective. This ensures high reliability for detecting actual defects while maintaining productivity by avoiding unnecessary thorough inspection of all structural members, especially those without defects.
Solution Approach 2:
The system incorporates feedback mechanisms where the results of initial X-ray imaging guide subsequent inspection decisions. Regions showing abnormal characteristics trigger targeted follow-up measurements, while normal regions are quickly cleared. This feedback-driven approach maintains high defect detection reliability while optimizing productivity by adapting inspection intensity to actual needs.
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 high-accuracy inspection and sorting of structural members, reducing the likelihood of deformation and improving the reliability of high pressure tanks by accurately detecting impurities and voids, thereby enhancing the production of fuel cell vehicles.
Implementation Method 1
an X-ray emission means for emitting X-ray beams through two or more paths
Implementation Method 2
one or more X-ray detection means for detecting X-ray beams that have passed through a structural member
Data Source
AI summary
An inspection apparatus and method are described for detecting, with high accuracy, whether a structure contains defects, where the inspection apparatus comprises: an X-ray emitting means (1a, 1b) for emitting X-rays through two or more paths; one or more X-ray detection means (3) for detecting the X-rays passing through the a structure (2); a multiple position distance measurement means (4) for measuring the distance from the X-ray emitting means to the structure at a plurality of positions; and an image processing means (5).