X-ray Testpiece Alignment via Mechanical Manipulator
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Solution Overview
Problem
Current methods for automatic defect recognition in testpieces using X-ray examination often result in incorrect detections due to inaccuracies in positioning, which cannot be fully corrected by existing image processing techniques, leading to a high number of false positives.
Innovation Solution
The method involves calculating the precise axis of rotation, angle of rotation, and displacement vector to align the positioning image with the reference image and relaying these values to a mechanical manipulator to achieve accurate positioning within the X-ray examination unit, allowing for a direct comparison without image conversion, thereby reducing incorrect detections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If image processing methods (distinctive points matching or pixel-by-pixel correction) are used to correct positioning inaccuracies, then some degree of alignment correction can be achieved, but incorrect detections still occur due to residual deviations
Solution Approach 1:
The patent replaces image processing correction methods with a mechanical positioning system. A mechanical manipulator adjusts the physical position of the testpiece based on calculated deviation values (rotation axis, rotation angle, displacement vector) derived from comparing the positioning image with the reference image. This mechanical adjustment achieves superior alignment precision compared to post-processing image correction, thereby eliminating incorrect detections while maintaining high defect recognition accuracy.
2Device complexity
If only three degrees of freedom are corrected using distinctive points matching, then computation is simpler, but alignment accuracy is insufficient for points other than the distinctive points
Solution Approach 1:
The patent extends the correction capability from only three degrees of freedom (two translations and one rotation) to six degrees of freedom by incorporating two additional rotational corrections. The mechanical manipulator can execute complex positioning adjustments including rotation about the beam axis and rotation about a perpendicular axis, enabling universal alignment correction for the entire testpiece surface, not just at distinctive points. This comprehensive correction achieves uniform high precision across all regions.
3Measurement precision
If pixel-by-pixel correction through similarity transformation is performed, then correction is applied over the whole comparison image, but a great deal of computation is required and deviations still occur
Solution Approach 1:
The patent performs alignment correction in advance by mechanically repositioning the testpiece before the X-ray examination. The system calculates the required positioning adjustments (rotation axis, rotation angle, displacement vector) from the positioning image comparison, then the mechanical manipulator executes these corrections physically. This preliminary mechanical correction eliminates the need for time-consuming pixel-by-pixel image transformation during defect analysis, significantly reducing processing time while achieving superior alignment precision.
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 significantly reduces incorrect detections by ensuring almost 100% congruence between the comparison image and the reference image, enabling more reliable defect recognition with minimal false positives.
Implementation Method 1
an X-ray examination unit with an X-ray tube, a detector
Data Source
AI summary
A method for automatic defect recognition in testpieces by means of an X-ray examination unit having a mechanical manipulator for positioning the testpiece in a beam path of the X-ray examination unit, wherein a positioning image of the testpiece is compared with an ideal reference image. An axis of rotation, an angle of rotation and a displacement vector are calculated in order to arrive at an exact congruence of the positioning image of the testpiece with the ideal reference image. The values of the axis of rotation, angle of rotation and displacement vector are then relayed to the mechanical manipulator and the latter then transfers the testpiece into the position corresponding to these values.