X-Ray Weld Imaging With Variable Angles for 3D Defect Resolution
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Solution Overview
Problem
Conventional x-ray weld inspection methods struggle to provide a detailed understanding of internal weld structures, especially when internal access is difficult or when defects are oriented in a way that makes them difficult to observe using 2D radiographic imaging.
Innovation Solution
The method involves imaging weld sections multiple times with different x-ray angles of incidence, using a system where the x-ray source and detector are independently movable, allowing for a more comprehensive understanding of the weld's internal structure by capturing multiple imaging data sets with varying angles of incidence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional 2D radiographic imaging is used, then the inspection process is simple and fast, but the depth resolution and detailed understanding of internal weld structures are insufficient
Solution Approach 1:
The patent transitions from 2D radiographic imaging to 3D tomographic imaging by introducing angular variation. The x-ray source and detector are moved along an arc trajectory to capture images from multiple angles, enabling depth resolution and three-dimensional reconstruction of weld structures. This dimensional change allows differentiation of defects at different depths within the weld.
Solution Approach 2:
The imaging system employs dynamic movement of the x-ray source and detector along an arc path. The source and detector are positioned on rotating or translating mechanisms that enable continuous angular adjustment during the inspection process. This dynamic positioning allows the system to capture projections from multiple angles, which are then reconstructed into 3D images of the weld interior.
2Loss of information
If multiple imaging data sets with different angles are captured, then the understanding of weld internal structure is enhanced, but the inspection time increases
Solution Approach 1:
The system implements periodic angular sampling during the inspection process. The x-ray source and detector rotate or translate through a predetermined angular range, capturing images at regularly spaced intervals. This periodic action ensures comprehensive coverage of the weld structure while maintaining a controlled number of measurement points, balancing information completeness with inspection duration.
Solution Approach 2:
The inspection process maintains continuous useful action by moving the x-ray source and detector along a smooth arc trajectory without interruption. The system continuously captures projection data throughout the angular range, ensuring no information gaps. This continuous scanning approach maximizes information acquisition efficiency while minimizing idle time between measurements.
3Measurement precision
If internal access to the pipeline is obtained for inspection, then the quality of weld inspection is improved, but the ease of operation is reduced due to difficult access requirements
Solution Approach 1:
The patent inverts the conventional inspection approach by moving the x-ray source and detector to the external side of the pipeline rather than requiring internal access. The imaging system is positioned outside the pipeline, and x-rays are directed through the pipeline wall to capture images of the weld from the external side. This inversion eliminates the need for pipeline shutdown, internal access, or complex positioning inside the pipeline while maintaining high inspection quality.
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 enhances the depth resolution and overall understanding of the weld, enabling the creation of more detailed and accurate images, including 3D representations, which can be crucial for identifying defects and ensuring weld integrity.
Implementation Method 1
Conventionally, such welds have been inspected by using a high strength, broad beam radioactive source, such as an x-ray or gamma-ray source
Implementation Method 2
expose an x-ray sensitive film plate on the opposite side of the pipeline to the x-ray source, for example... Using semiconductor detector substrates in x-ray imaging provides benefits in that digital processing of x-ray images is faster and more versatile, and the detector substrates are more sensitive to incoming high-energy photons than film
Data Source
AI summary
An x-ray weld inspection apparatus comprising: at least one x-ray source attached on a first mounting and at least one x-ray detector attached on a second mounting; a motor arrangement configured to move, using the first and second mountings, respectively, the at least one x-ray source and the at least one x-ray detector substantially along a weld; and a control device comprising memory and at least one processing core, configured to: control the motor arrangement to move the at least one x-ray source and the at least one x-ray detector during an x-ray weld scan substantially along the direction of the weld; compile image data from the at least one x-ray detector into an image; and reconstruct at least one part of the image based on additional position information estimated from image data.