CN114280083B - Detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of linear array camera - Google Patents
Detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of linear array camera Download PDFInfo
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Abstract
The invention discloses a detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of a linear array camera, which is characterized in that the high-speed refreshing and continuous shooting characteristics of the linear array camera are utilized, the problem that the original CNC detection mode of the large-size flat castings in the industrial X-ray nondestructive detection process is low in efficiency is solved, continuous complete surface pictures of the detected large-size flat castings are shot through the linear array camera, the complete surface pictures of the castings are sent to an image processing unit of the linear array camera, the image processing unit of the linear array camera automatically calculates and CNC programs, and a motion control unit receives CNC programs and controls an X-ray detection platform and X-ray acquisition equipment to shoot X-ray pictures and sends the X-ray pictures to an image processing unit. The invention omits the complex operation and long time consumption of CNC programming by operators, can automatically and rapidly finish the industrial X-ray nondestructive testing of large-size flat castings without manual intervention, and greatly improves the detection efficiency.
Description
Technical Field
The invention relates to the technical field of X-ray detection, in particular to a detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of a linear array camera.
Background
The industrial X-ray nondestructive detection is used for detecting that industrial castings are increasingly accepted by casting factories and upstream and downstream clients, and is an efficient method for improving product quality and perfecting quality control. The industrial X-ray nondestructive detection mainly uses the special penetrability of X-rays, an operator controls an X-ray detection mechanism to move and irradiate different parts of the casting on the premise of not damaging the casting, a perspective X-ray image of the casting is obtained, and finally whether the casting has internal quality defects is judged according to the X-ray image.
With the improvement of the product yield, the nondestructive detection method by controlling the motion of the X-ray detection mechanism by an operator greatly limits the detection efficiency. Later, CNC programming is utilized to detect the position, and the motion control unit controls the X-ray detection mechanism to move and acquire X-ray images, so that the detection efficiency of detecting castings with the same model or model in batches is improved to a certain extent.
CNC programmed X-ray nondestructive testing methods require programming a dedicated CNC program in advance for different shaped castings. The operator is required to control the X-ray detection mechanism to move to the detection position, record the detection position, and repeat the operation to complete CNC programming. As the number of casting models or models increases, a great deal of personnel and time are required to compile different CNC programs; the larger the casting size, the longer it takes to program a dedicated CNC program. For large-size flat castings, the time required for one manual CNC programming is even more up to tens of minutes.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides the detection method for realizing industrial X-ray nondestructive detection of the large-size flat casting based on the automatic CNC programming of the linear array camera, which greatly improves the detection efficiency of the large-size flat casting.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
a detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of a linear array camera is characterized by comprising the following steps: adopts a detection system consisting of a linear array camera, a linear array camera image processing unit, a motion control unit, an X-ray acquisition device, an X-ray detection platform and an X-ray image processing unit,
comprises the steps of,
s1, placing a detected large-size flat casting on an industrial X-ray detection platform, and enabling a motion control unit to start to control a linear array camera to move from one side of the detected large-size flat casting to the other side of the detected large-size flat casting according to a preset direction;
s2, synchronously starting to shoot continuous complete surface pictures of the detected large-size flat casting by using the linear array camera;
s3, transmitting the shot pictures to an image processing unit of the linear array camera by the linear array camera, and synthesizing continuous complete surface pictures of the complete large-size flat casting;
s4, the linear camera image processing unit calculates the minimum detection grid of the single detection view according to the coordinate parameter information received from the motion control unit;
s5, automatically identifying all detection areas of the detected large-size flat castings in the complete surface picture by the linear array camera image processing unit, and dividing detection grids on the complete surface picture of the large-size flat castings, wherein each grid corresponds to the position of an X-ray image detection visual field;
s6, the linear array camera image processing unit automatically performs CNC programming according to the divided detection grids, and sends the generated CNC program to the motion control unit;
s7, after the motion control unit receives the CNC program, controlling the X-ray detection platform to move, and informing the X-ray acquisition equipment to capture an X-ray image;
s8, the X-ray acquisition equipment sends the shot X-ray image to an X-ray image processing unit in real time; and an X-ray detection image is displayed on the image processing unit, so that an operator can judge whether the casting has quality defects or not, and detection is completed.
Further, the procedure produced through steps S1-S6 may be directly invoked when repeated inspection of batches of the same model is performed.
Further, in step S5, all the detection grids to be inspected are selected manually, and the linear camera image processing unit automatically performs CNC programming according to the selection result, and sends the programmed program to the motion control unit.
Further, the X-ray detection platform comprises a C-shaped arm used for setting X-ray acquisition equipment, a lifting slide rail used for controlling the C-shaped arm, and a horizontal slide rail used for bearing a workpiece, wherein the symmetrical middle part of the C-shaped arm is arranged on the lifting slide rail, the horizontal slide rail is arranged along the symmetrical central line of the C-shaped arm, and a turntable is arranged on the horizontal slide rail.
Further, the X-ray acquisition equipment comprises an X-ray source generator arranged at one end of the C-shaped arm and a flat panel detector arranged at the other end of the C-shaped arm, the X-ray source generator and the flat panel detector are opposite to each other, and the linear array camera and the X-ray source generator are coaxially arranged in an up-down overlapping mode.
Further, the automatic programming conversion algorithm of step S6 proceeds as follows,
(1) measuring and obtaining the distance from the surface side of the workpiece to the front end surface of an X-ray generator or a linear array camera in X-ray acquisition equipment, and recording the distance as an object distance f; the linear array camera moves at a constant speed in the vertical direction to scan and pick up a large-size flat casting surface picture, and the pixel sizes of the picture are px and py; the focal length of the X-ray acquisition device is known as F;
(2) calculating the side length (mm) of the large-size flat casting surface area corresponding to the effective acquisition imaging field of the X-ray acquisition equipment under the current object distance condition, and recording as the horizontal length L x And vertical length L y ：
Wherein: r is the proportion of the tower joint area required by X-ray multi-image detection; l (L) 0x And l 0y The horizontal and vertical dimensions (mm) of the sensor of the X-ray acquisition device, respectively;
L x 、L y namely, large-size leveling corresponding to a single detection grid in CNC programmingActual side length (mm) of the casting single detection area;
(3) the known effective (maximum) scanning imaging view angle alpha of the linear array camera is determined by a linear array camera sensor and parameters, and once the parameters of the linear array camera sensor are fixed, the angle alpha is a known fixed value; the side length (mm) of the effective scanning imaging window of the linear array camera is recorded as the horizontal length l 1x And vertical length l 1y (Linear array camera vertical travel distance l) 1y The size of the large-size flat casting surface picture shot by the linear array camera is known as p x 、p y The method comprises the steps of carrying out a first treatment on the surface of the Calculating a pixel-to-length (mm) conversion coefficient gamma x And gamma y ：
(4) Calculating the pixel size G of the minimum unit grid marked on the large-size flat casting picture obtained by scanning the linear array camera x 、G y ：
G x ＝L x ×γ x
G y ＝L y ×γ y
(5) The upper left corner of the large-size flat casting surface picture shot by the linear array camera is taken as the origin (0, 0) of a pixel coordinate system, and the middle pixel coordinate (x org ，y org ) The motion coordinate system origin corresponds to the actual detection platform; center point pixel coordinates (x) of a single grid on a large-size flat casting surface picture i ，y i ) Relative to the origin pixel coordinates (x org ，y org ) The offset of the X-ray detection platform in the actual motion coordinate system; according to the mapping relation between the pixel coordinate system and the actual motion coordinate system, calculating motor motion parameters of the motion position of a single CNC point in CNC programming(horizontal direction motion parameter D) x(i) And the motion parameter D in the vertical direction y(i) )：
Wherein k is x Is the conversion factor k of the motor moving in the horizontal direction y Is a conversion factor of the vertical direction motion motor;
(6) when CNC programming is performed to detect all grids, CNC programming is automatically generated in sequence, and the motor motion parameters D of the next adjacent grid are rapidly calculated according to the actual field size of the grids x(i+1) And D y(i+1) ：
D x(i+1) ＝D x(i) +L x ×k x
D y(i+1) ＝D y(i) +L y ×k y
The beneficial effects of the invention include: the complex operation and long time consumption of CNC programming by operators are omitted, industrial X-ray nondestructive testing of large-size flat castings can be automatically and rapidly completed without manual intervention, and the detection efficiency is greatly improved.
Drawings
FIG. 1 is a flow chart of the present invention;
FIG. 2 is a block diagram of the system architecture of the present invention;
fig. 3 is a schematic structural view of a detection apparatus according to an embodiment of the present invention.
Detailed Description
The invention will be described in further detail with reference to specific embodiments and drawings.
The invention discloses a detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of a linear array camera, which is shown in figures 1-3.
The linear array camera is a CCD or CMOS sensor camera which is formed by linearly arranging a single row or a plurality of rows, has the characteristics of continuously shooting an ultra-long object, high scanning frequency and high resolution, and can shoot continuous complete surface pictures of an ultra-large object.
The machine vision technology is that a machine vision product (namely an image pickup device, which is divided into CMOS, CCD and the like) is used for capturing a target image, the image is transmitted to a processing unit, the image is digitally analyzed and processed, the size, the shape, the color and the like are judged through pixel distribution, brightness conversion and the like, and then the action of a field device is controlled according to a judging result.
The CNC programming is to combine the computer with the numerical control directly, complete the numerical calculation by the computer, send out the control command directly to participate in the control process, compile and save a series of point location coordinates to form the CNC program. By executing the programmed CNC program, the position can be accurately and rapidly moved, and the control efficiency is improved.
The X-ray detection system structure of the invention is formed by connecting a linear array camera, a linear array camera image processing unit, a motion control unit, X-ray acquisition equipment, an X-ray detection platform (comprising a C-shaped arm) and an X-ray image processing unit.
The X-ray detection platform comprises a C-shaped arm used for setting X-ray acquisition equipment, a lifting slide rail used for controlling the C-shaped arm, and a horizontal slide rail used for bearing a workpiece, wherein the symmetrical middle part of the C-shaped arm is arranged on the lifting slide rail, the horizontal slide rail is arranged along the symmetrical central line of the C-shaped arm, and a turntable is arranged on the horizontal slide rail.
The X-ray acquisition equipment comprises an X-ray source generator arranged at one end of the C-shaped arm and a flat panel detector arranged at the other end of the C-shaped arm, and the X-ray source generator and the flat panel detector are opposite to each other. The preferred embodiment of the present invention is as shown in fig. 3: the linear array camera 1 and an X-ray source generator of the X-ray acquisition equipment 2 are coaxially and fixedly arranged in an up-down overlapping manner and are opposite to a flat panel detector of the X-ray acquisition equipment 2; the X-ray acquisition equipment is integrally fixed on the vertical movement detection C-shaped arm 3; the large-size flat casting to be inspected is placed on the central X-ray detection platform 4.
After the detection starts, the X-ray detection platform moves at a constant speed from top to bottom under the control of the motion control unit instruction; meanwhile, the linear array camera starts to work, a complete surface image of the large-size flat casting to be detected in the center of the X-ray detection platform is shot, and the shot image is sent to the linear array camera image processing unit;
the linear array camera image processing unit receives the motion parameters and the X-ray detection platform coordinate information transmitted by the picture and motion control unit; the linear array camera image processing unit automatically identifies the surface area of the detected large-size flat casting from the picture, automatically calculates the detection grid of the minimum detection view field of the X-ray acquisition equipment according to the motion parameters and the coordinate information, and marks and displays all the detection grids on the complete surface image of the large-size flat casting; the linear array camera image processing unit generates CNC programs according to automatic CNC programming of the detection grids;
the linear array camera image processing unit sends the CNC program to the motion control unit, and the motion control unit controls the X-ray detection platform to move and the X-ray acquisition equipment to capture an X-ray image according to the motion parameters recorded by the CNC program; the X-ray acquisition equipment transmits the X-ray image to the X-ray image processing unit, and an operator checks and judges the detection result of the X-ray image.
In an intelligent automatic mode, the linear array camera image processing system takes an automatic identification result of a large-size flat casting surface image as a detection area, and generates a CNC program by automatic CNC programming;
in the manual intervention mode, an operator selects all detection grids to be detected according to the detection technical requirement, confirms submission, and automatically generates a CNC program according to the selection result by the linear array camera image processing unit.
The CNC automatic programming conversion algorithm process is as follows,
(1) measuring and obtaining the distance from the surface side of the workpiece to the front end surface of an X-ray generator or a linear array camera in X-ray acquisition equipment, and recording the distance as an object distance f; the linear array camera moves at a constant speed in the vertical direction to scan and pick up a large-size flat casting surface picture, and the pixel sizes of the picture are px and py; the focal length of the X-ray acquisition device is known as F;
(2) calculating the side length (mm) of the large-size flat casting surface area corresponding to the effective acquisition imaging field of the X-ray acquisition equipment under the current object distance condition, and recording as waterFlat length L x And vertical length L y ：
Wherein: r is the proportion of the tower joint area required by X-ray multi-image detection; l (L) 0x And l 0y The horizontal and vertical dimensions (mm) of the sensor of the X-ray acquisition device, respectively;
L x 、L y the actual side length (mm) of a single detection area of the large-size flat casting corresponding to the single detection grid in CNC programming is obtained;
(3) the known effective (maximum) scanning imaging view angle alpha of the linear array camera is determined by a linear array camera sensor and parameters, and once the parameters of the linear array camera sensor are fixed, the angle alpha is a known fixed value; the side length (mm) of the effective scanning imaging window of the linear array camera is recorded as the horizontal length l 1x And vertical length l 1y (Linear array camera vertical travel distance l) 1y The size of the large-size flat casting surface picture shot by the linear array camera is known as p x 、p y The method comprises the steps of carrying out a first treatment on the surface of the Calculating a pixel-to-length (mm) conversion coefficient gamma x And gamma y ：
(4) Calculating the pixel size G of the minimum unit grid marked on the large-size flat casting picture obtained by scanning the linear array camera x 、G y ：
G x ＝L x ×γ x
G y ＝L y ×γ y
(5) The upper left corner of the large-size flat casting surface picture shot by the linear array camera is taken as the origin (0, 0) of a pixel coordinate system, and the middle pixel coordinate (x org ，y org ) The motion coordinate system origin corresponds to the actual detection platform; center point pixel coordinates (x) of a single grid on a large-size flat casting surface picture i ，y i ) Relative to the origin pixel coordinates (x org ，y org ) The offset of the X-ray detection platform in the actual motion coordinate system; according to the mapping relation between the pixel coordinate system and the actual motion coordinate system, calculating the motor motion parameter (horizontal direction motion parameter D) of the motion position of a single CNC point in CNC programming x(i) And the motion parameter D in the vertical direction y(i) )：
Wherein k is x Is the conversion factor k of the motor moving in the horizontal direction y Is a conversion factor of the vertical direction motion motor;
(6) when CNC programming is performed to detect all grids, CNC programming is automatically generated in sequence, and the motor motion parameters D of the next adjacent grid are rapidly calculated according to the actual field size of the grids x(i+1) And D y(i+1) ：
D x(i+1) ＝D x(i) +L x ×k x
D y(i+1) ＝D y(i) +L y ×k y
The invention has the advantages that:
1. dividing a detection area grid according to the complete surface picture of the large-size flat casting, and automatically performing CNC programming; the whole CNC programming process is completed by the linear array camera image processing unit, only 1s is needed, and no waiting of operators is needed. When detecting large-size flat castings, the whole CNC programming time is shortened to be within 5s from tens of minutes, and the detection efficiency is greatly improved.
2. The linear array camera efficiently captures the complete surface picture of the large-size flat casting; 2 m.1.5 m castings can be completely taken within 3s, and the obtained large-size flat castings are visual in complete surface pictures.
3. The full-surface picture of the large-size flat casting can prompt grids on the picture corresponding to the current detection part in real time in the whole X-ray detection process, and is visual.
The foregoing has described in detail the technical solutions provided by the embodiments of the present invention, and specific examples have been applied to illustrate the principles and implementations of the embodiments of the present invention, where the above description of the embodiments is only suitable for helping to understand the principles of the embodiments of the present invention; meanwhile, as for those skilled in the art, according to the embodiments of the present invention, there are variations in the specific embodiments and the application scope, and the present description should not be construed as limiting the present invention.
Claims (5)
1. A detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of a linear array camera is characterized by comprising the following steps: adopts a detection system consisting of a linear array camera, a linear array camera image processing unit, a motion control unit, an X-ray acquisition device, an X-ray detection platform and an X-ray image processing unit,
comprises the steps of,
s1, placing a detected large-size flat casting on an industrial X-ray detection platform, and enabling a motion control unit to start to control a linear array camera to move from one side of the detected large-size flat casting to the other side of the detected large-size flat casting according to a preset direction;
s2, synchronously starting to shoot continuous complete surface pictures of the detected large-size flat casting by using the linear array camera;
s3, transmitting the shot pictures to an image processing unit of the linear array camera by the linear array camera, and synthesizing continuous complete surface pictures of the complete large-size flat casting;
s4, the linear camera image processing unit calculates the minimum detection grid of the single detection view according to the coordinate parameter information received from the motion control unit;
s5, automatically identifying all detection areas of the detected large-size flat castings in the complete surface picture by the linear array camera image processing unit, and dividing detection grids on the complete surface picture of the large-size flat castings, wherein each grid corresponds to the position of an X-ray image detection visual field;
s6, the linear array camera image processing unit automatically performs CNC programming according to the divided detection grids, and sends the generated CNC program to the motion control unit; the automatic programming conversion algorithm is processed as follows,
(1) measuring and obtaining the distance from the surface side of the workpiece to the front end surface of an X-ray generator or a linear array camera in X-ray acquisition equipment, and recording the distance as an object distance f; the linear array camera moves at a constant speed in the vertical direction to scan and pick up a large-size flat casting surface picture, and the pixel sizes of the picture are px and py; the focal length of the X-ray acquisition device is known as F;
(2) calculating the side length of the large-size flat casting surface area corresponding to the effective acquisition imaging field of the X-ray acquisition equipment under the current object distance condition, and marking the side length as the horizontal length L x And vertical length L y ：
Wherein: r is the proportion of the tower joint area required by X-ray multi-image detection; l (L) 0x And l 0y The horizontal dimension and the vertical dimension of the sensor of the X-ray acquisition equipment are respectively;
L x 、L y the actual side length of a single detection area of the large-size flat casting corresponding to the single detection grid in CNC programming is obtained;
(3) the known effective scanning imaging view angle alpha of the linear array camera is determined by a linear array camera sensor and parameters, and once the parameters of the linear array camera sensor are fixed, the angle alpha is a known fixed value; the side length of the effective scanning imaging window of the linear array camera is recorded as the horizontal length l 1x And vertical length l 1y The size of the picture of the surface of the large-size flat casting taken by the linear array camera is known as p x 、p y The method comprises the steps of carrying out a first treatment on the surface of the Calculating the pixel-to-length conversion coefficient gamma x And gamma y ：
(4) Calculating the pixel size G of the minimum unit grid marked on the large-size flat casting picture obtained by scanning the linear array camera x 、G y ：
G x ＝L x ×γ x
G y ＝L y ×γ y
(5) The upper left corner of the large-size flat casting surface picture shot by the linear array camera is taken as the origin (0, 0) of a pixel coordinate system, and the middle pixel coordinate (x org ，y org ) The motion coordinate system origin corresponds to the actual detection platform; center point pixel coordinates (x) of a single grid on a large-size flat casting surface picture i ，y i ) Relative to the origin pixel coordinates (x org ，y org ) The offset of the X-ray detection platform in the actual motion coordinate system; according to the mapping relation between the pixel coordinate system and the actual motion coordinate system, calculating motor motion parameters of the motion position of a single CNC point in CNC programming, and calculating a horizontal direction motion parameter D x(i) And the motion parameter D in the vertical direction y(i) ：
Wherein k is x Is the conversion factor k of the motor moving in the horizontal direction y Is a conversion factor of the vertical direction motion motor;
(6) when CNC programming is performed to detect all grids, CNC programming is automatically generated in sequence, and the motor motion parameters D of the next adjacent grid are rapidly calculated according to the actual field size of the grids x(i+1) And D y(i+1) ：
D x(i+1 )＝D x(i) +L x ×k x
D y(i+1) ＝D y(i) +L y ×k y ；
S7, after the motion control unit receives the CNC program, controlling the X-ray detection platform to move, and informing the X-ray acquisition equipment to capture an X-ray image;
s8, the X-ray acquisition equipment sends the shot X-ray image to an X-ray image processing unit in real time; and an X-ray detection image is displayed on the image processing unit, so that an operator can judge whether the casting has quality defects or not, and detection is completed.
2. The detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of linear array cameras according to claim 1, which is characterized by comprising the following steps of: when the castings of the same model batch are repeatedly detected, the program produced through the steps S1-S6 is directly called.
3. The detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of linear array cameras according to claim 1, which is characterized by comprising the following steps of: in step S5, instead of manually selecting all the detection grids to be inspected, the linear camera image processing unit automatically performs CNC programming according to the selection result, and sends the programmed program to the motion control unit.
4. The detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of linear array cameras according to claim 1, which is characterized by comprising the following steps of: the X-ray detection platform comprises a C-shaped arm used for setting X-ray acquisition equipment, a lifting slide rail used for controlling the C-shaped arm, and a horizontal slide rail used for bearing a workpiece, wherein the symmetrical middle part of the C-shaped arm is arranged on the lifting slide rail, the horizontal slide rail is arranged along the symmetrical central line of the C-shaped arm, and a turntable is arranged on the horizontal slide rail.
5. The detection method for realizing industrial X-ray nondestructive detection of large-size flat castings based on automatic CNC programming of linear array cameras according to claim 4, wherein the detection method is characterized by comprising the following steps of: the X-ray acquisition equipment comprises an X-ray source generator arranged at one end of the C-shaped arm and a flat panel detector arranged at the other end of the C-shaped arm, wherein the X-ray source generator and the flat panel detector are opposite to each other, and the linear array camera and the X-ray source generator are coaxially arranged in an up-down overlapping mode.
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