JP2007240342A - Flaw detection apparatus and method - Google Patents

Abstract

An object of the present invention is to obtain flaw detection inspection data with good workability and reproducibility with high accuracy even when flaw detection is performed on an inspection object having a complicated shape.
An image processing unit (19) measures image data of an inspection object (11) and scanning trajectory data of a flaw detection part (12) flaw-scanned on the inspection object (11) with a predetermined fixed point (A) as a reference point. Calculates the three-dimensional shape data of the inspection object and the scanning trajectory data of the flaw detection unit 12 on the three-dimensional shape data based on the measured image data, and the coordinate correction unit 21 stores the past data stored in the storage unit 20. The coordinate deviation from the three-dimensional shape data of the inspection object 11 is corrected, the three-dimensional shape data of the current inspection object is made to coincide with the coordinates of the three-dimensional shape data of the past inspection object, and the past is displayed on the display device 22. The scanning trajectory data of the flaw detection part is displayed as a guide.
[Selection] Figure 1

Description

  The present invention relates to a flaw detection inspection apparatus and method for flaw detection of inspection objects having complicated shapes.

  There are various complicated shapes of components such as thermal power generation facilities and hydroelectric power generation facilities. For example, the turbine blade shape of a thermal power generation facility and the vane shape of a hydroelectric generation facility have a hydrodynamically efficient shape, and the elbow part of the pipe has a curved surface shape, and further, the vicinity of the boiler Some have a unique curved shape, such as a burner ring. For these facilities, there is a need to accurately evaluate the soundness by a technique such as non-destructive inspection, but at present, the work of flaw detection inspection is performed manually, and there is a problem in inspection accuracy.

As an ultrasonic flaw detection method for a defect portion of a three-dimensional inspection object having a complex free-form surface, the shape of the inspection object and the position and orientation size of the defect portion are displayed in a three-dimensional image, and the defect portion is accurate. There is one that can determine the measurement and coping method (see, for example, Patent Document 1).
JP-A-6-102258

  However, in Patent Document 1, since the shape of the inspection object and the position and orientation size of the defect portion are displayed in a three-dimensional image, it is possible to accurately measure the defect portion. The time is not taken into consideration for flaw detection.

  In thermal power generation facilities and hydroelectric power generation facilities, inspection objects are flaw-detected regularly or irregularly. In that case, the flaw detection part is scanned with respect to the same location of the same test target object, and the soundness of a test target object is evaluated compared with the past flaw detection test data. Therefore, if the part scanned at the flaw detection part is different, comparison with the past flaw detection inspection data is not appropriate, so the part scanned at the flaw detection part must be the same part.

  Conventionally, since flaw detection inspection is performed manually on the same part of the same inspection object, workability is poor, and when the inspection object has a complicated shape, scanning is performed at the flaw detection section. It is difficult to make the same place, and reproducibility is poor. Therefore, the accuracy of the obtained flaw detection inspection data is also low.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a flaw detection inspection apparatus and method capable of obtaining flaw detection inspection data with good workability and reproducibility with high accuracy even when flaw detection is performed on an inspection object having a complicated shape. Is to provide.

  The flaw detection inspection apparatus according to the invention of claim 1 is a sensor unit for measuring image data of an inspection object with respect to a predetermined fixed point as a reference point, and scanning trajectory data of a flaw detection part scanned on the inspection object; Based on the image data measured by the sensor unit, the image processing unit calculates the three-dimensional shape data of the inspection object and the scanning trajectory data of the flaw detection unit on the three-dimensional shape data, and is calculated by the image processing unit. Further, a storage unit for storing the three-dimensional shape data of the inspection object and scanning trajectory data of the flaw detection unit on the three-dimensional shape data, and the three-dimensional shape data of the current inspection object obtained by the image processing unit And the coordinate deviation of the 3D shape data of the past inspection object stored in the storage unit is corrected, and the 3D shape data of the current inspection object is changed to the coordinates of the 3D shape data of the past inspection object. one A coordinate correction unit to be displayed, and the three-dimensional shape data of the current inspection object is displayed in accordance with the coordinates corrected by the coordinate correction unit, and the past flaw detection stored in the storage unit on the three-dimensional shape data And a display device for guiding and displaying the scanning trajectory data of the part.

  The flaw detection inspection apparatus according to the invention of claim 2 is a sensor unit that measures image data of an inspection object with respect to a predetermined fixed point as a reference point, and scanning trajectory data of a flaw detection part scanned on the inspection object. Based on the image data measured by the sensor unit, the image processing unit calculates the three-dimensional shape data of the inspection object and the scanning trajectory data of the flaw detection unit on the three-dimensional shape data, and is calculated by the image processing unit. Further, a storage unit for storing the three-dimensional shape data of the inspection object and scanning trajectory data of the flaw detection unit on the three-dimensional shape data, and the three-dimensional shape data of the current inspection object obtained by the image processing unit And the coordinate deviation of the 3D shape data of the past inspection object stored in the storage unit is corrected, and the 3D shape data of the current inspection object is changed to the coordinates of the 3D shape data of the past inspection object. one And a scanning drive unit that scans the flaw detection unit according to the past scan trajectory data of the flaw detection unit stored in the storage unit on the three-dimensional shape data matched with the coordinates corrected by the coordinate correction unit It is characterized by comprising.

  The flaw detection inspection method according to the invention of claim 3 measures the image data of the inspection object and the scanning trajectory data of the flaw detection part scanned on the inspection object using a predetermined fixed point as a reference point, and the measured image 3D shape data of the inspection object and scanning trajectory data of the flaw detection part on the 3D shape data are calculated based on the data, and the calculated 3D shape data of the inspection object and the 3D shape data thereof are calculated. The scanning trajectory data of the flaw detection part above is stored, and if there is a deviation in the coordinates between the current 3D shape data of the inspection object and the stored 3D shape data of the past inspection object, the deviation is corrected. When the 3D shape data of the current inspection object is matched with the coordinates of the 3D shape data of the past inspection object, and the 3D shape data of the current inspection object is displayed by matching the corrected coordinates. Characterized in that it also guides display the scanning locus data of the past inspection unit in its three-dimensional shape data.

  The flaw detection inspection method according to the invention of claim 4 measures the image data of the inspection object and the scanning trajectory data of the flaw detection part scanned on the inspection object using a predetermined fixed point as a reference point, and the measured image 3D shape data of the inspection object and scanning trajectory data of the flaw detection part on the 3D shape data are calculated based on the data, and the calculated 3D shape data of the inspection object and the 3D shape data thereof are calculated. The scanning trajectory data of the flaw detection part above is stored, and if there is a deviation in the coordinates between the current 3D shape data of the inspection object and the stored 3D shape data of the past inspection object, the deviation is corrected. Then, the past flaw detection unit stored on the three-dimensional shape data in which the three-dimensional shape data of the current inspection object is matched with the coordinates of the past three-dimensional shape data of the inspection object Running Characterized by scanning the inspection unit in accordance with the trajectory data.

  According to the present invention, the three-dimensional shape data of the current inspection object is corrected by correcting the shift in coordinates between the three-dimensional shape data of the current inspection object and the three-dimensional shape data of the past inspection object, and the three-dimensional shape data of the current inspection object is converted to the past inspection. Matching the coordinates of the three-dimensional shape data of the object and guiding and displaying the scanning trajectory data of the past flaw detection part on the three-dimensional shape data, thereby improving the workability and reproducibility and improving the accuracy of the flaw detection data. . Further, when the flaw detection part is automatically scanned in accordance with the scan flaw data of the past flaw detection part instead of the guidance display of the scan flaw data of the past flaw detection part, the workability is further improved.

(First embodiment)
FIG. 1 is a block diagram of the flaw detection apparatus according to the first embodiment of the present invention. The inspection object 11 is a facility having a unique curved surface shape, and the flaw detection unit 12 performs flaw detection scanning on the inspection object 11 on the inspection object 11. The flaw detection unit 12 is supported by the link unit 13, and the flaw detection part of the inspection object 11 is flaw-scanned by driving the link unit 13 by the scanning mechanism unit 14. The flaw detection part 12 is various nondestructive inspection apparatuses, such as an ultrasonic probe, for example.

  Similarly, the sensor unit 15 is supported by the link unit 16, and the scanning mechanism unit 17 drives the link unit 16 to scan the surrounding space of the inspection object 11, and the image data of the inspection object 11 and the inspection object 11 are scanned. Scanning trajectory data of the flaw detection unit 12 that has been subjected to flaw detection scanning is measured. The sensor unit 15 is a sensor using, for example, a laser or a CCD camera.

  The scanning mechanism unit 17 of the sensor unit 15 is installed at a predetermined fixed point A, and moves the sensor unit 15 to measure image data of the inspection object 11 from a plurality of angular positions. The reason why the image data of the inspection object 11 is obtained from a plurality of angular positions is to obtain the three-dimensional shape data of the inspection object 11 by the image processing unit 19 of the arithmetic processing unit 18 described later.

In FIG. 1, image data is measured from a plurality of angular positions by moving one sensor unit 15. However, a plurality of sensor units 15 are provided, and image data at a plurality of angular positions are provided from the plurality of sensor units 15. May be obtained.

  Image data at a plurality of angular positions measured by the sensor unit 15 is input to the image processing unit 19 of the arithmetic processing device 18. The arithmetic processing unit 18 is a personal computer, for example. The image processing unit 19 calculates the three-dimensional shape data of the inspection object 11 and the scanning trajectory data of the flaw detection unit 12 on the three-dimensional shape data based on the image data at a plurality of angular positions measured by the sensor unit 15. Then, the storage unit 20 stores the three-dimensional shape data of the inspection object 11 and the scanning trajectory data of the flaw detection unit 12 on the three-dimensional shape data, which are the calculation results.

  Although not shown, the flaw detection inspection data measured by the flaw detection unit 12 may be stored in the storage unit 20 of the arithmetic processing unit 18 together with the scanning trajectory data of the flaw detection unit 12. The soundness of the inspection object 11 is evaluated based on the flaw detection data.

  Next, the coordinate correction unit 21 obtains the coordinates of the current three-dimensional shape data of the inspection object 11 obtained by the image processing unit 19 and the past three-dimensional shape data of the inspection object 11 stored in the storage unit 20. This correction corrects the deviation, and by this correction, the 3D shape data of the current inspection object 11 is made to coincide with the coordinates of the 3D shape data of the past inspection object 11, and 3 of the corrected current inspection object 3 is corrected. The dimensional shape data is output to the display device 22.

  The display device 22 displays the three-dimensional shape data of the current inspection object 11 in accordance with the coordinates corrected by the coordinate correction unit 21 and the past stored in the storage unit 20 on the three-dimensional shape data. The scanning trajectory data of the flaw detection section 11 is displayed as a guide. Thereby, the flaw detection part 12 can be flaw-scanned with respect to the same location of the same inspection object, and the reproducibility of flaw detection scan of the flaw detection part 12 can be improved.

  Next, correction of coordinates in the coordinate correction unit 21 will be described. When scanning the flaw detection unit 12 with respect to the same part of the same inspection object at regular intervals as in the regular inspection, the scanning mechanism unit 17 of the sensor unit 15 is installed at a predetermined fixed point A. It is difficult to install the scanning mechanism unit 17 of the sensor unit 15 so as to be completely coincident with the fixed point A. Even when the scanning mechanism 17 of the sensor unit 15 is completely aligned with the fixed point A, the position of the inspection object 11 is shifted, or the position of the fixed point A itself is shifted. . In such a case, a deviation occurs between the relative position between the sensor unit 15 and the inspection object 11 measured in the past and the current relative position between the sensor unit 15 and the inspection object 11.

  The coordinate correction unit 21 detects and corrects this deviation, and matches the current 3D shape data of the inspection object 11 with the coordinates of the 3D shape data of the past inspection object 11. Detection of a relative position shift between the sensor unit 15 and the inspection object 11 is detected by vector rotation and vector translation.

Now, in order to simplify the description, the rotation of a vector in two-dimensional coordinates will be described. FIG. 2 is an explanatory diagram of vector rotation. As shown in FIG. 2, with respect to a vector P ′ (P _x ′, P _y ′) indicating a relative position between the past sensor unit 15 and the inspection object 11, the current sensor unit 15 and the inspection object 11 are Assume that the relative position is a vector P (P _x , P _y ) rotated by an angle φ around the origin 0. In this case, the relationship shown in the equation (1) is established.

When the relationship of the expression (1) is expressed by a matrix, the expression (2) is obtained. In the equation (2), Rot (φ) is a rotation matrix.

To obtain a vector P ′ (P _x ′, P _y ′) obtained by rotating the vector P (P _x , P _y ) around the origin by an angle φ, the rotation matrix Rot (φ) can be multiplied from the left side of the vector P. It will be good. The rotation matrix Rot (φ) is obtained when the angle φ is obtained.

Next, the angle φ is obtained as follows. FIG. 3 is an explanatory diagram of the link unit 16 of the sensor unit 15. As shown in FIG. 3, it is assumed that the link portion 16 of the sensor portion 15 includes three links 23a, 23b, and 23c. The length of the link 23a is l ₁ , the length of the link 23b is l ₂ , the length of the link 23c is l ₃ , the angle formed by the link 23a and x is φ ₁ , and the angle formed by the link 23a and the link 23b is φ _2, when the angle formed between the links 23b and the link 23c and phi _3, (3) expression holds.

Since the length l _{1 of} the link 23a, the length l _{2 of} the link 23b, and the length l ₃ of the link 23c are known, the angle φ ₁ formed by the link 23a and x, and the angle φ formed by the link 23a and the link 23b _{2. In order} to obtain the angle φ ₃ formed by the link 23b and the link 23c, x and y in the expression (3) may be measured at three different positions of the inspection object 11. For example, x and y between the sensor unit 15 and the upper right end, lower right end, and upper left end of the inspection object 11 are measured, a simultaneous equation is established, and an angle φ ₁ formed by the link 23a and x, An angle φ ₂ formed by the link 23a and the link 23b and an angle φ ₃ formed by the link 23b and the link 23c are obtained. Then, by substituting these angles φ ₁ , φ ₂ , and φ ₃ into the equation (2), a vector P ′ (P _x ′, P _y ′) indicating the relative position between the past sensor unit 15 and the inspection object 11 is obtained. Match.

In the above description, rotation of a vector with two-dimensional coordinates has been described. However, the same idea can be obtained for rotation of a vector with three-dimensional coordinates. In the case of a three-dimensional vector, a rotation matrix Rot (x, φ), Rot (y, φ), Rot (z, φ) that rotates around the x-axis, y-axis, and z-axis by an angle φ is used. The rotation matrix Rot (x, φ), Rot (y, φ), and Rot (z, φ) are expressed by the equation (4).

It is also possible to correct coordinates by taking into account not only vector rotation but also vector translation. The translation of the vector P is expressed by equation (5).

That is, assuming that a vector that is translated by l _x , l _y , and l _z in the x-axis, y-axis, and z-axis directions is l, the vector P ′ represents the vector P in three-dimensional coordinates, and the x-axis, y-axis, z It is a vector when translated in the axial direction by l _x , l _y , and l _z , respectively. It is also possible to correct the coordinates in consideration of this vector l.

  Next, a case will be described in which a flaw detection inspection is performed on equipment having a complicated curved surface shape by using the flaw detection inspection apparatus according to the first embodiment of the present invention. 4 is a perspective view of a welded portion between the burner ring and the element tube in the vicinity of the boiler, and FIG. 5 is a partially cutaway sectional view of the welded portion between the burner ring and the element tube in FIG.

  For example, as shown in FIG. 4, the burner ring 24 is provided outside the boiler via the front plate 25, and a welded portion 27 between the burner ring 24 and the element tube 26 is a flaw detection location. As shown in FIG. 5, the flaw detection unit 12 is arranged in the vicinity of the welded portion 27 between the burner ring 24 and the element tube 26 and performs flaw detection scanning. The sensor 15 measures the scanning trajectory data of the flaw detection unit 12 and the image data of the burner ring 24 and the element tube 26 as the inspection object 11 when performing this flaw detection scanning.

As shown in FIG. 4, the scanning mechanism 17 of the sensor unit 15 is installed at a predetermined fixed point A, and the sensor unit 15 is moved to move the burner ring 24 and the element tube 26 near the welded portion 27 from a plurality of angular positions. Measure image data. In FIG. 4, image data in the vicinity of the welded portion 27 is obtained from three different angular positions. As described above, this is because the image processing unit 19 of the arithmetic processing unit 18 obtains the three-dimensional shape data in the vicinity of the burner ring 24 that is the inspection object 11 and the welded portion 27 of the element tube 26. Note that the angles φ ₁ , φ ₂ , and φ ₃ of the link portion 16 at each angular position are also measured together with the three-dimensional shape data. In FIG. 4, illustration of the scanning mechanism unit 14 and the link unit 13 of the flaw detection unit 12 is omitted.

  The image processing unit 19 of the calculation processing unit 18 calculates the three-dimensional shape data in the vicinity of the welded portion 27 and the scanning trajectory data of the flaw detection unit 12 on the three-dimensional shape data based on the image data thus measured. To do. Then, the coordinate correction unit 21 compares the past three-dimensional shape data in the vicinity of the welded portion 27 stored in the storage unit 20 with the current three-dimensional shape data in the vicinity of the welded portion 27, and whether there is a deviation in the coordinates. Determine if. If there is a shift in coordinates, the shift is corrected so that the current 3D shape data in the vicinity of the welded portion 27 matches the coordinates of the past 3D shape data in the vicinity of the welded portion 27.

Then, the three-dimensional shape data in the vicinity of the current welded portion 27 is displayed on the display device 22 in accordance with the corrected coordinates. At that time, the past scanning trajectory data of the flaw detection unit 12 is guided and displayed on the three-dimensional shape data. The worker scans the flaw detection unit 12 according to the guidance display displayed on the display device 22.

  According to the first embodiment, the scanning mechanism unit 17 of the sensor unit 15 is installed at a predetermined fixed point A, image data is measured from a plurality of angular positions, and the three-dimensional shape data of the inspection object 11 and The flaw detection scanning trajectory data of the flaw detection unit 12 is obtained, and the deviation of coordinates between the current 3D shape data of the inspection object 11 and the past 3D shape data of the inspection object 11 is corrected, and 3 of the current inspection object 3 is corrected. By matching the three-dimensional shape data with the coordinates of the three-dimensional shape data of the past inspection object and guiding and displaying the scanning trajectory data of the past flaw detection part on the three-dimensional shape data, the workability and reproducibility are improved, and the flaw detection is performed. The accuracy of inspection data is also improved.

(Second Embodiment)
FIG. 6 is a block diagram of a flaw detection inspection apparatus according to the second embodiment of the present invention. In the second embodiment, a scanning drive unit 28 that automatically scans the flaw detection unit 12 is provided in place of the display device 22 in the first embodiment shown in FIG. The same elements as those in FIG. 1 are denoted by the same reference numerals, and redundant description is omitted.

  In FIG. 6, the scanning drive unit 28 is input with the three-dimensional shape data matched with the coordinates corrected by the coordinate correction unit 21 and the scanning trajectory data of the past flaw detection unit 12 stored in the storage unit 20. The unit 28 drives the scanning mechanism unit 14 of the flaw detection unit 12 so that the flaw detection unit 12 scans according to the scanning trajectory data of the past flaw detection unit 12 on the three-dimensional shape data corrected by the coordinate correction unit 21. Thereby, the flaw detection part 12 can be automatically scanned according to the corrected coordinates.

  In this case, a display device 22 may be provided to display guidance for scanning trajectory data of the past flaw detection unit 12 together. In this case, it is possible to monitor the automatic flaw detection scanning by the scanning mechanism unit 14 of the flaw detection unit 12 with the display device 22.

  According to the second embodiment, since the flaw detection section 12 can be automatically scanned according to the scanning trajectory data of the past flaw detection section 12, the workability of the flaw detection inspection of the inspection object is further improved.

The block block diagram of the flaw detection inspection apparatus concerning the 1st Embodiment of this invention. Illustration of vector rotation. Explanatory drawing of the link part of the sensor part in the 1st Embodiment of this invention. A perspective view of a welded portion between a burner ring and an element pipe in the vicinity of the boiler; 4 is a partially cutaway cross-sectional view of the welded portion between the burner ring and element tube of FIG. The block block diagram of the flaw detection inspection apparatus concerning the 2nd Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 11 ... Inspection object, 12 ... Flaw detection part, 13 ... Link part, 14 ... Scanning mechanism part, 15 ... Sensor part, 16 ... Link part, 17 ... Scanning mechanism part, 18 ... Arithmetic processing unit, 19 ... Image processing part, DESCRIPTION OF SYMBOLS 20 ... Memory | storage part, 21 ... Coordinate correction part, 22 ... Display apparatus, 23 ... Link, 24 ... Burnering, 25 ... Front plate, 26 ... Element pipe | tube, 27 ... Welding part, 28 ... Scanning drive part

Claims (4)

  Based on the image data measured by the sensor unit that measures image data of the inspection object and scanning trajectory data of the flaw detection part that has been flaw-scanned on the inspection object with a predetermined fixed point as a reference point 3D shape data of the inspection object and scanning trajectory data of the flaw detection unit on the 3D shape data, 3D shape data of the inspection object calculated by the image processing unit, and A storage unit for storing scanning trajectory data of the flaw detection unit on the three-dimensional shape data, a three-dimensional shape data of the current inspection target obtained by the image processing unit, and a past inspection target stored in the storage unit A coordinate correction unit that corrects a deviation in coordinates with the three-dimensional shape data of the object and matches the three-dimensional shape data of the current inspection object with the coordinates of the three-dimensional shape data of the past inspection object; A display device that displays the three-dimensional shape data of the current inspection object in accordance with the corrected coordinates and guides and displays the scanning trajectory data of the past flaw detection portion stored in the storage portion on the three-dimensional shape data A flaw detection inspection apparatus characterized by comprising:   Based on the image data measured by the sensor unit that measures image data of the inspection object and scanning trajectory data of the flaw detection part that has been flaw-scanned on the inspection object with a predetermined fixed point as a reference point 3D shape data of the inspection object and scanning trajectory data of the flaw detection unit on the 3D shape data, 3D shape data of the inspection object calculated by the image processing unit, and A storage unit for storing scanning trajectory data of the flaw detection unit on the three-dimensional shape data, a three-dimensional shape data of the current inspection target obtained by the image processing unit, and a past inspection target stored in the storage unit A coordinate correction unit that corrects a deviation in coordinates with the three-dimensional shape data of the object and matches the three-dimensional shape data of the current inspection object with the coordinates of the three-dimensional shape data of the past inspection object; A flaw detection inspection comprising: a scan driving unit that scans the flaw detection unit according to the scan trajectory data of the past flaw detection unit stored in the storage unit on the three-dimensional shape data matched with the corrected coordinates apparatus.   The image data of the inspection object and the scanning trajectory data of the flaw detection part scanned on the inspection object are measured using a predetermined fixed point as a reference point, and the three-dimensional shape of the inspection object is measured based on the measured image data The data and the scanning trajectory data of the flaw detection part on the three-dimensional shape data are calculated, and the calculated three-dimensional shape data of the inspection object and the scanning trajectory data of the flaw detection part on the three-dimensional shape data are stored. When there is a deviation in the coordinates between the 3D shape data of the current inspection object and the stored 3D shape data of the past inspection object, the deviation is corrected and the 3D shape data of the current inspection object Is matched with the coordinates of the three-dimensional shape data of the past inspection object, and the three-dimensional shape data of the current inspection object is displayed in accordance with the corrected coordinates, and the past search is performed on the three-dimensional shape data. Flaw inspection method characterized by guiding displaying the scanning trace data parts.   The image data of the inspection object and the scanning trajectory data of the flaw detection part scanned on the inspection object are measured using a predetermined fixed point as a reference point, and the three-dimensional shape of the inspection object is measured based on the measured image data The data and the scanning trajectory data of the flaw detection part on the three-dimensional shape data are calculated, and the calculated three-dimensional shape data of the inspection object and the scanning trajectory data of the flaw detection part on the three-dimensional shape data are stored. When there is a deviation in the coordinates between the 3D shape data of the current inspection object and the stored 3D shape data of the past inspection object, the deviation is corrected and the 3D shape data of the current inspection object Is matched with the coordinates of the three-dimensional shape data of the past inspection object, and the flaw detection portion is scanned according to the scan trajectory data of the flaw detection portion stored on the three-dimensional shape data matched with the corrected coordinates. Flaw inspection wherein the.

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