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多自由度数字射线成像检测系统设计

李光保, 高栋, 路勇, 平昊, 周愿愿, 王飞

李光保, 高栋, 路勇, 平昊, 周愿愿, 王飞. 多自由度数字射线成像检测系统设计[J]. 焊接学报, 2023, 44(11): 14-21. DOI: 10.12073/j.hjxb.20221220003
引用本文: 李光保, 高栋, 路勇, 平昊, 周愿愿, 王飞. 多自由度数字射线成像检测系统设计[J]. 焊接学报, 2023, 44(11): 14-21. DOI: 10.12073/j.hjxb.20221220003
LI Guangbao, GAO Dong, LU Yong, PING Hao, ZHOU Yuanyuan, WANG Fei. Design of multi-degree-of-freedom digital radiographic testing system[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2023, 44(11): 14-21. DOI: 10.12073/j.hjxb.20221220003
Citation: LI Guangbao, GAO Dong, LU Yong, PING Hao, ZHOU Yuanyuan, WANG Fei. Design of multi-degree-of-freedom digital radiographic testing system[J]. TRANSACTIONS OF THE CHINA WELDING INSTITUTION, 2023, 44(11): 14-21. DOI: 10.12073/j.hjxb.20221220003

多自由度数字射线成像检测系统设计

基金项目: 国家重点研发计划(2018YFB1306803)
详细信息
    作者简介:

    李光保,1995年出生,博士,主要从事机电一体化控制、智能检测、航天制造加工技术的研究

  • 中图分类号: TG 409;TP 273

Design of multi-degree-of-freedom digital radiographic testing system

  • 摘要:

    针对目前运载火箭箱底、筒段、圆环零件的焊缝采用传统胶片照相进行检测,存在自动化程度低、过程繁琐、数字化程度低、且底片无法进行长期保存,无法满足当前多型号火箭并举下的快节奏研制需求. 运用X射线与成像板相结合的无损检测方法,采用双七轴机器人和同步升降转台作为运动执行机构,采用ADS多线程通信与Ethercat总线方式实现倍福控制器、成像检测软件、射线机、机器人和同步升降转台的实时通信,研发了一种基于机器人的多自由度数字射线成像检测系统,通过运动执行机构的路径规划与无损检测焊缝成像实现产品环缝、纵缝、变曲率焊缝的检测自动化,与传统胶片照相相比,检测效率提升5倍,检测精度提高42%,满足了目前对多型号火箭贮箱的检测工作.

    Abstract:

    At present, the traditional film photography is used to detect the welding seam of the bottom, barrel and ring parts of the launch vehicle, which has the disadvantages of low automation, complicated process and low digitization, and the negative film can't be preserved for a long time, so it can't meet the fast-paced development requirements of the current multi-type rockets. A robot-based multi-degree-of-freedom digital radiographic inspection system was developed by using the nondestructive inspection method combining X-ray and imaging board, using double seven-axis robot and synchronous lifting turntable as motion actuators, and using ADS multi-thread communication and Ethercat bus to realize the real-time communication among the controller, imaging inspection software, X-ray machine, robot and synchronous lifting turntable. Through the path planning of the motion actuator and the nondestructive inspection of weld seam imaging, the inspection automation of circumferential seam, longitudinal seam and variable curvature weld seam of products is realized. Compared with the traditional film photography, the inspection efficiency is increased by 5 times and the inspection accuracy is increased by 42%, which meets the current inspection work of multi-model rocket tanks.

  • 图  1   系统总体构成

    Figure  1.   Overall structure of the system

    图  2   KUKA KR50R2500工作空间(mm)

    Figure  2.   KUKA KR50R2500 Workspace

    图  3   双机器人工作空间

    Figure  3.   Double robot workspace

    图  4   控制系统总体架构

    Figure  4.   Overall architecture of control system

    图  5   单壁单影垂直透照示意图

    Figure  5.   Schematic diagram of vertical transmission of single wall and single shadow

    图  6   透照场示意图

    Figure  6.   Schematic diagram of transillumination field

    图  7   焊缝一次有效透照长度

    Figure  7.   Effective penetration length of weld at one time

    图  8   机器人控制和PLC的信号交互点信号

    Figure  8.   Signal interaction point signal between robot control and PLC

    图  9   双机器人协同控制连接

    Figure  9.   Cooperative control connection of two robots

    图  10   产品检测工艺流程

    Figure  10.   Process Flow of Product Inspection

    图  11   程序控制流程

    Figure  11.   Program control flow

    图  12   上位机显示屏界面

    Figure  12.   Upper computer display screen interface

    图  13   ADS通讯原理

    Figure  13.   ADS communication principle

    图  14   ADS程序结构

    Figure  14.   ADS program structure

    表  1   典型产品透照张数

    Table  1   Number of transmission photos of typical products

    产品检测部位胶片照相张数数字射线张数
    筒段纵缝(1 400 mm)3216
    箱底1380环缝8642
    3290环缝
    圆环瓜瓣纵缝4824
    半箱3350环缝6030
    下载: 导出CSV

    表  2   典型产品曝光参数

    Table  2   Typical product exposure parameters

    产品焊接方法检测部位管电压U/kV管电流I/mA积分时间t/ms采集帧数 帧/s
    筒段熔焊纵缝70530020
    箱底熔焊环缝70530020
    搅拌摩擦焊环缝65530020
    圆环熔焊纵缝62530020
    半箱熔焊环缝70530020
    锁底75540020
    下载: 导出CSV

    表  3   典型产品检测图像质量对比

    Table  3   Comparison of image quality of typical products

    产品焊接方法透照厚度
    dt/mm
    灵敏度mv/lux.s分辨率LP/mm归一化信噪比SNR/dB
    标准A级实测标准A级实测标准A级实测
    筒段熔焊8W13W15D10D1070>156
    箱底熔焊8W13W15D10D1070>132
    搅拌焊6W14W16D10D1070>128
    圆环熔焊8W13W15D10D1170>168
    半箱熔焊8W13W15D10D1070>172
    10W13W14D9D1070>177
    下载: 导出CSV

    表  4   检测效率对比

    Table  4   Comparison of detection efficiency

    序号型号产品图号零件用时(人*分钟)t/min效率
    提升
    DRRT
    1CZ-4RII2CDB044-0B后底301806倍
    2CZ-2DRI1XC0520-20前圆环301605倍
    3CZ-2DYI1XC0330-10筒段25803倍
    4CZ-2DYII2CBD02-0D半箱
    环缝
    301806倍
    5CZ-2DYII2CBD022-0B前底301806倍
    下载: 导出CSV
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出版历程
  • 收稿日期:  2022-12-19
  • 网络出版日期:  2023-08-17
  • 刊出日期:  2023-11-29

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