CN112098462A - Paint layer thickness infrared thermal imaging detection device and detection method - Google Patents
Paint layer thickness infrared thermal imaging detection device and detection method Download PDFInfo
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- CN112098462A CN112098462A CN202011127317.3A CN202011127317A CN112098462A CN 112098462 A CN112098462 A CN 112098462A CN 202011127317 A CN202011127317 A CN 202011127317A CN 112098462 A CN112098462 A CN 112098462A
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- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N25/00—Investigating or analyzing materials by the use of thermal means
- G01N25/72—Investigating presence of flaws
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- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/02—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness
- G01B21/08—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness
- G01B21/085—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness using thermal means
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Abstract
The invention discloses a paint layer thickness infrared thermal imaging detection device and a detection method, which comprises the following steps: the upper computer (1), the upper computer (1) is connected with the function generator (2); the function generator (2) is connected with the power amplifier (3); the power amplifier (3) is connected with the halogen lamp (5); the function generator (2) is connected with the thermal imager (4); the influence of paint layer thickness change and the influence of paint layer weathering in a detection result graph are distinguished from each other by changing the phase locking frequency to repeatedly measure and compare amplitude images and phase images of a standard test block and an actual object so as to detect the paint layer thickness of the electric power equipment; the technical problems that in the actual detection process, the detection result is also influenced by thermophysical property change caused by weathering of a paint layer coated on the surface of equipment, and therefore in a detection result image, the thermophysical property change and the influence caused by the thickness change of the paint layer are overlapped and mixed, so that the detection of the thickness of the paint layer is difficult and the like are solved.
Description
Technical Field
The invention belongs to the technical field of detection in the field of nondestructive detection, and particularly relates to an infrared thermal imaging detection device and a detection method for the thickness of a paint layer.
Background
For equipment and structural members which take steel and other metal materials which are easy to corrode as main bodies, such as power equipment, bridges, communication towers and the like, the equipment and the structural members are exposed to the external environment for a long time, so that the equipment and the structural members are extremely easy to corrode by factors such as water vapor in the atmosphere and the like, the structural strength is reduced, the service life is shortened, and the maintenance cost is increased while great potential safety hazards are brought. Therefore, in order to prevent the metal parts of the equipment from being damaged due to corrosion and prolong the service life of the equipment, a protective paint layer is usually coated on the surfaces of the metal parts of the equipment, so as to enhance the insulation, corrosion resistance and the like of the equipment.
The requirements on the material and thickness of the coated paint layer are different for different application scenes such as the paint layer on the surface of electric equipment, the paint layer on the surface of a bridge metal framework and the like. The material of the paint-removing layer is not referred to, and the paint layer coated on the surface of the metal part of the equipment needs to reach different thickness ranges according to the environment of the equipment and different corrosion prevention requirements. The coated paint layer needs to be thick enough to more effectively prevent the water in the atmosphere from being corroded inwards, and the metal components of the equipment below the paint layer are protected from being corroded; meanwhile, the coated paint layer cannot be too thick, otherwise, the internal stress of the material is too large, and the bonding strength between the paint layer and the bottom metal material is low, so that the paint layer is easy to fall off or cracks are generated. Meanwhile, as the equipment is exposed to the external environment for a long time, the protection paint layer is subjected to loss of different degrees due to long-time corrosion, so that the thickness of the paint layer is continuously thinned and uneven. Therefore, during the production and service period of the equipment, the detection of the thickness of the surface paint layer of the equipment becomes an important link for evaluating the quality of the surface paint layer and ensuring the long-term normal operation of the equipment.
In an electric power system, the thickness of a paint layer on the surface of electric equipment is usually detected regularly to ensure that the equipment does not have serious corrosion. At present, most of the commonly used detection methods are eddy current detection and ultrasonic detection methods, but the detection efficiency is low or the limit condition is large. The infrared thermal imaging nondestructive detection technology is a novel nondestructive detection technology and has the advantages of rapidness, non-contact, visualization, large detection area and the like. The phase-locked thermal imaging nondestructive testing technology is widely applied at present, and can overcome the defects of uneven heating and the like of a pulse method. For equipment and structural members which take steel and other metal materials which are easy to corrode as main bodies, such as power equipment, bridges, communication towers and the like, the equipment and the structural members are exposed to the external environment for a long time, so that the equipment and the structural members are extremely easy to corrode by factors such as water vapor in the atmosphere and the like, the structural strength is reduced, the service life is shortened, and the maintenance cost is increased while great potential safety hazards are brought. Therefore, in order to prevent the metal parts of the equipment from being damaged due to corrosion and prolong the service life of the equipment, a protective paint layer is usually coated on the surfaces of the metal parts of the equipment, so as to enhance the insulation, corrosion resistance and the like of the equipment.
The requirements on the material and thickness of the coated paint layer are different for different application scenes such as the paint layer on the surface of electric equipment, the paint layer on the surface of a bridge metal framework and the like. The material of the paint-removing layer is not referred to, and the paint layer coated on the surface of the metal part of the equipment needs to reach different thickness ranges according to the environment of the equipment and different corrosion prevention requirements. The coated paint layer needs to be thick enough to more effectively prevent the water in the atmosphere from being corroded inwards, and the metal components of the equipment below the paint layer are protected from being corroded; meanwhile, the coated paint layer cannot be too thick, otherwise, the internal stress of the material is too large, and the bonding strength between the paint layer and the bottom metal material is low, so that the paint layer is easy to fall off or cracks are generated. Meanwhile, as the equipment is exposed to the external environment for a long time, the protection paint layer is subjected to loss of different degrees due to long-time corrosion, so that the thickness of the paint layer is continuously thinned and uneven. Therefore, during the production and service period of the equipment, the detection of the thickness of the surface paint layer of the equipment becomes an important link for evaluating the quality of the surface paint layer and ensuring the long-term normal operation of the equipment.
In an electric power system, the thickness of a paint layer on the surface of electric equipment is usually detected regularly to ensure that the equipment does not have serious corrosion. At present, most of the commonly used detection methods are eddy current detection and ultrasonic detection methods, but the detection efficiency is low or the limit condition is large. The infrared thermal imaging nondestructive detection technology is a novel nondestructive detection technology and has the advantages of rapidness, non-contact, visualization, large detection area and the like. The phase-locked thermal imaging nondestructive testing technology is widely applied at present, can overcome the defects of uneven heating of a pulse method and the like, and can provide three-dimensional chromatographic images for representing defects of different depths in materials. Meanwhile, the amplitude image and the phase image obtained through algorithm calculation can judge the internal defect information of the object from multiple angles, and the detection capability and reliability are improved.
Due to the continuous change of the atmospheric environment, the existence of severe weather such as burning sun, heavy rain and the like can lead the surface paint layer to be weathered continuously, thereby changing the material characteristics so as to reduce the density and lose the function of blocking water vapor in the atmosphere. On the other hand, the change in material properties causes a change in thermal properties, which affects the film thickness measurement result. Therefore, a method is needed to separate the influence of the film thickness variation from the influence of the material thermophysical property variation in the detection result, and to improve the accuracy of the film thickness detection.
The thickness of the paint layer of the equipment is detected by utilizing a phase-locked method thermal imaging nondestructive testing technology, and the relative size of the temperature of an object is reflected by receiving thermal radiation by a thermal imager instead of absolute temperature measurement when the temperature of the object is detected by thermal imaging. Therefore, the measured signal may be affected by environment, hardware circuit, and the like to generate drift. Therefore, in the actual detection process, in order to accurately measure the thickness of the paint layer, the consistency of factors such as the environment and the like under multiple detections needs to be ensured, and the problems of temperature drift and the like under multiple measurement conditions are solved.
In addition, in the actual detection process, the detection result is also affected by the thermal property change caused by the weathering of the paint layer coated on the surface of the equipment, so that the thermal property change and the influence caused by the paint layer thickness change are superposed and mixed in the detection result image, thereby bringing difficulty to the detection of the paint layer thickness. Therefore, how to separate the influences of the two factors from each other so that the influences can be independently judged is a key problem to be solved. In order to mutually separate and decouple the influence of the thickness change of the paint layer and the influence of the weathering of the paint layer in the prior art, the weathering degree of the paint layer on the surface of the equipment needs to be accurately calibrated.
Disclosure of Invention
The technical problems to be solved by the invention are as follows: the utility model provides a paint layer thickness infrared thermal imaging detection device and detection method to solve in the actual testing process because the thermal rerum natura change that the weathering of the equipment surface paint layer leads to also can exert an influence to the testing result, consequently in the testing result image, it can be with the influence that paint layer thickness change produced superpose the mixture, thereby brings the technical problem such as difficulty for the detection of paint layer thickness.
The technical scheme of the invention is as follows:
an infrared thermal imaging detection device for the thickness of a paint layer, comprising: the upper computer is connected with the function generator; the function generator is connected with the power amplifier; the power amplifier is connected with the halogen lamp; the function generator is connected with the thermal imager.
The thermal imager and the halogen lamp are fixed at the top end of the fixed cover.
Handle parts are fixed on two sides of the fixed cover.
The rotary object placing table is fixed in the middle of the fixed cover.
The influence of paint layer thickness change and the influence of paint layer weathering in a detection result graph are distinguished from each other by changing the phase locking frequency to repeatedly measure and compare the amplitude image and the phase image of the standard test block and the actual object, so that the paint layer thickness of the electric power equipment is detected.
The detection method of the paint layer thickness infrared thermal imaging detection device specifically comprises the following steps:
The method for judging whether the actual object generates the weathering phenomenon according to the amplitude image and the phase image in the steps 2 and 3 comprises the following steps: assuming that the results obtained in the steps 2 and 3 are A 'and A' respectively; Φ', Φ "; observing the amplitude image A' in the detection result in the step 2, and if the gray value of each region in the result is not different, indicating that the paint layer is not weathered; if the signal value of a certain area X in the image is different from that of other areas, the efflorescence phenomenon of the paint layer of the area is indicated.
The standard paint layer test block is a paint layer and a flat plate with gradient change of weathering degree, and the material is the same as that used by actual detection equipment; from left to right, the thickness of the paint layer on the surface of the test block is changed in a gradient manner, the thickness of the paint layer in each layer is uniform, and the change range is the change range of the actual thickness of the paint layer of the detected equipment; from top to bottom, the weathering of the paint layer increases gradually from the non-weathering.
The invention has the beneficial effects that:
the invention realizes the rapid switching of the system detection target between the actual object and the standard test block through the designed phase-locked infrared thermal imaging detection system, and ensures the consistency of the environment and other conditions among multiple detections.
According to the method for detecting the thickness of the paint layer on the surface of the equipment through phase-locked method thermal imaging, the influence of the change of the thickness of the paint layer in a detection result graph is distinguished from the influence of the weathering of the paint layer. After the method is used for distinguishing, a paint layer thickness change image and a paint layer weathering defect image which does not contain paint layer thickness change can be obtained respectively, and the misjudgment rate of the paint layer thickness in the detection result is greatly reduced.
The technical problems that in the actual detection process, the detection result is also influenced by thermophysical property change caused by weathering of a paint layer coated on the surface of equipment, and therefore in a detection result image, the thermophysical property change and the influence caused by the thickness change of the paint layer are overlapped and mixed, so that the detection of the thickness of the paint layer is difficult and the like are solved.
Description of the drawings:
FIG. 1 is a schematic view of the apparatus of the present invention;
FIG. 2 is a schematic view of a standard paint test block.
Detailed Description
An infrared thermal imaging detection device for the thickness of a paint layer, comprising: the upper computer (1), the upper computer (1) is connected with the function generator (2); the function generator 2 is connected with the power amplifier 3; the power amplifier 3 is connected with a halogen lamp (5); the function generator 2 is connected to the thermal imager 4.
It also comprises a fixed cover 6, and the thermal imaging camera 4 and the halogen lamp 5 are fixed at the top end of the fixed cover 6.
The upper computer 1 controls the function generator 2 to output a modulation signal with specific frequency, and the modulation signal passes through the power amplifier 3 and then is input into the halogen lamp, so that the intensity of the halogen lamp 5 is changed according to a set frequency rule, and modulation excitation is realized. Meanwhile, the upper computer 1 is connected with the thermal imager 4 through the function generator 2, and the thermal imager 4 is controlled to collect image data through the modulation signal. The thermal imager 4 and the halogen lamp 5 are fixed on a structural member at the top of the cover by the fixed cover 6, and handle parts are arranged on two sides of the fixed cover 6. When large-scale equipment is detected in service, the equipment is usually immovable, so that the equipment can be detected by moving the whole fixed cover and the excitation and detection device through the handle, and the equipment detection device has high flexibility. Rotatory thing platform 7 of putting is fixed in the middle part position of fixed cover 6, puts and can fix on the thing platform and place standard test block and accessible host computer 1 control rotatory thing platform 7 in the steering wheel rotate realize detecting the target fast, the nimble switching between actual object and standard test block. In the paint layer thickness detection experiment of the actual object, the paint layer thickness of the actual object can be quantitatively detected by comparing the detection results of the actual object and the standard thickness test block. In the actual detection process, the actual object and the standard test block are quickly switched through the rotary table 7 without moving the detection head, the time interval between multiple detections is greatly shortened, the consistency of the conditions such as the environment and the circuit in the multiple detection time can be greatly ensured, and the difference of the infrared image signal values obtained by multiple detections is reduced.
The detection method can distinguish the influence of paint layer thickness change and the influence of paint layer weathering in a detection result graph from each other by changing the phase-locked frequency for multiple measurements and comparing the amplitude images and the phase images of the standard test block and the actual object, so as to detect the paint layer thickness of the electric equipment. The method specifically comprises the following steps:
the rotating object placing table 7 is rotated to the leftmost position, so that the system excitation and collection target is an actual object.
And step two, the function generator 2 is controlled by the upper computer 1 to generate a waveform with high frequency, and the temperature distribution of the surface of the sample is stimulated and collected. And executing the third step and the fourth step.
Due to the high phase-locking frequency, the modulated heat wave can only be transmitted to a shallow position under the paint layer but not to the interface of the surface paint layer and the internal metal part. Therefore, the influence of the thickness change of the paint layer on the detection result can be eliminated, and only the influence of the thermal property change of the paint layer caused by weathering can be focused.
Thirdly, controlling the function generator 2 to generate a waveform with proper frequency through the upper computer 1, enabling the modulated thermal wave to be transmitted to an interface between the paint layer and the bottom metal, and performing phase-locked excitation and collecting the surface temperature distribution of the sample.
Step four, acquiring image data obtained by the thermal imager 4 in the step through the upper computer 1, and acquiring an amplitude image A and a phase image phi through a four-point correlation, Fourier transform and other related phase extraction algorithms. Wherein, the obtained results of the steps and the ground are respectively A 'and A'; phi′,Φ″。
Observing step and detecting amplitude image A in result′And if the gray value of each region in the result is not obviously different, the paint layer is free from weathering phenomenon. If the signal value of a certain area X in the image is obviously different from that of other areas, the efflorescence phenomenon of the paint layer of the area is indicated.
Step fifthly, the rotary object placing table is rotated to the lowest position, so that the detection target of the system is a standard paint layer test block, and the steps of the second step, the third step and the fourth step are repeated.
As shown in fig. 2, the standard paint test block is a flat plate with a gradient of paint and weathering degree, and the material of the standard paint test block is the same as that of the actual detection equipment. From left to right, the thickness of the paint layer on the surface of the test block is changed in a gradient manner, the thickness of the paint layer in each layer is uniform, and the change range is the change range of the actual thickness of the paint layer of the detected equipment; from top to bottom, the weathering degree of the paint layer is never weatheredIt starts to increase gradually. Therefore, the standard test block can represent the change of the thickness and the weathering degree of the paint layer on the surface of the device and can play a role in scaling. Assuming that the thickness variation progression of the standard test block paint layer is N and the weathering degree variation progression is M, N amplitude images can be obtained through algorithm processing after detection
Sum phase image
Sixthly, aiming at the situation that the paint layer appearing in the fourth step is not weathered, namely an amplitude image A′The gray value of each area in the result has no obvious difference. Extracting the phase difference of the position in the phase image, phi
And step fifthly, phase images of different depth positions
Comparing the phase difference with the phase difference
The same image is assumed to have a sequence number i. Thus, region
The thickness d of the paint layer is the same as that of the defect area X in the actual object, and the thickness of the paint layer in the area is obtained.
With respect to a windy phenomenon in a certain region of the paint layer appearing in the step four, namely, an amplitude image A′The size of the X gray value of a certain area in the result is obviously different from that of other areas. Step-quietness is performed.
Step-wise, result plot against different degrees of efflorescence of standard test block
In finding standard test block with the step area in twoAnd X has the same signal value in the region j. Sixthly, performing the step VI again
To find out the phase difference
The same image is assumed to have a sequence number i. Thus, region
The thickness d of the paint layer is the same as that of the defect area X in the actual object, and the thickness of the paint layer in the area is obtained. Repeating the above operations to finally obtain a whole detection result graph of the thickness change of the surface paint layer.
Through the seven steps, the influence of the thickness change of the paint layer in the detection result graph and the influence of the weathering of the paint layer can be decomposed, so that the thickness of the paint layer of the power equipment can be accurately judged.
According to the method, the influence of the change of the thickness of the paint layer in the detection result graph and the influence of the weathering of the paint layer are distinguished from each other by changing the phase-locked frequency for multiple measurements and comparing the amplitude images and the phase images of the standard test block and the actual object, so that the thickness of the paint layer on the surface of the power equipment is detected.
Claims (8)
1. An infrared thermal imaging detection device for the thickness of a paint layer, comprising: host computer (1), its characterized in that: the upper computer (1) is connected with the function generator (2); the function generator (2) is connected with the power amplifier (3); the power amplifier (3) is connected with the halogen lamp (5); the function generator (2) is connected with the thermal imager (4).
2. The infrared thermal imaging detection device for the thickness of the paint layer as recited in claim 1, wherein: the thermal imaging device further comprises a fixed cover (6), and the thermal imaging instrument (4) and the halogen lamp (5) are fixed at the top end of the fixed cover (6).
3. The infrared thermal imaging detection device for the thickness of the paint layer as recited in claim 2, wherein: handle parts are fixed on two sides of the fixed cover (6).
4. The infrared thermal imaging detection device for the thickness of the paint layer as recited in claim 2, wherein: the rotary object placing table (7) is fixed at the middle position of the fixed cover.
5. The method for detecting the infrared thermal imaging detection device of the thickness of the paint layer as claimed in claim 1, wherein: the influence of paint layer thickness change and the influence of paint layer weathering in a detection result graph are distinguished from each other by changing the phase locking frequency to repeatedly measure and compare the amplitude image and the phase image of the standard test block and the actual object, so that the paint layer thickness of the electric power equipment is detected.
6. The method for detecting the infrared thermal imaging detection device of the thickness of the paint layer according to claim 5, wherein the method comprises the following steps: it specifically includes:
step 1, rotating the rotary object placing table to the leftmost position to enable a target excited and collected by a system to be an actual object;
step 2, controlling a function generator to generate a certain frequency waveform through an upper computer, exciting and collecting the surface temperature distribution of the sample;
step 3, controlling a function generator to generate a certain frequency waveform through an upper computer, enabling the modulated thermal wave to be transmitted to an interface between the paint layer and the bottom metal, performing phase-locked excitation and collecting the surface temperature distribution of the sample;
step 4, acquiring image data obtained by the thermal imager in the step 2 and the step 3 through an upper computer, and acquiring an amplitude image A and a phase image phi through a four-point correlation and Fourier transform correlation phase extraction algorithm; and judging whether the actual object generates the weathering phenomenon according to the amplitude image and the phase image in the steps 2 and 3.
Step 5, rotating the rotary object placing table to the lowest position to enable the detection target of the system to be a standard paint layer test block, and repeating the steps 2, 3 and 4; the standard test block can represent the change of the thickness and the weathering degree of the paint layer on the surface of the equipment and can be used for calibrationUsing; assuming that the thickness variation progression of the standard test block paint layer is N and the weathering degree variation progression is M, N amplitude images can be obtained through algorithm processing after detection
Sum phase image
Step 6, extracting the phase difference of the position in the phase image phi 'aiming at the paint layer which has no efflorescence phenomenon in the step 4, namely, the gray value of each area in the amplitude image A' result has no difference
And the phase images of different depth positions in the step 5
Comparing the phase difference with the phase difference
The same image, assuming its serial number is i; region(s)
The thickness d of the expressed paint layer is the same as that of the paint layer of the defect area X in the actual object, and the thickness of the paint layer of the area is obtained;
step 7, aiming at the phenomenon that a certain area of the paint layer appears in the step 4, namely the gray value of X in the certain area in the amplitude image A' result is different from that in other areas, comparing result graphs of different weathering degrees of standard test blocks
Finding a region j in the standard test block, wherein the size of the signal value of the region X in the standard test block is the same as that of the signal value of the region X in the step 2; step 6 is performed again at
To find out the phase difference
The same image, assuming its serial number is i; region(s)
The thickness d of the expressed paint layer is the same as that of the paint layer of the defect area X in the actual object, and the thickness of the paint layer of the area is obtained; finally, the whole detection result graph of the thickness change of the surface paint layer can be obtained.
7. The method for detecting the infrared thermal imaging detection device of the thickness of the paint layer according to claim 6, wherein the method comprises the following steps: the method for judging whether the actual object generates the weathering phenomenon according to the amplitude image and the phase image in the steps 2 and 3 comprises the following steps: assuming that the results obtained in the steps 2 and 3 are A 'and A' respectively; Φ', Φ "; observing the amplitude image A' in the detection result in the step 2, and if the gray value of each region in the result is not different, indicating that the paint layer is not weathered; if the signal value of a certain area X in the image is different from that of other areas, the efflorescence phenomenon of the paint layer of the area is indicated.
8. The method for detecting the infrared thermal imaging detection device of the thickness of the paint layer according to claim 6, wherein the method comprises the following steps: the standard paint layer test block is a paint layer and a flat plate with gradient change of weathering degree, and the material is the same as that used by actual detection equipment; from left to right, the thickness of the paint layer on the surface of the test block is changed in a gradient manner, the thickness of the paint layer in each layer is uniform, and the change range is the change range of the actual thickness of the paint layer of the detected equipment; from top to bottom, the weathering of the paint layer increases gradually from the non-weathering.
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