基于深度学习的承压设备焊接接头缺陷智能检测与评级

Deep Learning - Based Intelligent Detection and Grading of Weld Joint Defects in Pressure Equipment

  • 摘要:  针对传统承压设备焊接接头缺陷人工评片法存在的主观性强、效率低下、数据可追溯性差等问题,提出一种融合深度学习目标检测技术与NB/T47013标准的智能检测与评级方法。该方法通过构建焊接缺陷数据集并训练YOLOv8s模型(YOLOv8s是YOLO系列目标检测算法的轻量版,采用C2f模块与SPPF空间金字塔池化结构,兼具检测精度与推理速度优势),采用滑动窗口推理与坐标映射策略实现高分辨率底片的全区域缺陷识别与定位,结合DPI像素(DPI即每英寸像素数,是衡量图像数字化精度的核心参数,用于建立像素尺寸与物理尺寸的换算关系)到物理尺寸换算与工况参数自适应的评级规则引擎,完成缺陷参数精确计算与标准化质量评级,最终生成结构化检测报告。实验结果表明,该方法可有效识别气孔、裂纹、未焊透等多种缺陷类型,评级结果与标准一致性达95%,检测效率较人工评片提升5倍,为承压设备安全运行提供了高效、客观、可追溯的质量保障方案。

     

    Abstract:   
      Aiming at the problems of strong subjectivity, low efficiency, and poor data traceability in the traditional manual film evaluation method for defects in welded joints of pressure equipment, an intelligent detection and rating method integrating deep learning target detection technology and the NB/T47013 standard is proposed. A welding defect dataset is constructed and the YOLOv8s model (a lightweight version of the YOLO series target detection algorithms, adopting the C2f module and SPPF spatial pyramid pooling structure, which has both advantages of detection accuracy and inference speed) is trained. The sliding window inference and coordinate mapping strategy are used to realize full-region defect recognition and localization of high-resolution films. Combined with the DPI (dots per inch, a core parameter for measuring image digitization accuracy, used to establish the conversion relationship between pixel size and physical size) pixel-to-physical size conversion and the rating rule engine adaptive to working condition parameters, the accurate calculation of defect parameters and standardized quality rating are completed, and a structured detection report is finally generated. Experimental results show that the method can effectively identify various defect types such as porosity, cracks, and incomplete penetration. The consistency between the rating results and the standard reaches 95%, and the detection efficiency is 5 times higher than that of manual film evaluation. It provides an efficient, objective, and traceable quality assurance scheme for the safe operation of pressure equipment.

     

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