DOI: 10.29130/dubited.1866927 ISSN: 2148-2446

Design and Validation of an Automated X-Ray Imaging System for Pipe Weld Inspection

İsmail Ersöz, Ömer Buğra Seymen, Feti Yılmaz, Emre Küçük, Mücahit Soyaslan
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X-ray imaging is widely used for the inspection of welded pipes to detect internal defects such as discontinuities and weld imperfections. In this study, an automated X-ray imaging system capable of performing internal or external inspection depending on pipe diameter was designed and analyzed. Prior to the design stage, a site survey was conducted to determine system layout and material handling conditions, confirming the use of an overhead crane for pipe feeding. Based on process requirements, a modular inspection system was developed for pipes with diameters ranging from 40 mm to 508 mm and lengths between 6 m and 12 m. The pipes are transported by a rail-guided carrier vehicle to a positioning arm equipped with an X-ray tube, where imaging is performed at 25 cm intervals along the weld seam. Accurate alignment of the weld zone with the X-ray tube is achieved using a servo-driven positioning mechanism, providing a positioning accuracy of ±1 mm. A laser sensor is employed for position verification, while an absolute encoder integrated into the servo motor ensures reliable position detection during power interruptions. A height-adjustable mechanism was also designed to maintain proper image alignment on the inspection table. Unlike conventional conceptual inspection setups reported in the literature, the proposed system combines a modular mechanical architecture, servo-assisted positioning, finite element-based structural verification, and experimental validation within a manufacturable industrial inspection platform. Structural analyses revealed maximum stress values of 133.5 MPa in the arm group and 211.1 MPa in the rail vehicle group. Considering the yield strength of AISI 1040 steel, safety factors of 3.1 and 1.96 were obtained, satisfying the requirements of the Machinery Safety Regulation. Simulation results were validated through experimental tests conducted on the manufactured system.

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