CN103471793A - Metal-pipe leakage automatic detection system - Google Patents
Metal-pipe leakage automatic detection system Download PDFInfo
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- CN103471793A CN103471793A CN2013104207340A CN201310420734A CN103471793A CN 103471793 A CN103471793 A CN 103471793A CN 2013104207340 A CN2013104207340 A CN 2013104207340A CN 201310420734 A CN201310420734 A CN 201310420734A CN 103471793 A CN103471793 A CN 103471793A
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Abstract
The invention discloses a metal-pipe leakage automatic detection system and method, and relates to the technical field of metal pipe detection devices. The metal-pipe leakage automatic detection system comprises a PLC, an industrial personal computer, a position sensor, a pipe diameter identification system, a frequency converter, a carrier roller motor, a position detection coder, a CCD camera and a carrier roller. The industrial control computer is connected with the PLC in a dual-direction mode, the pipe diameter identification system, the position sensor and the position detection coder are electrically connected with input ends of the PLC, the carrier roller motor is electrically connected with the PLC through the frequency inverter, the CCD camera is electrically connected with the industrial personal computer, and a metal pipe to be detected is driven to rotate by the carrier roller motor. The metal-pipe leakage automatic detection system can achieve metal pipe leakage detection, improve working efficiency and reduce the rejection rate.
Description
Technical field
The present invention relates to metal tube detection technique field, relate in particular to the automatic checkout system of a kind of metal tube seepage (industrial be commonly called as sweating).
Background technology
In the prior art, the leak detection of metal tube hydraulic pressure is judged as manually-operated, at the leak detection station, two post works are set and carry out artificial visually examine's judgement, main basis for estimation is that whether fast-descending and pipe shaft have obvious washmarking to manual observation hydrostatic testing machine pressure, for detecting the serious pipe of pipe shaft seepage, the post personnel easily find and make the identification judgement, but during for the hydraulic pressure leak detection, pipe shaft only has the metal tube of seepage a little, due to light, the reasons such as visual angle, the post workman is not easy to observe, perhaps omit and detect some position, will exist so indivedual metal tubes not to be judged to useless and to enter into the problem of next process at this station, thereby affect the quality of metal tube.
CCD(Charge Coupled Device) industrial camera is compared civil camera, there is higher picture steadiness, high-transmission ability and high anti-jamming capacity, can carry out the Real-time Collection of view data, combining image is processed and recognition technology, the CCD industrial camera is widely used in industry spot and carries out Real-Time Monitoring and control, can greatly enhance productivity and save human cost.
As Japanese documentation JP3156764U discloses the technical scheme that the CCD industrial camera is applied to the metal tube leak detection, wherein, the direction of transfer of metal tube is for to carry out along the axial directions X of metal tube, and on the face perpendicular to tubular axis along metal tube circumferentially be evenly arranged four CCD camera image collection points so that the capture angle on pipe shaft the whole body can be covered comprehensively.This detection scheme has been realized the robotization detection, but also there are some following technological deficiencies: the one, can not automatically adapt to the leak detection requirement of multiple different tube diameters, when caliber is larger, due to metal tube uniform motion vertically only, four CCD cameras may be not enough to the whole body capture angle of comprehensive covering metal pipe, thereby be faced with the distance adjusted between image-forming block and metal tube to guarantee that a plurality of cameras can cover the problem of all surfaces of metal tube, even also need to increase the CCD camera, to guarantee capture covering metal tube-surface comprehensively; The 2nd, the casting work on the spot environment of metal tube is usually more severe, and the production space is very limited, newly added equipment will affect the layout of existing production line, no matter be that the whole body along metal tube evenly arranges four CCD camera image collection points, still be increased to as mentioned above the CCD camera image collection point more than four, the problem that all exists production line to adjust; The 3rd, adopt a plurality of CCD camera costs higher, to the control of equipment and workload that data are processed also corresponding the increasing.
Summary of the invention
Technical matters to be solved by this invention is to provide a kind of metal tube seepage automatic checkout system and method, described system can automatically detect and judge whether metal tube has breakthrough, sensing range can covering metal pipe pipe shaft all surfaces, guaranteed the quality of metal tube, reduce workman's labour intensity, improved work efficiency.
For solving the problems of the technologies described above, the technical solution used in the present invention is:
A kind of metal tube seepage automatic checkout system, comprise electric control system, pipe shaft image acquisition part and caliber recognition system, described caliber recognition system is for detection of the caliber of metal tube, and caliber information is sent to described electric control system, described electric control system makes metal tube according to default speed rotation according to pipe diameter size, described image acquisition part is gathered metal tube whole body image according to the default number of times of taking pictures according to pipe diameter size, judges that by the image comparison treatment technology seepage appears in which position of pipe shaft simultaneously.
Further, described pipe seepage automatic checkout system comprises the PLC controller, industrial computer, the CCD camera, industrial computer and described two-way connection of PLC controller, the CCD camera is electrically connected to industrial computer, also comprise position transducer, the caliber recognition system, frequency converter, the carrying roller motor, position probing scrambler and carrying roller, the caliber recognition system, position transducer and position probing scrambler are electrically connected to the PLC controller, the carrying roller motor is electrically connected to described PLC controller by frequency converter, described carrying roller motor is fixedly connected with carrying roller, carrying roller drives metal tube to be detected and rotates, the position probing scrambler is coaxial with carrying roller, in order to detect the anglec of rotation of metal tube, the anglec of rotation of the metal tube that the caliber of the metal tube that the PLC controller is identified according to the caliber recognition system and position coder detect is controlled frequency converter.
Further, described PLC controller is electrically connected to described caliber recognition system, according to the metal tube caliber of described caliber recognition system identification and the metal tube anglec of rotation of described position probing scrambler detection, described frequency converter is controlled.
Further, the above CCD camera be positioned at metal tube to be detected directly over.
Further, described caliber recognition system is positioned at left side or the right side of described metal tube to be detected.
Further, described carrying roller is provided with two groups, the two ends of supporting respectively metal tube, and every group of carrying roller comprises two carrying rollers, and described position transducer is between two carrying rollers, and described position probing scrambler is fixed on described carrying roller.
A kind of metal tube seepage automatic testing method that the present invention proposes is realized in accordance with the following steps: when metal tube to be detected enters into the leak detection station, position transducer is input to the PLC controller to the pipe signal that has detected; When the leak detection station being detected and metal tube has been arranged, the PLC controller is controlled the caliber recognition system and is started, and the caliber signal that the caliber recognition system is detected is delivered to the PLC controller; After identifying caliber information, the Program time delay in the PLC controller is given signal of industrial computer after the regular hour, and industrial computer receives that this signal rear drive CCD camera takes one group of metal tube the whole body picture; After all over having taken first group of photo to metal tube, the PLC controller drives the rotation of carrying roller motor, and the metal tube of different tube diameters is at the uniform velocity rotated according to different speed, and speed is regulated to control and realized by frequency converter.
In the rotating 360 degrees process, the CCD camera is taken many group photos, and the anglec of rotation detects by the position probing scrambler detection coaxial with carrying roller, and carrying roller contacts for point with metal tube to be detected, the carrying roller that prevents rotation causes scratch, interference detection results to the periphery of metal tube.The photo that industrial computer is taken after using image processing software to the metal tube hydraulic testing is analyzed, according to image software, data are processed, if seepage appears in the metal tube pipe shaft, automatically indicate leakage area and send alerting signal on the industrial computer display screen, record seepage information, as metal tube, not occur that seepage just is judged to be qualified.
Described system comprises electric control system and part of data acquisition, part of data acquisition comprises industrial computer, industrial computer is by the data of CCD collected by camera metal tube and carry out the data processing by the software in industrial computer, electric control system adopts PLC controller and sensor to realize, described system can automatically detect and judge whether metal tube has breakthrough, improve the quality of metal tube, reduced workman's labour intensity, improved work efficiency.
The accompanying drawing explanation
Below in conjunction with the drawings and specific embodiments, the present invention is further detailed explanation.
Fig. 1 is the control structure schematic diagram of metal tube seepage automatic checkout system of the present invention;
Fig. 2 is metal tube right view in metal tube seepage automatic checkout system of the present invention;
Wherein: 1, PLC controller 2, industrial computer 3, position transducer 4, caliber recognition system 5, frequency converter 6, carrying roller motor 7, position probing scrambler 8, CCD camera 9, metal tube to be detected 10, carrier roller mechanism.
Embodiment
As shown in Figure 1, a kind of metal tube seepage automatic checkout system, comprise PLC controller 1, industrial computer 2, position transducer 3, caliber recognition system 4, frequency converter 5, carrying roller motor 6, position probing scrambler 7, CCD camera 8 and carrier roller mechanism 10.Described industrial computer 2 and described two-way connection of PLC controller 1, caliber recognition system 4, position transducer 3 and position probing scrambler 7 are electrically connected to PLC controller 1, carrying roller motor 6 is electrically connected to the output terminal of described PLC controller 1 by frequency converter 5, described CCD camera 8 is electrically connected to industrial computer 2, described carrying roller motor 6 is fixedly connected with carrier roller mechanism 10, and carrier roller mechanism 10 drives metal tube 9 to be detected and rotates.
Preferably, in order to take pictures conveniently, described CCD camera 8 be positioned at metal tube 9 to be detected directly over, be used for taking before the metal tube test experience with experiment after the pipe shaft image.Because the coverage of CCD camera on metal tube is axial is limited, therefore the number of CCD camera is installed and determines according to the length of metal tube, in the time of in pipe shaft drops on a CCD camera shooting sample range fully, only start the work of a CCD camera and get final product.Described caliber recognition system 4 is positioned at left side or the right side of described metal tube to be detected 9, for identifying the information of caliber.Described carrier roller mechanism 10 is provided with two groups, every group two, described position transducer 3 is between two carrying rollers, described position probing scrambler 7 is fixed on described carrier roller mechanism 10, carrying roller motor 6 drives carrier roller mechanism 10 and rotates, and carrier roller mechanism 10 drives metal tube 9 to be detected and rotates, when metal tube 9 to be detected is put between two groups of carrier roller mechanisms 10, position transducer 3 perceives metal tube 9 and has placed, and sends relevant information to PLC controller 1.
As shown in Figure 2, every group of carrier roller mechanism 10 is positioned at the two ends of described metal tube to be detected 9, described carrier roller mechanism 10 forms point with two ends of metal tube 9 to be detected and contacts, in order to reduce carrying roller wearing and tearing to the metal tube body periphery in rotary course, and then avoid having influence on the pattern recognition of doing for detecting seepage.
The workflow of described system is as follows:
(1) after completing the hydraulic testing, metal tube 9 to be detected enters into the leak detection station, and position transducer 3 is sent to PLC controller 1 to the pipe signal that has detected;
(2) when the leak detection station being detected and metal tube has been arranged, PLC controller 1 is controlled caliber recognition system 4 and is started, and the caliber signal that caliber recognition system 4 is detected is sent to PLC controller 1;
(3) after identifying caliber information, the Program time delay in PLC controller 1 is given 2 one signals of industrial computer after the regular hour, and industrial computer 2 is received one group of metal tube the whole body photo of this signal rear drive CCD camera 8 shooting;
(4) after having taken first group of photo to metal tube 9 the whole body, PLC controller 1 drives 6 rotations of carrying roller motor, the caliber detected according to caliber recognition system 4, the PLC controller drives carrying roller motor 6 according to the rotational speed uniform rotation metal tube 9 of setting for the metal tube of different tube diameters, and speed is regulated to control by frequency converter 5 and realized; In the at the uniform velocity rotary course of 360 degree, the CCD camera, under industrial computer 2 is controlled, is taken several groups of photos according to caliber, and the anglec of rotation detects by the position probing scrambler 7 detection realizations coaxial with carrier roller mechanism 10.Because the rotational speed of carrier roller mechanism 10 and the shooting number of times of CCD camera all are complementary with caliber, therefore, can under minimum shooting number of times, effectively detect the seepage situation of metal tube.
(5) when the CCD camera is taken, the photo that industrial computer is taken after using image processing software to the metal tube hydraulic testing is processed, use image processing method to data analysis, if seepage appears in the metal tube pipe shaft, automatically indicate leakage area and send alerting signal on the industrial computer display screen, record seepage information, as metal tube, not occur that seepage just is judged to be qualified.Whether the principle that image processing software in industrial computer there are differences according to painted, colourity, reflecting rate, index of refraction etc., identifying the metal tube pipe shaft that utilizes the CCD camera imaging to take has the seepage situation.
(6) metal tube, after completing rotation leak detection in a week, enters next station.
Described system comprises electric control system and part of data acquisition, and part of data acquisition comprises industrial computer, and industrial computer passes through the pipe shaft view data of CCD collected by camera metal tube, and carries out the data processing by the image processing software in industrial computer.Electric control system adopts PLC controller and sensor to realize, described system can automatically detect and judge whether metal tube has breakthrough, has guaranteed the quality of metal tube, has reduced workman's labour intensity, has improved work efficiency.
Applied a concrete enforcement example herein principle of the present invention and embodiment thereof are set forth, the explanation of above embodiment is just with helping understand method of the present invention and core concept thereof.It should be pointed out that for the person of ordinary skill of the art, can also carry out some improvement and modification to the present invention under the premise without departing from the principles of the invention, these improvement and modification also will fall in the protection domain of the claims in the present invention.
Claims (10)
1. a metal tube seepage automatic checkout system, comprise electric control system (1, 3, 5, 6, 7, 10) and pipe shaft image acquisition part (2, 8), it is characterized in that, also comprise caliber recognition system (4), described caliber recognition system (4) is for detection of the caliber of metal tube, and caliber information is sent to described electric control system, described electric control system makes metal tube according to default speed rotation according to pipe diameter size, described image acquisition part according to pipe diameter size according to the default frequency of taking pictures to gathering metal tube whole body image, process judgement pipe shaft seepage place by image simultaneously.
2. metal tube seepage automatic checkout system as claimed in claim 1, it is characterized in that described electric control system comprises PLC controller (1), position transducer (3), position probing scrambler (7), frequency converter (5), carrying roller motor (6) and carrier roller mechanism (10), described position transducer (3) and described position probing scrambler (7) are electrically connected to PLC controller (1), described carrying roller motor (6) is electrically connected to PLC controller (1) by described frequency converter (5), described carrying roller motor (6) drives metal tube to rotate by carrier roller mechanism (10).
3. metal tube seepage automatic checkout system as claimed in claim 2, it is characterized in that described PLC controller (1) is electrically connected to described caliber recognition system (4), according to the metal tube caliber of described caliber recognition system (4) identification and the metal tube anglec of rotation of described position probing scrambler (7) detection, described frequency converter (5) is controlled.
4. metal tube seepage automatic checkout system as claimed in claim 1, is characterized in that described image acquisition part (2,8) comprises industrial computer (2) and CCD camera (8).
5. metal tube seepage automatic checkout system as claimed in claim 4, is characterized in that described industrial computer (2) carries out the image processing and records detection information when described CCD camera (8) gathers image.
6. metal tube seepage automatic checkout system as claimed in claim 3, is characterized in that, described PLC controller (1) is controlled described carrying roller motor (6) and at the uniform velocity rotated with the speed drive metal tube of presetting.
7. metal tube seepage automatic checkout system as claimed in claim 5, it is characterized in that the above CCD camera (8) be arranged in the leak detection station directly over.
8. metal tube seepage automatic checkout system as claimed in claim 1, is characterized in that described caliber recognition system (4) is positioned at left side or the right side of metal tube to be detected.
9. metal tube seepage automatic checkout system as claimed in claim 2, it is characterized in that described carrier roller mechanism (10) is provided with two groups, one group comprises two carrying rollers, described position transducer (3) is positioned between two groups of carrier roller mechanisms (10), and described position probing scrambler (7) is coaxially installed with the monomer carrying roller of carrier roller mechanism (10).
10. a metal tube seepage automatic testing method, it comprises following detecting step:
A. position transducer (3) detects metal tube and whether enters the leak detection station;
If b. metal tube puts in place, PLC controller (1) starts caliber recognition system (4), and described caliber recognition system (4) is sent to caliber information in described PLC controller (1);
C. described PLC controller (1) drives carrying roller motor (6) to rotate according to pipe diameter size according to preset rotation speed, and the carrying roller motor rotates metal tube by carrier roller mechanism (10);
D. sending the driving instruction to carrying roller motor (6) simultaneously, described PLC controller (1) sends instruction to industrial computer (2), described industrial computer (2) starts the CCD camera according to the preset frequency shooting pipe shaft photo with the pipe diameter size coupling after receiving instruction, described industrial computer (2) synchronously starts to process image, has judged whether the seepage situation;
If e. seepage is arranged, described industrial computer (2) indicates seepage place and sends alerting signal on the pipe shaft photograph image.
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| Application Number | Priority Date | Filing Date | Title |
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| CN2013104207340A CN103471793A (en) | 2013-09-16 | 2013-09-16 | Metal-pipe leakage automatic detection system |
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| CN2013104207340A CN103471793A (en) | 2013-09-16 | 2013-09-16 | Metal-pipe leakage automatic detection system |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104307711A (en) * | 2014-09-02 | 2015-01-28 | 新兴铸管股份有限公司 | Metal pipe axial shift realtime correcting device and method |
| CN105181261A (en) * | 2015-05-22 | 2015-12-23 | 南通市通润汽车零部件有限公司 | Welding tightness detection machine and method using detection machine to detect welding tightness |
| WO2016026358A1 (en) * | 2014-08-19 | 2016-02-25 | 杭州乔戈里科技有限公司 | 360-degree detection device and method for visual defects of roller |
| CN106764461A (en) * | 2017-01-11 | 2017-05-31 | 昆山巴城路地管业科技有限公司 | A kind of intellectualized detection device and its method of work for pipe detection |
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| WO2016026358A1 (en) * | 2014-08-19 | 2016-02-25 | 杭州乔戈里科技有限公司 | 360-degree detection device and method for visual defects of roller |
| CN104307711A (en) * | 2014-09-02 | 2015-01-28 | 新兴铸管股份有限公司 | Metal pipe axial shift realtime correcting device and method |
| CN104307711B (en) * | 2014-09-02 | 2017-04-26 | 新兴铸管股份有限公司 | Metal pipe axial shift realtime correcting device and method |
| CN105181261A (en) * | 2015-05-22 | 2015-12-23 | 南通市通润汽车零部件有限公司 | Welding tightness detection machine and method using detection machine to detect welding tightness |
| CN106764461A (en) * | 2017-01-11 | 2017-05-31 | 昆山巴城路地管业科技有限公司 | A kind of intellectualized detection device and its method of work for pipe detection |
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Application publication date: 20131225 |