CN112882435A - Data acquisition and image processing control system and method suitable for narrow space - Google Patents
Data acquisition and image processing control system and method suitable for narrow space Download PDFInfo
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- G—PHYSICS
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Abstract
The invention provides a data acquisition and image processing control system and method suitable for a narrow space, which comprises the following steps: the control device comprises a signal acquisition unit and a control unit, wherein the signal acquisition unit acquires a plurality of signals and provides the signals to the control unit, and the control unit judges and sends a control instruction; the workstation is coupled between the control device and the walking trolley, acquires images and receives the control instruction of the control device; and the walking trolley is in communication connection with the control device and the workstation and receives the control instruction of the control device to carry out field operation. The invention controls the monitoring system in real time and analyzes the environmental data, realizes the integrated processing requirement of the nuclear power pipeline monitoring system, the graphic processing system and the welding process, relieves the labor intensity of welding technicians and reduces the influence of the construction environment on the welding quality.
Description
Technical Field
The invention belongs to the field of narrow space data monitoring and control, and provides a data acquisition and image processing control system and method suitable for a narrow space.
Background
In the development of nuclear power industry in China, welding work is one of core works for manufacturing nuclear power equipment, the problems encountered in engineering are solved by advanced equipment and an efficient welding process, the production efficiency is improved, the working quality is improved, the continuous pursuit of welding workers is realized, and the selection of welding equipment is particularly important. The existing equipment for nuclear power on-site production has low automation degree, and most of the equipment depends on welding workers or gas shield automatic welding for welding. If semi-automatic manual gas shielded welding is still adopted for welding the welding seam in the narrow space, the welding efficiency is very low, and certain hidden danger is also existed for the safety of a welder. The development of high-efficiency automatic welding technology (automatic welding equipment and process) for welding the welding seam in the narrow space has great significance for improving the production quality and the production efficiency.
With the change of computer, communication, intelligent sensing and intelligent control technologies, data has become a new natural resource, and the realization of human-object interconnection, human-environment interconnection and human-machine interconnection becomes an important development trend in the future.
In the process of building the nuclear power station, the gradual application and intelligent control requirements of welding automation are further improved, and the interaction of data, human and machines through different data systems plays a key role in quality control.
At present, some stainless steel pipelines with smaller pipe diameters exist in a main steam system and a coolant system, because the internal space of the pipelines is limited, constructors cannot enter the pipelines to observe and monitor, the traditional operation method mainly depends on site construction experience and visual observation to carry out quality control, and the main technical difficulty lies in that:
firstly, operators cannot effectively sense and acquire the internal environment of the pipeline, such as welding temperature, gas flow, illuminance and the like, the monitoring of the welding seam quality is mainly observed through a weld crater gap, and emergency measures cannot be taken for abnormal conditions of narrow space;
secondly, data acquisition adopts traditional parameter record mode among the welding process, and interference immunity is poor, is difficult to combine real-time environment and real-time accurate feedback of welding condition to welding personnel, can't satisfy online or long-range acquisition demand, only relies on personal experience and easily leads to the pipeline welding easily to produce the defect.
Disclosure of Invention
It is to be understood that both the foregoing general description and the following detailed description of the present disclosure are exemplary and explanatory and are intended to provide further explanation of the disclosure as claimed.
The invention aims at the problems that welding construction information and data of a stainless steel pipeline in a nuclear power site are difficult to acquire in a limited environment and welding and control monitoring cannot be carried out synchronously, and provides a data acquisition and image processing control system and method suitable for a narrow space of a nuclear medium pipeline.
In order to solve the above technical problem, the present invention provides a data acquisition and image processing control system suitable for a narrow space, comprising:
the control device comprises a signal acquisition unit and a control unit, wherein the signal acquisition unit acquires a plurality of signals and provides the signals to the control unit, and the control unit judges and sends a control instruction;
the workstation is coupled between the control device and the walking trolley, acquires images and receives the control instruction of the control device;
and the walking trolley is in communication connection with the control device and the workstation and receives the control instruction of the control device to carry out field operation.
Preferably, the invention further provides a data acquisition and image processing control system suitable for narrow space, which is characterized in that,
the signal acquisition unit comprises a voltage acquisition device, a Hall sensor, a gyroscope, a gas detection sensor and a temperature detection sensor.
Preferably, the invention further provides a data acquisition and image processing control system suitable for narrow space, which is characterized in that,
the control instruction comprises brightness adjustment of the LED lamp module through the light driving unit, gas control through the gas control unit, control of the motor and the electric appliance of the walking trolley through the driving unit, and control of the image acquisition unit through the workstation.
Preferably, the present invention further provides a data acquisition and image processing control system suitable for a narrow space, wherein the control device further comprises:
and the PLC conversion unit is used for carrying out proportional conversion on the acquired data of the signal acquisition unit to obtain signals including current, voltage and welding speed in the welding process.
Preferably, the present invention further provides a data acquisition and image processing control system suitable for a narrow space, wherein the workstation further comprises:
and the human-computer interaction unit is used for reading and writing the numerical value of the PLC control unit and sending an instruction to the driving unit through the PLC control unit so as to control the movement direction and speed of the walking trolley and the electric appliance.
Preferably, the invention further provides a data acquisition and image processing control system suitable for a narrow space, which is characterized in that the image acquisition unit comprises a molten pool camera.
The invention further provides a method, which adopts any one of the data acquisition and image processing control systems suitable for the narrow space, and is characterized by comprising the following steps:
step S1, initializing, including setting parameters of the acquisition unit;
step S2, starting detection including gas, temperature and brightness;
step S3, judging whether the brightness belongs to the range of the collectable brightness, if not, supplementing the brightness and then returning to the step S3 for judgment;
step S4, determine if the average gradient range of the image exceeds the setting? If the distance exceeds the preset range, the method returns to the step S4 to judge after adjusting the focal length.
Preferably, the present invention further provides a method, characterized in that the method further comprises:
and step S5, sharpening the molten pool image meeting the requirements of brightness and focal length, and storing and recording.
Preferably, the present invention further provides a method, wherein the step S2 further includes:
and acquiring initial oxygen content data of the inner wall of the pipeline to be welded, detecting whether the oxygen content standard reaches a set value after argon is filled, and if the oxygen content standard does not reach the set value, warning, and if the oxygen content standard reaches the set value, entering step S3.
Preferably, in step S3, the image mean IM of the collectable luminance range satisfies:
50≤IM≤70。
preferably, the present invention further provides a method, wherein in step S7, the image mean gradient satisfies:
0.8≤MG≤2.0。
compared with the prior art, the system and the method have the following advantages:
the method and the device realize the acquisition of initial welding preparation environment data and the acquisition and analysis of the quality of a molten pool in the welding process, meet the requirements of rapid and accurate detection of the quality of the inner wall weld joint in the nuclear power field automatic welding, and improve the welding quality and the construction efficiency.
Drawings
Embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings. Reference will now be made in detail to the preferred embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. Further, although the terms used in the present disclosure are selected from publicly known and used terms, some of the terms mentioned in the specification of the present disclosure may be selected by the applicant at his or her discretion, the detailed meanings of which are described in relevant parts of the description herein. Furthermore, it is required that the present disclosure is understood, not simply by the actual terms used but by the meaning of each term lying within.
The above and other objects, features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description of the present invention with reference to the accompanying drawings.
FIG. 1 is a block diagram of a data acquisition and image processing control system for small spaces according to the present invention;
FIG. 2 further illustrates a detailed block diagram of the components of the workstation 100 and the control device 200 therein;
fig. 3 is a flowchart of the control method of the present invention.
Reference numerals
100-workstation
101-image acquisition unit
102-human-computer interaction unit
200-control device
201-voltage collector
202-hall sensor
203-gyroscope
204-PLC control unit
205-gas detection sensor
206-temperature detection sensor
207-LED lamp module
208-gas control Unit
209-light drive unit
210-signal acquisition unit
220-PLC conversion unit
300-walking trolley
301-drive unit
Detailed Description
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings used in the description of the embodiments will be briefly introduced below. It is obvious that the drawings in the following description are only examples or embodiments of the application, from which the application can also be applied to other similar scenarios without inventive effort for a person skilled in the art. Unless otherwise apparent from the context, or otherwise indicated, like reference numbers in the figures refer to the same structure or operation.
As used in this application and the appended claims, the terms "a," "an," "the," and/or "the" are not intended to be inclusive in the singular, but rather are intended to be inclusive in the plural unless the context clearly dictates otherwise. In general, the terms "comprises" and "comprising" merely indicate that steps and elements are included which are explicitly identified, that the steps and elements do not form an exclusive list, and that a method or apparatus may include other steps or elements.
The relative arrangement of the components and steps, the numerical expressions, and numerical values set forth in these embodiments do not limit the scope of the present application unless specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective portions shown in the drawings are not drawn in an actual proportional relationship for the convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate. In all examples shown and discussed herein, any particular value should be construed as merely illustrative, and not limiting. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, further discussion thereof is not required in subsequent figures.
In the description of the present application, it is to be understood that the orientation or positional relationship indicated by the directional terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal" and "top, bottom", etc., are generally based on the orientation or positional relationship shown in the drawings, and are used for convenience of description and simplicity of description only, and in the case of not making a reverse description, these directional terms do not indicate and imply that the device or element being referred to must have a particular orientation or be constructed and operated in a particular orientation, and therefore, should not be considered as limiting the scope of the present application; the terms "inner and outer" refer to the inner and outer relative to the profile of the respective component itself.
Spatially relative terms, such as "above … …," "above … …," "above … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial relationship to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is turned over, devices described as "above" or "on" other devices or configurations would then be oriented "below" or "under" the other devices or configurations. Thus, the exemplary term "above … …" can include both an orientation of "above … …" and "below … …". The device may be otherwise variously oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
It should be noted that the terms "first", "second", and the like are used to define the components, and are only used for convenience of distinguishing the corresponding components, and the terms have no special meanings unless otherwise stated, and therefore, the scope of protection of the present application is not to be construed as being limited. Further, although the terms used in the present application are selected from publicly known and used terms, some of the terms mentioned in the specification of the present application may be selected by the applicant at his or her discretion, the detailed meanings of which are described in relevant parts of the description herein. Further, it is required that the present application is understood not only by the actual terms used but also by the meaning of each term lying within.
In order to meet the requirements of monitoring the internal environment of a nuclear power pipeline and quickly and accurately analyzing the internal environment condition, a narrow space data acquisition and image processing control system is utilized, an operator can realize the functional operations of walking, rotation, illumination control, airflow monitoring, environmental temperature, various signal data acquisition and the like of an internal monitoring mechanism according to a control interface, and meanwhile, the effective control and quality analysis judgment of the image acquisition quality in the welding process are realized based on the communication established by a camera and the control system.
Fig. 1 is a block diagram of a data acquisition and image processing control system suitable for use in a small space according to the present invention.
The control system comprises three parts: the working station 100, the control device 200 and the pipeline inner wall walking trolley 300.
Fig. 2 further illustrates a detailed block diagram of the components of the workstation 100 and the control device 200 therein.
The control device 200 includes a signal acquisition unit 210, a PLC conversion unit 220, a PLC control unit 204, an LED lamp module 206, a light driving unit 209, and a gas control unit 208.
The signal acquisition unit 210 is configured to acquire signals including voltage, position, speed, gas, temperature, and the like, and the signals are acquired by the voltage acquisition unit 201, the hall sensor 202, the speed detection gyroscope 203, the gas detection sensor 205, and the temperature detection sensor 206, respectively.
The pipeline inner wall walking trolley 300 is connected with the control device 200 through a communication line, and the front end of the trolley 300 is provided with a temperature detection sensor 206, an LED lamp module 207, a gas detection sensor 205 and an image acquisition unit 101.
Preferably, the image capturing unit 101 may be a weld pool camera for capturing a weld pool image.
The PLC control unit 204 in the control device 200 establishes communication with the C # program through the PLC program, and mainly performs centralized control and processing on the analog quantities provided by the different modules and the signal acquisition unit 210, respectively. The objects controlled by the PLC control unit 204 include motor speed regulation and direction control, welding current and voltage and welding speed, robot lighting loop and gas control, etc. The other part comprises reading and writing of a data block of the PLC, calling of a camera monitoring function, judging of the image quality of a molten pool, and displaying, recording and saving of welding data, which will be described in detail later. The control device 200 of the system of the invention transmits the output data of the signal acquisition unit 210 such as the voltage collector 201, the hall sensor 202, the gyroscope 203, the gas detection sensor 205, the temperature detection sensor 206 and the like to the PLC conversion unit 220, and obtains the current, the voltage and the welding speed in the welding process through proportional conversion. The PLC control unit 204 continuously reads the current, voltage, welding speed, etc. data and displays them on the control panel. The PLC control unit 204 performs welding in combination with judgment conditions in the process, when the current and the voltage are greater than certain values, the welding machine starts to record welding data, the welding data is recorded every second, and the recorded data is stored in a workstation.
Specific judgment conditions and operations relate to: and judging the image quality and the forming effect according to the acquired molten pool image. Firstly, acquiring an image quality effect, if the image quality effect does not meet the requirements, sending a control instruction to adjust the object distance between the weld bead and the acquisition camera and walking and positioning, enabling the camera to be parallel to the horizontal plane and the lens to keep a certain angle with the weld bead, combining the equipped LED lamp set, acquiring appropriate brightness to achieve a more ideal acquisition state, and ensuring the information of the molten pool to be clear and complete. And then, processing and analyzing the image by using an image processing program of the control system, finishing sharpening processing on the image, and finally synchronously storing the sharpened image and the welding process data to a workstation.
The PLC control unit 204 in the control device 200 controls and adjusts the brightness of the LED lamp module 207 through the light driving unit 209, adjusts the argon gas used in the welding environment through the gas control unit 208, and controls the motor speed regulation and direction, the welding current voltage, the welding speed, and the like of the traveling carriage 300 through the driving unit 301.
The system also comprises four display units on the man-machine interaction unit 102:
the real-time data window of the internal environment of the pipeline comprises oxygen content monitoring data, early warning prompt, illuminance display data, environment temperature and camera temperature monitoring data;
a welding process information data window mainly displays real-time acquisition and storage settings of welding current, welding voltage and welding speed;
thirdly, a camera monitors a display window, and the camera mainly displays a molten pool signal in a walking trolley control process and a welding process, and the system provides a local storage function;
and fourthly, controlling the window by the walking trolley, and mainly comprising the functions of trolley walking, rotation, camera object distance adjustment data writing and display.
The following describes the implementation of the whole control method in detail with reference to a data acquisition and image processing control system suitable for narrow space according to a preferred embodiment, as shown in fig. 3.
Step S1, before welding, the walking trolley 300 is controlled to move to the position of a weld crater through the man-machine interaction unit 102 of the workstation 100, and initialization setting is carried out;
the initialization includes matching the speed and direction of the motor, the register address of the switch of the electric appliance and the data block address of the PLC in the PLC control unit 204, calling a library file, and implementing communication between the workstation 100 and the PLC control unit 204 using a TCP/IP protocol. The workstation 100 is used as an upper computer of the PLC, can read and write the numerical value in the PLC data block through the human-computer interaction unit 102, and then sends an instruction to the driving unit 301 through the PLC to control the motor and the electrical appliance, so that the control of the moving direction and speed of the walking trolley 300 and the switch of the electrical appliance can be realized at the PC end.
Meanwhile, in this step, main parameters of the molten pool captured image capturing unit 101 are also set:
acquisition frequency: 25FPS/S, pixel bit depth 12bit
A shutter mode: rolling screen
Triggering a mode: the acquisition is continuous, and the image acquisition size is 1280 × 824 pixels.
In order to reduce the influence of welding arc light on the image of the molten pool, a 35mm lens is selected as the lens and is adjusted to be proper in focal length and aperture.
Step S2, automatically calling the weld pool to acquire the image acquisition unit 101, and displaying the image information of the weld craters on the workstation 100 when the image acquisition unit 101 is connected;
step S3, the gas detection sensor 205 is turned on, and the initial oxygen content data of the inner wall of the stainless steel pipe at the position to be welded is obtained and recorded and stored. Then, externally-connected argon gas is filled into the pipeline, the pipeline is detected by the gas detection sensor 205 every 2min until the standard content of the oxygen content is less than or equal to 0.1 percent, otherwise, an early warning indicator lamp flickers for prompting;
step S4, the temperature detection sensor 206 is turned on to acquire the environmental temperature data of the inner wall of the stainless steel pipe, and the data is recorded and stored. Because the heat is large in the welding process and the welding process is in a closed environment, the temperature detection sensor 206 monitors and records the welding temperature on one hand, and monitors and controls the working temperature of the molten pool image acquisition unit 101 and other electronic hardware on the other hand, and when the working temperature exceeds a preset range, the early warning indicator lamp flickers and prompts whether to stop welding or not;
step S5, controlling the light driving unit 209 to connect with the LED lamp module 207, and adaptively adjusting the brightness of the inner wall of the pipeline;
the LED lamp modules 207 are divided into two groups, one group is arranged on the body of the walking trolley 300, and light is provided to guide the trolley 300 to move to a welding position in a dark limited space; and a group of light sources are arranged around the image acquisition unit 101 and used as active light sources to illuminate the dim light areas of the welding openings.
Specifically, the workstation 100 determines the brightness of the image information of the molten pool, and determines whether the brightness is in the range of the collectable brightness:
50≤IM≤70
wherein IM is an image mean value;
if not, go to step S6;
step S6, the PLC control unit 204 controls the LED lamp module 207 to supplement brightness through the light driving unit 209 until the crater information and the molten pool are clearly visible and judged correctly, and effectively collects and processes the molten pool image; if the brightness is within the range of the collectable brightness, the step S7 is entered;
step S7, the workstation 100 determines whether the average gradient of the image is within the determination range according to the acquired molten pool image:
0.8≤MG≤2.0
wherein MG is the average gradient;
step S8, if the judgment in the step S7 exceeds the range, an object distance adjusting command is sent to the trolley 300, the distance between the object distance acquisition of the front end of the trolley 300 and the back weld joint is adjusted, the focal length is adjusted according to 1cm/S, and the step S7 is returned to judge again until the average gradient of the molten pool image meets the range;
step S9, after obtaining the brightness and the focal length meeting the requirements through steps S5 and S7, the workstation 100 sharpens the molten pool by using roberts differential algorithm, i.e. removing interference, obtaining the distinction between the molten pool image with higher contrast and the collected background image, and improving the detail precision:
wherein (p, q) is a pixel point of the molten pool image f (x, y), and an image with better molten pool quality characteristics is obtained after processing.
S10: after welding starts, the three acquisition modules of the voltage acquisition device, the Hall sensor and the speed detection gyroscope are used for respectively acquiring welding current, welding voltage and welding speed in the welding process, acquiring frequency 1 time/S, continuously reading three types of data in the PLC control unit 204 by the workstation 100, simultaneously acquiring the inner wall temperature monitoring test result obtained in the step S4 and the molten pool real-time characteristic image obtained in the step S9, and displaying, recording and storing in real time on an interface.
A preferred embodiment will now be described which uses a phi 455mm x 45mm 304 stainless steel tube for the image acquisition test, with a U-shaped bevel, and a narrow gap bevel. The welding information collection of joint mainly is the backing weld, adopts circumferential welding, and electric arc does not swing among the welding process, uses pulse welding, and main welding parameter information is shown as table 1:
TABLE 1
The invention solves the problems that the real-time information in the nuclear power limited space pipeline is difficult to obtain, and the welding line process in the narrow space of the nuclear medium pipeline is difficult to effectively control and judge the forming quality, realizes the acquisition of the initial welding preparation environment data and the collection and analysis of the quality of the molten pool in the welding process, meets the requirements of the nuclear power site automatic welding on the rapidness, the accuracy and the detection of the quality of the welding line on the inner wall, and improves the welding quality and the construction efficiency.
The foregoing shows and describes the general principles and features of the present invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed.
Having thus described the basic concept, it will be apparent to those skilled in the art that the foregoing disclosure is by way of example only, and is not intended to limit the present application. Various modifications, improvements and adaptations to the present application may occur to those skilled in the art, although not explicitly described herein. Such modifications, improvements and adaptations are proposed in the present application and thus fall within the spirit and scope of the exemplary embodiments of the present application.
Also, this application uses specific language to describe embodiments of the application. Reference throughout this specification to "one embodiment," "an embodiment," and/or "some embodiments" means that a particular feature, structure, or characteristic described in connection with at least one embodiment of the present application is included in at least one embodiment of the present application. Therefore, it is emphasized and should be appreciated that two or more references to "an embodiment" or "one embodiment" or "an alternative embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, some features, structures, or characteristics of one or more embodiments of the present application may be combined as appropriate.
Aspects of the present application may be embodied entirely in hardware, entirely in software (including firmware, resident software, micro-code, etc.) or in a combination of hardware and software. The above hardware or software may be referred to as "data block," module, "" engine, "" unit, "" component, "or" system. The processor may be one or more Application Specific Integrated Circuits (ASICs), Digital Signal Processors (DSPs), digital signal processing devices (DAPDs), Programmable Logic Devices (PLDs), Field Programmable Gate Arrays (FPGAs), processors, controllers, microcontrollers, microprocessors, or a combination thereof. Furthermore, aspects of the present application may be represented as a computer product, including computer readable program code, embodied in one or more computer readable media. For example, computer-readable media may include, but are not limited to, magnetic storage devices (e.g., hard disk, floppy disk, magnetic strips … …), optical disks (e.g., Compact Disk (CD), Digital Versatile Disk (DVD) … …), smart cards, and flash memory devices (e.g., card, stick, key drive … …).
The computer readable medium may comprise a propagated data signal with the computer program code embodied therein, for example, on a baseband or as part of a carrier wave. The propagated signal may take any of a variety of forms, including electromagnetic, optical, and the like, or any suitable combination. The computer readable medium can be any computer readable medium that can communicate, propagate, or transport the program for use by or in connection with an instruction execution system, apparatus, or device. Program code on a computer readable medium may be propagated over any suitable medium, including radio, electrical cable, fiber optic cable, radio frequency signals, or the like, or any combination of the preceding.
Having thus described the basic concept, it will be apparent to those skilled in the art that the foregoing disclosure is by way of example only, and is not intended to limit the present application. Various modifications, improvements and adaptations to the present application may occur to those skilled in the art, although not explicitly described herein. Such modifications, improvements and adaptations are proposed in the present application and thus fall within the spirit and scope of the exemplary embodiments of the present application.
Also, this application uses specific language to describe embodiments of the application. Reference throughout this specification to "one embodiment," "an embodiment," and/or "some embodiments" means that a particular feature, structure, or characteristic described in connection with at least one embodiment of the present application is included in at least one embodiment of the present application. Therefore, it is emphasized and should be appreciated that two or more references to "an embodiment" or "one embodiment" or "an alternative embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, some features, structures, or characteristics of one or more embodiments of the present application may be combined as appropriate.
Similarly, it should be noted that in the preceding description of embodiments of the application, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure aiding in the understanding of one or more of the embodiments. This method of disclosure, however, is not intended to require more features than are expressly recited in the claims. Indeed, the embodiments may be characterized as having less than all of the features of a single embodiment disclosed above.
Numerals describing the number of components, attributes, etc. are used in some embodiments, it being understood that such numerals used in the description of the embodiments are modified in some instances by the use of the modifier "about", "approximately" or "substantially". Unless otherwise indicated, "about", "approximately" or "substantially" indicates that the number allows a variation of ± 20%. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximations that may vary depending upon the desired properties of the individual embodiments. In some embodiments, the numerical parameter should take into account the specified significant digits and employ a general digit preserving approach. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the range are approximations, in the specific examples, such numerical values are set forth as precisely as possible within the scope of the application.
Although the present application has been described with reference to the present specific embodiments, it will be recognized by those skilled in the art that the foregoing embodiments are merely illustrative of the present application and that various changes and substitutions of equivalents may be made without departing from the spirit of the application, and therefore, it is intended that all changes and modifications to the above-described embodiments that come within the spirit of the application fall within the scope of the claims of the application.
Claims (11)
1. A data acquisition and image processing control system suitable for narrow and small space, characterized by comprising:
the control device comprises a signal acquisition unit and a control unit, wherein the signal acquisition unit acquires a plurality of signals and provides the signals to the control unit, and the control unit judges and sends a control instruction;
the workstation is coupled between the control device and the walking trolley, acquires images and receives the control instruction of the control device;
and the walking trolley is in communication connection with the control device and the workstation and receives the control instruction of the control device to carry out field operation.
2. The narrow space data acquisition and image processing control system as claimed in claim 1,
the signal acquisition unit comprises a voltage acquisition device, a Hall sensor, a gyroscope, a gas detection sensor and a temperature detection sensor.
3. The narrow space data acquisition and image processing control system as claimed in claim 2,
the control instruction comprises brightness adjustment of the LED lamp module through the light driving unit, gas control through the gas control unit, control of the motor and the electric appliance of the walking trolley through the driving unit, and control of the image acquisition unit through the workstation.
4. The narrow space data acquisition and image processing control system according to claim 3, wherein said control device further comprises:
and the PLC conversion unit is used for carrying out proportional conversion on the acquired data of the signal acquisition unit to obtain signals including current, voltage and welding speed in the welding process.
5. The narrow space data acquisition and image processing control system as claimed in claim 4, wherein said workstation further comprises:
and the human-computer interaction unit is used for reading and writing the numerical value of the PLC control unit and sending an instruction to the driving unit through the PLC control unit so as to control the movement direction and speed of the walking trolley and the electric appliance.
6. The narrow-space data acquisition and image processing control system according to claim 5,
the image acquisition unit comprises a molten pool camera.
7. A method for using any one of claims 1 to 6 in a data acquisition and image processing control system for small spaces, the method comprising:
step S1, initializing, including setting parameters of the acquisition unit;
step S2, starting detection including gas, temperature and brightness;
step S3, judging whether the brightness belongs to the range of the collectable brightness, if not, supplementing the brightness and then returning to the step S3 for judgment;
step S4, determine if the average gradient range of the image exceeds the setting? If the distance exceeds the preset range, the method returns to the step S4 to judge after adjusting the focal length.
8. The method of claim 7, further comprising:
and step S5, sharpening the molten pool image meeting the requirements of brightness and focal length, and storing and recording.
9. The method of claim 8,
the step S2 further includes:
and acquiring initial oxygen content data of the inner wall of the pipeline to be welded, detecting whether the oxygen content standard reaches a set value after argon is filled, and if the oxygen content standard does not reach the set value, warning, and if the oxygen content standard reaches the set value, entering step S3.
10. The method according to claim 9, wherein in the step S3, the image mean IM of the acquirable luminance range satisfies:
50≤IM≤70。
11. the method according to claim 9, wherein in the step S7, the image mean gradient satisfies:
0.8≤MG≤2.0。
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Application publication date: 20210601 |