CN117236756A - Intelligent control system for pipe fitting welding forming based on machine vision - Google Patents
Intelligent control system for pipe fitting welding forming based on machine vision Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 265
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- 230000003749 cleanliness Effects 0.000 claims description 23
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Abstract
The invention relates to the field of intelligent manufacturing, in particular to an intelligent control system for pipe welding forming based on machine vision, which comprises a pipe image acquisition module, a pipe information analysis module, a welding data acquisition module, a welding deviation analysis module, a management database and a pipe quality comprehensive analysis module.
Description
Technical Field
The invention relates to the field of intelligent manufacturing, in particular to an intelligent control system for pipe welding forming based on machine vision.
Background
The machine vision technology is a technology for analyzing and processing images or videos by using a computer and a corresponding algorithm, and is widely applied to the welding field along with the continuous improvement of the industrial automation degree and the development of the intelligent manufacturing industry, and the requirements on welding quality and efficiency are higher and higher when the pipe fitting welding is used as a key technology.
In conventional pipe welding, an experienced welder is usually required to operate, and the quality of a welding line is ensured by naked eye judgment and manual measurement, however, the method has the following defects, and the method is particularly characterized in the following aspects:
1. the control requirements of traditional pipe fitting welding on welding parameters are higher, such as welding current, voltage, welding speed and the like, the welding process needs operation by operators with abundant experience, but due to the skill level and experience difference of different operators, the operation is inaccurate, so that the welding quality is negatively influenced, and meanwhile, the naked eye judgment and the manual measurement are used for evaluating the welding quality, so that the welding quality is easily influenced by the personal experience and subjective judgment of a welder, and the inconsistency and the reliability of the welding quality are possibly reduced.
2. Traditional pipe fitting welding can ignore counterpoint data monitoring and analysis of pipe fitting, leads to skew or dislocation between the pipe fitting, influences pipe fitting welded connection accuracy, lacks the clean data monitoring to pipe fitting counterpoint region, leads to the cleanliness before pipe fitting welding not up to standard, and the accumulation of pollutant and impurity can influence pipe fitting welding quality.
3. The lack of real-time monitoring and recording, the traditional method does not provide real-time monitoring and recording functions, and key parameters in the welding process cannot be accurately tracked, so that corrective measures are difficult to take in time when problems are found, and quality tracing and continuous improvement are difficult.
Disclosure of Invention
In order to solve the technical problems, the invention is realized by the following technical scheme: machine vision-based intelligent control system for pipe welding forming, comprising: and the pipe fitting image acquisition module is used for acquiring the pipe fitting image before welding through the camera and recording the pipe fitting image as a pipe fitting information image.
The pipe fitting information acquisition module is used for acquiring the wall thickness of the pipe fitting through the pipe fitting information image, and monitoring alignment data of the pipe fitting, pipe fitting welding chamfer angle setting data and cleaning data of a pipe fitting alignment area, wherein the alignment data of the pipe fitting comprise a gap area, a dislocation distance and a deflection angle between the pipe fittings, and the pipe fitting welding chamfer angle setting data comprise angles and chamfer areas of two pipe fitting chamfer angles.
The pipe fitting information analysis module is used for analyzing and obtaining the alignment accuracy between the pipe fitting and the pipe fitting, the opening conformity of the welding chamfer and the cleanliness of the pipe fitting according to the alignment data of the pipe fitting, the opening data of the welding chamfer of the pipe fitting and the cleaning data of the alignment area of the pipe fitting, and marking the alignment accuracy, the opening conformity and the cleanliness of the welding chamfer as epsilon, gamma and lambda respectively, so that the quality conformity of the pipe fitting is obtained through comprehensive analysis.
And the welding data acquisition module is used for detecting the temperature and the pressure of the pipe welding point at each time point and the actual voltage, current and welding speed of each time point when the pipe is welded in the pipe welding process.
The welding deviation analysis module is used for analyzing the temperature and pressure of the welding point of the pipe fitting at each time point to obtain the temperature deviation degree and the pressure deviation degree of the welding point of the pipe fitting; and meanwhile, extracting standard voltage, current and welding speed corresponding to the wall thickness of the pipe fitting according to the wall thickness of the pipe fitting, comparing the standard voltage, current and welding speed with actual voltage, current and welding speed at each time point when the pipe fitting is welded, analyzing and obtaining the welding efficiency deviation degree of the pipe fitting, and comprehensively analyzing and obtaining the welding process influence parameters of the pipe fitting by combining the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree of the pipe fitting welding point.
And the management database is used for storing maximum allowable values of gap area, dislocation distance and deflection angle between the pipe fittings, and standard voltage, current and welding speed corresponding to the quality level of the pipe fittings and the wall thickness of the pipe fittings.
And the pipe fitting quality comprehensive analysis module is used for marking the welded pipe fitting as a formed pipe fitting, analyzing and obtaining comprehensive quality evaluation parameters of the formed pipe fitting according to the quality coincidence degree of the pipe fitting and the welding process influence parameter of the pipe fitting, and comparing the comprehensive quality evaluation parameters with a preset comprehensive quality evaluation parameter range so as to obtain the welding quality condition of the formed pipe fitting.
As a preferred solution, the method for analyzing the alignment accuracy between the pipe fittings specifically includes the following steps: the method comprises the steps of firstly, obtaining a pipe fitting information image, respectively marking two pipe fittings to be welded in the pipe fitting information image as a first pipe fitting and a second pipe fitting, obtaining a gap area between the first pipe fitting and the second pipe fitting in the pipe fitting information image by utilizing an edge detection algorithm, extracting the area of the gap area, and marking the area as a gap area s1 between the pipe fittings.
Step two, respectively selecting the center point of the welding surface of the first pipe fitting and the center point of the welding surface of the second pipe fitting as reference points according to the pipe fitting information images, measuring the horizontal distance and the vertical distance between the reference points of the first pipe fitting and the second pipe fitting, respectively marking as d1 and d2, and passing through the formulaThe misalignment distance d between the tubes is obtained.
Third, reading the horizontal distance and the vertical distance between the reference points of the first pipe fitting and the second pipe fitting, and substituting the horizontal distance and the vertical distance into a formulaA skew angle θ between the pipe elements is obtained.
Fourth, the gap area, the dislocation distance and the deflection angle between the pipe fittings are respectively read and substituted into a formulaThe obtained alignment accuracy epsilon, s1', d ', theta ' between the pipe fittings are respectively expressed as maximum allowable values of the gap area, the dislocation distance and the deflection angle between the pipe fittings, a1 is expressed as a correction factor of the set alignment accuracy between the pipe fittings, and e is expressed as a natural constant.
As a preferable scheme, the analysis method for the opening conformity of the welding chamfer specifically comprises the following steps: the first step, respectively obtaining the chamfering length and the chamfering thickness of the first pipe fitting and the second pipe fitting according to the pipe fitting information image, respectively marking the chamfering length and the chamfering thickness as l1 and l2, and delta 1 and delta 2, and passing through the formulaObtaining a first tubeAngle θ formed by chamfering the member and the second pipe 1 ”、θ 2 ”。
Reading the chamfer lengths of the first pipe fitting and the second pipe fitting, measuring the chamfer widths of the first pipe fitting and the second pipe fitting, obtaining the chamfer areas of the first pipe fitting and the second pipe fitting by multiplying the chamfer lengths of the first pipe fitting and the second pipe fitting by the chamfer widths of the first pipe fitting and the second pipe fitting, and marking the chamfer areas as s respectively 1 ”、s 2 ”。
Step three, respectively reading the chamfer angles and the chamfer areas of the first pipe fitting and the second pipe fitting, and passing through the formulaObtaining a difference coefficient of chamfer angle opening between the pipe fittings>Wherein θ is 0 、s 0 The values are respectively expressed as the set angle for chamfering the pipe fitting and the standard value of the area for chamfering the pipe fitting, phi 1 and phi 2 are respectively expressed as the angle difference value for chamfering the pipe fitting and the weight factor of the area difference value for chamfering the pipe fitting, and phi 1+ phi 2 = 1.
Fourth, reading a difference coefficient formed by chamfering between the pipe fittings, and passing through a formulaAnd obtaining the opening conformity gamma of the welding chamfer, wherein e is expressed as a natural constant, and a2 is expressed as a correction factor of the opening conformity of the welding chamfer.
As a preferred scheme, the specific analysis method of the pipe fitting cleanliness is as follows: acquiring a pipe fitting information image, individually dividing a pipe fitting alignment area, carrying out gray processing on the pipe fitting alignment area, marking the image after gray processing as a pipe fitting alignment gray image, detecting a gray value of each pixel point in the pipe fitting alignment gray image, comparing the gray value with a set pipe fitting alignment standard gray value range, screening and counting the number of pixels with all gray values which are not in the pipe fitting alignment standard gray value range, marking the number as rho, and simultaneously extracting the pipe fittingThe total pixel number of the para-gray image is recorded as ρ 0 Substituting it into formulaObtaining the cleaning degree lambda' in the alignment range of the pipe fitting by the formula +.>The pipe cleanliness lambda, a3 is obtained as a correction factor for the pipe cleanliness.
As a preferable scheme, the specific analysis method of the quality conformity of the pipe fitting is as follows: respectively reading the alignment accuracy between the pipe fittings, the opening conformity of the welding chamfer angles and the cleaning degree of the pipe fittings, and substituting the alignment accuracy, the opening conformity and the cleaning degree into a formulaThe quality conformity psi of the pipe fitting is obtained, wherein eta 1, eta 2 and eta 3 are respectively expressed as weight factors of the alignment accuracy between the pipe fitting, the opening conformity of the welding chamfer and the pipe fitting cleanliness.
As a preferred scheme, the specific analysis process of the welding deviation analysis module comprises the following steps: the first step is to measure the temperature of the welding point at each time point during pipe welding and the pressure exerted by the welding gun on the welding point of the pipeline during the welding process by a temperature sensor and a pressure sensor, which are respectively marked as TT i 、PT i I is expressed as the number of the i-th time point, i=1, 2,..n, which is compared to the standard temperature and pressure of the pipe fitting weld, by the formulaObtaining the temperature deviation delta TT and the pressure deviation delta PT, TT of the welding point of the pipe fitting 0 、PT 0 Respectively, the standard temperature and pressure of the pipe fitting welds.
Step two, measuring the actual voltage and current at each time point when the pipe fitting is welded, and recording the actual voltage and current as U i 、I i And tracking the pipe welding area by image processing technology and measuring the welding at each time pointThe connection speed is denoted as V i Extracting the wall thickness of the pipe fitting, reading standard voltage, current and welding speed corresponding to the wall thickness of the pipe fitting, comparing the standard voltage, current and welding speed with actual voltage, current and welding speed at each time point when the pipe fitting is welded, and obtaining the standard voltage, current and welding speed by a formulaObtaining welding efficiency deviation sigma of pipe fitting, wherein U 0 、I 0 、V 0 Respectively expressed as standard voltage, current and welding speed corresponding to the pipe wall thickness, and eta 4 is the correction factor of the welding efficiency deviation degree of the pipe.
As a preferable scheme, the specific analysis method of the welding process influence parameters of the pipe fitting is as follows: respectively reading the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree of the welding point of the pipe fitting, and substituting the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree into a formulaObtaining the welding process influencing parameters of the pipe fitting>Where η5 is denoted as a correction factor for the welding process influencing parameter of the pipe and e is denoted as a natural constant.
As a preferred embodiment, the specific analysis method of the comprehensive quality evaluation parameter of the formed pipe comprises the following steps: firstly, respectively reading quality conformity of the pipe fitting and influence parameters of a welding process, and passing through a formulaAnd obtaining a comprehensive quality evaluation parameter χ of the formed pipe fitting, wherein η6 and η7 are respectively expressed as a quality conformity of the formed pipe fitting and a weight factor of a welding process influence parameter, and η6+η7=1 and e is expressed as a natural constant.
And secondly, comparing the comprehensive quality evaluation parameters of the formed pipe fitting with the set comprehensive quality evaluation parameter ranges corresponding to the quality levels, screening the quality levels corresponding to the comprehensive quality evaluation parameters of the formed pipe fitting, further obtaining the quality level of the formed pipe fitting, and if the quality level of the formed pipe fitting is lower than the set quality level of the pipe fitting, marking the formed pipe fitting as a disqualified pipe fitting.
Compared with the prior art, the invention has the following beneficial effects: 1. according to the system, the alignment data of the pipe fitting, the welding chamfer setting data of the pipe fitting and the cleaning data of the pipe fitting alignment area are monitored, the alignment accuracy between the pipe fitting and the pipe fitting, the setting conformity of the welding chamfer and the pipe fitting cleanliness are obtained through analysis, the quality conformity of the pipe fitting is further obtained through comprehensive analysis, the connection accuracy of the pipe fitting is ensured, the problems of deviation or dislocation and the like are avoided, whether the welding chamfer meets the requirements or not is evaluated, the accumulation of impurities and pollutants is reduced, and the risks of pipe fitting blockage and corrosion are reduced.
2. The system analyzes and obtains the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree of the welding point of the pipe fitting by detecting the temperature and the pressure of the welding point of the pipe fitting and the actual voltage, the current and the welding speed of each time point when the pipe fitting is welded, further comprehensively analyzes and obtains the influence parameters of the welding process, is favorable for evaluating the temperature control condition in the welding process, ensures that the temperature of the welding point is in a safe range, avoids the welding quality problem caused by overheat or supercooling, can evaluate the pressure control condition in the welding process by detecting and analyzing the pressure, ensures the pressure stability of the welding point, can know the efficiency condition of the welding process, finds potential problems, and timely takes measures to improve the welding efficiency and quality.
3. The system obtains the comprehensive quality evaluation parameters of the pipe fitting through analyzing the quality conformity of the formed pipe fitting and the influence parameters of the welding process of the formed pipe fitting, compares the comprehensive quality evaluation parameters with the preset comprehensive quality evaluation parameter range, further obtains the welding quality condition of the formed pipe fitting, is beneficial to judging the welding quality condition of the formed pipe fitting, and timely discovers and solves the quality problem, thereby ensuring that the welding quality of the pipe fitting meets the expected requirement.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed for the description of the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a diagram illustrating a system module connection according to the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, the intelligent control system for welding forming of a pipe fitting based on machine vision of the invention comprises a pipe fitting image acquisition module, a pipe fitting information analysis module, a welding data acquisition module, a welding deviation analysis module, a management database and a pipe fitting quality comprehensive analysis module.
The management database is connected with the key information analysis module, the pipe quality comprehensive analysis module and the welding deviation analysis module, the pipe quality comprehensive analysis module is connected with the pipe information acquisition module, the pipe information analysis module and the welding deviation analysis module, the pipe image acquisition module is connected with the pipe information acquisition module and the welding data acquisition module, and the welding data acquisition module is connected with the welding deviation analysis module.
And the pipe fitting image acquisition module is used for acquiring the pipe fitting image before welding through the camera and recording the pipe fitting image as a pipe fitting information image.
The pipe fitting information acquisition module is used for acquiring the wall thickness of the pipe fitting through the pipe fitting information image, and monitoring alignment data of the pipe fitting, pipe fitting welding chamfer angle setting data and cleaning data of a pipe fitting alignment area, wherein the alignment data of the pipe fitting comprise a gap area, a dislocation distance and a deflection angle between the pipe fittings, and the pipe fitting welding chamfer angle setting data comprise angles and chamfer areas of two pipe fitting chamfer angles.
The pipe fitting information analysis module is used for analyzing and obtaining the alignment accuracy between the pipe fitting and the pipe fitting, the opening conformity of the welding chamfer and the cleanliness of the pipe fitting according to the alignment data of the pipe fitting, the opening data of the welding chamfer of the pipe fitting and the cleaning data of the alignment area of the pipe fitting, and marking the alignment accuracy, the opening conformity and the cleanliness of the welding chamfer as epsilon, gamma and lambda respectively, so that the quality conformity of the pipe fitting is obtained through comprehensive analysis.
The analysis method of the alignment accuracy between the pipe fittings specifically comprises the following steps: the method comprises the steps of firstly, obtaining a pipe fitting information image, respectively marking two pipe fittings to be welded in the pipe fitting information image as a first pipe fitting and a second pipe fitting, obtaining a gap area between the first pipe fitting and the second pipe fitting in the pipe fitting information image by utilizing an edge detection algorithm, extracting the area of the gap area, and marking the area as a gap area s1 between the pipe fittings.
Step two, respectively selecting the center point of the welding surface of the first pipe fitting and the center point of the welding surface of the second pipe fitting as reference points according to the pipe fitting information images, measuring the horizontal distance and the vertical distance between the reference points of the first pipe fitting and the second pipe fitting, respectively marking as d1 and d2, and passing through the formulaThe misalignment distance d between the tubes is obtained.
Third, reading the horizontal distance and the vertical distance between the reference points of the first pipe fitting and the second pipe fitting, and substituting the horizontal distance and the vertical distance into a formulaA skew angle θ between the pipe elements is obtained.
Fourth, the gap area, the dislocation distance and the deflection angle between the pipe fittings are respectively read and substituted into a formulaObtaining alignment accuracy epsilon, s1', d ', theta ' between the pipe fittingsThe maximum allowable values of the gap area, the dislocation distance and the deflection angle between the pipe fittings are shown, a1 is shown as a correction factor of the set alignment accuracy between the pipe fittings, and e is shown as a natural constant; by analyzing the gap area, the dislocation distance and the deflection angle between the pipe fittings, the welding accuracy and reliability can be ensured, the efficiency and the reliability of the welding process can be improved, the manual operation errors can be reduced, whether deviation conditions such as deflection, inclination or dislocation exist or not can be detected by analyzing the alignment data, a smaller deviation value indicates more accurate alignment, and a larger deviation value indicates inaccurate alignment.
The analysis method for the opening conformity of the welding chamfer specifically comprises the following steps: the first step, respectively obtaining the chamfering length and the chamfering thickness of the first pipe fitting and the second pipe fitting according to the pipe fitting information image, respectively marking the chamfering length and the chamfering thickness as l1 and l2, and delta 1 and delta 2, and passing through the formula Obtaining an angle theta formed by chamfering the first pipe fitting and the second pipe fitting 1 ”、θ 2 ”。
Reading the chamfer lengths of the first pipe fitting and the second pipe fitting, measuring the chamfer widths of the first pipe fitting and the second pipe fitting, obtaining the chamfer areas of the first pipe fitting and the second pipe fitting by multiplying the chamfer lengths of the first pipe fitting and the second pipe fitting by the chamfer widths of the first pipe fitting and the second pipe fitting, and marking the chamfer areas as s respectively 1 ”、s 2 ”。
Step three, respectively reading the chamfer angles and the chamfer areas of the first pipe fitting and the second pipe fitting, and passing through the formulaObtaining a difference coefficient of chamfer angle opening between the pipe fittings>Wherein θ is 0 、s 0 The values are respectively expressed as the set angle for chamfering the pipe fitting and the standard value of the area for chamfering the pipe fitting, phi 1 and phi 2 are respectively expressed as the angle difference value for chamfering the pipe fitting and the weight factor of the area difference value for chamfering the pipe fitting, and phi 1+ phi 2 = 1.
Fourth, reading a difference coefficient formed by chamfering between the pipe fittings, and passing through a formulaObtaining the opening conformity gamma of the welding chamfer, wherein e is expressed as a natural constant, and a2 is expressed as a correction factor of the opening conformity of the welding chamfer; according to the welding chamfer setting data of the pipe fitting, the setting conformity of the chamfer can be evaluated, the welding chamfer is formed by chamfering the edge of a welding seam at the joint of the pipe fitting, so that the strength and the quality of a welding joint are improved, whether the chamfer meets the design specification and the requirements can be determined by analyzing the setting data, and the accuracy and the consistency of the chamfer can influence the quality of the welding joint.
The specific analysis method of the pipe fitting cleanliness comprises the following steps: acquiring a pipe fitting information image, individually dividing a pipe fitting alignment area, carrying out gray processing on the pipe fitting information image, marking the image after gray processing as a pipe fitting alignment gray image, detecting a gray value of each pixel point in the pipe fitting alignment gray image, comparing the gray value with a set pipe fitting alignment standard gray value range, screening and counting the number of pixels with all gray values which are not in the pipe fitting alignment standard gray value range, marking as rho, and simultaneously extracting the total number of pixels of the pipe fitting alignment gray image, marking as rho 0 Substituting it into formulaObtaining the cleaning degree lambda' in the alignment range of the pipe fitting by the formula +.>Obtaining a tube cleanliness lambda, a3 being a correction factor for the tube cleanliness; cleanliness is the cleanliness of the surface of a pipe by analyzing the cleaning dataIt is possible to detect the presence of dirt, grease or other contaminants on the pipe surface and evaluate the degree of cleanliness for acceptability.
The concrete analysis method of the quality conformity of the pipe fitting comprises the following steps: respectively reading the alignment accuracy between the pipe fittings, the opening conformity of the welding chamfer angles and the cleaning degree of the pipe fittings, and substituting the alignment accuracy, the opening conformity and the cleaning degree into a formulaObtaining quality conformity psi of the pipe fittings, wherein eta 1, eta 2 and eta 3 are respectively expressed as weight factors of alignment accuracy, welding chamfer opening conformity and pipe fitting cleanliness between the pipe fittings; the quality conformity of the pipe fitting is analyzed, the production process of the pipe fitting is optimized, the quality control and quality management of the pipe fitting are improved, the purpose of improving the quality of the pipe fitting is achieved, the connection and welding between the pipe fitting are ensured to meet the requirements, the occurrence of quality problems and potential faults is reduced, and the overall production efficiency and quality are improved.
And the welding data acquisition module is used for detecting the temperature and the pressure of the pipe welding point at each time point and the actual voltage, current and welding speed of each time point when the pipe is welded in the pipe welding process.
The welding deviation analysis module is used for analyzing the temperature and pressure of the welding point of the pipe fitting at each time point to obtain the temperature deviation degree and the pressure deviation degree of the welding point of the pipe fitting; and meanwhile, extracting standard voltage, current and welding speed corresponding to the wall thickness of the pipe fitting according to the wall thickness of the pipe fitting, comparing the standard voltage, current and welding speed with actual voltage, current and welding speed at each time point when the pipe fitting is welded, analyzing and obtaining the welding efficiency deviation degree of the pipe fitting, and comprehensively analyzing and obtaining the welding process influence parameters of the pipe fitting by combining the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree of the pipe fitting welding point.
The specific analysis process of the welding deviation analysis module comprises the following steps: the first step, the temperature of the welding point at each time point during pipe welding and the pressure exerted by the welding gun on the welding point of the pipeline during the welding process are respectively measured by a temperature sensor and a pressure sensor, and the temperature and the pressure are respectively measuredIs marked as TT i 、PT i I is expressed as the number of the i-th time point, i=1, 2,..n, which is compared to the standard temperature and pressure of the pipe fitting weld, by the formula Obtaining the temperature deviation delta TT and the pressure deviation delta PT, TT of the welding point of the pipe fitting 0 、PT 0 Standard temperature and pressure, expressed as tube welds, respectively; obtaining the temperature deviation degree and the pressure deviation degree of the welding point of the pipe fitting according to the temperature and the pressure analysis of the welding point of the pipe fitting at each time point; and meanwhile, extracting standard voltage, current and welding speed corresponding to the wall thickness of the pipe fitting according to the wall thickness of the pipe fitting, comparing the standard voltage, current and welding speed with actual voltage, current and welding speed at each time point when the pipe fitting is welded, analyzing and obtaining the welding efficiency deviation degree of the pipe fitting, and comprehensively analyzing and obtaining the welding process influence parameters of the pipe fitting by combining the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree of the pipe fitting welding point.
Obtaining the temperature deviation degree and the pressure deviation degree of the welding point of the pipe fitting according to the temperature and the pressure analysis of the welding point of the pipe fitting at each time point; meanwhile, standard voltage, current and welding speed corresponding to the wall thickness of the pipe fitting are extracted according to the wall thickness of the pipe fitting, and are compared with actual voltage, current and welding speed at each time point when the pipe fitting is welded, so that the welding efficiency deviation degree of the pipe fitting is obtained through analysis, and the welding process influence parameters of the pipe fitting are obtained through comprehensive analysis by combining the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree of the welding point of the pipe fitting; by comparing the actual data with the standard data, the temperature and pressure control condition of the welding point of the pipe fitting can be determined, and the stability and consistency of the welding process can be evaluated.
Step two, measuring the actual voltage and current at each time point when the pipe fitting is welded, and recording the actual voltage and current as U i 、I i And tracking the pipe welding area by image processing technique and measuring the welding speed at each time point, denoted as V i Extracting the wall thickness of the pipe fitting, reading standard voltage, current and welding speed corresponding to the wall thickness of the pipe fitting, comparing the standard voltage, current and welding speed with actual voltage, current and welding speed at each time point when the pipe fitting is welded, and obtaining the standard voltage, current and welding speed by a formulaObtaining welding efficiency deviation sigma of pipe fitting, wherein U 0 、I 0 、V 0 Respectively representing standard voltage, current and welding speed corresponding to the wall thickness of the pipe fitting, wherein eta 4 represents a correction factor of the welding efficiency deviation degree of the pipe fitting; by analyzing the degree of deviation in welding efficiency, the stability and consistency of the welding process can be evaluated to determine if there is too high or too low welding energy resulting in quality problems.
The specific analysis method of the influence parameters of the pipe fitting welding process comprises the following steps: respectively reading the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree of the welding point of the pipe fitting, and substituting the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree into a formulaObtaining the welding process influencing parameters of the pipe fitting>Wherein η5 is expressed as a correction factor of a welding process influence parameter of the pipe, and e is expressed as a natural constant; by analyzing the number of influencing parameters in the welding process, main factors causing unqualified welding quality can be found out, and corresponding measures are taken for adjustment and improvement so as to improve the stability and controllability of the welding quality of the pipe fitting.
And the management database is used for storing maximum allowable values of gap area, dislocation distance and deflection angle between the pipe fittings, and standard voltage, current and welding speed corresponding to the quality level of the pipe fittings and the wall thickness of the pipe fittings.
And the pipe fitting quality comprehensive analysis module is used for marking the welded pipe fitting as a formed pipe fitting, analyzing and obtaining comprehensive quality evaluation parameters of the formed pipe fitting according to the quality coincidence degree of the pipe fitting and the welding process influence parameter of the pipe fitting, and comparing the comprehensive quality evaluation parameters with a preset comprehensive quality evaluation parameter range so as to obtain the welding quality condition of the formed pipe fitting.
The specific analysis method of the comprehensive quality evaluation parameters of the formed pipe fitting comprises the following steps: firstly, respectively reading quality conformity of the pipe fitting and influence parameters of a welding process, and passing through a formulaAnd obtaining a comprehensive quality evaluation parameter χ of the formed pipe fitting, wherein η6 and η7 are respectively expressed as a quality conformity of the formed pipe fitting and a weight factor of a welding process influence parameter, and η6+η7=1 and e is expressed as a natural constant.
Secondly, comparing the comprehensive quality evaluation parameters of the formed pipe fitting with the set comprehensive quality evaluation parameter ranges corresponding to the quality levels, screening the quality levels corresponding to the comprehensive quality evaluation parameters of the formed pipe fitting, further obtaining the quality level of the formed pipe fitting, and if the quality level of the formed pipe fitting is lower than the set quality level of the pipe fitting, marking the formed pipe fitting as a disqualified pipe fitting; by comprehensively evaluating the quality of the formed pipe, the welding quality can be comprehensively controlled and improved, the welding quality management level is improved, the quality stability and consistency of the pipe are ensured, and guidance and basis are provided for quality improvement.
The system obtains the quality conformity of the pipe fitting through analysis, ensures the connection accuracy of the pipe fitting, avoids the problems of deviation or dislocation and the like, evaluates whether the welding chamfer accords with requirements, reduces the accumulation of impurities and pollutants, helps to evaluate the temperature control condition and the pressure control condition in the welding process by analyzing the influence parameters of the welding process, knows the efficiency condition of the welding process, discovers potential problems, timely takes measures to improve the welding efficiency and quality, obtains the comprehensive quality evaluation parameters of the pipe fitting by combining the quality conformity and the welding process influence parameter analysis, further knows the welding quality condition of the formed pipe fitting, helps to judge the welding quality condition of the formed pipe fitting, and timely discovers and solves the quality problem, thereby ensuring that the welding quality of the pipe fitting meets the expected requirements.
The foregoing is merely illustrative and explanatory of the principles of this invention, as various modifications and additions may be made to the specific embodiments described, or similar arrangements may be substituted by those skilled in the art, without departing from the principles of this invention or beyond the scope of this invention as defined in the claims.
Claims (8)
1. Machine vision-based intelligent control system for pipe welding forming, which is characterized by comprising:
the pipe fitting image acquisition module is used for acquiring a pipe fitting image before welding through the camera and recording the pipe fitting image as a pipe fitting information image;
the pipe fitting information acquisition module is used for acquiring the wall thickness of the pipe fitting through a pipe fitting information image, and monitoring alignment data of the pipe fitting, pipe fitting welding chamfer angle setting data and cleaning data of a pipe fitting alignment area, wherein the alignment data of the pipe fitting comprise a gap area, a dislocation distance and a deflection angle between the pipe fittings, and the pipe fitting welding chamfer angle setting data comprise angles and chamfer angle setting areas of two pipe fitting chamfers;
the pipe fitting information analysis module is used for analyzing and obtaining the alignment accuracy between the pipe fittings, the opening conformity of the welding chamfer and the cleanliness of the pipe fittings according to the alignment data of the pipe fittings, the opening data of the welding chamfer of the pipe fittings and the cleaning data of the alignment area of the pipe fittings, and respectively marking the alignment accuracy, the opening conformity and the cleanliness of the welding chamfer of the pipe fittings as epsilon, gamma and lambda, so that the quality conformity of the pipe fittings is obtained through comprehensive analysis;
the welding data acquisition module is used for detecting the temperature and the pressure of the pipe fitting welding point at each time point and the actual voltage, current and welding speed of each time point when the pipe fitting is welded in the pipe fitting welding process;
the welding deviation analysis module is used for analyzing the temperature and pressure of the welding point of the pipe fitting at each time point to obtain the temperature deviation degree and the pressure deviation degree of the welding point of the pipe fitting; meanwhile, standard voltage, current and welding speed corresponding to the wall thickness of the pipe fitting are extracted according to the wall thickness of the pipe fitting, and are compared with actual voltage, current and welding speed at each time point when the pipe fitting is welded, so that the welding efficiency deviation degree of the pipe fitting is obtained through analysis, and the welding process influence parameters of the pipe fitting are obtained through comprehensive analysis by combining the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree of the welding point of the pipe fitting;
the management database is used for storing maximum allowable values of gap area, dislocation distance and deflection angle between the pipe fittings, and standard voltage, current and welding speed corresponding to the quality level of the pipe fittings and the wall thickness of the pipe fittings;
and the pipe fitting quality comprehensive analysis module is used for marking the welded pipe fitting as a formed pipe fitting, analyzing and obtaining comprehensive quality evaluation parameters of the formed pipe fitting according to the quality coincidence degree of the pipe fitting and the welding process influence parameter of the pipe fitting, and comparing the comprehensive quality evaluation parameters with a preset comprehensive quality evaluation parameter range so as to obtain the welding quality condition of the formed pipe fitting.
2. The intelligent control system for welding forming of pipe fittings based on machine vision according to claim 1, wherein: the analysis method of the alignment accuracy between the pipe fittings specifically comprises the following steps:
the method comprises the steps of firstly, acquiring a pipe fitting information image, respectively marking two pipe fittings to be welded in the pipe fitting information image as a first pipe fitting and a second pipe fitting, acquiring a gap area between the first pipe fitting and the second pipe fitting in the pipe fitting information image by utilizing an edge detection algorithm, extracting the area of the gap area, and marking the area as a gap area s1 between the pipe fittings;
step two, respectively selecting the center point of the welding surface of the first pipe fitting and the center point of the welding surface of the second pipe fitting as reference points according to the pipe fitting information images, measuring the horizontal distance and the vertical distance between the reference points of the first pipe fitting and the second pipe fitting, respectively marking as d1 and d2, and passing through the formulaObtaining a dislocation distance d between the pipe fittings;
third, reading the horizontal distance and the vertical distance between the reference points of the first pipe fitting and the second pipe fitting, substituting the horizontal distance and the vertical distance into the reference pointsTo formula (I)Obtaining a deflection angle theta between the pipe fittings;
fourth, the gap area, the dislocation distance and the deflection angle between the pipe fittings are respectively read and substituted into a formulaThe obtained alignment accuracy epsilon, s1', d ', theta ' between the pipe fittings are respectively expressed as maximum allowable values of the gap area, the dislocation distance and the deflection angle between the pipe fittings, a1 is expressed as a correction factor of the set alignment accuracy between the pipe fittings, and e is expressed as a natural constant.
3. The intelligent control system for welding forming of pipe fittings based on machine vision according to claim 2, wherein: the analysis method for the opening conformity of the welding chamfer specifically comprises the following steps:
the first step, respectively obtaining the chamfering length and the chamfering thickness of the first pipe fitting and the second pipe fitting according to the pipe fitting information image, respectively marking the chamfering length and the chamfering thickness as l1 and l2, and delta 1 and delta 2, and passing through the formula Obtaining the angle theta' formed by chamfering the first pipe fitting and the second pipe fitting 1 、θ″ 2 ；
Reading the chamfer lengths of the first pipe fitting and the second pipe fitting, measuring the chamfer widths of the first pipe fitting and the second pipe fitting, obtaining the chamfer areas of the first pipe fitting and the second pipe fitting by multiplying the chamfer lengths of the first pipe fitting and the second pipe fitting by the chamfer widths of the first pipe fitting and the second pipe fitting, and respectively marking the chamfer areas as s' 1 、s″ 2 ；
Third step, respectively reading the first tubesThe angle and the chamfer area of the chamfering of the piece and the second pipe fitting are calculated by the formulaObtaining a difference coefficient of chamfer angle between pipe fittingsWherein θ is 0 、s 0 Respectively representing the standard values of the set pipe fitting chamfer angle and the set chamfer area, wherein phi 1 and phi 2 are respectively represented as the angle difference value of the pipe fitting chamfer angle and the weight factor of the chamfer area difference value, and phi 1+ phi 2 = 1;
fourth, reading a difference coefficient formed by chamfering between the pipe fittings, and passing through a formulaAnd obtaining the opening conformity gamma of the welding chamfer, wherein e is expressed as a natural constant, and a2 is expressed as a correction factor of the opening conformity of the welding chamfer.
4. The intelligent control system for welding forming of pipe fittings based on machine vision according to claim 1, wherein: the specific analysis method of the pipe fitting cleanliness comprises the following steps: acquiring a pipe fitting information image, individually dividing a pipe fitting alignment area, carrying out gray processing on the pipe fitting information image, marking the image after gray processing as a pipe fitting alignment gray image, detecting a gray value of each pixel point in the pipe fitting alignment gray image, comparing the gray value with a set pipe fitting alignment standard gray value range, screening and counting the number of pixels with all gray values which are not in the pipe fitting alignment standard gray value range, marking as rho, and simultaneously extracting the total number of pixels of the pipe fitting alignment gray image, marking as rho 0 Substituting it into formulaObtaining the cleaning degree lambda' in the alignment range of the pipe fitting by the formula +.>The pipe cleanliness lambda, a3 is obtained as a correction factor for the pipe cleanliness.
5. The intelligent control system for welding forming of pipe fittings based on machine vision according to claim 1, wherein: the concrete analysis method of the quality conformity of the pipe fitting comprises the following steps: respectively reading the alignment accuracy between the pipe fittings, the opening conformity of the welding chamfer angles and the cleaning degree of the pipe fittings, and substituting the alignment accuracy, the opening conformity and the cleaning degree into a formulaThe quality conformity psi of the pipe fitting is obtained, wherein eta 1, eta 2 and eta 3 are respectively expressed as weight factors of the alignment accuracy between the pipe fitting, the opening conformity of the welding chamfer and the pipe fitting cleanliness.
6. The intelligent control system for welding forming of pipe fittings based on machine vision according to claim 5, wherein: the specific analysis process of the welding deviation analysis module comprises the following steps:
the first step is to measure the temperature of the welding point at each time point during pipe welding and the pressure exerted by the welding gun on the welding point of the pipeline during the welding process by a temperature sensor and a pressure sensor, which are respectively marked as TT i 、PT i I is expressed as the number of the i-th time point, i=1, 2,..n, which is compared to the standard temperature and pressure of the pipe fitting weld, by the formula Obtaining the temperature deviation delta TT and the pressure deviation delta PT, TT of the welding point of the pipe fitting 0 、PT 0 Standard temperature and pressure, expressed as tube welds, respectively;
second, each pipe fitting is measured during weldingThe actual voltage and current at the time point is recorded as U i 、I i And tracking the pipe welding area by image processing technique and measuring the welding speed at each time point, denoted as V i Extracting the wall thickness of the pipe fitting, reading standard voltage, current and welding speed corresponding to the wall thickness of the pipe fitting, comparing the standard voltage, current and welding speed with actual voltage, current and welding speed at each time point when the pipe fitting is welded, and obtaining the standard voltage, current and welding speed by a formulaObtaining welding efficiency deviation sigma of pipe fitting, wherein U 0 、I 0 、V 0 Respectively expressed as standard voltage, current and welding speed corresponding to the pipe wall thickness, and eta 4 is the correction factor of the welding efficiency deviation degree of the pipe.
7. The intelligent control system for welding forming of pipe fittings based on machine vision according to claim 6, wherein: the specific analysis method of the influence parameters of the pipe fitting welding process comprises the following steps: respectively reading the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree of the welding point of the pipe fitting, and substituting the temperature deviation degree, the pressure deviation degree and the welding efficiency deviation degree into a formulaObtaining the welding process influencing parameters of the pipe fitting>Where η5 is denoted as a correction factor for the welding process influencing parameter of the pipe and e is denoted as a natural constant.
8. The intelligent control system for welding forming of pipe fittings based on machine vision according to claim 7, wherein: the specific analysis method of the comprehensive quality evaluation parameters of the formed pipe fitting comprises the following steps:
firstly, respectively reading quality conformity of the pipe fitting and influence parameters of a welding process, and passing through a formulaObtaining a comprehensive quality evaluation parameter χ of the formed pipe fitting, wherein η6 and η7 are respectively expressed as a quality conformity of the formed pipe fitting and a weight factor of a welding process influence parameter, and η6+η7=1 and e is expressed as a natural constant;
and secondly, comparing the comprehensive quality evaluation parameters of the formed pipe fitting with the set comprehensive quality evaluation parameter ranges corresponding to the quality levels, screening the quality levels corresponding to the comprehensive quality evaluation parameters of the formed pipe fitting, further obtaining the quality level of the formed pipe fitting, and if the quality level of the formed pipe fitting is lower than the set quality level of the pipe fitting, marking the formed pipe fitting as a disqualified pipe fitting.
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