CN101793872A - Whole spiral tube body flaw detection system capable of tube end flaw detection - Google Patents
Whole spiral tube body flaw detection system capable of tube end flaw detection Download PDFInfo
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- CN101793872A CN101793872A CN 201010113520 CN201010113520A CN101793872A CN 101793872 A CN101793872 A CN 101793872A CN 201010113520 CN201010113520 CN 201010113520 CN 201010113520 A CN201010113520 A CN 201010113520A CN 101793872 A CN101793872 A CN 101793872A
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Abstract
The invention relates to a whole spiral tube body flaw detection system capable of tube end flaw detection, which is characterized in that a weld tracker is arranged between a weld tube end detection device and weld sonde bodies; and a tube tail detection device, a tube end sonde body and a tube head detection device are arranged between a base material tube end detection device and base material sonde bodies in sequence. A flaw detection control system comprises a display screen, an operation panel, a programmable logic controller (PLC), an ultrasonic flaw detection system and an image tracking system. The control process of the flaw detection control system is as follows: 1) program startup; 2) weld center searching; 3) flaw detection of the weld tube head; 4) tube head position searching; 5) flaw detection of the base material tube head; 6) flaw detection of the tube body; 7) flaw detection of the weld tube tail; 8) tube tail position searching; 9) flaw detection of the base material tube tail; and 10) completion. The system has the following benefits: the system realizes automation of whole spiral tube body flaw detection, reduces the cost of human resources and is convenient, reliable, simple, practical, strong in universality and long in service life.
Description
Technical field
The present invention relates to the spiral pipe inspection field, relate in particular to a kind of whole spiral tube body fault detection system with the pipe end flaw detection.
Background technology
Adopting automatic ultrasonic inspection at present is to check and the very cost-effective means of control spiral submerged welded pipe weldquality, also be that each important pipeline is produced necessary detection means in recent years, increase along with the requirement of steel pipe, each producer all adopts the spiral pipe automatic crack detection system, realized automatic flaw detection, improved inspection speed, but, most of producer is in the automatic flaw detection process of whole steel pipe, two flaw detection districts need be set: seam inspection district and mother metal flaw detection district, bring very big trouble to production process; Simultaneously at all weld seam probes all on a weld seam probe body, in the automatic flaw detection process in order to guarantee that weld seam probe all drops on the steel pipe, the weld seam blind area of causing pipe end is about 300mm, though the grouping of mother metal probe falls in mother metal automatic flaw detection process, but because the size of probe itself, also causing the mother metal blind area can not carry out automatic flaw detection in the 30mm scope, so after automatic flaw detection is finished, also need the two ends of two professionals at steel pipe, visit instrument with hand two pipe ends of spiral steel pipe are carried out manual flaw detection, bring very big inconvenience to the robotization flaw detection like this, increase the flaw detection time of every steel pipe, influenced manufacturing schedule and production efficiency; Because flaw detection personnel weariness working causes omission sometimes, influence the reliability and the accuracy of steel tube flaw detection simultaneously.
Summary of the invention
In order to overcome the above problems, the purpose of this invention is to provide a kind of whole spiral tube body automatic crack detection system with the pipe end flaw detection, seam inspection and mother metal flaw detection are integrated, realize the robotization flaw detection of whole spiral tube body, increased pipe end automatic flaw detection simultaneously, solve the pipe end blind zone problem, improved inspection speed, guaranteed the reliability and the accuracy of spiral pipe flaw detection.
For achieving the above object, the present invention is achieved through the following technical solutions:
A kind of whole spiral tube body fault detection system with the pipe end flaw detection, comprise portal frame, driving, weld seam probe frame, the mother metal probe holder, the welded tube end detecting device, mother metal pipe end pick-up unit, the weld seam probe body, the mother metal sonde body, carrying roller, the flaw detection control system, it is characterized in that, between welded tube end detecting device and weld seam probe body, be provided with weld tracker, between mother metal pipe end pick-up unit and mother metal sonde body, set gradually pipe tail pick-up unit, the pipe end sonde body, the tube head pick-up unit, portal frame is provided with driving, in driving, weld seam probe frame and mother metal probe holder are set, welded tube end detecting device and weld seam probe body are set on the weld seam probe frame, be disposed with mother metal pipe end pick-up unit on the mother metal probe holder, pipe tail pick-up unit, the pipe end sonde body, tube head pick-up unit and mother metal sonde body, spiral pipe to be checked are arranged on the carrying roller under the portal frame; Weld tracker comprises weld seam camera and laser pen, the tube head pick-up unit comprises the tube head anteposition inspection that sets gradually, position inspection and tube head camera behind the tube head, pipe tail pick-up unit comprises the pipe tail anteposition inspection that sets gradually, position inspection and pipe tail camera behind the pipe tail, described flaw detection control system comprises display screen, guidance panel, the PLC Programmable Logic Controller, ultrasonic fault detection system, image tracking system, the PLC Programmable Logic Controller respectively with display screen, guidance panel, the driving motor, the carrying roller motor, the welded tube end detecting device, mother metal pipe end pick-up unit, the tube head pick-up unit, pipe tail pick-up unit, the weld seam probe frame lifting motor, mother metal probe holder lifting motor, weld seam probe body lifting solenoid valve, pipe end sonde body lifting solenoid valve, mother metal sonde body lifting solenoid valve, ultrasonic fault detection system, image tracking system is connected, image tracking system is connected with laser pen with camera respectively, described ultrasonic fault detection system comprises seam inspection unit and mother metal flaw detection unit, the weld seam probe body is connected with the seam inspection unit, and the pipe end sonde body links to each other with mother metal flaw detection unit respectively with the mother metal sonde body.
The position inspection is reflective photoelectric switch behind position inspection behind described welded tube end detecting device, mother metal pipe end pick-up unit, the inspection of tube head anteposition, the tube head, the inspection of pipe tail anteposition, the pipe tail.
Described image tracking system comprises computing machine, image pick-up card, analog output unit and digital input-output card, and computing machine is connected with image pick-up card, analog output unit and digital input-output card respectively.
Described flaw detection control system is a core with the PLC Programmable Logic Controller, and the control procedure of its flaw detection is as follows:
1) flaw detection program start: move driving, seek spiral pipe weld seam pipe end;
2) seek the weld seam center automatically: after the welded tube end detecting device detects spiral pipe to be checked, stop to move driving, the carrying roller rotation, image tracking system is sought weld seam automatically by weld tracker, and after detecting the weld seam center, carrying roller stops operating;
3) weld seam tube head automatic flaw detection: driving continues to move ahead, and the grouping of weld seam probe body falls, the beginning weld joint tracking, and the carrying roller rotating speed is controlled in proportion with the driving translational speed;
4) seek the tube head position automatically: after mother metal pipe end pick-up unit detects spiral pipe pipe end to be checked, the carrying roller stall, when spiral pipe tube head to be checked walks to tube head pick-up unit following time, the position inspection is 1 o'clock behind the tube head anteposition inspection of tube head pick-up unit and the tube head, driving retreats, tube head anteposition inspection up to the tube head pick-up unit is 1, and the position inspection is 0 o'clock behind the tube head, and driving stops to move;
5) mother metal tube head automatic flaw detection: after driving stopped, the automatic flaw detection of mother metal tube head was finished in the carrying roller rotation, and the pipe end sonde body lifts automatically;
6) full body flaw detection: after the automatic flaw detection of mother metal tube head was finished, image tracking system found the weld seam center once more, the carrying roller stall, the weld seam probe body falls automatically, the beginning weld joint tracking, and driving continues to move, the mother metal sonde body falls successively, body is carried out the flaw detection of weld seam and mother metal;
7) welded tube tail automatic flaw detection: the welded tube end detecting device detects less than behind the spiral pipe to be checked, and driving continues to move ahead, and when image tracking system detects weld seam not behind the center, stops weld joint tracking, and the grouping of weld seam probe body is lifted;
8) seek pipe tail position automatically: mother metal pipe end pick-up unit detects less than behind the spiral pipe pipe end to be checked, the carrying roller stall, the mother metal sonde body all lifts, when spiral pipe tube head to be checked walks to pipe tail pick-up unit following time, the position inspection is 0 o'clock behind the pipe tail anteposition inspection of tube head pick-up unit and the pipe tail, and driving retreats, and is 0 up to the tube head anteposition inspection of managing the tail pick-up unit, the position inspection is 1 o'clock behind the pipe tail, and driving stops to move;
9) mother metal pipe tail automatic flaw detection: after driving stopped, the pipe end sonde body fell, and the automatic flaw detection of mother metal pipe tail is finished in the carrying roller rotation, and the pipe end sonde body lifts;
10) flaw detection EOP (end of program): after the automatic flaw detection of mother metal pipe tail is finished, image tracking system finds the weld seam center once more by pipe tail camera, continue original full body flaw detection process, driving continues to move ahead, after the mother metal sonde body all lifts, the steel pipe stall moves to the portal frame original position after the driving, driving stops.
Compared with prior art, the invention has the beneficial effects as follows: realized the robotization of whole spiral tube body flaw detection, flaw detection has very high reliability and accuracy to whole spiral tube body, reduced cost of human resources, system is convenient and reliable, simple and practical, be convenient to safeguard, versatility is extremely strong, long service life.
Description of drawings
Fig. 1 is a kind of structural representation of the whole spiral tube body fault detection system with pipe end flaw detection;
Fig. 2 is the side view of Fig. 1;
Fig. 3 is the partial enlarged drawing of traveled portion;
Fig. 4 is the present invention's control system block diagram of detecting a flaw;
Fig. 5 is the image tracking system structured flowchart;
Fig. 6 is a workflow block diagram of the present invention.
Embodiment
Below in conjunction with accompanying drawing the specific embodiment of the present invention is described further:
See Fig. 1, Fig. 2, Fig. 3, a kind of whole spiral tube body fault detection system with the pipe end flaw detection, comprise portal frame 1, driving 2, weld seam probe frame 3, mother metal probe holder 4, welded tube end detecting device 5, mother metal pipe end pick-up unit 6, weld seam probe body 7, mother metal sonde body 8, carrying roller 9, between welded tube end detecting device 5 and weld seam probe body 7, weld tracker 20 is set, between mother metal pipe end pick-up unit 6 and mother metal sonde body 8, set gradually pipe tail pick-up unit 10, pipe end sonde body 11, tube head pick-up unit 12, portal frame 1 is provided with driving 2, in driving 2, weld seam probe frame 3 and mother metal probe holder 4 are set, welded tube end detecting device 5 and weld seam probe body 7 are set on the weld seam probe frame 3, be disposed with mother metal pipe end pick-up unit 6 on the mother metal probe holder 4, pipe tail pick-up unit 10, pipe end sonde body 11, tube head pick-up unit 12 and mother metal sonde body 8, spiral pipe 13 to be checked are arranged on the carrying roller 9 under the portal frame 1; Weld tracker 20 comprises weld seam camera 21 and laser pen 22, tube head pick-up unit 12 comprises position inspection 15 and tube head camera 17 behind the tube head anteposition inspection 14 that sets gradually, the tube head, pipe tail pick-up unit 10 comprises position inspection 19 and pipe tail camera 16 behind the pipe tail anteposition inspection 18 that sets gradually, the pipe tail, and position inspection 19 is reflective photoelectric switch behind position inspection 15 behind welded tube end detecting device 5, mother metal pipe end pick-up unit 6, tube head anteposition inspection 14, the tube head, pipe tail anteposition inspection 18, the pipe tail.
See Fig. 4, the flaw detection control system comprises display screen, guidance panel, the PLC Programmable Logic Controller, ultrasonic fault detection system, image tracking system, the PLC Programmable Logic Controller respectively with display screen, guidance panel, the driving motor, the carrying roller motor, the welded tube end detecting device, mother metal pipe end pick-up unit, the tube head pick-up unit, pipe tail pick-up unit, the weld seam probe frame lifting motor, mother metal probe holder lifting motor, weld seam probe body lifting solenoid valve, pipe end sonde body lifting solenoid valve, mother metal sonde body lifting solenoid valve, ultrasonic fault detection system, image tracking system is connected, image tracking system is connected with laser pen with camera respectively, camera is separately positioned on weld tracker among the embodiment, the tube head pick-up unit, on the pipe tail pick-up unit, laser pen is arranged on the weld tracker.What the PLC Programmable Logic Controller adopted is Siemens's 300 Programmable Logic Controllers, Siemens's touch-screen that display panel adopts, guidance panel is provided with various switches, realize the various workflows of system by the parameter setting on various switches and the display panel on the guidance panel, can understand the run action and the state of system by the state of display panel; The PLC Programmable Logic Controller provides flaw detection beginning and end signal to ultrasonic fault detection system, so that ultrasonic fault detection system forms flaw detection form and result of detection, ultrasonic fault detection system comprises seam inspection unit and mother metal flaw detection unit, weld joint ultrasonic probe in the weld seam probe body is connected with the seam inspection unit, the basic waveform data of welding bead flaw detection are provided for ultrasonic fault detection system, mother metal ultrasonic probe in the mother metal sonde body is connected with ultrasonic fault detection system mother metal flaw detection unit, and the basic waveform data of mother metal flaw detection are provided for ultrasonic fault detection system; The PLC Programmable Logic Controller provides to image tracking system and follows the tracks of the beginning end signal, receives the weld seam center signal that image tracking system returns, so that the control probe rises and falls automatically.
See Fig. 5, image tracking system comprises computing machine, image pick-up card, analog output unit and digital input-output card, computing machine is connected with image pick-up card, analog output unit and digital input-output card respectively, collect the weld image of each camera by the image pick-up card in the computing machine, image tracking system software butt welded seam image through computing machine is analyzed, digital input/output signal is controlled, simultaneously the side-play amount in the tracing process is exported to the flaw detection control system by analog output unit.
See Fig. 6, flaw detection control system of the present invention is a core with the PLC Programmable Logic Controller, and the control procedure of its flaw detection is as follows:
1) flaw detection program start: behind " flaw detection starts " switch, " flaw detection starts " pilot lamp is bright, waits for entering the flaw detection operation after 1.5 seconds, prompting " just looking for pipe end " on display panel, " wait pipe end " moves driving to spiral pipe direction to be checked, seeks spiral pipe weld seam pipe end;
2) seek the weld seam center automatically: after the welded tube end detecting device detects spiral pipe to be checked, show that on display screen " weld seam pipe end " is effective, the pilot lamp of weld seam pipe end is bright, stop to move driving, the carrying roller rotation, image tracking system is sought weld seam automatically, show " seeking weld seam ", after detecting the weld seam center, show " looking for the weld seam success ", carrying roller stops operating;
3) weld seam tube head automatic flaw detection: driving continues to move ahead, and the grouping of weld seam probe body falls automatically, the beginning weld joint tracking, and the carrying roller rotating speed is controlled in proportion with the driving translational speed;
4) seek the tube head position automatically: after mother metal pipe end pick-up unit detects spiral pipe pipe end to be checked, the carrying roller stall, all the weld seam probe body lifts automatically, when spiral pipe tube head to be checked walks to tube head pick-up unit following time, the position inspection is 1 o'clock behind the tube head anteposition inspection of tube head pick-up unit and the tube head, and driving retreats, and examining up to the tube head anteposition of tube head pick-up unit is 1, the position inspection is 0 o'clock behind the tube head, and driving stops to move.
5) mother metal tube head automatic flaw detection: after driving stops, the pipe end sonde body falls automatically, carrying roller is two weeks of rotation automatically, and image tracking system is sought weld seam automatically, find the center of weld seam in the tube head camera image, the pipe end sonde body lifts automatically, when finding weld seam not in the center of tube head camera image, the pipe end sonde body falls once more automatically, after spiral pipe to be checked rotated for two weeks, finish the automatic flaw detection of mother metal tube head, the pipe end sonde body lifts automatically;
6) full body flaw detection: after the automatic flaw detection of mother metal tube head was finished, image tracking system found the weld seam center once more, the carrying roller stall, the weld seam probe body falls automatically, the beginning weld joint tracking, and driving continues to move, the grouping of mother metal sonde body falls successively, body is carried out the flaw detection of weld seam and mother metal;
7) welded tube tail automatic flaw detection: the welded tube end detecting device detects less than behind the spiral pipe to be checked, driving continues to move ahead, and the grouping of weld seam probe body is lifted automatically, when image tracking system detects weld seam not behind the center, stop weld joint tracking, lift other weld seam probe body.
8) seek pipe tail position automatically: mother metal pipe end pick-up unit detects less than behind the spiral pipe pipe end to be checked, the carrying roller stall, the mother metal sonde body all lifts automatically, when spiral pipe tube head to be checked walks to pipe tail pick-up unit following time, the position inspection is 0 o'clock behind the pipe tail anteposition inspection of tube head pick-up unit and the pipe tail, and driving retreats, and is 0 up to the tube head anteposition inspection of managing the tail pick-up unit, the position inspection is 1 o'clock behind the pipe tail, and driving stops to move.
9) mother metal pipe tail automatic flaw detection: after driving stops, the pipe end sonde body falls automatically, carrying roller is two weeks of rotation automatically, and image tracking system is sought weld seam automatically, find the center of weld seam in pipe tail camera image, the pipe end sonde body lifts automatically, when finding weld seam not in the center of pipe tail camera image, the pipe end sonde body falls once more automatically, after spiral pipe to be checked rotated for two weeks, finish the automatic flaw detection of mother metal pipe tail, the pipe end sonde body lifts automatically;
10) flaw detection EOP (end of program): after the automatic flaw detection of mother metal pipe tail is finished, image tracking system finds the weld seam center once more by pipe tail camera, enters original full body flaw detection process automatically, and the mother metal that does not originally lift probe all falls, continue full body flaw detection, driving continues to move ahead, and the grouping of mother metal sonde body is lifted successively, after the mother metal sonde body all lifts, the steel pipe stall, move to the portal frame original position after the driving, driving stops, and " flaw detection starts " lamp goes out.
Advantage of the present invention is:
1) the present invention is integrated seam inspection and mother metal flaw detection, realizes the whole spiral tube body flaw detection, has reduced the flaw detection region area, has reduced the flaw detection operation.
2) the weld seam probe body on the weld seam probe frame has become 4 groups of sonde bodies, can guarantee when the weld seam non-destructive inspection for pipe end, realizes grouping control, thereby reduces weld joint blind area.
3) increase the pipe end probe at the mother metal probe holder, behind the pipe end probe, increased the tube head checkout gear, realized that the pipe end probe is servo-actuated at tube head, reduced tube head flaw detection blind area; Increased pipe tail checkout gear before the pipe end probe, realization pipe end probe is trailed moving at pipe, reduces pipe tail flaw detection blind area.
4) whole fault detection system has increased image tracking system, realizes the control of butt welded seam probe holder, has guaranteed that weld seam probe always at the both sides of weld seam invariant position, has improved the accuracy of seam inspection; In image tracking system, increased simultaneously pipe end weld seam Spot detection function, pipe end weld seam center signal is provided for the PLC Programmable Logic Controller, when pipe end weld seam center signal, the pipe end probe lifts automatically, when no pipe end weld seam center signal, the pipe end probe falls automatically, realizes automatically lifting and falling of pipe end probe, really realizes the automation of non-destructive inspection for pipe end.
Claims (4)
1. whole spiral tube body fault detection system with pipe end flaw detection, comprise portal frame, driving, weld seam probe frame, the mother metal probe holder, the welded tube end detecting device, mother metal pipe end pick-up unit, the weld seam probe body, the mother metal sonde body, carrying roller, the flaw detection control system, it is characterized in that, between welded tube end detecting device and weld seam probe body, be provided with weld tracker, between mother metal pipe end pick-up unit and mother metal sonde body, set gradually pipe tail pick-up unit, the pipe end sonde body, the tube head pick-up unit, portal frame is provided with driving, in driving, weld seam probe frame and mother metal probe holder are set, welded tube end detecting device and weld seam probe body are set on the weld seam probe frame, be disposed with mother metal pipe end pick-up unit on the mother metal probe holder, pipe tail pick-up unit, the pipe end sonde body, tube head pick-up unit and mother metal sonde body, spiral pipe to be checked are arranged on the carrying roller under the portal frame; Weld tracker comprises weld seam camera and laser pen, the tube head pick-up unit comprises the tube head anteposition inspection that sets gradually, position inspection and tube head camera behind the tube head, pipe tail pick-up unit comprises the pipe tail anteposition inspection that sets gradually, position inspection and pipe tail camera behind the pipe tail, described flaw detection control system comprises display screen, guidance panel, the PLC Programmable Logic Controller, ultrasonic fault detection system, image tracking system, the PLC Programmable Logic Controller respectively with display screen, guidance panel, the driving motor, the carrying roller motor, the welded tube end detecting device, mother metal pipe end pick-up unit, the tube head pick-up unit, pipe tail pick-up unit, the weld seam probe frame lifting motor, mother metal probe holder lifting motor, weld seam probe body lifting solenoid valve, pipe end sonde body lifting solenoid valve, mother metal sonde body lifting solenoid valve, ultrasonic fault detection system, image tracking system is connected, image tracking system is connected with laser pen with camera respectively, described ultrasonic fault detection system comprises seam inspection unit and mother metal flaw detection unit, the weld seam probe body is connected with the seam inspection unit, and the pipe end sonde body links to each other with mother metal flaw detection unit respectively with the mother metal sonde body.
2. a kind of whole spiral tube body fault detection system according to claim 1 with the pipe end flaw detection, it is characterized in that the position inspection is reflective photoelectric switch behind position inspection behind described welded tube end detecting device, mother metal pipe end pick-up unit, the inspection of tube head anteposition, the tube head, the inspection of pipe tail anteposition, the pipe tail.
3. a kind of whole spiral tube body fault detection system according to claim 1 with the pipe end flaw detection, it is characterized in that, described image tracking system comprises computing machine, image pick-up card, analog output unit and digital input-output card, and computing machine is connected with image pick-up card, analog output unit and digital input-output card respectively.
4. a kind of whole spiral tube body fault detection system with the pipe end flaw detection according to claim 1 is characterized in that described flaw detection control system is a core with the PLC Programmable Logic Controller, and the control procedure of its flaw detection is as follows:
1) flaw detection program start: move driving, seek spiral pipe weld seam pipe end;
2) seek the weld seam center automatically: after the welded tube end detecting device detects spiral pipe to be checked, stop to move driving, the carrying roller rotation, image tracking system is sought weld seam automatically by weld tracker, and after detecting the weld seam center, carrying roller stops operating;
3) weld seam tube head automatic flaw detection: driving continues to move ahead, and the grouping of weld seam probe body falls, the beginning weld joint tracking, and the carrying roller rotating speed is controlled in proportion with the driving translational speed;
4) seek the tube head position automatically: after mother metal pipe end pick-up unit detects spiral pipe pipe end to be checked, the carrying roller stall, when spiral pipe tube head to be checked walks to tube head pick-up unit following time, the position inspection is 1 o'clock behind the tube head anteposition inspection of tube head pick-up unit and the tube head, driving retreats, tube head anteposition inspection up to the tube head pick-up unit is 1, and the position inspection is 0 o'clock behind the tube head, and driving stops to move;
5) mother metal tube head automatic flaw detection: after driving stopped, the automatic flaw detection of mother metal tube head was finished in the carrying roller rotation, and the pipe end sonde body lifts automatically;
6) full body flaw detection: after the automatic flaw detection of mother metal tube head was finished, image tracking system found the weld seam center once more, the carrying roller stall, the weld seam probe body falls automatically, the beginning weld joint tracking, and driving continues to move, the mother metal sonde body falls successively, body is carried out the flaw detection of weld seam and mother metal;
7) welded tube tail automatic flaw detection: the welded tube end detecting device detects less than behind the spiral pipe to be checked, and driving continues to move ahead, and when image tracking system detects weld seam not behind the center, stops weld joint tracking, and the grouping of weld seam probe body is lifted;
8) seek pipe tail position automatically: mother metal pipe end pick-up unit detects less than behind the spiral pipe pipe end to be checked, the carrying roller stall, the mother metal sonde body all lifts, when spiral pipe tube head to be checked walks to pipe tail pick-up unit following time, the position inspection is 0 o'clock behind the pipe tail anteposition inspection of tube head pick-up unit and the pipe tail, and driving retreats, and is 0 up to the tube head anteposition inspection of managing the tail pick-up unit, the position inspection is 1 o'clock behind the pipe tail, and driving stops to move;
9) mother metal pipe tail automatic flaw detection: after driving stopped, the pipe end sonde body fell, and the automatic flaw detection of mother metal pipe tail is finished in the carrying roller rotation, and the pipe end sonde body lifts;
10) flaw detection EOP (end of program): after the automatic flaw detection of mother metal pipe tail is finished, image tracking system finds the weld seam center once more by pipe tail camera, continue original full body flaw detection process, driving continues to move ahead, after the mother metal sonde body all lifts, the steel pipe stall moves to the portal frame original position after the driving, driving stops.
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