High-speed wire coil winding type measurement system and measurement method

Abstract

This invention discloses a high-speed wire rod coil shape measurement system and method. The system includes: a PLC unit; a coil transport trolley position measurement unit located at the beginning of the transport channel; a coil presence / absence detection unit located at the end of the transport channel; and a coil scanning unit located after the coil presence / absence detection unit. The coil presence / absence detection unit is signal-connected to the PLC unit; the coil transport trolley position measurement unit is network-connected to the PLC unit; and the coil scanning unit is network-connected to the PLC unit. During the process of the coil transport trolley carrying the measured coil along the channel past the coil presence / absence detection unit and the coil scanning unit, the PLC unit determines the length and radius data of the measured coil and generates the coil shape quality data. Thus, measuring the coil length and radius and evaluating the coil shape quality during coil transportation is beneficial for safe production.

Description

Technical Field

[0001] This invention belongs to the field of automation technology for bar and wire rod rolling in the metallurgical industry, and particularly relates to a measurement system and method for measuring the coil shape of high-strength wire coils. Background Technology

[0002] The final step in the production process of high-speed wire rod (hereinafter referred to as high-speed wire) coils is packaging and warehousing. Before warehousing, quality inspection of the coil shape is the last checkpoint in coil quality management.

[0003] Currently, high-speed wire rod warehouses have largely implemented unmanned overhead crane systems, which use these cranes to lift unloaded wire rod coils from the unloading platform into the warehouse. The unmanned crane system uses electromagnetic chucks to lift the coils, transport them to their designated storage locations, and then release them. This method of picking up and transporting coils using electromagnetic chucks places extremely high demands on the flatness of the coil surface. If the surface flatness is insufficient, the adhesion area between the coil and the electromagnetic chuck will be too small. Once a large gap appears between the coil and the chuck, unstable adhesion can easily occur during lifting, leading to problems such as steel falling or dropping, causing equipment damage and other safety accidents. The resulting economic losses and social impact are difficult for production enterprises to bear.

[0004] Therefore, it is necessary to know the roll type information such as length and diameter of the roll before hoisting. This is beneficial for determining the flatness of the roll surface and for the electromagnetic chuck to accurately pick up the roll and allocate storage space reasonably. Summary of the Invention

[0005] To overcome the shortcomings of existing technologies, this invention provides a high-speed wire rod coil shape measurement system and method. During the coil transportation process, the coil length and radius are measured, and the coil shape quality is evaluated to determine whether the coil flatness is up to standard. This facilitates the accurate picking up of the coil by the electromagnetic chuck, reasonable allocation of storage space, prevention of steel drop accidents during hoisting, and ensures safe production.

[0006] In a first aspect, the present invention provides a high-speed offline coil type measurement system, comprising:

[0007] PLC unit;

[0008] The position measurement unit of the winding trolley is located at the beginning of the winding channel;

[0009] The detection unit for whether the coil has a detection function is located at the end of the coil transport channel;

[0010] A reel scanning unit is disposed after the reel presence / absence detection unit;

[0011] The presence or absence detection unit of the reel is connected to the signal of the PLC unit;

[0012] The position measurement unit of the winding trolley is network-connected to the PLC unit;

[0013] The reel scanning unit is network-connected to the PLC unit;

[0014] During the process of the trolley carrying the tested coil passing through the coil presence / absence detection unit and the coil scanning unit along the channel, the PLC unit determines the length and radius data of the tested coil and generates the coil type quality data of the tested coil.

[0015] Furthermore, the position measurement unit of the winding trolley includes a laser rangefinder sensor;

[0016] The coil presence / absence detection unit includes a laser beam sensor;

[0017] The reel scanning unit includes a laser line scanning sensor.

[0018] In a second aspect, the present invention provides a method for measuring the roll shape of a high-speed offline coil, implemented using a coil shape measurement system as described in the first aspect, the measurement method comprising:

[0019] As the trolley lifts the tested coil and moves along the winding channel, the trolley position measurement unit located at the beginning of the winding channel detects the real-time position of the trolley.

[0020] When the trolley lifts the coil to be tested into the detection area of ​​the coil presence / absence detection unit, the coil presence / absence detection unit generates a first trigger signal and sends it to the PLC unit.

[0021] The PLC unit obtains first position data from the position measurement unit of the winding trolley based on the first trigger signal received.

[0022] When the trolley lifts the tested coil away from the detection area of ​​the coil presence / absence detection unit, the coil presence / absence detection unit generates a second trigger signal and sends it to the PLC unit.

[0023] The PLC unit obtains second position data from the position measurement unit of the winding trolley based on the received second trigger signal;

[0024] The PLC unit processes the first position data and the second position data to determine the length data of the tested reel.

[0025] Furthermore, it also includes: the PLC unit controls the reel scanning unit to start scanning its scanning area according to the first trigger signal received, wherein the reel scanning unit generates scanning data of the reel under test when scanning its scanning area;

[0026] The PLC unit controls the reel scanning unit to stop scanning its scanning area based on the received second trigger signal;

[0027] The PLC unit processes the scanning data obtained from the reel scanning unit to determine the radius data of the reel under test;

[0028] The PLC unit determines the roll shape quality data of the tested roll based on the radius data of the tested roll.

[0029] Further, the PLC unit processes the scan data of the tested reel obtained from the reel scanning unit to determine the radius data of the tested reel, including:

[0030] M sets of arc data are extracted from the scan data of the tested coil, wherein each set of arc data is used to indicate the geometric data of each feature point corresponding to the scan data of a unit length of the tested coil, and M is a positive integer;

[0031] A preset number of feature points are selected from each set of arc data to generate the line estimation radius of the tested coil determined by the preset number of feature points.

[0032] The set of estimated radii of the M lines corresponding to the M sets of arc data is taken as the radius data of the tested coil.

[0033] Furthermore, the geometric data of the feature points includes:

[0034] The distance B between the position corresponding to the feature point on the unit length of the reel and the reel scanning unit;

[0035] The distance A between the highest point of the outer contour of the unit length coil and the coil scanning unit;

[0036] On a vertical plane that is located at the same level as the coil scanning unit and is perpendicular to the central axis of the coil being measured, the angle α between the line connecting the position of the feature point on the unit length coil and the coil scanning unit and the vertically downward direction;

[0037] Accordingly, the estimated point radius r of the tested coil, determined by the geometric data of the feature points, is generated using the following formula:

[0038]

[0039] The average of the point estimation radii of the tested coil determined by the preset number of feature points is used as the line estimation radius.

[0040] Furthermore, the roll quality data includes qualified and unqualified.

[0041] The PLC unit determines the roll type quality data of the tested roll based on the radius data of the tested roll, including:

[0042] Determine the algebraic average of the estimated radii of the M lines;

[0043] The difference between each estimated line radius and the algebraic average is taken as the corresponding radius deviation, and the maximum value, minimum value and absolute value algebraic average of the radius deviations corresponding to the M estimated line radii are determined.

[0044] The difference between the maximum value and the minimum value is taken as the radius deviation range;

[0045] When the radius deviation range is less than a first preset value and the algebraic average of the absolute values ​​is less than a second preset value, the roll quality of the tested coil is determined to be qualified, wherein the first preset value is greater than the second preset value.

[0046] When the radius deviation range is greater than a first preset value, or the algebraic average of the absolute values ​​is greater than a second preset value, the roll quality of the tested coil is determined to be unqualified.

[0047] Further, the PLC unit processes the first position data and the second position data to determine the length data of the measured reel, including:

[0048] The PLC unit determines the length of the tested reel by the difference between the second position data and the first position data.

[0049] Further, the first trigger signal includes a rising edge signal, and the second trigger signal includes a falling edge signal; or

[0050] The first trigger signal includes a falling edge signal, and the second trigger signal includes a rising edge signal.

[0051] Furthermore, it also includes:

[0052] The PLC unit sends the radius data, length data, and roll type quality data of the tested coil to the crane system with which it is connected.

[0053] The present invention will be further described below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0054] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. However, it should be understood that these drawings are designed for illustrative purposes only and are not intended to limit the scope of the present invention. Furthermore, unless specifically indicated, these drawings are intended only to conceptually illustrate the structural construction described herein and are not necessarily drawn to scale.

[0055] Figure 1 This is a schematic diagram of the composition of the high-speed wire coil unwinding winding measurement system according to an embodiment of this application;

[0056] Figure 2 This is a top view of the high-speed wire coil unwinding measurement system according to an embodiment of this application;

[0057] Figure 3 This is a side view schematic diagram of the high-speed wire coil unwinding measurement system according to an embodiment of this application;

[0058] Figure 4 A cross-sectional view of a high-speed wire coil unwinding type measurement system according to an embodiment of this application;

[0059] Figure 5 This is a schematic diagram of the outer contour point cloud obtained by the coil scanning unit of the high-wire coil type measurement system according to an embodiment of this application;

[0060] Figure 6A This is a schematic diagram illustrating the principle of the algorithm for the radius of a unit length coil in the high-strength wire coil type measurement method according to an embodiment of this application;

[0061] Figure 6B This is a schematic diagram illustrating the principle of the multi-point positioning center algorithm and radius algorithm for feature points in the high-wire coil type measurement method of this application embodiment;

[0062] Figure label:

[0063] 1. Laser rangefinder sensor; 2. Coil transport trolley; 3. Coil; 4. Laser beam sensor; 5. Laser scanning sensor; 6. Gantry frame; 7. Unloading table; 10. Coil transport trolley position measurement unit; 20. Network switch; 30. PLC unit; 40. Coil presence / absence detection unit; 50. Coil scanning unit; 60. Crane system. Detailed Implementation

[0064] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0065] In order to accurately describe the technical content of this application and to accurately understand this application, the following explanations or definitions of the terms used in this specification are given before describing the specific embodiments.

[0066] Coil typically refers to small-diameter round steel bars coiled into a disc. The physical parameters of a coil include: inner diameter, outer diameter (i.e., the diameter of the coil on its outer contour or outer surface), length, and weight.

[0067] When the flatness of the coil is poor, the surface of the coil may be uneven. For example, the diameter deviation of the coil may be large along the length direction or along the circumferential direction.

[0068] PROFINET is a next-generation automation bus standard based on industrial Ethernet technology. PROFINET enables communication configuration between components after they are connected. The PROFINET protocol supports star, bus, and ring topologies.

[0069] The technical solutions of the embodiments of this application are described in detail below.

[0070] like Figure 1 As shown in the figure, the high-speed offline coil shape measurement system of this application includes: a PLC unit 30; a coil transport trolley position measurement unit 10, which is located at the beginning of the coil transport channel; a coil presence / absence detection unit 40, which is located at the end of the coil transport channel; and a coil scanning unit 50, which is located after the coil presence / absence detection unit 40 along the direction of the coil transport channel toward the unloading table. The coil presence / absence detection unit 40 is signal-connected to the PLC unit 30; the coil transport trolley position measurement unit 10 is network-connected to the PLC unit 30; and the coil scanning unit 50 is network-connected to the PLC unit 30. During the process of the coil transport trolley carrying the coil to be tested passing through the coil presence / absence detection unit 40 and the coil scanning unit 50 along the channel, the PLC unit determines the length data and radius data of the coil to be tested and generates the coil shape quality data of the coil to be tested.

[0071] Typically, the PLC unit is located in the electrical room to control the entire process of coil unloading and hoisting into the warehouse in the high-speed wire rod production line. For example, it controls the reciprocating movement of the coil transport trolley along the channel, controls the coil transport trolley to stop at the unloading position of the unloading table, and after the unloaded coil is put down, it returns to the unloading port in the opposite direction. Further details are omitted.

[0072] like Figure 1As shown, the crane system 60, PLC unit 30, reel scanning unit 50, and reel transport trolley position measurement unit 10 are all connected to the switch 20, communicating via the PROFINET protocol. The reel presence / absence detection unit 40 is connected to the digital input interface DI of the PLC unit 30 via a cable, such as a hard wire.

[0073] In some embodiments, based on the TCP / IP protocol, the PLC unit acquires the scanning data obtained by the reel scanning unit 50 in real time at preset sampling times (e.g., 50ms, which can be set, such as being set to an integer multiple of the scanning frequency of the reel scanning unit 50).

[0074] In some embodiments, based on the TCP / IP protocol, the PLC unit acquires the real-time position of the winding trolley detected by the winding trolley position measurement unit 10 every preset sampling time (e.g., 50ms, which can be set, such as being set to an integer multiple of the detection frequency when the winding trolley position measurement unit 10 detects the distance).

[0075] In some embodiments, based on the TCP / IP protocol, the PLC unit sends the generated length data, radius data, and roll type quality data of the tested roll to the crane system 60 every preset sampling time (e.g., 50ms, which can be set, such as an integer multiple of the update frequency when the crane system 60 updates the roll information).

[0076] In this way, the PLC unit realizes data acquisition, data analysis and network communication of the entire roll shape measurement system.

[0077] like Figure 1 , Figure 2 (Top-down view) Figure 3 and Figure 4 As shown, the winding trolley 2 is an unmanned vehicle, controlled by a PLC unit 30 for winding pick-up, movement, and unloading. The winding trolley 2 is equipped with a tray that can be raised and lowered vertically (e.g., in the Z direction). Figure 2 The high-speed production line coil 3 is taken out from the feeding port on the right side (not shown in the figure) and placed horizontally (with the central axis of coil 3 located in the horizontal plane rather than the vertical plane) on the pallet. The coil transport trolley then transports the coil along the transport channel (its extension direction is denoted as the x-direction, and in the horizontal plane, the direction perpendicular to the x-direction is denoted as y) to... Figure 2 The unloading platform 7 shown on the left side of the image has its central axis aligned with the central axis of the transport channel during the winding process. Furthermore, the unloading channel of the unloading platform is connected to the transport channel and coincides with its central axis. Also, when the transport trolley is a wheel-rail type, the channel is typically equipped with rails to support the transport trolley.

[0078] Typically, the feeding port is located at one end of the unloading channel, and its position remains fixed. The unloading table usually has a preset number of unloading positions, such as three or more, allowing it to hold multiple coils. From left to right, as... Figure 2 As shown, the coil transport trolley sequentially unloads multiple coils transported from front to back into various unloading positions. Therefore, the distance the coil transport trolley moves along the transport and unloading channels varies when unloading coils into different unloading positions.

[0079] like Figure 1 and Figure 3 As shown, the laser rangefinder 1 of the coil transport trolley position measuring unit 10 is located at one end of the coil transport channel, that is, the end opposite to the unloading table 7; the laser reflector of the coil transport trolley position measuring unit 10 ( Figure 3 A laser (not shown) is disposed on the end face of the winding trolley 2, opposite to the laser rangefinder 1. The laser emitted by the laser rangefinder 1 illuminates the laser reflector and is reflected back to the laser rangefinder 1. In this way, the laser rangefinder 1 can determine the distance between itself and the laser reflector, and use this distance to indicate the position of the winding trolley 2 along the winding channel.

[0080] In some embodiments, a laser rangefinder sensor is used to detect the position of a winding trolley. It is installed at the end of the winding trolley's channel, and a laser reflector is installed on the end face of the winding trolley. First, the laser rangefinder sensor is positioned at the end of the winding channel, with its emitted laser beam parallel to the central axis or extension direction of the channel. Then, the laser reflector is positioned on the winding trolley. The center of the laser reflector is positioned on the longitudinal centerline of the trolley, and the installation height of the laser reflector on the winding trolley is adjusted so that the laser beam emitted by the laser rangefinder sensor and the center of the laser reflector are at the same horizontal plane or height, until the laser beam from the laser sensor and the center of the reflector are aligned in a straight line. Subsequently, the winding trolley is controlled to move from its minimum position to its maximum position. The position of the laser beam on the reflector is observed, and the laser sensor for the winding trolley's position is fine-tuned to ensure that the laser beam spot remains near the center of the reflector during the winding trolley's movement. This ensures accurate measurement of the winding trolley's position. Once set up, as the winding trolley moves back and forth along the channel, the laser beam from the laser rangefinder can always be emitted to the center of the reflector, thus improving the accuracy and precision of distance measurement. Preferably, the detection accuracy of the laser rangefinder is ±1mm.

[0081] like Figure 1 and Figure 2 As shown, the laser beam sensor 4, which includes a transmitter and a receiver, forms a detection area, indicating whether or not the detection unit 40 is installed on the coil. Figure 3 The receiver is shown in the image. Figure 4The transmitter is shown in the image. Figure 2 As shown, the coil presence or absence detection unit 40 is located at the end of the coil transport channel or the beginning of the unloading channel, that is, at the end adjacent to the unloading table.

[0082] like Figure 4 As shown, when the trolley 2 carrying the coil begins to pass the coil presence / absence detection unit 40, it enters the aforementioned detection area. The laser emitted by the transmitter is blocked by the coil, and the receiver cannot receive the laser emitted by the transmitter. When the trolley 2 no longer passes the coil presence / absence detection unit 40, it leaves the aforementioned detection area. The laser emitted by the transmitter is not blocked by the coil, and the receiver receives the laser emitted by the transmitter. Thus, the laser beam sensor 4 can generate a low-level signal when the laser is not blocked and a high-level signal when the laser is blocked. A falling edge trigger signal is generated when the blocking switches to unblocked; a rising edge trigger signal is generated when the blocking switches to blocked. In this way, during the transport of the coil by the trolley, the rising and falling edges of the signal detect the process of the coil appearing and disappearing within the detection area.

[0083] Furthermore, the level signal generated by the laser beam sensor 4 can be filtered in the time domain to prevent erroneous measurement information caused by the laser passing through the gaps in the coil due to insufficient blocking of the laser (i.e., generating a level signal indicating that the coil has left the detection area while it is still in the detection area), or by DI flickering (i.e., generating a level signal indicating that the coil has left the detection area while it is still in the detection area). This also avoids erroneous measurements caused by human error or other unforeseen factors. Preferably, the error of the laser beam sensor is no greater than 5 mm.

[0084] The above filtering of the level signal in the time domain can include: introducing a preset reel passage time to check the rationality of the generated level signal. For example, if a DI flash is detected but the duration of the level signal is less than the preset reel passage time, it can be considered that an incorrect level signal or noise has been generated.

[0085] like Figure 3 and Figure 4 As shown, the laser beam sensor 4, including the transmitter and receiver, is set at a height that is at least 5cm higher than the rising position of the coil trolley tray, so that the emitted laser beam is fully blocked by the coil placed on the tray.

[0086] The above explanation uses the example of generating a low-level signal when the laser is not blocked to illustrate the working principle and process of the coil presence / absence detection unit 40. In some embodiments, a high-level signal can also be generated when the laser is not blocked, thereby similarly realizing the working principle and process of the coil presence / absence detection unit 40, which will not be elaborated further.

[0087] like Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, the roll scanning unit 50 is equipped with a laser scanning sensor 5. (As indicated...) Figure 3 and Figure 4 As shown, the coil presence / absence detection unit 40 and the coil scanning unit 50 are arranged in the same vertical plane. Along the extension direction of the conveying channel, the coil presence / absence detection unit 40 and the coil scanning unit 50 are in the same position.

[0088] like Figure 2 , Figure 3 and Figure 4 As shown, the coil transport trolley 2 carries the coil through the scanning area of ​​the laser scanning sensor 5 (reference). Figure 5 As shown, when the scanning area falls on the upper surface of the coil and covers a unit length of coil, the laser scanning sensor scans each unit length of coil one by one according to a preset scanning frequency to obtain the corresponding scanning data, such as... Figure 5 The diagram schematically illustrates the outer contour point cloud of each unit length of the coil and the outer contour point cloud of the spliced ​​coil. Preferably, the laser scanning sensor 5 is a 2D laser scanner.

[0089] like Figure 2 and Figure 4 As shown, the portal frame 6 spans both sides of the unloading platform 7. The laser scanning sensor 5 is positioned at the center of the upper crossbeam of the portal frame 6, with its center aligned with the centerline of the winding trolley and the passageway. Its scanning area can cover the entire outer circumference of the coil, thus enabling a complete scan of the outer contour of the upper surface of the coil. When the winding trolley 2 lifts the coil 3 and passes directly beneath it, the laser scanning sensor 5 acquires the point cloud of the upper surface contour of the coil.

[0090] The high-speed offline coil shape measurement method of this application embodiment is implemented using the aforementioned coil shape measurement system and includes the following steps:

[0091] 1) When the trolley lifts the tested coil and moves along the winding channel, the trolley position measurement unit set at the beginning of the winding channel detects the real-time position of the trolley.

[0092] 2) When the trolley lifts the tested coil into the detection area of ​​the coil presence / absence detection unit, the coil presence / absence detection unit generates a first trigger signal and sends it to the PLC unit.

[0093] 3) The PLC unit obtains the first position data from the position measurement unit of the winding trolley based on the first trigger signal received;

[0094] 4) When the trolley lifts the tested coil away from the detection area of ​​the coil presence / absence detection unit, the coil presence / absence detection unit generates a second trigger signal and sends it to the PLC unit;

[0095] 5) The PLC unit obtains second position data from the position measurement unit of the winding trolley based on the received second trigger signal;

[0096] 6) The PLC unit processes the first position data and the second position data to determine the length data of the measured coil.

[0097] The above length data is for Figure 3 The L shown is parallel to the direction of the central axis of the coil.

[0098] In some embodiments, the first trigger signal includes a rising edge signal and the second trigger signal includes a falling edge signal; or the first trigger signal includes a falling edge signal and the second trigger signal includes a rising edge signal.

[0099] In some embodiments, it also includes:

[0100] 7) The PLC unit controls the reel scanning unit to start scanning its scanning area according to the first trigger signal received, wherein the reel scanning unit generates scanning data of the reel under test when scanning its scanning area.

[0101] 8) Upon receiving the second trigger signal, the PLC unit controls the reel scanning unit to stop scanning its scanning area;

[0102] 9) The PLC unit processes the scanning data obtained from the coil scanning unit to determine the radius data of the coil under test; the PLC unit determines the roll quality data of the coil under test based on the radius data of the coil under test.

[0103] In the time span between the PLC unit receiving the first trigger signal and receiving the second trigger signal, the reel scanning unit periodically scans its scanning area to obtain the scanning data of the reel under test.

[0104] Thus, the PLC unit controls the laser scanning sensor to start or stop scanning based on the trigger signal generated by the acquired laser beam sensor. When the reel is within its scanning area, it scans the upper surface of the reel; when the reel leaves the scanning area, it stops scanning. Precise control of starting and stopping scanning avoids the power consumption and invalid data caused by continuing scanning when there is no reel in the scanning area. Precise control of starting and stopping scanning also facilitates the comprehensive acquisition of the point cloud corresponding to the upper surface contour along the entire length of the reel.

[0105] The above radius data is for Figure 3 As shown in the diagram, each radial direction of R is perpendicular to the direction of the central axis of the coil.

[0106] Specifically, the PLC unit processes the scan data of the tested reel obtained from the reel scanning unit to determine the radius data of the tested reel, including:

[0107] M sets of arc data are extracted from the scan data of the tested coil, wherein each set of arc data is used to indicate the geometric data of each feature point corresponding to the scan data of a unit length of the tested coil;

[0108] A preset number of feature points are selected from each set of arc data to generate the line estimation radius of the tested coil determined by the preset number of feature points.

[0109] The set of estimated radii of the M lines corresponding to the M sets of arc data is taken as the radius data of the tested coil.

[0110] The number M of the above arc data is usually determined based on the number of scan data sets obtained by the laser scanning sensor at a preset scanning frequency. It can also be roughly estimated based on the coil length and the moving speed of the winding trolley.

[0111] As explained above, when the coil length fluctuates significantly, the number of arc data sets M corresponding to each tested coil may change and is not a fixed value. This allows for a comprehensive and complete acquisition of the point cloud corresponding to the upper surface contour along the entire coil length, enabling a more complete and comprehensive determination of the estimated radii of each line. This, in turn, facilitates accurate assessment of the smoothness of the outer contour based on the radius data, and ultimately determines whether the coil quality is up to standard.

[0112] like Figure 2 , Figure 3 and Figure 5As shown, along the vertical plane, the laser scanning sensor 5 scans the feature points of the outer contour of each unit length of the coil and generates a set of scanning data. As the coil transport trolley moves along the channel (e.g., in the x-direction), it acquires each set of scanning data corresponding to each feature point on the entire outer contour of the coil, such as the head point cloud, tail point cloud, and point cloud corresponding to each unit length of the coil. It should be understood that the total number of feature points included in each set of scanning data is related to the resolution of the laser scanning sensor 5, such as 128 lines, 256 lines, etc.

[0113] like Figure 6A , Figure 6B As shown, the geometric data of the feature point includes: the distance B between the position corresponding to the feature point on the unit length coil and the coil scanning unit; the distance A between the highest point of the outer contour of the unit length coil and the coil scanning unit; and the angle α between the line connecting the position corresponding to the feature point on the unit length coil and the coil scanning unit and the vertically downward direction on a vertical plane that is perpendicular to the central axis of the coil being measured and the coil scanning unit.

[0114] Accordingly, the estimated point radius r of the tested coil, determined by the geometric data of the feature points, is generated using the following formula:

[0115]

[0116] The average of the point estimation radii of the tested coil determined by the preset number of feature points is used as the line estimation radius.

[0117] like Figure 6A As shown, in some embodiments, the set of arc data can be used to generate the estimated point radius r1 of the measured coil determined by the geometric data of feature point P1; the estimated point radius r2 of the measured coil determined by the geometric data of feature point P2; and the estimated point radius r3 of the measured coil determined by the geometric data of feature point P3. In this way, by using the geometric data of multiple feature points in each set of arc data to determine multiple estimated point radii, a more comprehensive and complete sample of coil radius can be collected in the circumferential direction, making the determined estimated line radius corresponding to the unit length of the coil closer to the actual coil and reducing measurement error.

[0118] Thus, the PLC unit determines multiple sets of arc data based on the scanning data (e.g., outer contour point cloud) generated by the acquired laser scanning sensor, and then determines the estimated radius of multiple points and the estimated radius of a single line corresponding to each unit length of the roll.

[0119] As described above, when the specified average of the estimated radii of the tested coil determined by the preset number of feature points is used as the estimated line radius, the specified average can be the median determined by sorting the multiple estimated radii from smallest to largest, used to indicate the average level of the radii at the corresponding positions of each feature point in the circumferential direction; or it can be the arithmetic mean obtained by taking the sum of the multiple estimated radii after dividing by the number of estimated radii, used to indicate the central tendency of the radii at the corresponding positions of each feature point in the circumferential direction. Preferably, the arithmetic mean is taken as the specified average.

[0120] The following explains the reasoning process behind the aforementioned formula. For example... Figure 6A and Figure 6B As shown in the aforementioned formula, α is the angle between the laser beam emitted by the laser scanning sensor 5 towards each feature point on the outer contour and the vertically downward direction, in degrees; A is the distance between the laser scanning sensor 5 and the vertex on the outer contour of the coil, in mm; and B is the distance between the laser scanning sensor 5 and the feature point on the outer contour, in mm. These three values ​​can be determined based on the scanning data generated by the coil scanning unit and are known quantities, while the point estimation radius r is an unknown quantity.

[0121] Let C be the intermediate variable. Then, according to trigonometric functions and their formulas, we can obtain:

[0122] M = sinα * B;

[0123] D = cosα * BA;

[0124] C = rD; The above is the algorithm for locating the center of a circle at multiple points;

[0125] According to the Pythagorean theorem, we can obtain:

[0126] C 2 +M 2 =r 2 ;

[0127] After transforming the above univariate equation for the unknown r, we obtain r as:

[0128] The above is the radius algorithm.

[0129] In summary, the multi-point positioning circle center algorithm and radius algorithm are accurate in principle and simple to calculate, which helps to improve the calculation efficiency and accuracy of point estimation radius.

[0130] In some embodiments, the roll quality data includes qualified and unqualified.

[0131] The PLC unit determines the roll type quality data of the tested roll based on the radius data of the tested roll, including:

[0132] Determine the algebraic average of the estimated radii of the M lines;

[0133] The difference between each estimated line radius and the algebraic average is taken as the corresponding radius deviation, and the maximum value, minimum value and absolute value algebraic average of the radius deviations corresponding to the M estimated line radii are determined.

[0134] The difference between the maximum value and the minimum value is taken as the radius deviation range;

[0135] When the radius deviation range is less than a first preset value and the algebraic average of the absolute values ​​is less than a second preset value, the roll quality of the tested coil is determined to be qualified, wherein the first preset value is greater than the second preset value.

[0136] When the radius deviation range is greater than a first preset value, or the algebraic average of the absolute values ​​is greater than a second preset value, the roll quality of the tested coil is determined to be unqualified.

[0137] Thus, the PLC unit determines the radius distribution based on the acquired radius distribution data of each line along the length of the tested coil, thereby evaluating the surface flatness of the coil and determining the coil quality data.

[0138] In some embodiments, geometric data of four feature points are selected from each set of arc data, and the corresponding estimated radius r is calculated for each point; then, the algebraic average r of the four estimated radii is calculated. 均 Let be the line estimate radius of the unit length coil corresponding to this set of arc data. By combining the line estimate radii of all unit length coils into a set, we can obtain the line estimate radius *r* corresponding to all sets of arc data for the entire coil. n ={r i The set of}, 1≤i≤M, is the radius data of the tested coil mentioned above.

[0139] In some embodiments, the following radius statistics are calculated for the radius data of the tested coil to evaluate the surface flatness of the coil, i.e., the coil surface quality analysis algorithm.

[0140] Average deviation:

[0141] Maximum deviation range:

[0142] In some embodiments, when the coil diameter is 1200 mm, the aforementioned first preset value is 15 mm; the aforementioned second preset value is 35 mm. Accordingly, when the average deviation is less than 15 mm, the roll quality number K = true indicates good quality; when it exceeds this range, it indicates poor roll quality K = false.

[0143] In conclusion, the algorithm for analyzing the surface quality of coils is accurate in principle and simple in calculation, which helps to improve the efficiency and rationality of coil surface quality assessment.

[0144] In some embodiments, the estimated line radius or deviation corresponding to each unit length of the coil can be visualized according to their positional relationship on the coil, and the flatness or coil quality of the coil can be intuitively displayed by means of the radius distribution along the length direction.

[0145] In some embodiments, the PLC unit processes the first position data and the second position data to determine the length data of the measured reel, including:

[0146] The PLC unit determines the length of the tested reel by the difference between the second position data and the first position data.

[0147] In some embodiments, the coil length is calculated according to the following formula: L 卷 =S 尾 -S 头 S 尾 The actual position of the coil transport trolley in the channel, measured in mm, is the moment when the coil is detected to have disappeared during transport. 头 The actual position of the trolley on the channel, measured in mm, is the moment when the coil is detected from nothing to something during the transport process of the coil trolley lifting the coil.

[0148] In this way, the PLC unit determines the actual position of the winding trolley based on the rising and falling edges generated by the laser beam sensor and the distance between the winding trolley and the laser rangefinder sensor. Based on the two position data, it determines the length of the winding to be unwound, which has high accuracy and good reliability.

[0149] Referring to the foregoing description, after the coil transport trolley lifts the coil and transports it to the unloading table, the pallet lowers and the coil is placed down. Furthermore, the actual position where the coil is placed on the unloading table, i.e., the specific unloading position, can be determined based on the rising and falling signals of the pallet on the coil transport trolley and the position data detected by the position detection unit.

[0150] refer to Figure 1 As shown, in some embodiments, it also includes:

[0151] 10) The PLC unit sends the radius data, length data, and roll type quality data of the tested coil to the crane system with which it is connected.

[0152] In this way, after the PLC unit 30 sends the coil radius, length, and coil type quality to the crane system, the crane system 60 can reasonably control the electromagnetic chuck to accurately pick up the coil, reasonably allocate storage positions, prevent steel falling accidents during hoisting, and ensure safe production based on the radius data, length data, and coil type quality data of the coil being tested.

[0153] Thus, this high-speed offline coil measurement system and method can assist the crane in accurately lifting materials, improve the accuracy of material data, and avoid steel falling accidents during the lifting process.

[0154] In some embodiments, the aforementioned PLC unit is provided with a coil length calculation unit, which is used to implement the aforementioned steps of processing the first position data and the second position data to determine the length data of the coil under test, and will not be described again.

[0155] In some embodiments, the aforementioned PLC unit is provided with a coil radius and contour point cloud analysis unit to realize the aforementioned processing of the scanning data obtained from the coil scanning unit to determine the radius data of the coil under test; the step of the PLC unit determining the roll type quality data of the coil under test based on the radius data of the coil under test will not be described in detail.

[0156] In some embodiments, the aforementioned PLC unit is provided with a DI module and at least one digital input interface (DI) for electrical connection with the aforementioned laser beam sensor.

[0157] refer to Figures 1 to 6A , Figure 6B As shown, the high-speed production line coil shape measurement system of this embodiment is deployed on a high-speed production line. Using the aforementioned coil shape measurement method, it measures the coil shape of the production line and coordinates the overhead crane system to achieve warehousing. For example, the moving speed of the coil transport trolley in the channel is 680 mm / s, the minimum coil length is 1600 mm, and the maximum coil length is 2300 mm. Based on the above data, the time for the coil to pass through the laser scanning sensor is between 2352 ms and 3380 ms. When the scanning frequency of the laser scanning sensor is 25 Hz, the single scan duration of the coil is approximately 40 ms (25 data sets per second), so the unit length of the coil is approximately 27.2 mm. Based on the shortest passing time of 2352 ms, the number of scans is 58.8, yielding 58 or 59 sets of scan data; based on the longest passing time of 3380 ms, the number of scans is 84.5, yielding 84 or 85 sets of scan data. Each set of scan data corresponds to the outer contour point cloud of a unit length coil.

[0158] The PLC unit analyzes 58 to 85 sets of scan data and calculates the radius data of the coil. The coil quality is inspected based on the average tolerance of the radius. If any non-compliance is found, the central control room operator will be notified in a timely manner.

[0159] In summary, the wire rod coil shape measurement method of this application employs laser ranging technology, laser scanning technology, multi-point positioning center and radius algorithm, and coil surface quality analysis algorithm to supplement coil production data, including information such as coil length and diameter, thus improving coil quality inspection methods and enabling timely detection of coil shape abnormalities. Simultaneously, this system also provides positive guidance for the coil hoisting process during warehousing. Currently, coil warehousing largely relies on unmanned cranes for hoisting, lacking manual steel lifting confirmation. If the coil shape quality is poor or the surface is uneven, attempting to lift the steel can easily lead to steel drop accidents. Applying this system will help improve subsequent warehousing processes.

[0160] In the description of this invention, it should be understood that the aforementioned fits, alignments, or adaptations have fitting accuracy, dimensional tolerances, shape errors, contour errors, and / or form and position errors, etc., which are known to those skilled in the art, and will not be elaborated further. The aforementioned blocks, plates, rods, frames, and sheets have the ratio of transverse dimensions to longitudinal dimensions, dimensional tolerances, shape errors, contour errors, and / or form and position errors, fitting accuracy, etc., which are known to those skilled in the art, and will not be elaborated further.

[0161] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0162] In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0163] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection (e.g., welding, bonding, threading, screws, pins, rivets, etc.) or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0164] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0165] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0166] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

[0167] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

[0168] The above description is illustrative only and not restrictive of the present invention. Those skilled in the art will understand that many modifications, variations or equivalents can be made without departing from the spirit and scope defined by the claims, and all such modifications, variations or equivalents will fall within the protection scope of the present invention.

Claims

1. A high-speed offline coil-type measurement system, characterized in that, include: PLC unit; The position measurement unit of the winding trolley is located at the beginning of the winding channel; The detection unit for whether the coil has a detection function is located at the end of the coil transport channel; A reel scanning unit is disposed after the reel presence / absence detection unit; The presence or absence detection unit of the reel is connected to the signal of the PLC unit; The position measurement unit of the winding trolley is network-connected to the PLC unit; The reel scanning unit is network-connected to the PLC unit; The PLC unit, the roll scanning unit, and the roll transport trolley position measurement unit are respectively connected to the switch and communicate using the PROFINET protocol. As the trolley lifts the tested coil and moves along the winding channel, the trolley position measurement unit located at the beginning of the winding channel detects the real-time position of the trolley. When the trolley lifts the coil to be tested into the detection area of ​​the coil presence / absence detection unit, the coil presence / absence detection unit generates a first trigger signal and sends it to the PLC unit. The PLC unit obtains first position data from the position measurement unit of the winding trolley based on the first trigger signal received. When the trolley lifts the tested coil away from the detection area of ​​the coil presence / absence detection unit, the coil presence / absence detection unit generates a second trigger signal and sends it to the PLC unit. The PLC unit obtains second position data from the position measurement unit of the winding trolley based on the received second trigger signal; The PLC unit processes the first position data and the second position data to determine the length data of the measured reel. The PLC unit, upon receiving the first trigger signal, controls the reel scanning unit to begin scanning its scanning area, wherein the reel scanning unit generates scanning data of the reel under test while scanning its scanning area; the PLC unit, upon receiving the second trigger signal, controls the reel scanning unit to stop scanning its scanning area; the PLC unit extracts M sets of arc data from the scanning data of the reel under test, wherein each set of arc data is used to indicate the geometric data of each feature point corresponding to the scanning data of a unit length of the reel under test, and M is a positive integer; a preset number of feature points are selected from each set of arc data to generate the line estimation radius of the reel under test determined by the preset number of feature points. The set of estimated radii of the M lines corresponding to the M sets of arc data is taken as the radius data of the tested coil; the PLC unit determines the coil shape quality data of the tested coil based on the radius data of the tested coil; the geometric data of the feature point includes: the distance B between the position corresponding to the feature point on the unit length coil and the coil scanning unit; the distance A between the highest point of the outer contour of the unit length coil and the coil scanning unit; and the angle between the line connecting the position corresponding to the feature point on the unit length coil and the coil scanning unit and the vertically downward direction on a vertical plane that is perpendicular to the central axis of the tested coil and the vertical plane that is perpendicular to the central axis of the tested coil. ; Accordingly, the estimated point radius of the tested coil, determined by the geometric data of the feature points, is generated using the following formula. : ； The average of the point estimation radii of the tested coil determined by the preset number of feature points is used as the line estimation radius. The roll quality data includes qualified and unqualified; The PLC unit determines the roll type quality data of the tested roll based on the radius data of the tested roll, including: Determine the algebraic average of the estimated radii of the M lines; The difference between each estimated line radius and the algebraic average is taken as the corresponding radius deviation, and the maximum value, minimum value and absolute value algebraic average of the radius deviations corresponding to the M estimated line radii are determined. The difference between the maximum value and the minimum value is taken as the radius deviation range; When the radius deviation range is less than a first preset value and the algebraic average of the absolute values ​​is less than a second preset value, the roll quality of the tested coil is determined to be qualified, wherein the first preset value is greater than the second preset value. When the radius deviation range is greater than a first preset value, or the algebraic average of the absolute values ​​is greater than a second preset value, the roll quality of the tested coil is determined to be unqualified.

2. The roll shape measurement system according to claim 1, characterized in that, The position measurement unit of the winding trolley includes a laser rangefinder sensor; The coil presence / absence detection unit includes a laser beam sensor; The reel scanning unit includes a laser line scanning sensor.

3. The roll shape measurement system according to claim 1, characterized in that, The PLC unit processes the first position data and the second position data to determine the length data of the measured reel, including: The PLC unit determines the length of the tested reel by the difference between the second position data and the first position data.

4. The roll shape measurement system according to claim 1, characterized in that, The first trigger signal includes a rising edge signal, and the second trigger signal includes a falling edge signal; or The first trigger signal includes a falling edge signal, and the second trigger signal includes a rising edge signal.

5. The roll shape measurement system according to claim 1, characterized in that, Also includes: The PLC unit sends the radius data, length data, and roll type quality data of the tested coil to the crane system with which it is connected.

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