A method for intelligent positioning and monitoring of core rod insertion rods

Abstract

This invention discloses an intelligent positioning and monitoring method for mandrel insertion, comprising: acquiring images of the roller conveyor using an image acquisition device and defining a reference axis for the roller conveyor; in response to detecting that a capillary tube has entered the image acquisition area and is fixed on the positioning roller conveyor, the image acquisition device begins continuous image acquisition and uploads the image data to an intelligent control device; processing the image data using a semantic segmentation network model to obtain the coordinate positions of the capillary tube and the mandrel, and defining a central axis based on the coordinate positions of the capillary tube and the mandrel for positioning; establishing multiple thresholds based on the coordinate positions, the central axis, and the roller conveyor reference axis, and performing real-time early warning judgments during the non-contact and contact stages of the mandrel and the capillary tube respectively; in response to exceeding any threshold, the intelligent control device issues an alarm and stops the roller conveyor operation. By monitoring the position of the mandrel and the capillary tube in real time, abnormal situations can be warned in a timely manner during the insertion process, effectively reducing safety risks and cost losses.

Description

Technical Field

[0001] This invention relates to the field of machine vision inspection technology, and in particular to a method for intelligent positioning and monitoring of mandrel insertion rods. Background Technology

[0002] Continuous rolling mill rolling is one of the main deformation processes in the production of hot-rolled seamless steel pipes. After piercing, the round cast billet forms a rough tube, which is then transported to the front of the rolling mill via a traverse trolley. A mandrel is then inserted into the rough tube, and the continuous rolling mill shuts off to form the steel pipe. During this process, situations may occur where the mandrel fails to insert into the rough tube or is inserted off-center, leading to production accidents. Furthermore, asymmetrical insertion of the mandrel can damage the steel pipe. Therefore, it is essential to add intelligent detection equipment before rolling to monitor the mandrel's entry into the rough tube and its deviation status in real time.

[0003] Before the mandrel is inserted into the capillary tube, its positioning must be monitored to ensure it is correctly inserted. If the position is incorrect, timely feedback should be provided for early warning. If misalignment or passive displacement occurs after the mandrel is inserted into the capillary tube, a signal should be immediately sent to the linear rack to stop its operation.

[0004] Therefore, there is a need to improve the existing intelligent positioning and monitoring method for mandrel insertion rods. Summary of the Invention

[0005] In view of this, the purpose of this invention is to propose a method for intelligent positioning and monitoring of mandrel insertion rods. By monitoring the position of the mandrel and capillary tube in real time, the method can provide timely warnings of abnormal situations during the insertion process, thereby effectively reducing safety risks and cost losses.

[0006] To achieve the above objectives, embodiments of the present invention provide a method for intelligent positioning and monitoring of a core rod insertion rod, comprising the following steps:

[0007] The roller conveyor image is acquired using an image acquisition device, and the roller conveyor reference axis is delineated.

[0008] In response to the detection that the capillary tube has entered the image acquisition area and is fixed on the positioning roller, the image acquisition device starts continuous image acquisition and uploads the image data to the intelligent control device.

[0009] Image data is processed using a semantic segmentation network model to obtain the coordinates of the capillary tube and mandrel. The central axis is then delineated based on the coordinates of the capillary tube and mandrel for localization.

[0010] Multiple thresholds are set based on coordinate position, central axis, and roller conveyor reference axis. Real-time early warning judgments are made in the non-contact and contact stages between the mandrel and the tube. In response to exceeding any threshold, the intelligent control device will issue an alarm and stop the roller conveyor operation.

[0011] In some embodiments, the image acquisition device includes a first image acquisition device and a second image acquisition device. The first image acquisition device is disposed above the roller conveyor to monitor the positional offset of the mandrel and the capillary in the width direction of the roller conveyor, and the second image acquisition device is disposed to the side of the roller conveyor to monitor the positional offset of the mandrel and the capillary in the vertical direction of the roller conveyor.

[0012] In some implementations, processing image data based on a semantic segmentation network model includes:

[0013] The image data outputs a pixel-level semantic category map, with background category 0, core rod category 1, and capillary category 2. The semantic category objects are split and the objects are selected using a standard bounding rectangle. The vertex coordinates of the standard bounding rectangle are the pixel coordinates of the category objects. The minimum bounding rectangle is used for object selection, and the central axis corresponding to the minimum bounding rectangle is the central axis of the category objects.

[0014] In some embodiments, acquiring images of the roller conveyor and delineating the roller conveyor reference axis using an image acquisition device includes:

[0015] The roller conveyor image is acquired by an image acquisition device, the roller conveyor position coordinates are obtained, and the roller conveyor reference axis is delineated based on the roller conveyor position coordinates.

[0016] In some embodiments, the roller conveyor reference axis includes an axis along the length of the roller conveyor and an axis along the width of the roller conveyor.

[0017] In some implementations, real-time early warning judgment during the non-contact stage between the mandrel and the capillary tube includes:

[0018] A first threshold is set based on the angle between the central axis of the mandrel and the center line of the roller conveyor; a second threshold is set based on the distance between the central axis of the mandrel and the center line of the roller conveyor; and a third threshold is set based on the angle between the central axis of the mandrel and the length axis of the roller conveyor. During continuous image acquisition, in response to real-time data exceeding the first threshold and / or the second threshold and / or the third threshold, the intelligent control device will issue an alarm and stop the operation of the roller conveyor.

[0019] In some implementations, the early warning judgment during the contact stage between the mandrel and the capillary includes:

[0020] In the direction of roller conveyor operation, a fourth threshold is set based on the difference between the coordinate positions of the mandrel end point and the capillary end point. In response to the real-time difference between the mandrel end point position and the capillary end point position exceeding the fourth threshold, the intelligent control device will issue an alarm and stop the roller conveyor operation.

[0021] In some implementations, the early warning judgment during the contact stage between the mandrel and the capillary includes:

[0022] In the direction of roller conveyor operation, a fifth threshold is set based on the angle between the mandrel center axis and the capillary center axis. In response to the real-time angle between the mandrel center axis and the capillary center axis exceeding the fifth threshold, the intelligent control device will issue an alarm and stop the roller conveyor operation.

[0023] In some embodiments, the roller conveyor includes a conveying roller conveyor and a positioning roller conveyor. The tube is fed into the positioning roller conveyor via a feeding rotary arm, and the mandrel is placed on the conveying roller conveyor and inserted into the tube via the roller conveyor.

[0024] In some implementations, the intelligent control device is further equipped with a display that shows image information and alarm information in real time.

[0025] The present invention has at least the following beneficial technical effects:

[0026] This invention proposes an intelligent positioning and monitoring method for mandrel insertion. It uses visual detection to locate the relative positions of the mandrel and the capillary tube, and compares these positions to identify any abnormalities during the insertion process, providing timely warnings and stopping the linear rack. This intelligent monitoring reduces mandrel misalignment, lowers safety risks, and effectively prevents unevenness caused by mandrel misalignment, thus reducing cost losses. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of an embodiment of the intelligent positioning and monitoring method for the core rod insertion rod provided by the present invention;

[0029] Figure 2 A schematic diagram of an embodiment of the intelligent positioning and monitoring device for core rod insertion provided by the present invention;

[0030] Figure 3 This is a schematic diagram of an embodiment of the positional relationship between the mandrel and the capillary tube in the horizontal direction of the roller conveyor during the non-contact stage of the insertion rod provided by the present invention.

[0031] Figure 4 This is a schematic diagram of an embodiment of the positional relationship between the mandrel and the capillary tube in the vertical direction of the roller conveyor during the non-contact stage of the insertion rod provided by the present invention.

[0032] Figure 5 This is a schematic diagram of an embodiment of the positional relationship between the mandrel and the capillary during the insertion stage provided by the present invention. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be further described in detail below with reference to specific examples and the accompanying drawings.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. For example, terms such as “length,” “width,” “upper,” “lower,” “left,” “right,” “front,” “rear,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” and “outer” indicate orientations or positions based on the orientations or positions shown in the accompanying drawings and are for ease of description only, and should not be construed as limiting the technical solution.

[0035] The terms "comprising" and "having," and any variations thereof, used in the specification, claims, and accompanying drawings of this invention are intended to cover non-exclusive inclusion; the terms "first," "second," etc., used in the specification, claims, and accompanying drawings are used to distinguish different objects, not to describe a particular order. "A plurality of" means two or more, unless otherwise explicitly specified.

[0036] In the description and claims of this invention and the foregoing drawings, when an element is referred to as "fixed to," "mounted to," "disposed on," or "connected to" another element, it can be located directly or indirectly on that other element. For example, when an element is referred to as "connected to" another element, it can be directly or indirectly connected to that other element.

[0037] Furthermore, the reference to "embodiment" herein means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0038] like Figure 1 The diagram shown is a schematic representation of an embodiment of the intelligent positioning and monitoring method for the mandrel insertion rod provided by the present invention, which includes the following steps:

[0039] S1. Acquire images of the roller conveyor using an image acquisition device and delineate the reference axis of the roller conveyor;

[0040] S2. In response to the detection that the capillary tube has entered the image acquisition area and is fixed on the positioning roller, the image acquisition device starts continuous image acquisition and uploads the image data to the intelligent control device.

[0041] S3. Use a semantic segmentation network model to process image data to obtain the coordinate positions of capillaries and mandrels, and delineate the central axis based on the coordinate positions of capillaries and mandrels for localization.

[0042] S4. Multiple thresholds are set based on coordinate position, central axis and roller reference axis. Real-time early warning judgment is performed in the non-contact stage and contact stage between mandrel and capillary. In response to exceeding any threshold, the intelligent control device will issue an alarm and stop the operation of the roller.

[0043] Furthermore, the image acquisition device includes a first image acquisition device and a second image acquisition device, such as... Figure 2 The diagram shows the device from different perspectives, and the direction of roller movement, the width of roller movement, and the vertical direction of roller movement are marked. The length direction of roller movement mentioned below is either the same as or opposite to the direction of roller movement, and will not be repeated hereafter. The first image acquisition device is set above the roller movement, i.e., the top-view camera in the figure, and is used to monitor the positional offset of the mandrel and capillary tube in the width direction of the roller movement. The second image acquisition device is set to the side of the roller movement, i.e., the side-view camera in the figure, and is used to monitor the positional offset of the mandrel and capillary tube in the vertical direction of the roller movement.

[0044] Furthermore, such as Figure 2 As shown in the figure, the roller conveyor includes a conveying roller conveyor and a positioning roller conveyor. The tube is fed into the positioning roller conveyor through the feeding rotary arm, and the mandrel is set on the conveying roller conveyor and inserted into the tube through the roller conveyor.

[0045] Furthermore, in S1, acquiring the roller conveyor image and defining the roller conveyor reference axis through the image acquisition device includes:

[0046] Before the mandrel and capillary are moved in, the roller conveyor image is acquired by the image acquisition device, the roller conveyor position coordinates are obtained, and the roller conveyor reference axis is delineated based on the roller conveyor position coordinates. The roller conveyor reference axis includes the roller conveyor length direction axis and the roller conveyor width direction axis.

[0047] Furthermore, in S3, image data processing based on the semantic segmentation network model includes:

[0048] The image data outputs a pixel-level semantic category map, with background category 0, core category 1, and capillary category 2. The semantic category objects (core and capillary) are split into segments, and the objects are selected using a standard bounding rectangle. The vertex coordinates of the standard bounding rectangle are the pixel coordinates of the category objects (core and capillary). The minimum bounding rectangle is used for object selection, and the central axis corresponding to the minimum bounding rectangle is the central axis of the category objects.

[0049] Furthermore, in S4, such as Figure 3 and Figure 4As shown, during the non-contact stage between the mandrel and the capillary tube, monitoring and early warning are performed based on the angle or distance relationship between the central axes of the mandrel and the capillary tube and the roller conveyor axis. Specifically, this includes:

[0050] like Figure 4 As shown, a first threshold is established based on the angle between the central axis of the mandrel and the center line of the roller conveyor. In some embodiments, the first threshold is set to 5°.

[0051] like Figure 4 As shown, a second threshold is established based on the distance between the central axis of the mandrel and the center line of the roller conveyor. In some embodiments, the second threshold is set to 20 mm.

[0052] like Figure 3 As shown, a third threshold is established based on the angle between the central axis of the mandrel and the axis of the roller conveyor along its length. In some embodiments, the third threshold is set to 10°.

[0053] During continuous image acquisition, in response to real-time data exceeding the first threshold and / or the second threshold and / or the third threshold, the intelligent control device will issue an alarm and stop the roller conveyor operation. That is, under normal conditions, the angle between the central axis of the mandrel and the width axis of the roller conveyor is no greater than 5°, the distance between the central axis of the mandrel and the width axis of the roller conveyor is no greater than 20mm, and the angle between the central axis of the mandrel and the length axis of the roller conveyor is no greater than 10°.

[0054] In some embodiments, early warning judgment during the contact stage between the mandrel and the capillary includes:

[0055] In the direction of roller conveyor operation, a fourth threshold is established based on the difference between the coordinates of the mandrel endpoint and the capillary tube endpoint. If the real-time difference between the mandrel endpoint and the capillary tube endpoint exceeds this fourth threshold, the intelligent control device will issue an alarm and stop the roller conveyor. The threshold for the difference between the rightmost endpoint coordinate of the mandrel and the rightmost endpoint coordinate of the capillary tube is 0, and the threshold for the difference between the leftmost endpoint coordinate of the mandrel and the leftmost endpoint coordinate of the capillary tube is also 0. This indicates that the mandrel and capillary tube are completely overlapped in the diagram. When the difference between their rightmost endpoints is greater than 0, it indicates that the mandrel has exceeded the capillary tube; when the difference between their leftmost endpoints is greater than 0, it indicates that the mandrel has not fully inserted into the capillary tube. Both are abnormal situations, and the intelligent control system will issue an alarm.

[0056] In other embodiments, the early warning judgment during the contact stage between the mandrel and the capillary includes:

[0057] like Figure 5As shown, in the roller conveyor running direction, a fifth threshold is established based on the angle between the mandrel center axis and the capillary center axis. In response to the real-time angle between the mandrel center axis and the capillary center axis exceeding the fifth threshold, the intelligent control device issues an alarm and stops the roller conveyor operation. The fifth threshold is set to 5°. Figure 5 As shown in -A, when the angle between the mandrel's central axis and the capillary's central axis is no greater than 5°, it indicates a normal mandrel insertion state. Figure 5 As shown in -B, when the angle between the mandrel center axis and the capillary center axis is greater than 5°, it indicates an abnormal insertion state and triggers an alarm.

[0058] Furthermore, the intelligent control device is equipped with a display screen that shows image information and alarm information in real time.

[0059] This invention proposes an intelligent positioning and monitoring method for mandrel insertion. It uses visual detection to pinpoint the relative positions of the mandrel and the capillary tube, and by comparing these positions, it identifies any abnormalities during the insertion process, provides timely warnings, and controls the linear rack to stop operating. This intelligent monitoring reduces mandrel misalignment, lowers safety risks, and effectively prevents unevenness caused by mandrel misalignment, thus reducing cost losses.

[0060] The above are exemplary embodiments disclosed in this invention. However, it should be noted that various changes and modifications can be made without departing from the scope of the embodiments of this invention as defined by the claims. The functions, steps, and / or actions of the methods according to the disclosed embodiments described herein do not need to be performed in any particular order. Furthermore, although the elements disclosed in the embodiments of this invention may be described or claimed individually, they may be understood as multiple unless explicitly limited to a singular number.

[0061] It should be understood that, as used herein, the singular form “a” is intended to include the plural form as well, unless the context clearly supports an exception. It should also be understood that, as used herein, “and / or” refers to any and all possible combinations of one or more of the associated listed items.

[0062] The embodiment numbers disclosed in the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0063] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the invention (including the claims) is limited to these examples. Within the framework of the invention, technical features of the above embodiments or different embodiments can be combined, and many other variations of different aspects of the invention exist, which are not provided in the details for the sake of brevity. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the protection scope of the invention.

Claims

1. A method for intelligent positioning and monitoring of a core rod insertion rod, characterized in that, include: The roller conveyor image is acquired using an image acquisition device, and the roller conveyor reference axis is delineated. In response to the detection that the capillary tube has entered the image acquisition area and is fixed on the positioning roller, the image acquisition device starts continuous image acquisition and uploads the image data to the intelligent control device. The image data is processed using a semantic segmentation network model to obtain the coordinate positions of the capillary tube and the mandrel, and the central axis is delineated based on the coordinate positions of the capillary tube and the mandrel for positioning. Based on the coordinate position, the central axis, and the roller conveyor reference axis, multiple thresholds are set. Real-time early warning judgments are made in the non-contact and contact stages between the mandrel and the tube. In response to exceeding any of the thresholds, the intelligent control device will issue an alarm and stop the roller conveyor operation. Real-time early warning judgment during the non-contact stage between the mandrel and the capillary tube includes: A first threshold is established based on the angle between the central axis of the mandrel and the center line of the roller conveyor; a second threshold is established based on the distance between the central axis of the mandrel and the center line of the roller conveyor; and a third threshold is established based on the angle between the central axis of the mandrel and the length axis of the roller conveyor. During continuous image acquisition, in response to real-time data exceeding the first threshold and / or the second threshold and / or the third threshold, the intelligent control device issues an alarm and stops the operation of the roller conveyor. Early warning judgment during the contact stage between the mandrel and the capillary includes: In the direction of roller conveyor operation, a fourth threshold is set based on the difference between the coordinate positions of the mandrel end point and the capillary end point. In response to the real-time difference between the mandrel end point position and the capillary end point position exceeding the fourth threshold, the intelligent control device issues an alarm and stops the roller conveyor operation.

2. The intelligent positioning and monitoring method for the core rod insertion rod according to claim 1, characterized in that, The image acquisition device includes a first image acquisition device and a second image acquisition device. The first image acquisition device is disposed above the roller conveyor to monitor the positional offset of the mandrel and the capillary tube in the width direction of the roller conveyor. The second image acquisition device is disposed on the side of the roller conveyor to monitor the positional offset of the mandrel and the capillary tube in the vertical direction of the roller conveyor.

3. The intelligent positioning and monitoring method for the core rod insertion rod according to claim 1, characterized in that, Processing the image data based on a semantic segmentation network model includes: Based on the image data, a pixel-level semantic category map is output, with background category 0, core category 1, and capillary category 2. The semantic category objects are split, and object selection is performed using a standard bounding rectangle. The vertex coordinates of the standard bounding rectangle are the pixel coordinates of the category objects. Object selection is also performed using a minimum bounding rectangle, with the central axis corresponding to the minimum bounding rectangle being the central axis of the category objects.

4. The intelligent positioning and monitoring method for the core rod insertion rod according to claim 1, characterized in that, Acquiring images of the roller conveyor and defining the roller conveyor reference axis using an image acquisition device includes: The roller conveyor image is acquired by an image acquisition device, the roller conveyor position coordinates are obtained, and the roller conveyor reference axis is delineated based on the roller conveyor position coordinates.

5. The intelligent positioning and monitoring method for the core rod insertion rod according to claim 4, characterized in that, The roller conveyor reference axis includes the roller conveyor length direction axis and the roller conveyor width direction axis.

6. The intelligent positioning and monitoring method for the core rod insertion rod according to claim 1, characterized in that, Early warning judgment during the contact stage between the mandrel and the capillary includes: In the direction of roller conveyor operation, a fifth threshold is set based on the angle between the mandrel center axis and the capillary center axis. In response to the real-time angle between the mandrel center axis and the capillary center axis exceeding the fifth threshold, the intelligent control device issues an alarm and stops the roller conveyor operation.

7. The intelligent positioning and monitoring method for the core rod insertion rod according to claim 1, characterized in that, The roller conveyor includes a conveying roller conveyor and a positioning roller conveyor. The tube is fed into the positioning roller conveyor via a feeding rotary arm, and the mandrel is placed on the conveying roller conveyor and inserted into the tube via the roller conveyor.

8. The intelligent positioning and monitoring method for the core rod insertion rod according to claim 1, characterized in that, The intelligent control device is further equipped with a display, which displays image information and alarm information in real time.

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