A vision-based adaptive particle size variable gap flux screening device

Abstract

The present application relates to the field of welding automation, and is a visual adaptive particle size variable gap flux screening device. In view of the problem that the equipment needs to be frequently replaced with different specifications of screen meshes during the selection of submerged arc welding flux recovery, the present application designs a visual adaptive particle size variable gap flux screening device. The torque feedback system based on current is used to realize the detection of the screen mesh protection system for the screen mesh stuck; the visual adaptive screening acceleration method is used to realize the screening acceleration function of the visual adaptive adjustment system.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of welding, and is a visual-based adaptive particle size variable gap flux screening device. BACKGROUND

[0002] Screening is a very important separation method. Among the current screening methods, the most effective and widely used one is screening using a screen. Taking submerged arc welding as an example, in the welding process, the flux needs to be recovered and screened for reuse. Most of the submerged arc welding flux recovery and reuse technologies use a screen to separate the flux and slag. Submerged arc welding fluxes have different sizes, so when using these screening devices that use a screen, different specifications of screens need to be frequently replaced. With the increasing automation of welding processes, such devices that require component replacement each time obviously cannot meet the use requirements, and also cause waste of manpower and cannot adapt to large-scale use.

[0003] There are currently some variable aperture screening devices. The more common ones can be roughly divided into two types. One type uses screen interlacing to achieve a certain range of screen hole changes, and the other type uses a special mechanical structure to achieve a similar function. Referring to the published technical solutions of patent application numbers CN202121927566.0 and CN202311542855.2, a variable aperture sand screening device for construction engineering and an adjustable corn seed screening device are disclosed. The former uses two screens interlaced to adjust the size of the screen holes, and the latter uses a variable diameter sleeve and an elastic contraction opening to change the size of the screen holes. However, the screen used in the former will elastically deform during work and cause uncontrollable changes in the aperture. In addition, if the screen holes are stuck when changing the aperture, the two screens may separate or partially deform. The latter occupies a large amount of space, which greatly reduces the number of screen holes available for screening and greatly affects the screening efficiency. These two methods are obviously not suitable for submerged arc welding fluxes with multiple size specifications. SUMMARY

[0004] The purpose of the present application is to provide a screening device that can adaptively change the size and shape of the screen holes, as well as a control and protection method.

[0005] The specific working content of each part of the device is as follows:

[0006] The gap-controllable screen is composed of two groups of fine metal rods perpendicular to each other, with both ends of each group of metal rods connected to a support. A bearing is used to fix one group of metal rods to the screen support, and the spacing of all metal rods can be changed by changing the included angle between the metal rod support and the screen support. Assuming that the included angle between the metal rod support and the screen support is The maximum distance of the metal rods is l, and the distance between all the metal rods is d = l cos a. The distance between the metal rods can be controlled by controlling the angle between the metal rod holder and the screen holder. Since the metal rod holder is fixed in the middle of the screen holder, it will not move. The two midpoints of a set of metal rod holders form a line, and the two holders and any metal rod form a parallelogram. According to the properties of a parallelogram, all the metal rods are parallel to this line, and the two sets of metal rods are perpendicular to each other. Therefore, the middle line of the two sets of metal rods is always perpendicular, and the two sets of metal rods are always perpendicular. Therefore, it can be known that the screen holes are always rectangular. By independently adjusting the distance between the two sets of metal rods, the size of the screen holes can be changed, and the shape of the screen holes can be changed from a rectangle to a square or from a square to a rectangle. Therefore, the shape and size of the screen holes can be controlled by using two sets of perpendicular metal rods.

[0007] The rotating and dumping frame itself is composed of a support arm and a base, and has two degrees of freedom. The two form a simple gimbal, which can control the sun screen to complete the rotating or dumping action. The parts in the feeding port that are too large in volume to pass through the screen can be transferred to other positions by dumping the feeding port. At the same time, small range movement of the two shafts can also shake the screen, which can be used to speed up the screening process.

[0008] The working principle of each system is as follows:

[0009] The visual self-adaptive adjustment system detects the size of the screening target particles entering the feeding port in real time, and adjusts the shape and size of the screen holes of the gap-controllable screen when the size changes.

[0010] If the screen is deformed and triggers protection, that is, when the screen is stuck, the system will control the screen to tilt backward, and use gravity to make the things in the feeding port move away from the screen. The protruding part behind the feeding port can prevent the things in the feeding port from being dumped out.

[0011] When the camera detects that the material in the feeding port has moved away from the screen, it will clear the stuck screen through screen hole change, then complete the predetermined screen hole change, and then restore the position of the feeding port to continue working.

[0012] At the same time, the camera also monitors the feeding and screening speed. When the material in the feeding port is accumulated, the screen can be shaken to speed up the screening process by controlling the rotating and dumping frame to move in a small range, or the vibration of the controllable vibration motor attached to the gap-controllable screen holder can be adjusted to speed up the screening process.

[0013] The screen protection system can detect whether the screen is stuck in real time when the screen aperture changes, thus ensuring that the screen structure will not be deformed or damaged. Its screen detection process mainly utilizes the screen to adjust the motor's operating current. The motor's operating current can be used to calculate the motor's output torque. This is because when the screen is stuck, the motor cannot rotate, and the controller, detecting that the motor has not reached the target angle, will automatically increase the operating current to increase the motor torque.

[0014] Beneficial effects of the invention:

[0015] When the size of the flux particles changes, the screen can adaptively adjust its mesh size to fit the change, while maintaining the integrity of the screen during the adjustment process. The additional tilting function provided by the equipment structure perfectly solves the problem of cleaning large-volume waste. Combined with an additional controllable vibration motor, it can accelerate the screening process when needed, ensuring that the screening speed keeps up with the feeding speed. The equipment has high adaptability and can be easily adapted to various working scenarios. Attached Figure Description

[0016] Figure 1 Overall structure diagram of a vision-based adaptive particle size variable gap flux screening device

[0017] In the diagram: 1-Camera; 2-Screen support; 3-Controllable vibration motor; 4-Feed inlet; 5-Screen tilt angle control motor; 6-Support arm; 7-Rotating tilting frame controller; 8-Base.

[0018] Figure 2 Detailed image of the end point of the metal rod of the screen

[0019] Figure 3 Diagram showing the connection between the screen metal rod and the metal rod support.

[0020] In the diagram: 9 - Metal rod of the screen; 10 - Metal rod support of the screen.

[0021] Figure 4 Diagram of a screen with controllable gap

[0022] Figure 5 Screen support structure diagram

[0023] Figure 6 Installation effect diagram of the adjustable gap screen on the screen support

[0024] In the diagram: 11 - Screen adjustment motor.

[0025] Figure 7 Filtering part of the complete structure diagram

[0026] Figure 8 Rotating tilting truss structure diagram

[0027] Figure: 12 - Support arm rotation control motor.

[0028] Figure 9 Effect of the rotation dump extension movement

[0029] Figure 10 Vision based adaptive granule size variable gap flux screener feed chute tilt state

[0030] Figure 11 Vision based adaptive granule size variable gap flux screener dump state

[0031] Figure 12 Device adaptive control flowchart

[0032] Figure 13 Screen protection system flowchart

[0033] Figure 14 Screen automatic clog removal function flowchart

[0034] Figure 15 Screen adaptive screening acceleration method flowchart DETAILED DESCRIPTION

[0035] In order to make the purpose, technical solutions and advantages of the present application clearer, a specific feasible design scheme is combined with the drawings to further illustrate the present application. However, the embodiments of the present application are not limited to this.

[0036] Scheme one: large particle submerged arc welding flux recovery.

[0037] First step: install the device, and at the same time install the conveying belt for feeding and collecting at appropriate positions below the feed chute and the screen and near the rotation dump extension.

[0038] Second step: start the self-checking of the device, set the screening target to large particle flux, and set the impurities to small particle debris and large pieces of slag.

[0039] Third step: adjust the position of the feed chute, adjust the screen hole to the minimum, and enter the ready state.

[0040] Fourth step: the feed chute enters a certain volume of material, the system identifies the flux particles, adjusts the screen hole to slightly smaller than the size of the flux to screen small particle impurities. The small particle impurities are screened out at the discharge outlet, and the target flux and large volume slag are stored in the feed chute. Therefore, the position of the rotation dump extension is adjusted before screening so that the discharge outlet is aligned with the conveying belt that receives the impurities. The camera will detect the screening speed during the screening process, and if necessary, the acceleration function will be started to accelerate the screening to wait for the accumulation of flux in the feed chute.

[0041] Fifth Step: After the small particle impurities are screened out, the system adjusts the screen mesh to slightly larger than the size of the flux to start separating the flux and slag. The desired flux comes out of the discharge outlet. The rotary dump frame is adjusted to the position before screening to make the discharge outlet align with the conveyor belt that receives the flux.

[0042] Sixth Step: After the screening is completed, the slag is dumped. The process from the fourth step to the sixth step is repeated.

[0043] Solution Two: Small Particle Submerged Arc Welding Flux Recovery

[0044] First Step: Install the equipment. Install the conveying belts for feeding and collecting at appropriate positions below the screen mesh and near the rotary dump frame.

[0045] Second Step: Start the equipment for self-checking. Set the screening target to small particle flux and set the impurities to be the larger particle debris and large pieces of slag.

[0046] Third Step: Adjust the feeding position, adjust the screen mesh to the smallest, and enter the ready state.

[0047] Fourth Step: Feed the feeding port. The system identifies the flux particles. The system adjusts the screen mesh to slightly larger than the size of the flux to start separating the flux and slag.

[0048] Fifth Step: The desired flux comes out of the discharge outlet. The system identifies the slag accumulation in the feeding port. The feeding is stopped after the slag accumulation reaches a certain volume.

[0049] Sixth Step: Dump the slag. The process from the fourth step to the sixth step is repeated.

Claims

1. A vision-based adaptive particle size variable gap flux screening device, characterized in that: The screening device consists of a gap-controllable screen, a screen protection system, a vision adaptive adjustment system, and a rotating tilting frame. The gap-controllable screen is composed of two sets of screening components stacked vertically. Each set of screening components includes thin metal rods and metal rod supports. Both ends of the thin metal rods are connected to the metal rod supports via movable shafts. The thin metal rods of the upper and lower sets of screening components are perpendicular to each other. A drive shaft is installed at the midpoint of the metal rod support, mounted on the screen support and connected to a screen adjustment motor fixed to the screen support. By driving the metal rod support to rotate via the screen adjustment motor, the angle between the metal rod support and the screen support can be adjusted, thereby synchronously changing the spacing between the thin metal rods. The screen protection system is used for... The screen mesh of the controllable gap screen is protected during the mesh adjustment process. The visual adaptive adjustment system is used to detect the particle size of the target to be screened entering the feed inlet in real time, and then adjusts the mesh shape and size of the controllable gap screen in real time through the screen adjustment motor. The visual adaptive adjustment system also detects the feed accumulation and screening rate, thereby controlling the operation of the rotating tilting frame and / or the controllable vibration motor. The rotating tilting frame includes a support arm and a base. The controllable gap screen is mounted on the support arm of the rotating tilting frame through drive shafts set on both sides of the screen support. It is used to shake the screen in a small range and to pour the material that cannot pass through the screen to other positions to complete the screening and separation process.

2. The vision-based adaptive particle size variable gap flux screening device according to claim 1, characterized in that: The screen protection system is based on the current feedback system of the screen adjustment motor and is applied during the adjustment of the shape and size of the screen mesh. By detecting the working current of the screen adjustment motor, it can detect whether the adjustment of the mesh is blocked by an object.

3. The vision-based adaptive particle size variable gap flux screening device according to claim 1, characterized in that: The device utilizes a vision-based adaptive screening acceleration method to achieve screening acceleration: the vision-based adaptive screening acceleration method uses visual recognition technology to detect the material accumulation height at the feed inlet to determine whether the screening rate meets the requirements. When the screening rate cannot meet the requirements, the vision adaptive adjustment system can sequentially activate and adjust the controllable vibration motor installed on the gap controllable screen support, and drive the rotating tilting frame to shake within a small range through the rotating tilting frame controller, thereby accelerating the screening process.

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