Spiral steel pipe diameter monitoring and early warning device and early warning method

Abstract

The invention provides a spiral steel pipe diameter monitoring and early warning device and an early warning method. The early warning method comprises the following steps: S1, setting a standard diameter value and a tolerance; s2, the horizontal distance measured by the three displacement sensors and the vertical distance between every two adjacent displacement sensors are obtained, and the outer diameter of the spiral steel pipe is obtained through calculation; s3, judging whether the absolute value of the difference between the outer diameter of the spiral steel pipe and the standard diameter value is within a tolerance range, and if so, entering S4; otherwise, sending out standard exceeding information; s4, whether the difference value of the outer diameters of every two adjacent obtained spiral steel pipes is increased or not is judged, and if yes, information that the error trend is too large is sent out; otherwise, going to S5; s5, judging whether the difference values between the external diameters of all the spiral steel pipes and the standard diameter value obtained in continuous third time are positive numbers or negative numbers or not, and if yes, sending same-side error information; otherwise, sending normal information. Before the tolerance is not exceeded, early warning can be carried out according to the error condition of the spiral steel pipe.

Description

Technical Field

[0001] The present invention relates to the technical field of spiral steel pipe diameter early warning, and in particular to a spiral steel pipe diameter monitoring and early warning device and an early warning method. Background Art

[0002] With the development of science and technology, more and more steel is used. Spiral steel pipes are widely used in water supply projects, petrochemical industry, chemical industry, electric power industry, agricultural irrigation, and urban construction; they can be used for liquid transportation, such as water supply or drainage. They can also be used for gas transportation, such as gas, steam or liquefied petroleum gas. They can also be used as structures, such as piling pipes or bridges. Spiral steel pipes are made of strip steel coils as raw materials, extruded at room temperature, and the strip steel coils are fed into the forming unit. After winding, a round tube blank with an open gap is formed, and the weld gap is controlled at 1 to 3 mm. The weld is then welded by automatic double-wire double-sided submerged arc welding process to form a spiral steel pipe.

[0003] In the prior art, in order to ensure that the entire outer diameter of the spiral steel pipe is circular, the diameter of the spiral steel pipe needs to be monitored during the production process to ensure that it is within a certain error. When judging the error of traditional spiral steel pipes, they generally only measure whether it exceeds the specified threshold. After exceeding the threshold, an alarm message is issued, and the operator then adjusts the spiral steel pipe forming unit to ensure that its diameter is within a certain range. In actual detection, there is generally a certain distance between the diameter detection end and the spiral steel pipe forming end. Therefore, this early warning method will actually result in a long section of spiral steel pipe that does not meet the regulations and needs to be polished, which is very inconvenient for subsequent operations. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a spiral steel pipe diameter monitoring and early warning device and an early warning method to solve the problem that the spiral steel pipe diameter cannot be monitored and alarmed in advance in the prior art.

[0005] The technical solution adopted by the present invention to solve the above problem is: a spiral steel pipe diameter monitoring and early warning method, comprising the following steps:

[0006] S1. The processor sets the standard diameter value and tolerance of the spiral steel pipe;

[0007] S2, the processor obtains at a first interval the horizontal distances from the outer wall of the spiral steel pipe measured by the first displacement sensor, the second displacement sensor and the third displacement sensor which are arranged on the same vertical line and at equal intervals, and the vertical distance between the first displacement sensor and the second displacement sensor, and calculates the outer diameter of the spiral steel pipe;

[0008] S3, the processor determines whether the absolute value of the difference between the outer diameter of the spiral steel pipe and the standard diameter value is within the tolerance. If so, it proceeds to step S4; otherwise, it issues an over-standard information and returns to step S2;

[0009] S4, the processor determines whether the difference between the outer diameters of two adjacent spiral steel pipes obtained within the second consecutive time is increasing. If so, it issues a message indicating that the error trend is too large, and returns to step S2; otherwise, it proceeds to step S5;

[0010] S5, the processor determines whether the differences between the outer diameters of all spiral steel pipes obtained within the third consecutive time and the standard diameter values ​​are all positive or negative. If so, a same-side error message is issued and the process returns to step S2; otherwise, a normal message is issued and the process returns to step S2;

[0011] Among them, the second time and the third time are both greater than the first time.

[0012] Compared with the prior art, the advantages of the present invention are that it can issue an alarm message in advance if the error trend of the spiral steel pipe becomes larger and larger before the tolerance is exceeded, or if the error is always deviating from the same side, so as to facilitate timely adjustment of the spiral steel pipe forming and prevent the appearance of a spiral steel pipe that is too long.

[0013] Preferably, in step S2, the following steps are specifically included:

[0014] S21, obtaining a horizontal spacing L1 measured by the first displacement sensor, obtaining a horizontal spacing L2 measured by the second displacement sensor, obtaining a horizontal spacing L3 measured by the third displacement sensor, and obtaining a vertical spacing A between the first displacement sensor and the second displacement sensor;

[0015] S22. When the spiral steel pipe is stationary, the radius R of the static spiral steel pipe is calculated by the following formula:

[0016]

[0017] Among them, ΔL1=|L1-L2|, ΔL2=|L3-L1|;

[0018] Then the outer diameter of the static spiral steel pipe is D=2R.

[0019] The technical effect achieved by adopting this technical solution is that the outer diameter of the spiral steel pipe can be obtained by only obtaining the horizontal spacing of the three displacement sensors and the vertical spacing of adjacent displacement sensors, which facilitates data processing.

[0020] Preferably, when the spiral steel pipe rotates, the time k for the spiral steel pipe to rotate one circle is calculated:

[0021]

[0022] Wherein, T is the wall thickness of the spiral steel pipe, v is the conveying speed of the steel plate wound into the spiral steel pipe, and α is the angle between the steel plate and the spiral steel pipe;

[0023] The average radius of the dynamically rotating spiral steel pipe at τ seconds is calculated by the following formula

[0024]

[0025] Then the outer diameter of the spiral steel pipe at τ seconds is

[0026] The technical effect achieved by adopting this technical solution is: the average outer diameter of the spiral steel pipe during rotation is obtained by integration, which is convenient for calculation.

[0027] Preferably, in step S2, the processor displays the outer diameter of the spiral steel pipe calculated each time in combination with the standard diameter value and the tolerance through a line graph.

[0028] The technical effect achieved by adopting this technical solution: displaying through a line graph facilitates real-time monitoring and obtaining diameter information of the spiral steel pipe.

[0029] Preferably, the exceeding standard information, excessive error trend information, same-side error information and normal information are all indicated by indicator lights of different colors and / or sound indications of different frequencies and volumes.

[0030] The technical effect achieved by adopting this technical solution is that different colors of indicator lights, different sound rates and volumes can reflect a variety of different information.

[0031] Preferably, the third time is greater than the second time.

[0032] Preferably, the first time is 1 second, the second time is 10 seconds, and the third time is 30 seconds.

[0033] Preferably, the tolerance is 5 mm.

[0034] Another technical solution adopted by the present invention to solve the above problem is: an early warning device for monitoring and early warning method of spiral steel pipe diameter, comprising:

[0035] Support rollers, used to support the spiral steel pipe;

[0036] The displacement sensor is used to measure the distance from the outer wall of the spiral steel pipe, and includes a first displacement sensor, a second displacement sensor and a third displacement sensor which are arranged on the same vertical line and at equal intervals;

[0037] A monitoring and processing module, used for obtaining the outer diameter of the spiral steel pipe according to the displacement sensor and judging whether it is within a specified range, comprising a processor, wherein the processor is electrically connected to the first displacement sensor, the second displacement sensor and the third displacement sensor;

[0038] The alarm module is used to send out an alarm message when the outer diameter of the spiral steel pipe exceeds a specified range, and includes an indicator light and a buzzer, and the indicator light and the buzzer are both electrically connected to the processor.

[0039] Compared with the prior art, the advantages of the present invention are that the alarm module can issue different alarm information for different specified ranges, which is convenient for early perception of the diameter of the spiral steel pipe and can handle abnormal conditions in advance.

[0040] Preferably, the supporting rollers include a first roller and a third roller rollingly connected to the outer side wall of the spiral steel pipe, and a second roller rollingly connected to the inner side wall of the spiral steel pipe, and the second roller is arranged between the first roller and the third roller.

[0041] The technical effect achieved by adopting this technical solution is as follows: the spiral steel pipe can be limited by the first roller, the second roller and the third roller, thereby avoiding inaccurate diameter measurement errors caused by the rotation deviation of the spiral steel pipe. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 This is a structural schematic diagram of a spiral steel pipe diameter monitoring and early warning device of the present invention;

[0043] Figure 2 It is a schematic diagram of the two-dimensional coordinates of the outer surface of the spiral steel pipe measured by the displacement sensor in the spiral steel pipe diameter monitoring and early warning method of the present invention;

[0044] Figure 3 A schematic diagram of a dynamic spiral steel pipe in a spiral steel pipe diameter monitoring and early warning method of the present invention;

[0045] Figure 4 A schematic diagram of a spiral steel pipe diameter monitoring and early warning method of the present invention showing a line graph of the measured diameter of the spiral steel pipe;

[0046] Figure 5 The present invention is a flow chart of a spiral steel pipe diameter monitoring and early warning method.

[0047] Explanation of the accompanying drawings: 1- spiral steel pipe; 2- displacement sensor; 21- first displacement sensor; 22- second displacement sensor; 23- third displacement sensor; 3- support roller; 31- first roller; 32- second roller; 33- third roller. DETAILED DESCRIPTION

[0048] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0049] Embodiment 1

[0050] like Figures 1 to 5 As shown, this embodiment relates to a spiral steel pipe diameter monitoring and early warning method, comprising the following steps:

[0051] S1, the processor sets the standard diameter value and tolerance of the spiral steel pipe 1;

[0052] S2, the processor obtains at a first interval the horizontal distances from the outer wall of the spiral steel pipe 1 measured by the first displacement sensor 21, the second displacement sensor 22 and the third displacement sensor 23 which are arranged on the same vertical line and at equal intervals, and the vertical distance between the first displacement sensor 21 and the second displacement sensor 22, and calculates the outer diameter of the spiral steel pipe 1;

[0053] S3, the processor determines whether the absolute value of the difference between the outer diameter of the spiral steel pipe 1 and the standard diameter value is within the tolerance. If so, it proceeds to step S4; otherwise, it issues an over-standard information to instruct the operator to adjust the spiral steel pipe forming unit, and returns to step S2;

[0054] S4, the processor determines whether the difference in the outer diameters of two adjacent spiral steel pipes 1 obtained within the second consecutive time is increasing. If so, it issues a message indicating that the error trend is too large, instructs the operator to adjust the spiral steel pipe forming unit, and returns to step S2; otherwise, it goes to step S5;

[0055] In this step, for example, the outer diameters of four spiral steel pipes 1 are successively obtained as 1020.3, 1020.1, 1019.8, and 1019.4, and the diameter differences between two adjacent ones are 0.2, 0.3, and 0.4, which means that the difference is increasing.

[0056] S5, the processor determines whether the differences between the outer diameters of all spiral steel pipes 1 obtained within the third consecutive time and the standard diameter values ​​are all positive or negative. If so, a same-side error message is issued to instruct the operator to adjust the spiral steel pipe forming unit and return to step S2; otherwise, a normal message is issued and the process returns to step S2;

[0057] Among them, the second time and the third time are both greater than the first time.

[0058] Before the tolerance is exceeded, an alarm message can be issued in advance if the error trend of the spiral steel pipe 1 is getting bigger and bigger, or if the error is always deviating from the same side, so as to adjust the forming of the spiral steel pipe 1 in time and prevent the appearance of a spiral steel pipe 1 that is too long.

[0059] In the above process, the operator can adjust the spiral steel pipe forming unit without stopping the machine.

[0060] In step S2, the following steps are specifically included:

[0061] S21, obtaining a horizontal distance L1 measured by the first displacement sensor 21, obtaining a horizontal distance L2 measured by the second displacement sensor 22, obtaining a horizontal distance L3 measured by the third displacement sensor 23, and obtaining a vertical distance A between the first displacement sensor 21 and the second displacement sensor 22;

[0062] S22, when the spiral steel pipe 1 is stationary, if Figure 2 The figure shows the geometric relationship of the distance measured by the displacement sensor 2, where O1, O2, and O3 are the positions measured by the three displacement sensors, respectively, and a system is established with O2 as the origin of the coordinate system; where ΔL1 = |L1-L2|, ΔL2 = |L3-L1|;

[0063] Draw perpendicular bisectors l1 and l2 of the straight lines O2O1 and O2O3 respectively. According to the geometric theorem, the intersection of l1 and l2 is the center of the circle measured by the laser sensor.

[0064] The equations of the lines l1 and l2 are

[0065]

[0066]

[0067] The intersection of the two straight lines is

[0068]

[0069] According to the distance formula Get

[0070]

[0071] Then the outer diameter D of the static spiral steel pipe 1 is 2R.

[0072] It is only necessary to obtain the horizontal spacing between three displacement sensors and the vertical spacing between adjacent displacement sensors to obtain the outer diameter of the spiral steel pipe, which is convenient for data processing.

[0073] When the spiral steel pipe 1 rotates, Figure 3 As shown, the median diameter corresponds to the circumference C = π (DT), in mm; T is the wall thickness of the spiral steel pipe 1, in mm;

[0074] Length of one pitch plate Unit: mm;

[0075] The angle α between the steel plate and the spiral steel pipe 1,

[0076] Wherein, B is the width of spiral tube sheet, in mm;

[0077] The time k for a spiral steel pipe 1 to rotate one circle is calculated as follows:

[0078]

[0079] Wherein, v is the conveying speed of the steel plate wound into the spiral steel pipe 1.

[0080] Set the frequency of displacement sensor 2 to once per second, that is, measure one R value per second. From the τ-k+1th second to the τth second, a circle is measured, which is equivalent to measuring the arc by dividing the circle into k equal parts. The average radius value measured within τ-k+1 to τ seconds is obtained to obtain the average radius of the spiral tube. That is, the average radius of the dynamically rotating spiral steel pipe 1 at the τth second is calculated by the following formula:

[0081]

[0082] Then the outer diameter of spiral steel pipe 1 at τ seconds is

[0083] The average outer diameter of the spiral steel pipe during rotation is obtained by integration to facilitate calculation.

[0084] like Figure 4 As shown, in step S2, the processor displays the outer diameter of the spiral steel pipe 1 calculated each time in combination with the standard diameter value and the tolerance through a line graph.

[0085] The outer diameter of the spiral steel pipe 1 obtained in real time is combined with the standard diameter value and tolerance to draw a line graph on the time axis, and the line graph is used to display the outer diameter of the spiral steel pipe 1, so as to facilitate real-time monitoring and acquisition of the diameter information of the spiral steel pipe.

[0086] Among them, the exceeding standard information, the excessive error trend information, the same-side error information and the normal information are all indicated by indicator lights of different colors and / or sound indications of different frequencies and volumes.

[0087] For example, the exceeding standard information may be: a red light indicating exceeding standard is continuously on, and an alarm sound is turned on;

[0088] The error trend is too large information can be: the red light of the trend is too large is continuously on, and the high-frequency warning sound is turned on and the volume is gradually increased;

[0089] The same-side error information can be: the yellow light of the same-side error is continuously on, and the buzzer keeps beeping;

[0090] Normal information may be: the indicator lights are off and the buzzer does not sound.

[0091] In this embodiment, the third time is greater than the second time. The first time is 1 second, the second time is 10 seconds, and the third time is 30 seconds.

[0092] The tolerance is 5mm, so it can be divided into upper deviation 5mm and lower deviation 5mm.

[0093] Embodiment 2

[0094] See also Figure 1 As shown, this embodiment relates to an early warning device for a spiral steel pipe diameter monitoring and early warning method, comprising

[0095] A supporting roller 3, used for supporting the spiral steel pipe 1;

[0096] The displacement sensor 2 is used to measure the distance from the outer wall of the spiral steel pipe 1, and includes a first displacement sensor 21, a second displacement sensor 22 and a third displacement sensor 23 which are arranged on the same vertical line and at equal intervals;

[0097] A monitoring and processing module, used to obtain the outer diameter of the spiral steel pipe 1 according to the displacement sensor 2 and determine whether it is within a specified range, including a processor, and the processor is electrically connected to the first displacement sensor 21, the second displacement sensor 22 and the third displacement sensor 23;

[0098] The alarm module is used to send out an alarm message when the outer diameter of the spiral steel pipe 1 exceeds a specified range, and includes an indicator light and a buzzer, and both the indicator light and the buzzer are electrically connected to the processor.

[0099] The alarm module can issue different alarm messages for different specified ranges, making it easy to perceive the diameter of the spiral steel pipe in advance and deal with abnormal conditions in advance.

[0100] The supporting roller 3 includes a first roller 31 and a third roller 33 which are rollingly connected to the outer wall of the spiral steel pipe 1 , and a second roller 32 which is rollingly connected to the inner wall of the spiral steel pipe 1 . The second roller 32 is arranged between the first roller 31 and the third roller 33 .

[0101] The first roller 31, the second roller 32 and the third roller 33 can limit the spiral steel pipe, thereby preventing the spiral steel pipe from rotating and deviating, thereby preventing inaccurate diameter measurement errors.

[0102] The beneficial effects of the present invention are: before the tolerance is exceeded, an alarm message can be issued in advance for the situation where the error trend of the spiral steel pipe 1 is getting larger and larger, and the error situation of deviating from the same side is always in progress, so as to facilitate timely adjustment of the molding of the spiral steel pipe 1 in advance and prevent the appearance of a spiral steel pipe 1 that is too long.

[0103] The above description shows and describes several preferred embodiments of the present invention, but as mentioned above, it should be understood that the present invention is not limited to the form disclosed herein, and should not be regarded as excluding other embodiments, but can be used in various other combinations, modifications and environments, and can be modified within the scope of the invention concept described herein through the above teachings or the technology or knowledge of the relevant field. Changes and variations made by those skilled in the art do not depart from the spirit and scope of the present invention, and should be within the scope of protection of the claims attached to the present invention.

[0104] Although the disclosure is disclosed as above, the protection scope of the disclosure is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the disclosure, and these changes and modifications will fall within the protection scope of the present invention.

Claims

1. A spiral steel pipe diameter monitoring and early warning method, characterized in that: The steps include: S1, the processor sets the standard diameter value and tolerance of the spiral steel pipe (1); S2, the processor obtains at a first time interval the horizontal distances from the outer wall of the spiral steel pipe (1) measured by the first displacement sensor (21), the second displacement sensor (22) and the third displacement sensor (23) which are arranged on the same vertical line and at equal intervals, and the vertical distance between the first displacement sensor (21) and the second displacement sensor (22), and calculates the outer diameter of the spiral steel pipe (1); S3, the processor determines whether the absolute value of the difference between the outer diameter of the spiral steel pipe (1) and the standard diameter value is within the tolerance. If so, the process proceeds to step S4; otherwise, an over-standard information is issued and the process returns to step S2; S4, the processor determines whether the difference in the outer diameters of two adjacent spiral steel pipes (1) obtained within a second period of time is increasing. If so, a message indicating that the error trend is too large is issued and the process returns to step S2; otherwise, the process proceeds to step S5; S5, the processor determines whether the differences between the outer diameters of all spiral steel pipes (1) obtained within the third consecutive time and the standard diameter values ​​are all positive or negative. If so, a same-side error message is issued and the process returns to step S2; otherwise, a normal message is issued and the process returns to step S2; Among them, the second time and the third time are both greater than the first time.

2. A spiral steel pipe diameter monitoring and early warning method according to claim 1, characterized in that: In step S2, the following steps are specifically included: S21, obtaining a horizontal spacing L1 measured by the first displacement sensor (21), obtaining a horizontal spacing L2 measured by the second displacement sensor (22), obtaining a horizontal spacing L3 measured by the third displacement sensor (23), and obtaining a vertical spacing A between the first displacement sensor (21) and the second displacement sensor (22); S22. When the spiral steel pipe (1) is stationary, the radius R of the static spiral steel pipe (1) is calculated by the following formula: Among them, ΔL1=|L1-L2|, ΔL2=|L3-L1|; Then the outer diameter D of the static spiral steel pipe (1) is 2R.

3. A spiral steel pipe diameter monitoring and early warning method according to claim 2, characterized in that: When the spiral steel pipe (1) rotates, the time k for the spiral steel pipe (1) to rotate one circle is calculated as follows: Wherein, T is the wall thickness of the spiral steel pipe (1), v is the conveying speed of the steel plate wound into the spiral steel pipe (1), and α is the angle between the steel plate and the spiral steel pipe (1); The average radius of the dynamically rotating spiral steel pipe (1) at the τth second is calculated by the following formula: Then the outer diameter of the spiral steel pipe (1) at τ seconds is 4. The spiral steel pipe diameter monitoring and early warning method according to claim 1 is characterized by: In step S2, the processor displays the outer diameter of the spiral steel pipe (1) obtained by each calculation in combination with the standard diameter value and the tolerance through a line graph.

5. The spiral steel pipe diameter monitoring and early warning method according to claim 1 is characterized by: The exceeding standard information, excessive error trend information, same-side error information and normal information are all indicated by indicator lights of different colors and / or sound indications of different frequencies and volumes.

6. The spiral steel pipe diameter monitoring and early warning method according to claim 1 is characterized by: The third time is greater than the second time.

7. A spiral steel pipe diameter monitoring and early warning method according to claim 6, characterized in that: The first time is 1 second, the second time is 10 seconds, and the third time is 30 seconds.

8. The spiral steel pipe diameter monitoring and early warning method according to claim 1 is characterized by: The tolerance is 5 mm.

9. An early warning device for the spiral steel pipe diameter monitoring and early warning method according to any one of claims 1 to 8, characterized in that: include A support roller (3) for supporting the spiral steel pipe (1); A displacement sensor (2) for measuring the distance from the outer wall of the spiral steel pipe (1), comprising a first displacement sensor (21), a second displacement sensor (22) and a third displacement sensor (23) which are arranged on the same vertical line and at equal intervals; A monitoring processing module, used for obtaining the outer diameter of the spiral steel pipe (1) according to the displacement sensor (2) and judging whether it is within a specified range, comprising a processor, wherein the processor is electrically connected to the first displacement sensor (21), the second displacement sensor (22) and the third displacement sensor (23); The alarm module is used to issue an alarm message when the outer diameter of the spiral steel pipe (1) exceeds a specified range, and comprises an indicator light and a buzzer, wherein the indicator light and the buzzer are both electrically connected to the processor.

10. The early warning device of the spiral steel pipe diameter monitoring and early warning method according to claim 9, characterized in that: The supporting roller (3) comprises a first roller (31) and a third roller (33) which are rollingly connected to the outer wall of the spiral steel pipe (1), and a second roller (32) which is rollingly connected to the inner wall of the spiral steel pipe (1), wherein the second roller (32) is arranged between the first roller (31) and the third roller (33).

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