Intelligent defect identification device and method for stainless steel medium plate

Abstract

The invention discloses an intelligent defect identification device and method for a stainless steel medium plate, and belongs to a morphology detection system and method, the intelligent defect identification device comprises a programmable controller PLC, a controlled object connected with a control line of the programmable controller PLC, and a detection system connected with a signal line of the programmable controller PLC; the controlled object comprises a servo driving system, a human-computer interface, a roller conveyor and a gantry system; the detection system provides trigger signals for the Kepler velocimeter, the laser, the laser range finder and the scanner. The method comprises the steps of software design of the control system of the intelligent defect identification device for the stainless steel medium-thickness plate, hardware design of the control system of the intelligent defect identification device for the stainless steel medium-thickness plate, hardware design of the detection system and software design of the detection system. According to the invention, electrical control, an industrial visual inspection technology, motor control and an industrial field bus communication function are integrated, and intelligent identification of defects of the stainless steel medium and thick plate can be realized.

Description

Technical Field

[0001] The invention relates to a shape detection system and method, in particular to an intelligent defect recognition device and method for medium and thick stainless steel plates. Background Art

[0002] Stainless steel plates are widely used in construction, automobiles, ships and other industrial fields due to their excellent corrosion resistance and mechanical properties. However, during the production and processing, these plates may have various surface defects, such as scratches, pits, cracks, oxide scale, etc. These defects not only affect the appearance of the material, but also may reduce its performance and durability.

[0003] Identifying these defects is crucial to ensuring product quality. Traditional defect detection methods mainly rely on manual inspection, but this method is not only labor-intensive, but also easily affected by subjective factors, making it difficult to ensure the accuracy and consistency of detection. With the advancement of technology, automated detection technology has gradually become mainstream. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide an intelligent identification device and method for defects in medium and thick stainless steel plates, which integrates electrical control, industrial visual inspection technology, motor control and industrial field bus communication functions, and can realize intelligent identification of defects in medium and thick stainless steel plates.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is: An intelligent defect recognition device for stainless steel medium and thick plates comprises a programmable controller (PLC), a controlled object connected to a control line of the programmable controller (PLC), and a detection system connected to a signal line of the programmable controller (PLC); the controlled object comprises a servo drive system, a human-machine interface, a roller conveyor and a gantry system; the detection system provides trigger signals for a Kepler velocimeter, a laser, a laser rangefinder and a scanner respectively.

[0006] A further improvement of the technical solution of the present invention is that the servo drive system includes a servo driver, a servo motor, a stepper motor driver, a stepper motor, a frequency converter and a three-phase asynchronous motor.

[0007] A further improvement of the technical solution of the present invention is that the gantry system includes two mobile gantries and one static gantry, the static gantry is fixed, the two sub-beams can be lifted and lowered independently, the two mobile gantries move along the Y axis, and each gantry includes three sub-beams.

[0008] A further improvement of the technical solution of the present invention is that the detection system includes a signal converter, a laser, an industrial camera, a scanner, a laser rangefinder and a Kepler speedometer.

[0009] A further improvement of the technical solution of the present invention is that the communication mode between the programmable controller PLC and the servo driver is ENTHERCAT, the communication mode between the programmable controller PLC and the stepper motor driver is a digital I / O port, and the communication mode between the programmable controller PLC and the frequency converter is 485.

[0010] A further improvement of the technical solution of the present invention is that the communication mode between the programmable controller PLC and the Kepler speed meter is 485, and the communication mode between the programmable controller PLC and the laser rangefinder is an analog I / O port.

[0011] A further improvement of the technical solution of the present invention is that the scanner is installed on a slide, and the transmission mode of the slide is synchronous belt transmission.

[0012] A method for intelligently identifying defects in stainless steel medium and thick plates comprises the following steps: Step 1: The programmable controller PLC controls the servo drive through ENTHERCAT communication networking, and designs the servo drive unit; the programmable controller PLC controls the stepper motor drive through high-speed digital I / O ports and low-speed digital I / O ports, and designs the stepper drive unit. The high-speed digital I / O ports and low-speed digital I / O ports are combined to maximize the number of axis groups supported by the PLC; the programmable controller PLC controls the frequency converter through 485, and thus designs the frequency converter control unit; Step 2: PLC control program design; PLC control program design includes main program, communication subroutine, narrow plate automatic scanning program, wide plate automatic scanning program, gantry manual mode program, inverter control subroutine and automatic height adjustment program; Step 3: Human-machine interface design based on the general monitoring and control system; The human-machine interface design based on the general monitoring and control system includes the design of welcome interface, operation interface, automatic interface, manual interface 1, manual interface 2 and manual interface 3; Step 4: Hardware design of the detection system; the laser rangefinder of the steel plate thickness detection system collects the steel plate thickness through the analog input module, and the Kepler velocimeter of the steel plate speed detection system outputs a 24V pulse signal through a signal converter to trigger the laser, improve the accuracy of the trigger signal, and the industrial camera takes pictures in real time; Step 5: Design of detection system software.

[0013] A further improvement of the technical solution of the present invention is that in the hardware design of the detection system, an industrial camera takes pictures in real time to perform planar positioning of surface defects of the steel plate, two lasers detect the depth of defects of the steel plate, and three-dimensional detection of defects of the steel plate is achieved through the industrial camera and two lasers.

[0014] Due to the adoption of the above technical solution, the technical progress achieved by the present invention is: 1. The present invention is a stainless steel medium and thick plate defect detection device which integrates electrical control, industrial visual inspection technology, motor control and industrial field bus communication functions.

[0015] 2. The stainless steel medium and thick plate defect detection device significantly improves the accuracy of detection through high-precision sensors and intelligent algorithms. The device uses advanced image recognition technology to identify and classify various defects in real time, including cracks, inclusions and deformations, greatly reducing the possibility of missed detection and false detection. Its intelligent characteristics enable the equipment to automatically adjust parameters such as the height of the gantry beam to adapt to steel plates of different thicknesses and materials, ensuring the consistency and reliability of detection. In addition, the device significantly reduces dependence on manual operation through automated operation and data analysis, reduces labor costs and improves production efficiency. Overall, this detection device not only ensures high-precision detection, but also realizes intelligent management, promoting industrial production to develop in a more efficient and economical direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is an electrical principle block diagram of an intelligent stainless steel plate defect identification device of the present invention; Figure 2 It is a basic structural schematic diagram of an intelligent device for identifying defects of medium and thick stainless steel plates of the present invention; Figure 3 It is a partial structural schematic diagram of a detection system of an intelligent device for identifying defects of medium and thick stainless steel plates of the present invention; Figure 4 It is a partial structural schematic diagram of a detection system of an intelligent device for identifying defects in medium and thick stainless steel plates of the present invention; Among them, 1-1, human-machine interface, 1-2, programmable controller PLC, 1-3, stepper motor driver, 1-4, servo driver, 1-5, frequency converter, 1-6, stepper motor, 1-7, servo motor, 1-8, three-phase asynchronous motor; 2-1. Laser rangefinder, 2-2. Kepler velocimeter, 2-3. Laser, 2-4. Roller conveyor, 2-5. Industrial camera, 2-6. Scanner. DETAILED DESCRIPTION

[0017] The present invention is further described in detail below with reference to the accompanying drawings and embodiments: like Figure 1-4As shown, a device for intelligently identifying defects in medium and thick stainless steel plates, the wiring of the programmable controller PLC 1-2 is composed of control lines, signal lines and power lines. The control lines are connected to other controlled objects, respectively controlling the drive system, the human-machine interface (touch screen) 1-1, the roller conveyor 2-4 and the gantry system. The signal lines are connected to the detection system, respectively providing trigger signals for the laser rangefinder 2-1, the Kepler velocimeter 2-2, the laser 2-3, the industrial camera 2-5 and the scanner 2-6.

[0018] The servo drive system includes Huichuan servo driver 1-4, Huichuan servo motor 1-7, stepper motor driver 1-3, stepper motor 1-6, domestic inverter 1-5 and three-phase asynchronous motor 1-8. The gantry system includes 2 mobile gantries and 1 static gantry. The static gantry is fixed and the two sub-beams can be raised and lowered independently. The 2 mobile gantries can move along the Y axis, and each gantry has three sub-beams. The two mobile gantries are driven by a servo motor 1-7 with a reducer. During the scanning process of the scanner 2-6, the two mobile gantries move toward each other along the Y axis. This way of moving toward each other helps to improve the efficiency and accuracy of the scanning.

[0019] The detection system includes a signal converter, a laser 2-3, an industrial camera 2-5, a scanner 2-6, a laser rangefinder 2-1 and a Kepler velocimeter 2-2.

[0020] The scanner 2-6 is installed on a slide, and the drive mode of the slide is synchronous belt drive. The position of the scanner 2-6 can be changed in real time according to the scanning requirements. This method expands the scanning range of the scanner and is suitable for various plate types.

[0021] The automation of the gantry system can be achieved through the programmable controller PLC1-2 and the control drive system, and the intelligence of the medium and thick plate defect identification device can be achieved through the detection system.

[0022] A method for realizing an intelligent defect identification device for medium and thick stainless steel plates comprises the following steps: Step 1: The programmable controller PLC 1-2 controls the servo driver 1-4 through the ENTHERCAT communication network, thereby designing the servo drive unit; the programmable controller PLC 1-2 controls the stepper motor driver 1-3 through the high-speed digital I / O port and the low-speed digital I / O port, thereby designing the stepper drive unit. The combination of the high-speed digital I / O port and the low-speed digital I / O port makes the maximum use of the number of axis groups supported by the PLC; the programmable controller PLC controls the frequency converter 1-5 through 485, thereby designing the frequency converter control unit; Step 2: PLC control program design mainly includes main program, communication subroutine, narrow plate automatic scanning program, wide plate automatic scanning program, gantry manual mode program, inverter control subroutine and automatic height adjustment program; The main program framework includes: (1) power-on start; (2) real-time data collection; (3) template selection; (4) automatic scanning program; The communication subroutine is divided into two parts: reading and writing. The main framework of the scanning program is: (1) start taking pictures; (2) automatically adjust the height; (3) after the second stage limit is triggered, the mobile gantry starts moving; The difference between the wide board and narrow board automatic scanning programs lies in the movement trajectory of the gantry. The inverter control subprogram is mainly divided into forward and reverse rotation; The main framework of the automatic height adjustment subroutine: (1) distance measurement; (2) judging whether the distance meter is working normally; (3) calculating the thickness of the steel plate and the moving distance; (4) longitudinal movement of the gantry.

[0023] Step 3: The human-computer interface design based on MCGS mainly includes the design of welcome interface, operation interface, automatic interface, manual interface 1, manual interface 2, and manual interface 3; Among them, the operation interface mainly includes 3 manual interfaces, automatic interface, motor and roller diagnosis interface. Manual interface 1 mainly includes the inching and continuous movement of 5 servo motors, manual interface 2 mainly includes the inching and continuous movement of 4 stepping motors, manual interface 3 mainly includes the movement trajectory setting of wide plate and narrow plate, automatic interface mainly includes the display of information such as steel plate thickness, gantry movement status and operation buttons, etc., and motor and roller diagnosis interface mainly includes the display of information such as motor and roller speed; Step 4: The hardware design of the detection system mainly includes: the laser rangefinder 2-1 of the steel plate thickness detection system realizes the acquisition of the steel plate thickness through the analog input module, the Kepler velocimeter 2-2 outputs a 24V pulse signal through the signal converter, thereby triggering the laser 2-3, improving the accuracy of the trigger signal, and the industrial camera 2-5 takes pictures in real time. The industrial camera 2-5 cooperates with the laser 2-3 to realize the three-dimensional detection of defects in stainless steel medium and thick plates; In the hardware design of the detection system, the programmable controller PLC controls the Kepler speed meter 2-2 through 485 to detect the speed and length of the detection object in real time; In the hardware design of the detection system, the industrial camera 2-5 takes pictures in real time to perform planar positioning of surface defects of the steel plate, and the two lasers 2-3 detect the depth of defects of the steel plate. The industrial camera 2-5 and the two lasers 2-3 finally realize three-dimensional detection of defects of the steel plate.

[0024] Step 5: Design of detection system software.

Claims

1. An intelligent device for identifying defects in medium and thick stainless steel plates, characterized in that: The invention comprises a programmable controller (PLC) (1-2), a controlled object connected to a control line of the programmable controller (PLC) (1-2), and a detection system connected to a signal line of the programmable controller (PLC) (1-2); the controlled object comprises a servo drive system, a human-machine interface (1-1), a roller conveyor and a gantry system; and the detection system provides trigger signals for a Kepler speedometer (2-2), a laser (2-3), a laser rangefinder (2-1) and a scanner (2-6).

2. The intelligent defect identification device for medium and thick stainless steel plates according to claim 1 is characterized in that: The servo drive system comprises a servo driver (1-4), a servo motor (1-7), a stepper motor driver (1-3), a stepper motor (1-6), a frequency converter (1-5) and a three-phase asynchronous motor (1-8).

3. The intelligent defect identification device for medium and thick stainless steel plates according to claim 1 is characterized in that: The gantry system comprises two movable gantries and one stationary gantry, the stationary gantry is fixed, the two auxiliary beams can be lifted and lowered independently, the two movable gantries move along the Y axis, and each gantry comprises three auxiliary beams.

4. The intelligent defect identification device for medium and thick stainless steel plates according to claim 1 is characterized in that: The detection system comprises a signal converter, a laser (2-3), an industrial camera (2-5), a scanner (2-6), a laser rangefinder (2-1) and a Kepler velocimeter (2-2).

5. The intelligent defect identification device for medium and thick stainless steel plates according to claim 2 is characterized in that: The communication method between the programmable controller PLC (1-2) and the servo driver (1-4) is ENTHERCAT, the communication method between the programmable controller PLC (1-2) and the stepper motor driver (1-3) is a digital I / O port, and the communication method between the programmable controller PLC (1-2) and the frequency converter (1-5) is 485.

6. The intelligent defect identification device for medium and thick stainless steel plates according to claim 4 is characterized in that: The communication method between the programmable controller PLC (1-2) and the Kepler speed meter (2-2) is 485, and the communication method between the programmable controller PLC (1-2) and the laser rangefinder (2-1) is an analog I / O port.

7. The intelligent defect identification device for medium and thick stainless steel plates according to claim 4 is characterized in that: The scanner (2-6) is installed on a slide, and the drive mode of the slide is synchronous belt drive.

8. An intelligent method for identifying defects in medium and thick stainless steel plates, characterized by: The intelligent defect identification device for medium and thick stainless steel plates according to any one of claims 1 to 7 comprises the following steps: Step 1: The programmable controller PLC (1-2) controls the servo driver (1-4) through the ENTHERCAT communication network, and designs the servo drive unit; the programmable controller PLC (1-2) controls the stepper motor driver (1-3) through the high-speed digital I / O port and the low-speed digital I / O port, and designs the stepper drive unit. The high-speed digital I / O port and the low-speed digital I / O port are combined to maximize the number of axis groups supported by the PLC; the programmable controller PLC (1-2) controls the frequency converter (1-5) through 485, and designs the frequency converter control unit; Step 2: PLC control program design; PLC control program design includes main program, communication subroutine, narrow plate automatic scanning program, wide plate automatic scanning program, gantry manual mode program, inverter control subroutine and automatic height adjustment program; Step 3: Human-machine interface design based on the general monitoring and control system; The human-machine interface design based on the general monitoring and control system includes the design of welcome interface, operation interface, automatic interface, manual interface 1, manual interface 2 and manual interface 3; Step 4: Hardware design of the detection system; the laser rangefinder of the steel plate thickness detection system collects the steel plate thickness through the analog input module, and the Kepler velocimeter (2-2) of the steel plate speed detection system outputs a 24V pulse signal through the signal converter, thereby triggering the laser (2-3) to improve the accuracy of the trigger signal, and the industrial camera (2-5) takes pictures in real time; Step 5: Design of detection system software.

9. The intelligent method for identifying defects in medium and thick stainless steel plates according to claim 8, characterized in that: In the hardware design of the detection system, the industrial camera (2-5) takes pictures in real time to perform planar positioning of surface defects on the steel plate, and the two lasers (2-3) detect the depth of the defects on the steel plate. The industrial camera (2-5) and the two lasers (2-3) realize three-dimensional detection of defects on the steel plate.

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