Annular inner wall defect detection device and detection system

Abstract

The invention relates to an annular inner wall defect detection device and a detection system. The device comprises a base disc, a shell, a rotating table, an integrated motor, a sensor adapter plate and a line laser sensor, the machine shell is fixed to the base disc, the rotating table is connected to the top of the machine shell, and the integrated motor is located on one side of the rotating table and used for being connected with the rotating table and driving the rotating table to rotate. The line laser sensors are arranged at the two ends of the sensor adapter plate respectively, and the sensor adapter plate is connected to the rotating table. An industrial personal computer and a controller are installed in the machine shell, and a corresponding upper computer software system runs in the industrial personal computer and is connected with and controls the robot body. According to the invention, the appearance, the surface surplus height, the width, the alignment tolerance and the like of the pipeline welding seam can be measured, the size is smaller, the operation is longer, the welding seam identification speed is higher, more detection results can be obtained by limited resources, the identification and scanning effects are better, and the analysis result is more accurate.

Description

Technical Field

[0001] The invention relates to the technical field of machine vision detection, and in particular to a ring-shaped inner wall defect detection device. Background Art

[0002] Railways, highways, water transport, aviation and pipelines are the five main modes of transportation in modern society. Pipeline transportation is a mode of transportation that uses pipelines as a means of transportation to transport liquid and gas materials over long distances. It is also the most special mode of transportation. Compared with other modes of transportation, pipeline transportation has the advantages of large transportation volume, 24-hour uninterrupted transportation, good continuity, no influence of weather factors during transportation, and low unit cargo transportation costs. At present, pipeline networks are generally assembled by welding, so it is particularly important to ensure the welding quality of pipe joints. Engineering accidents caused by pipeline weld quality problems are common. Manual weld detection is not only cumbersome and time-consuming, but also has great limitations. It is far from meeting the requirements of high efficiency, safety, and short cycle. At present, the mainstream automated equipment for weld detection uses two methods: machine vision image processing and line laser detection.

[0003] Machine vision detection methods need to combine multiple technologies such as image acquisition, image processing, feature recognition, and feature extraction. At present, in the industrial field, the research on pre-weld detection is much deeper and more extensive than the research on post-weld detection. Weld detection is a convenient research on weld positioning, weld identification, and weld tracking. At present, a university research team has applied ant colony algorithm and neural network algorithm to robot welding, which greatly improves the anti-interference ability, stability and accuracy of the weld tracking system.

[0004] Laser detection technology is a measurement technology that not only uses light sources for assistance, but also uses image processing. Its proposal solves the difficulty of image matching in stereoscopic vision. It has high resolution, fast speed, strong anti-interference and high precision. In addition, its equipment is simple to install and easy to implement, and has been widely used in medical plastic surgery, industrial measurement, mapping and automatic control. With the development of laser detection technology, it has also promoted the development of welding automation, especially in the detection of welds. Both at home and abroad, in-depth research has been conducted on the application technology of laser detection technology in welding, and certain results have been achieved. For example, Modular Vision System of Canada has developed a three-dimensional laser vision sensor for welded joints with root errors or openings of only 0.050mm. It can track welding at a speed of 20m / min and maintain a tracking accuracy of 0.020mm.

[0005] Although machine vision weld detection technology is more efficient, non-contact, and has a wider range of applicability than traditional weld detection, the line laser detection solution has the advantages of high accuracy, large range, fast measurement speed, and good system flexibility in weld detection while meeting the requirements of non-contact and getting rid of the limitations of traditional weld detection. Therefore, the present invention comprehensively considers the selection of line laser technology to detect pipeline welds and proposes a ring inner wall defect detection device. Summary of the invention

[0006] The purpose of the present invention is to overcome the problems existing in the prior art and to provide a ring-shaped inner wall defect detection device. Compared with traditional detection methods and traditional detection machines, the present invention has many advantages such as smaller size, longer operation time, faster weld recognition speed, more detection results obtained with limited resources, better recognition and scanning effects, and more accurate analysis results.

[0007] In order to achieve the above technical objectives and the above technical effects, the present invention is implemented through the following technical solutions: A ring-shaped inner wall defect detection device, the device comprises a base plate, a housing, a rotating table, an integrated motor, a sensor adapter plate and a line laser sensor constituting a measuring module; wherein: The housing is fixed on the base plate, the rotating platform is connected to the top of the housing, and the integrated motor is located on one side of the rotating platform, and is used to connect and drive the rotating platform to rotate; The line laser sensors are respectively arranged at two ends of a sensor adapter plate, and the sensor adapter plate is connected to a rotating platform; An industrial computer and a controller are installed inside the casing. A corresponding upper computer software system runs inside the industrial computer and is connected to control the robot body.

[0008] Furthermore, the sensor adapter plate, rotating table, housing and base are collinear on the central axis of the pipeline when connected for operation, and the base is mounted on the robot body so that it can move axially and rotate along the central axis of the pipeline.

[0009] A ring inner wall defect detection system, the system includes a host computer software system, the host computer software system is divided into a basic layer, a business layer and an application layer, wherein: The basic layer, as a hardware part, includes an industrial computer, a line laser sensor, a control module and a motion module, wherein the motion module includes an integrated motor with an encoder and a rotating table; The business layer, as a logical function implementation layer, includes a data acquisition module, an IO monitoring module, a data processing module, an algorithm module and a function module; The application layer acts as an output layer, interacting directly with the user so that the structure and analysis of the processed data can be displayed.

[0010] Furthermore, in the business layer, the relevant parameters of the entire system are customized in the system setting interface, and the system setting is divided into motion setting, sensor controller setting, recognition mode setting and other settings; The motion settings include the serial port number and baud rate when the industrial computer is connected to the integrated motor, and the speed, acceleration and deceleration of the integrated motor when the line laser sensor rotates; The sensor control setting is used to call the controller program number in the identification mode and the detection mode respectively; The identification mode setting is provided with an identification timer, weld height, axial allowable deviation and weld width tolerance, and the identification timer is the interval time of each sampling in the identification mode; The other settings include switching settings of the detection module, manual button selection, sensor radial deviation and sensor axial distance. The detection module works in two states: identification mode and detection mode. The two mode switchings of the detection module include manual switching mode and automatic switching mode. The manual switching mode includes clicking the switching button on the UI interface and the physical button on the device panel. The automatic switching mode is used to identify welds in real time. After the weld is found, it automatically switches to the detection mode. After the scanning is completed, it switches to the identification mode, and so on. The radial deviation of the sensor is the distance parameter of the luminous surfaces of the dual sensors, and the axial distance of the sensor is the deviation parameter of the axial direction of the dual sensors.

[0011] Furthermore, the data acquisition module includes sensor data acquisition, encoder data acquisition, position data acquisition and controller communication data. The data acquisition module is connected and communicates with the controller of the line laser sensor via Ethernet. The controller is connected to the line laser sensor via a corresponding interface. When the line laser sensor collects data, the data is transmitted to the industrial computer through the controller. The integrated motor is an integrated stepping servo motor, which serves as an integrated motion control terminal. It communicates with the integrated motor through an RS interface, thereby collecting the motor position information in real time.

[0012] Furthermore, the IO monitoring module includes status display, independent thread creation, input quantity monitoring and signal slot feedback. The industrial computer has a GPIO port, and adopts status display and physical button operation. The status display adopts a three-color display light, and the corresponding status is displayed through different colors. The physical button operation corresponds to the input port of the GPIO port, and the corresponding action is controlled by reading the status of this input port.

[0013] Furthermore, the data processing module includes thread pool maintenance, data compression, data storage and data analysis. The thread pool maintenance replaces the data processing in the main thread in the form of thread pool to improve the response speed of the main thread; the data processing module sets classes related to data operations, which include data compression, data storage and data analysis to support import and export operations on the application layer, so as to facilitate data collection during the movement of the device. After the movement, the detection data is imported for display and analysis.

[0014] Furthermore, the overall operation process of the system includes the following steps: Step S10-1: The robot body is in position and sends a signal of being in position; Step S10-2: After receiving the in-position signal, the industrial computer starts the measurement module; Step S10-3: the measurement module switches to the weld identification mode; Step S10-4: Check whether the device movement is finished, if so, jump to step S10-10, if not, go to the next step; Step S10-5: In the recognition mode, the movement of the device is detected and the data acquired by the line laser sensor is processed in real time; Step S10-6: Determine whether a weld seam appears. If not, return to the previous step to continue testing. If yes, proceed to the next step. Step S10-7: When a weld appears, communicate with the robot body and send a signal for the robot to stop moving; Step S10-8: the measuring module switches to the weld detection mode to detect the weld; Step S10-9: After the measurement module completes the detection, it sends a signal, and the robot body continues to move, while the measurement module is switched to the recognition mode, and the cycle repeats until the movement ends; Step S10-10: Exit the measurement module.

[0015] The beneficial effects of the present invention are: First, the dual probes of the present invention work together to filter out noise data such as motion vibration and more accurately measure the inner diameter of the pipeline.

[0016] Secondly, in the process of traversing the scanning contour sequence, the present invention takes the point with the maximum standard deviation as the point where the weld exists, so that the weld identification is faster.

[0017] Third, the present invention develops a high-resolution motor equipped with a high-resolution encoder, triggers sensor detection in an external triggering form, and uses a turntable with a large speed ratio to ensure the stability of the scanning process and achieve high-precision motion control. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1It is a schematic diagram of the structure and composition of an annular inner wall defect detection device according to an embodiment of the present invention; Figure 2 It is a software and hardware detection system of an annular inner wall defect detection device according to an embodiment of the present invention; Figure 3 It is a schematic diagram of the structure of an annular inner wall defect detection device according to an embodiment of the present invention when operating ideally inside a pipeline; Figure 4 This is a diagram of the architecture of a ring inner wall defect detection system according to an embodiment of the present invention; Figure 5 is a diagram of the configuration of an annular inner wall defect detection system according to an embodiment of the present invention; Figure 6 It is a schematic diagram of two switching schemes when switching detection modules in the system setting of an embodiment of the present invention; Figure 7 It is a structural diagram of different positions of an annular inner wall defect detection device of an embodiment of the present invention when actually operating inside a pipeline; Figure 8 This is the overall operation process of the annular inner wall defect detection device according to one embodiment of the present invention. DETAILED DESCRIPTION

[0019] The present invention will be described in detail below with reference to the accompanying drawings and in combination with embodiments.

[0020] A ring inner wall defect detection device, such as Figure 1 As shown, the device includes a base plate 100, a housing 200, a rotating table 300, an integrated motor 400, a sensor adapter plate 500 and a line laser sensor 600 constituting a measuring module; wherein: The housing 200 is fixed on the base plate 100, the rotating platform 300 is connected to the top of the housing 200, and the integrated motor 400 is located on one side of the rotating platform 300, and is used to connect and drive the rotating platform to rotate; The line laser sensors 600 are respectively arranged at both ends of the sensor adapter plate 500, and the sensor adapter plate 500 is connected to the rotating platform 300; like Figure 2 As shown, an industrial computer 201 and a controller 202 are installed inside the housing 200 . A corresponding upper computer software system 203 runs inside the industrial computer 201 and is connected to control a robot body 204 .

[0021] like Figure 3As shown, the figure includes a pipeline 900, a line laser sensor 600 and its excitation laser 700, and the sensor adapter plate 500, the rotating table 300, the housing 200 and the base plate 100 are colinear on the pipeline center axis 800 when connected for operation, and the base plate 100 is installed on the robot body 204 so that it can move axially and rotate along the pipeline center axis 800.

[0022] A ring inner wall defect detection system, such as Figure 4 As shown, the system includes a host computer software system 203, which is divided into a basic layer 10, a business layer 20 and an application layer 30, wherein: The base layer 10 as a hardware part includes an industrial computer 201, a line laser sensor 600, a control module 401 and a motion module 402, wherein the motion module 402 includes an integrated motor 400 with a built-in encoder and a rotating table 300; The business layer 20 is a logic function implementation layer, including a data acquisition module 20-1, an IO monitoring module 20-2, a data processing module 20-3, an algorithm module 20-4 and a function module 20-5; The application layer 30 acts as an output layer and directly interacts with the user so that the structure and analysis of the processed data can be displayed.

[0023] In the business layer 20, the relevant parameters of the entire system are customized in the system setting 501 interface, such as Figure 5 As shown, the system setting 501 is divided into motion setting 501-1, sensor controller setting 501-2, recognition mode setting 501-3 and other settings 501-4; The motion setting 501-1 includes the serial port number and baud rate when the industrial computer 201 is connected to the integrated motor 400, and the speed, acceleration and deceleration of the integrated motor 400 when the line laser sensor 600 rotates; The sensor control setting 501-2 is used to call the controller program number in the identification mode 603 and the detection mode 604 respectively; The identification mode setting 501-3 is provided with an identification timer, weld height, axial allowable deviation and weld width tolerance, and the identification timer is the interval time of each sampling under the identification mode 603; The other settings 501-4 include the switch settings of the detection module, manual button selection, sensor radial deviation and sensor axial distance. The detection module works in two states: identification mode 603 and detection mode 604. Figure 6As shown, the two mode switches of the detection module include a manual switching mode 601 and an automatic switching mode 602. The manual switching mode 601 includes clicking a switching button on the UI interface and a physical button on the device panel. The automatic switching mode 602 is used to identify welds in real time. After the weld is found, it automatically switches to the detection mode 604. After the scanning is completed, it switches to the identification mode 603, and so on. The radial deviation of the sensor is the distance parameter of the light-emitting surface of the dual sensors, and the axial distance of the sensor is the deviation parameter of the axial direction of the dual sensors.

[0024] The data acquisition module 20-1 includes sensor data acquisition, encoder data acquisition, position data acquisition and controller communication data. The data acquisition module 20-1 is connected and communicates with the controller 202 of the line laser sensor 600 via Ethernet. The controller 202 is connected to the line laser sensor 600 via a corresponding interface. When the line laser sensor 600 collects data, the data is transmitted to the industrial computer 201 through the controller 202. The integrated motor 400 is an integrated stepping servo motor. As an integrated motion control terminal, it communicates with the integrated motor 400 via an RS485 interface, thereby collecting the motor position information in real time.

[0025] The IO monitoring module 20-2 includes status display, independent thread creation, input quantity monitoring and signal slot feedback. The industrial computer 201 has a GPIO port, which uses status display and physical button operation. The status display uses a three-color display light to display the corresponding status through different colors. The physical button operation corresponds to the input port of the GPIO port, and the corresponding action is controlled by reading the status of this input port.

[0026] The data processing module 20-3 includes thread pool maintenance, data compression, data storage and data analysis. The thread pool maintenance replaces the data processing in the main thread in the form of thread pool to improve the response speed of the main thread; the data processing module 20-3 sets classes related to data operations, which include data compression, data storage and data analysis to support import and export operations on the application layer 30, so as to facilitate data collection during the movement of the device. After the movement, the detection data is imported for display and analysis.

[0027] like Figure 7 As shown, the figure includes the pipeline center axis 800, the sensor rotation center axis 901 and the sensor track 902. The distance between the sensor rotation center axis 901 and the pipeline center axis 800 is x, and the pipeline radius is r. When the line laser sensor 600 excites the laser 700 through the pipeline center axis 800, it is taken as position 1. At position 1, the distance from the sensor rotation center axis 901 to the pipeline is rotated 90° and the distance is y1. The y1 is the sum of the sensor reading value and the sensor track radius. At this time, it can be obtained: , Line laser sensor 600 passes position 1 and rotates to any position After the angle is changed, it is taken as position 2. At position 2, the distance from the sensor rotation center axis 901 to the pipeline is rotated 90° and taken as y2. The same as y1 can be obtained: , After rotating the weld for one circle and scanning all contours, the three-dimensional shape of the pipeline can be restored by fitting, and the defects (corrosion, cuts) and morphology (straight welds and spiral welds) based on the elevation data can be displayed.

[0028] like Figure 8 As shown, the overall operation process of the system includes the following steps: Step S10-1: The robot body 204 is in position and sends a position signal; Step S10-2: After receiving the in-position signal, the industrial computer 201 starts the measurement module; Step S10-3: the measurement module switches to the weld identification mode 603; Step S10-4: Check whether the device movement is finished, if so, jump to step S10-10, if not, go to the next step; Step S10-5: in the recognition mode 603, the movement of the device is detected and the data acquired by the line laser sensor 600 is processed in real time; Step S10-6: Determine whether a weld seam appears. If not, return to the previous step to continue testing. If yes, proceed to the next step. Step S10-7: When a weld appears, communicate with the robot body 204 and send a signal for the robot to stop moving; Step S10-8: the measurement module switches to the weld detection mode 604 to detect the weld; Step S10-9: After the measurement module completes the detection, a signal is sent, and the robot body 204 continues to move, while the measurement module is switched to the identification mode 603, and the cycle repeats until the movement ends; Step S10-10: Exit the measurement module.

[0029] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A ring-shaped inner wall defect detection device, characterized in that: The device comprises a base plate (100) constituting a measurement module, a housing (200), a rotating platform (300), an integrated motor (400), a sensor adapter plate (500) and a line laser sensor (600); wherein: The housing (200) is fixed on the base plate (100), the rotating platform (300) is connected to the top of the housing (200), and the integrated motor (400) is located on one side of the rotating platform (300) and is used to connect to and drive the rotating platform to rotate; The line laser sensors (600) are respectively arranged at two ends of a sensor adapter plate (500), and the sensor adapter plate (500) is connected to a rotating platform (300); An industrial computer (201) and a controller (202) are installed inside the housing (200); a corresponding host computer software system (203) runs inside the industrial computer (201) and is connected to control the robot body (204).

2. The annular inner wall defect detection device according to claim 1, characterized in that: The sensor adapter plate (500), the rotating platform (300), the housing (200) and the base plate (100) are colinearly located on the central axis (800) of the pipeline when in connection operation, and the base plate (100) is mounted on the robot body (204) so ​​as to enable axial movement and fixed-axis rotation along the central axis (800) of the pipeline.

3. A detection system for an annular inner wall defect detection device according to any one of claims 1 to 2, characterized in that: The system comprises a host computer software system (203), wherein the host computer software system (203) is divided into a basic layer (10), a business layer (20) and an application layer (30), wherein: The basic layer (10) as a hardware part includes an industrial computer (201), a line laser sensor (600), a control module (401) and a motion module (402), wherein the motion module (402) includes an integrated motor (400) with a built-in encoder and a rotating table (300); The business layer (20) serves as a logic function implementation layer, and includes a data acquisition module (20-1), an IO monitoring module (20-2), a data processing module (20-3), an algorithm module (20-4) and a function module (20-5); The application layer (30) acts as an output layer and directly interacts with the user so that the structure and analysis of the processed data can be displayed.

4. The annular inner wall defect detection system according to claim 3, characterized in that: In the business layer (20), relevant parameters of the entire system are customized in a system setting (501) interface, and the system setting (501) is divided into motion setting (501-1), sensor controller setting (501-2), recognition mode setting (501-3) and other settings (501-4); The motion settings (501-1) include the serial port number and baud rate when the industrial computer (201) is connected to the integrated motor (400), and the speed, acceleration and deceleration of the integrated motor (400) when the line laser sensor (600) rotates; The sensor control setting (501-2) calls the controller program number in the identification mode (603) and the detection mode (604) respectively; The identification mode setting (501-3) is provided with an identification timer, weld height, axial allowable deviation and weld width tolerance, and the identification timer is the interval time of each sampling in the identification mode (603); The other settings (501-4) include the switching settings of the detection module, manual button selection, sensor radial deviation and sensor axial distance. The detection module works in two states: identification mode (603) and detection mode (604). The two mode switches of the detection module include manual switching mode (601) and automatic switching mode (602). The manual switching mode (601) includes clicking the switching button on the UI interface and the physical button on the device panel. The automatic switching mode (602) is used to identify the weld in real time. After the weld is found, it automatically switches to the detection mode (604). After the scanning is completed, it switches to the identification mode (603), and so on. The sensor radial deviation is the distance parameter of the dual sensor light-emitting surface, and the sensor axial distance is the deviation parameter of the dual sensor axial direction.

5. The annular inner wall defect detection system according to claim 3 or 4, characterized in that: The data acquisition module (20-1) includes sensor data acquisition, encoder data acquisition, position data acquisition and controller communication data. The data acquisition module (20-1) is connected to and communicates with a controller (202) of a line laser sensor (600) via Ethernet. The controller (202) is connected to the line laser sensor (600) via a corresponding interface. When the line laser sensor (600) acquires data, the data is transmitted to the industrial computer (201) via the controller (202). The integrated motor (400) is an integrated stepping servo motor, which serves as an integrated motion control terminal and communicates with the integrated motor (400) via an RS485 interface, thereby acquiring motor position information in real time.

6. The annular inner wall defect detection system according to claim 3 or 4, characterized in that: The IO monitoring module (20-2) includes status display, independent thread creation, input quantity monitoring and signal slot feedback. The industrial computer (201) has a GPIO port and adopts status display and physical button operation. The status display adopts a three-color display light, and the corresponding status is displayed through different colors. The physical button operation corresponds to the input port of the GPIO port, and the corresponding action is controlled by reading the status of this input port.

7. The annular inner wall defect detection system according to claim 3 or 4, characterized in that: The data processing module (20-3) includes thread pool maintenance, data compression, data storage and data analysis. The thread pool maintenance replaces the main thread with a thread pool to process data, thereby improving the response speed of the main thread. The data processing module (20-3) sets classes related to data operations, including data compression, data storage and data analysis, to support import and export operations on the application layer (30), so as to facilitate data collection during the movement of the device. After the movement is completed, the detection data is imported for display and analysis.

8. The annular inner wall defect detection system according to claim 3 or 4, characterized in that: The overall operation process of the system includes the following steps: Step S10-1: the robot body (204) is in position and sends a position signal; Step S10-2: after receiving the in-position signal, the industrial computer (201) starts the measurement module; Step S10-3: the measurement module switches to a weld identification mode (603); Step S10-4: Check whether the device movement is finished, if so, jump to step S10-10, if not, go to the next step; Step S10-5: in the recognition mode (603), the movement of the device is detected and the data acquired by the line laser sensor (600) is processed in real time; Step S10-6: Determine whether a weld seam appears. If not, return to the previous step to continue testing. If yes, proceed to the next step. Step S10-7: When a weld appears, communicate with the robot body (204) and send a signal for the robot to stop moving; Step S10-8: the measuring module switches to the weld detection mode (604) to detect the weld; Step S10-9: After the measurement module completes the detection, a signal is sent, and the robot body (204) continues to move, while the measurement module is switched to the identification mode (603), and the cycle is repeated until the movement is completed; Step S10-10: Exit the measurement module.

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