An automatic pipe releasing method and an automatic pipe releasing system

Abstract

The present application relates to the technical field of submerged arc welded pipe outer anticorrosion production, and particularly relates to an automatic pipe removing method and an automatic pipe removing system, which aims to solve the problem of high labor intensity and low work efficiency caused by manual operation in the existing pipe removing operation. The present application provides an automatic pipe removing method, a pipe head of a first steel pipe and a pipe tail of a second steel pipe are in contact and run along an axis, in an automatic control mode, an image sensor emits a light beam, the width of the light beam irradiated on the steel pipe is L1, the axial linear velocity of a steel pipe roller is n1, and the position signal duration detected by the image sensor for the pipe head and the pipe tail is t1; when the image sensor detects the pipe head and the pipe tail, a detection signal is sent to a PLC control system, at this time, the PLC timer starts timing, and when t1 >= L1 / 2n1, the PLC control system sends a control command to the roller frequency converter to execute a pipe removing action. The present application realizes automatic control of the pipe removing process, and improves production efficiency without personnel operation.

Description

Technical Field

[0001] This invention relates to the field of external corrosion protection production technology for submerged arc welded pipes, and particularly to an automatic pipe removal method and system. Background Technology

[0002] In the anti-corrosion production process of submerged arc welded pipes, the outer surface of the steel pipe undergoes shot blasting to achieve a morphology that meets process requirements. During this process, after shot blasting, the ends of the steel pipes connected on the conveyor rollers need to be quickly separated to facilitate the pipes' entry into the next processing step. The pipe ends are connected on the rollers; during the separation operation, it is necessary to confirm that the connection is in the correct position before executing the separation action to quickly detach the pipe ends. Currently, pipe separation is done manually, which is labor-intensive and inefficient. Summary of the Invention

[0003] The purpose of this invention is to provide an automatic pipe removal method and an automatic pipe removal system to solve the problems of high labor intensity and low work efficiency caused by the need for manual operation in existing pipe removal operations.

[0004] To solve the above-mentioned technical problems, the technical solution provided by the present invention is as follows:

[0005] In a first aspect, the present invention provides an automatic pipe removal method, wherein the head of the first steel pipe and the tail of the second steel pipe are in contact with each other and run along the axis. In the automatic control mode, the image sensor emits a light beam, the width of the light beam illuminating the steel pipe is L1, the axial linear velocity of the steel pipe roller is n1, and the duration of the position signal detected by the image sensor at the head and tail of the pipe is t1.

[0006] When the image sensor detects the pipe head and tail, it sends a detection signal to the PLC control system. At this time, the PLC timer starts timing. When t1≥L1 / 2n1, the PLC control system sends a control command to the roller conveyor frequency converter to execute the pipe removal action.

[0007] Furthermore,

[0008] After the PLC control system sends a control command to the roller conveyor frequency converter, the roller conveyor frequency converter accelerates its operation using a constant torque control mode, so that the conveyor rollers can drive the steel pipes at high speed to the next process to complete the pipe removal action.

[0009] Furthermore,

[0010] The end of the conveyor roller is equipped with a limit protection sensor. When the pipe head senses the limit protection sensor, the roller motor automatically stops running to prevent the steel pipe from exceeding the process range.

[0011] Furthermore,

[0012] The roller conveyor frequency converter is a Siemens G120 frequency converter with a 1-to-5 control mode.

[0013] Furthermore,

[0014] The Profinet distributed master-slave control mode is adopted, with the PLC control system as the master station and the Siemens G120 frequency converter and image sensor as the slave stations.

[0015] Furthermore,

[0016] The PLC master station and the touch screen use Profinet for communication. The touch screen is used to display real-time values ​​from the image sensor, the real-time position of the steel pipe, the operating status, and alarm information.

[0017] Secondly, the present invention provides an automatic tube removal system based on the aforementioned automatic tube removal method, including an image sensor, a conveyor roller, a telescopic support, a PLC control system, and a roller frequency converter;

[0018] The conveyor roller conveyor is used to convey steel pipes;

[0019] The image sensor is located on the side of the conveyor roller conveyor;

[0020] The telescopic bracket is connected to the image sensor, and the telescopic bracket can extend and retract along its own length to adjust the vertical height of the image sensor;

[0021] The image sensor is electrically connected to the PLC control system, and the PLC control system is electrically connected to the roller conveyor frequency converter.

[0022] Furthermore,

[0023] The telescopic support includes a first rod and a second rod;

[0024] The first rod is inserted into the second rod and is slidably connected to the second rod;

[0025] The image sensor is connected to the first rod.

[0026] Furthermore,

[0027] It also includes an adjusting screw;

[0028] The adjusting screw passes through the second rod and abuts against the first rod.

[0029] Furthermore,

[0030] It also includes a touchscreen;

[0031] The touchscreen is electrically connected to the PLC control system.

[0032] In summary, the technical effects achieved by this invention are as follows:

[0033] This invention employs an image sensor to detect the position of the connection between the pipe head and tail in real time within the pipe removal area. Combined with a PLC algorithm to control the roller conveyor speed during pipe removal, it achieves the effect of rapid pipe separation during the removal process. This enables automatic control of pipe removal after shot blasting. This invention avoids process congestion and equipment downtime caused by untimely pipe removal, thus preventing disruption to the production process. It achieves automatic control of the pipe removal process, eliminating the need for manual operation, improving production efficiency, and reducing the labor intensity of on-site personnel. It optimizes job positions and ensures accurate control during the pipe removal process, solving the problems of high labor intensity and low work efficiency caused by the need for manual operation in existing pipe removal operations. Attached Figure Description

[0034] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0035] Figure 1 This is a schematic diagram of the automatic disconnection system provided in an embodiment of the present invention;

[0036] Figure 2 This is a structural diagram of an automatic disconnection system.

[0037] Icons: 1-Tube head; 2-Tube tail; 3-Image sensor; 31-Sensor beam; 32-Beam width; 4-Telescopic bracket; 41-First rod; 42-Second rod; 5-Adjusting screw. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0039] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0040] The following detailed description of some embodiments of the present invention is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0041] Currently, in the production process of anti-corrosion submerged arc welded pipes, pipe removal is done manually, which is labor-intensive and inefficient.

[0042] In view of this, the present invention provides an automatic pipe removal method. The head 1 of the first steel pipe and the tail 2 of the second steel pipe are in contact and run along the axis. In automatic control mode, the image sensor 3 emits a light beam with a width L1 on the steel pipe. The axial linear velocity of the steel pipe roller is n1. The image sensor 3 detects the position signals of the head 1 and the tail 2 for a duration of t1. When the image sensor 3 detects the head 1 and the tail 2, it sends a detection signal to the PLC control system. At this time, the PLC timer starts timing. When t1≥L1 / 2n1, the PLC control system sends a control command to the roller frequency converter to execute the pipe removal action.

[0043] This invention employs an image sensor 3 to detect the position of the connecting part of the steel pipe head 1 and tail 2 in real time in the pipe removal area. Combined with a PLC algorithm to control the roller conveyor speed during pipe removal, it achieves the effect of rapid pipe removal during the process, realizing automatic control of pipe removal after shot blasting. This invention can avoid process congestion and equipment downtime caused by untimely pipe removal, thus affecting the production process. It realizes automatic control of the pipe removal process, eliminating the need for manual operation, improving production efficiency, and reducing the labor intensity of on-the-job personnel. It achieves job optimization and accurate control during the pipe removal process, solving the problems of high labor intensity and low work efficiency caused by the need for manual operation in existing pipe removal operations.

[0044] The automatic pipe disconnection method provided in this embodiment employs an automatic pipe disconnection system, which is described below. Figure 1 and Figure 2 The structure of the automatic disconnection system is described.

[0045] Reference Figure 1 and Figure 2 The automatic tube removal system includes an image sensor 3, a conveyor roller, a telescopic support 4, a PLC control system, and a roller frequency converter.

[0046] The steel pipe is located on the conveyor roller, which is used to transport the steel pipe; the image sensor 3 is set on the side of the conveyor roller; the telescopic bracket 4 is connected to the image sensor 3, and the telescopic bracket 4 can extend and retract along its own length to adjust the vertical height of the image sensor 3; the image sensor 3 is electrically connected to the PLC control system, and the PLC control system is electrically connected to the roller frequency converter.

[0047] Specifically, an image recognition sensor is installed on the side of the conveyor roller in the tube removal area. The sensor head is equipped with a dedicated image processing IC and the controller is equipped with a high-performance CPU to process the visual image at high speed. The image intelligently identifies the position of the connection between the tube head 1 and the tube tail 2, and sends a signal to the PLC control system. The PLC control system then controls the roller G120 frequency converter to accelerate the operation and execute the tube removal action.

[0048] In an optional embodiment, the telescopic bracket 4 includes a first rod 41 and a second rod 42; the first rod 41 is inserted into and slidably connected to the second rod 42; the image sensor 3 is connected to the first rod 41. This embodiment also includes an adjusting screw 5; the adjusting screw 5 passes through the second rod 42 and abuts against the first rod 41.

[0049] Specifically, during normal operation, the head 1 of the first steel pipe and the tail 2 of the second steel pipe are in contact and move along the axis. The image sensor 3, mounted on the telescopic bracket 4, emits a sensor beam 31 in real time. The width of the beam illuminating the steel pipe is the beam width 32. After the head 1 and tail 2 remain within the beam width 32 for a certain period of time, the pipe detachment action begins. The telescopic bracket 4 is used to adjust the vertical position of the image sensor 3 according to the diameter of the steel pipe, ensuring that the image sensor 3 maintains optimal operating conditions.

[0050] In automatic control mode, let the width of the image sensor 3 illuminating the steel pipe be L1, the axial linear velocity of the steel pipe roller conveyor be n1, and the duration of the position signal detected by the image sensor 3 at the pipe head 1 and pipe tail 2 be t1. When the sensor detects the pipe head 1 and pipe tail 2, it sends a detection signal to the PLC control system. At this time, the PLC timer starts timing. In order to avoid malfunctions caused by interference signals, when t1≥L1 / 2n1, the PLC sends a control command to the G120 roller conveyor frequency converter to execute the pipe removal action. The frequency converter adopts constant torque control mode to accelerate the operation, and the conveyor roller conveyor drives the steel pipe to the next process at high speed to complete the pipe removal action.

[0051] In an optional implementation, a limit protection sensor is added to the end of the conveyor roller. When the pipe head senses the sensor, the roller motor automatically stops running to prevent the steel pipe from exceeding the process range.

[0052] In an optional implementation, to avoid the influence of ambient light in the factory on the detection effect of the image sensor, an automatic light source that adapts to changes in ambient light is added within the detection range of the image sensor. This embodiment adopts a Profinet distributed master-slave control mode. The PLC control system is a Siemens S7-1500 PLC, which serves as the master station, mainly responsible for sensor signal acquisition, data processing, and actuator control. The slave stations are a Siemens G120 frequency converter and image sensor 3 using a 1-to-5 control method, mainly responsible for remote operation, roller conveyor motor control, and sensor data reading. The PLC master station and the touch screen communicate using Profinet, displaying real-time values ​​of image sensor 3, real-time position of the steel pipe, operating status, and alarm information.

[0053] In this embodiment, the PLC control system consists of a CPU module, a digital input / output module, and an ET200MP substation. Its main functions include sensor data acquisition and processing, motor control, and touchscreen communication.

[0054] The automatic disconnection system provided in this embodiment has the following features:

[0055] (1) This embodiment is equipped with a dedicated 4-piece glass lens, which can minimize the impact of deformation and distortion, and can achieve stable detection under a wide field of view and when far away from the connection part of the tube head 1 and tube tail 2.

[0056] (2) In this embodiment, the detection part can be set up in a short time to achieve efficient detection. The image intelligent recognition technology starts from various viewpoints to find the part with the greatest difference in color, brightness, area, shape, edge and other conditions between the calibrated pipe head 1 and pipe tail 2 connection part and the uncalibrated steel pipe. The optimal detection is automatically performed to complete the parameter setting.

[0057] (3) For steel pipe identification conditions with motion changes, the steel pipe can be observed by sensors and self-learned to add detection conditions and realize multi-condition logical combination judgment, thereby realizing efficient intelligent recognition of pipe head 1 and pipe tail 2 images.

[0058] This embodiment is applied to the pipe removal process in the external corrosion protection production of submerged arc welded pipes. By using image sensors to detect the position of the pipe head and tail, an automatic pipe removal precision control technology is formed, achieving automatic pipe removal. The implementation of the automatic pipe removal system transforms the pipe removal operation from manual to automatic control. The system operates stably and reliably with 100% efficiency. It merges the operations of the lateral movement vehicle and pipe removal, and the automatic pipe removal control method avoids process congestion and equipment downtime caused by untimely pipe removal, thus preventing disruption to the production process. It effectively reduces the labor intensity of operators, improves the automation level of on-site equipment, and increases equipment operating efficiency.

[0059] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An automatic tube disconnection method, characterized in that, The head of the first steel pipe and the tail of the second steel pipe are in contact and run along the axis. In automatic control mode, the image sensor emits a light beam, the width of the light beam on the steel pipe is L1, the axial linear velocity of the steel pipe roller is n1, and the duration of the position signal detected by the image sensor at the head and tail of the pipe is t1. When the image sensor detects the pipe head and tail, it sends a detection signal to the PLC control system. At this time, the PLC timer starts timing. When t1≥L1 / 2n1, the PLC control system sends a control command to the roller conveyor frequency converter to execute the pipe removal action.

2. The automatic tube disconnection method according to claim 1, characterized in that, After the PLC control system sends a control command to the roller conveyor frequency converter, the roller conveyor frequency converter accelerates its operation using a constant torque control mode, so that the conveyor rollers can drive the steel pipes at high speed to the next process to complete the pipe removal action.

3. The automatic tube disconnection method according to claim 1, characterized in that, The end of the conveyor roller is equipped with a limit protection sensor. When the pipe head senses the limit protection sensor, the roller motor automatically stops running to prevent the steel pipe from exceeding the process range.

4. The automatic tube disconnection method according to claim 1, characterized in that, The roller conveyor frequency converter is a Siemens G120 frequency converter with a 1-to-5 control mode.

5. The automatic tube disconnection method according to claim 4, characterized in that, The Profinet distributed master-slave control mode is adopted, with the PLC control system as the master station and the Siemens G120 frequency converter and image sensor as the slave stations.

6. The automatic tube disconnection method according to claim 5, characterized in that, The PLC master station and the touch screen use Profinet for communication. The touch screen is used to display real-time values ​​from the image sensor, the real-time position of the steel pipe, the operating status, and alarm information.

7. An automatic disconnection system based on the automatic disconnection method as described in any one of claims 1-6, characterized in that, Includes image sensors, conveyor rollers, telescopic supports, PLC control system, and roller frequency converter; The conveyor roller conveyor is used to convey steel pipes; The image sensor is located on the side of the conveyor roller conveyor; The telescopic bracket is connected to the image sensor, and the telescopic bracket can extend and retract along its own length to adjust the vertical height of the image sensor; The image sensor is electrically connected to the PLC control system, and the PLC control system is electrically connected to the roller conveyor frequency converter.

8. The automatic disconnection system according to claim 7, characterized in that, The telescopic support includes a first rod and a second rod; The first rod is inserted into the second rod and is slidably connected to the second rod; The image sensor is connected to the first rod.

9. The automatic disconnection system according to claim 8, characterized in that, It also includes an adjusting screw; The adjusting screw passes through the second rod and abuts against the first rod.

10. The automatic disconnection system according to claim 7, characterized in that, It also includes a touchscreen; The touchscreen is electrically connected to the PLC control system.

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