A method and system for automatically measuring the edge position of a board

Abstract

The present application relates to the technical field of spiral welded pipe production, and particularly relates to a plate edge position automatic measurement method and a plate edge measurement system, which aims to solve the problems of high labor intensity of operators, low production efficiency and inability to guarantee the operation quality of the head alignment in the existing spiral welded pipe production process. The present application provides a plate edge position automatic measurement method, wherein the plate head position before flattening is L1, the calibration value before flattening is L2, the position difference before flattening is L3, L3=L1-L2; the plate head position before shearing is L4, the calibration value before shearing is L5, the position difference before shearing is L6, L6=L4-L5; the vertical roll displacement value L7=|L6-L3|, and the vertical roll motor is controlled to move according to the vertical roll displacement value after logical operation and processing of the above parameters by a PLC control system. When L6-L3 is negative, the vertical roll moves in a first direction; when L6-L3 is positive, the vertical roll moves in a second direction; when L7

Description

Technical Field

[0001] This invention relates to the field of spiral welded pipe production technology, and in particular to an automatic plate edge position measurement method and plate edge measurement system. Background Technology

[0002] The production of spiral welded pipes involves processes such as uncoiling, leveling, and shearing. Currently, at least two operators are required for the leveling and shearing processes. The existing method involves one operator controlling the forward and backward movement of the steel plate, while the other measures the difference between the head and tail positions of the plate with a tape measure before leveling and before shearing. The tail position is then manually controlled by a vertical roller to align the edges of the head and tail before shearing. Manual measurements are inaccurate, and the preparatory work before leveling is cumbersome, failing to establish an efficient process control system.

[0003] Therefore, the operators suffer from high labor intensity and low production efficiency, and the welding head position cannot guarantee the quality of the welding head operation. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic measurement method and system for plate edge position, in order to solve the problems of high labor intensity and low production efficiency of operators in the uncoiling and matching positions of existing spiral welded pipe production processes, and the inability of the matching welding positions to guarantee the quality of the matching work.

[0005] To solve the above-mentioned technical problems, the technical solution provided by the present invention is as follows: In a first aspect, the present invention provides an automatic measurement method for the edge position of a board, which uses a board edge measurement system. The board edge measurement system is set up before leveling and before shearing. The board edge measurement system includes a laser measurement device and a PLC control system. The laser measuring device is equipped with a laser length measuring sensor and a mechanical guide wheel. The mechanical guide wheel abuts against the edge of the steel plate, and the laser length measuring sensor emits a laser point to the mechanical guide wheel. In automatic control mode, the position of the board head before leveling is L1, where L1 is the distance from the laser point of the laser length measuring sensor to the mechanical guide wheel before leveling. L1 is the known measurement value, the calibration value before leveling is L2, where L2 is the known setting value, and the position difference before leveling is L3. Then L3 = L1 - L2. The position of the plate head before shearing is L4, where L4 is the distance from the laser point of the laser length measuring sensor before shearing to the mechanical guide wheel. L4 is a known measurement value. The calibration value before shearing is L5, where L5 is a known setting value. The position difference before shearing is L6, so L6 = L4 - L5. The vertical roller is connected to the steel plate and is used to adjust the position of the steel plate edge. The vertical roller motor drives the vertical roller to move, and the vertical roller displacement value is L7, where L7 = |L6-L3|. After the PLC control system processes the above parameters through logic calculation, it controls the vertical roller motor to move according to the vertical roller displacement value. When L6-L3 is negative, the vertical roller moves in the first direction and drives the steel plate to move in the first direction. When L6-L3 is positive, the vertical roller moves in the second direction and drives the steel plate to move in the second direction. When L7 < L8, the vertical roller stops moving. L8 is the set reference value, which makes the value of L7 approach zero.

[0006] Furthermore, a Profibus DP distributed master-slave control mode is adopted, with a Siemens S7-300 PLC as the master station and the vertical roller control system and touch screen system as slave stations. The vertical roller control system is used to control the vertical roller, and the touch screen system is used to set data and display real-time data.

[0007] Furthermore, the PLC master station and slave station use the Profibus DP communication method.

[0008] Furthermore, the vertical roller control system is a Siemens MM440 controller.

[0009] Secondly, the present invention provides a board edge measurement system based on the aforementioned automatic board edge position measurement method, the board edge measurement system further comprising a floating device and a data acquisition module; The floating device is connected to the mechanical roller, and the floating device can drive the mechanical roller to move so that the mechanical roller moves synchronously with the edge of the steel plate. The laser length measuring sensor is electrically connected to the data acquisition module.

[0010] Furthermore, the floating device includes a floating guide cylinder; The laser length measuring sensor is fixed above the floating guide cylinder, and the mechanical guide wheel is connected to the output end of the floating guide cylinder; A flat plate is installed on the mechanical wheel, and the laser length measuring sensor emits a laser point that illuminates the flat plate, which is white.

[0011] Furthermore, the plate edge measurement system also includes a touch screen system and a vertical roller control system; The touch screen system is electrically connected to the PLC control system; The vertical roller control system is electrically connected to the PLC control system.

[0012] Furthermore, the plate edge measurement system also includes a fixing plate; The fixing plate is located on the side of the steel plate, and the floating guide cylinder is connected to the fixing plate.

[0013] Furthermore, the plate edge measurement system also includes a main support; The main support is configured as a cross-shaped support, and the main support is provided with a horizontal plate and a vertical plate. The vertical plate is set vertically, and the horizontal plate is perpendicular to the vertical plate. The fixed plate is slidably connected to the horizontal plate; The horizontal plate is slidably connected to the vertical plate.

[0014] Furthermore, the horizontal plate has a first long groove along its own length direction, and the fixed plate is provided with a first slider, which extends into the first long groove. The vertical plate has a second long groove along its length, and the horizontal plate has a second slider that extends into the second long groove.

[0015] In summary, the technical effects achieved by this invention are as follows: This invention obtains the real-time position of the steel plate edge through program logic calculations. The system automatically adjusts the steel plate position based on the calculation results, making the vertical roller displacement value L7 approach zero. This automates the steel plate position adjustment at the uncoiling and heading station, allowing operators to independently control the steel plate to the appropriate position for shearing. This enables a single person to complete the work that previously required two people, reducing labor intensity, improving production efficiency and steel pipe welding quality. Simultaneously, it ensures high-quality and high-standard heading at the heading welding station, providing production assurance for improving the quality of subsequent processes. This invention solves the problems of high labor intensity, low production efficiency, and the inability to guarantee heading quality in the existing spiral welded pipe production process at the uncoiling and heading station. Attached Figure Description

[0016] 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.

[0017] Figure 1 This is a structural diagram of the plate edge measurement system provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the plate edge measurement system provided in an embodiment of the present invention.

[0018] Icons: 1-Laser length measuring sensor; 2-Mechanical guide wheel; 3-Floating guide cylinder; 4-Fixed plate; 41-First slider; 5-Main support; 51-Horizontal plate; 51a-Second slider; 52-Vertical plate. Detailed Implementation

[0019] 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.

[0020] 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.

[0021] 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.

[0022] The existing spiral welded pipe production process suffers from high labor intensity and low production efficiency at the uncoiling and head-joining positions, and the head-joining welding position cannot guarantee the quality of the head-joining operation.

[0023] In view of this, the present invention provides an automatic measurement method for the edge position of a steel plate, using an edge measurement system. The edge measurement system is installed both before leveling and before shearing. The edge measurement system includes a laser measuring device and a PLC control system. The laser measuring device is equipped with a laser length measuring sensor 1 and a mechanical guide wheel 2. The mechanical guide wheel 2 abuts against the edge of the steel plate, and the laser length measuring sensor 1 emits a laser point to the mechanical guide wheel 2. In automatic control mode, the position of the plate head before leveling is L1, where L1 is the distance from the laser point emission point of the laser length measuring sensor 1 to the mechanical guide wheel 2 before leveling, and L1 is a known measured value. The calibration value before leveling is L2, where L2 is a known set value. The position difference before leveling is L3, so L3 = L1 - L2. The position of the plate head before shearing is L4, where L4 is the distance from the laser length measuring sensor 1 before shearing. The distance from the laser point emitting point of device 1 to the mechanical guide wheel 2 is L4, which is a known measured value. The calibration value before shearing is L5, which is a known set value. The position difference before shearing is L6, so L6 = L4 - L5. The vertical roller is connected to the steel plate, and the vertical roller motor drives the vertical roller to move, which is used to adjust the position of the edge of the steel plate. The vertical roller displacement value is L7, and L7 = |L6 - L3|. After the above parameters are processed by the logic operation of the PLC control system, the vertical roller motor is controlled to move according to the vertical roller displacement value. When L6 - L3 is negative, the vertical roller moves in the first direction and drives the steel plate to move in the first direction. When L6 - L3 is positive, the vertical roller moves in the second direction and drives the steel plate to move in the second direction. When L7 < L8, the vertical roller stops moving. L8 is a set reference value, which makes the value of L7 approach zero.

[0024] This invention obtains the real-time position of the steel plate edge through program logic calculations. The system automatically adjusts the steel plate position based on the calculation results, making the vertical roller displacement value L7 approach zero. This automates the steel plate position adjustment at the uncoiling and heading station, allowing operators to independently control the steel plate to the appropriate position for shearing. This enables a single person to complete the work that previously required two people, reducing labor intensity, improving production efficiency and steel pipe welding quality. Simultaneously, it ensures high-quality and high-standard heading at the heading welding station, providing production assurance for improving the quality of subsequent processes. This invention solves the problems of high labor intensity, low production efficiency, and the inability to guarantee heading quality in the existing spiral welded pipe production process at the uncoiling and heading station.

[0025] The automatic plate edge position measurement method provided in this embodiment uses a plate edge measurement system, which will be described below in conjunction with... Figure 1 and Figure 2 The structure and shape of the plate edge measurement system are described in detail.

[0026] Reference Figure 1 and Figure 2 The plate edge measurement system includes a laser measurement device, a floating device, a data acquisition module, and a PLC control system.

[0027] The laser measuring device is equipped with a laser length measuring sensor 1 and a mechanical guide wheel 2. The mechanical guide wheel 2 abuts against the edge of the steel plate, and the laser length measuring sensor 1 emits a laser point to the mechanical guide wheel 2. The floating device is connected to the mechanical guide wheel 2, and the floating device can drive the mechanical guide wheel 2 to move so that the mechanical guide wheel 2 moves synchronously with the edge of the steel plate.

[0028] In an optional embodiment, the floating device includes a floating guide cylinder 3, a laser length measuring sensor 1 fixed above the floating guide cylinder 3, and a mechanical guide wheel 2 connected to the output end of the floating guide cylinder 3. The extension and retraction of the floating guide cylinder 3 controls the mechanical guide wheel 2 to contact the edge of the steel plate to be measured. The laser point emitted by the laser length measuring sensor 1 illuminates the flat surface of the mechanical guide wheel 2, accurately acquiring the real-time length value of the extended portion of the floating guide cylinder 3. The flat surface improves the stability of the measurement; to ensure measurement accuracy, the flat surface on the mechanical guide wheel 2 is white.

[0029] In an optional embodiment, this example also includes a fixed plate 4 and a main support 5. The plate edge measuring system is divided into two sets, fixed before leveling and before shearing, respectively. The floating guide cylinder 3 is fixed to the main support 5 via the fixed plate 4. The fixed plate 4 is located on the side of the steel plate, and the floating guide cylinder 3 is connected to the fixed plate 4. The main support 5 is a cross-shaped support, and the main support 5 includes a horizontal plate 51 and a vertical plate 52. The vertical plate 52 is vertically arranged, and the horizontal plate 51 is perpendicular to the vertical plate 52. The fixed plate 4 is slidably connected to the horizontal plate 51; the horizontal plate 51 is slidably connected to the vertical plate 52.

[0030] In an optional embodiment, the horizontal plate 51 has a first long groove along its own length direction, and the fixed plate 4 is provided with a first slider 41. The first slider 41 extends into the first long groove and can slide in the first long groove so that the laser measuring device can move laterally; the vertical plate 52 has a second long groove along its own length direction, and the horizontal plate 51 is provided with a second slider 51a. The second slider 51a extends into the second long groove so that the laser measuring device can move vertically.

[0031] Specifically, the horizontal plate 51 and the vertical plate are equipped with adjustment slots, which can adjust the laser measuring device horizontally and vertically to meet the requirements of measuring the edge distance of steel plates of different specifications.

[0032] In an optional implementation, the laser length measuring sensor 1 is electrically connected to the data acquisition module. Specifically, the data acquisition module includes an analog input module and is electrically connected to the PLC control system.

[0033] In an optional implementation, this embodiment further includes a touch screen system and a vertical roller control system; the touch screen system is electrically connected to the PLC control system, and the vertical roller control system is electrically connected to the PLC control system.

[0034] The control principle involved in this embodiment is as follows: Before shearing and leveling, a plate edge measurement system is installed. Floating guide cylinder 3 is horizontally mounted on main support 5 via fixed plate 4. Laser length sensor 1 is fixed above floating guide cylinder 3, and mechanical guide roller 2 is fixed in front of floating guide cylinder 3. The floating guide cylinder 3 enables synchronous movement of the top roller and the edge of the steel plate. Laser length sensor 1 emits a laser point that illuminates the flat plate of mechanical guide roller 2, thereby collecting the real-time length value of the extension of floating guide cylinder 3. The analog input module transmits the collected sensor signal to the CPU module. The collected signal is converted and logically processed by the PLC system. The result of the calculation controls the vertical roller motor to adjust the direction of the vertical roller movement in real time, thereby realizing automatic adjustment of the plate edge position.

[0035] In automatic control mode, let: the position of the plate head before leveling be L1 (measured known value), the calibration value before leveling be L2 (set known value), and the position difference before leveling be L3. Then L3 = L1 - L2. The position of the plate head before shearing is L4 (measured known value), the calibration value before shearing be L5 (set known value), and the position difference before shearing be L6. Then L6 = L4 - L5. The vertical roller displacement value L7 = |L6 - L3|. After the above parameters are processed by the PLC control system logic, the vertical roller motor is controlled to move according to the vertical roller displacement value. When L6 - L3 is negative, the vertical roller moves in the first direction and drives the steel plate to move in the first direction, i.e., southward. When L6 - L3 is positive, the vertical roller moves in the second direction and drives the steel plate to move in the second direction, i.e., northward. When L7 < L8, the vertical roller stops moving. L8 is a set reference value that makes the value of L7 approach zero.

[0036] In this embodiment, the plate edge measuring system before shearing and the plate edge measuring system before leveling are both set on the north-facing side of the steel plate, that is, the mechanical guide roller is in close contact with the north-facing edge of the steel plate; in this embodiment, the steel plate is transported from west to east, and the first direction and the second direction in this embodiment are north-south directions. Specifically, the first direction is the direction of southward movement, and the second direction is the direction of northward movement; the vertical roller moves in the north-south direction, which can drive the steel plate to move in the north-south direction.

[0037] This embodiment employs a Profibus DP distributed master-slave control mode, using a Siemens S7-300 PLC as the master station. This master station primarily handles sensor signal acquisition, data processing (real-time data from the laser measuring device, and motion control signals for the vertical rollers), and actuator control. The slave station consists of a Siemens MM440 controller and a touchscreen system. The controller mainly controls the vertical roller's motion, and the roller's speed is adjustable and can be set on the touchscreen. The touchscreen system primarily displays calibration values, board edge positions, roller speed settings, operating status, and alarm information. The PLC master and slave stations communicate using Profibus DP. An asynchronous fault interrupt block is added to the software programming to prevent PLC shutdown in case of communication failures at substations, ensuring normal system operation. The hardware uses communication cables and connectors with stronger anti-interference capabilities. The wiring of the communication connectors must meet specifications, the shielding layer of the communication cable must be crimped to the grounding terminal, and the communication cable and power supply lines are laid separately to avoid interference with the communication lines.

[0038] The PLC control system consists of a CPU module, a digital input module, a digital output module, an analog input module, and a Siemens MM440 controller (slave). It mainly completes the acquisition and processing of sensor data, and the movement and speed control of the vertical roller.

[0039] In this embodiment, a laser length measuring sensor is used in conjunction with a floating device connected to the edge of the steel plate to detect the real-time position of the plate edge. The measured data is processed by a PLC system, and the result is used to control the movement direction and speed of the vertical roller through a frequency converter, thereby achieving automatic adjustment of the steel plate position before shearing.

[0040] In this embodiment, the use of laser length measuring sensor 1 ensures the accuracy and stability of the collected data; the use of floating guide cylinder 3 adjusts the position of the guide wheel in real time according to the width of the steel plate edge, so that the guide wheel is in close contact with the steel plate edge in real time.

[0041] This embodiment is applied to the uncoiling and alignment process of spiral welded pipes. It can measure in real time during the operation and automatically control the position of the steel plate edge before leveling and shearing, realizing the automation of steel plate position adjustment at the uncoiling and alignment station. This allows the operator to independently operate and control the steel plate to the appropriate position for shearing, reducing the labor intensity of the operator, improving production efficiency, optimizing the job, and ensuring high quality and high standards for the alignment at the alignment welding station.

[0042] 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 measurement method for the edge position of a board, characterized in that, The board edge measurement system is used, and it is set up before leveling and before shearing. The board edge measurement system includes a laser measuring device and a PLC control system. The laser measuring device is equipped with a laser length measuring sensor and a mechanical guide wheel. The mechanical guide wheel abuts against the edge of the steel plate, and the laser length measuring sensor emits a laser point to the mechanical guide wheel. In automatic control mode, the position of the board head before leveling is L1, where L1 is the distance from the laser point of the laser length measuring sensor to the mechanical guide wheel before leveling. L1 is the known measurement value, the calibration value before leveling is L2, where L2 is the known setting value, and the position difference before leveling is L3. Then L3 = L1 - L2. The position of the plate head before shearing is L4, where L4 is the distance from the laser point of the laser length measuring sensor before shearing to the mechanical guide wheel. L4 is a known measurement value. The calibration value before shearing is L5, where L5 is a known setting value. The position difference before shearing is L6, so L6 = L4 - L5. The vertical roller is connected to the steel plate and is used to adjust the position of the steel plate edge. The vertical roller motor drives the vertical roller to move, and the vertical roller displacement value is L7, where L7 = |L6-L3|. After the PLC control system processes the above parameters through logic calculation, it controls the vertical roller motor to move according to the vertical roller displacement value. When L6-L3 is negative, the vertical roller moves in the first direction and drives the steel plate to move in the first direction. When L6-L3 is positive, the vertical roller moves in the second direction and drives the steel plate to move in the second direction. When L7 < L8, the vertical roller stops moving. L8 is the set reference value, which makes the value of L7 approach zero.

2. The automatic measurement method for the edge position of a board according to claim 1, characterized in that, The Profibus DP distributed master-slave control mode is adopted, with a Siemens S7-300 PLC as the master station and the vertical roller control system and touch screen system as slave stations. The vertical roller control system is used to control the vertical roller, and the touch screen system is used to set data and display real-time data.

3. The automatic measurement method for the edge position of a board according to claim 2, characterized in that, The PLC master and slave stations communicate using the Profibus DP protocol.

4. The automatic measurement method for the edge position of a board according to claim 2, characterized in that, The vertical roller control system is a Siemens MM440 controller.

5. A board edge measurement system based on the automatic board edge position measurement method as described in any one of claims 1-4, characterized in that, The plate edge measurement system also includes a floating device and a data acquisition module; The floating device is connected to the mechanical roller, and the floating device can drive the mechanical roller to move so that the mechanical roller moves synchronously with the edge of the steel plate. The laser length measuring sensor is electrically connected to the data acquisition module.

6. The plate edge measurement system according to claim 5, characterized in that, The floating device includes a floating guide cylinder; The laser length measuring sensor is fixed above the floating guide cylinder, and the mechanical guide wheel is connected to the output end of the floating guide cylinder; A flat plate is installed on the mechanical wheel, and the laser length measuring sensor emits a laser point that illuminates the flat plate, which is white.

7. The plate edge measurement system according to claim 5, characterized in that, It also includes a touch screen system and a vertical roller control system; The touch screen system is electrically connected to the PLC control system; The vertical roller control system is electrically connected to the PLC control system.

8. The plate edge measurement system according to claim 6, characterized in that, It also includes a fixing plate; The fixing plate is located on the side of the steel plate, and the floating guide cylinder is connected to the fixing plate.

9. The plate edge measurement system according to claim 8, characterized in that, It also includes the main support frame; The main support is configured as a cross-shaped support, and the main support is provided with a horizontal plate and a vertical plate, the vertical plate is set vertically, and the horizontal plate is perpendicular to the vertical plate; The fixed plate is slidably connected to the horizontal plate; The horizontal plate is slidably connected to the vertical plate.

10. The plate edge measurement system according to claim 9, characterized in that, The horizontal plate has a first long groove along its own length direction, and the fixed plate is provided with a first slider, which extends into the first long groove. The vertical plate has a second long groove along its own length, and the horizontal plate has a second slider that extends into the second long groove.

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