Medium-frequency elbow pipe angle real-time monitoring system and monitoring method

Abstract

The invention discloses a real-time monitoring system and method for the angle of an intermediate-frequency bent pipe. Most pipe bending equipment adopts a mode of measuring an angle after forming, and the equipment is adjusted according to a measurement result. The method not only is low in efficiency, but also possibly causes increase of the rejection rate, and an existing angle monitoring technology is difficult to adapt to high-temperature and high-dynamic complex working conditions in the pipe bending process, and cannot provide real-time angle data in the pipe bending process. The device comprises an arc length detection device which is installed in a bent pipe and synchronously moves along with the pipe; the data processing module is used for receiving the arc length data transmitted by the detection device and calculating a bending angle in real time by combining a preset bending radius; the signal transmission module is used for transmitting the angle data to a control system to realize real-time feedback; the display and alarm module is used for displaying the bending angle and deviation in real time, and when the deviation exceeds an allowable range, an alarm device is triggered. The method is used for real-time monitoring of the medium-frequency elbow pipe angle.

Description

Technical Field

[0001] The present invention relates to the technical field of pipe bending processing, and in particular to a medium frequency pipe bending angle real-time monitoring system and a monitoring method. Background Art

[0002] Pipe bending technology is an important part of mechanical processing and manufacturing, and is widely used in industries such as petroleum, chemical, electric power, construction and shipbuilding. As an advanced pipe bending process, medium frequency pipe bending uses medium frequency induction heating to locally heat the pipe to a plastic state, and uses mechanical force to achieve bending and forming. Medium frequency pipe bending technology has the advantages of high efficiency, high precision and strong adaptability, and is particularly suitable for the processing of large diameter and thick wall pipes.

[0003] However, in the medium frequency pipe bending process, the control and accuracy of the bending angle are crucial to product quality. Existing methods for monitoring the bending angle usually have the following problems:

[0004] Post-measurement method: Most tube bending equipment measures the angle after forming and adjusts the equipment based on the measurement results. This method is not only inefficient, but may also lead to increased scrap rates.

[0005] Lack of real-time monitoring means: The existing angle monitoring technology is difficult to adapt to the complex working conditions of high temperature and high dynamics during the pipe bending process, and cannot provide real-time angle data during the pipe bending process.

[0006] Insufficient accuracy: Traditional angle sensors are greatly affected by mechanical installation accuracy, vibration and temperature, and the measurement results often have large errors.

[0007] In order to solve the above problems, there is an urgent need for a new method that can monitor the bending angle in real time and accurately during the pipe bending process to improve the processing accuracy and production efficiency of the pipe bending. Summary of the invention

[0008] In view of the above-mentioned deficiencies in the prior art, the present invention provides a medium frequency pipe bending angle real-time monitoring system and monitoring method.

[0009] The purpose of the present invention is to be achieved through the following technical solutions:

[0010] A medium frequency pipe bending angle real-time monitoring system, which comprises: an arc length detection device, which is installed inside the pipe bending and moves synchronously with the pipe;

[0011] A data processing module, used to receive arc length data transmitted by the detection device, and calculate the bending angle in real time in combination with a preset bending radius;

[0012] Signal transmission module, used to transmit angle data to the control system to achieve real-time feedback;

[0013] The display and alarm module is used to display the bending angle and deviation in real time. When the deviation exceeds the allowable range, the alarm device is triggered.

[0014] The said medium frequency bending pipe angle real-time monitoring system, the said arc length detection device is composed of a roller assembly, an encoder and a fixed bracket;

[0015] The roller assembly is in contact with the inner wall of the curved pipe, and the roller diameter is used to ensure measurement accuracy;

[0016] The encoder calculates the real-time arc length through the rotation angle of the roller;

[0017] The fixed bracket is used to maintain the stable operation of the roller assembly and ensure that the roller and the pipe maintain constant contact.

[0018] In the medium frequency pipe bending angle real-time monitoring system, the data processing module is divided into a sampling module, a calculation module and a storage module, and the sampling module is used to collect real-time data of the roller assembly at a fixed frequency;

[0019] The calculation module is used to calculate the bending angle;

[0020] The storage module is used to record real-time arc length and angle data to facilitate subsequent quality analysis.

[0021] In the medium frequency pipe bending angle real-time monitoring system, the signal transmission module adopts wireless or wired communication mode for transmission.

[0022] A monitoring method for a medium frequency pipe bending angle real-time monitoring system, the method comprising the following steps:

[0023] Step 1: Start the pipe bending equipment. The operator starts the pipe bending equipment and prepares for the pipe bending operation, ensuring that the equipment operates normally and enters the standby state;

[0024] Step 2: Set the target angle and bending radius. According to the process requirements, the operator sets the target bending angle θ in the control system. target and bending radius R, which will be used as reference values ​​for the pipe bending operation and for subsequent angle monitoring and adjustment;

[0025] Step 3: Start the arc length detection device, activate the arc length detection device, start to record the arc length L(t) inside the bending pipe in real time during the bending process, and transmit the data to the data processing module in real time for processing;

[0026] Step 4: Data processing and angle calculation: Perform real-time calculation based on the bending radius R to obtain the current bending angle θ(t) and compare it with the target angle θ target Make comparisons and calculate the angle deviation;

[0027] Step 5: Display and alarm. The calculation results are visualized through the display and alarm module. The operator can monitor the bending angle in real time. If the angle deviation exceeds the preset allowable error range, the system will issue an alarm signal to remind the operator to take corresponding adjustment measures.

[0028] Step 6: Check the angle deviation. The system checks the deviation between the current bending angle and the target angle |θ target -θ(t)|, to determine whether it is within the allowable error range and ensure that the bending angle is within the acceptable range;

[0029] Step 7: Equipment adjustment. If the angle deviation exceeds the allowable range, the operator shall adjust the equipment parameters (such as thrust, speed, etc.) in time according to the prompts of the display and alarm module to ensure that the bending angle is close to the target value and prevent error accumulation.

[0030] Step 8: Complete the pipe bending operation. When the target angle or deviation value reaches the predetermined allowable error range, the pipe bending operation is completed and the system ends real-time monitoring to ensure that the bending angle of the product meets the quality requirements.

[0031] The monitoring method of the medium frequency bending angle real-time monitoring system, the bending angle calculation process is:

[0032] (1) After receiving L(t), the data processing module matches and calculates the preset bending radius R and outputs the current angle θ(t) in real time;

[0033] (2) By setting the target angle θ target , calculate the current angle deviation Δθ = θ target -θ(t);

[0034] (3) If |Δθ| exceeds the set range, an alarm signal is generated.

[0035] The monitoring method of the medium frequency pipe bending angle real-time monitoring system, the signal transmission and feedback are specifically as follows:

[0036] (1) Signal transmission;

[0037] The calculated bending angle θ(t) and deviation Δθ are transmitted to the control system of the pipe bending equipment through a wireless module or a wired connection. The real-time angle θ(t) and deviation Δθ are displayed on the operation panel for easy monitoring by the operator. When the deviation exceeds the allowable range, the system automatically issues an alarm and stops the pipe bending operation or adjusts the equipment parameters to prevent quality problems.

[0038] (2) Feedback control;

[0039] According to the real-time angle data and deviation value, adjust the key parameters of the pipe bending equipment, adjust the thrust of the pipe bending equipment, and ensure that the bending angle meets the expectations; speed control: adjust the propulsion speed of the pipe bending equipment to avoid the accumulation of angle deviation.

[0040] Beneficial effects:

[0041] 1. The present invention realizes real-time angle monitoring and feedback control in the pipe bending process by introducing a real-time arc length detection device and combining mathematical calculation and intelligent control technology.

[0042] 2. The bending angle and deviation calculated by the present invention are transmitted to the control system of the pipe bending equipment through a wireless module or a wired connection, and the real-time angle and deviation are displayed on the operation panel for easy monitoring by the operator. When the deviation exceeds the allowable range, the system automatically issues an alarm, stops the pipe bending operation or adjusts the equipment parameters to prevent quality problems.

[0043] 3. The present invention adjusts key parameters of the pipe bending equipment according to real-time angle data and deviation values, such as thrust control: adjusting the thrust of the pipe bending equipment to ensure that the bending angle meets expectations; speed control: adjusting the propulsion speed of the pipe bending equipment to avoid angle deviation accumulation. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 Schematic diagram of the module of the present invention

[0045] Figure 2 It is a schematic diagram of the real-time monitoring process of the present invention. DETAILED DESCRIPTION

[0046] Reference Figure 1-Figure 2 , arc length detection module, which is used to detect the arc length generated during the pipe bending process in real time. The arc length detection module can be installed inside the pipe bending process through a contact sensor (such as a roller encoder) or a non-contact sensor (such as a laser, optical or ultrasonic sensor), and moves synchronously with the pipe to record the arc length data in real time;

[0047] The arc length detection device is installed inside the bending part of the pipe. It contacts the inner wall of the bent pipe through a contact roller and records the cumulative distance of the roller rolling in real time as the arc length L(t);

[0048] Data processing module: The data processing module receives the arc length data L(t) transmitted by the arc length detection module, and performs real-time calculation based on the bending radius R. Calculate the bending angle θ(t). At the same time, the module can calculate the angle θ with the target target The deviation generates a feedback signal.

[0049] The signal transmission module uses wired or wireless communication to transmit the angle and deviation signals generated by the data processing module to the pipe bending equipment control system to achieve real-time data interaction.

[0050] Display and alarm module: The display and alarm module is used to visualize the real-time angle information θ(t) and deviation Δθ, which is convenient for operators to monitor in real time. target When the fault occurs, the module will send out an alarm signal to remind the operator or directly trigger the system protection mechanism.

[0051] The pipe bending equipment system receives the feedback signal transmitted by the signal transmission module. The operator dynamically adjusts the operating parameters of the equipment (such as thrust and speed) according to the real-time monitored bending angle data to ensure that the bending angle meets the expected target and avoids deviation accumulation.

[0052] The implementation principle of the present invention ensures the accuracy of the pipe bending operation by real-time monitoring of the angle change during the pipe bending process. The arc length detection device consists of a roller assembly, an encoder and a fixed bracket: the roller assembly contacts the inner wall of the bent pipe, and the roller diameter D ensures the measurement accuracy. The encoder: through the roller rotation angle Calculate real-time arc length The fixed bracket is used to maintain the stable operation of the roller assembly and ensure that the roller maintains constant contact with the pipe. During the pipe bending process, the arc length detection module records the arc length data of the pipe in real time and calculates the current bending angle θ(t) based on the relationship with the bending radius R. The data processing module compares the actual measured bending angle with the target angle θ target The deviation is detected by the sensor and a feedback signal is generated. When the angle deviation exceeds the allowable error range, the signal transmission module transmits the deviation signal to the bending equipment control system, triggers an alarm and adjusts equipment parameters (such as thrust and speed). The display and alarm module visualizes the angle data for operators to monitor and adjust in real time. The entire system ensures that the bending angle meets the expected requirements through real-time feedback and adjustment mechanisms, thereby improving production accuracy, reducing deviations, and avoiding equipment damage or product failure.

[0053] The data processing module is divided into sampling module, calculation module and storage module:

[0054] Sampling module: collects real-time data of the roller assembly at a fixed frequency.

[0055] Calculation module: Formula based Calculate the bend angle.

[0056] Storage module: records real-time arc length and angle data for subsequent quality analysis.

[0057] The control module makes feedback adjustments based on the real-time deviation Δθ:

[0058] Thrust control: adjust the thrust of the pipe bending equipment to correct angle deviation.

[0059] Speed ​​control: Avoid deviation accumulation by adjusting the propulsion speed of the equipment.

[0060] Reference Figure 2 The method for real-time monitoring of the angle of a medium frequency pipe bend comprises the following steps:

[0061] Step 1: Start the pipe bending equipment. The operator starts the pipe bending equipment and prepares for the pipe bending operation, ensuring that the equipment operates normally and enters the standby state.

[0062] Step 2: Set the target angle and bending radius. According to the process requirements, the operator sets the target bending angle θ in the control system. target and bending radius R, which will be used as reference values ​​for the pipe bending operation and for subsequent angle monitoring and adjustment.

[0063] Step 3: Start the arc length detection device, activate the arc length detection device, start to record the arc length L(t) inside the bending pipe in real time during the bending process, and transmit the data to the data processing module for processing in real time.

[0064] Step 4: Data processing and angle calculation: Perform real-time calculation based on the bending radius R to obtain the current bending angle θ(t) and compare it with the target angle θ target Compare and calculate the angle deviation.

[0065] Step 5: Display and alarm, the calculation results are visualized through the display and alarm module, and the operator can monitor the bending angle in real time. If the angle deviation exceeds the preset allowable error range, the system will issue an alarm signal to remind the operator to take corresponding adjustment measures.

[0066] Step 6: Check the angle deviation. The system checks the deviation between the current bending angle and the target angle |θ target -θ(t)|, judge whether it is within the allowable error range and ensure that the bending angle is within the acceptable range.

[0067] Step 7: Equipment adjustment. If the angle deviation exceeds the allowable range, the operator shall adjust the equipment parameters (such as thrust, speed, etc.) in time according to the prompts of the display and alarm module to ensure that the bending angle is close to the target value and prevent error accumulation.

[0068] Step 8: Complete the pipe bending operation. When the target angle or deviation value reaches the predetermined allowable error range, the pipe bending operation is completed and the system ends real-time monitoring to ensure that the bending angle of the product meets the quality requirements.

[0069] The present invention realizes real-time monitoring of the bending angle during medium frequency pipe bending by combining an arc length measurement device with a data processing module. The working principle is as follows:

[0070] (1) Real-time measurement and recording of arc length

[0071] Installation of the detection device: Fix the detection device inside or outside the bending part of the pipe so that it can move synchronously with the bending of the pipe.

[0072] For contact measurement, the device uses a roller or encoder to contact the inner wall of the pipe and records the cumulative distance of the roller rolling as the arc length L in real time.

[0073] For non-contact measurement, the device uses optical sensors, laser sensors or ultrasonic ranging equipment to measure the curvature of its motion path relative to a fixed point in real time and calculate the arc length.

[0074] Arc length data recording: The detection device converts the measured arc length data L(t) into digital signals at each time point and transmits them to the data processing module.

[0075] (2) Bending angle calculation:

[0076] The calculation of the bending angle θ is based on the following formula:

[0077]

[0078] in:

[0079] L: The real-time arc length of the bent pipe, provided by the detection device.

[0080] R: Bending radius, which is set by the tube bending equipment and kept constant.

[0081] Calculation process:

[0082] ① After receiving L(t), the data processing module matches it with the preset bending radius R and outputs the current angle θ(t) in real time.

[0083] ② By setting the target angle θ target , calculate the current angle deviation Δθ = θ target -θ(t)

[0084] ③If |Δθ| exceeds the set range, an alarm signal is generated.

[0085] 3. Signal transmission and feedback

[0086] (1) Signal transmission: The calculated bending angle θ(t) and deviation Δθ are transmitted to the control system of the pipe bending equipment through a wireless module or a wired connection. The real-time angle θ(t) and deviation Δθ are displayed on the operation panel for easy monitoring by the operator. When the deviation exceeds the allowable range, the system automatically issues an alarm and stops the pipe bending operation or adjusts the equipment parameters to prevent quality problems.

[0087] (2) Feedback control: Adjust the key parameters of the pipe bending equipment according to the real-time angle data and deviation value. For example, thrust control: adjust the thrust of the pipe bending equipment to ensure that the bending angle meets the expectations; speed control: adjust the propulsion speed of the pipe bending equipment to avoid the accumulation of angle deviation.

[0088] The medium frequency pipe bending angle real-time monitoring method of the present invention accurately controls and monitors the pipe bending angle through arc length detection, data processing, signal transmission and real-time display technology. Its advantages are: real-time detection of pipe bending arc length and calculation of angle to ensure angle accuracy and reduce human error; reminder of operator adjustment of angle through display and alarm module to avoid deviation accumulation and improve operational reliability and safety; real-time data interaction function makes equipment adjustment more dynamic and improves production efficiency; visualization and intelligent alarm simplify operation and reduce equipment failure. This method has obvious advantages in improving pipe bending angle accuracy, reducing losses and improving automation.

Claims

1. A medium frequency pipe bending angle real-time monitoring system, characterized by :Its components include: an arc length detection device, which is installed inside the bent pipe and moves synchronously with the pipe; A data processing module, used to receive arc length data transmitted by the detection device, and calculate the bending angle in real time in combination with a preset bending radius; Signal transmission module, used to transmit angle data to the control system to achieve real-time feedback; The display and alarm module is used to display the bending angle and deviation in real time. When the deviation exceeds the allowable range, the alarm device is triggered.

2. According to claim 1, a medium frequency pipe bending angle real-time monitoring system is characterized in that : The arc length detection device is composed of a roller assembly, an encoder and a fixed bracket; The roller assembly is in contact with the inner wall of the curved pipe, and the roller diameter is used to ensure measurement accuracy; The encoder calculates the real-time arc length through the rotation angle of the roller; The fixed bracket is used to maintain the stable operation of the roller assembly and ensure that the roller and the pipe maintain constant contact.

3. According to claim 1, a medium frequency pipe bending angle real-time monitoring system is characterized by: The data processing module is divided into a sampling module, a calculation module and a storage module. The sampling module is used to collect real-time data of the roller assembly at a fixed frequency; The calculation module is used to calculate the bending angle; The storage module is used to record real-time arc length and angle data to facilitate subsequent quality analysis.

4. According to claim 1, a medium frequency pipe bending angle real-time monitoring system is characterized in that :The signal transmission module adopts wireless or wired communication mode for transmission.

5. A monitoring method using a medium frequency pipe bending angle real-time monitoring system according to any one of claims 1 to 4, characterized in that: The method comprises the following steps: Step 1: Start the pipe bending equipment. The operator starts the pipe bending equipment and prepares for the pipe bending operation, ensuring that the equipment operates normally and enters the standby state; Step 2: Set the target angle and bending radius. According to the process requirements, the operator sets the target bending angle θ in the control system. target and bending radius R, which will be used as reference values ​​for the pipe bending operation and for subsequent angle monitoring and adjustment; Step 3: Start the arc length detection device, activate the arc length detection device, start to record the arc length L(t) inside the bending pipe in real time during the bending process, and transmit the data to the data processing module in real time for processing; Step 4: Data processing and angle calculation: Perform real-time calculation based on the bending radius R to obtain the current bending angle θ(t) and compare it with the target angle θ target Make comparisons and calculate the angle deviation; Step 5: Display and alarm. The calculation results are visualized through the display and alarm module. The operator can monitor the bending angle in real time. If the angle deviation exceeds the preset allowable error range, the system will issue an alarm signal to remind the operator to take corresponding adjustment measures. Step 6: Check the angle deviation. The system checks the deviation between the current bending angle and the target angle |θ targer -θ(t)|, to determine whether it is within the allowable error range and ensure that the bending angle is within the acceptable range; Step 7: Equipment adjustment. If the angle deviation exceeds the allowable range, the operator shall adjust the equipment parameters (such as thrust, speed, etc.) in time according to the prompts of the display and alarm module to ensure that the bending angle is close to the target value and prevent error accumulation. Step 8: Complete the pipe bending operation. When the target angle or deviation value reaches the predetermined allowable error range, the pipe bending operation is completed and the system ends real-time monitoring to ensure that the bending angle of the product meets the quality requirements.

6. The monitoring method of a medium frequency pipe bending angle real-time monitoring system according to claim 5 is characterized by: The bending angle calculation process is: (1) After receiving L(t), the data processing module matches and calculates the preset bending radius R and outputs the current angle θ(t) in real time; (2) By setting the target angle θ target , calculate the current angle deviation Δθ = θ targer -θ(t); (3) If |Δθ| exceeds the set range, an alarm signal is generated.

7. The monitoring method of a medium frequency pipe bending angle real-time monitoring system according to claim 5 is characterized by: The signal transmission and feedback are specifically as follows: (1) Signal transmission; The calculated bending angle θ(t) and deviation Δθ are transmitted to the control system of the pipe bending equipment through a wireless module or a wired connection. The real-time angle θ(t) and deviation Δθ are displayed on the operation panel for easy monitoring by the operator. When the deviation exceeds the allowable range, the system automatically issues an alarm and stops the pipe bending operation or adjusts the equipment parameters to prevent quality problems. (2) Feedback control; According to the real-time angle data and deviation value, adjust the key parameters of the pipe bending equipment, adjust the thrust of the pipe bending equipment, and ensure that the bending angle meets the expectations; speed control: adjust the propulsion speed of the pipe bending equipment to avoid the accumulation of angle deviation.

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