Pipe end forming control system for automobile metal pipe fitting machining

Abstract

The invention relates to the technical field of abnormity control, and particularly discloses a pipe end forming control system for automobile metal pipe fitting processing, which comprises a pipe end forming device, an acquisition module, a processing module, a processing module and a control module, and is characterized in that a minimum circumcircle of a pipe end is marked in a front image of the pipe end of an automobile metal pipe fitting, the area of the minimum circumcircle is determined, and an area difference value is calculated; the processing module is used for acquiring a deviation value of the automobile metal pipe fitting in the acquisition period and generating a coordinate point; determining an initial image, and obtaining a target image based on the initial image; determining a sub-definition domain, and obtaining a judgment parameter based on the function relation of the target image in the single sub-definition domain; and the judgment module is used for calculating a judgment value, counting an abnormal proportion and determining abnormal equipment according to the abnormal proportion. The abnormal pipe end forming equipment can be determined, and production efficiency reduction caused by abnormity of the pipe end forming equipment is avoided.

Description

Technical Field

[0001] The invention relates to the technical field of abnormal control, and in particular to a pipe end forming control system for processing automobile metal pipes. Background Art

[0002] Automotive metal pipes are key components in automobile manufacturing and are widely used in engines, brake systems, fuel systems, air conditioning systems, etc. They are usually made of high-strength steel, stainless steel, aluminum or copper and are resistant to high temperatures, corrosion and pressure.

[0003] The tube end forming of metal pipe fittings refers to the specific processing of both ends of metal pipe fittings. In this process, high precision requirements are placed on the shape of the tube ends. The precision of tube end forming directly affects the sealing and assembly effect of the pipe fittings. High-precision forming technology can ensure the perfect fit between the pipe fittings and the connectors, reduce the risk of leakage, and improve the reliability of the system.

[0004] In the prior art, for the finished automobile metal pipe fittings, the quality inspectors generally determine whether the shape of the pipe end is qualified, and rework the unqualified automobile metal pipe fittings. However, in actual situations, the automobile metal pipe fittings may be unqualified due to the abnormality of the pipe end forming equipment itself. At this time, even if the automobile metal pipe fittings are reworked, the reworked automobile metal pipe fittings may still be unqualified due to the abnormality of the pipe end forming equipment itself, which has an adverse effect on production efficiency. Based on this, a pipe end forming control system for automobile metal pipe processing is proposed to determine the abnormal pipe end forming equipment to avoid affecting production efficiency. Summary of the invention

[0005] The purpose of the present invention is to provide a tube end forming control system for automobile metal pipe processing to solve the following technical problems:

[0006] For the finished workpiece, the quality inspector usually determines whether the shape of the end of the processed metal pipe is qualified, and reworks the unqualified workpiece. However, in actual situations, the workpiece may be unqualified due to abnormalities in the processing equipment. In this case, even if the workpiece is reworked, it may still be unqualified due to the abnormalities in the processing equipment, which has an adverse effect on production efficiency.

[0007] The purpose of the present invention can be achieved by the following technical solutions:

[0008] A tube end forming control system for automobile metal tube processing, including a tube end forming device, including:

[0009] Acquisition module: obtain the processed automobile metal pipe fittings, collect the front image of the pipe end of the automobile metal pipe fittings, mark the minimum circumscribed circle of the pipe end in the front image, determine the area S of the minimum circumscribed circle, and calculate the area difference ΔS=|S-Sys|, where Sys represents the preset standard area of ​​the pipe end;

[0010] Processing module: obtaining a deviation value C of the processed automobile metal pipe within a preset collection period, wherein the deviation value is determined based on the area difference corresponding to the processed automobile metal pipe, and generating a coordinate point (a, Ca), wherein Ca represents the deviation value of the ath processed automobile metal pipe within the collection period;

[0011] Connect two adjacent coordinate points to obtain an initial image, and use the initial image within a preset standard definition domain [1, N] as a target image f(x), where N represents the minimum total number of automotive metal pipes that have been processed by a single pipe end forming device within the acquisition cycle;

[0012] Divide the standard definition domain into n sub-definition domains of the same length, where n is a preset number, and obtain judgment parameters based on a functional relationship F(x) of the target image in a single sub-definition domain, wherein the judgment parameters include an average deviation value D and a maximum change rate D' of the deviation value;

[0013] Judgment module: calculate judgment value η is a preset correction coefficient and the abnormal proportion is counted. The abnormal proportion is the proportion of the deviation value in a single sub-definition domain that is greater than the deviation value of other pipe end forming equipment. The mean of the abnormal proportion is calculated. When the mean is greater than or equal to the preset mean threshold, the corresponding pipe end forming equipment is marked as an abnormal equipment and reported.

[0014] As a further solution of the present invention: in the processing module, the process of determining the deviation value based on the area difference of the processed automobile metal pipe specifically includes:

[0015] Setting the deviation level, which includes no deviation, first-level deviation, second-level deviation and third-level deviation;

[0016] When the area difference ΔS=0, the deviation level is no deviation;

[0017] When the area difference ΔS<ΔS', the deviation level is the first-level deviation, and ΔS' is the preset area deviation value;

[0018] When the area difference ΔS'<ΔS<1.5ΔS', the deviation level is a second-level deviation;

[0019] When the area difference is 1.5ΔS'<ΔS, the deviation level is level 3 deviation;

[0020] When the deviation level is no deviation, first-level deviation, second-level deviation and third-level deviation, the corresponding deviation values ​​are A, A, A+1, A+2, respectively, where A is a preset value and A is an integer.

[0021] As a further solution of the present invention: in the processing module, when the area difference is a number of level three deviations greater than or equal to a preset safety number, the corresponding pipe end forming equipment is judged to be an abnormal equipment and reported.

[0022] As a further solution of the present invention: in the processing module, the process of obtaining the judgment parameter specifically includes:

[0023] Calculate the mean deviation

[0024] The peak points and valley points of the target image within the single sub-definition domain are taken as reference points, and the starting point and end point of the target image within the single sub-definition domain are taken as reference points, the rate of change of the deviation value between two adjacent reference points is calculated, and the maximum value is obtained as the maximum rate of change D' of the deviation value.

[0025] As a further solution of the present invention: in the processing module, a single sub-definition domain is [1, N / n].

[0026] As a further solution of the present invention: in the acquisition module, the front image of the tube end of the automobile metal pipe is acquired at a preset position.

[0027] As a further solution of the present invention: in the judgment module, when the pipe end forming equipment G is not an abnormal equipment and there is a deviation value in a certain sub-definition domain that is greater than the ratio b ≥ 0.8 of the deviation values ​​of other pipe end forming equipment, the pipe end forming equipment G is marked as a target equipment and the staff is prompted.

[0028] Beneficial effects of the present invention: In the present invention, firstly, the specific shape and size of the tube end of each pipe fitting are accurately obtained through image acquisition, and the area difference is determined, so as to quantify the deviation between the tube end of each metal pipe fitting and the standard, so as to provide basic data for subsequent analysis; the tube ends of automobile metal pipe fittings of different types and processes correspond to different standard tube end areas, which can be set by the staff and are not limited here; based on the area difference, the deviation value of each pipe fitting is generated, and the relationship between the tube fitting deviation and the serial number of the automobile metal pipe fitting is established through the coordinate points, that is, the initial image, and finally the target image is obtained; by converting the area difference into the deviation value, the complexity of processing tiny area differences can be reduced, and converting the area difference into the deviation value helps to simplify the processing of tiny differences, because when the area difference is directly processed, the value may be very subtle, especially in high-precision processing, it is difficult to quantify and distinguish, and the area difference may have very small numerical differences, such as 0.001, 0.0005, etc., and this precision is difficult to effectively use in actual operation. Through this deviation value conversion and division, the entire detection and monitoring process becomes simpler The method is clean and efficient, avoiding the complexity of dealing with small numerical changes. Then, the standard domain is divided to obtain sub-domains. After the sub-domains are divided, the starting point of each sub-domain is set to 1. There is no need to offset or adjust the starting points of different sub-domains during analysis, which reduces the consideration of index changes in the data processing process and simplifies the calculation and comparison steps. Then, the judgment parameter is obtained according to the functional relationship F(x) of the target image in a single sub-domain to reduce the amount of data processed at a single time and the complexity of the data. Finally, the performance of the pipe end forming equipment in a sub-domain is measured by the judgment value. Specifically, the larger the average deviation value D, the greater the deviation of the area difference, and the larger the judgment value should be. The larger the judgment value is used as the judgment standard for the worse performance of the pipe end forming equipment in the subsequent part, and the other parameters can refer to the above ideas. Finally, the abnormal proportion is counted, and the abnormal equipment is determined according to the abnormal proportion. It can be understood that the abnormal proportion reflects the performance comparison between different pipe end forming equipment. The larger the abnormal proportion, the worse the performance of a certain pipe end forming equipment is compared with the other equipment, and the more likely it is that there is an abnormality. The present invention can determine the presence of abnormal pipe end forming equipment, thereby avoiding the decrease in production efficiency caused by the abnormality of the pipe end forming equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention will be further described below in conjunction with the accompanying drawings.

[0030] Figure 1 The present invention is a schematic flow chart of a tube end forming control system for automobile metal tube processing. DETAILED DESCRIPTION

[0031] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] See also Figure 1 As shown, the present invention is a tube end forming control system for automobile metal pipe processing, including a tube end forming device, including:

[0033] Acquisition module: obtain the processed automobile metal pipe fittings, collect the front image of the pipe end of the automobile metal pipe fittings, mark the minimum circumscribed circle of the pipe end in the front image, determine the area S of the minimum circumscribed circle, and calculate the area difference ΔS=|S-Sys|, where Sys represents the preset standard area of ​​the pipe end;

[0034] Processing module: obtaining a deviation value C of the processed automobile metal pipe within a preset collection period, wherein the deviation value is determined based on the area difference corresponding to the processed automobile metal pipe, and generating a coordinate point (a, Ca), wherein Ca represents the deviation value of the ath processed automobile metal pipe within the collection period;

[0035] Connect two adjacent coordinate points to obtain an initial image, and use the initial image within a preset standard definition domain [1, N] as a target image f(x), where N represents the minimum total number of automotive metal pipes that have been processed by a single pipe end forming device within the acquisition cycle;

[0036] Divide the standard definition domain into n sub-definition domains of the same length, where n is a preset number, and obtain judgment parameters based on a functional relationship F(x) of the target image in a single sub-definition domain, wherein the judgment parameters include an average deviation value D and a maximum change rate D' of the deviation value;

[0037] Judgment module: calculate judgment value η is a preset correction coefficient and the abnormal proportion is counted. The abnormal proportion is the proportion of the deviation value in a single sub-definition domain that is greater than the deviation value of other pipe end forming equipment. The mean of the abnormal proportion is calculated. When the mean is greater than or equal to the preset mean threshold, the corresponding pipe end forming equipment is marked as an abnormal equipment and reported.

[0038] It should be noted that, firstly, the specific shape and size of the pipe end of each pipe fitting is accurately obtained through image acquisition, and the area difference is determined, so as to quantify the deviation between the pipe end of each metal pipe fitting and the standard, thereby providing basic data for subsequent analysis; the pipe ends of automobile metal pipe fittings of different types and processes correspond to different standard pipe end areas, which can be set by the staff and are not limited here; based on the area difference, the deviation value of each pipe fitting is generated, and the relationship between the pipe fitting deviation and the serial number of the automobile metal pipe fitting is established through the coordinate points, that is, the initial image, and finally the target image is obtained; by converting the area difference into the deviation value, the complexity of processing small area differences can be reduced, and converting the area difference into the deviation value helps to simplify the processing of small differences, because when directly processing the area difference, the value may be very subtle, especially in high-precision processing, which is difficult to quantify and distinguish, and the area difference may have very small numerical differences, such as 0.001, 0.0005, etc., and this precision is difficult to effectively use in actual operation. Through this deviation value conversion and division, the entire detection and monitoring process becomes more concise and efficient, The complexity of dealing with small numerical changes is avoided; then the standard domain is divided to obtain sub-domains, and after the sub-domains are divided, the starting point of each sub-domain is set to 1. There is no need to offset or adjust the starting points of different sub-domains during analysis, which reduces the consideration of index changes in the data processing process and simplifies the calculation and comparison steps; then, the judgment parameter is obtained according to the functional relationship F(x) of the target image in a single sub-domain to reduce the amount of data processed in a single time and the complexity of the data; finally, the performance of the pipe end forming equipment in a sub-domain is measured by the judgment value. Specifically, the larger the average deviation value D, the greater the deviation of the area difference, and the larger the judgment value should be. The larger the judgment value is used as the judgment standard for the worse performance of the pipe end forming equipment in the subsequent section, and the remaining parameters can refer to the above ideas; finally, the abnormal proportion is counted, and the abnormal equipment is determined according to the abnormal proportion; it can be understood that the abnormal proportion reflects the performance comparison between different pipe end forming equipment. The larger the abnormal proportion, the worse the performance of a certain pipe end forming equipment compared with the other equipment, and the more likely it is that there is an abnormality.

[0039] In another preferred embodiment of the present invention, in the processing module, the process of determining the deviation value based on the area difference of the processed automobile metal pipe specifically includes:

[0040] Setting the deviation level, which includes no deviation, first-level deviation, second-level deviation and third-level deviation;

[0041] When the area difference ΔS=0, the deviation level is no deviation;

[0042] When the area difference ΔS<ΔS', the deviation level is the first-level deviation, and ΔS' is the preset area deviation value;

[0043] When the area difference ΔS'<ΔS<1.5ΔS', the deviation level is a second-level deviation;

[0044] When the area difference is 1.5ΔS'<ΔS, the deviation level is level 3 deviation;

[0045] When the deviation level is no deviation, first-level deviation, second-level deviation and third-level deviation, the corresponding deviation values ​​are A, A, A+1, A+2, respectively, where A is a preset value and A is an integer.

[0046] It is worth noting that by dividing the deviation levels into no deviation, first level, second level and third level deviation, instead of processing the specific deviation value of each pipe fitting one by one, the complexity of the data is greatly simplified. The original area difference can have an infinite number of values, and after classifying them into several fixed levels, the system only needs to process limited deviation level information. At the same time, the system no longer needs to perform detailed calculations and comparisons for the deviation values ​​of each workpiece, but only needs to classify them based on the preset deviation levels, which reduces data redundancy and the complexity of the processing flow; by simplifying the complex area difference into levels and setting the deviation value based on the level (A, A+1, A+2, etc.), the processing process avoids the precise calculation of the specific value of each deviation, which reduces the calculation steps, especially when processing large quantities of workpieces, it can significantly reduce the use of computing resources; in actual operation, the saving of computing resources helps the system to perform real-time more efficiently. Monitoring, by reducing the reliance on precise values, can allow the system to respond and feedback quickly, reduce computing delays, and improve monitoring and feedback capabilities; the original area difference can be any real number, ranging from extremely small values ​​to larger values. The traditional processing method requires the specific area difference of each workpiece to be calculated and compared. This processing method requires the system to process a large number of floating-point operations. As the number of workpieces increases, the complexity of the calculation presents a linear or higher-order growth; for each metal pipe fitting, if the accuracy requirement is very high, the system may need to process the difference to multiple decimal places. This floating-point calculation is not only time-consuming, but also requires more memory resources; by setting the deviation level, the area difference is classified into four levels: no deviation, first-level deviation, second-level deviation, and third-level deviation. For each processed metal pipe fitting, its area difference is classified into the corresponding deviation level instead of directly processing the specific difference.

[0047] In another preferred embodiment of the present invention, in the processing module, when the area difference is a number of level three deviations greater than or equal to a preset safety number, the corresponding pipe end forming equipment is judged to be an abnormal equipment and reported.

[0048] It is understandable that equipment may malfunction during operation, resulting in the processed metal pipes failing to meet preset standards. Level 3 deviation means that the processed automotive metal pipes have undergone significant deviations. If level 3 deviations occur frequently and the number continues to increase, it means that the equipment deviation is no longer a short-term fluctuation, but a continuous one. Continuing to operate such equipment may result in the emergence of a large number of unqualified products, increasing rework costs or product scrap rates. By reporting abnormal equipment in a timely manner, the faulty equipment can be quickly processed to prevent it from continuing to produce unqualified products.

[0049] In another preferred embodiment of the present invention, in the processing module, the process of obtaining the judgment parameter specifically includes:

[0050] Calculate the mean deviation

[0051] The peak points and valley points of the target image within the single sub-definition domain are taken as reference points, and the starting point and end point of the target image within the single sub-definition domain are taken as reference points, the rate of change of the deviation value between two adjacent reference points is calculated, and the maximum value is obtained as the maximum rate of change D' of the deviation value.

[0052] In another preferred embodiment of the present invention, in the processing module, a single sub-domain is [1, N / n].

[0053] It should be noted that through segmented processing, each calculation and analysis only needs to be performed within a smaller range, which effectively reduces the resource consumption of a single calculation and enables the entire system to process larger-scale data.

[0054] In another preferred embodiment of the present invention, in the acquisition module, the front image of the tube end of the automobile metal tube is acquired at a preset position.

[0055] It is worth noting that the preset position can ensure that each image collected is at the same angle, distance and lighting conditions. This makes each collected tube end image consistent, avoiding errors caused by different collection positions. The collected consistent data is helpful for subsequent processing and analysis to determine whether there is any abnormality in the tube end forming equipment.

[0056] In another preferred embodiment of the present invention, in the judgment module, when the pipe end forming equipment G is not an abnormal equipment and there is a deviation value in a certain sub-definition domain that is greater than the ratio b ≥ 0.8 of the deviation values ​​of other pipe end forming equipment, the pipe end forming equipment G is marked as a target equipment and the staff is prompted.

[0057] It is worth noting that during the manufacturing process, manual operational errors (such as improper placement of raw materials, adjustment errors, etc.) may lead to large deviations in the tube end forming of a batch or a sub-domain, rather than abnormalities in the tube end forming equipment. At this time, prompts should be given to the workers to remind them to check for possible operational errors or process parameter setting problems, thereby avoiding batch product quality problems caused by improper operation and ensuring production consistency.

[0058] The above is a detailed description of an embodiment of the present invention, but the content is only a preferred embodiment of the present invention and cannot be considered to limit the scope of implementation of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the scope of the patent coverage of the present invention.

Claims

1. A tube end forming control system for automobile metal pipe processing, comprising a tube end forming device, characterized in that: include: Acquisition module: obtain the processed automobile metal pipe fittings, collect the front image of the pipe end of the automobile metal pipe fittings, mark the minimum circumscribed circle of the pipe end in the front image, determine the area S of the minimum circumscribed circle, and calculate the area difference ΔS=|S-Sys|, where Sys represents the preset standard area of ​​the pipe end; Processing module: obtaining a deviation value C of the processed automobile metal pipe within a preset collection period, wherein the deviation value is determined based on the area difference corresponding to the processed automobile metal pipe, and generating a coordinate point (a, Ca), wherein Ca represents the deviation value of the ath processed automobile metal pipe within the collection period; Connect two adjacent coordinate points to obtain an initial image, and use the initial image within a preset standard definition domain [1, N] as a target image f(x), where N represents the minimum total number of automotive metal pipes that have been processed by a single pipe end forming device within the acquisition cycle; Divide the standard definition domain into n sub-definition domains of the same length, where n is a preset number, and obtain judgment parameters based on a functional relationship F(x) of the target image in a single sub-definition domain, wherein the judgment parameters include an average deviation value D and a maximum change rate D' of the deviation value; Judgment module: calculate judgment value η is a preset correction coefficient, and the abnormal proportion is counted. The abnormal proportion is the proportion of the deviation value in a single sub-definition domain that is greater than the deviation value of the remaining pipe end forming equipment. The mean of the abnormal proportion is calculated. When the mean is greater than or equal to the preset mean threshold, the corresponding pipe end forming equipment is marked as an abnormal equipment and reported.

2. A tube end forming control system for automobile metal tube processing according to claim 1, characterized in that: In the processing module, the process of determining the deviation value based on the area difference of the processed automobile metal pipe specifically includes: Setting the deviation level, which includes no deviation, first-level deviation, second-level deviation and third-level deviation; When the area difference ΔS=0, the deviation level is no deviation; When the area difference ΔS<ΔS', the deviation level is the first-level deviation, and ΔS' is the preset area deviation value; When the area difference ΔS'<ΔS<1.5ΔS', the deviation level is a second-level deviation; When the area difference is 1.5ΔS'<ΔS, the deviation level is level 3 deviation; When the deviation level is no deviation, first-level deviation, second-level deviation and third-level deviation, the corresponding deviation values ​​are A, A, A+1, A+2, respectively, where A is a preset value and A is an integer.

3. A tube end forming control system for automobile metal tube processing according to claim 2, characterized in that: In the processing module, when the area difference is a number of level three deviations greater than or equal to a preset safety number, the corresponding pipe end forming equipment is judged to be an abnormal equipment and reported.

4. A tube end forming control system for automobile metal tube processing according to claim 1, characterized in that: In the processing module, the process of obtaining the judgment parameter specifically includes: Calculate the mean deviation The peak points and valley points of the target image within the single sub-definition domain are taken as reference points, and the starting point and end point of the target image within the single sub-definition domain are taken as reference points, the rate of change of the deviation value between two adjacent reference points is calculated, and the maximum value is obtained as the maximum rate of change D' of the deviation value.

5. The tube end forming control system for automobile metal tube processing according to claim 1, characterized in that: In the processing module, a single sub-domain is [1, N / n].

6. The tube end forming control system for automobile metal tube processing according to claim 1, characterized in that: In the acquisition module, the front image of the tube end of the automobile metal tube is acquired at a preset position.

7. The tube end forming control system for automobile metal tube processing according to claim 1, characterized in that: In the judgment module, when the pipe end forming equipment G is not an abnormal equipment and there is a deviation value in a certain sub-definition domain that is greater than the deviation value of other pipe end forming equipment by a ratio b≥0.8, the pipe end forming equipment G is marked as a target equipment and the staff is prompted.

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