A tube end forming control system for automotive metal pipe fitting processing

Abstract

The present invention relates to the technical field of abnormal control, and specifically discloses a pipe end forming control system for the processing of automotive metal pipe fittings, including a pipe end forming device, comprising: a collection module: marking the minimum circumscribed circle of the pipe end in the front image of the pipe end of the automotive metal pipe fitting, determining the area of the minimum circumscribed circle and calculating the area difference; a processing module: obtaining the deviation value of the automotive metal pipe fitting within the collection period and generating coordinate points; determining an initial image and obtaining a target image based on the initial image; determining a sub-domain and obtaining a judgment parameter based on the functional relationship of the target image within a single sub-domain; a judgment module: calculating a judgment value and counting the abnormal proportion, and determining an abnormal device according to the abnormal proportion. The present invention can determine the pipe end forming device with abnormalities, avoiding the decrease in production efficiency caused by the abnormalities of the pipe end forming device.

Description

Technical Field

[0001] The present invention relates to the technical field of abnormal control, and particularly to a tube end forming control system for processing automotive metal pipe fittings. Background Art

[0002] Automotive metal pipe fittings are key components in automotive manufacturing and are widely used in engine, braking system, fuel system, air conditioning system, etc. They are usually made of materials such as high-strength steel, stainless steel, aluminum or copper, and have the characteristics of high temperature resistance, corrosion resistance and pressure resistance.

[0003] The tube end forming of metal pipe fittings refers to performing specific processing on both ends of metal pipe fittings. In this process, there are high-precision requirements for the shape of the tube ends. The precision of tube end forming directly affects the sealing performance and assembly effect of the pipe fittings. A high-precision forming process can ensure a 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 processed automotive metal pipe fittings, generally, quality inspection personnel determine whether the tube end shape is qualified, and rework the unqualified automotive metal pipe fittings. However, in actual situations, it may be that the tube end forming equipment itself has abnormalities, resulting in unqualified automotive metal pipe fittings. At this time, even if the automotive metal pipe fittings are reworked, it may still be unqualified due to the abnormalities of the tube end forming equipment itself, which has an adverse impact on production efficiency. Based on this, a tube end forming control system for processing automotive metal pipe fittings is proposed to determine the tube end forming equipment with abnormalities and 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 processing automotive metal pipe fittings, and solve the following technical problems:

[0006] For the processed workpieces, generally, quality inspection personnel determine whether the tube end shape of the processed metal pipe fittings is qualified, and rework the unqualified workpieces. However, in actual situations, it may be that the workpieces are unqualified due to abnormalities of the processing equipment. At this time, even if the workpieces are reworked, it may still be unqualified due to the abnormalities of the processing equipment, which has an adverse impact 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 processing automotive metal pipe fittings, including a tube end forming device, comprising:

[0009] Acquisition module: Obtain the processed automotive metal pipe fittings, collect the front image of the pipe end of the automotive 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: Obtain the deviation value C of the processed automotive metal pipe fittings within a preset acquisition period. The deviation value is determined based on the area difference corresponding to the processed automotive metal pipe fittings, and generate coordinate points (a, Ca), where Ca represents the deviation value of the ath processed automotive metal pipe fitting within the acquisition period;

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

[0012] Divide the standard domain into n sub-domains with the same length, where n is a preset quantity. Obtain judgment parameters based on the functional relationship F(x) of the target image within a single sub-domain. The judgment parameters include the average deviation value D and the maximum change rate D' of the deviation value;

[0013] Judgment module: Calculate the judgment value η is a preset correction coefficient and count the abnormal proportion. The abnormal proportion is the proportion of the deviation value within a single sub-domain being greater than the deviation values of the other pipe end forming devices. Calculate the average value of the abnormal proportion. When the average value is greater than or equal to the preset average threshold, mark the corresponding pipe end forming device as an abnormal device and report it.

[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 automotive metal pipe fittings specifically includes:

[0015] Set deviation levels, which include 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 first-level deviation, where ΔS' is a preset area deviation value;

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

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

[0020] When the deviation levels are the above-mentioned 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 number of the third-level deviation of the area difference is greater than or equal to a preset safety number, it is determined that the corresponding pipe end forming device is an abnormal device and a report is made.

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

[0023] Calculating the average deviation value

[0024] Taking the peak point and valley point of the target image in a single sub-domain as reference points, and taking the starting point and ending point of the target image in the single sub-domain as reference points, calculating the change rate of the deviation value between adjacent two reference points, and obtaining the maximum value among them as the maximum change rate D' of the deviation value.

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

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

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

[0028] Advantages of the present invention: In the present invention, first, the specific shape and size of the pipe 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 pipe end of each metal pipe fitting and the standard, thereby providing basic data for subsequent analysis; the pipe end of automotive metal pipe fittings of different types and processes corresponds to different standard areas of the pipe end, which can be specifically set by the staff and are not limited here; based on the area difference, a deviation value of each pipe fitting is generated, and the relationship between the pipe fitting deviation and the serial number of the automotive metal pipe fitting is established through coordinate points, namely the initial image, and finally the target image is obtained; by converting the area difference into a deviation value, the complexity of processing minute area differences can be reduced. Converting the area difference into a deviation value helps to simplify the processing of minute differences because when directly processing the area difference, the values may be very minute. Especially in high-precision machining, it is difficult to quantify and distinguish. The area difference may have very small numerical differences, such as 0.001, 0.0005, etc. Such precision is difficult to effectively utilize in actual operations. Through this conversion and division of deviation values, the entire detection and monitoring process becomes more concise and efficient, avoiding the complexity of processing minute numerical changes; then, the standard domain is divided to obtain sub-domains. After dividing the sub-domains, the starting point of each sub-domain is set to 1. When analyzing, there is no need to offset or adjust the starting points of different sub-domains, reducing the consideration of index changes in the data processing process and simplifying the calculation and comparison steps; then, according to the functional relationship F(x) of the target image within a single sub-domain, a judgment parameter is obtained to reduce the amount of data processed each time and the complexity of the data; finally, the performance of the pipe end forming equipment within 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 judgment value should be larger. Subsequently, the larger the judgment value is used as the judgment criterion for the worse performance of the pipe end forming equipment, and the other parameters can refer to the above ideas; finally, the abnormal proportion is statistically analyzed, 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 to the other equipment, and the more likely it is to be abnormal. The present invention can determine the pipe end forming equipment with abnormalities and avoid the decline in production efficiency caused by the abnormalities of the pipe end forming equipment. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0030] Figure 1 It is a flow chart of a pipe end forming control system for processing automotive metal pipe fittings according to the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0031] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0032] Please refer to Figure 1 As shown, the present invention is a tube end forming control system for processing automotive metal pipe fittings, including a tube end forming device, including:

[0033] Acquisition module: Obtain the processed automotive metal pipe fittings, collect the front image of the tube end of the automotive metal pipe fittings, mark the minimum circumscribed circle of the tube 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 tube end;

[0034] Processing module: Obtain the deviation value C of the processed automotive metal pipe fittings within a preset acquisition period. The deviation value is determined based on the area difference corresponding to the processed automotive metal pipe fittings, and generate coordinate points (a, Ca), where Ca represents the deviation value of the a-th processed automotive metal pipe fitting within the acquisition period;

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

[0036] Divide the standard domain into n sub-domains with the same length, where n is a preset quantity. Obtain judgment parameters based on the functional relationship F(x) of the target image within a single sub-domain. The judgment parameters include the average deviation value D and the maximum change rate D' of the deviation value;

[0037] Judgment module: Calculate the judgment value η is a preset correction coefficient and count the abnormal proportion. The abnormal proportion is the proportion of the deviation value within a single sub-domain that is greater than the deviation values of the other tube end forming devices. Calculate the mean value of the abnormal proportion. When the mean value is greater than or equal to the preset mean threshold, mark the corresponding tube end forming device as an abnormal device and report it.

[0038] It should be noted that first, the specific shape and size of the pipe 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 pipe end of each metal pipe fitting and the standard, providing basic data for subsequent analysis; the pipe end of automotive metal pipe fittings of different types and processes corresponds to different standard areas of the pipe end, which can be specifically set by the staff and are not limited here; based on the area difference, a deviation value of each pipe fitting is generated, and the relationship between the pipe fitting deviation and the serial number of the automotive metal pipe fitting is established through coordinate points, that is, the initial image, and finally the target image is obtained; by converting the area difference into a deviation value, the complexity of processing minute area differences can be reduced. Converting the area difference into a deviation value helps simplify the processing of minute differences because when directly dealing with area differences, the values may be very subtle, especially in high-precision machining, where it is difficult to quantify and distinguish. The area difference may have very small numerical differences, such as 0.001, 0.0005, etc. Such precision is difficult to effectively utilize in actual operations. Through this deviation value conversion and division, the entire detection and monitoring process becomes more concise and efficient, avoiding the complexity of dealing with minute numerical changes; then, the standard domain is divided to obtain sub-domains. After dividing the sub-domains, the starting point of each sub-domain is set to 1. During analysis, there is no need to offset or adjust the starting points of different sub-domains, reducing the consideration of index changes during the data processing process and simplifying the calculation and comparison steps; then, according to the functional relationship F(x) of the target image within a single sub-domain, a judgment parameter is obtained to reduce the amount of data processed at one time and the complexity of the data; finally, the performance of the pipe end forming equipment within 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. Subsequently, the worse the performance of the pipe end forming equipment is judged based on a larger judgment value. The other parameters can refer to the above ideas; finally, the abnormal proportion is statistically analyzed, 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 to the other equipment, and the more likely it is to be abnormal.

[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 automotive metal pipe fittings specifically includes:

[0040] Set deviation levels, and the deviation levels include 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 first-level deviation, where ΔS' is a preset area deviation value;

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

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

[0045] When the deviation levels are the no deviation, primary deviation, secondary deviation, and tertiary deviation as described above, 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 classifying the deviation levels into no deviation, primary, secondary, and tertiary deviations instead of dealing with the specific deviation values of each pipe fitting one by one, the complexity of the data is greatly simplified. The original area differences can have infinitely many values, but after classifying them into several fixed levels, the system only needs to process the limited deviation level information. At the same time, the system no longer needs to perform fine calculations and comparisons for the deviation values of each workpiece, but only needs to classify based on the preset deviation levels, which reduces data redundancy and the complexity of the processing flow; by simplifying the complex area differences into levels and setting deviation values (such as A, A + 1, A + 2, etc.) based on the levels, the processing process avoids precisely calculating the specific values of each deviation, which reduces the calculation steps. Especially when dealing with a large number of workpieces, it can significantly reduce the use of computing resources; in actual operation, the savings in computing resources help the system to perform real-time monitoring more efficiently. By reducing the dependence on precise numerical values, the system can respond and feedback quickly, reduce the operation delay, and improve the monitoring and feedback capabilities; the original area differences can be any real numbers, ranging from extremely small values to relatively large values. Traditional processing methods need to calculate and compare the specific area differences of each workpiece, and 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 shows linear or higher-order growth; for each metal pipe fitting, if a high precision is required, the system may need to process the differences to several decimal places. This kind of floating-point calculation is not only time-consuming but also requires more memory resources; by setting the deviation levels, the area differences are classified into four levels: no deviation, primary deviation, secondary deviation, and tertiary deviation. For each processed metal pipe fitting, its area difference is classified into the corresponding deviation level instead of directly dealing with the specific difference.

[0047] In another preferred embodiment of the present invention, in the processing module, when the number of the area differences with the tertiary deviation is greater than or equal to the preset safety number, it is determined that the corresponding pipe end forming device is an abnormal device and a report is made.

[0048] It is understandable that the equipment may malfunction during operation, resulting in the processed metal pipe fittings not meeting the preset standards. The third-level deviation indicates that a relatively large deviation has occurred in the processed automotive metal pipe fittings. If the third-level deviation appears frequently and the quantity continues to increase, it means that the deviation of the equipment is not a short-term fluctuation but a continuous one. Continuing to operate such equipment may lead to the appearance of a large number of unqualified products, increasing the rework cost or the product rejection rate. By reporting the 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 parameters specifically includes:

[0050] Calculate the average deviation value

[0051] Take the peak points and valley points of the target image within a single sub-domain as reference points, and also take the starting point and ending point of the target image within a single sub-domain as reference points. Calculate the change rate of the deviation value between adjacent reference points, and obtain the maximum value among them as the maximum change rate 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 carried out within a smaller range, thereby effectively reducing the resource consumption of a single calculation, enabling 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 pipe end of the automotive metal pipe fitting is acquired at a preset position.

[0055] It is worth noting that the preset position can ensure that each acquired image is at the same angle, distance, and lighting conditions. This makes each acquired pipe end image consistent, avoiding errors caused by different acquisition positions. The acquired consistent data is helpful for subsequent processing and analysis to determine whether there is an abnormality in the pipe 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 proportion b≥0.8 that the deviation value within a certain sub-domain is greater than that of the other pipe end forming equipment, mark the pipe end forming equipment G as the target equipment and give a prompt to the staff.

[0057] It should be noted that during the manufacturing process, manual operation errors (such as improper placement of raw materials, incorrect adjustment, etc.) may lead to significant deviations in the tube end forming of a certain batch or within a certain sub-domain, rather than being caused by abnormalities in the tube end forming equipment. At this time, prompt the workers to remind them to check for possible operation errors or process parameter setting problems, so as to avoid batch product quality problems caused by improper operation and ensure production consistency.

[0058] The above has described an embodiment of the present invention in detail, but the content described is only a preferred embodiment of the present invention and cannot be considered as limiting the scope of implementation of the present invention. All equivalent changes and improvements made according to the scope of the application of the present invention should still fall within the scope covered by the patent of the present invention.

Claims

1. A tube end forming control system for automotive metal pipe fitting processing, including tube end forming equipment, characterized in that, Including: Acquisition module: Obtain the processed automotive metal pipe fittings, collect the front image of the pipe end of the automotive 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: Obtain the deviation value C of the processed automotive metal pipe fittings within a preset acquisition period. The deviation value is determined based on the area difference corresponding to the processed automotive metal pipe fittings, and generate coordinate points (a, Ca), where Ca represents the deviation value of the a-th processed automotive metal pipe fitting within the acquisition period. Connect adjacent two coordinate points to obtain an initial image, and use the initial image within the preset standard domain [1, N] as the target image f(x), where N represents the minimum value of the total number of processed automotive metal pipe fittings by a single pipe end forming device within the acquisition period. Divide the standard domain into n sub-domains with the same length, where n is a preset quantity. Obtain judgment parameters based on the functional relationship F(x) of the target image within a single sub-domain. The judgment parameters include the average deviation value D and the maximum change rate D' of the deviation value. Judgment module: Calculate the judgment value η is a preset correction coefficient, and the abnormal ratio is statistically calculated. The abnormal ratio is the ratio of the deviation value in a single sub-domain being greater than the deviation values of the other pipe end forming devices. Calculate the mean value of the abnormal ratio. When the mean value is greater than or equal to the preset mean threshold, mark the corresponding pipe end forming device as an abnormal device and report it.

2. The tube end forming control system for processing automotive metal pipe fittings 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 automotive metal pipe fittings specifically includes: Set deviation levels, which include 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 first-level deviation, where ΔS' is a preset area deviation value. When the area difference ΔS' < ΔS < 1.5ΔS', the deviation level is second-level deviation. When the area difference 1.5ΔS' < ΔS, the deviation level is third-level deviation. When the deviation levels are 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 processing automotive metal pipe fittings according to claim 2, characterized in that, In the processing module, when the number of third-level deviation area differences is greater than or equal to a preset safety quantity, determine the corresponding pipe end forming device as an abnormal device and report it.

4. A tube end forming control system for processing automotive metal pipe fittings according to claim 1, characterized in that, In the processing module, the process of obtaining the judgment parameters specifically includes: Calculate the average deviation value Take the peak points and valley points of the target image within a single sub-domain as reference points, and take the starting point and ending point of the target image within a single sub-domain as reference points. Calculate the change rate of the deviation value between adjacent two reference points, and obtain the maximum value among them as the maximum change rate D' of the deviation value.

5. A tube end forming control system for processing automotive metal pipe fittings 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 pipe fitting processing according to claim 1, characterized in that, In the acquisition module, the front image of the pipe end of the automotive metal pipe fittings is collected at a preset position.

7. A tube end forming control system for processing automotive metal pipe fittings according to claim 1, characterized in that, In the described judgment module, when the pipe end forming device G is not an abnormal device and the proportion b of the deviation value in a certain sub-domain being greater than the deviation values of the other pipe end forming devices is ≥ 0.8, the pipe end forming device G is marked as the target device and a prompt is given to the staff.

Images