Irregular weld polishing speed regulation method, controller and polishing system

Abstract

This invention relates to a method, controller, and grinding system for adjusting the grinding speed of irregular welds. The method includes: acquiring a grinding target image of the workpiece; wherein the grinding target image includes the weld to be ground and a predetermined shape marker set on the workpiece; determining the area scaling ratio of the actual object in the grinding target image based on the shape and actual size of the predetermined shape marker; acquiring the height information of the weld; determining the volume of the weld based on the area scaling ratio and the height information; and setting the moving speed of the grinding device based on the volume. This invention can automatically adjust the moving speed of the grinding device in the grinding system according to the volume of the irregular weld, effectively improving the grinding efficiency and weld quality.

Description

Technical Field

[0001] This invention relates to the field of metal surfacing technology in nuclear power plants, and particularly to a method for adjusting the grinding speed of irregular welds, a controller, and a grinding system. Background Technology

[0002] Nuclear power plants have a large number of pipes and equipment connected by welding. After welding, the shape and size of the welds are uneven and may even be defective. In order to ensure that the sealing, integrity and reliability of the welds meet safety requirements, the welds need to be ground by grinding equipment to reduce the risk of stress concentration.

[0003] To improve work efficiency and safety, nuclear power plants currently typically use grinding systems or grinding robots to remotely grind welds. However, due to the uneven size and path distribution of welds, the required moving speed of the grinding device within the system varies. Inappropriate speed can easily lead to under-grinding or over-grinding, affecting weld quality. Currently, during weld grinding, workers need to remotely adjust the moving speed of the grinding device by visually assessing the actual weld condition through a camera. This method suffers from insufficient intelligence, poor efficiency, and the actual grinding effect is influenced by the worker's experience, posing a risk of human error and compromising nuclear power plant safety. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method, controller and grinding system for adjusting the grinding speed of irregular welds.

[0005] The technical solution adopted by this invention to solve its technical problem is: constructing a method for adjusting the grinding speed of irregular weld seams, comprising:

[0006] Acquire a grinding target image of the workpiece to be welded; wherein the grinding target image includes the weld seam to be ground and a predetermined shape marker set on the workpiece to be welded;

[0007] The area scaling ratio of the actual object in the polishing target image is determined based on the shape and actual size of the set shape calibrator.

[0008] Collect the height information of the weld;

[0009] The volume of the weld is determined based on the area expansion / contraction ratio and the height information;

[0010] The moving speed of the grinding device is set according to the volume.

[0011] Preferably, the step of setting the moving speed of the grinding device according to the volume includes:

[0012] The volume interval in which the volume is located is determined according to a preset set of volume intervals, and the velocity value corresponding to the volume interval is determined and recorded as the velocity to be set; wherein, the set of volume intervals includes multiple volume intervals and multiple velocity values ​​corresponding to each volume interval;

[0013] Set the moving speed of the grinding device to the desired speed.

[0014] Preferably, the plurality of volume intervals in the volume interval set includes: ( ), [ ), [ )as well as[ );in, < < .

[0015] Preferably, the The range is 0.8 mm. 3 Up to 1.2 mm 3 ; and / or

[0016] The The range is 5.5 mm. 3 Up to 6.5 mm 3 ; and / or

[0017] The The range is 8 mm 3 Up to 10 mm 3 .

[0018] Preferably, the plurality of velocity values ​​within the volume range include those related to ( ), [ ), [ )and[ The first speed value, the second speed value, the third speed value, and the fourth speed value are sequentially arranged from smallest to largest; wherein, the first speed value is the minimum moving speed of the polishing device, and the fourth speed value is the maximum moving speed of the polishing device.

[0019] Preferably, the shape marker is a square sheet structure.

[0020] Preferably, the step of determining the area scaling ratio of the actual object in the polishing target image based on the shape and actual size of the set shape calibrator includes:

[0021] Based on the shape of the set shape calibrator, the pixel region corresponding to the set shape calibrator is determined in the polishing target image;

[0022] Determine the pixel length and pixel width of the pixel region, and calculate the pixel area of ​​the pixel region;

[0023] The actual area of ​​the set shape calibration object is calculated based on its actual dimensions.

[0024] The area scaling ratio is obtained by calculating the quotient of the actual area divided by the pixel area.

[0025] Preferably, the height information includes multiple pixel heights corresponding to each pixel of the weld in the grinding target image;

[0026] In the step of determining the volume of the weld seam based on the area scaling ratio and the height information, the expression for the volume is:

[0027] ; Indicates the volume, This indicates the area scaling ratio. equal to 1 pixel 2 , This represents the pixel height of the pixel in the i-th row and j-th column of the weld in the target image being polished.

[0028] Preferably, the step of acquiring the polishing target image of the workpiece to be welded includes: capturing the polishing target image using a depth camera;

[0029] The step of acquiring the height information of the weld seam includes: acquiring the distance information between the welded object and the depth camera through the depth camera, and analyzing the distance information to obtain the height information.

[0030] The present invention also constructs a controller, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of the above-described irregular weld seam grinding speed adjustment method.

[0031] The present invention also constructs a polishing system, comprising:

[0032] Set shape markers for placement near the weld seam;

[0033] A depth camera is positioned directly opposite the set shape marker, used to simultaneously capture images of the set shape marker and the weld and output an image of the grinding target;

[0034] A supplementary light is used to provide illumination for the depth camera;

[0035] A grinding device for grinding the weld seam;

[0036] A moving mechanism for moving the grinding device; and

[0037] The controller described above.

[0038] The technical solution of this invention can automatically adjust the moving speed of the grinding device in the grinding system according to the volume of the irregular weld. This not only avoids insufficient or excessive grinding and improves the quality of the weld, but also helps to improve the efficiency and intelligent process of weld grinding, reduce the risk of human error, and play a positive role in saving human resources in nuclear power plants and improving the safety of nuclear power plants. Attached Figure Description

[0039] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the accompanying drawings:

[0040] Figure 1 This is a schematic diagram of the grinding system in related technologies;

[0041] Figure 2 This is a flowchart of the speed adjustment method for grinding irregular welds in some embodiments of the present invention;

[0042] Figure 3 This is a flowchart of step S5 in some embodiments of the present invention;

[0043] Figure 4 This is a circuit structure block diagram of the controller in some embodiments of the present invention;

[0044] Figure 5 This is a schematic diagram of a portion of the grinding system in some embodiments of the present invention;

[0045] Figure 6 yes Figure 5 Another structural diagram of the polishing system in the embodiment. Detailed Implementation

[0046] To provide a clearer understanding of the technical features, objectives, and effects of the present invention, specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0047] It should be noted that the flowcharts shown in the accompanying drawings are merely illustrative and do not necessarily include all content and operations / steps, nor do they necessarily have to be performed in the described order. For example, some operations / steps can be broken down, while others can be combined or partially combined; therefore, the actual execution order may change depending on the specific circumstances.

[0048] The block diagrams shown in the accompanying drawings are merely functional entities and do not necessarily correspond to physically independent entities. That is, these functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor devices and / or microcontroller devices.

[0049] It should be noted that, for ease of understanding, the working principle of the present invention will be explained below using the welded object as a pipe. It should be understood that the welded object can also be other metal objects, which are also within the scope of protection of the present invention.

[0050] The grinding system uses existing grinding equipment found in nuclear power plants, such as... Figure 1 As shown, the grinding system includes a grinding device 4 (i.e., a grinding wheel), a moving mechanism 5 for controlling the movement of the grinding device 4, and a controller (not shown) for controlling the operation of the grinding device 4 and the moving mechanism 5. The moving mechanism 5 may include a moving track or a robotic arm, which is mechanically connected to the grinding device 4 and can drive the grinding device to move. An electric track is preferred when welding pipes; please refer to [reference needed]. Figure 1 The electric track includes a circular track and a moving device mechanically connected to the grinding device 4 and capable of sliding on the circular track. The circular track can be fully or partially enclosed around the pipe 20. Figure 1 (Belonging to the full enclosure category), the moving device consists of a motor, which can drive the polishing device 4 to move circumferentially along the pipe 10 according to the control of the controller. For specific implementation schemes, please refer to the prior art, which will not be repeated here. Understandably, if the object to be polished is flat, an electric track can also be used, simply replacing the circular track with a straight track. For objects with irregular shapes to be polished, it is preferable to use an existing robotic arm to control the movement of the polishing device 4.

[0051] Figure 2 This is a flowchart illustrating the speed adjustment method for grinding irregular welds in some embodiments of the present invention. This method automatically adjusts the moving speed of the grinding device in the grinding system according to the volume of the irregular weld. Please refer to... Figure 2 The method for adjusting the grinding speed of irregular welds may include steps S1, S2, S3, S4 and S5.

[0052] Step S1 includes: acquiring a grinding target image of the workpiece; wherein the grinding target image includes the weld to be ground and a predefined shape marker set on the workpiece. In this step, the workpiece is provided with a predefined shape marker positioned near the weld, and the predefined shape marker is simultaneously captured in the grinding target image. That is, the grinding target image simultaneously includes part or all of the weld to be ground, as well as the full view of the predefined shape marker. Moreover, the shape and size of the predefined shape marker are predetermined and serve as a reference for determining the volume ratio of the weld in the grinding target image to the actual weld.

[0053] In some embodiments, an image of the polishing target can be captured by a camera (such as a depth camera). To ensure that the shape of the set shape marker in the polishing target image remains as consistent as possible with the shape of the set shape marker when viewed from above, the camera is preferably positioned directly opposite the view surface of the set shape marker, that is, the lens axis of the camera is perpendicular to the view surface of the set shape marker (i.e., the surface opposite to the pipe surface).

[0054] Furthermore, the preferred shape marker is a square sheet structure. Of course, the sheet structure can also be other shapes, such as ellipses. However, the advantage of using a square sheet structure is that the square shape is simple yet distinctive (uniform length and width), making it easy to identify. Additionally, the method for calculating the pixel area in subsequent steps is simple, which helps simplify the algorithm and save processor computing resources.

[0055] In some embodiments, the shape calibrator can be a square sheet structure with a side length of 10 mm.

[0056] To improve the accuracy of identifying the designated shape marker in the target image of the grinding process, the color of the top-viewed surface of the designated shape marker is preferably set to a color different from the color of the pipe surface and weld.

[0057] Step S2 includes: determining the area scaling ratio of the actual object in the polishing target image based on the shape and actual size of the set shape calibrator.

[0058] In some embodiments, the area scaling ratio can be determined by: determining the pixel region corresponding to the set shape calibrator in the polishing target image based on the shape of the set shape calibrator; determining the pixel length and pixel width of the pixel region, and calculating the pixel area of ​​the pixel region; calculating the actual area of ​​the set shape calibrator according to the actual size of the set shape calibrator; and calculating the quotient of the actual area divided by the pixel area to obtain the area scaling ratio.

[0059] In this embodiment, since the shape of the set shape marker is known, an area that matches the shape of the set shape marker can be extracted from the polishing target image using an existing algorithm (such as a trained square image recognition model) to obtain the pixel area; then, after determining the pixel length and pixel width of the pixel area, the product of the pixel length and pixel width can be calculated to obtain the pixel area.

[0060] Step S3 includes: acquiring the height information of the weld. The height information includes the pixel heights corresponding to each pixel of the weld in the target image being ground.

[0061] In some embodiments, the height information can be obtained by: a depth camera acquiring distance information between the object being welded and the depth camera, and analyzing the distance information to obtain the height information. In this embodiment, the depth camera has a ranging function, so it can acquire multiple pixel distances between each pixel in the grinding target image and the depth camera, thereby obtaining the distance information; considering that the set shape calibration object has a certain thickness, the set shape calibration object can be identified first using step S2, and pixel areas with similar or even identical shapes to the set shape calibration object can be extracted using existing algorithms to obtain the remaining image; for the remaining image, since the height of the weld is significantly higher than the height of the pipe body, the pixel point farthest from the depth camera can be regarded as the pixel corresponding to the pipe body, that is, the farthest pixel distance in the remaining image can be determined as the pipe pixel distance between the pipe and the depth camera. Then, the distance information of each pixel in the remaining image is subtracted from the pipe pixel distance to obtain the pixel height corresponding to each pixel in the remaining image, thus forming the height information. It should be noted that the pipe has a certain curvature, and the pipe surface is not actually flat. However, due to the limited field of view that the depth camera can capture and the large radius of the nuclear power plant pipe, the actual height variation of the pipe body in the polishing target image is small, and the curvature variation can be ignored. Therefore, the pipe surface in the polishing target image can be regarded as a plane. Of course, in order to obtain height information more accurately, the pipe pixel distance can also be compensated by combining the outer diameter of the pipe. For example, the staff can set a compensation value based on experience. Adding the compensation value to the pipe pixel distance (the compensation value decreases as the pipe diameter increases) can achieve compensation and reduce the error of the height information.

[0062] Step S4 includes: determining the volume of the weld based on the area expansion / contraction ratio and height information.

[0063] In some embodiments, the volume can be expressed as: ; Indicates volume, Indicates the area scaling ratio. equal to 1 pixel2 , This represents the pixel height of the i-th row and j-th column pixel in each pixel of the weld seam in the target image being polished.

[0064] Step S5 includes setting the moving speed of the grinding device according to the volume. In this step, the moving speed of the grinding device is set by sending a control command to the moving mechanism.

[0065] like Figure 3 As shown, in some embodiments, the moving speed of the polishing device can be set by performing steps S51 and S52.

[0066] Step S51 includes: determining the volume interval where the volume is located according to the preset volume interval set, determining the velocity value corresponding to the volume interval, and recording it as the velocity to be set; wherein, the volume interval set includes multiple volume intervals and multiple velocity values ​​corresponding to each volume interval.

[0067] In some embodiments, the plurality of volume ranges in the volume range set may include: ( ), [ ), [ )as well as[ ), < < .in, The range can be 0.8 mm. 3 Up to 1.2 mm 3 Preferably 1 mm 3 ; The range can be 5.5 mm. 3 Up to 6.5 mm 3 Preferably 6 mm 3 . The range can be 8 mm 3 Up to 10mm 3 Preferably 9 mm 3 .

[0068] Step S52 includes: setting the moving speed of the grinding device to a desired speed. The multiple speed values ​​within the volume range set may include those related to (…). ), [ ), [ )and[ The first speed value, the second speed value, the third speed value, and the fourth speed value are arranged sequentially from smallest to largest; where the first speed value is the minimum moving speed that the grinding device can be set to, and the fourth speed value is the maximum moving speed that the grinding device can be set to.

[0069] Understandably, the technical solution of the present invention can automatically adjust the moving speed of the grinding device in the grinding system according to the volume of the irregular weld, which can not only avoid insufficient or excessive grinding and improve the quality of the weld, but also help to improve the efficiency and intelligent process of weld grinding, reduce the risk of human error, and play a positive role in saving human resources in nuclear power plants and improving the safety of nuclear power plants.

[0070] Figure 4 This is a circuit structure block diagram of the controller in some embodiments of the present invention. The controller may include a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the steps of the irregular weld seam grinding speed adjustment method provided in the embodiments of the present invention.

[0071] The present invention also provides a polishing system, such as Figure 5 and Figure 6 As shown, the polishing system may include a shape calibration object 1, a depth camera 2, a fill light 3, a polishing device 4, a moving mechanism 5, and a controller 6 provided in this embodiment of the invention.

[0072] The shape marker 1 is used to be placed near the weld. The shape marker 1 can be placed directly on the pipe or fixed to the surface of the pipe by magnetic attraction, adhesive, or other means.

[0073] The depth camera 2 is positioned relative to the set shape calibration object 1 to simultaneously capture images of the set shape calibration object 1 and the weld 7 and output an image of the grinding target.

[0074] The fill light 3 is used to provide supplemental lighting for the depth camera 2 to improve the image quality of the polished target.

[0075] The grinding device 4 is used to grind the weld 7. Specifically, the grinding device 4 can be a grinding wheel machine.

[0076] The moving mechanism 5 is mechanically connected to the grinding device 4 and can move the grinding device 4 under the control of the controller 6.

[0077] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0078] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0079] The steps of the methods or algorithms described in conjunction with the embodiments disclosed herein can be implemented directly by hardware, a software module executed by a processor, or a combination of both. The software module can be located in random access memory (RAM), main memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disk, removable disk, CD-ROM, or any other form of storage medium known in the art.

[0080] It is understood that the above embodiments only illustrate preferred embodiments of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can freely combine the above technical features without departing from the concept of the present invention, and can also make several modifications and improvements, all of which fall within the protection scope of the present invention. Therefore, all equivalent transformations and modifications made with respect to the scope of the claims of the present invention should fall within the scope of the claims of the present invention.

Claims

1. A method for adjusting the grinding speed of irregular weld seams, characterized in that, include: Acquire a grinding target image of the workpiece to be welded; wherein the grinding target image includes the weld seam to be ground and a predetermined shape marker set on the workpiece to be welded; The area scaling ratio of the actual object in the polishing target image is determined based on the shape and actual size of the set shape calibrator. Collect the height information of the weld; The volume of the weld is determined based on the area expansion / contraction ratio and the height information; The moving speed of the grinding device is set according to the volume.

2. The method for adjusting the grinding speed of irregular welds according to claim 1, characterized in that, The step of setting the moving speed of the grinding device according to the volume includes: The volume interval in which the volume is located is determined according to a preset set of volume intervals, and the velocity value corresponding to the volume interval is determined and recorded as the velocity to be set; wherein, the set of volume intervals includes multiple volume intervals and multiple velocity values ​​corresponding to each volume interval; Set the moving speed of the grinding device to the desired speed.

3. The method for adjusting the grinding speed of irregular welds according to claim 2, characterized in that, The multiple volume ranges in the volume range set include: ( ), [ ), [ )as well as[ );in, < < .

4. The method for adjusting the grinding speed of irregular welds according to claim 3, characterized in that, The The range is 0.8mm. 3 Up to 1.2 mm 3 ; and / or The The range is 5.5 mm. 3 Up to 6.5 mm 3 ; and / or The The range is 8 mm 3 Up to 10 mm 3 .

5. The method for adjusting the grinding speed of irregular welds according to claim 3, characterized in that, The multiple velocity values ​​within the volume range include those related to ( ), [ ), [ )and[ The first speed value, the second speed value, the third speed value, and the fourth speed value are sequentially arranged from smallest to largest; wherein, the first speed value is the minimum moving speed of the polishing device, and the fourth speed value is the maximum moving speed of the polishing device.

6. The method for adjusting the grinding speed of irregular welds according to any one of claims 1 to 5, characterized in that, The defined shape marker is a square-shaped sheet structure.

7. The method for adjusting the grinding speed of irregular welds according to claim 6, characterized in that, The step of determining the area scaling ratio of the actual object in the polishing target image based on the shape and actual size of the set shape calibrator includes: Based on the shape of the set shape calibrator, the pixel region corresponding to the set shape calibrator is determined in the polishing target image; Determine the pixel length and pixel width of the pixel region, and calculate the pixel area of ​​the pixel region; The actual area of ​​the set shape calibration object is calculated based on its actual dimensions. The area scaling ratio is obtained by calculating the quotient of the actual area divided by the pixel area.

8. The method for adjusting the grinding speed of irregular welds according to claim 7, characterized in that, The height information includes multiple pixel heights corresponding to each pixel of the weld in the grinding target image; In the step of determining the volume of the weld seam based on the area scaling ratio and the height information, the expression for the volume is: ; Indicates the volume, This indicates the area scaling ratio. equal to 1 pixel 2 , This represents the pixel height of the pixel in the i-th row and j-th column of the weld in the target image being polished.

9. The method for adjusting the grinding speed of irregular welds according to claim 6, characterized in that, The step of acquiring the polishing target image of the workpiece to be welded includes: capturing the polishing target image using a depth camera; The step of acquiring the height information of the weld seam includes: acquiring the distance information between the welded object and the depth camera through the depth camera, and analyzing the distance information to obtain the height information.

10. A controller comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the steps of the irregular weld seam grinding speed adjustment method according to any one of claims 1 to 9.

11. A polishing system, characterized in that, include: Set shape markers for placement near the weld seam; A depth camera is positioned directly opposite the set shape marker, used to simultaneously capture images of the set shape marker and the weld and output an image of the grinding target; A supplementary light is used to provide illumination for the depth camera; A grinding device for grinding the weld seam; A moving mechanism for moving the grinding device; as well as The controller as described in claim 10.

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