Square rectangular welded pipe roll bending forming roll position online feedback adjusting system and using method

Abstract

The invention belongs to the technical field of welded pipe forming, and particularly relates to a square rectangular welded pipe roll bending forming roll position on-line feedback adjusting system and a using method of the square rectangular welded pipe roll bending forming roll position on-line feedback adjusting system. The roll bending unit comprises a plurality of roll bending forming assemblies which are arranged in sequence; the visual acquisition system comprises a plurality of visual acquisition units and a tilt angle sensor group, and the tilt angle sensor group comprises a plurality of tilt angle sensing units matched with the roll bending forming assemblies in number; the upper computer is in signal connection with the visual acquisition system, the roll bending unit and the tilt angle sensor group; the roll bending forming assembly is provided with a lower roll fixedly arranged and an upper roll vertically arranged in a lifting mode, the upper roll is in transmission connection with a roll position adjusting device, the roll position adjusting device is electrically connected with the upper computer, and the inclination angle sensing unit is connected to the upper portion of the upper roll. The invention further discloses a using method of the online feedback adjusting system. The system can improve the forming quality of the welded pipe, reduce the labor intensity and further improve the intelligent degree of roll bending forming of the welded pipe.

Description

Technical Field

[0001] This invention belongs to the field of welded pipe forming technology, and particularly relates to an online feedback adjustment system for the roller position of rectangular welded pipe roll bending forming and its usage method. Background Technology

[0002] In the roll bending process of rectangular welded pipes, in order to meet the needs of products with different specifications and sizes, the same roll bending production line often needs to frequently change production tasks. Whenever product specifications are changed, a key and tedious step is to precisely adjust the roll positions of each pass on the production line.

[0003] Currently, roller position adjustment mainly relies on manual operation. This process is highly experience-dependent and labor-intensive. Operators need to manually pre-adjust the roller position for each pass based on the specifications of the target pipe material, their personal experience, and their understanding of the equipment status. It is an extremely physically demanding and technically challenging task.

[0004] After the roller positions are pre-adjusted, multiple trial roller bends are usually required to verify the rationality of each roller position. Operators repeatedly thread the tape, stop the machine to measure the dimensions, and then adjust the roller positions based on the measurement results. This process is not only time-consuming and significantly reduces the effective utilization rate of the production line, but also inevitably produces defective tubes with unqualified dimensions, resulting in a waste of resources and manpower.

[0005] After the roller positions are properly adjusted, the welded pipe roll bending process begins. Roll bending is a multi-pass, continuous, and gradual process. If there is a slight deviation in the roller gap distance in a particular pass, this deviation will directly affect the sheet metal being formed, causing its cross-sectional shape and metal flow to deviate from the ideal state. This error will be transmitted and amplified as the sheet metal enters subsequent passes. Even if the roller positions in subsequent passes are precise, it is difficult to completely correct the cross-sectional shape deviation caused by the previous passes, ultimately affecting product quality.

[0006] In summary, existing roller position adjustment methods suffer from several drawbacks: strong reliance on experience, high labor intensity, significant modifications to existing roller bending units, high costs, and a lack of online feedback adjustment for roller position. To address these issues, there is an urgent need for an online feedback adjustment system for the roller position of rectangular welded pipe roller bending forming, along with its operational method. Summary of the Invention

[0007] The purpose of this invention is to provide an online feedback adjustment system and method for adjusting the roller position of rectangular welded pipe roll bending forming, in order to solve the above-mentioned problems.

[0008] To achieve the above object, the present invention provides the following solutions:

[0009] An online feedback adjustment system for the position of rectangular welded pipe bending forming rollers includes:

[0010] A profile support, wherein a base is provided below the profile support;

[0011] A roller bending unit is connected to the platform, and the roller bending unit includes several roller bending forming components arranged in sequence.

[0012] A vision acquisition system is connected below the profile support. The vision acquisition system includes several vision acquisition units. The number of vision acquisition units matches the number of the roll forming components. The vision acquisition units are located on one side of the discharge end of the roll forming components.

[0013] An inclination sensor group is connected to the roll bending unit, and the inclination sensor group includes a plurality of inclination sensing units in a number that matches the roll bending forming assembly.

[0014] The host computer is connected to the vision acquisition system, the roller bending unit, and the tilt sensor group via signals.

[0015] The roll bending forming assembly has a fixed lower roll and a vertically lifting upper roll. The upper roll is driven by a roll position adjustment device, which is electrically connected to the upper electromechanical unit. The tilt angle sensing unit is connected above the upper roll.

[0016] Optionally, the profile support includes support frames at both ends and a load-bearing crossbeam fixed between the two support frames, and a plurality of the vision acquisition units are fixed on the load-bearing crossbeam.

[0017] Optionally, the roll forming assembly includes:

[0018] Two symmetrically arranged archways, with a lower bearing box fixedly connected to the bottom of each archway, and the two ends of the lower rollers respectively rotatably connected to the corresponding lower bearing boxes;

[0019] The upper bearing box is vertically slidably disposed inside the archway via a sliding groove. The upper roller is axially connected to a roller shaft in the middle. The two ends of the roller shaft are rotatably connected to the corresponding upper bearing box. The roller position adjustment device is connected to the top of the two archways and is drivenly connected to the two upper bearing boxes.

[0020] Optionally, the roller position adjustment device includes two lifting parts, which are installed on the corresponding archway;

[0021] The lifting unit includes:

[0022] The archway cover is fixedly attached to the top of the archway;

[0023] An adjusting screw is vertically installed in the slide groove. The bottom end of the adjusting screw is rotatably engaged with the slide groove, and the top end of the adjusting screw passes through the archway cover. The archway cover is rotatably connected to the adjusting screw, and the adjusting screw is threadedly connected to the upper bearing box.

[0024] The driven bevel gear is shafted to the top of the adjusting screw;

[0025] The driving bevel gear meshes with the driven bevel gear;

[0026] The servo motor is fixed to the archway cover by servo motor fixing screws at its fixed end. The servo motor output shaft is connected to the drive bevel gear shaft. The servo motor is electrically connected to the host computer through a servo motor controller.

[0027] Optionally, the tilt sensing unit includes:

[0028] The tilt sensor base is fixed at both ends to the top of the corresponding upper bearing box via base fixing screws;

[0029] The tilt sensor is fixed to the middle of the tilt sensor base by tilt sensor fixing screws, and the tilt sensor is electrically connected to the host computer.

[0030] Optionally, the visual acquisition unit includes:

[0031] A line laser is fixedly mounted on the profile support, and the line laser is electrically connected to the upper electromechanical unit;

[0032] An industrial camera is fixedly mounted on the profile bracket, and the industrial camera is electrically connected to the host computer.

[0033] A method for using an online feedback adjustment system for the position of a rectangular welded pipe roll bending forming roller, comprising the following steps:

[0034] Step 1: According to the roller pattern, the operator sequentially adjusts the theoretical forming angle for each pass. The data is input to the host computer, which then processes it according to the theoretical forming angle for each pass. The height of the upper roll in the roll bending forming assembly for the corresponding pass is pre-adjusted by each of the roll position adjustment devices.

[0035] Step 2: Start the sheet material threading process and collect the actual forming contour curve and laser line contour point cloud data for each pass through several vision acquisition units of the vision acquisition system.

[0036] The host computer obtains a point cloud map based on the actual forming contour curve and the laser line contour point cloud reconstruction map for each pass, and calculates the actual forming angle based on the point cloud map. ;

[0037] Step 3: The host computer calculates the theoretical forming angle for each pass. and the actual forming angle The difference is obtained from the angle difference. ;

[0038] Based on the angle difference Obtain the roller position adjustment distance And adjust the distance according to the roller position. The corresponding upper roll position is adjusted using the roll position adjustment device;

[0039] Step 4: Repeat steps 2 and 3 until the angle difference is reached. The absolute value is less than or equal to the set threshold;

[0040] Step 5: Begin production and periodically record the angle difference. When the angle difference If the absolute value is greater than the set threshold, repeat step four until the angle difference is reached. The absolute value is less than or equal to the set threshold.

[0041] Optionally, the actual forming angle The steps to obtain it are as follows:

[0042] Fit the straight edge portion of the point cloud map and calculate the included angle between two straight edge portions.

[0043] Optionally, calculating the included angle includes the following steps:

[0044] Step 1: Set the fitting lines for the two straight-edge portions as follows: and A coordinate system is established with the top-left vertex of the point cloud as the origin, the horizontal direction to the right of the point cloud as the positive x-axis, and the vertical direction upward of the point cloud as the positive y-axis. The equations of the two fitted lines are obtained by fitting them using the least squares method:

[0045] ;

[0046] in, and These are the slopes of the two lines, respectively. and These are the intercepts, where the intercept is the point where the two fitted lines intersect at the y-axis, and x is... The x-coordinate and y-coordinate of any point on the graph are given by the graph. The y-coordinate of any point on the graph;

[0047] Step 2: The intersection point P(x) of the two fitted lines p ,y p This can be obtained by solving the following equation:

[0048] ;

[0049] The coordinates of the intersection point P obtained after solving are shown below:

[0050] ; ;

[0051] Step 3: Select the endpoints of each fitted line closest to the intersection point, and denote them as follows: and Two direction vectors are constructed. and Through formula The actual forming angle was calculated. .

[0052] Optionally, the roller position adjustment distance The acquisition process includes the following steps:

[0053] Step 1: During the roller position adjustment process, the host computer records the roller position adjustment amount d for each pass and the corresponding angle change monitored by the vision acquisition system. ;

[0054] Step 2: Calculate the roller position adjustment amount d and the corresponding angle change of the roller bending unit. The ratio of these two values ​​is denoted as k, where k is a constant.

[0055] ;

[0056] Step 3: Based on the actual forming angle From the perspective of theoretical formation Calculate the angle difference ;

[0057] ;

[0058] Step 4: Based on the angle difference The roller position adjustment distance is calculated. ;

[0059] ;

[0060] like The actual forming angle Greater than the theoretical forming angle ,at this time That is, the upper roller needs to be adjusted downwards; if The actual forming angle Smaller than the theoretical forming angle ,at this time That is, the upper roller needs to be adjusted upwards.

[0061] Compared with the prior art, the present invention has the following advantages and technical effects:

[0062] This invention uses a vision acquisition system to monitor the actual forming profile curve of each pass in real time, calculate the actual forming angle, and compare it with the forming angle of the theoretical profile curve of the corresponding pass in the roll pattern to calculate the difference. Based on the difference, a signal is sent to the servo motor controller to realize online feedback adjustment of the roll position. This invention requires minimal modification to the existing roll bending unit, solves the problem of waste pipe and wasted time during the sheet metal threading process, improves the forming quality of welded pipe, reduces labor intensity, and further enhances the intelligence level of welded pipe roll bending forming. Attached Figure Description

[0063] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly described below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0064] Figure 1 This is a schematic diagram of the online feedback adjustment system for the rectangular welded pipe bending forming roller position of the present invention.

[0065] Figure 2 This is a top view of the structure of the rectangular welded pipe roll bending forming roll position online feedback adjustment system of the present invention;

[0066] Figure 3 This is a schematic diagram of the roll bending forming assembly of the present invention;

[0067] Figure 4 This is a front view of the roll bending forming assembly structure of the present invention;

[0068] Figure 5 This is an exploded view of the roller position adjustment device of the present invention;

[0069] Figure 6 This is a flowchart illustrating the usage method of the online feedback adjustment system for the rectangular welded pipe roll bending forming roller of the present invention.

[0070] Among them, 100 is the host computer; 200 is the roller position adjustment device; 300 is the vision acquisition system; 301 is the line laser; 302 is the industrial camera; 400 is the profile support; 500 is the tilt sensor group; 600 is the roller bending unit; 700 is the servo motor controller; 601 is the forming pass; 602 is the flat roller inlet pass; 001 is the upper roller; 002 is the roller shaft; 003 is the tilt sensor base; 004 is the archway; 005 is the archway cover; 006 is the servo motor fixing screw; 007 is the servo motor; 008 is the adjusting screw; 009 is the tilt sensor fixing screw; 010 is the base fixing screw; 011 is the upper bearing box; 012 is the lower bearing box; 013 is the fixing bushing; 014 is the servo motor output shaft; 015 is the driving bevel gear; 016 is the driven bevel gear; 017 is the pressure ring; and 018 is the thrust ball bearing. Detailed Implementation

[0071] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. 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 making creative efforts are within the scope of protection of the present invention.

[0072] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0073] Reference Figures 1 to 6 This invention discloses an online feedback adjustment system for the position of rectangular welded pipe roll bending forming rollers, comprising:

[0074] Profile bracket 400, with a base underneath;

[0075] The roller bending unit 600 is connected to the base and includes several roller bending forming components arranged in sequence.

[0076] A vision acquisition system 300 is connected below the profile support 400. The vision acquisition system 300 includes several vision acquisition units. The number of vision acquisition units matches the number of roll forming components. The vision acquisition units are located on the discharge end side of the roll forming components.

[0077] Inclination sensor group 500 is connected to roll bending unit 600. Inclination sensor group 500 includes a number of inclination sensing units that match the number of roll bending forming components.

[0078] The host computer 100 is connected to the vision acquisition system 300, the roller bending unit 600, and the tilt sensor group 500 via signals.

[0079] The roll forming assembly has a fixed lower roll and a vertically lifting upper roll 001. The upper roll 001 is connected to a roll position adjustment device 200, which is electrically connected to the host computer 100. The tilt angle sensing unit is connected above the upper roll 001.

[0080] During use, the operator should adjust the theoretical forming angle for each pass according to the roller pattern. The data is input to the host computer 100, which then calculates the theoretical forming angle for each pass. The height of the upper roll 001 in the roll bending forming assembly for the corresponding pass is pre-adjusted by the roll position adjustment device 200; the sheet metal threading is started, and the angle difference is calculated by the upper computer 100 through the image information of several vision acquisition units of the vision acquisition system 300. The host computer 100 calculates the angle difference. Obtain the roller position adjustment distance And adjust the distance according to the roller position. Use the roller position adjustment device 200 to adjust the corresponding upper roller 001 to the appropriate position.

[0081] The roll bending unit 600 includes several roll bending forming components arranged in sequence. The roll bending forming component located at one end of the roll bending unit 600 serves as the flat roll inlet pass 602, and each of the remaining roll bending forming components serves as a forming pass 601, and they are arranged sequentially after the flat roll inlet pass 602.

[0082] This invention uses a 300-degree vision acquisition system to monitor the actual forming profile curve of each pass in real time, calculate the actual forming angle, and compare it with the forming angle of the theoretical profile curve of the corresponding pass in the roll pattern to calculate the difference. Based on the difference, a signal is sent to the servo motor controller to realize online feedback adjustment of the roll position. This invention requires minimal modification to the existing roll bending unit, solves the problem of waste pipe and wasted time during the sheet metal threading process, improves the forming quality of welded pipe, reduces labor intensity, and further enhances the intelligence level of welded pipe roll bending forming.

[0083] As an optional implementation, the profile bracket 400 includes support frames at both ends and a load-bearing crossbeam fixed between the two support frames, and a plurality of vision acquisition units are fixed on the load-bearing crossbeam.

[0084] As an optional implementation, the roll forming assembly includes:

[0085] Two symmetrical archways 004 are arranged. The bottom of the archway 004 is fixedly connected to a lower bearing box 012. The two ends of the lower roller are respectively rotatably connected to the corresponding lower bearing box 012.

[0086] The upper bearing box 011 is vertically slidably installed inside the archway 004 via a slide groove. The upper roller 001 is axially connected to the roller shaft 002 in the middle. The two ends of the roller shaft 002 are rotatably connected to the corresponding upper bearing box 011. The roller position adjustment device 200 is connected to the top of the two archways 004.

[0087] As an optional implementation, the roller position adjustment device 200 includes two lifting parts, which are mounted on the corresponding archway 004;

[0088] The lifting unit includes:

[0089] The archway cover 005 is fixed to the top of the archway 004;

[0090] Adjusting screw 008 is vertically set in the slide groove. The bottom end of adjusting screw 008 is rotatably engaged with the slide groove. The top end of adjusting screw 008 is set through the archway cover 005. The archway cover 005 is rotatably connected to adjusting screw 008. Adjusting screw 008 is threadedly connected to upper bearing box 011.

[0091] Driven bevel gear 016 is shaft-connected to the top of adjusting screw 008;

[0092] The driving bevel gear 015 meshes with the driven bevel gear 016;

[0093] Servo motor 007 is fixed to the archway cover 005 by servo motor fixing screw 006. Servo motor output shaft 014 of servo motor 007 is shaft-connected to drive bevel gear 015. Servo motor 007 is electrically connected to host computer 100 through servo motor controller 700.

[0094] As an optional implementation, the tilt sensing unit includes:

[0095] The tilt sensor base 003 is fixed at both ends to the top of the corresponding upper bearing box 011 by base fixing screws 010;

[0096] The tilt sensor is fixed to the middle of the tilt sensor base 003 by tilt sensor fixing screw 009, and the tilt sensor is electrically connected to the host computer 100.

[0097] As an optional implementation, the visual acquisition unit includes:

[0098] Line laser 301 is fixedly connected to profile bracket 400 and electrically connected to host computer 100.

[0099] Industrial camera 302 is fixedly attached to profile bracket 400 and electrically connected to host computer 100.

[0100] The present invention comprises a host computer 100, a roller position adjustment device 200, a vision acquisition system 300, a profile support 400, an inclination sensor group 500, a roller bending machine 600, and a servo motor controller 700.

[0101] The host computer 100 serves as the control center of the online feedback adjustment system for the roll position of the rectangular welded pipe. It establishes a communication link with the vision acquisition system 300 through a gigabit Ethernet interface to achieve real-time monitoring of the actual forming angle of the rectangular welded pipe. It also interacts with the tilt sensor group 500 and the servo motor controller 700 in real time through a physical interface to exchange sensor data and control commands, thereby achieving precise roll position adjustment.

[0102] The vision acquisition system 300 consists of independent vision acquisition units composed of several line lasers 301 and industrial cameras 302. Each vision acquisition unit is arranged along the bearing beam of the profile support 400 after each forming pass 601, and its number is equal to the number of forming passes 601.

[0103] Specifically, a communication link is established between the industrial camera 302 and the host computer 100 via a gigabit Ethernet interface.

[0104] Specifically, when traditional fixed-wavelength lasers are used to detect highly reflective metals such as stainless steel or dark oxide surfaces, they are prone to overexposure of stripes or collapse of the signal-to-noise ratio, resulting in failure of contour extraction. Therefore, a line laser 301 should be configured according to the spectral reflectance characteristics of the material.

[0105] Specifically, adjust the position of the load-bearing beam of the profile bracket 400 to ensure that the field of view of the industrial camera 302 installed on the beam completely covers the outline of the sheet metal.

[0106] The roll bending unit 600 consists of a flat roll guide pass 602 equipped with a roll position adjustment device 200 and sequentially arranged forming passes 601. Specifically, the roll position adjustment device 200 is installed at the top of the archway cover 005 and consists of a servo motor 007, an orthogonally meshed drive bevel gear 015, and a driven bevel gear 016. The output shaft 014 of the servo motor drives the drive bevel gear 015 to rotate, which in turn drives the driven bevel gear 016 through a 90° orthogonal transmission. The driven bevel gear 016 has an internal thread machined in its center, forming a precision thread pair with the vertically installed adjusting screw 008. When the driven bevel gear 016 rotates, it generates relative rotation through the threaded engagement with the adjusting screw 008, converting the horizontal rotational motion into the vertical displacement of the adjusting screw 008. This drives the upper bearing boxes 011 on both sides of the upper roll 001 to rise and fall synchronously within the guide groove of the archway 004, achieving precise roll position adjustment.

[0107] Specifically, the outer surface of the hub of the driven bevel gear 016 and the inner hole of the pressure ring 017 are both machined with mating threads. The two are screwed together to form a threaded pair, realizing the axial locking and fixation of the driven bevel gear 016 and the thrust ball bearing 018. At the same time, the driving bevel gear 015 is rigidly connected to the output shaft 014 of the servo motor through the fixed bushing 013.

[0108] Specifically, each of the two archway pressure caps 005 of the 600 roller bending unit is equipped with a set of roller position adjustment devices 200 at the top of each pass.

[0109] Specifically, the two servo motors 007 in each pass are connected to the same servo motor controller 700, and communicate with the servo motor controller 700 through the host computer 100 to control the roller position adjustment.

[0110] The tilt sensor group 500 is centered and fastened to the central axis of the tilt sensor base 003 by the tilt sensor fixing screw 009, ensuring that the measurement reference coincides with the symmetry plane of the roller system.

[0111] Specifically, the tilt sensor base 003 is fastened to the top of the two upper bearing boxes 011 on the same side of each pass by the base fixing screw 010.

[0112] A method for using an online feedback adjustment system for the position of a rectangular welded pipe roll bending forming roller, comprising the following steps:

[0113] Step 1: According to the roller pattern, the operator sequentially adjusts the theoretical forming angle for each pass. The data is input to the host computer 100, which then calculates the theoretical forming angle for each pass. The height of the upper roll 001 in the roll bending forming assembly for the corresponding pass is pre-adjusted by the roll position adjustment device 200.

[0114] Step 2: Start the sheet material threading process and collect the actual forming contour curve and laser line contour point cloud data for each pass through several vision acquisition units of the vision acquisition system 300.

[0115] The host computer 100 obtains a point cloud map based on the actual forming contour curve and laser line contour point cloud reconstruction map for each pass, and calculates the actual forming angle based on the point cloud map. ;

[0116] Step 3: The host computer calculates the theoretical forming angle for each pass. and actual forming angle The difference is obtained from the angle difference. ;

[0117] Based on the angle difference Obtain the roller position adjustment distance And adjust the distance according to the roller position. Use the roller position adjustment device 200 to adjust the position of the corresponding upper roller 001;

[0118] Step 4: Repeat steps 2 and 3 until the angle difference is reached. The absolute value is less than or equal to the set threshold;

[0119] Step 5: Begin production and periodically record the angle difference. When the angle difference If the absolute value is greater than the set threshold, repeat step four until the angle difference is greater than the threshold value. The absolute value is less than or equal to the set threshold.

[0120] See Figure 6 Please refer to the following steps for details:

[0121] S1. The operator starts the host computer 100, industrial camera 302 and line laser 301 in sequence to ensure that the industrial camera 302 and the host computer 100 are successfully connected.

[0122] S2. The operator inputs the forming angle of the theoretical contour curve for each pass in the roller pattern into the host computer 100.

[0123] Specifically, according to the roll pattern, the theoretical profile curve of the rectangular welded pipe has several bends in each pass. The operator sequentially assigns the theoretical forming angles corresponding to all the bends. Input into host computer 100;

[0124] S3. Start the sheet material threading process. The host computer 100 displays in real time the actual forming contour curve of each pass monitored by the industrial camera 302 and the laser line contour point cloud reconstruction map after image processing.

[0125] Specifically, the laser line is first separated from the background by color thresholding, then the image is denoised, then the segmented image is skeletonized to compress the laser line into a center line with a width of one pixel, and finally the laser line contour point cloud reconstruction image is obtained by extracting continuous pixels on the skeleton line.

[0126] S4. The host computer 100 calculates the actual forming angle for each pass based on the laser point cloud data after image processing.

[0127] S5, The host computer 100 calculates the roller adjustment distance based on the difference between the theoretical forming angle and the actual forming angle. This then sends a signal to the servo motor controller 700, controlling the roller position adjustment device 200 to start working.

[0128] S6. During the roller position adjustment process, the host computer 100 receives in real time the tilt angle value monitored by the tilt angle sensor group 500 installed in the middle of the upper bearing housing 011 on both the left and right sides, and dynamically compensates the roller position adjustment distance accordingly. .

[0129] S7. Repeat steps S3-S6 until the absolute value of the angle difference is less than or equal to the set threshold, then lock the current roller position and complete the online feedback adjustment of the sheet material threading roller position.

[0130] S8. After the sheet metal is threaded, continuous production of rectangular welded pipes begins, with the forming angle of the actual contour curve monitored in real time during the forming process.

[0131] S9. By comparing the calculation with the theoretical value, if the absolute value of the difference is greater than the set threshold, repeat S5-S6 until the absolute value of the difference is less than or equal to the set threshold, complete the online feedback adjustment of the roller position during the forming process, and generate the process deviation log for this batch.

[0132] As an optional implementation method, the actual forming angle The steps to obtain it are as follows:

[0133] Fit the straight edge portion of the point cloud image and calculate the angle between two straight edge portions.

[0134] As an optional implementation, calculating the included angle includes the following steps:

[0135] Step 1: Define the fitted lines for the two straight sides as follows: and A coordinate system is established with the top-left vertex of the point cloud as the origin, the horizontal direction to the right of the point cloud as the positive x-axis, and the vertical direction upward of the point cloud as the positive y-axis. The equations of the two fitted lines are obtained by fitting them using the least squares method:

[0136] ;

[0137] in, and These are the slopes of the two lines, respectively. and These are the intercepts, which are the points where the two fitted lines intersect at the y-axis, and x is... The x-coordinate and y-coordinate of any point on the graph are given by the graph. The y-coordinate of any point on the graph;

[0138] Step 2: The intersection point P(x) of the two fitted lines p ,y p This can be obtained by solving the following equation:

[0139] ;

[0140] The coordinates of the intersection point P obtained after solving are shown below:

[0141] ; ;

[0142] Step 3: Select the endpoints of each fitted line closest to the intersection point, and denote them as follows: and Two direction vectors are constructed. and Through formula The actual forming angle is calculated. .

[0143] As an optional implementation method, the roller position adjustment distance The acquisition process includes the following steps:

[0144] Step 1: During the roller position adjustment process, the host computer 100 records the roller position adjustment amount d for each pass and the corresponding angle change amount monitored by the vision acquisition system 300.

[0145] Step 2: Calculate the roller position adjustment amount d and the corresponding angle change of the roller bending unit. The ratio of these two values ​​is denoted as k, where k is a constant.

[0146] ;

[0147] Step 3: Based on the actual forming angle From the perspective of theoretical formation Calculate the angle difference ;

[0148] ;

[0149] Step 4: Based on the angle difference The roller position adjustment distance was calculated. ;

[0150] ;

[0151] like The actual forming angle Greater than the theoretical forming angle ,at this time That is, the upper roller 001 needs to be adjusted downwards; if The actual forming angle Smaller than the theoretical forming angle ,at this time This means that the upper roller 001 needs to be adjusted upwards.

[0152] As an additional implementation method, during the roll position adjustment process, in order to offset the influence of roll frame deformation error and roll position adjustment device 200 assembly error on the roll position adjustment accuracy and ensure the levelness of the upper roll 001, the host computer 100 receives the tilt angle value monitored by the tilt angle sensor group 500 in real time, and dynamically compensates the adjustment distance of each roll position adjustment device 200 accordingly.

[0153] As an additional implementation method, when the host computer 100 detects the angle difference... The absolute value is less than or equal to the set threshold. At this time, the host computer 100 sends a signal to the servo motor controller 700 to lock the position of the current servo motor output shaft 014, thereby locking the current roller position.

[0154] As an additional implementation method, during the continuous production of rectangular welded pipes, S4 is executed cyclically, and the host computer 100 monitors the actual forming angle in real time. .

[0155] As an additional implementation method, in the continuous production of rectangular welded pipes, the forming speed is denoted as... When the host computer 100 detects the angle difference of a certain pass... The absolute value is greater than the set threshold. At that time, the host computer 100 records the sequence number of the pass, sends a signal to the servo motor controller 700 to start roller position adjustment, and starts timing from the moment a defective forming angle is detected until the angle difference reaches the specified value. The absolute value is less than or equal to the set threshold. Stop timing and lock the current roller position. The time length is denoted as t. According to the formula... Calculate the forming length l of the rectangular welded pipe when the roller position is adjusted during the forming process, and record the sequence number and forming length l in the process deviation log of the host computer 100 to facilitate quality traceability and reverse analysis of process parameters.

[0156] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0157] The embodiments described above are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by persons skilled in the art should fall within the scope of protection defined by the claims of the present invention.

Claims

1. A system for online feedback adjustment of the roller position in the bending and forming of rectangular welded pipes, characterized in that, include: A profile bracket (400) is provided with a base underneath the profile bracket (400); A roll bending unit (600) is connected to the platform, and the roll bending unit (600) includes a plurality of roll bending forming components arranged in sequence. A vision acquisition system (300) is connected below the profile support (400). The vision acquisition system (300) includes a plurality of vision acquisition units. The number of vision acquisition units matches the number of the roll forming components. The vision acquisition units are located on one side of the discharge end of the roll forming components. An inclination sensor group (500) is connected to the roll bending unit (600), and the inclination sensor group (500) includes a plurality of inclination sensing units in a number matching the roll bending forming assembly. The host computer (100) is connected to the vision acquisition system (300), the roller bending unit (600) and the tilt sensor group (500) by signal connection; The roll forming assembly has a fixed lower roll and a vertically lifting upper roll (001). The upper roll (001) is connected to a roll position adjustment device (200), which is electrically connected to the host computer (100). The tilt angle sensing unit is connected above the upper roll (001).

2. The online feedback adjustment system for the roll position of a rectangular welded pipe bending forming roller according to claim 1, characterized in that: The profile support (400) includes support frames at both ends and a load-bearing beam fixed between the two support frames, and a plurality of vision acquisition units are fixed on the load-bearing beam.

3. The online feedback adjustment system for the roll position of a rectangular welded pipe bending forming roller according to claim 1, characterized in that, The roll forming assembly includes: Two symmetrically arranged archways (004) are provided, with a lower bearing box (012) fixedly connected to the bottom of each archway (004), and the two ends of the lower roller are rotatably connected to the corresponding lower bearing box (012). The upper bearing box (011) is vertically slidably disposed inside the archway (004) via a sliding groove. The upper roller (001) is axially connected to a roller shaft (002) in the middle. The two ends of the roller shaft (002) are respectively rotatably connected to the corresponding upper bearing box (011). The roller position adjustment device (200) is connected to the top of the two archways (004) and is drively connected to the two upper bearing boxes (011).

4. The online feedback adjustment system for the roll position of a rectangular welded pipe bending forming roller according to claim 3, characterized in that: The roller position adjustment device (200) includes two lifting parts, which are installed on the corresponding archway (004); The lifting unit includes: The archway cover (005) is fixed to the top of the archway (004); An adjusting screw (008) is vertically installed in the slide groove. The bottom end of the adjusting screw (008) is rotatably engaged with the slide groove. The top end of the adjusting screw (008) passes through the archway cover (005). The archway cover (005) is rotatably connected to the adjusting screw (008). The adjusting screw (008) is threadedly connected to the upper bearing box (011). Driven bevel gear (016) is axially connected to the top of the adjusting screw (008); The driving bevel gear (015) meshes with the driven bevel gear (016); The servo motor (007) is fixed to the archway cover (005) by a servo motor fixing screw (006). The servo motor output shaft (014) of the servo motor (007) is axially connected to the active bevel gear (015). The servo motor (007) is electrically connected to the host computer (100) through a servo motor controller (700).

5. The online feedback adjustment system for the roll position of a rectangular welded pipe bending forming roller according to claim 3, characterized in that, The tilt sensing unit includes: The tilt sensor base (003) is fixed at both ends to the top of the corresponding upper bearing box (011) by base fixing screws (010); The tilt sensor is fixed in the middle of the tilt sensor base (003) by tilt sensor fixing screw (009), and the tilt sensor is electrically connected to the host computer (100).

6. The online feedback adjustment system for the roll position of a rectangular welded pipe bending forming roller according to claim 1, characterized in that, The visual acquisition unit includes: A line laser (301) is fixedly connected to the profile bracket (400), and the line laser (301) is electrically connected to the host computer (100); An industrial camera (302) is fixedly mounted on the profile bracket (400), and the industrial camera (302) is electrically connected to the host computer (100).

7. A method of using an online feedback adjustment system for the position of a rectangular welded pipe roll bending forming roller, comprising using the online feedback adjustment system for the position of a rectangular welded pipe roll bending forming roller as described in any one of claims 1-6, characterized in that... Includes the following steps: Step 1: According to the roller pattern, the operator sequentially adjusts the theoretical forming angle for each pass. The data is input to the host computer (100), which then calculates the theoretical forming angle for each pass. The height of the upper roll (001) in the roll bending forming assembly for the corresponding pass is pre-adjusted by each of the roll position adjustment devices (200); Step 2: Start the sheet material threading process and collect the actual forming contour curve and laser line contour point cloud data for each pass through several vision acquisition units of the vision acquisition system (300). The host computer (100) obtains a point cloud map based on the actual forming contour curve and the laser line contour point cloud reconstruction map for each pass, and calculates the actual forming angle based on the point cloud map. ; Step 3: The host computer (100) calculates the theoretical forming angle for each pass. and the actual forming angle The difference is obtained from the angle difference. ; Based on the angle difference Obtain the roller position adjustment distance And adjust the distance according to the roller position. The roller position adjustment device (200) is used to adjust the position of the corresponding upper roller (001); Step 4: Repeat steps 2 and 3 until the angle difference is reached. The absolute value is less than or equal to the set threshold; Step 5: Begin production and periodically record the angle difference. When the angle difference If the absolute value is greater than the set threshold, repeat step four until the angle difference is reached. The absolute value is less than or equal to the set threshold.

8. The method of using the online feedback adjustment system for the roll position of a rectangular welded pipe bending forming roller according to claim 7, characterized in that, The actual forming angle The steps to obtain it are as follows: Fit the straight edge portion of the point cloud map and calculate the included angle between two straight edge portions.

9. The method of using the online feedback adjustment system for the roll position of a rectangular welded pipe bending forming system according to claim 8, characterized in that, Calculating the included angle includes the following steps: Step 1: Set the fitting lines for the two straight-edge portions as follows: and A coordinate system is established with the top-left vertex of the point cloud as the origin, the horizontal direction to the right of the point cloud as the positive x-axis, and the vertical direction upward of the point cloud as the positive y-axis. The equations of the two fitted lines are obtained by fitting them using the least squares method: ； in, and These are the slopes of the two lines, respectively. and These are the intercepts, where the intercept is the point where the two fitted lines intersect at the y-axis, and x is... The x-coordinate and y-coordinate of any point on the graph are given by the graph. The y-coordinate of any point on the graph; Step 2: The intersection point P(x) of the two fitted lines p ,y p This can be obtained by solving the following equation: ； The coordinates of the intersection point P obtained after solving are shown below: ； ； Step 3: Select the endpoints of each fitted line closest to the intersection point, and denote them as follows: and Two direction vectors are constructed. and Through formula The actual forming angle was calculated. .

10. The method of using the online feedback adjustment system for the roll position of a rectangular welded pipe bending forming system according to claim 9, characterized in that, The roller position adjustment distance The acquisition process includes the following steps: Step 1: During the roller position adjustment process, the host computer (100) records the roller position adjustment amount d for each pass and the corresponding angle change monitored by the vision acquisition system (300). ; Step 2: Calculate the roller position adjustment amount d and the corresponding angle change of the roller bending unit. The ratio of these two values ​​is denoted as k, where k is a constant. ； Step 3: Based on the actual forming angle From the perspective of theoretical formation Calculate the angle difference ; ； Step 4: Based on the angle difference The roller position adjustment distance is calculated. ; ； like The actual forming angle Greater than the theoretical forming angle ,at this time That is, the upper roller (001) needs to be adjusted downwards; if The actual forming angle Smaller than the theoretical forming angle ,at this time That is, the upper roller (001) needs to be adjusted upward.

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