Intelligent heat setting equipment for pipes and control method of intelligent heat setting equipment

Abstract

The invention relates to the technical field of automatic heat setting of medical polymer pipes, in particular to intelligent heat setting equipment for pipes and a control method of the intelligent heat setting equipment. The material transfer unit is provided with a shaping mold plate and a guide rail, a shaping mold is provided with a shaping cavity, and the guide rail drives the shaping mold plate to linearly move between the heating unit and the cooling unit; the heating unit is provided with a heating module for performing non-contact heating on the workpiece and a heating monitoring module for performing heating temperature monitoring and visual image monitoring on the workpiece; the cooling unit is provided with a cooling module and a cooling monitoring module and is used for cooling the workpiece, cooling temperature monitoring and visual image monitoring; and the program control unit is used for collecting and analyzing the material transfer signal and the temperature signal and generating a feedback control signal for processing control. The device has the effects that the temperature monitoring accuracy in the product heating process is improved, and the quality of pipe products of the same batch has good consistency.

Description

Technical Field

[0001] This application relates to the field of automatic heat setting technology for medical polymer tubing, and in particular to an intelligent heat setting device for tubing and its control method. Background Technology

[0002] In the field of medical polymer consumables, there is a large demand for consumable products in clinical practice. For example, some common tubular consumable products such as ureteral stents and pigtail catheters require shaping at both ends and special shaping of the tube body.

[0003] In related technologies, common heat setting of polymer consumables often uses hot air circulating ovens with metal mandrels or direct contact between heating plates and setting molds. By pre-setting process parameters such as temperature and time, only the temperature inside the oven or heating plate is monitored during production, ignoring the heat conduction process the product must undergo to reach the preset temperature. This results in uncontrolled heating time parameters. Such equipment typically has only one heating coil or one hot air device, heating the area within its coverage area at the set temperature, while other areas are heated at lower temperatures without monitoring. This leads to uneven temperature distribution in different locations within the setting mold or oven, making it difficult to guarantee the consistency of appearance and dimensions in the same batch of heat-set products. After setting, the products are manually removed and their appearance quality and dimensions are manually inspected, which is inefficient. Issues such as creases or dimensional deviations cannot be detected in time, posing a risk of missed inspections.

[0004] Regarding the aforementioned technologies, traditional equipment can only control the heating temperature inside the oven cavity or the heating plate, without monitoring the heating temperature and heating time at the product shaping position. It also cannot solve the problem of temperature differences between different positions inside the cavity or different positions on the heating plate, resulting in large quality differences among products in the same batch. Improvements are still needed. Summary of the Invention

[0005] In order to improve the accuracy of temperature monitoring during the product heating process and to ensure better consistency in the quality of pipe products in the same batch, this application provides an intelligent heat setting device for pipes and its control method.

[0006] Firstly, this application provides an intelligent heat-setting device for pipes: A smart heat-setting device for pipes, comprising: The rack unit is equipped with mounting brackets to provide a foundation for the mounting structure; The material transfer unit is equipped with a shaping mold plate and a guide rail. The shaping mold has a shaping cavity. The guide rail is fixedly connected to the frame unit and is used to drive the shaping mold plate to move linearly between the heating unit and the cooling unit. The heating unit is equipped with a heating module and a heating monitoring module. The heating module is used for non-contact heating of the workpiece to be heated, and the heating monitoring module is used for monitoring the heating temperature and visual image of the workpiece. The cooling unit is equipped with a cooling module and a cooling monitoring module. The cooling module is used to cool the workpiece after heating, and the cooling monitoring module monitors the cooling temperature and visual images of the workpiece. The program control unit is equipped with a material control system, an image processing system, and a temperature control system. It collects and analyzes material transmission signals and temperature signals, and generates feedback control signals to control the heating unit, material transmission unit, and cooling unit.

[0007] Optionally, the heating module includes a heating plate and an insulation plate. The heating plates are arranged in a vertically opposite manner, and each heating plate is provided with an array of multiple non-contact heaters. The heating power of each non-contact heater can be controlled independently. The heating monitoring module includes a heating temperature sensor and a heating monitoring camera. The temperature monitoring range of the heating temperature sensor, the imaging range of the heating monitoring camera, and the heating range of the heating module cover the area of ​​the shaping mold plate.

[0008] Optionally, the cooling module is configured as a clamping plate cooling method to perform clamping contact cooling on the workpiece. It is equipped with cooling plates arranged vertically opposite each other, a refrigeration unit, connecting pipes and an insulation plate. The upper cooling plate is connected to the frame by a cylinder and can be controlled to press down to clamp the shaping plate between the two cooling plates. There is a flow channel in the middle of the cooling plate for coolant to flow. The end of the flow channel is provided with an inlet and an outlet for coolant, both of which are connected to the refrigeration unit through connecting pipes. The cooling monitoring module is integrated into the cooling plate and includes a cooling temperature sensor and a cooling monitoring camera whose temperature monitoring range and camera range both cover the area of ​​the shaping mold plate.

[0009] Secondly, this application provides a control method for an intelligent heat-setting device for pipes, employing the following technical solution: A control method for an intelligent heat-setting device for pipes includes: The material transfer step is equipped with a material timing positioning strategy, which is used by the program control unit to send displacement control signals to the material transfer unit, driving the shaping mold plate loaded with the pipe workpiece to be shaped to move linearly along the guide rail to the preset heating position of the heating unit, and simultaneously triggering the heating monitoring module to enter the working preparation state, so as to achieve precise alignment between the material and the heating position. The heating adjustment step is equipped with a heating parameter adaptation strategy, which is used by the program control unit to preset the heating power threshold and target heating temperature range according to the material characteristics of the pipe to be shaped, and control multiple non-contact heaters of the heating module to adjust the heating power individually to perform non-contact heating of the pipe to be shaped. The cooling adjustment step is equipped with a cooling parameter adaptation strategy. After the heating process meets the preset requirements, the program control unit drives the shaping mold plate to move to the preset cooling position of the cooling unit through the material control system. At the same time, it controls the cylinder of the cooling module to drive the upper cooling plate to press down and clamp the shaping mold plate between the upper and lower cooling plates. The finalization evaluation step is equipped with a finalization quality analysis strategy. The program control unit integrates temperature data and visual image data from the heating and cooling processes. The image processing system analyzes the finalization dimensional accuracy and appearance integrity of the pipe. Combined with the temperature control system, it verifies whether the temperature curve matches the preset process curve to determine whether the finalization effect of the pipe meets the qualified index threshold.

[0010] Optionally, the heating adjustment step further includes: The heating monitoring module collects real-time heating temperature signals and visual images of the heating status of the pipe, which are then transmitted to the temperature control system and image processing system for analysis. This process determines whether the real-time heating temperature is within the target heating temperature range and whether there are any heating abnormalities on the appearance of the pipe. If not, the heating power of the corresponding heater is dynamically adjusted.

[0011] Optionally, the cooling regulation step further includes: The coolant is delivered to the cooling plate channel by the refrigeration unit. The real-time cooling temperature signal and visual image signal of the cooling status of the pipe are collected by the cooling monitoring module and transmitted to the temperature control system and image processing system for analysis. The system determines whether the real-time cooling temperature meets the target cooling temperature requirements and whether there is cooling deformation of the pipe. If not, the coolant temperature or coolant flow rate of the refrigeration unit is adjusted.

[0012] Optionally, the type approval evaluation step further includes: Based on the comparison and analysis of the qualified index thresholds, if they are met, a finalization completion signal is generated, which drives the material transfer unit to output the finished product. If the parameters do not meet the requirements, the non-compliant parameters and corresponding adjustment schemes will be stored in the process database of the program control unit, and the preset values ​​such as heating power threshold and cooling parameters for subsequent similar pipe materials will be updated.

[0013] Optional, also includes: The real-time data acquisition step is configured with a partitioned acquisition strategy, which connects the temperature sensor and camera embedded in the device through the real-time data acquisition module. The temperature sensor is arranged in a matrix to collect real-time temperature data of each corresponding partition on the shaping mold plate. The camera collects real-time image data of the pipe and transmits it synchronously to the signal analysis module. The signal comprehensive analysis step is configured with a multi-dimensional analysis strategy, which is used by the signal analysis module to receive real-time temperature data and image data, calculate the instantaneous deviation between the real-time temperature of each zone and the set temperature of the target temperature curve; based on image data conversion and algorithm processing, calculate the actual physical dimensions and dimensional deviations of the pipe, and locate the location of pipe defects and classify defect types through defect detection algorithms; The power dynamic control step is equipped with a dual-parameter coupling control strategy, which is used by the temperature control system to retrieve the instantaneous temperature deviation and size deviation output by the signal analysis module, calculate the basic temperature adjustment power and size compensation power respectively through preset formulas, and superimpose them to obtain the final heating power, control the output power of the heating module, and limit the power output range.

[0014] Optionally, in the signal synthesis and analysis step: The instantaneous temperature deviation is expressed by the formula Calculation, where Let be the instantaneous temperature deviation of the i-th partition at time t. Set the temperature at time t in the target temperature curve. Let t be the measured temperature of the i-th partition at time t.

[0015] Optionally, in the power dynamic control step: the base temperature regulation power is calculated using the first formula: ; The size compensation power is calculated using the second formula. ; The final heating power is calculated using the third formula. ; in, Let be the power adjustment amount of the heater in the i-th zone at time t. This is the proportional gain coefficient. This is the integral gain coefficient. The differential gain coefficient, For size-compensated power, This is the dimensional deviation weighting coefficient.

[0016] In summary, this application includes at least one of the following beneficial technical effects: 1. Significantly improves product quality consistency. Through zoned intelligent temperature control, combined with real-time monitoring of product quality using camera images, the size and appearance of each product are precisely controlled within the threshold range. 2. For non-conforming products that exceed the acceptance threshold, the images captured by the camera are analyzed and monitored in real time, and the products are identified and marked during the process. After the process is completed, the production workers directly remove the non-conforming products according to the positions indicated by the machine, saving the cost of manual inspection. The machine performs 100% inspection, which greatly reduces the risk of non-conforming products flowing into the next process compared to manual inspection. 3. Without changing the product materials and structure, through precise process control and real-time cyclical feedback of process parameters and product status monitoring, the process parameters are made infinitely close to the glass transition temperature, achieving a shaping effect close to the mechanical limits of existing materials. 4. For products with different structural or material requirements for different shaping parameters, one-time shaping can be achieved. By heating in zones, the heating parameters of each part can be precisely controlled, which is beneficial to adjusting the overall mechanical properties of the product. Furthermore, multiple processes are combined into one step, improving production efficiency and avoiding adverse effects on other materials of the product caused by multiple shaping processes. The status and parameters of each product during the production process are recorded, achieving one-to-one traceability, which is beneficial to the product process optimization and risk analysis process. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the intelligent heat-setting equipment for pipes in this application.

[0018] Figure 2 This is a schematic diagram of the left-side structure of the intelligent heat-setting equipment for pipes in this application.

[0019] Figure 3 This is a schematic diagram of the cooling unit structure in this application.

[0020] Figure 4 This is a schematic diagram of the configuration of the sensors in the heater and heating unit in this application.

[0021] Figure 5 This is a schematic diagram of the cooling plate flow channel and the configuration of each sensor in the cooling unit in this application.

[0022] Figure 6 This is a logic diagram of the control method for the intelligent heat-setting equipment for pipes in this application.

[0023] Figure 7 This is a schematic diagram of the analysis logic of the signal analysis module in this application.

[0024] Figure 8 This is a schematic diagram of the module connections of the defect detection algorithm in this application.

[0025] Explanation of reference numerals in the attached figures: 1. Frame unit; 2. Material transfer unit; 21. Shaping mold plate; 211. Cavity; 22. Guide rail; 3. Heating unit; 31. Heating module; 311. Heating plate; 3111. Non-contact heater; 32. Heating monitoring module; 321. Heating temperature sensor; 322. Heating monitoring camera; 4. Cooling unit; 41. Cooling module; 411. Cooling plate; 412. Cylinder; 413. Refrigeration unit; 414. Connecting pipeline; 42. Cooling monitoring module; 421. Cooling temperature sensor; 422. Cooling monitoring camera; 5. Program control unit; 51. Screen; 52. Switch. Detailed Implementation

[0026] To make the purpose, technical solution, and advantages of this application clearer, the following description is provided in conjunction with the appendix. Figure 1-8 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0027] The embodiments of the present invention will now be described in further detail with reference to the accompanying drawings.

[0028] This application discloses an intelligent heat-setting device for pipes, referring to... Figure 1-3 As shown, the intelligent heat-setting equipment for pipes includes: frame unit 1, material transfer unit 2, heating unit 3, cooling unit 4, and program control unit 5.

[0029] Rack unit 1 provides the structural foundation for the equipment, and all other units are mounted on rack unit 1.

[0030] The material transfer unit 2 consists of a shaping mold plate 21 and a guide rail 22. The shaping mold plate 21 has a cavity 211 with the expected shaping shape. The guide rail 22 is connected to the frame unit 1 and can drive the shaping mold plate 21 to move linearly between the heating unit 3 and the cooling unit 4.

[0031] The heating unit 3 consists of a heating module 31 and a heating monitoring module 32. The heating module 31 consists of two heating plates 311 and an insulation plate 312. Each heating plate has multiple non-contact heaters 3111 arranged in a matrix. The heating power of each heater can be controlled individually. The heating monitoring module 32 consists of a heating temperature sensor 321 and a heating monitoring camera 322, which are embedded inside the heating plate 311 of the heating module 31. The heating module 31, the heating temperature sensor 321 and the heating monitoring camera 322 can all cover the area of ​​the shaping mold plate 21.

[0032] The cooling unit 4 consists of a cooling module 41 and a cooling monitoring module 42. The cooling module 41 is a clamp-type cooling system, consisting of two cooling plates 411 (upper and lower), a cylinder 412, a chiller 413, connecting pipes 414, and an insulating plate 415. The upper cooling plate 411 is connected to the frame unit 1 by the cylinder 412 and can be controlled to press down, clamping the shaping mold plate 21 between the two cooling plates 411. The cooling plates 411 have a flow channel 4111 in the middle for coolant to flow through. The end of the flow channel 4111 has an inlet and an outlet for coolant, both of which are connected to the chiller 413 via the connecting pipes 414. The cooling monitoring module 42 is integrated into the cooling plate 411 and consists of a cooling temperature sensor 421 and a cooling monitoring camera 422.

[0033] The heating unit 3, cooling unit 4, and material transfer unit 2 can all be controlled by the program control unit 5. The shaping mold plate 21 moves between the heating unit 3 and the cooling unit 4 via the guide rail 22 of the material transfer unit 2. The heating unit 3, cooling unit 4, material transfer unit 2, and program control unit 5 are all mounted on the frame unit.

[0034] The program control unit 5 consists of a screen 51, a switch 52, and control buttons, and has a built-in motion control system, image processing system, and temperature control system.

[0035] A control method for an intelligent heat-setting device for pipes is provided, which is built into a program control unit 5. Information collected by the heating temperature sensors 321 and 421 of the heating unit 3 and the heating monitoring cameras 322 and 422 of the cooling unit 4 is transmitted back to the program control unit 5. Upon receiving the temperature information, the program control unit compares it with the set temperature in real time to obtain a temperature difference value. Then, combining image processing analysis, it checks whether any abnormalities have occurred in the shaped pipe within the control range of the corresponding heater. Based on the temperature, size, and appearance, it adjusts the power of the heater 3111 or the cooling temperature and flow rate of the chiller 413 accordingly. All process parameters, process parameter adjustments, and equipment status are displayed in real time on the screen and recorded in the memory of the program control unit 5.

[0036] In this embodiment, after the equipment is powered on, the program control unit 5 automatically performs a system self-test, comprehensively checking the connection status of each unit and the working performance of components such as sensors. After the self-test passes, the operator selects the process formula required for the current production through the screen 51, and the program control unit 5 then retrieves the corresponding parameter settings from the database, including key data such as the temperature range of each heating zone, heating rate, holding time, cooling parameters, and quality inspection standards.

[0037] The operator places the pipe to be shaped into the cavity 211 of the shaping mold plate 21 in the material transfer unit 2 as required. After ensuring that the pipe is completely fitted into the cavity 211, the operator confirms the loading is complete on the screen 51 and starts the processing program.

[0038] Upon receiving the start command, the program control unit 5 first controls the material transfer unit 2 to transport the shaping mold plate 21 along the guide rail 22 to the corresponding position below the heating plate 311. The heating unit 3 immediately begins operation, with each zone heater 3111 heating according to the set parameters. During this period, the program control unit 5 monitors the processing status in real time through the temperature control system. The heating temperature sensor 321 continuously collects the surface temperature data of the pipe and feeds it back to the program control unit 5. The system dynamically adjusts the output power of each heater 3111 through a control algorithm to ensure that the temperature remains stable within the predetermined range.

[0039] Simultaneously, the image processing system operates in parallel: the heating monitoring camera 322 continuously captures images of the pipe and transmits them to the program control unit 5 in real time. The system calculates the actual diameter of the pipe using algorithms such as edge detection and compares it with the standard value. If a deviation is found, the temperature setting of the relevant heating zone is automatically adjusted. At the same time, the defect identification module of the image processing system analyzes the image data in real time. Once an anomaly is identified, the temperature setting of the relevant heating zone is adjusted accordingly. For abnormal shadows or other defect features that indicate creases or dents that exceed the acceptable range, the system immediately records the location of the problematic pipe.

[0040] Once the system determines that the heating process is complete, the program control unit 5 will control the material transfer unit 2 to transfer the shaping mold plate 21 to the cooling unit 4. After the cooling unit 4 is started, the cylinder 412 drives the upper cooling plate 411 to press down, clamping the shaping mold plate 21 between the two cooling plates 411. At the same time, the liquid pump built into the refrigeration unit 413 pumps coolant into the cooling plates through the connecting pipe 414, allowing it to circulate in the cooling plate channels and evenly remove the heat from the shaping mold plate 21 and the pipe. The cooling rate is controlled by adjusting the coolant flow rate. During the cooling process, the monitoring module in the cooling unit is the same as in the heating unit, monitoring and recording the pipe temperature and appearance in real time, and adjusting the coolant temperature and flow rate in real time based on the judgment results.

[0041] After the cooling process is completed, the program control unit 5 judges the quality of the processed product: the system comprehensively analyzes the temperature curve, dimensional measurement data, and defect detection results recorded throughout the process, determines whether it is qualified or not, and binds and saves the detection results with information such as the product batch number. All raw data, process parameters, and quality inspection results are completely stored in the system database. For products judged as unqualified by the system, the presence and location of the unqualified product will be highlighted on screen 51 at the end of production, and the operator can accurately remove it according to the problem location indicated by the system.

[0042] Based on the same inventive concept, embodiments of the present invention provide a control method for an intelligent heat-setting device for pipes, comprising: The material transfer step is equipped with a material timing positioning strategy, which is used by the program control unit to send displacement control signals to the material transfer unit, driving the shaping mold plate loaded with the pipe workpiece to be shaped to move linearly along the guide rail to the preset heating position of the heating unit, and simultaneously triggering the heating monitoring module to enter the working preparation state, so as to achieve precise alignment between the material and the heating position. The heating adjustment step is equipped with a heating parameter adaptation strategy. The program control unit presets the heating power threshold and target heating temperature range according to the material characteristics of the pipe to be shaped, and controls multiple non-contact heaters of the heating module to adjust the heating power individually to perform non-contact heating of the pipe to be shaped. At the same time, the heating monitoring module collects the real-time heating temperature signal and heating status visual image signal of the pipe, and transmits them to the temperature control system and image processing system for analysis to determine whether the real-time heating temperature is within the target heating temperature range and whether there is any heating abnormality in the appearance of the pipe. If they do not meet the requirements, the heating power of the corresponding heater is dynamically adjusted. The cooling adjustment step is equipped with a cooling parameter adaptation strategy. After the heating process meets the preset requirements, the program control unit drives the shaping mold plate to move to the preset cooling position of the cooling unit through the material control system. At the same time, it controls the cylinder of the cooling module to drive the upper cooling plate to press down, clamping the shaping mold plate between the upper and lower cooling plates. The coolant is delivered to the cooling plate channel through the refrigeration unit. Combined with the real-time cooling temperature signal and cooling status visual image signal of the pipe collected by the cooling monitoring module, the data is transmitted to the temperature control system and image processing system for analysis to determine whether the real-time cooling temperature meets the target cooling temperature requirements and whether there is cooling deformation of the pipe. If not, the coolant temperature or coolant flow rate of the refrigeration unit is adjusted. The finalization evaluation step includes a finalization quality analysis strategy. This strategy integrates temperature data and visual image data from the heating and cooling processes into the program control unit. The image processing system analyzes the dimensional accuracy and appearance integrity of the pipe during finalization. Combined with the temperature control system, it verifies whether the temperature curve matches the preset process curve to determine whether the finalization effect meets the acceptable threshold. If it does, a finalization completion signal is generated, driving the material transfer unit to output the finished product. If it does not, the unacceptable parameters and corresponding adjustment schemes are stored in the process database of the program control unit. This updates the preset values ​​such as heating power threshold and cooling parameters for subsequent similar pipes, achieving iterative optimization of the finalization process.

[0043] In addition, it also includes: The real-time data acquisition step is configured with a partitioned acquisition strategy, which connects the temperature sensor and camera embedded in the device through the real-time data acquisition module. The temperature sensor is arranged in a matrix to collect real-time temperature data of each corresponding partition on the shaping mold plate. The camera collects real-time image data of the pipe and transmits it synchronously to the signal analysis module. The signal comprehensive analysis step is configured with a multi-dimensional analysis strategy, which is used by the signal analysis module to receive real-time temperature data and image data, calculate the instantaneous deviation between the real-time temperature of each zone and the set temperature of the target temperature curve; based on image data conversion and algorithm processing, calculate the actual physical dimensions and dimensional deviations of the pipe, and locate the location of pipe defects and classify defect types through defect detection algorithms; In the signal synthesis and analysis step, the instantaneous temperature deviation is expressed by the formula... Calculation, where Let be the instantaneous temperature deviation of the i-th partition at time t. Set the temperature at time t in the target temperature curve. Let t be the measured temperature of the i-th partition at time t.

[0044] The power dynamic control step is configured with a dual-parameter coupling control strategy, which is used by the temperature control system to retrieve the instantaneous temperature deviation and size deviation output by the signal analysis module, calculate the basic temperature adjustment power and size compensation power respectively through preset formulas, and superimpose them to obtain the final heating power, control the output power of the heating module, and limit the power output range at the same time. In the power dynamic control steps, such as Figure 7 As shown, the basic temperature regulation power is calculated using the first formula: ; Size compensation power is calculated using the second formula. ; The final heating power is calculated using the third formula. ; in, Let be the power adjustment amount of the heater in the i-th zone at time t. This is the proportional gain coefficient. This is the integral gain coefficient. The differential gain coefficient, For size-compensated power, This is the dimensional deviation weighting coefficient. For example, with a target temperature of 180℃, Kp=5.0, Ki=0.1, Kd=1.0, and a dimensional deviation weighting α=8.0 (1mm dimensional deviation, 8W compensation power), the heating power output range is limited to [0,100]% (0-1000W). When T=0s, the initial temperature is 25℃, ΔLi=0, and ei(t)=180-25=155℃; =0 (initially 0); = =1550; Wi(t)=(5*155)+0+(1*1550)=775+0+1550=2325w; ΔW=0, Wi=2325+0=2325w, exceeding the maximum power limit, operating at maximum power.

[0045] In addition, a signal analysis module is provided to receive the actual temperature and image data sent by the data acquisition module and perform the following operations: The first step is to calculate the instantaneous deviation ei(t) between the real-time temperature of each zone and the set temperature in the target temperature curve. The second step involves capturing images using a camera, converting the color image into a grayscale image, applying the Canny edge detection algorithm to obtain a binary image, extracting the pixel contour of the pipe, and calculating the actual physical diameter Da based on the pre-stored pixel scaling factor K. Simultaneously, based on the dimensional change rate and the actual physical diameter, the dimensional deviation ΔLi between the final size and the standard size is obtained. Rate of change of size: V(t) = Pixel scaling factor: K=

[0046] Final dimension: D = V(t)·(t-t0) + Da The third step is the defect detection algorithm, such as... Figure 8 As shown, image acquisition via camera provides high-quality input for the algorithm. A high-precision template matching algorithm calculates the similarity at each location, instantly locating the product's coordinates and rotation angle within the image. This template matching algorithm provides a stable spatial reference for subsequent analysis modules. Next, Sobel edge analysis is used to segment defect areas. A 3×3 convolution kernel is used to calculate pixel gradient magnitudes in both horizontal and vertical directions, effectively enhancing the detection sensitivity of weak edge areas. Closure processing is then performed, calculating the rate of curvature change point by point along key contours to find the starting point of creases and the boundary of depressions, checking for smoothness and continuity of the contours. Simultaneously, the texture analysis module generates a gray-level co-occurrence matrix, extracting key features from it to quantify the depth and clarity of the texture. Creases exhibit high contrast, quantifying the uniformity and regularity of the texture. Depressions or wear typically exhibit low energy. The extracted feature values ​​are compared with preset thresholds; a matching score higher than the threshold indicates success, otherwise, a "product defect" message is displayed. The system also directly confirms the defect location based on the physical position corresponding to the camera's field of view, performing fine-grained defect classification.

[0047] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0048] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.

Claims

1. A smart heat-setting device for pipes, characterized in that, include: Rack unit (1) is used to provide the mounting structure foundation; The material transfer unit (2) is provided with a shaping mold plate (21) and a guide rail (22). The shaping mold has a shaping cavity. The guide rail (22) is fixedly connected to the frame unit (1) and is used to drive the shaping mold plate (21) to move linearly between the heating unit (3) and the cooling unit (4). The heating unit (3) is provided with a heating module (31) and a heating monitoring module (32). The heating module (31) is used to perform non-contact heating on the workpiece to be heated, and the heating monitoring module (32) is used to monitor the heating temperature and visual image of the workpiece. The cooling unit (4) is provided with a cooling module (41) and a cooling monitoring module (42). The cooling module (41) is used to cool the workpiece after heating, and the cooling monitoring module (42) monitors the cooling temperature and visual image of the workpiece. The program control unit (5) is equipped with a material control system, an image processing system and a temperature control system. It collects and analyzes material transmission signals and temperature signals, and generates feedback control signals to control the heating unit (3), the material transmission unit (2) and the cooling unit (4).

2. The intelligent heat-setting equipment for pipes according to claim 1, characterized in that, The heating module (31) includes a heating plate (311) and an insulation plate. The heating plates (311) are arranged in a vertically opposite manner. Each heating plate (311) is provided with an array of multiple non-contact heaters (3111). The heating power of each non-contact heater (3111) can be controlled individually. The heating monitoring module (32) includes a heating temperature sensor (321) and a heating monitoring camera (322). The temperature monitoring range of the heating temperature sensor (321), the imaging range of the heating monitoring camera (322), and the heating range of the heating module (31) cover the area of ​​the shaping mold plate (21).

3. The intelligent heat-setting equipment for pipes according to claim 1, characterized in that, The cooling module (41) is configured as a clamping plate cooling method to perform clamping contact cooling on the workpiece. It is equipped with cooling plates (411) arranged opposite to each other, a refrigerator (413), a connecting pipe (414) and an insulating plate. The upper cooling plate (411) is connected to the frame by a cylinder (412) and can be controlled to press down to clamp the shaping plate between the two cooling plates (411). There is a flow channel in the middle of the cooling plate (411) for the coolant to flow. The inlet and outlet of the coolant are set at the end of the flow channel, and both are connected to the refrigerator (413) through the connecting pipe (414). The cooling monitoring module (42) is integrated into the cooling plate (411) and includes a cooling temperature sensor (421) and a cooling monitoring camera (422) whose temperature monitoring range and camera range both cover the area of ​​the shaping mold plate (21).

4. A control method for an intelligent heat-setting equipment for pipes, applied to an intelligent heat-setting equipment for pipes as described in any one of claims 1-3, comprising a material control system, an image processing system, and a temperature control system equipped with a program control unit, used to synchronously acquire material transmission signals, temperature signals, and visual image signals and realize processing control, characterized in that, include: The material transfer step is equipped with a material timing positioning strategy, which is used by the program control unit to send displacement control signals to the material transfer unit, driving the shaping mold plate loaded with the pipe workpiece to be shaped to move linearly along the guide rail to the preset heating position of the heating unit, and simultaneously triggering the heating monitoring module to enter the working preparation state, so as to achieve precise alignment between the material and the heating position. The heating adjustment step is equipped with a heating parameter adaptation strategy, which is used by the program control unit to preset the heating power threshold and target heating temperature range according to the material characteristics of the pipe to be shaped, and control multiple non-contact heaters of the heating module to adjust the heating power individually to perform non-contact heating of the pipe to be shaped. The cooling adjustment step is equipped with a cooling parameter adaptation strategy. After the heating process meets the preset requirements, the program control unit drives the shaping mold plate to move to the preset cooling position of the cooling unit through the material control system. At the same time, it controls the cylinder of the cooling module to drive the upper cooling plate to press down and clamp the shaping mold plate between the upper and lower cooling plates. The finalization evaluation step is equipped with a finalization quality analysis strategy. The program control unit integrates temperature data and visual image data from the heating and cooling processes. The image processing system analyzes the finalization dimensional accuracy and appearance integrity of the pipe. Combined with the temperature control system, it verifies whether the temperature curve matches the preset process curve to determine whether the finalization effect of the pipe meets the qualified index threshold.

5. The control method for an intelligent heat-setting device for pipes according to claim 4, characterized in that, The heating adjustment step further includes: The heating monitoring module collects real-time heating temperature signals and visual images of the heating status of the pipe, which are then transmitted to the temperature control system and image processing system for analysis. This process determines whether the real-time heating temperature is within the target heating temperature range and whether there are any heating abnormalities on the appearance of the pipe. If not, the heating power of the corresponding heater is dynamically adjusted.

6. The control method for an intelligent heat-setting device for pipes according to claim 5, characterized in that, The cooling regulation step also includes: The coolant is delivered to the cooling plate channel by the refrigeration unit. The real-time cooling temperature signal and visual image signal of the cooling status of the pipe are collected by the cooling monitoring module and transmitted to the temperature control system and image processing system for analysis. The system determines whether the real-time cooling temperature meets the target cooling temperature requirements and whether there is cooling deformation of the pipe. If not, the coolant temperature or coolant flow rate of the refrigeration unit is adjusted.

7. The control method for an intelligent heat-setting device for pipes according to claim 4, characterized in that, The finalization evaluation step also includes: Based on the comparison and analysis of the qualified index thresholds, if they are met, a finalization completion signal is generated, which drives the material transfer unit to output the finished product. If the parameters do not meet the requirements, the non-compliant parameters and corresponding adjustment schemes will be stored in the process database of the program control unit, and the preset values ​​such as heating power threshold and cooling parameters for subsequent similar pipe materials will be updated.

8. The control method for an intelligent heat-setting device for pipes according to claim 4, characterized in that, Also includes: The real-time data acquisition step is configured with a partitioned acquisition strategy, which connects the temperature sensor and camera embedded in the device through the real-time data acquisition module. The temperature sensor is arranged in a matrix to collect real-time temperature data of each corresponding partition on the shaping mold plate. The camera collects real-time image data of the pipe and transmits it synchronously to the signal analysis module. The signal comprehensive analysis step is configured with a multi-dimensional analysis strategy, which is used by the signal analysis module to receive real-time temperature data and image data, calculate the instantaneous deviation between the real-time temperature of each zone and the set temperature of the target temperature curve; based on image data conversion and algorithm processing, calculate the actual physical dimensions and dimensional deviations of the pipe, and locate the location of pipe defects and classify defect types through defect detection algorithms; The power dynamic control step is equipped with a dual-parameter coupling control strategy, which is used by the temperature control system to retrieve the instantaneous temperature deviation and size deviation output by the signal analysis module, calculate the basic temperature adjustment power and size compensation power respectively through preset formulas, and superimpose them to obtain the final heating power, control the output power of the heating module, and limit the power output range.

9. The control method for an intelligent heat-setting device for pipes according to claim 8, characterized in that, In the signal synthesis and analysis steps: The instantaneous temperature deviation is expressed by the formula Calculation, where Let be the instantaneous temperature deviation of the i-th partition at time t. Set the temperature at time t in the target temperature curve. Let be the measured temperature of the i-th partition at time t.

10. The control method for an intelligent heat-setting device for pipes according to claim 8, characterized in that, In the power dynamic control step: the basic temperature regulation power is calculated using the first formula: ; The size compensation power is calculated using the second formula. ; The final heating power is calculated using the third formula. ; in, Let be the power adjustment amount of the heater in the i-th zone at time t. This is the proportional gain coefficient. This is the integral gain coefficient. The differential gain coefficient, For size-compensated power, This is the dimensional deviation weighting coefficient.

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