A straightening process and apparatus for steel pipes
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- HUNAN YIGE SPECIAL STEEL TECH CO LTD
- Filing Date
- 2026-03-16
- Publication Date
- 2026-05-26
Smart Images
Figure CN121892532B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of steel pipe processing technology, specifically to a steel pipe straightening process and a steel pipe straightening device using the process. Background Technology
[0002] During production and transportation, steel pipes are prone to bending deformation due to external forces, affecting the accuracy of subsequent processing and assembly, as well as the safety of use. Therefore, straightening is a critical step in steel pipe processing. Existing steel pipe straightening processes typically employ a conventional workflow of "measurement-parameter calculation-straightening-retest." In the measurement stage, only data related to the bending of the steel pipe are collected, without considering the influence of the steel pipe's surface condition on the measurement data. This can easily lead to abnormal measurement data due to surface contaminants, minor scratches, etc., resulting in deviations in the calculation of straightening parameters, causing over-straightening or under-straightening, and affecting the straightening quality.
[0003] Meanwhile, in existing straightening processes, each time an anomaly is detected on the steel pipe surface, the straightening fine-tuning parameters must be recalculated, which is cumbersome and inefficient. Furthermore, the lack of a systematic anomaly data accumulation mechanism prevents parameter reuse and continuous optimization of measurement accuracy, making it difficult to meet the demands of large-scale, high-precision steel pipe straightening. In addition, existing straightening equipment often requires additional dedicated detection or adjustment components, increasing equipment costs, and has poor adaptability, failing to flexibly adapt to the straightening of steel pipes of different specifications and materials. Summary of the Invention
[0004] The purpose of this invention is to provide a steel pipe straightening process and equipment. By optimizing the linkage logic between measurement and straightening, it can achieve accurate determination of measurement data and rapid adaptation of straightening parameters, thereby improving the quality and efficiency of straightening.
[0005] The above-mentioned technical objective of the present invention is achieved through the following technical solution:
[0006] A steel pipe straightening process includes the following steps:
[0007] Step 1: Select the steel pipe to be straightened, check the surface roughness of its runout test section and ensure that it meets the straightening requirements, place the steel pipe at the straightening station and complete the positioning;
[0008] Step 2: Position and clamp both ends of the steel pipe to ensure stable clamping without damaging the surface of the steel pipe;
[0009] Step 3: Perform multi-dimensional runout measurement on the steel pipe, collect and process the data, determine the bending runout, bending direction and bending position of the steel pipe, and record the initial runout data;
[0010] Step 4: Combining the steel pipe's own parameters and the bending data obtained from the test, perform fitting analysis on the bending shape of the steel pipe and calculate the straightening parameters to determine the final straightening parameters; for steel pipes with a large range of initial bending amount, match the corresponding straightening parameters according to the initial bending amount group.
[0011] Step 5: Locate the bending direction of the steel pipe and move the bending position to the straightening point. After supporting the steel pipe, apply a loading force, monitor the deformation state of the steel pipe in real time, and dynamically adjust the loading parameters to achieve closed-loop control straightening.
[0012] Step 6: Retest the straightened steel pipe to determine if it meets the preset qualification standard. If it meets the standard, the straightening is completed and the straightening process data is recorded. If it does not meet the standard, repeat the straightening and retesting process.
[0013] Step 7: Remove the support and clamping of the steel pipe, take out the steel pipe, view and export the straightening data through the access control mechanism, and use the historical traceability mechanism to realize process monitoring and equipment maintenance;
[0014] During the measurement process in step 3, relevant auxiliary detection data on the surface of the steel pipe are collected simultaneously. The auxiliary detection data is correlated with the runout measurement data, the validity of the runout measurement data is determined, the measurement data is processed according to the determination result, and the abnormal information is fed back to step 4 to adjust the straightening parameters.
[0015] In a preferred embodiment, in step 1, a surface roughness tester is used to detect the surface roughness of the steel pipe runout test section, and the surface roughness requirement is better than Ra6.3; the steel pipe is placed at the straightening station by manual or mechanical handling to ensure that the steel pipe axis is parallel to the straightening station baseline and the positioning deviation does not exceed ±0.5mm.
[0016] In a preferred embodiment, in step 1, the diameter of the steel pipe to be straightened is 30-80mm, the wall thickness is ≤6mm, and the length is 1200mm-3000mm; for steel pipes with a surface roughness lower than Ra6.3, they are marked as specially treated workpieces, and no filtering is performed during subsequent measurements. Straightening is carried out according to the full runout standard.
[0017] In a preferred embodiment, in step 2, the two ends of the steel pipe are axially positioned by a positioning cylinder with a positioning deviation controlled within ±0.02mm. Floating clamping claws are used to clamp the two ends of the steel pipe with a clamping force controlled within 50-100kN to ensure that the steel pipe has no radial displacement or surface damage after clamping.
[0018] In a preferred embodiment, in step 3, three sets of mobile high-precision measuring components are used to move at a constant speed along the length of the steel pipe, while simultaneously driving the steel pipe to rotate at a constant speed. After collecting the steel pipe runout data, a low-pass filtering algorithm is used for filtering. The bending parameters of the steel pipe are calculated by the PLC, and the initial runout data is stored in the data acquisition unit with a storage accuracy of 0.001mm.
[0019] In a preferred embodiment, in step 4, the least squares method is used to fit and analyze the bending morphology of the steel pipe, and the theoretical straightening amount is calculated according to the formula F=k×Δ×D, where F is the theoretical loading force, k is the material coefficient, Δ is the bending runout, and D is the diameter of the steel pipe; the deviation is corrected by a PID algorithm based on historical straightening data, and the deviation correction accuracy is ±0.001mm; the initial bending amount is divided into three intervals: 0-0.2mm, 0.2-0.5mm, and 0.5-1.0mm, and each interval corresponds to a different straightening force gradient and loading number.
[0020] In a preferred embodiment, in step 5, the loading positioning accuracy is ±0.02mm, the average number of straightening loadings per point is 1-2 times / point, and the duration of a single loading is 1-2s; the contact area between the straightening end and the steel pipe is 50-100mm², and the distance between the straightening end and the step position of the steel pipe is not less than 10mm, and it does not act on the step position of the steel pipe.
[0021] In a preferred embodiment, the auxiliary detection data is the light reflection intensity data of the steel pipe surface. A correlation judgment model is constructed by combining the surface roughness data detected in step 1 to determine the validity of the runout measurement data. The measurement data is processed according to the judgment result, and the abnormal information is fed back to step 4 to adjust the straightening parameters in a targeted manner.
[0022] In a preferred embodiment, in step 5, for brittle steel pipes, the loading force and deformation are monitored in real time during the straightening process. When the deformation suddenly increases by more than 0.01 mm / s, the loading is stopped immediately. In step 6, if the retest fails, the straightening and retesting process is repeated no more than 3 times. If it exceeds 3 times, the workpiece is judged as unqualified.
[0023] A steel pipe straightening device, which applies the aforementioned steel pipe straightening process.
[0024] Compared with the prior art, the present invention has the following beneficial effects:
[0025] 1. This invention introduces surface light reflection intensity data into the runout measurement process and constructs an association judgment model by combining it with surface roughness data. This enables accurate determination of the validity of runout measurement data, solves the problems of measurement deviation and inaccurate calculation of straightening parameters caused by surface anomalies in existing processes, significantly improves straightening accuracy, and reduces the straightening defect rate.
[0026] 2. Construct a correlation database between surface anomalies and fine-tuning of straightening parameters to enable rapid parameter retrieval for similar anomalies without repeated calculations, significantly improving straightening efficiency; at the same time, dynamically optimize the correlation judgment model through data accumulation to continuously improve measurement accuracy and straightening adaptability, breaking through the inherent limitations of existing processes.
[0027] 3. The entire process does not require the introduction of any new special equipment. It can be achieved by relying on the measurement, clamping, and data processing modules of existing straightening equipment. There is no need to increase equipment costs. It is compatible with existing processing procedures, has strong practicality, and is easy to promote and apply on a large scale.
[0028] 4. Different straightening parameters and support spacing are set for steel pipes of different specifications and materials. At the same time, targeted loading monitoring is carried out for brittle steel pipes to further improve the adaptability and safety of the straightening process and expand the scope of application of the process.
[0029] 5. Through access control and historical traceability mechanisms, standardized management of calibration data and traceability of the process can be achieved, which facilitates process optimization and quality control and improves production management. Attached Figure Description
[0030] Figure 1 This invention relates to a process flow diagram of a steel pipe straightening process.
[0031] Figure 2 This is a front view of a steel pipe straightening device according to the present invention.
[0032] Figure 3 This invention relates to a side view of a steel pipe straightening device. Detailed Implementation
[0033] The present invention will be further described in detail below with reference to the accompanying drawings.
[0034] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention. Example 1
[0035] like Figure 1 As shown, a steel pipe straightening process includes the following steps:
[0036] Step 1: Select the steel pipe to be straightened, check the surface roughness of its runout test section and ensure that it meets the straightening requirements, place the steel pipe at the straightening station and complete the positioning;
[0037] Step 2: Position and clamp both ends of the steel pipe to ensure stable clamping without damaging the surface of the steel pipe;
[0038] Step 3: Perform multi-dimensional runout measurement on the steel pipe, collect and process the data, determine the bending runout, bending direction and bending position of the steel pipe, and record the initial runout data;
[0039] Step 4: Combining the steel pipe's own parameters and the bending data obtained from the test, perform fitting analysis on the bending shape of the steel pipe and calculate the straightening parameters to determine the final straightening parameters; for steel pipes with a large range of initial bending amount, match the corresponding straightening parameters according to the initial bending amount group.
[0040] Step 5: Locate the bending direction of the steel pipe and move the bending position to the straightening point. After supporting the steel pipe, apply a loading force, monitor the deformation state of the steel pipe in real time, and dynamically adjust the loading parameters to achieve closed-loop control straightening.
[0041] Step 6: Retest the straightened steel pipe to determine if it meets the preset qualification standard. If it meets the standard, the straightening is completed and the straightening process data is recorded. If it does not meet the standard, repeat the straightening and retesting process.
[0042] Step 7: Remove the support and clamping of the steel pipe, take out the steel pipe, view and export the straightening data through the access control mechanism, and use the historical traceability mechanism to realize process monitoring and equipment maintenance;
[0043] During the measurement process in step 3, relevant auxiliary detection data on the surface of the steel pipe are collected simultaneously. The auxiliary detection data is correlated with the runout measurement data, the validity of the runout measurement data is determined, the measurement data is processed according to the determination result, and the abnormal information is fed back to step 4 to adjust the straightening parameters.
[0044] During the process, steel pipes to be straightened are first selected. Surface roughness testing equipment is used to inspect the runout testing section of the steel pipes, and pipes that do not meet the roughness requirements are discarded. Then, qualified steel pipes are placed at the straightening station by manual or mechanical handling, and their position is adjusted so that the axis is parallel to the station's baseline, completing the positioning. Subsequently, the two ends of the steel pipe are axially positioned and clamped using a positioning clamping mechanism to avoid clamping damage and radial displacement. A multi-dimensional measurement component is activated, moving along the length of the steel pipe and driving it to rotate, collecting and processing runout data. Simultaneously, auxiliary surface inspection data of the steel pipe is collected. The two types of data are correlated and compared to determine the validity of the runout data. Abnormal data is processed and fed back to the straightening parameter calculation stage. Combining the steel pipe's own parameters, bending data, and valid runout data, a fitting algorithm is used to calculate the straightening parameters. For steel pipes with large initial bending spans... The pipes are grouped and matched with parameters according to intervals; the bending position of the steel pipe is moved to the straightening point, and a loading force is applied after support. The deformation status is monitored in real time and the loading parameters are dynamically adjusted to achieve closed-loop straightening; after straightening, a retest is performed. If it passes, the data is recorded and the pipe is removed; if it fails, the straightening and retesting are repeated; finally, the exported data can be viewed through access management, and the process and maintenance equipment are monitored using a historical traceability mechanism. Under this setting, the entire steel pipe straightening process can be accurately and controllably achieved. By correlating auxiliary detection data with fluctuation data, deviations in straightening parameters caused by abnormal data are avoided, thus improving straightening accuracy. Grouping and matching straightening parameters are adapted to steel pipes with different degrees of bending, and closed-loop control ensures the stability of the straightening process. Access management and historical traceability enable standardized data management and process traceability, reducing the straightening defect rate, improving production management level, and eliminating the need for additional special equipment, thus adapting to the existing processing flow.
[0045] Furthermore, in step 1, a surface roughness tester is used to detect the surface roughness of the runout test section of the steel pipe, and the surface roughness requirement is better than Ra6.3; the steel pipe is placed at the straightening station by manual or mechanical handling to ensure that the axis of the steel pipe is parallel to the baseline of the straightening station and the positioning deviation does not exceed ±0.5mm.
[0046] During the execution process, in step 1, the surface roughness tester probe is tightly fitted to the steel pipe runout test section, and the probe is moved at a uniform speed to complete the full test section inspection. The test data is read in real time, and steel pipes with a roughness better than Ra6.3 are selected. For qualified steel pipes, manual handling or mechanical gripper handling is selected according to the production scale. During the handling process, collision deformation of the steel pipe is avoided. After the steel pipe is placed in the straightening station, the position of the steel pipe is adjusted by the positioning reference component. The parallelism between the steel pipe axis and the station reference line is checked by a ruler or laser positioning instrument. After adjusting to a positioning deviation of no more than ±0.5mm, it is fixed. Under this setting, the surface condition of the steel pipe can be accurately detected by the surface roughness tester, avoiding measurement errors and straightening quality problems caused by excessive roughness. Precise control of the steel pipe positioning deviation and axis parallelism provides a precise reference for subsequent runout measurement and straightening operations, ensuring the stability and accuracy of subsequent processes, reducing straightening deviations caused by positioning deviations, and improving the consistency of straightening quality.
[0047] Furthermore, the diameter of the steel pipe to be straightened is 30-80mm, the wall thickness is ≤6mm, and the length is 1200mm-3000mm; for steel pipes with a surface roughness lower than Ra6.3, they are marked as specially treated workpieces, and no filtering is performed during subsequent measurements. Straightening is carried out according to the full runout standard.
[0048] During the execution process, in step 1, the diameter and length of the steel pipe to be straightened are measured using calipers and measuring tape, and the wall thickness is measured using a wall thickness gauge. Steel pipes with a diameter of 30-80mm, a wall thickness of ≤6mm, and a length of 1200mm-3000mm are selected. For steel pipes with a surface roughness lower than Ra6.3 after surface roughness testing, they are marked as special-treatment workpieces using a marking pen or electronic marking. In the subsequent step 3, the low-pass filtering function of the measurement system is turned off, and the total runout data of the steel pipe is directly collected without filtering. During subsequent straightening, the straightening parameters are adjusted strictly according to the full runout qualification standard. Under this setting, the range of steel pipe specifications suitable for the process can be clearly defined, ensuring the process's relevance and adaptability, and avoiding straightening failure due to steel pipe specifications exceeding the suitable range. For special workpieces with substandard roughness, differentiated measurement and straightening methods are used to avoid filtering to cover up surface defects and actual bending conditions of the steel pipe, ensuring the straightening accuracy of special workpieces, reducing the failure rate of special workpiece straightening, and expanding the applicability of the process.
[0049] Furthermore, in step 2, the two ends of the steel pipe are axially positioned by a positioning cylinder with a positioning deviation controlled within ±0.02mm. Floating clamping claws are used to clamp the two ends of the steel pipe with a clamping force controlled within 50-100kN to ensure that the steel pipe has no radial displacement or surface damage after clamping.
[0050] During execution, in step 2, the positioning cylinder is activated, driving the cylinder piston rod to push the positioning pins, which then press against the center holes at both ends of the steel pipe. A displacement sensor detects the positioning deviation in real time, and the cylinder stroke is adjusted to control the positioning deviation within ±0.02mm, completing the axial positioning. Subsequently, the floating clamping jaws open, enclosing both ends of the steel pipe, and clamping force is gradually applied. A pressure sensor monitors the clamping force in real time, adjusting it to a range of 50-100kN. During clamping, the buffer structure of the floating clamping jaws prevents rigid clamping from damaging the steel pipe surface. After clamping, a displacement sensor detects radial displacement in the steel pipe, and the clamping state is locked once no displacement is detected. With this setup, high-precision axial positioning can be achieved through the positioning cylinder, ensuring that the steel pipe axis coincides with the baseline of the straightening equipment, providing a precise positioning basis for subsequent runout measurement and straightening. The floating clamping jaws, combined with controllable clamping force, ensure clamping stability while preventing surface damage and radial displacement of the steel pipe, reducing the impact of the clamping process on the straightening quality, and improving straightening accuracy and steel pipe surface quality.
[0051] Furthermore, in step 3, three sets of mobile high-precision measuring components are used to move at a constant speed along the length of the steel pipe, while simultaneously driving the steel pipe to rotate at a constant speed. After collecting the runout data of the steel pipe, a low-pass filtering algorithm is used for filtering. The bending parameters of the steel pipe are calculated by the PLC, and the initial runout data is stored in the data acquisition unit with a storage accuracy of 0.001mm.
[0052] During execution, in step 3, three sets of mobile high-precision measuring components are activated, with a set moving speed maintained at a constant rate. Simultaneously, the steel pipe flipping mechanism is activated to drive the steel pipe to flip at a constant speed, ensuring that the measuring components can collect full-dimensional runout data in the circumferential direction of the steel pipe. The displacement sensors of the measuring components collect runout data in real time and transmit the data to the PLC control system. The PLC uses a low-pass filtering algorithm to process the data, filtering out invalid data such as environmental interference and measurement noise, and retaining valid runout data. The PLC's built-in algorithm analyzes and calculates the valid data to obtain the bending runout, bending direction, and bending position of the steel pipe. The system measures bending parameters and transmits initial runout data to the data acquisition unit, storing it with a precision of 0.001mm for easy traceability and parameter optimization. In this setup, three sets of mobile measuring components, working in conjunction with pipe rotation, enable multi-dimensional, all-around runout measurement of the pipe, ensuring comprehensive data accuracy. A low-pass filtering algorithm effectively filters out invalid interference data, improving the accuracy of the measurement data. The PLC precisely calculates bending parameters, providing a reliable basis for subsequent straightening parameter calculations. High-precision data storage enables traceability of measurement data, facilitating subsequent process optimization and quality control, further improving straightening accuracy.
[0053] Furthermore, in step 4, the least squares method is used to fit and analyze the bending morphology of the steel pipe, and the theoretical straightening amount is calculated according to the formula F=k×Δ×D, where F is the theoretical loading force, k is the material coefficient, Δ is the bending runout, and D is the diameter of the steel pipe. The deviation is corrected by using a PID algorithm based on historical straightening data, with a deviation correction accuracy of ±0.001mm. The initial bending amount is divided into three intervals: 0-0.2mm, 0.2-0.5mm, and 0.5-1.0mm, with different straightening force gradients and loading times set for each interval.
[0054] During execution, in step 4, the bending runout and bending direction data obtained in step 3 are input into the PLC control system. The least squares method is used to fit the bending shape of the steel pipe to simulate the actual bending curve of the steel pipe. The material coefficient k is determined according to the steel pipe material and substituted into the formula F=k×Δ×D to calculate the theoretical loading force F. Historical straightening data of steel pipes of the same specification and material stored in the data acquisition unit are retrieved, and the PID algorithm is used to correct the deviation of the theoretical loading force to ensure that the deviation correction accuracy reaches ±0.001mm. According to the initial bending amount, it is divided into three categories: 0-0.2mm, 0.2-0.5mm, and 0.5-1.0mm. The system uses a range of parameters, each with a preset straightening force gradient and loading number. For steel pipes with initial bending amounts in different ranges, the corresponding straightening parameters are matched to determine the final straightening parameters. Under this setting, the least squares method fits the bending shape, accurately restoring the actual bending state of the steel pipe and providing a reliable basis for calculating the theoretical straightening amount. The PID algorithm, combined with historical data, corrects deviations, improving the accuracy of the straightening parameters and avoiding poor straightening caused by deviations between theoretical parameters and actual requirements. Straightening parameters are matched in groups according to bending amount ranges to adapt to steel pipes with different degrees of bending, avoiding over- or under-straightening, improving straightening quality and efficiency, and ensuring the consistency of straightening for steel pipes with different degrees of bending.
[0055] Furthermore, in step 5, the loading positioning accuracy is ±0.02mm, the average number of straightening loadings per point is 1-2 times / point, and the duration of a single loading is 1-2 seconds; the contact area between the straightening end and the steel pipe is 50-100mm², and the distance between the straightening end and the step position of the steel pipe is not less than 10mm, and it does not act on the step position of the steel pipe.
[0056] During execution, in step 5, based on the straightening parameters and bending position determined in step 4, the bending position of the steel pipe is precisely moved to the straightening point using a positioning mechanism. The position of the straightening end is adjusted to ensure that the distance between the straightening end and the step position of the steel pipe is not less than 10mm, avoiding application of force to the step position. The contact area between the straightening end and the steel pipe is adjusted to maintain it within the range of 50-100mm². The loading mechanism is then activated, applying a loading force with a loading positioning accuracy of ±0.02mm. Loading is performed at each straightening point 1-2 times per point, with the duration of each loading cycle controlled... During the 1-2 second loading process, the deformation status of the steel pipe is monitored in real time, and the deformation data is fed back to the PLC to dynamically adjust the loading parameters, realizing closed-loop control straightening. Under this setting, high-precision loading positioning ensures the accuracy of the straightening action point and avoids straightening misalignment caused by positioning deviation. Reasonable control of contact area, loading times and loading duration can ensure the straightening effect while avoiding damage to the steel pipe surface and local stress concentration. The steel pipe step positions are avoided to prevent deformation or damage at the steps, improving the straightening quality and the integrity of the steel pipe. Closed-loop control further ensures the stability and accuracy of the straightening process.
[0057] Furthermore, the auxiliary detection data is the light reflection intensity data of the steel pipe surface. Combined with the surface roughness data detected in step 1, an association judgment model is constructed to determine the validity of the runout measurement data. The measurement data is processed according to the judgment result, and the abnormal information is fed back to step 4 for targeted adjustment of the straightening parameters.
[0058] During the execution process, when performing step 3 measurement, the simple light sensor mounted on the measurement component is activated to synchronously collect light reflection intensity data on the steel pipe surface, with the collection frequency consistent with the vibration data collection frequency. The collected light reflection intensity data is correlated with the surface roughness data at the corresponding location detected in step 1 to construct a correlation judgment model and set judgment criteria. The vibration measurement data collected in step 3 is compared with the criteria in the correlation judgment model to determine whether the vibration data is valid. For vibration data determined to be invalid, resampling and measurement are performed, and data anomaly information (such as abnormal reflection intensity fluctuations or mismatch with roughness data) is transmitted. Proceed to step 4; In step 4, when calculating the straightening parameters, the straightening parameters of the corresponding measurement section are adjusted in a targeted manner based on the anomaly information to ensure that the straightening parameters are adapted to the actual condition of the steel pipe. Under this setting, the light reflection intensity data is used as auxiliary detection data, and a correlation model is constructed in combination with the surface roughness data. This can accurately identify the abnormal data fluctuations caused by impurities and minor scratches on the surface of the steel pipe, avoiding invalid data from interfering with the calculation of straightening parameters. Through the feedback of abnormal information and the targeted adjustment of parameters, the adaptability of the straightening parameters is improved, solving the straightening deviation problem caused by abnormal measurement data in the existing process, and further improving the straightening accuracy and consistency of straightening quality.
[0059] Furthermore, in step 5, for brittle steel pipes, the loading force and deformation are monitored in real time during the straightening process. When the deformation suddenly increases by more than 0.01 mm / s, the loading is stopped immediately. In step 6, if the retest fails, the straightening and retesting process is repeated no more than 3 times. If it exceeds 3 times, the workpiece is judged as unqualified.
[0060] During execution, in step 5, it is first determined whether the steel pipe is a brittle steel pipe (determined based on the steel pipe material parameters). If it is a brittle steel pipe, the real-time monitoring module for loading force and deformation is activated to collect loading force data and steel pipe deformation data in real time and calculate the rate of change of deformation. When a sudden increase in deformation is detected, with the rate of change exceeding 0.01 mm / s, the PLC immediately issues a command to stop the loading mechanism to prevent the brittle steel pipe from breaking or severely deforming due to excessive force. In step 6, during retesting, if the straightened steel pipe does not meet the qualification standard, the repeated straightening process is initiated, and the steps are executed again. Step 5 involves straightening and step 6 involves retesting, recording the number of repetitions. If the steel pipe fails to meet the standard after three repetitions, it is marked as a defective workpiece and transferred to the subsequent processing flow, where it will not be straightened again. Under this setting, considering the characteristics of brittle steel pipes, the loading is stopped in a timely manner by monitoring the rate of change of deformation in real time, effectively avoiding damage problems such as fracture and deformation of brittle steel pipes, improving the safety of the straightening process and the straightening pass rate of brittle steel pipes. Limiting the number of repetitions of straightening avoids the waste of time and cost caused by ineffective straightening, improves production efficiency, and at the same time ensures the quality of straightened workpieces, preventing defective workpieces from flowing into subsequent processes.
[0061] Furthermore, in step 5, the support spacing is adjusted proportionally according to the diameter and length of the steel pipe, with the ratio of support spacing to steel pipe length being 1:3-1:4; when the diameter of the steel pipe is 80mm, the support spacing is not less than 800mm; if the yield strength of the steel pipe material is higher than 600Mpa, the support spacing is increased by 10%-20%; if the loading position deviates from the midpoint of the steel pipe, the support spacing is increased by 50mm for every 100mm increase in deviation distance.
[0062] During execution, when supporting the steel pipe in step 5, first obtain parameters such as the diameter, length, material yield strength, and loading position of the steel pipe; calculate the benchmark support spacing according to the steel pipe diameter and length at a ratio of 1:3-1:4; if the steel pipe diameter is 80mm, compare the calculated benchmark support spacing with 800mm, and take the larger value as the final support spacing; if the yield strength of the steel pipe material is higher than 600Mpa, increase the benchmark support spacing by 10%-20%; if the loading position deviates from the midpoint of the steel pipe, measure the deviation distance, and for every 100mm deviation, increase the existing support spacing by 50mm, adjust the position of the support mechanism, and after completing the support spacing adjustment, perform loading straightening. Under this setting, the support spacing is dynamically adjusted according to the steel pipe specifications, material, and loading position to ensure support stability and avoid secondary bending or deformation of the steel pipe during the straightening process; for large-diameter, high-yield-strength steel pipes and cases where the loading position deviates from the midpoint, optimize the support spacing to further improve support reliability, ensure the stability of the straightening process, reduce straightening deviation, and improve straightening accuracy and the straightness of the steel pipe after straightening.
[0063] Furthermore, the correlation judgment model is a three-dimensional correlation judgment model of reflection intensity, roughness, and runout. Only measurement segment data with reflection intensity fluctuation ≤5% and matching with the roughness data at the corresponding position and deviation ≤0.01Ra can be used as the basis for calculating bending parameters. For measurement segments with reflection intensity fluctuation exceeding the range or not matching with the roughness data, a single sampling measurement is performed again, and the measurement segment is marked as a surface abnormal segment. The targeted fine-tuning range of the straightening parameters is 3%-5% of the conventional parameters.
[0064] During execution, when performing steps 3 and 4, a three-dimensional correlation judgment model of reflection intensity, roughness, and runout is constructed. The surface roughness data detected in step 1, the illumination reflection intensity data collected in step 3, and the runout measurement data are correlated and matched according to the corresponding measurement segments. A judgment criterion is set: the reflection intensity fluctuation is ≤5% and the deviation from the corresponding roughness data is ≤0.01Ra. Measurement segment data that meets this criterion is judged as valid data and used as the basis for calculating the bending parameters in step 4. For measurement segments with reflection intensity fluctuation exceeding 5% or deviation from the roughness data exceeding 0.01Ra, the measurement component is controlled to re-sample and measure the measurement segment, and the measurement segment is marked by the system. For the abnormal surface section; in step 4, when adjusting the straightening parameters, for this abnormal surface section, make targeted fine adjustments within a range of 3%-5% of the conventional straightening parameters to determine the straightening parameters for this section. Under this setting, the three-dimensional correlation judgment model can more accurately determine the validity of the runout measurement data compared to single correlation, effectively distinguishing between temporary attached debris and inherent roughness anomalies on the steel pipe surface, and avoiding data misjudgment; resampling ensures the accuracy of the abnormal measurement section data, and marking the abnormal surface section facilitates subsequent traceability and processing; the targeted fine adjustment range of 3%-5% can adapt to the actual state of the abnormal surface section, and avoid over- or under-adjustment, further improving the accuracy of the straightening parameters and ensuring the straightening quality of the abnormal surface section.
[0065] Furthermore, for the marked surface anomaly segments, their location, anomaly type, and corresponding straightening parameter fine-tuning data are recorded simultaneously to construct an association database of surface anomalies and straightening parameter fine-tuning. When straightening steel pipes of the same specification and material in the future, if the same type of surface anomaly is detected during the measurement process in step 3, the corresponding fine-tuning parameters in the association database can be directly called without recalculating the parameters, thus achieving rapid adaptation of straightening parameters. At the same time, by continuously accumulating anomaly data and fine-tuning parameters, the judgment threshold of the three-dimensional association judgment model is dynamically optimized.
[0066] During execution, after fine-tuning the parameters of the surface anomaly segment in step 4, the specific location, anomaly type (such as excessive reflection intensity fluctuation or mismatch between roughness and reflection intensity), and corresponding straightening parameter fine-tuning data of the surface anomaly segment are recorded simultaneously. This data is then organized and stored in a related database, categorized by steel pipe specification and material. When straightening steel pipes of the same specification and material subsequently, if a surface anomaly of the same type as in the database is detected during the measurement in step 3, the system automatically retrieves the corresponding straightening parameter fine-tuning data from the database and directly applies it to the straightening parameter adjustment in step 4, without recalculating the fine-tuning parameters. Simultaneously, each time new surface anomaly data is added... After adjusting the corresponding fine-tuning parameters, the system automatically and dynamically optimizes the judgment threshold of the three-dimensional correlation judgment model, making the judgment criteria more consistent with the surface anomalies in actual production. Under this setting, the construction of the correlation database enables the reuse of straightening fine-tuning parameters, avoiding the need to recalculate parameters every time a surface anomaly occurs, greatly improving straightening efficiency and reducing manual calculation costs. Dynamically optimizing the judgment threshold of the three-dimensional correlation judgment model can continuously improve the accuracy of judging the validity of fluctuating data, reduce data misjudgment, further improve the adaptability of straightening parameters and straightening quality, forming a closed loop of "anomaly identification - parameter fine-tuning - data accumulation - model optimization", breaking through the inherent limitations of existing processes. Example 2
[0067] like Figures 1 to 3 As shown, a steel pipe straightening device is used, employing the steel pipe straightening process described in Example 1.
[0068] During execution, the steel pipe straightening equipment includes a straightening station, a positioning and clamping mechanism, a multi-dimensional measurement component, a straightening execution mechanism, a data processing module, and a storage module. These components work together to execute the process described in Example 1. The positioning and clamping mechanism performs the positioning and clamping operation in step 2; the multi-dimensional measurement component performs the runout measurement and auxiliary detection data acquisition operation in step 3; the straightening execution mechanism performs the support and loading straightening operation in step 5; the data processing module performs data processing, correlation determination, parameter calculation, and dynamic optimization operations; and the storage module stores measurement data, straightening data, and a correlation database. After the equipment is started, it sequentially completes operations such as steel pipe positioning, clamping, measurement, parameter calculation, straightening, re-measurement, pipe removal, and data management according to the process steps, realizing full automation of the steel pipe straightening process. Under this setting, the equipment is precisely adapted to the above-mentioned steel pipe straightening process, without the need for additional special parts, with a simple structure and low cost. All components work together to realize full automation of the steel pipe straightening process, improving production efficiency. It can accurately execute various technical features in the process, ensuring straightening accuracy and quality, adapting to steel pipes of different specifications and materials, meeting the needs of large-scale, high-precision steel pipe straightening, while realizing standardized data management and process traceability.
[0069] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Unless otherwise specified, an element defined by the phrase "comprising..." or "including..." does not exclude the presence of additional elements in the process, method, article, or terminal device that includes said element. Additionally, in this document, "greater than," "less than," "exceeding," etc., are understood to exclude the stated number; "above," "below," "within," etc., are understood to include the stated number.
[0070] The above description of the embodiments is provided to facilitate understanding and use of the present invention by those skilled in the art. It is obvious to those skilled in the art that various modifications can be easily made to the embodiments, and the general principles described herein can be applied to other embodiments without creative effort. Therefore, the present invention is not limited to the above embodiments. Improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the present invention should be within the protection scope of the present invention.
Claims
1. A steel pipe straightening process, characterized in that, Includes the following steps: Step 1: Select the steel pipe to be straightened, check the surface roughness of its runout test section and ensure that it meets the straightening requirements, place the steel pipe at the straightening station and complete the positioning; Step 2: Position and clamp both ends of the steel pipe to ensure stable clamping without damaging the surface of the steel pipe; Step 3: Perform multi-dimensional runout measurement on the steel pipe, collect and process the data, determine the bending runout, bending direction and bending position of the steel pipe, and record the initial runout data; Step 4: Combining the steel pipe's own parameters and the bending data obtained from the test, perform fitting analysis on the bending shape of the steel pipe and calculate the straightening parameters to determine the final straightening parameters; for steel pipes with a large range of initial bending amount, match the corresponding straightening parameters according to the initial bending amount group. Step 5: Locate the bending direction of the steel pipe and move the bending position to the straightening point. After supporting the steel pipe, apply a loading force, monitor the deformation state of the steel pipe in real time, and dynamically adjust the loading parameters to achieve closed-loop control straightening. Step 6: Retest the straightened steel pipe to determine if it meets the preset qualification standard. If it meets the standard, the straightening is completed and the straightening process data is recorded. If it does not meet the standard, repeat the straightening and retesting process. Step 7: Remove the support and clamping of the steel pipe, take out the steel pipe, view and export the straightening data through the access control mechanism, and use the historical traceability mechanism to realize process monitoring and equipment maintenance; During the measurement process in step 3, relevant auxiliary detection data on the surface of the steel pipe are collected simultaneously. The auxiliary detection data is correlated with the runout measurement data, the validity of the runout measurement data is determined, the measurement data is processed according to the determination result, and the abnormal information is fed back to step 4 to adjust the straightening parameters. In step 1, a surface roughness tester is used to detect the surface roughness of the runout test section of the steel pipe. The surface roughness requirement is better than Ra6.
3. The steel pipe is placed at the straightening station by manual or mechanical handling to ensure that the axis of the steel pipe is parallel to the baseline of the straightening station and the positioning deviation does not exceed ±0.5mm. The auxiliary detection data is the light reflection intensity data of the steel pipe surface. Combined with the surface roughness data detected in step 1, an association judgment model is constructed to determine the validity of the runout measurement data. The measurement data is processed according to the judgment result, and the abnormal information is fed back to step 4 to adjust the straightening parameters in a targeted manner. Only measurement data with a reflection intensity fluctuation of ≤5% and matching with the corresponding roughness data, and a deviation of ≤0.01Ra, can be used as the basis for calculating bending parameters. For measurement segments with reflection intensity fluctuations exceeding the range or not matching the roughness data, a single sampling measurement should be performed again, and the measurement segment should be marked as a surface abnormality segment. The targeted fine-tuning of the straightening parameters should be 3%-5% of the conventional parameters.
2. The steel pipe straightening process according to claim 1, characterized in that, In step 1, the diameter of the steel pipe to be straightened is 30-80mm, the wall thickness is ≤6mm, and the length is 1200mm-3000mm. For steel pipes with a surface roughness lower than Ra6.3, they are marked as specially treated workpieces. No filtering is performed during subsequent measurements, and straightening is carried out according to the full runout standard.
3. The steel pipe straightening process according to claim 1, characterized in that, In step 2, the two ends of the steel pipe are axially positioned by the positioning cylinder, with the positioning deviation controlled within ±0.02mm. The two ends of the steel pipe are clamped by floating clamping claws, with the clamping force controlled within 50-100kN to ensure that the steel pipe has no radial displacement or surface damage after clamping.
4. The steel pipe straightening process according to claim 1, characterized in that, In step 3, three sets of mobile high-precision measuring components are used to move at a constant speed along the length of the steel pipe, while simultaneously driving the steel pipe to rotate at a constant speed. After collecting the runout data of the steel pipe, a low-pass filtering algorithm is used for filtering. The bending parameters of the steel pipe are calculated by the PLC, and the initial runout data is stored in the data acquisition unit with a storage accuracy of 0.001mm.
5. The steel pipe straightening process according to claim 1, characterized in that, In step 4, the least squares method is used to fit and analyze the bending morphology of the steel pipe, and the theoretical straightening amount is calculated according to the formula F=k×Δ×D, where F is the theoretical loading force, k is the material coefficient, Δ is the bending runout, and D is the diameter of the steel pipe. The deviation is corrected by using a PID algorithm based on historical straightening data, with a deviation correction accuracy of ±0.001mm. The initial bending amount is divided into three intervals: 0-0.2mm, 0.2-0.5mm, and 0.5-1.0mm, and different straightening force gradients and loading times are set for each interval.
6. The steel pipe straightening process according to claim 1, characterized in that, In step 5, the loading positioning accuracy is ±0.02mm, the average number of straightening loadings per point is 1-2 times / point, and the duration of a single loading is 1-2 seconds; the contact area between the straightening end and the steel pipe is 50-100mm², and the distance between the straightening end and the step position of the steel pipe is not less than 10mm, and it does not act on the step position of the steel pipe.
7. The steel pipe straightening process according to claim 1, characterized in that, In step 5, for brittle steel pipes, the loading force and deformation are monitored in real time during the straightening process. When the deformation suddenly increases by more than 0.01 mm / s, the loading is stopped immediately. In step 6, if the retest fails, the straightening and retesting process is repeated no more than 3 times. If it exceeds 3 times, the workpiece is judged as unqualified.
8. A steel pipe straightening device, characterized in that, The steel pipe straightening process described in any one of claims 1 to 7 shall be applied.