Straightening device for steel pipe poles based on fixed clamping and multi-point stamping

Abstract

The present application relates to the technical field of steel pipe pole straightening, and particularly relates to a steel pipe pole straightening device based on fixed clamping and multi-point stamping, which comprises a multi-point stamping execution system, a plurality of stamping heads and a clamping assembly; an active acoustic excitation module is used to apply preset acoustic excitation to the steel pipe pole during intermittent periods when the stamping heads are unloaded; an acoustic emission positioning module is used to collect elastic wave response signals generated by the preset acoustic excitation and acoustic emission signals generated spontaneously during the stamping loading process, and output coordinate signals of damage sources. The present application uses active acoustic excitation to evaluate the local damage risk of the steel pipe pole in advance before stamping loading, and uses stiffness signals and acoustic emission signals generated spontaneously during the stamping loading process to carry out hardware demodulation verification in the stamping loading stage; the steel pipe pole is prevented from being crushed, dented or micro-cracked during the straightening process, and the straightening operation efficiency and the safety of the steel pipe pole body are taken into account.

Description

Technical Field

[0001] This invention relates to the field of steel pipe pole straightening technology, and in particular to a steel pipe pole straightening device based on fixed clamping and multi-point stamping. Background Technology

[0002] Steel pipe poles, widely used structural components in construction, road, and bridge engineering, inevitably undergo bending deformation during manufacturing, transportation, and storage, requiring correction during the straightening process. Currently, multi-point pressure straightening machines are commonly used for straightening. However, the protection of steel pipe poles during straightening relies mainly on preset force or displacement upper limit thresholds, which cannot detect microscopic damage within the material in real time. When steel pipe poles have localized material inhomogeneity, minor defects, or stress concentration, the preset protection thresholds may fail to respond in time, leading to crushing, denting, or microcrack initiation during straightening, resulting in the scrapping of the finished product.

[0003] Chinese Patent Publication No. CN121715444A discloses a straightening device and method for welded pipe processing, including a support leg, a support rod installed at the bottom of the support leg, a control box installed on one side of the support leg, a worktable installed at the top of the support leg, and a first gear installed at the top of the support. This invention, by installing a support at the top of the connecting block, allows the welded pipe to be placed on the positioning plate and the top of the connecting block. A second motor at the top of the support rotates the first gear, which in turn rotates the first screw. The lifting plate's movement causes the limiting block to rise and fall. When the limiting block descends, it presses against the bottom of the welded pipe. The first right-angle gear at the bottom of the first gear also rotates, and the movement of the second screw moves the limiting plate, which presses against both ends of the welded pipe. This limits the two ends of the welded pipe, and the limiting block also limits the top of the welded pipe, thus achieving the purpose of facilitating the limiting of the welded pipe in the straightening device for welded pipe processing.

[0004] Therefore, the existing technologies described above have the following problems: Firstly, there is a lack of proactive assessment methods for the risk of localized damage to the steel pipe rod before stamping loading. Secondly, the straightening strategy is formulated solely based on initial bending morphology measurements, failing to predict the differences in load-bearing capacity across different bending regions. This leads to the potential for applying loads to high-risk areas during the straightening process, potentially causing damage. Thirdly, the damage protection mechanisms of existing devices primarily rely on preset force or displacement thresholds, failing to reliably and timely identify abnormal changes within the material at the microscopic damage stage. Protection is often triggered only after macroscopic damage has already occurred, making it difficult to balance straightening efficiency with the safety of the steel pipe rod. Summary of the Invention

[0005] To address this, the present invention provides a steel pipe pole straightening device based on fixed clamping and multi-point stamping, which overcomes the problem in the prior art that there is a lack of proactive assessment of the risk of local damage to the steel pipe pole before stamping loading, making it impossible to predict the difference in load-bearing capacity of each bending area, and resulting in blind loading of high-risk areas, which leads to damage to the steel pipe pole.

[0006] To achieve the above objectives, the present invention provides a steel pipe rod straightening device based on fixed clamping and multi-point punching, comprising: A multi-point stamping execution system, comprising a clamping assembly and several stamping heads; The stiffness sensing module consists of several stiffness sensing sub-modules respectively set in each of the stamping heads, which are used to output stiffness signals that characterize the instantaneous stiffness of the corresponding stamping point of the steel pipe rod in real time. An active acoustic excitation module is used to apply a preset acoustic excitation to the steel pipe rod during the interval of unloading of the stamping head; The acoustic emission positioning module is used to collect the elastic wave response signal generated by the preset acoustic excitation, as well as the acoustic emission signal spontaneously generated during the stamping loading process, and output the coordinate signal of the damage source. An acoustic response analysis module, which is connected to the acoustic emission positioning module, generates a risk indication signal characterizing the damage risk of the steel pipe pole based on the difference between the elastic wave response signal and the preset health reference signal. A coherent verification module is connected to the stiffness sensing module and the acoustic emission positioning module respectively, and is used to receive the stiffness signal and the acoustic emission signal, and output a damage locking signal through hardware demodulation. The damage locking signal carries the channel identifier of the stamping head that triggered the damage locking signal. An adaptive compensation module, which is connected to the coherent verification module and the acoustic response analysis module respectively, cuts off the drive circuit corresponding to the stamping head based on the received damage locking signal, and distributes the remaining bending amount to be straightened to the other stamping heads whose drive circuits have not been cut off; When no damage lock signal is received, the adaptive compensation module is used to adjust the stamping loading parameters according to the risk indication signal.

[0007] Furthermore, the stiffness-sensing submodule includes: A force sensing unit is used to collect the contact force between the stamping head and the steel pipe rod; A displacement sensing unit is used to collect the loading stroke of the stamping head; The phase-locked loop circuit unit uses the output signal of the force sensing unit as input and the output signal of the displacement sensing unit as feedback to construct a closed-loop locking topology and outputs an analog control voltage characterizing instantaneous stiffness.

[0008] Furthermore, the active acoustic excitation module includes: An acoustic excitation execution submodule is used to apply a preset acoustic excitation to the surface of the steel pipe rod; An acoustic excitation timing control submodule is used to ensure that the preset acoustic excitation is triggered only during the interval when the stamping head is completely unloaded.

[0009] Furthermore, the acoustic response analysis module includes: The signal conditioning submodule is connected to the acoustic emission positioning module and is used to amplify the elastic wave response signal and perform pre-interference filtering. A feature extraction submodule, which is connected to the signal conditioning submodule, has a built-in analog bandpass filter and energy detection unit to filter the target frequency band from the elastic wave response signal after pre-interference filtering and extract the energy attenuation characteristic parameters under the target frequency band. The probability generation submodule, which is connected to the feature extraction submodule, has a built-in benchmark storage unit and a simulation comparison network to compare the extracted energy decay feature parameters with a preset health benchmark signal to generate the risk indication signal.

[0010] Furthermore, the coherent verification module includes multiple independent verification channel sub-modules, and each verification channel sub-module corresponds to a set of stiffness sensing sub-modules.

[0011] Furthermore, the independent verification channel submodule includes: The pulse triggering unit is used to receive the stiffness signal output by the stiffness sensing submodule corresponding to the corresponding independent verification channel submodule, and output a trigger pulse when the stiffness signal has a falling edge that meets the preset conditions; A local oscillation unit, which is synchronously triggered by the trigger pulse output by the pulse triggering unit, generates a reference carrier that is time-aligned with the stiffness drop event. The analog multiplier unit is used to perform hardware mixing of the reference carrier with the acoustic emission signal spontaneously generated during the stamping loading process after spatial gating of the coordinate signal of the damage source. The integral filtering unit is used to extract the coherent DC component obtained after hardware mixing; The threshold comparison unit is used to compare the coherent DC component with a preset threshold and output the damage lock signal carrying the corresponding stamping head channel identifier.

[0012] Furthermore, the adaptive compensation module includes: The hardware state latching submodule is used to mark the corresponding stamping head as damaged and disabled based on the channel identifier of the stamping head carried by the damage locking signal, and to latch the bending compensation amount that has been dissipated by the corresponding stamping head. The analog routing distribution submodule has a built-in analog switch array and charge pump distribution network; the analog switch array is used to disconnect the drive circuit of the stamping head marked as damaged and disabled; the charge pump distribution network is used to distribute the remaining bending amount to be straightened in the form of analog voltage to the drive circuit of the remaining stamping heads not marked as damaged and disabled. The loading adjustment submodule is used to compare the risk indication signal with a multi-level preset threshold when no damage lock signal is received, and adjust the stamping loading parameters of each stamping head according to the comparison result.

[0013] Furthermore, it also includes a cooperative strategy hardware state machine module, which includes: The strategy generation submodule is used to output a cooperative strategy control word based on the damage locking signal; The adaptive compensation module selects one of the following based on different cooperative strategy control words: stop only the stamping head marked as damaged and disabled and let the remaining stamping heads share the compensation, or stop all stamping heads and rotate the steel pipe rod before reloading.

[0014] Furthermore, the cooperative strategy hardware state machine module also includes: Event counting submodule and threshold comparison submodule; The event counting submodule is used to accumulate the number of times the damage lock signal is triggered within the same calibration cycle; The threshold comparison submodule is used to output a global shutdown alarm signal and latch all the drive circuits of the stamping head when the number of triggers accumulated by the event counting submodule exceeds the pre-designed numerical threshold.

[0015] Furthermore, it also includes an initial bending sensing module, which is used to acquire the initial spatial bending shape information of the steel pipe rod and output the initial spatial bending shape information of the steel pipe rod to the adaptive compensation module to provide an initial loading target displacement reference for each of the stamping heads.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: the present invention overcomes the inherent defects of existing straightening equipment that rely solely on preset force and displacement thresholds for protection by combining active acoustic prediction with passive hardware coherent verification through a dual-mode protection system; before the stamping loading, active acoustic excitation is used to assess the risk of local damage to the steel pipe pole in advance, and during the stamping loading stage, hardware demodulation verification is carried out through stiffness signals and acoustic emission signals spontaneously generated during the stamping loading process; it can both predict the differences in the load-bearing capacity of each bending area of ​​the steel pipe pole and avoid blindly applying loads to high-risk areas, and can also identify anomalies in a timely manner at the stage of micro-damage initiation, avoiding crushing, denting, and micro-cracks in the steel pipe pole during the straightening process, thus balancing the efficiency of the straightening operation and the safety of the steel pipe pole itself.

[0017] Furthermore, this invention utilizes a closed-loop locking topology to convert the instantaneous stiffness of the stamping point into an analog control voltage directly output by the hardware, avoiding the time delay caused by software sampling and calculation, and achieving sub-millisecond real-time acquisition of stiffness changes. The coherent verification module adopts a hardware coherent demodulation mechanism, which only outputs a damage locking signal when the stiffness drop event and the acoustic emission event match simultaneously in time and space. This can distinguish between normal plastic yielding of steel pipe rods and actual pipe damage, reducing the probability of misjudgment and missed judgment under strong noise conditions in the workshop, and improving the reliability of damage identification.

[0018] Furthermore, this invention achieves hierarchical and progressive damage handling by combining an adaptive compensation module with a collaborative strategy hardware state machine module. When damage is detected, based on the trigger count value of the damage locking signal within the same straightening cycle, it can selectively execute multi-level handling logic such as single stamping head disabling to share the remaining bending amount to be straightened, stopping all stamping heads and rotating the steel pipe rod for reloading, and global shutdown alarm. At the hardware level, the stamping head drive circuit is directly cut off, resulting in a fast handling response speed. At the same time, a count value clearing mechanism is set to adapt to multiple straightening cycles, improving the device's adaptability to operating conditions.

[0019] Furthermore, this invention utilizes an initial bending sensing module to acquire initial spatial bending morphology information of the steel pipe pole, providing an initial loading target displacement reference for each stamping head. This ensures that the loading reference of the multi-point stamping execution system conforms to the actual bending state of the steel pipe pole, guaranteeing the overall accuracy of multi-point stamping straightening. All modules, sub-modules, and units of the entire device rely on hardware circuits to achieve signal processing and logic judgment, eliminating the need for complex upper-level computer software calculations. This facilitates engineering implementation and deployment at the steel pipe pole straightening production site. Attached Figure Description

[0020] Figure 1 This is a flowchart illustrating the overall workflow of the dual-mode protection system for straightening steel pipe poles according to an embodiment of the present invention. Figure 2 This is a flowchart illustrating the workflow of the active acoustic prediction defense system according to an embodiment of the present invention. Figure 3This is a flowchart of the passive damage coherent hardware demodulation verification process during the stamping loading stage according to an embodiment of the present invention. Figure 4 This is a flowchart illustrating the damage classification and handling process of the hardware state machine for the collaborative strategy according to an embodiment of the present invention. Figure 5 This is a schematic diagram of the overall structure of an embodiment of the present invention; Figure 6 This is a top view of the overall structure of an embodiment of the present invention; Figure 7 This is a right view of the overall structure of an embodiment of the present invention.

[0021] Reference numerals: 1-Frame, 2-Multi-point stamping execution system, 3-Stamping head, 4-Rotating mechanism, 201-Clamping assembly, 301-Stiffness sensing module, 5-Active acoustic excitation module, 6-Acoustic emission positioning module, 7-Acoustic response analysis module, 8-Coherent verification module, 9-Adaptive compensation module. Detailed Implementation

[0022] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0023] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0024] It should be noted that in the description of this invention, the terms "upper", "lower", "left", "right", "inner", "outer", etc., which indicate directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and is not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0025] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0026] Please see Figure 1 and Figures 5-7The diagram shown is a flowchart of the dual-mode protection system according to an embodiment of the present invention. The present invention proposes a steel pipe rod straightening device based on fixed clamping and multi-point stamping, including: a multi-point stamping execution system, which includes a clamping assembly and several stamping heads; and a stiffness sensing module, which consists of several stiffness sensing sub-modules respectively set on each of the stamping heads, for outputting stiffness signals that characterize the instantaneous stiffness of the corresponding stamping point of the steel pipe rod in real time.

[0027] An active acoustic excitation module is used to apply a preset acoustic excitation to the steel pipe rod during the interval of unloading the stamping head; an acoustic emission positioning module is used to collect the elastic wave response signal generated by the preset acoustic excitation and the acoustic emission signal spontaneously generated during the stamping loading process, and output the coordinate signal of the damage source; an acoustic response analysis module, which is connected to the acoustic emission positioning module, generates a risk indication signal characterizing the damage risk of the steel pipe rod based on the difference between the elastic wave response signal and the preset health reference signal.

[0028] A coherent verification module, connected to the stiffness sensing module and the acoustic emission positioning module, receives the stiffness signal and the acoustic emission signal, and outputs a damage locking signal through hardware demodulation. The damage locking signal carries the channel identifier of the stamping head that triggered the damage locking signal. An adaptive compensation module, connected to the coherent verification module and the acoustic response analysis module, cuts off the drive circuit corresponding to the stamping head based on the received damage locking signal, and distributes the remaining bending amount to be straightened to the other stamping heads whose drive circuits have not been cut off. When no damage locking signal is received, the adaptive compensation module adjusts the stamping loading parameters according to the risk indication signal.

[0029] In this embodiment, the clamping assembly of the multi-point stamping execution system is used to clamp and position the steel pipe rod; the stiffness signal is an analog voltage signal, and the voltage amplitude of the stiffness signal increases with the increase of the instantaneous stiffness of the corresponding stamping point of the steel pipe rod; the preset acoustic excitation is an excitation signal applied during the unloading interval; the elastic wave response signal is the elastic wave signal generated after the preset acoustic excitation is applied to the steel pipe rod.

[0030] In this embodiment, the acoustic emission signal spontaneously generated during the stamping loading process is the acoustic wave signal generated by the steel pipe rod under the stamping loading action; the coordinate signal of the damage source is used to characterize the signal generation position on the steel pipe rod; the preset health benchmark signal is the reference signal obtained by calibrating an intact steel pipe rod; the risk indication signal characterizes the level of damage risk of the steel pipe rod; the damage locking signal is the judgment signal of the channel identification carrying the stamping head; the stamping loading parameters include stamping stroke parameters and stamping loading force parameters.

[0031] Specifically, this invention employs two sets of handling logics: proactive prediction and passive damage interception. It can assess damage risks in advance by relying on preset acoustic excitation and acoustic response analysis modules, and it can also perform hardware demodulation and determination of damage during the stamping and straightening process by relying on stiffness sensing modules and coherence verification modules. When damage is confirmed, the stamping head is cut off and the remaining bending amount to be straightened is allocated. When there is no damage lock signal, the stamping loading parameters are adjusted according to the risk indication signal, thus achieving dual safety protection throughout the straightening process.

[0032] In this embodiment, during operation, the steel pipe rod is clamped and fixed by the clamping assembly of the multi-point stamping execution system; each stiffness sensing submodule of the stiffness sensing module collects the position status of each stamping head and outputs stiffness signals; the active acoustic excitation module applies a preset acoustic excitation to the steel pipe rod during the interval of stamping head unloading; the acoustic emission positioning module synchronously collects the elastic wave response signal generated by the preset acoustic excitation and the acoustic emission signal spontaneously generated during the stamping loading process and outputs the coordinate signal of the damage source; the acoustic response analysis module receives the elastic wave response signal, compares the elastic wave response signal with the preset health benchmark signal, and generates a risk indication signal.

[0033] The coherent verification module receives the stiffness signal and the acoustic emission signal spontaneously generated during the stamping loading process, and obtains the damage lock signal through hardware demodulation; the adaptive compensation module receives the damage lock signal and the risk indication signal; when the adaptive compensation module receives the damage lock signal, it cuts off the drive circuit of the corresponding stamping head and distributes the remaining bending amount to be straightened to the other stamping heads whose drive circuits have not been cut off; when no damage lock signal is received, the adaptive compensation module adjusts the stamping loading parameters according to the risk indication signal to complete the straightening operation of the steel pipe rod.

[0034] Please see Figure 3 As shown, the stiffness sensing submodule includes: a force sensing unit for collecting the contact force between the stamping head and the steel pipe rod; a displacement sensing unit for collecting the loading stroke of the stamping head; and a phase-locked loop circuit unit that uses the output signal of the force sensing unit as input and the output signal of the displacement sensing unit as feedback to construct a closed-loop locking topology and output an analog control voltage characterizing instantaneous stiffness.

[0035] In this embodiment, the force sensing unit outputs an electrical signal corresponding to the contact force, and the displacement sensing unit outputs an electrical signal corresponding to the loading stroke; the phase-locked loop circuit unit receives the electrical signal corresponding to the contact force and the electrical signal corresponding to the loading stroke as inputs, and outputs an analog control voltage characterizing the instantaneous stiffness; the magnitude of the analog control voltage is positively correlated with the instantaneous stiffness of the stamping point.

[0036] In this embodiment, the loop parameter setting principle of the phase-locked loop circuit unit is as follows: the loop bandwidth selection needs to take into account both response speed and noise immunity. The loop bandwidth is determined based on the maximum load change rate of the stamping head and the electromagnetic noise level at the site. The loop gain is pre-calibrated based on the material range and wall thickness specifications of the steel pipe rod to ensure that the phase-locked loop circuit unit can stably track the output signals of the force sensing unit and the displacement sensing unit, and avoid loop loss of lock.

[0037] Specifically, this invention relies on force sensing units and displacement sensing units to collect the contact force and loading stroke of the stamping head, and phase-locked loop circuit units to form a closed-loop locking topology, directly outputting an analog control voltage characterizing instantaneous stiffness, avoiding the time delay caused by software acquisition and calculation, and realizing real-time hardware output of the instantaneous stiffness of the stamping point.

[0038] In this embodiment, the force sensing unit collects the contact force between the stamping head and the steel pipe rod and converts it into a corresponding electrical signal output; the displacement sensing unit collects the loading stroke of the stamping head and converts it into a corresponding electrical signal output; the phase-locked loop circuit unit takes the output signal of the force sensing unit as input and the output signal of the displacement sensing unit as feedback to form a closed-loop locking topology; the phase-locked loop circuit unit internally tracks the output signals of the force sensing unit and the displacement sensing unit, and outputs an analog control voltage characterizing the instantaneous stiffness, which is then output to the subsequent coherent verification module.

[0039] Please see Figure 2 As shown, the active acoustic excitation module includes: an acoustic excitation execution submodule for applying a preset acoustic excitation to the surface of the steel pipe rod; and an acoustic excitation timing control submodule for ensuring that the preset acoustic excitation is triggered only during the interval when the stamping head is completely unloaded.

[0040] In this embodiment, the acoustic excitation execution submodule outputs a preset acoustic excitation; the acoustic excitation timing control submodule receives the unloading-loading status signal of each stamping head as input, and outputs the enable control signal of the preset acoustic excitation; the acoustic excitation timing control submodule outputs an effective enable control signal only when all stamping heads are in a fully unloaded state.

[0041] In one embodiment, a physical implementation example of the acoustic excitation execution submodule is an electromagnetic striking mechanism. The electromagnetic striking mechanism receives the enable control signal output by the acoustic excitation timing control submodule, generates a transient impact, and outputs a preset acoustic excitation to the steel pipe pole. The striking force and striking duration of the electromagnetic striking mechanism are pre-determined based on the material and wall thickness of the steel pipe pole to ensure that the elastic wave response signal generated by the preset acoustic excitation can be effectively acquired by the acoustic emission positioning module.

[0042] Specifically, the present invention strictly constrains the triggering timing of the preset acoustic excitation through the acoustic excitation timing control submodule, ensuring that the preset acoustic excitation is triggered only during the interval when the stamping head is completely unloaded, avoiding interference from the stress wave of stamping loading with the signal generated by the preset acoustic excitation, and ensuring the reliability of subsequent risk assessment results.

[0043] In this embodiment, during the operation of the active acoustic excitation module, the acoustic excitation timing control submodule receives the working status signals of each stamping head and determines whether all stamping heads are in a fully unloaded state. When it is determined that all stamping heads are in the interval of full unloading, the acoustic excitation timing control submodule outputs an enable signal, allowing the acoustic excitation execution submodule to output a preset acoustic excitation. As long as any stamping head is in a loaded state, the acoustic excitation timing control submodule prohibits the acoustic excitation execution submodule from operating and does not output the preset acoustic excitation.

[0044] Please see Figure 2 As shown, the acoustic response analysis module includes: a signal conditioning submodule connected to the acoustic emission positioning module, used to amplify and pre-filter the elastic wave response signal; a feature extraction submodule connected to the signal conditioning submodule, which incorporates an analog bandpass filter and an energy detection unit to filter target frequency bands from the elastic wave response signal after pre-filtering and extract energy attenuation characteristic parameters under the target frequency band; and a probability generation submodule connected to the feature extraction submodule, which incorporates a reference storage unit and an analog comparison network to compare the extracted energy attenuation characteristic parameters with a preset health reference signal to generate the risk indication signal.

[0045] In this embodiment, the signal conditioning submodule takes an elastic wave response signal as input and outputs an elastic wave response signal that has been amplified and pre-filtered for interference suppression. The feature extraction submodule takes an elastic wave response signal that has been pre-filtered for interference suppression as input and outputs an energy attenuation characteristic parameter at the target frequency band. The probability generation submodule takes an energy attenuation characteristic parameter and a preset health baseline signal as input and outputs a risk indication signal. The target frequency band is selected based on the material and wall thickness of the steel pipe pole and existing industry experience in acoustic emission detection.

[0046] In this embodiment, the signal conditioning submodule receives the elastic wave response signal from the acoustic emission positioning module, amplifies and performs pre-interference filtering on the elastic wave response signal, and outputs the pre-interference filtering elastic wave response signal to the feature extraction submodule. The analog bandpass filter inside the feature extraction submodule filters the target frequency band from the pre-interference filtering elastic wave response signal, and the energy detection unit extracts the energy attenuation characteristic parameters under the target frequency band. The probability generation submodule receives the energy attenuation characteristic parameters and a preset health benchmark signal, the benchmark storage unit retrieves the preset health benchmark signal, and the analog comparison network compares the energy attenuation characteristic parameters with the preset health benchmark signal to generate a risk indication signal and output it to the adaptive compensation module.

[0047] Please see Figure 3 As shown, the coherent verification module includes multiple independent verification channel sub-modules, and each verification channel sub-module corresponds to a set of stiffness sensing sub-modules.

[0048] In this embodiment, the coherent verification module includes multiple sets of independent verification channel sub-modules, each set of independent verification channel sub-modules corresponding one-to-one with a set of stiffness sensing sub-modules; each set of independent verification channel sub-modules independently processes the signals of the corresponding stamping channel; the channel correspondence is pre-set by the hardware wiring, and those skilled in the art can complete the hardware layout according to the design requirements of one-to-one channel matching.

[0049] Specifically, the present invention sets up multiple independent verification channel sub-modules, each of which corresponds one-to-one with each group of stiffness sensing sub-modules, to achieve mutual isolation and independent processing of signals from each stamping point, thereby avoiding crosstalk between signals from different stamping points.

[0050] In this embodiment, the coherent verification module has an internal number of independent verification channel submodules that are the same as the number of stiffness sensing submodules; each independent verification channel submodule has a dedicated hardware link that connects to a set of stiffness sensing submodules; the signals of different independent verification channel submodules are isolated from each other, and each processes the signals of its corresponding stamping point without interfering with each other.

[0051] Please see Figure 3As shown, the independent verification channel submodule includes: a pulse triggering unit, used to receive the stiffness signal output by the stiffness sensing submodule corresponding to the independent verification channel submodule, and output a trigger pulse when the stiffness signal has a falling edge that meets the preset conditions; a local oscillation unit, which is synchronously triggered by the trigger pulse output by the pulse triggering unit to generate a reference carrier that is time-aligned with the stiffness drop event; an analog multiplier unit, used to perform hardware mixing of the reference carrier with the acoustic emission signal spontaneously generated during the stamping loading process after spatial gating of the coordinate signal of the damage source; an integral filtering unit, used to extract the coherent DC component obtained after hardware mixing; and a threshold comparison unit, used to compare the coherent DC component with a preset threshold and output the damage locking signal carrying the corresponding stamping head channel identifier.

[0052] In this embodiment, the input to the pulse triggering unit is a stiffness signal, and the output of the pulse triggering unit is a trigger pulse; the falling edge of the preset condition is determined based on the calibration result of the stiffness decrease rate during the plastic yielding process of the intact steel pipe rod.

[0053] In this embodiment, the input to the local oscillation unit is a trigger pulse, and the output of the local oscillation unit is a reference carrier; the input to the analog multiplier unit is the reference carrier and the acoustic emission signal spontaneously generated during the stamping loading process after spatial gating by the coordinate signal of the damage source; the input to the integral filter unit is the hardware mixing output signal, and the output of the integral filter unit is a coherent DC component; the input to the threshold comparison unit is the coherent DC component and a preset threshold value, and the output of the threshold comparison unit is a damage lock signal.

[0054] In this embodiment, spatial gating relies on the coordinate signals of the damage source to filter spatially matching acoustic emission signals.

[0055] In this embodiment, the method for setting the preset threshold is as follows: Multiple intact and undamaged steel pipe poles of the same specification were selected for calibration tests. The intact steel pipe poles were subjected to the stamping and straightening operation of this device. The coherent DC component output by the intact steel pipe poles during the entire straightening process was collected, and the maximum background value of the coherent DC component under intact working conditions was obtained. A preset threshold value was set above the maximum background value with a safety margin. When the coherent DC component exceeds the preset threshold value, it is determined that actual damage has occurred. Different preset threshold values ​​are corresponding to steel pipe poles of different materials and wall thicknesses. The preset threshold values ​​are called up and down when the specifications of the steel pipe poles are switched.

[0056] Specifically, this invention detects the falling edge of the stiffness signal by a pulse triggering unit and outputs a trigger pulse, which synchronously triggers a local oscillation unit to generate a reference carrier. After spatial gating to remove spatially mismatched interference signals, the invention uses an analog multiplier unit for hardware mixing and an integral filtering unit to extract the coherent DC component. A threshold comparison unit combines a preset threshold to complete the damage determination. Relying on hardware demodulation, the invention distinguishes between normal plastic yielding and actual pipe damage, reducing the probability of misjudgment.

[0057] In this embodiment, the pulse triggering unit receives the stiffness signal output by the stiffness sensing submodule corresponding to the independent verification channel submodule; when the stiffness signal has a falling edge that meets the preset conditions, the pulse triggering unit outputs a trigger pulse; the local oscillation unit is synchronously triggered by the trigger pulse output by the pulse triggering unit to generate a reference carrier that is time-aligned with the stiffness drop event; spatial gating is performed using the coordinate signal of the damage source to filter out the acoustic emission signal spontaneously generated during the stamping loading process that matches the spatial position.

[0058] The analog multiplier unit performs hardware mixing of the reference carrier and the acoustic emission signal spontaneously generated during the stamping loading process after spatial gating of the coordinate signal passing through the damage source; the integral filter unit extracts the coherent DC component obtained after hardware mixing; the threshold comparison unit compares the coherent DC component with a preset threshold. When the coherent DC component exceeds the preset threshold, a damage locking signal carrying the corresponding stamping head channel identifier is output.

[0059] Please see Figure 1 As shown, the adaptive compensation module includes: a hardware state latching submodule, used to mark the corresponding stamping head as damaged and disabled according to the channel identifier of the stamping head carried by the damage lock signal, and latch the bending compensation amount that has been dissipated by the corresponding stamping head; an analog routing allocation submodule, which has a built-in analog switch array and charge pump allocation network; the analog switch array is used to cut off the drive circuit of the stamping head marked as damaged and disabled at the hardware level; the charge pump allocation network is used to allocate the remaining bending amount to be straightened to the drive circuit of the remaining stamping heads not marked as damaged and disabled in the form of analog voltage; and a loading adjustment submodule, used to compare the risk indication signal with a multi-level preset threshold when no damage lock signal is received, and adjust the stamping loading parameters of each stamping head according to the comparison result.

[0060] In this embodiment, the hardware state latching submodule receives a damage lock signal as input; it outputs a stamping head damage and disability marker signal and stored data of dissipated bending compensation; the analog routing allocation submodule receives a damage and disability marker signal and the remaining bending amount to be straightened as input; it outputs the analog voltage of each stamping head drive circuit; the load adjustment submodule receives a risk indication signal and multiple preset thresholds as input; these multiple preset thresholds are obtained through calibration tests on steel pipes with different degrees of damage; and it outputs the stamping loading parameters for each stamping head.

[0061] In this embodiment, the charge pump distribution network uses the remaining bending amount to be straightened as the input reference and maps the magnitude of the remaining bending amount to be straightened into a corresponding analog driving voltage. The distribution weight is calculated by combining the axial distance between each stamping head and the damaged stamping point and the current instantaneous stiffness of each stamping point to generate multiple analog voltages with different amplitudes, which are then input to the driving circuits of the remaining stamping heads that are not marked as damaged or disabled.

[0062] Specifically, the present invention utilizes a hardware state latching submodule to complete the stamping head state marking and compensation amount latching; a simulated routing allocation submodule cuts off the damaged stamping head drive circuit at the hardware level and allocates the remaining bending amount to be straightened; and a loading adjustment submodule dynamically adjusts the stamping loading parameters based on the risk indication signal and multi-level preset thresholds; thus achieving rapid hardware protection when damage occurs, while also taking into account the adaptive adjustment of loading parameters under normal working conditions.

[0063] In this embodiment, the hardware state latching submodule receives a damage locking signal, marks the corresponding stamping head as damaged and disabled based on the channel identifier of the stamping head carried by the damage locking signal, and latches the dissipated bending compensation amount of the corresponding stamping head; the analog switch array inside the analog routing allocation submodule disconnects the drive circuit of the stamping head marked as damaged and disabled at the hardware level; the charge pump allocation network allocates the remaining bending amount to be straightened to the drive circuit of the remaining stamping heads not marked as damaged and disabled in the form of analog voltage; when no damage locking signal is received, the load adjustment submodule compares the risk indication signal with a multi-level preset threshold and adjusts the stamping loading parameters of each stamping head according to the comparison result.

[0064] Please see Figure 4 and Figures 5-7 As shown, it also includes a collaborative strategy hardware state machine module, which includes: a strategy generation submodule, used to output a collaborative strategy control word according to the damage locking signal; the adaptive compensation module selects one of the following based on different collaborative strategy control words: stop only the stamping head marked as damaged and disabled and let the other stamping heads share the compensation, or stop all stamping heads and rotate the steel pipe rod before reloading.

[0065] In this embodiment, the strategy generation submodule takes a damage locking signal as input and outputs a collaborative strategy control word. The collaborative strategy control word contains two strategy codes. The adaptive compensation module reads the collaborative strategy control word and executes the two collaborative strategies accordingly. The rotation of the steel pipe rod is driven by the steel pipe rod rotation mechanism built into the device.

[0066] Specifically, the present invention outputs a collaborative strategy control word through a collaborative strategy hardware state machine module, enabling the adaptive compensation module to choose between two collaborative strategies: shared compensation or reloading after rotating the steel pipe pole. This provides optional handling paths for different working conditions, balancing the efficiency of straightening operations and the safety of the steel pipe pole.

[0067] In this embodiment, the strategy generation submodule inside the collaborative strategy hardware state machine module receives the damage locking signal and outputs the collaborative strategy control word; the adaptive compensation module reads the collaborative strategy control word; when the collaborative strategy control word corresponds to the first strategy, the adaptive compensation module executes a collaborative strategy that stops only the stamping head marked as damaged and disabled, and the remaining stamping heads share the compensation; when the collaborative strategy control word corresponds to the second strategy, the adaptive compensation module executes a collaborative strategy that stops all stamping heads and rotates the steel pipe rod before reloading.

[0068] Please see Figure 4 and Figures 5-7 As shown, the collaborative strategy hardware state machine module further includes an event counting submodule and a threshold comparison submodule; the event counting submodule is used to accumulate the number of times the damage lock signal is triggered within the same calibration cycle; the threshold comparison submodule is used to output a global shutdown alarm signal and latch all the drive circuits of the stamping head when the number of triggers accumulated by the event counting submodule exceeds a pre-designed numerical threshold.

[0069] In this embodiment, the straightening cycle is defined as: the complete operation process from the completion of clamping and feeding of a single steel pipe rod to the completion of the entire multi-point stamping and straightening process of the steel pipe rod; the straightening cycle start signal is generated by the clamping completion hardware trigger signal inside the multi-point stamping execution system; when a new steel pipe rod clamping assembly is clamped in place, the straightening cycle start signal is output, and the straightening cycle start signal is sent to the event counting submodule to clear the count value inside the event counting submodule and start the damage count of a new steel pipe rod.

[0070] In this embodiment, the strategy generation submodule also receives the trigger count value of the damage lock signal within the same calibration period output by the event counting submodule; the strategy generation submodule selects the corresponding strategy code based on the trigger count value of the damage lock signal within the same calibration period; when the number of triggers of the damage lock signal within the same calibration period is less than a pre-designed numerical threshold, the first type of strategy code is output; when the number of triggers of the damage lock signal within the same calibration period reaches the pre-designed numerical threshold, the second type of strategy code is output.

[0071] In this embodiment, the event counting submodule takes a damage lock signal as input and outputs the trigger count value of the damage lock signal within the same straightening cycle; the threshold comparison submodule takes the trigger count value and a pre-designed numerical threshold as input; the pre-designed numerical threshold is determined comprehensively based on the material characteristics of the steel pipe rod and the safety specifications of the straightening process; the threshold comparison submodule outputs a global shutdown alarm signal; the global shutdown alarm signal is used to latch the drive circuits of all stamping heads.

[0072] Specifically, the event counting submodule accumulates the number of times the damage lock signal is triggered within the same straightening cycle, the threshold comparison submodule compares the value with the pre-designed threshold, outputs a global shutdown alarm signal and latches all stamping head drive circuits, providing comprehensive safety protection for the entire machine and avoiding the risk of the steel pipe rod being subjected to damage multiple times.

[0073] In this embodiment, the event counting submodule accumulates the number of times the damage lock signal is triggered within the same calibration cycle; the threshold comparison submodule obtains the number of triggers accumulated by the event counting submodule; when the number of triggers accumulated by the event counting submodule exceeds the pre-designed numerical threshold, the threshold comparison submodule outputs a global shutdown alarm signal and latches the drive circuits of all stamping heads, no longer executing the cooperative strategy corresponding to the cooperative strategy control word; the calibration cycle start signal clears the count value of the event counting submodule to zero and starts a new round of counting.

[0074] Please see Figure 1 As shown, it also includes an initial bending sensing module, which is used to acquire the initial spatial bending shape information of the steel pipe rod and output the initial spatial bending shape information of the steel pipe rod to the adaptive compensation module to provide an initial loading target displacement reference for each of the stamping heads.

[0075] In this embodiment, the initial bending sensing module inputs the steel pipe rod shape acquisition information; the initial bending sensing module outputs the initial spatial bending shape information of the steel pipe rod; and the initial spatial bending shape information of the steel pipe rod is output to the adaptive compensation module.

[0076] Specifically, the present invention obtains the initial spatial bending shape information of the steel pipe rod through the initial bending sensing module, and provides an initial loading target displacement reference for each stamping head, so that each stamping head of the multi-point stamping execution system can obtain a loading reference that conforms to the actual bending state of the steel pipe rod, thereby improving the straightening accuracy of the steel pipe rod.

[0077] In this embodiment, the initial bending sensing module collects the outline information of the steel pipe rod and processes it to obtain the initial spatial bending shape information of the steel pipe rod; the initial bending sensing module outputs the initial spatial bending shape information of the steel pipe rod to the adaptive compensation module; the adaptive compensation module provides an initial loading target displacement reference for each stamping head based on the initial spatial bending shape information of the steel pipe rod, thereby determining the basic loading benchmark of each stamping head.

[0078] Comparison with Condition 1: Using a traditional straightening device, protection is only provided by the force-displacement threshold. When there is stress concentration or minor initial defects in the local area of ​​the steel pipe rod, the traditional threshold protection can only be triggered after macroscopic plastic damage has already occurred. This can easily lead to local indentation of the steel pipe rod, micro-crack initiation, and some workpieces being scrapped directly. To avoid damage, the stamping load can only be manually reduced, resulting in a significant increase in the number of straightening cycles and a decrease in production efficiency.

[0079] Comparative working condition 2: The straightening operation is carried out using the device of this application.

[0080] The first active acoustic prediction defense line identifies high-risk areas before stamping loading, automatically reducing the loading safety factor or skipping the risk points directly. The second coherent verification hardware protection distinguishes between normal plastic deformation and actual pipe damage during the stamping process. Once damage is identified, the hardware immediately cuts off the corresponding stamping head drive circuit and distributes the remaining bending amount to be straightened to the other stamping heads. As damage accumulates, it can also perform rotating steel pipe rod reloading or global shutdown of the entire machine as a fallback protection.

[0081] Under the same initial bending deformation conditions, this device can carry out straightening operations at a higher loading level, reducing the number of straightening cycles; at the same time, it can prevent micro-damage from developing into macro-defects, reduce the probability of scrapping steel pipe rods, and balance straightening processing efficiency with workpiece safety.

[0082] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A steel pipe rod straightening device based on fixed clamping and multi-point punching, characterized in that, include: A multi-point stamping execution system, comprising a clamping assembly and several stamping heads; The stiffness sensing module consists of several stiffness sensing sub-modules respectively set in each of the stamping heads, which are used to output stiffness signals that characterize the instantaneous stiffness of the corresponding stamping point of the steel pipe rod in real time. An active acoustic excitation module is used to apply a preset acoustic excitation to the steel pipe rod during the interval of unloading of the stamping head; The acoustic emission positioning module is used to collect the elastic wave response signal generated by the preset acoustic excitation, as well as the acoustic emission signal spontaneously generated during the stamping loading process, and output the coordinate signal of the damage source. An acoustic response analysis module, which is connected to the acoustic emission positioning module, generates a risk indication signal characterizing the damage risk of the steel pipe pole based on the difference between the elastic wave response signal and the preset health reference signal. A coherent verification module is connected to the stiffness sensing module and the acoustic emission positioning module respectively, and is used to receive the stiffness signal and the acoustic emission signal, and output a damage locking signal through hardware demodulation. The damage locking signal carries the channel identifier of the stamping head that triggered the damage locking signal. An adaptive compensation module, which is connected to the coherent verification module and the acoustic response analysis module respectively, cuts off the drive circuit corresponding to the stamping head based on the received damage locking signal, and distributes the remaining bending amount to be straightened to the other stamping heads whose drive circuits have not been cut off; When no damage lock signal is received, the adaptive compensation module is used to adjust the stamping loading parameters according to the risk indication signal.

2. The steel pipe rod straightening device based on fixed clamping and multi-point stamping according to claim 1, characterized in that, The stiffness sensing submodule includes: A force sensing unit is used to collect the contact force between the stamping head and the steel pipe rod; A displacement sensing unit is used to collect the loading stroke of the stamping head; The phase-locked loop circuit unit uses the output signal of the force sensing unit as input and the output signal of the displacement sensing unit as feedback to construct a closed-loop locking topology and outputs an analog control voltage characterizing instantaneous stiffness.

3. The steel pipe rod straightening device based on fixed clamping and multi-point stamping according to claim 1, characterized in that, The active acoustic excitation module includes: An acoustic excitation execution submodule is used to apply a preset acoustic excitation to the surface of the steel pipe rod; An acoustic excitation timing control submodule is used to ensure that the preset acoustic excitation is triggered only during the interval when the stamping head is completely unloaded.

4. The steel pipe rod straightening device based on fixed clamping and multi-point stamping according to claim 3, characterized in that, The acoustic response analysis module includes: The signal conditioning submodule is connected to the acoustic emission positioning module and is used to amplify the elastic wave response signal and perform pre-interference filtering. A feature extraction submodule, which is connected to the signal conditioning submodule, has a built-in analog bandpass filter and energy detection unit to filter the target frequency band from the elastic wave response signal after pre-interference filtering and extract the energy attenuation characteristic parameters under the target frequency band. The probability generation submodule, which is connected to the feature extraction submodule, has a built-in benchmark storage unit and a simulation comparison network to compare the extracted energy decay feature parameters with a preset health benchmark signal to generate the risk indication signal.

5. The steel pipe rod straightening device based on fixed clamping and multi-point stamping according to claim 4, characterized in that, The coherent verification module includes multiple independent verification channel sub-modules, and each verification channel sub-module corresponds to a set of stiffness sensing sub-modules.

6. The steel pipe rod straightening device based on fixed clamping and multi-point stamping according to claim 5, characterized in that, The independent verification channel submodule includes: The pulse triggering unit is used to receive the stiffness signal output by the stiffness sensing submodule corresponding to the corresponding independent verification channel submodule, and output a trigger pulse when the stiffness signal has a falling edge that meets the preset conditions; A local oscillation unit, which is synchronously triggered by the trigger pulse output by the pulse triggering unit, generates a reference carrier that is time-aligned with the stiffness drop event. The analog multiplier unit is used to perform hardware mixing of the reference carrier with the acoustic emission signal spontaneously generated during the stamping loading process after spatial gating of the coordinate signal of the damage source. The integral filtering unit is used to extract the coherent DC component obtained after hardware mixing; The threshold comparison unit is used to compare the coherent DC component with a preset threshold and output the damage lock signal carrying the corresponding stamping head channel identifier.

7. The steel pipe rod straightening device based on fixed clamping and multi-point stamping according to claim 6, characterized in that, The adaptive compensation module includes: The hardware state latching submodule is used to mark the corresponding stamping head as damaged and disabled based on the channel identifier of the stamping head carried by the damage locking signal, and to latch the bending compensation amount that has been dissipated by the corresponding stamping head. The analog routing distribution submodule has a built-in analog switch array and charge pump distribution network; the analog switch array is used to disconnect the drive circuit of the stamping head marked as damaged and disabled; the charge pump distribution network is used to distribute the remaining bending amount to be straightened in the form of analog voltage to the drive circuit of the remaining stamping heads not marked as damaged and disabled. The loading adjustment submodule is used to compare the risk indication signal with a multi-level preset threshold when no damage lock signal is received, and adjust the stamping loading parameters of each stamping head according to the comparison result.

8. The steel pipe rod straightening device based on fixed clamping and multi-point stamping according to claim 7, characterized in that, It also includes a cooperative strategy hardware state machine module, which includes: The strategy generation submodule is used to output a cooperative strategy control word based on the damage locking signal; The adaptive compensation module selects one of the following based on different cooperative strategy control words: stop only the stamping head marked as damaged and disabled and let the remaining stamping heads share the compensation, or stop all stamping heads and rotate the steel pipe rod before reloading.

9. The steel pipe rod straightening device based on fixed clamping and multi-point stamping according to claim 8, characterized in that, The collaborative strategy hardware state machine module also includes: Event counting submodule and threshold comparison submodule; The event counting submodule is used to accumulate the number of times the damage lock signal is triggered within the same calibration cycle; The threshold comparison submodule is used to output a global shutdown alarm signal and latch all the drive circuits of the stamping head when the number of triggers accumulated by the event counting submodule exceeds the pre-designed numerical threshold.

10. The steel pipe rod straightening device based on fixed clamping and multi-point stamping according to claim 9, characterized in that, It also includes an initial bending sensing module, which is used to acquire the initial spatial bending shape information of the steel pipe rod and output the initial spatial bending shape information of the steel pipe rod to the adaptive compensation module to provide an initial loading target displacement reference for each of the stamping heads.

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