Annular inner wall defect detection device

Abstract

The utility model relates to an annular inner wall defect detection device. The device comprises a base disc, a shell, a rotary table, an integrated motor, a sensor adapter plate and a line laser sensor, the machine shell is fixed to the base disc, the rotating table is connected to the top of the machine shell, and the integrated motor is located on one side of the rotating table and used for being connected with the rotating table and driving the rotating table to rotate. The line laser sensors are arranged at the two ends of the sensor adapter plate respectively, and the sensor adapter plate is connected to the rotating table. An industrial personal computer and a controller are installed in the machine shell, and a corresponding upper computer software system runs in the industrial personal computer and is connected with and controls the robot body. According to the utility model, the appearance, the surface surplus height, the width, the alignment tolerance and the like of the pipeline welding seam can be measured, the size is smaller, the operation is longer, the welding seam identification speed is higher, more detection results can be obtained by limited resources, the identification and scanning effects are better, and the analysis result is more accurate.

Description

Technical Field

[0001] The utility model relates to the technical field of machine vision detection, in particular to a device for detecting defects on the inner wall of a ring. Background Art

[0002] Railway, highway, water transportation, aviation and pipeline are the five main modes of transportation in modern society. Pipeline transportation is a long-distance transportation method that uses pipelines as transportation tools for transporting liquid and gaseous materials, and it is also the most special transportation method. Compared with other transportation methods, pipeline transportation has the advantages of large transportation volume, continuous transportation for 24 hours, good continuity, being unaffected by weather factors during transportation, and low unit cargo transportation cost. Currently, pipeline networks are generally formed by welding, so it is particularly important to ensure the welding quality of pipe joints. Engineering accidents caused by pipeline weld quality problems are not uncommon. Manual weld inspection is not only cumbersome and time-consuming, but also has great limitations, and it can no longer meet the requirements of high efficiency, safety, and short cycle. Currently, the mainstream automated devices for weld inspection mainly adopt two methods: machine vision image processing and line laser detection.

[0003] The machine vision detection method needs to combine multiple technologies such as image acquisition, image processing, feature recognition, and feature extraction. Currently, in the industrial field, the research on pre-weld inspection of welds is much deeper and more extensive than that on post-weld inspection of welds. Weld inspection focuses on research in aspects such as weld positioning, weld recognition, and weld tracking. Currently, a university research team has applied the ant colony algorithm and neural network algorithm to robot welding, greatly improving the anti-interference ability, stability, and accuracy of the weld tracking system.

[0004] Laser detection technology is a measurement technology that not only uses a light source for assistance but also uses image processing. Its emergence solves the difficulty of image matching in stereo vision, and it has high resolution, high speed, strong anti-interference ability, and high accuracy. In addition, its equipment is simple to install and easy to implement, and it has been widely used in medical plastic surgery, industrial measurement, surveying and mapping, and automation control. With the development of laser detection technology, it has also promoted the development of welding automation, especially in the detection of welds. In-depth research has been carried out on the application technology of laser detection technology in welding at home and abroad, and certain achievements have been made. For example, Modular Vision System Company in Canada developed a three-dimensional laser vision sensor for a welded joint with a root error or opening of only 0.050 mm, which can track welding at a speed of 20 m / min and maintain a tracking accuracy of 0.020 mm.

[0005] Although the weld detection technology of machine vision is more efficient than traditional weld detection, has non-contact characteristics, and has a wider applicability, the line laser detection scheme in weld detection, while meeting the non-contact requirement and getting rid of the limitations of traditional weld detection, also has the advantages of high precision, large measurement range, fast measurement speed, and good system flexibility. Therefore, considering comprehensively, the present utility model selects the line laser technology to detect pipeline welds and proposes an annular inner wall defect detection device. Summary of the Utility Model

[0006] The purpose of the present utility model is to overcome the problems existing in the prior art and provide an annular inner wall defect detection device. Compared with traditional detection methods and traditional detection machines, the present utility model has various advantages such as smaller volume, longer operation time, faster weld recognition speed, obtaining more detection results with limited resources, better recognition and scanning effects, and more accurate analysis results.

[0007] To achieve the above technical purposes and reach the above technical effects, the present utility model is realized through the following technical solutions:

[0008] An annular inner wall defect detection device, which includes a base plate, a machine shell, a rotating table, an integrated motor, a sensor adapter board, and a line laser sensor that constitute a measurement module; among them:

[0009] The machine shell is fixed on the base plate, the rotating table is connected to the top of the machine shell, and the integrated motor is located on one side of the rotating table for connecting and driving the rotating table to rotate;

[0010] The line laser sensors are respectively arranged at both ends of the sensor adapter board, and the sensor adapter board is connected to the rotating table;

[0011] An industrial control computer and a controller are installed inside the machine shell, and a corresponding upper computer software system runs in the industrial control computer and is connected to control the robot body.

[0012] Further, when the sensor adapter board, the rotating table, the machine shell, and the base plate are connected and operating, they are collinear with the pipeline central axis. The base plate is installed on the robot body to make it axially move and rotate around a fixed axis along the pipeline central axis.

[0013] The beneficial effects of the present utility model are:

[0014] First, the two probes of the present utility model work together to filter out noise data such as motion vibration and measure the inner diameter of the pipeline more accurately.

[0015] Second, in the present utility model, a high-resolution motor is developed and equipped with a high-resolution encoder, and the sensor is triggered in an external trigger form, and a rotating table with a large speed ratio is used to ensure the stability of the scanning process and achieve high-precision motion control. Description of the Drawings

[0016] Figure 1 It is the structure and composition schematic diagram of the annular inner wall defect detection device according to an embodiment of the present utility model;

[0017] Figure 2 It is the software and hardware detection system of the annular inner wall defect detection device according to an embodiment of the present utility model;

[0018] Figure 3 It is the structure schematic diagram of the annular inner wall defect detection device according to an embodiment of the present utility model when operating ideally inside the pipeline;

[0019] Figure 4 It is the architecture diagram of the annular inner wall defect detection system according to an embodiment of the present utility model;

[0020] Figure 5 It is the setting diagram of the annular inner wall defect detection system according to an embodiment of the present utility model;

[0021] Figure 6 It is the schematic diagram of two switching schemes when the detection module is switched in the system setting according to an embodiment of the present utility model;

[0022] Figure 7 It is the structure diagram of different positions of the annular inner wall defect detection device according to an embodiment of the present utility model when operating actually inside the pipeline;

[0023] Figure 8 It is the overall operation flow of the annular inner wall defect detection device according to an embodiment of the present utility model. Specific embodiments

[0024] The present utility model will be described in detail below with reference to the accompanying drawings and in conjunction with embodiments.

[0025] An annular inner wall defect detection device, as Figure 1 shown, the device includes a base plate 100, a housing 200, a rotating table 300, an integrated motor 400, a sensor adapter plate 500, and a line laser sensor 600 that constitute a measurement module; wherein:

[0026] The housing 200 is fixed on the base plate 100, the rotating table 300 is connected to the top of the housing 200, and the integrated motor 400 is located on one side of the rotating table 300 for connecting and driving the rotating table to rotate;

[0027] The line laser sensors 600 are respectively arranged at both ends of the sensor adapter plate 500, and the sensor adapter plate 500 is connected to the rotating table 300;

[0028] As Figure 2As shown, an industrial computer 201 and a controller 202 are installed inside the casing 200. The industrial computer 201 runs a corresponding host computer software system 203 and is connected to control the robot body 204.

[0029] As Figure 3 shown, the figure includes a pipeline 900, a line laser sensor 600 and its excitation laser 700. When the sensor adapter board 500, the rotary table 300, the casing 200 and the base plate 100 are connected and operating, they are collinear on the central axis 800 of the pipeline. The base plate 100 is installed on the robot body 204 to move axially and rotate about a fixed axis along the central axis 800 of the pipeline.

[0030] As Figure 4 shown, it is a detection system based on this device. The system includes a host computer software system 203, and the host computer software system 203 is divided into a basic layer 10, a service layer 20 and an application layer 30, where:

[0031] The basic layer 10 is the hardware part, including an industrial computer 201, a line laser sensor 600, a control module 401 and a motion module 402. The motion module 402 includes an integrated motor 400 with a built-in encoder and a rotary table 300;

[0032] The service layer 20 is the logical function implementation layer, including a data acquisition module 20-1, an IO monitoring module 20-2, a data processing module 20-3, an algorithm module 20-4 and a function module 20-5;

[0033] The application layer 30 is the output layer, directly interacting with the user to display the results after data processing and analysis.

[0034] In the service layer 20, the relevant parameters of the entire system are custom-set in the system settings 501 interface. As Figure 5 shown, the system settings 501 are divided into motion settings 501-1, sensor controller settings 501-2, recognition mode settings 501-3 and other settings 501-4;

[0035] The motion settings 501-1 include the serial port number and baud rate when the industrial computer 201 is connected to the integrated motor 400, and the speed and acceleration / deceleration of the integrated motor 400 when the line laser sensor 600 rotates;

[0036] The sensor control settings 501-2 call the controller program numbers in the recognition mode 603 and the detection mode 604 respectively;

[0037] The recognition mode settings 501-3 are provided with a recognition timer, weld height, axial allowable deviation and weld width tolerance. The recognition timer is the interval time for each sampling in the recognition mode 603.

[0038] The other settings 501-4 include the switching setting of the detection module, manual button selection, sensor radial deviation, and sensor axial distance. The detection module operates in two states: the recognition mode 603 and the detection mode 604. As Figure 6 shown, the switching between the two modes of the detection module includes a manual switching mode 601 and an automatic switching mode 602. The manual switching mode 601 includes clicking the switching button on the UI interface and the physical button on the device panel. The automatic switching mode 602 is used to identify the weld seam in real time. After the weld seam is found, it automatically switches to the detection mode 604. After the scanning is completed, it switches back to the recognition mode 603, and so on. The sensor radial deviation is the distance parameter of the light-emitting surfaces of the two sensors, and the sensor axial distance is the deviation parameter of the axes of the two sensors.

[0039] The data acquisition module 20-1 includes sensor data acquisition, encoder data acquisition, position data acquisition, and controller communication data. The data acquisition module 20-1 is connected to and communicates with the controller 202 of the line laser sensor 600 through Ethernet. The controller 202 connects to the line laser sensor 600 through the corresponding interface. When the line laser sensor 600 acquires data, the data is transmitted to the industrial control computer 201 through the controller 202. The integrated motor 400 is an integrated stepper servo motor. As an integrated motion control terminal, it communicates with the integrated motor 400 through the RS485 interface to acquire the motor position information in real time.

[0040] The IO monitoring module 20-2 includes status display, independent thread creation, input quantity monitoring, and signal slot feedback. The industrial control computer 201 has GPIO ports and uses status display and physical button operations. The status display uses a three-color display lamp to display the corresponding status through different colors. The physical button operation corresponds to the input port of the GPIO. The corresponding action is controlled by reading the status of this input port.

[0041] The data processing module 20-3 includes thread pool maintenance, data compression, data storage, and data parsing. Thread pool maintenance replaces processing data in the main thread in the form of a thread pool to improve the response speed of the main thread. The data processing module 20-3 sets classes related to data operations, including data compression, data storage, and data parsing, to support import and export operations on the application layer 30, facilitating data acquisition during the movement of the device. After the movement ends, the detection data is imported for display and analysis.

[0042] As Figure 7As shown in the figure, the figure includes the pipeline central axis 800, the sensor rotation central axis 901, and the sensor trajectory 902. The distance between the sensor rotation central axis 901 and the pipeline central axis 800 is x, and the radius of the pipeline is taken as r. When the line laser sensor 600 emits the laser 700 passing through the pipeline central axis 800, it is taken as position 1. At position 1, the distance from the sensor rotation central axis 901 to the pipeline after rotating 90° is taken as y1. The y1 is the sum of the value read by the sensor and the radius of the sensor trajectory. At this time, it can be obtained that:

[0043] ,

[0044] After the line laser sensor 600 rotates through an arbitrary angle at position 1, it is taken as position 2. At position 2, the distance from the sensor rotation central axis 901 to the pipeline after rotating 90° is taken as y2. The y2 can be obtained in the same way as y1:

[0045] ,

[0046] After scanning the weld seam and processing all the contours by rotating one week, the three-dimensional shape of the pipeline can also be fitted and restored, and the defects (corrosion, incision) and the shape (straight weld seam and spiral weld seam) based on the elevation data can be displayed.

[0047] As Figure 8 shown, the overall operation process of this system includes the following steps:

[0048] Step S10-1: The robot body 204 takes its place and sends a signal indicating it is in place;

[0049] Step S10-2: After receiving the signal indicating it is in place, the industrial control computer 201 starts the measurement module;

[0050] Step S10-3: The measurement module switches to the weld seam recognition mode 603;

[0051] Step S10-4: Check whether the movement of the device has ended. If so, jump to step S10-10. If not, enter the next step;

[0052] Step S10-5: In the recognition mode 603, when the movement of the device is detected, the data obtained by the line laser sensor 600 is processed in real time;

[0053] Step S10-6: Judge whether there is a weld seam. If not, return to the previous step to continue detection. If so, enter the next step;

[0054] Step S10-7: When a weld seam appears, communicate with the robot body 204 and send a signal to stop the movement of the robot;

[0055] Step S10-8: The measurement module switches to the weld seam detection mode 604 to detect the weld seam;

[0056] Step S10-9: After the measurement module finishes detection, it sends out a signal, and the robot body 204 continues to move. At the same time, the measurement module is switched to the recognition mode 603, and this process repeats until the movement ends;

[0057] Step S10-10: Exit the measurement module.

[0058] Those skilled in the art of the present technology can understand that the relevant modules involved in the present utility model and the functions they implement can be achieved by loading conventional computer software programs or relevant protocols in the prior art on the improved hardware and the devices, components or systems constituted thereby, rather than improving the computer software programs or relevant protocols in the prior art. For example, the improved computer hardware system can still achieve the specific functions of the hardware system by loading the existing software operating system. Therefore, it can be understood that the innovation of the present utility model lies in the improvement of the hardware modules in the prior art and their connection and combination relationships, rather than merely the improvement of the software or protocol loaded in the hardware modules to achieve relevant functions.

[0059] The above are only the preferred embodiments of the present utility model and are not intended to limit the present utility model. For those skilled in the art, various changes and modifications can be made to the present utility model. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. An annular inner wall defect detection device, characterized in that, The device includes a base plate (100), a housing (200), a rotary table (300), an integrated motor (400), a sensor adapter board (500), and a line laser sensor (600) that constitute a measurement module; among which: The housing (200) is fixed on the base plate (100), the rotary table (300) is connected to the top of the housing (200), and the integrated motor (400) is located on one side of the rotary table (300) for connecting and driving the rotary table to rotate; The line laser sensors (600) are respectively arranged at both ends of the sensor adapter board (500), and the sensor adapter board (500) is connected to the rotary table (300); An industrial control computer (201) and a controller (202) are installed inside the housing (200), and a corresponding upper computer software system (203) runs in the industrial control computer (201) and is connected to control the robot body (204).

2. The annular inner wall defect detection device according to claim 1, characterized in that, When the sensor adapter board (500), the rotary table (300), the housing (200), and the base plate (100) are connected and operating, they are collinear on the central axis (800) of the pipeline. The base plate (100) is installed on the robot body (204) to enable axial movement and fixed-axis rotation along the central axis (800) of the pipeline.

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