A visual automatic tracking system for detecting defects in a welded spiral tube
Patent Information
- Application Number
- CN202522297811.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-30
- Publication Date
- 2026-10-09
- Estimated Expiration
- 2035-10-30
AI Technical Summary
目前这种行走速度与旋转速度的匹配在理论上是没有问题的，但在实际探伤过程中由于焊接螺旋管的圆柱度误差和直线度误差都比较大，与理论计算值偏差较大,这就导致探头会与焊缝频繁碰撞；且目前市场上都是靠理论计算和测量计算的结果给PLC，通过PLC来控制伺服电机的速度来匹配螺旋式的焊缝进行探伤，这种方式对于不规则的螺旋管就会增加工作量，降低探伤效率，无法满足生产需求
针对背景技术中提到的问题，本实用新型将对上述传统的理论计算探伤装置增加视觉系统，用视觉系统对螺旋焊缝进行实时测量，实时反馈给PLC控制器，PLC控制伺服电机实时调整速度来匹配不规则的螺旋焊缝，从而实现对不规则螺旋焊缝的自动跟踪且探伤的目的。
Smart Images
Figure CN224840852U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the technical field of automatic visual tracking systems for flaw detection, and discloses an automatic visual tracking system for flaw detection of welded spiral pipes, belonging to the field of visual intelligence technology. Background Technology
[0002] The flaw detection vision automatic tracking system is an automated system that integrates machine vision, automatic control and precision drive technology. It is used in industrial inspection scenarios to locate and track targets (such as welds, defect locations, etc.) in real time and guide inspection equipment to operate accurately. It is widely used in quality inspection processes in fields such as welding, pipe manufacturing, and machining.
[0003] Because the weld seams of welded spiral pipes with diameters of φ500mm-φ2000mm and lengths of 12-20 meters are spiral rather than straight, weld flaw detection requires the equipment's rotation speed to match the probe's travel speed so that the probes on both sides travel precisely along the weld seam. While theoretically this matching of travel and rotation speeds is not problematic, in actual flaw detection, the cylindricity and straightness errors of the welded spiral pipe are relatively large, deviating significantly from theoretical calculations. This leads to frequent collisions between the probe and the weld seam. Furthermore, current market practices rely on theoretical and measurement calculations to provide PLCs, which then control the servo motor speed to match the spiral weld seam for flaw detection. This method increases workload and reduces detection efficiency for irregular spiral pipes, failing to meet production needs. Utility Model Content
[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing an automatic visual tracking system for flaw detection of welded spiral pipes.
[0005] To achieve the above objectives, the present invention adopts the following technical solution: An automatic visual tracking system for flaw detection of welded spiral pipes includes a display, a PLC controller, and a flaw detector. The display and the PLC controller are connected for data interaction via a communication line. A vision system is fixedly installed at the probe of the flaw detector. Both the flaw detector and the vision system are connected to the PLC controller via digital interfaces. A servo system and a rotary system are provided on one side of the PLC controller.
[0006] As a further embodiment of this utility model, the servo system generally consists of a servo driver and a servo motor, the PLC controller is connected to the driver through a communication interface, and the rotary encoder in the rotary system can be connected to the PLC controller as a feedback element.
[0007] As a further embodiment of this invention, the servo motor in the servo system is connected to the rotating component of the rotating system, and the servo driver of the servo system receives the control signal from the PLC controller.
[0008] As a further embodiment of this utility model, the connection relationship between the PLC controller, display screen, flaw detector, vision system, servo system and rotary system is centered on the PLC as the core control hub.
[0009] Compared with the prior art, the present invention has the following beneficial effects: To address the problems mentioned in the background art, this utility model adds a vision system to the aforementioned traditional theoretical calculation flaw detection device. The vision system measures the spiral weld in real time and provides real-time feedback to the PLC controller. The PLC controls the servo motor to adjust its speed in real time to match the irregular spiral weld, thereby achieving the purpose of automatic tracking and flaw detection of irregular spiral welds. Attached Figure Description
[0010] Figure 1 This is a flowchart illustrating the mechanical structure of this utility model. Figure 2 This is a diagram showing the distribution of weld seams and probes in this utility model. Figure 3 This is a schematic diagram showing the proximity and collision between the weld seam and the probe of this utility model; Figure 4 This is a schematic diagram of the display screen structure of this utility model; Figure 5 This is a schematic diagram of the controller structure of this utility model.
[0011] In the diagram: 1. Display screen; 2. PLC controller; 3. Flaw detector; 4. Vision system; 5. Servo system; 6. Rotation system. Detailed Implementation
[0012] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the present utility model will be further described below in conjunction with specific embodiments.
[0013] In the description of this utility model, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0014] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," and "connected," etc., should be interpreted broadly. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0015] Reference Figures 1-5 An automatic visual tracking system for flaw detection of welded spiral pipes includes a display, a PLC controller 2, and a flaw detector 3. The display and the PLC controller 2 are connected for data interaction via a communication line. A vision system 4 is fixedly installed at the probe of the flaw detector 3. Both the flaw detector 3 and the vision system 4 are connected to the PLC controller 2 via digital interfaces. A servo system 5 and a rotary system 6 are provided on one side of the PLC controller 2.
[0016] In practice, a vision system 4 is added to the traditional theoretical calculation flaw detection device. The vision system 4 measures the spiral weld in real time and provides feedback to the PLC controller 2. The PLC controller 2 is the connection center of all structures, responsible for data processing, command issuance, and process scheduling. The PLC controller 2 controls the servo system 5, rotation system 6, vision system 4, and flaw detector 3 to work together. Driven by the servo system 5 and rotation system 6, the flaw detector 3 and vision system 4 perform flaw detection and automatic tracking of the weld. The motor of the servo system 5 adjusts its speed in real time to match the irregular spiral weld, thereby achieving the purpose of automatic tracking and flaw detection of irregular spiral welds. Figure 1 The overall equipment process structure diagram shows that the circumferential rotation of the towing wheel and the longitudinal movement of the probe structure are used to detect flaws in the rotating weld. A vision system 4 is installed at the probe to identify the weld.
[0017] In this embodiment, the servo system 5 is generally composed of a servo driver and a servo motor. The PLC controller 2 is connected to the driver through a communication interface. The rotary encoder in the rotary system 6 can be connected to the PLC controller 2 as a feedback element.
[0018] In operation, the vision system 4 identifies the weld seam and sends feedback to the PLC controller. The PLC controller then calculates and outputs the results to the rotary motor of the tow wheel and the longitudinal movement motor of the probe structure. The rotary motor of the tow wheel, typically a servo motor, adjusts its rotational speed or phase to synchronously correct the workpiece's rotational posture, compensating for circumferential offsets in the weld seam, such as trajectory deviations during the rotation of a spiral welded pipe, ensuring the weld seam moves along a preset path. The longitudinal movement motor of the probe, also primarily a servo motor, adjusts the probe's longitudinal movement speed or position according to instructions, compensating for axial offsets in the weld seam, ensuring the probe always follows the weld seam trajectory. Both motors need to achieve coordinated control, especially for complex trajectories such as spiral weld seams, requiring precise synchronization of rotary and longitudinal movements via electronic gear ratios to avoid trajectory decoupling.
[0019] In this embodiment, the servo motor in the servo system 5 is connected to the rotating component of the rotating system 6, and the servo driver of the servo system 5 receives the control signal from the PLC controller 2.
[0020] In operation, the rotary encoder in the rotating system 6 can be connected to the PLC controller 2 as a feedback element. The rotary encoder converts the angular displacement of the rotating system 6 into a digital signal. The PLC uses a high-speed counter to count the pulse signals, thereby obtaining information such as the position and speed of the rotating system 6, and achieving precise control of the rotating system 6. The servo system 5 can provide power and precise control for the rotating system 6. The encoder in the servo motor feeds back the motor's rotational position and speed to the servo driver, forming a closed-loop control to improve the control accuracy and stability of the rotating system 6.
[0021] In this embodiment, the connection between the PLC controller 2, display screen 1, flaw detector 3, vision system 4, servo system 5 and rotary system 6 is centered on the PLC as the core control hub.
[0022] In operation, PLC controller 2 serves as the central connection for all components, responsible for data processing, instruction issuance, and process scheduling. The entire system, centered on PLC controller 2, forms a closed loop of detection, analysis, control, execution, and feedback, ensuring the precise and stable operation of the automated process.
[0023] From the above description, it can be seen that the above embodiments of this utility model achieve the following technical effects: A vision system 4 is added to the traditional theoretical calculation flaw detection device. The vision system 4 performs real-time measurement of the spiral weld and provides real-time feedback to the PLC controller 2. The PLC controller 2 is the connection center of all structures, responsible for data processing, instruction issuance, and process scheduling. The PLC controller 2 controls the servo system 5, the rotation system 6, the vision system 4, and the flaw detector 3 to cooperate, so that the flaw detector 3 and the vision system 4, driven by the servo system 5 and the rotation system 6, perform flaw detection on the weld and automatically track it. The motor of the servo system 5 adjusts its speed in real time to match the irregular spiral weld, thereby achieving the purpose of automatic tracking and flaw detection of the irregular spiral weld.
[0024] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model.
Claims
1. A visual automatic tracking system for flaw detection of welded spiral pipes, comprising a display, a PLC controller (2), and a flaw detector (3), characterized in that, The display and the PLC controller (2) are connected via a communication line for data interaction. A vision system (4) is fixedly installed at the probe of the flaw detector (3). Both the flaw detector (3) and the vision system (4) are connected to the PLC controller (2) via a digital interface. A servo system (5) and a rotary system (6) are provided on one side of the PLC controller (2).
2. The automatic visual tracking system for flaw detection of welded spiral pipes according to claim 1, characterized in that, The servo system (5) is generally composed of a servo driver and a servo motor. The PLC controller (2) is connected to the driver through a communication interface. The rotary encoder in the rotary system (6) can be connected to the PLC controller (2) as a feedback element.
3. The automatic visual tracking system for flaw detection of welded spiral pipes according to claim 2, characterized in that, The servo motor in the servo system (5) is connected to the rotating component of the rotating system (6), and the servo driver of the servo system (5) receives the control signal from the PLC controller (2).
4. The automatic visual tracking system for flaw detection of welded spiral pipes according to claim 1, characterized in that, The connection between the PLC controller (2), display screen (1), flaw detector (3), vision system (4), servo system (5) and rotary system (6) is centered on the PLC as the core control hub.