Information processing method, control device and welding device

Abstract

To provide an information processing method and the like which can suitably execute welding repair on a pipeline corroded part.SOLUTION: In an information processing method, a computer is caused to execute processing of acquiring an image obtained by imaging a corroded part of a pipeline, detecting the contour of a first depression that is recessed more than the periphery and the contour of a second depression that is located inside the first depression and is even further recessed than the first depression from the image, and outputting a welding instruction to perform build-up welding on the first depression after performing build-up welding on the second depression to a welder on the basis of the detection results of the contours of the first depression and second depression.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an information processing method, a control device, and a welding device. [Background technology]

[0002] In pipes for transporting oil, natural gas, etc., various forms of corrosion occur due to metal oxidation, etc., impairing the functionality of the pipes. Therefore, workers enter the pipes and carry out build-up welding repairs to cover the surface of the pipes with metal.

[0003] Methods for supporting this welding repair of piping have been proposed. For example, Patent Document 1 discloses an in-pipe repair device that includes a welding torch, a robot arm that supports the welding torch, a visual sensor that acquires image information of the repair location, and a control unit that recognizes the repair location based on the image information and controls the welding torch and the robot arm to perform the welding repair. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2022-177479 A Summary of the Invention [Problem to be solved by the invention]

[0005] According to one aspect, an object of the present invention is to provide an information processing method and the like that can suitably carry out welding repair of a corroded portion of a pipe. [Means for solving the problem]

[0006] In one aspect, an information processing method includes a computer executing a process of acquiring an image of a corroded portion of a pipe, detecting from the image an outline of a first recess that is recessed relative to the surrounding areas and an outline of a second recess that is located within the first recess and is further recessed than the first recess, and performing build-up welding on the second recess based on the detection results of the outlines of the first recess and the second recess, and then outputting a welding instruction to a welding machine to perform build-up welding on the first recess. Effect of the Invention

[0007] In one aspect, welding repair of a corroded portion of a pipe can be suitably carried out. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a schematic diagram showing the appearance of a welding device. [Diagram 2] FIG. 2 is a block diagram showing a configuration example of a welding device. [Diagram 3] FIG. 2 is a block diagram showing a configuration example of a control device. [Figure 4] FIG. 2 is an explanatory diagram showing the configuration of a corroded portion in a pipe. [Diagram 5] FIG. 13 is an explanatory diagram showing an example image of a corroded portion. [Figure 6] 11 is an explanatory diagram relating to a detection process of a second recess. FIG. [Figure 7] FIG. 11 is an explanatory diagram relating to a process for identifying a welding path. [Figure 8] FIG. 11 is an explanatory diagram relating to a process for identifying a welding path. [Figure 9] FIG. 4 is an explanatory diagram illustrating an example of a processing procedure executed by a control device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] The present invention will now be described in detail with reference to the drawings showing embodiments thereof. (Embodiment 1) In this embodiment, a welding device that performs welding repair of recesses (corroded parts) scattered inside a pipe due to corrosion of the pipe will be described. Fig. 1 is a schematic diagram showing the appearance of welding device 11. Fig. 2 is a block diagram showing an example of the configuration of welding device 11.

[0010] As shown in Figures 1 and 2, welding apparatus 11 includes a welding machine 14 having a welding torch 12 and a robot arm 13, a camera 16 that takes images inside pipe 15, a grounding mechanism 20 for grounding welding machine 14 to the pipe, a control device 17 that controls welding torch 12, robot arm 13, and an installation mechanism, a generator 18 that supplies power to welding machine 14, camera 16, grounding mechanism 20, and control device 17, a light 21 for illuminating recess 30, a gas cylinder 22 that stores shielding gas to be supplied to welding torch 12 of welding machine 14, a controller 23 for inputting commands to control device 17, and one or more carts 24 on which these are placed.

[0011] The pipe 15 to be repaired is often made of carbon steel. The cart 24 may be composed of one unit, or when composed of two or more units, the units may be connected to each other via a connecting part.

[0012] The welding machine 14 is, for example, a semi-automatic welding machine (GMAW; CO 2 The welding machine 14 is a gas-shielded arc welding machine and uses a welding method called Gas Metal Arc Welding. This welding method called Gas Metal Arc Welding uses CO 2 These include welding or MAG welding.

[0013] Welding machine 14 can automatically perform welding inside pipe 15 according to a program stored in control device 17. Welding machine 14 has welding torch 12 including a tangential wire that also serves as a welding rod and a gas nozzle on the outside of the tangential wire, and a robot arm 13 that supports welding torch 12. The tangential wire constitutes an electrode during gas-shielded arc welding.

[0014] Welding machine 14 has a power supply circuit (not shown) that receives power from generator 18 and supplies power to each part. Welding machine 14 has a ground wire 19 that is electrically connected to pipe 15. Welding machine 14 can perform welding repair on recessed portion (corroded portion) 30 of pipe 15.

[0015] The grounding mechanism 20 is interposed in the middle of the earth wire 19 connected to the welding machine 14. The grounding mechanism 20 has, for example, a drum around which the earth wire 19 is wound, and a motor that rotates the drum. The motor is, for example, a servo motor.

[0016] The grounding mechanism 20 can, for example, by controlling the motor to rotate forward or reverse and the drum to rotate forward or reverse under the control of the control device 17, thereby abutting the tip of the earth wire 19 against the inner surface of the pipe 15 or moving the tip of the earth wire 19 away from the inner surface of the pipe 15.

[0017] The configuration of grounding mechanism 20 is not limited to that described above, and may be, for example, a mechanism for pressing the tip of earth wire 19 against pipe 15 using a reciprocating mechanism such as a spindle.

[0018] The robot arm 13 is, for example, configured as an orthogonal three-axis mobile robot (X-axis, Y-axis, Z-axis moving table), but may be configured as any other multi-joint arm type robot.

[0019] Camera 16 is composed of a general camera or video camera having an imaging element (a CCD (Charge Coupled Device) sensor or a CMOS (Complementary Metal Oxide Semiconductor) sensor) and a lens, and can capture images of the state inside pipe 15. The images captured by camera 16 are sent to control device 17 and stored in a storage device of control device 17.

[0020] The control device 17 is configured with a general PC (personal computer), but may be configured with other one-chip microcomputers, ASICs (Application Specific Integrated Circuits), other computers, and the like.

[0021] The control device 17 includes, for example, a CPU (Central Processing Unit), storage devices such as a ROM (Read Only Memory), a RAM (Random Access Memory), a HDD (Hard Disk Drive), and a SSD (Solid State Drive), an internal bus connecting these devices, and various driver ICs (Integrated Circuits) electrically connected to the CPU for driving the motor of the robot arm 13 and controlling the welding torch.

[0022] The storage device stores various control programs (control software) for controlling the robot arm 13 and welding torch 12 of the welding machine 14. The storage device also stores an image analysis program (image analysis software) for analyzing images captured by the camera 16. The storage device can store images sent from the camera 16 at any time.

[0023] The controller 23 has a plurality of operation buttons 25 for the operator to input commands, and a display unit 26 for displaying the commands input by the operator via the operation buttons 25 and for displaying error messages from the control device 17.

[0024] The generator 18 is configured as a general diesel engine generator. The cart 24 is configured as a general cart 24 (trolley) made of a metal material. The cart 24 has a motor and a gear box, and is self-propelled by the motor supplied with power from the generator 18 (power supply circuit of the welding machine 14) under the control of the control device 17, but may also be capable of moving forward and backward by the manual power of the manager.

[0025] The lighting 21 can receive power from the generator 18 and illuminate the inside of the pipe 15. The lighting 21 is, for example, an LED lighting. As described later, the lighting 21 according to this embodiment is configured in a ring shape, and emits illumination light from multiple directions toward the recess 30 by the LED light source revolving around a ring-shaped orbit.

[0026] The gas cylinder 22 contains a shielding gas (CO 2 The gas supply device 14 receives control from a welding machine 14 and adjusts the amount of shielding gas to supply the shielding gas to the gas nozzle of the welding torch 12.

[0027] FIG. 3 is a block diagram showing an example of the configuration of the control device 17.

[0028] Control device 17 includes control unit 170, main memory unit 171, and auxiliary memory unit 172. Control unit 170 is a calculation device such as one or more CPUs, and executes various information processing related to welding device 11. Main memory unit 171 is a temporary storage area such as RAM, and temporarily stores data necessary for calculations by control unit 170. Auxiliary memory unit 172 is a storage device such as ROM, and stores program P (program product) that causes control unit 170 to execute processing, and other data.

[0029] The control device 17 may include a reading unit for reading the portable storage medium 17a and may read the program P from the portable storage medium 17a. The control device 17 may also download the program P from another computer.

[0030] Fig. 4 is an explanatory diagram showing the configuration of a corroded portion in pipe 15. Fig. 4A shows a cross section of recess 30 (corroded portion). The present embodiment will be outlined below.

[0031] The recesses 30 formed by corrosion inside the pipe 15 have various shapes (contours), sizes, and depths. Therefore, simply tracing the recesses 30 with a circle of a certain size does not allow the recesses 30 to be filled uniformly, and therefore it is necessary to correctly recognize the shape of the recesses 30.

[0032] 4A, the recess 30 has a two-stage structure, including a first recess 31 that is recessed one stage from the surrounding normal portion, and a second recess 32 that is located within the first recess 31 and is recessed further than the first recess 31. Therefore, in order to perform welding, it is necessary to deal with the depth, and it is necessary to fill the deep second recess 32 by one layer first, and then fill the shallow first recess 31 as the second layer.

[0033] Therefore, the control device 17 detects the contours of the first recess 31 and the second recess 32 from the image of the recess 30 captured by the camera 16. Then, the control device 17 outputs a welding instruction to the welding machine 14 to perform build-up welding on the first recess 31 after performing build-up welding on the second recess 32.

[0034] 4B shows how camera 16 captures an image of recess 30 in pipe 15. Control device 17 causes camera 16 to capture an image of recess 30 while lighting 21 irradiates illumination light onto recess 30.

[0035] The illumination 21 according to the present embodiment has a ring-like shape. The camera 16 captures an image of the recess 30 through a hollow portion of the ring of the illumination 21. The illumination 21 irradiates the recess 30 with illumination light from each direction on the circumference by rotating an LED light source around a ring-like orbit. As described later, the control device 17 detects a shaded portion, which is created by superimposing a plurality of images irradiated with illumination light from each direction, as the second recess 32.

[0036] Further, the lighting 21 irradiates infrared light and visible light, respectively, in accordance with instructions from the control device 17, and the camera 16 captures images of the recess 30 irradiated with infrared light and visible light, respectively. FIG. 5 is an explanatory diagram showing example images of a corroded portion. FIG. 5 illustrates an image (first image) of the recess 30 irradiated with infrared light, and an image (second image) of the recess 30 irradiated with visible light. The top two images in FIG. 5 show infrared light images, and the bottom two images show visible light images. The left two images in FIG. 5 show the original captured images of the recess 30, and the right two images show images in which the contour of the recess 30 has been expanded outward by a predetermined width (e.g., several mm).

[0037] Since the recess 30 has been scraped off in advance, the metal surface is exposed, and the reflectance of infrared light and visible light is high. Therefore, the control device 17 irradiates the recess 30 with infrared light and visible light, respectively, using the lighting 21, and obtains an infrared light image and a visible light image of the recess 30. The control device 17 compares the obtained infrared light image and visible light image to detect the contour of the first recess 31 based on the difference in color tone contrast.

[0038] The control device 17 bulges the detected outline of the first recess 31 outward by a predetermined width. The outline is bulged in order to include small corroded parts scattered around the first recess 31 as a single mass. Through the above process, the control device 17 specifies the range in which build-up welding is to be performed.

[0039] On the other hand, the second recess 32, which is deeply corroded, cannot be detected by the detection method for the first recess 31, so the contour of the second recess 32 is detected by overlaying multiple images illuminated with illumination light from different directions, as described below.

[0040] Fig. 6 is an explanatory diagram relating to the detection process of the second recess 32. Fig. 6 conceptually illustrates an image in which illumination light is irradiated onto the second recess 32 from different directions (four directions in Fig. 6).

[0041] As shown in Fig. 6, by irradiating the second recess 32 with illumination light from around the second recess 32, a shadow is created inside the second recess 32. The control device 17 rotates the LED light source of the ring-shaped illumination 21 to obtain multiple images irradiated with illumination light from each direction on the circumference. The control device 17 superimposes these images to obtain an image in which the entire inside of the second recess 32 is shaded. The control device 17 identifies the shape of this shaded portion to detect the contour of the second recess 32.

[0042] Through the above process, the control device 17 detects the contour of the second recess 32. For the same reason as in the case of the first recess 31, the control device 17 expands the contour of the second recess 32 by a predetermined width. In this way, the control device 17 identifies the area where build-up welding is performed as the first layer (the second recess 32) and the area where build-up welding is performed as the second layer (the first recess 31).

[0043] 7 and 8 are explanatory diagrams relating to the process of identifying the welding path. Based on the detection results of the first recessed portion 31 and the second recessed portion 32 detected above, the control device 17 identifies the welding path to be traced by the welding torch 12, and outputs a welding instruction.

[0044] First, the control device 17 identifies a welding path for the second recessed portion 32 that is deeply corroded. In this case, as shown in Fig. 7, the control device 17 identifies the center of gravity of the second recessed portion 32, and identifies the intersections between a plurality of (e.g., 24) straight lines extending radially from the center of gravity and the contour of the second recessed portion 32.

[0045] Then, as shown in Fig. 8, control device 17 specifies a frame line connecting the intersections as a first welding path 81 to be traced by welding torch 12. Note that the area surrounded by a dashed line in Fig. 8 represents a weld width (5 mm in the case of welding device 11 according to the present embodiment) to be filled by build-up welding.

[0046] Next, the control device 17 narrows the frame line, which is the welding path, by a predetermined width (5 mm) toward the center of gravity of the second recess 32, thereby specifying the second welding path 82. Specifically, the control device 17 shifts the apex of the frame line (the intersection with the contour of the second recess 32) by a predetermined width toward the center of gravity, thereby specifying the second welding path. In the same manner, the control device 17 narrows the frame line by a predetermined width each toward the center of gravity, thereby specifying the third, fourth, ... welding paths for performing build-up welding in a Baumkuchen shape. The control device 17 continues to specify the welding path until the distance from the frame line to the center of gravity becomes shorter than the predetermined width and the frame line cannot be reduced any further. The control device 17 outputs a welding instruction to the welder 14 to sequentially perform build-up welding along each of the specified welding paths (frame lines), thereby causing the welder 14 to perform welding. This completes the welding of the second recess 32.

[0047] Next, the control device 17 performs welding on the first recess 31, which is shallowly corroded. As with the second recess 32, the control device 17 also identifies the intersections between the first recess 31 and a plurality of straight lines extending radially from the center of gravity of the first recess 31, and identifies a frame line connecting the identified intersections as a welding path. The control device 17 then outputs a welding instruction to the welding machine 14 to perform build-up welding in a Baumkuchen shape by narrowing the frame line by a predetermined width toward the center of gravity.

[0048] As described above, by carrying out build-up welding in a Baumkuchen pattern on the second recess 32 which is deeply corroded and then the first recess 31 which is shallowly corroded, the recess 30 can be filled uniformly.

[0049] Fig. 9 is an explanatory diagram showing an example of a processing procedure executed by the control device 17. The processing contents executed by the control device 17 will be described with reference to Fig. 9. The control unit 170 of the control device 17 drives the illumination 21 to illuminate the recess 30 (step S11). Specifically, the control unit 170 drives the illumination 21 to irradiate infrared light and visible light. The control unit 170 also drives the illumination 21 so that the LED light source revolves along a ring-shaped track. The control unit 170 acquires an image of the recess 30 irradiated with infrared light and visible light by the illumination 21 from the camera 16 (step S12).

[0050] The control unit 170 detects the contour of the first recess 31 by comparing an image (first image) in which the recess 30 is irradiated with infrared light with an image (second image) in which the recess 30 is irradiated with visible light (step S13). The control unit 170 also detects the contour of the second recess 32 by superimposing multiple images in which the recess 30 is irradiated with illumination light from the ring-shaped illumination 21 from different directions and identifying shaded areas (step S14).

[0051] The control unit 170 detects intersections between the contour of the second recess 32 and a plurality of straight lines extending radially from the center of gravity of the second recess 32 (step S15). The control unit 170 specifies a frame line connecting the detected intersections as a welding path (step S16). The control unit 170 outputs a welding instruction to the welder 14 (welding robot) to perform build-up welding along the specified welding path (frame line) (step S17).

[0052] The control unit 170 determines whether the frame line defined as the welding path cannot be reduced any further (step S18). If it is determined that reduction is possible (S18: NO), the control unit 170 narrows the frame line by a predetermined width toward the center of gravity of the second recess 32 to identify a new welding path (step S19), and returns the process to step S17. In this case, the control unit 170 outputs a welding instruction to the welding machine 14 to perform build-up welding along the new welding path.

[0053] When it is determined that the frame line cannot be reduced (S18: YES), the control unit 170 detects the intersection points between the outline of the first recess 31 and a plurality of straight lines extending radially from the center of gravity of the first recess 31 (step S20). The control unit 170 specifies the frame line connecting the detected intersection points as a welding path (step S21). The control unit 170 outputs a welding instruction to the welding machine 14 to perform build-up welding along the specified welding path (step S22).

[0054] The control unit 170 determines whether the frame line of the welding path cannot be reduced any further (step S23). If it is determined that reduction is possible (S23: NO), the control unit 170 narrows the frame line by a predetermined width toward the center of gravity of the first recess 31 to identify a new welding path (step S24), and returns the process to step S22. If it is determined that reduction is impossible (S23: YES), the control unit 170 ends the series of processes.

[0055] As described above, according to this embodiment, welding repair of a corroded portion of a pipe can be suitably carried out.

[0056] The embodiments disclosed herein are illustrative in all respects and should not be considered as limiting. The scope of the present invention is defined by the claims, not by the above meaning, and is intended to include all modifications within the scope and meaning equivalent to the claims. [Explanation of symbols]

[0057] 11 Welding equipment 12 Welding torch 13 Robot Arm 14 Welding machine 15 Piping 16 Cameras 17 Control device 170 Control section 171 Main memory 172 Auxiliary storage P Program 20 Earthing mechanism 21 Lighting 22 Gas Cylinder 23 Controller 24 Cart 25 Operation Buttons 26 Display section 30 Recess 31 First recess 32 Second recess

Claims

1. An image of the corroded part of the pipe is captured, Detecting from the image a contour of a first recess that is recessed more than its surroundings and a contour of a second recess that is located within the first recess and recessed further than the first recess; Based on a detection result of the contours of the first recess and the second recess, a welding instruction is output to a welding machine to perform build-up welding on the first recess after build-up welding on the second recess. An information processing method in which processing is performed by a computer.

2. Obtaining a first image by irradiating the corroded portion with infrared light and a second image by irradiating the corroded portion with visible light; A contour of the first recess is detected based on the first image and the second image. The information processing method according to claim 1 .

3. acquiring a plurality of images of the corroded portion irradiated with illumination light from different directions; A plurality of the images are superimposed to identify a shaded portion, thereby detecting an outline of the second recess. The information processing method according to claim 1 .

4. detecting points of intersection between a plurality of straight lines extending radially from a center of gravity of the first recess and a contour of the second recess; A frame line connecting each of the detected intersections is identified as a welding path. The welding instruction is output to narrow the frame line by a predetermined width toward the center of gravity of the recess. The information processing method according to claim 1 .

5. A control device including a control unit, The control unit: An image of the corroded part of the pipe is captured, Detecting from the image a contour of a first recess that is recessed more than its surroundings and a contour of a second recess that is located within the first recess and recessed further than the first recess; Based on a detection result of the contours of the first recess and the second recess, a welding instruction is output to a welding machine to perform build-up welding on the first recess after build-up welding on the second recess. Control device.

6. A welding device including a welding machine for welding a corroded portion of a pipe, a camera for capturing an image of the corroded portion, a ring-shaped light for emitting infrared light and visible light, and a control device for controlling the welding machine, the camera, and the light, The control device, A first image in which the corroded portion is irradiated with infrared light and a second image in which the corroded portion is irradiated with visible light are obtained from the camera; Detecting an outline of a first recess in the pipe that is recessed relative to surrounding areas based on the first image and the second image; acquiring, from the camera, a plurality of images of the corroded portion irradiated with illumination light from different directions using the ring-shaped illumination; detecting an outline of a second recess that is located within the first recess and is recessed further than the first recess by superimposing a plurality of the images and identifying a shaded portion; Based on a detection result of the contours of the first recess and the second recess, a welding instruction is output to the welding machine to perform build-up welding on the first recess after build-up welding on the second recess. Welding equipment.

Images