ERW Steel Pipe Weld Monitoring via Light-Emission Misalignment Detection
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Solution Overview
Problem
Existing methods for monitoring electric resistance welding fail to precisely detect misalignment due to end faces becoming mirror surfaces, leading to incorrect temperature profile measurements and potential mistaken detection of misalignment.
Innovation Solution
The solution involves capturing images of the light emitting regions at the abutting position of the steel plate using an imaging device, processing the images to detect unevenness, and calculating the areas of light emitting regions on both sides to accurately determine misalignment, even with small step differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature profile measurement is performed on end faces, then welding quality monitoring is achieved, but mirror surfaces cause measurement errors and mistaken detection of misalignment
Solution Approach 1:
The patent introduces light emitting regions as an intermediary indicator to indirectly assess welding quality. Instead of directly measuring temperature profiles on mirror surfaces, the system detects light emission characteristics (intensity, distribution, pattern) from the weld zone, which serve as a mediator to infer welding status without being affected by surface reflectivity issues
Solution Approach 2:
The patent utilizes color/luminance changes in the light emitting regions as an indicator of welding quality. By monitoring variations in light intensity and color characteristics during the welding process, the system can detect welding abnormalities without relying on temperature profile measurements that are corrupted by mirror surface reflections
2Measurement precision
If misalignment detection is performed using existing methods, then welding quality monitoring is attempted, but mirror surfaces lead to incorrect measurements and potential mistaken detection
Solution Approach 1:
The patent uses light emitting regions as an intermediary to detect misalignment. By analyzing the spatial distribution and intensity patterns of light emission from the weld zone, the system can determine misalignment status without directly measuring the mirror surfaces that cause detection errors
Solution Approach 2:
The patent detects misalignment by identifying asymmetric patterns in light emission distribution. When misalignment occurs, the light emitting regions exhibit characteristic asymmetric intensity distributions or positional shifts that can be detected and used to quantify the misalignment magnitude
3Manufacturing precision
If end faces are treated to remove oxides, then welding quality is improved, but the end faces become mirror surfaces that interfere with light-based detection methods
Solution Approach 1:
The patent converts the harmful effect of mirror surfaces (which interfere with detection) into a beneficial indicator. The same light reflection properties that cause measurement errors are utilized to enhance the visibility and detectability of light emitting regions, making the welding zone more conspicuous for optical detection purposes
Solution Approach 2:
The patent employs color/luminance analysis of light emitting regions to overcome detection difficulties caused by mirror surfaces. By monitoring changes in light intensity and color characteristics during welding, the system can reliably detect welding status despite the reflective nature of the prepared end faces
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for precise detection of misalignment without being affected by mirror surfaces, effectively reducing the likelihood of mistaken detection and improving the quality of electric resistance welded steel pipes.
Implementation Method 1
capturing images of the light emitting regions at the abutting position of the metal plate
Implementation Method 2
high frequency resistance welding... two end parts in its circumferential direction made to converge to a V-shape are heated to melt
Implementation Method 3
induction heating welding... two end parts in its circumferential direction made to converge to a V-shape are heated to melt
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The objective of the present invention is to enable accurate detection of a mismatch during electric resistance welding. This operation monitoring device for high-frequency resistance welding and induction heated welding of an electric resistance welded steel pipe, in which a strip-shaped metal sheet is continuously formed into a cylindrical shape by means of a group of rollers while being conveyed from an upstream side to a downstream side, and in which the two edge portions, in the circumferential direction, of the metal sheet, which are caused to converge into a V-shape, are caused to melt by the application of heat and are caused to abut one another, is characterized by being provided with a means for detecting a mismatch by recognizing a non-uniformity between light-emitting regions of a metal part, on both sides, in the circumferential direction, of the abutting position on an outer surface or an inner surface of the metal plate, on the basis of an image of a region including a V-convergence location, which is a location at which the two edge portions in the circumferential direction converge into said V-shape, and said metal part which is caused to flow out onto the surface of the metal plate by means of an electromagnetic force downstream of the V-convergence location, wherein said image is captured by means of an image capturing device from an outer surface side or an inner surface side of the metal plate that has been formed into said cylindrical shape.