Side-View CCD Imaging for Electric-Resistance-Welded Pipe Molten State Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for monitoring the state of electric-resistance-welded pipe production, such as those using cameras and fiber scopes, face challenges in accurately capturing the molten state and butting state due to issues like inverted V-shape welds and insufficient image resolution, leading to difficulties in controlling heat input and detecting defects like scale inclusion.
Innovation Solution
A system that uses relay lenses and an insulated container with a CCD camera and data processing system to capture high-definition images of the welded parts, analyze the molten state and butting state, and display results for improved control and defect detection, allowing for real-time monitoring and adjustment of welding parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a camera is placed directly above the weld point to take still images, then the imaging system is simple to implement, but the butting state (inverted V-shape) cannot be distinguished from suitable states, making heat input state monitoring inaccurate
Solution Approach 1:
The patent transitions from top-down imaging (single dimension) to side-view imaging (different dimension), allowing the imaging means to capture the butting state and molten pool shape from a lateral perspective, thereby distinguishing inverted V-shape welds from suitable weld configurations
2Ease of operation
If a fiber scope is used to obtain images of welded parts, then the imaging device can be positioned inside the pipe, but the image resolution is insufficient and images between fibers show clearance, creating a mesh state that obscures weld face details
Solution Approach 1:
The patent extracts the imaging means from the constrained fiber scope configuration and positions it externally at the side of the welded parts, eliminating the mesh artifact problem while maintaining internal observation capability through strategic positioning of the imaging device
Solution Approach 2:
The patent replaces the fiber optic mechanical system with a direct digital imaging system (CCD camera) that captures high-resolution images of the welded parts from the side, providing superior image quality for analyzing molten state and butting configuration
3Measurement precision
If relay lenses are used to relay images from welded parts, then high-definition images can be obtained, but the container must be made of insulated material to prevent noise interference, increasing device complexity
Solution Approach 1:
The patent introduces a container made of heat-insulating material as an intermediary between the high-temperature welded parts and the imaging system, blocking thermal noise and electromagnetic interference while allowing optical signals to pass through, thus protecting the sensitive imaging and relay lens components
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 system enables high-precision analysis and display of welding states, enhancing response control, productivity, and operator efficiency while reducing noise interference and improving the accuracy of defect detection in electric-resistance-welded pipe production.
Implementation Method 1
relay an image based on light emitted from the welded parts
Implementation Method 2
container containing said relay lenses and made at least in part by an insulated material
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
A system and method for monitoring the molten state for enabling a molten state, butting state, or other state of electric-resistance-welded pipe on-line more accurately than in the past are provided. That is, a mirror 23 provided at a front end side inside a container 21 receives light emitted by the welded parts 5 of the tube-shaped steel strip 1 themselves through heat resistant glass 22 from the side direction and reflects the image of the welded parts 5 of the tube-shaped steel strip 1 in the direction of a relay lens 24 provided at a base end side of a relay lens unit 13. The relay lenses 24 relay the image of the welded parts 5 of the tube-shaped steel strip 1 to a conversion lens 12, then the conversion lens 12 forms that image on the imaging area of a CCD camera 11. Therefore, it is possible to capture the welded parts 5 of the tube-shaped steel strip 1 from the side direction by a resolution in accordance with the resolution of the CCD camera 11 and possible to obtain information of the welded parts 5 of the tube-shaped steel strip 1 more accurately than in the past and on-line.