Welded Steel Pipe Seam Detection Using Difference Imaging
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Solution Overview
Problem
Existing methods for detecting the position of the seam and heated portions in welded steel pipes face challenges such as surface irregularities, temperature-induced disturbances, oxide film effects, and high operational costs, leading to inaccurate positioning and reliability issues.
Innovation Solution
A position detection device that uses an irradiation unit to emit light and an imaging device to capture images of the seam and heated portions, both with and without light, allowing for the calculation of a difference image to accurately determine their positions, with controlled light irradiation and imaging timing to account for positional deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual observation and manual alignment are used to position the heating device, then operational simplicity is maintained, but positioning accuracy deteriorates due to pass line variation and pipe twisting
Solution Approach 1:
The patent replaces manual visual observation and mechanical alignment with an automated optical detection system. A detection device captures images of the seam portion and heated portion, and a control unit automatically calculates positional deviation, eliminating the need for operator intervention while improving accuracy.
Solution Approach 2:
The patent uses image capture to create a visual copy of the pipe surface, seam portion, and heated portion. This allows the system to analyze positional relationships without physical contact or manual measurement, enabling automated detection and correction of alignment deviations.
2Measurement precision
If the operation line is temporarily stopped to monitor the seam portion, then detection accuracy is improved, but productivity deteriorates
Solution Approach 1:
The detection device is designed to operate continuously during pipe conveyance without requiring line stoppage. The imaging and detection processes are integrated into the production flow, allowing real-time monitoring and correction while maintaining continuous manufacturing operations.
Solution Approach 2:
The patent replaces manual monitoring that requires line stoppage with automated optical detection that operates during continuous conveyance. The system captures images and calculates positional deviations in real-time, eliminating the need to halt production for quality checks.
3Difficulty of detecting and measuring
If electromagnetic detection methods are used to detect seam portion position, then direct detection capability is improved, but reliability deteriorates due to temperature distribution disturbances
Solution Approach 1:
The patent replaces electromagnetic detection methods with optical image-based detection. By using visual imaging rather than electromagnetic sensing, the system avoids interference from temperature distribution variations and oxide films that affect electromagnetic methods, thereby improving reliability.
Solution Approach 2:
The patent changes the detection parameter from electromagnetic properties to optical properties. This parameter change allows detection to proceed independently of temperature-induced electromagnetic variations, providing more reliable and stable detection results in high-temperature environments.
4Difficulty of detecting and measuring
If marking methods are used to identify seam portion position, then detection capability is improved, but manufacturing precision deteriorates due to marker reading errors
Solution Approach 1:
The patent uses direct optical imaging of the actual seam portion and heated portion rather than indirect marker reading. By capturing images of the actual features of interest, the system eliminates errors associated with marker application, reading, and interpretation, achieving higher positioning precision.
Solution Approach 2:
The patent extracts and eliminates the intermediate marker element from the detection process. Instead of using markers as intermediaries to indicate seam position, the system directly images and analyzes the seam portion and heated portion themselves, removing a source of potential error.
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 solution enables accurate and reliable detection of seam and heated portions, reducing operational costs and improving positioning accuracy, while also simplifying the detection process.
Implementation Method 1
a first image of the seam portion and the heated portion irradiated with light from the irradiation unit (21) and a second image of the seam portion and the heated portion not irradiated with light
Data Source
AI summary
A position detection device for a seam portion and a heated portion of a welded steel pipe detects a position of the seam portion of the welded steel pipe and a position of the heated portion generated by heating the seam portion and/or near the seam portion, and includes: an irradiation unit configured to emit light; an imaging device configured to capture a first image of the seam portion and the heated portion irradiated with light and a second image of the seam portion and the heated portion not irradiated with light; and a control device configured to control light irradiation by the irradiation unit and an imaging timing of the imaging device.