Weld Bead Imaging for Automated Steel Pipe Misalignment Measurement
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Solution Overview
Problem
The existing methods for measuring misalignment in welded steel pipes, particularly based on the API5L specification, are not automated and require manual complex measurements, making them time-consuming and inefficient.
Innovation Solution
A misalignment measurement system that includes a marker plate with a length reference pattern, an imaging unit to capture image data, and an arithmetic device to calculate the misalignment amount, allowing for automatic measurement of the bead portion's boundary shape in the cross section of a welded steel pipe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual measurement method is used, then measurement flexibility is maintained, but measurement time and labor load increase significantly
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated imaging system that captures cross-sectional images of the welded steel pipe and uses image processing to automatically calculate misalignment. The arithmetic device processes the captured images to determine the distance between the weld bead and the pipe axis, eliminating the need for manual measurement while significantly improving measurement speed and consistency.
2Loss of time
If automated imaging system is introduced, then measurement efficiency improves, but system complexity increases
Solution Approach 1:
The imaging system is designed to serve multiple functions: capturing cross-sectional images, processing images to identify weld bead positions, calculating misalignment values, and potentially integrating with the manufacturing facility's quality control system. This multi-functionality reduces the need for separate dedicated devices for each measurement step, thereby limiting the increase in system complexity while maintaining high measurement efficiency.
3Manufacturing precision
If misalignment measurement is required by API5L specification, then weld quality control improves, but measurement complexity and time requirement increase
Solution Approach 1:
The system enables self-service quality control by automatically capturing images of the weld cross-section, processing the images to identify the weld bead boundary and pipe axis, and calculating the misalignment value without requiring external manual intervention. The arithmetic device autonomously performs all measurement calculations based on the captured image data, reducing measurement complexity while maintaining high precision required by API5L specification.
Data Source
AI summary
A misalignment measurement system of the present invention includes: a marker plate on which a pattern serving as a length reference for length measurement is drawn; an imaging unit configured to image, as image data together with the marker plate, a bead portion in a cross section of a welded portion on which the marker plate is provided; and an arithmetic device configured to calculate a misalignment amount of the bead portion based on the image data captured by the imaging unit.