Welded Steel Pipe Seam Detection Using Reflected and Self-Emitted Light
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Solution Overview
Problem
Existing methods for detecting the seam and heated portions of welded steel pipes face challenges such as accuracy issues due to temperature changes, oxide film interference, and the need for costly and complex equipment, leading to inefficiencies and safety concerns in the manufacturing process.
Innovation Solution
A position detection device using a combination of imaging reflected light and self-emitted light from the seam and heated portions, capturing images with and without irradiation, allows for accurate detection by calculating differences in luminance values to identify the seam and heated positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual observation and manual alignment are used to align the seam portion and heated portion, then the operator can identify the seam position, but the operator is exposed to red heat light which causes loss of gloss, difficulty of visual recognition, and safety concerns
Solution Approach 1:
The patent introduces an intermediary detection device (camera or sensor system) that captures images of the seam portion without requiring the operator to directly observe the red heat light. The detection device acts as a mediator between the seam portion and the operator, allowing accurate position detection while protecting the operator from harmful thermal radiation and improving safety conditions
2Measurement precision
If the operation line is temporarily stopped to monitor the seam portion, then accurate monitoring can be achieved, but manufacturing efficiency decreases
Solution Approach 1:
The patent implements continuous monitoring of the seam portion during the operation line's normal operation. The detection device continuously captures images or signals to track the seam position without interrupting the manufacturing process, thereby maintaining both high monitoring accuracy and manufacturing efficiency simultaneously
3Measurement precision
If electromagnetic methods are used to detect the seam portion, then direct detection is possible, but the detection is affected by temperature distribution and material uniformity changes
Solution Approach 1:
The patent transitions from electromagnetic detection parameters (which are sensitive to temperature and material properties) to optical detection parameters (light reflection and self-emission characteristics). This parameter change allows the detection system to identify the seam portion based on surface optical properties that remain stable under temperature variations and annealing conditions, thereby improving detection reliability
4Measurement precision
If costly and complex equipment is used for detection, then detection capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs relatively simple and cost-effective detection devices such as standard cameras or basic optical sensors instead of expensive electromagnetic detection equipment. These affordable devices capture optical images or signals to identify the seam position, achieving sufficient detection capability while significantly reducing manufacturing costs and system complexity
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 method enables precise and cost-effective detection of seam and heated portions, improving manufacturing efficiency and safety by reducing reliance on costly equipment and minimizing the impact of oxide films and temperature variations.
Implementation Method 1
imaging reflected light of light irradiated from an irradiation unit to a seam portion
Implementation Method 2
imaging self-emitted light of an object at a high temperature
Data Source
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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. The position detection device includes an irradiation unit that emits light, an imaging device that captures 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 that controls light irradiation by the irradiation unit and an imaging timing of the imaging device.