大型直缝焊管挠度检测系统研究
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摘要
直线度是大型直缝焊管的主要形位误差,直接影响运输管线的安装。实现大型直缝焊管过弯矫直,首先要检测焊管轴线方向各点的挠度。如何快速准确的测量焊管的挠度是一个亟待解决的测量问题。挠度的测量可以用传统方法也可以使用光学方法,相比而言光学方法具有以下优点:非接触、高分辨率、快速反应并且更为准确。
本文在了解国内外挠度检测现状的基础上,对大型直缝焊管挠度的检测原理进行了研究,分析和比较了多种检测方案,在此基础上进行了测量装置的总体结构设计。结合大型直缝焊管的尺寸和形状特点,选择了optoNCDT 1302激光反射式位移传感器作为传感器元件。建立了相应的数学模型,完成了测量系统的方案设计和结构设计。
以软件开发平台虚拟仪器为出发点,就虚拟仪器的概念、典型结构及产生过程进行了说明,并就虚拟仪器软件平台LabVIEW的功能、特点及使用方法进行了介绍。根据虚拟仪器的设计原则和方法,检测系统采用了模块化设计。详细阐述了大型直缝焊管挠度检测软件系统中主要功能模块的设计和实现。
对不同挠度的φ76×800mm直缝焊管进行了挠曲线检测实验。通过对系统进行稳定性实验、重复性实验、三坐标测量仪测量对比实验,验证了大型直缝焊管挠度检测系统的可行性和可靠性。
As a major shape error of large-diameter longitudinal seam weld steel pipe, deflection error affects the quality of pipeline's installation. Before straightening to large-diameter longitudinal seam weld steel pipes, deflection along the axis must be known firstly. How to measure straightness error of weld pipe's deflection with a high accuracy and a high speed has been a metrology problem which has not been fixed properly by now. Deflection can be measured and surveyed by traditional mechanical methods and optical means. Optical deflection measuring system has the advantages of nor-contact, high resolution, fast response, and so on.
To begin with, the measuring principle of deflection for the large-diameter longitudinal seam weld steel pipe is discussed in this paper, which is based on the research of the status in domestic and the trends of overseas in this area. Many measuring methods are analyzed and compared here. According to this, the overall structure of the measuring apparatus has been contrived. With the shape and size characteristic, OptoNCDT 1302 Reflective Laser Displacement Sensor is chosen. The mathematical model has been created accordingly. The structure and scheme designs for the measuring system have been realized.
And then taking the Virtual Instrument software as a starting point, the concept, typical structure and development process of Virtual Instrument are illuminated. Also the function characteristics and operation methods of virtual instrument software environment LabVIEW are introduced here. According to the Virtual Instrument 's principle of design, the system has used the modular design. Then, the realization of the main acquisition and processing functions of deflection detection system program procedures of large-diameter longitudinal seam weld steel pipes are specified detailedly.
At last, deflection examinations are carried on with the longitudinal seam welded pipeφ75×800mm with different amount of deflection. Through the experiments of stability, repeatability, measurement data comparison with the Three coordinates measuring machine’s, the feasibility and reliability of the measurement system is testified.
本文在了解国内外挠度检测现状的基础上,对大型直缝焊管挠度的检测原理进行了研究,分析和比较了多种检测方案,在此基础上进行了测量装置的总体结构设计。结合大型直缝焊管的尺寸和形状特点,选择了optoNCDT 1302激光反射式位移传感器作为传感器元件。建立了相应的数学模型,完成了测量系统的方案设计和结构设计。
以软件开发平台虚拟仪器为出发点,就虚拟仪器的概念、典型结构及产生过程进行了说明,并就虚拟仪器软件平台LabVIEW的功能、特点及使用方法进行了介绍。根据虚拟仪器的设计原则和方法,检测系统采用了模块化设计。详细阐述了大型直缝焊管挠度检测软件系统中主要功能模块的设计和实现。
对不同挠度的φ76×800mm直缝焊管进行了挠曲线检测实验。通过对系统进行稳定性实验、重复性实验、三坐标测量仪测量对比实验,验证了大型直缝焊管挠度检测系统的可行性和可靠性。
As a major shape error of large-diameter longitudinal seam weld steel pipe, deflection error affects the quality of pipeline's installation. Before straightening to large-diameter longitudinal seam weld steel pipes, deflection along the axis must be known firstly. How to measure straightness error of weld pipe's deflection with a high accuracy and a high speed has been a metrology problem which has not been fixed properly by now. Deflection can be measured and surveyed by traditional mechanical methods and optical means. Optical deflection measuring system has the advantages of nor-contact, high resolution, fast response, and so on.
To begin with, the measuring principle of deflection for the large-diameter longitudinal seam weld steel pipe is discussed in this paper, which is based on the research of the status in domestic and the trends of overseas in this area. Many measuring methods are analyzed and compared here. According to this, the overall structure of the measuring apparatus has been contrived. With the shape and size characteristic, OptoNCDT 1302 Reflective Laser Displacement Sensor is chosen. The mathematical model has been created accordingly. The structure and scheme designs for the measuring system have been realized.
And then taking the Virtual Instrument software as a starting point, the concept, typical structure and development process of Virtual Instrument are illuminated. Also the function characteristics and operation methods of virtual instrument software environment LabVIEW are introduced here. According to the Virtual Instrument 's principle of design, the system has used the modular design. Then, the realization of the main acquisition and processing functions of deflection detection system program procedures of large-diameter longitudinal seam weld steel pipes are specified detailedly.
At last, deflection examinations are carried on with the longitudinal seam welded pipeφ75×800mm with different amount of deflection. Through the experiments of stability, repeatability, measurement data comparison with the Three coordinates measuring machine’s, the feasibility and reliability of the measurement system is testified.
引文
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2杨秀琴.我国钢管工业的现状、问题与发展前景[J].钢管,2008,37(1):12-17
3高颖,李强,孟宪昌.JCO钢管成形仿真技术研究[J].铸造技术,2009,30(1):77
4兰兴昌,张海军,于百勤,等.大口径直缝埋弧焊管成型技术的进步[J].钢管,2006,35(1):166-171
5李宏.直缝埋弧焊钢管生产线预弯工艺[J].焊管,2006,29(1):55-57
6 M S J Hashmi. A spects of tube and pipe manufacturing processes : Meter to nanometer diameter [j]. Journal of Materials Processing Technology ,2006,179(5):5-10
7吴鹏.直径螺旋焊管管端扩径的数值模拟于实验研究[D].秦皇岛:燕山大学,2001:23-30
8蔡星周.大口径直缝焊管机械扩径工艺过程的数值模拟与多目标参数优化[D].秦皇岛:燕山大学,2007:55-63
9 Chen X-Y , Guo B-F , Jin M , et al . Optimization of forming parameters of cylinders in mechanical expanding process [ J ] . Journal of Plasticity Engineering , 2006 , 13(6) :24-28
10陈晓艳.机械扩径过程的数值模拟与工艺参数优化[D] .秦皇岛:燕山大学,2006:35-40
11肖曙红,郑时雄.大口径直缝焊管机械扩径成形机理研究[J ] .锻压装备与制造技术,2004 , (05) :81-84
12 G Palumbo , L Tricarico . Effect of forming and calibration operations on the final shape of large diameter welded tubes[J] . Journal of Materials Processing Technology ,2005 ,164-165 (5) :1089-1098.
13 M D Herynk , S Kyriakides , A Onouf riou , et al . Effects of the UOE/ UOC pipe manufacturing processes on pipe collapse pressure [ J ] . International Journal of Mechanical Sciences ,2007 ,49 (5) :533-553.
14刘京雷,黄克坚,阮峰.大口径直缝焊管JCO成形过程的有限元分析[J].材料科学与工艺,2007,15(5):693-696.
15 D V Jauregui,K R White,C B Woodward,K R Leitch.Noncontact photogrammetric measurement of vertical bridge deflection.Journal of Bridge Engineeing,2003.212-222.
16 T C Hutchinson,F Kuester.Monitoring global earthquake-induced demands using vision-based sensors.IEEE Transaction on Instrumentation and Measurement,2004: 31-36
17 C Forno, S Brown, R A Hunt, A M Kearney, S Oldfield. Measurement of deformation of a bridge by moire photography and photogrammetry.Strain,1991: 83-87
18 Jauregui David V,White Kenneth R, Woodward Clinton B, Leitch Kenneth R, Noncontact photogrammetric measurement of vertical bridge deflection. Journal of Bridge Engineering,2003: 212-222
19 Yoneyama S,Kitagawa A, Iwata S,Tani K.Bridge deflection measurement using digital image correlation.Proceedings of the 2006 SEM Annual Conference and Exposition on Experimental and Applied Mechanics,2006: 1720-1729
20 Jauregui David V,White Kenneth R,Woodward Clinton B.Noncontact photogrammetric measurement of vertical bridge deflection.Journal of Bridge Engineering,2003: 212-222.
21孙路,丁杰雄,CCD挠度测量系统的研究,Practical Measurement Technology,2002,1(1): 6-11
22陈仁文,孙亚飞,陈勇,一种利用光反射原理测量小位移的新方法,Spectroscopy and Spectral Analysis,2004,24(1):21-24
23 Ming-Chih Weng,Xiaodong Lu,Trumper D L.Vibration control offlexible beams using sensor averaging and actuator averaging methods.IEEE Transactions on Control Systems Technology,2002:568-577
24 Trumper David L,Weng Ming-chih,Ritter Robert J.Magnetic suspension and vibration control of beams for non.contact processing.IEEE Conference on Control Applications—Proceedings,1999: 551-557
25 Vogel F,Toulouse B. A low-cost medium-resolution rangefinder based on the self-mixing effect in a VCSEL.IEEE Transactions on Instrumentation and Measurement.2005.428-43l.
26 Morgan C, Bordovsky M, White I, Griffiths R. Noncontact vibration sensors based on current modulated external cavity semiconductor lasers. 1EE Proceedings-Optoelectronics, 2000:413-416
27 Kury P, Zahl P, Horn-von Hoegen.Precise calibration for surface stress induced optical deflection measurements.Review of Scientific Instruments.2004:2211-2212
28 Yoneyama S, KitagwaA, Kitamura K,Kikuta H.Deflection distribution measurement of steel structure using digital image correlation.Proceedings of SPIE-The International Society for Optical Engineering, Optical Diagnostics,2005:1-8
29周忠漠等,GPS卫星测量原理与应用,北京:北京测绘出版社,1993:23-50
30 P. A. Fuchs, G A. Washer S. B. Chase and M. Moore. Laser-based instrumentation for bridge load testing.Journal of Performance of Constructed Facilities,2004:213-218
31 C. Frohlich, M. Mettenleiter, F. Hartl, G. Dalton and D. Hines.Imaging laser radar for 3-D modeling of real world environments. Sensor Review,2000: 273-281
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