管道自动焊接中焊缝检测和焊接参数控制系统的研究
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摘要
随着石油天然气及石油化工工业的发展，管道建设处于发展的高峰期。焊缝位置和焊接参数是影响管道焊接质量的重要因素，因此其中涉及的检测和控制技术得到广泛的关注和研究。本文根据现有管道自动焊接技术的特点和不足，研制出有效的焊缝检测和焊接参数控制系统，能够实时准确地调整焊枪位置、控制焊枪运动轨迹，获得合乎要求的焊缝。
焊缝检测系统采用CCD光学传感技术，综合多种图像处理算法，能够在50m/h的焊接速度下快速准确地检测出焊缝边缘，并运算求得焊接偏移参数，通过接口卡传输给焊接参数控制系统。系统具有实时性、非接触、检测准确、运行稳定等特点。
焊接参数是控制焊枪运动轨迹的参数，本焊接参数控制系统利用串口通信的方法实现参数传输，通过角度传感技术定位焊接管道位置并进行相应参数的切换，以电机控制卡为核心，通过控制软件驱动焊枪完成焊接参数规定的焊接过程。焊枪摆速能够准确控制在30mm/s~50mm/s范围内变化。系统控制简单、精确，在焊接现场能稳定可靠地工作，抗干扰能力强，各项技术指标符合生产要求。
本论文的创新点：
针对焊缝图像的特点，采用多种算法综合处理的方法，实现了快速且准确的检测。
采用串口通信技术和角度传感技术，有效实现了焊接参数传输和切换。
采用专用电机控制卡控制、软件驱动焊枪执行机构的方法，可靠性高，响应快，控制简单。
With the development of petroleum gas and petrochemical industry, the pipeline is built in the peak period. Welding seam position and weld parameter are important factors to influence pipeline quality, so the detection and control technology involved is concerned much and studied much. According to the characteristic and deficiency of the existing automatic pipeline welding technology, the dissertation introduces effective welding seam detection and weld parameter control system, which can real-time adjust the position and control the orbit of welding gun accurately. As the result, high quality seam is obtained.
Based on the CCD optical sensing technology, the welding seam detection system can detect out the seam edge fast and accurately by means of algorithms such as median filter, image segmentation, contour tracking and Hough transformation. Then the offset parameter can be calculated and transmitted to the control system by certain
interface card. The system has such characteristic as real-time, non-contact. Experiments show that this system can work steadily and can obtain accurate detection results.
Weld parameter is used to regulate the orbit of welding gun. Based on such technology as serial communication, angle sensing, and motor control, the weld parameter system can realize parameter transmission, pipeline positioning, parameter switch, and welding gun driving. The swing speed of welding gun can be changed from 30mm/s to 50mm/s. The system shows such performances as easy to operate, steady running status, good anti-jamming ability, which fit finely the welding requirements. The major innovations achieved in the dissertation are as follows:
Certain kinds of algorithms are adopted according to the characteristic of welding seam image. The seam detection system realizes real-time image process with these algorithms.
Serial communication and angle sensing technology is used in weld parameter control system with which transmission and switch of parameter can be realized.
Welding gun can run accurately and reliably in term of weld parameter with special motor control card and control software.
焊缝检测系统采用CCD光学传感技术，综合多种图像处理算法，能够在50m/h的焊接速度下快速准确地检测出焊缝边缘，并运算求得焊接偏移参数，通过接口卡传输给焊接参数控制系统。系统具有实时性、非接触、检测准确、运行稳定等特点。
焊接参数是控制焊枪运动轨迹的参数，本焊接参数控制系统利用串口通信的方法实现参数传输，通过角度传感技术定位焊接管道位置并进行相应参数的切换，以电机控制卡为核心，通过控制软件驱动焊枪完成焊接参数规定的焊接过程。焊枪摆速能够准确控制在30mm/s~50mm/s范围内变化。系统控制简单、精确，在焊接现场能稳定可靠地工作，抗干扰能力强，各项技术指标符合生产要求。
本论文的创新点：
针对焊缝图像的特点，采用多种算法综合处理的方法，实现了快速且准确的检测。
采用串口通信技术和角度传感技术，有效实现了焊接参数传输和切换。
采用专用电机控制卡控制、软件驱动焊枪执行机构的方法，可靠性高，响应快，控制简单。
With the development of petroleum gas and petrochemical industry, the pipeline is built in the peak period. Welding seam position and weld parameter are important factors to influence pipeline quality, so the detection and control technology involved is concerned much and studied much. According to the characteristic and deficiency of the existing automatic pipeline welding technology, the dissertation introduces effective welding seam detection and weld parameter control system, which can real-time adjust the position and control the orbit of welding gun accurately. As the result, high quality seam is obtained.
Based on the CCD optical sensing technology, the welding seam detection system can detect out the seam edge fast and accurately by means of algorithms such as median filter, image segmentation, contour tracking and Hough transformation. Then the offset parameter can be calculated and transmitted to the control system by certain
interface card. The system has such characteristic as real-time, non-contact. Experiments show that this system can work steadily and can obtain accurate detection results.
Weld parameter is used to regulate the orbit of welding gun. Based on such technology as serial communication, angle sensing, and motor control, the weld parameter system can realize parameter transmission, pipeline positioning, parameter switch, and welding gun driving. The swing speed of welding gun can be changed from 30mm/s to 50mm/s. The system shows such performances as easy to operate, steady running status, good anti-jamming ability, which fit finely the welding requirements. The major innovations achieved in the dissertation are as follows:
Certain kinds of algorithms are adopted according to the characteristic of welding seam image. The seam detection system realizes real-time image process with these algorithms.
Serial communication and angle sensing technology is used in weld parameter control system with which transmission and switch of parameter can be realized.
Welding gun can run accurately and reliably in term of weld parameter with special motor control card and control software.
引文
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[5]APW-1型油气管线自动焊接设备及工艺, 中国石油天然气集团公司工程技术研究院, 2000
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[8]MTV-1881Ex CCD B/W Camera User’s Manual, Taiwan: Mintron Enterprise Co., LTD., 1999
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[13]刘文耀, 光电图像处理, 北京: 电子工业出版社, 2002, 107~108
[14]夏玮, 李朝晖, 中值滤波的快速算法, 计算机工程与设计, 2002
[15]章毓晋, 图像分割, 北京: 科学出版社, 2001, 9~12
[16]王坤明, 朱双东, 张超, 自动选取阈值方法比较研究, 抚顺石油学院学报,
2002
[17]付忠良, 图像阈值选取方法—Otsu方法的推广, 计算机应用, 2000, 20(5): 37~39
[18]杨述斌, 图像边缘检测技术概述, 武汉化工学院学报, 2003
[19]杜秀娟, 射线照相焊缝缺陷的识别与分类, 青海师专学报, 2002
[20]何斌, 马天予, 王运坚等, Visual C++数字图像处理, 北京: 人民邮电出版社,
2001, 426~428
[21]OK系列PCI图像卡用户指南辅助材料, 北京: 嘉恒中自图像技术有限公司, 2001
[22]Visual C++6.0入门与提高, 北京: 清华大学出版社, 1999, 23~27
[23]PCL-711B Analog and Digital I/O Card User’s Manual, Taiwan: Advantech Co., Ltd., 2000
[24]Advantech DLL Drivers User’s Manual and Programmer’s Reference. Taiwan: Advantech Co., Ltd., 2000
[25]黄战华, 雷建龙, 蔡怀宇等, 微机原理与接口技术, 北京: 机械工业出版社, 2002, 88~98
[26]无接触角度传感器用户说明, 北京通磁伟业传感技术有限公司, 2002
[27]谭浩强, C程序设计, 北京: 清华大学出版社, 1994, 83~85
[28]PCL-839 3-axis High Speed Stepping Motor Control Card User’s Manual, Taiwan: Advantech Co., Ltd., 2000
[29]吴平川, 路同浚, 孟宪超等, 带钢板表面缺陷CCD检测方法的研究, 黑龙江自动化技术与应用, 1999, 18(5): 39~41, 44
[30]薛实福, 李庆祥, 精密仪器设计, 北京；清华大学出版社, 1991, 12~16
[2]王其隆, 弧焊过程中质量实时传感与控制, 北京: 机械工业出版社, 2000, 45~60
[3]厚板大坡口焊缝自动跟踪系统的研制, 第十次全国焊接会议论文集, 2001
[4]林尚扬, 陈善本, 李成桐, 焊接机器人及其应用, 北京: 机械工业出版社, 2000, 137~138
[5]APW-1型油气管线自动焊接设备及工艺, 中国石油天然气集团公司工程技术研究院, 2000
[6]孙立新, 戴士杰, 李慨, 基于线结构光多道焊跟踪系统图像处理, 焊接学报, 2002
[7]王庆有, CCD应用技术, 天津: 天津大学出版社, 2000, 164~166
[8]MTV-1881Ex CCD B/W Camera User’s Manual, Taiwan: Mintron Enterprise Co., LTD., 1999
[9]张凤林, 孙学珠, 工程光学, 天津: 天津大学出版社, 1996, 36~41
[10]OK系列PCI图像卡用户手册, 北京: 嘉恒中自图像技术有限公司, 2001
[11]王耀南, 李树涛, 毛建旭, 计算机图像处理与识别技术, 北京: 高等教育出版社, 2001, 74~79
[12]刘榴娣, 刘明奇, 党长民, 实用数字图像处理, 北京: 北京理工大学出版社, 1998, 94~100, 181~182
[13]刘文耀, 光电图像处理, 北京: 电子工业出版社, 2002, 107~108
[14]夏玮, 李朝晖, 中值滤波的快速算法, 计算机工程与设计, 2002
[15]章毓晋, 图像分割, 北京: 科学出版社, 2001, 9~12
[16]王坤明, 朱双东, 张超, 自动选取阈值方法比较研究, 抚顺石油学院学报,
2002
[17]付忠良, 图像阈值选取方法—Otsu方法的推广, 计算机应用, 2000, 20(5): 37~39
[18]杨述斌, 图像边缘检测技术概述, 武汉化工学院学报, 2003
[19]杜秀娟, 射线照相焊缝缺陷的识别与分类, 青海师专学报, 2002
[20]何斌, 马天予, 王运坚等, Visual C++数字图像处理, 北京: 人民邮电出版社,
2001, 426~428
[21]OK系列PCI图像卡用户指南辅助材料, 北京: 嘉恒中自图像技术有限公司, 2001
[22]Visual C++6.0入门与提高, 北京: 清华大学出版社, 1999, 23~27
[23]PCL-711B Analog and Digital I/O Card User’s Manual, Taiwan: Advantech Co., Ltd., 2000
[24]Advantech DLL Drivers User’s Manual and Programmer’s Reference. Taiwan: Advantech Co., Ltd., 2000
[25]黄战华, 雷建龙, 蔡怀宇等, 微机原理与接口技术, 北京: 机械工业出版社, 2002, 88~98
[26]无接触角度传感器用户说明, 北京通磁伟业传感技术有限公司, 2002
[27]谭浩强, C程序设计, 北京: 清华大学出版社, 1994, 83~85
[28]PCL-839 3-axis High Speed Stepping Motor Control Card User’s Manual, Taiwan: Advantech Co., Ltd., 2000
[29]吴平川, 路同浚, 孟宪超等, 带钢板表面缺陷CCD检测方法的研究, 黑龙江自动化技术与应用, 1999, 18(5): 39~41, 44
[30]薛实福, 李庆祥, 精密仪器设计, 北京；清华大学出版社, 1991, 12~16