CN110345881A - 焊缝几何形状的感测 - Google Patents

焊缝几何形状的感测 Download PDF

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CN110345881A
CN110345881A CN201910271298.2A CN201910271298A CN110345881A CN 110345881 A CN110345881 A CN 110345881A CN 201910271298 A CN201910271298 A CN 201910271298A CN 110345881 A CN110345881 A CN 110345881A
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sensor
axis
measurement position
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CN110345881B (zh
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R.瑞兹
E.哈斯费克
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GEORGE FISHER PIPELINE SYSTEM CO Ltd
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Abstract

一种用于感测管线部件、优选塑料管道之间的塑料对接焊缝的焊缝几何形状的方法和装置，包括以下步骤：相对于管线部件（优选塑料管道）之间的对接焊缝粗略手动定位光学传感器，优选地在管道外直径处，其中传感器大致垂直于管道中心轴线对准，传感器沿传感器轴线或围绕传感器轴线自动接近测量位置，在每个接近的测量位置通过传感器获取可见的焊缝几何形状和/或数据，通过所获取的数据，优选地通过算法确定最佳测量位置，传感器沿传感器轴线或围绕传感器轴线自动接近最佳测量位置，获取焊缝几何形状以确定焊缝的质量，分析和判断在优化的测量位置处获取的焊缝几何形状的测量。

Description

焊缝几何形状的感测
技术领域
本发明涉及一种用于感测管线部件（优选塑料管道）之间的塑料对接焊缝的焊缝几何形状的方法和装置，其中该装置包括光学传感器和载体装置，其中载体装置具有驱动器和用于定位传感器的传感器轴线。
背景技术
检查对接焊接用于焊接的质量控制。在此利用哪一种方法将管道和/或配件对接焊接都没有任何作用，无论是通过非接触式IR焊接方法，通过接触加热元件的经典对接焊接方法，或另一方法。根据待焊接的管道和/或配件，即它们的尺寸、它们的塑性、所应用的焊接技术等，焊缝必须具有特定的形状和/或尺寸，这可以光学地检查。与此相对应，存在准则和/或规范，其精确地限定了接缝必须如何出现和/或关于管道和/或配件性质和焊接性质必须具有什么允许的尺寸，以使它们对应于要求。迄今为止，通常已经进行了由合格技术人员进行的手动光学判断，技术人员基于他已知的规范和准则来比较和判断所得到的焊缝。
在这种情况下不利的是，由技术人员的判断非常耗时并且因此非常昂贵。而且，这种判断也不一致地相等，因为人为因素起着重要作用，并且检查并不总是由同一技术人员进行。
JP 2000289115A公开了借助于超声传感器检查塑料管的焊接，由此还可以实现关于内部（其不可见）的管壁的熔合的陈述。
该检查具有高支出的缺点，因为这种检查非常耗时，因为必须非常精确地执行超声传感器和/或焊缝相对于超声传感器的放置，这需要长配置时间。
EP 2 963 380 A1公开了一种用于检查对接焊接的装置，其中该检查通常直接在焊接管道的装置中进行，并且因此不再需要焊缝相对于传感器的精确对准。
在这种情况下不利的是，检查只能在焊接之后直接进行，并且不能在单独的、可能更晚的检查中进行，因为随后在装置中的卡紧和相应的对准几乎不可能。
发明内容
本发明的目的是提出一种方法和与其相关联的装置，其允许通过能够避免焊缝相对于传感器的精确定位而快速且容易地进行对接焊缝的光学检查。
根据本发明，该目的通过以下实现：用于感测管线部件（优选塑料管道）之间的塑料对接焊缝的焊缝几何形状的方法包括以下步骤：
• 相对于管线部件（优选塑料管道）之间的对接焊缝粗略手动定位光学传感器，优选地在管道外直径处，其中传感器大致垂直于管道中心轴线对准，
• 传感器沿传感器轴线或围绕传感器轴线自动和/或自主接近测量位置，
• 在每个接近的测量位置通过传感器获取可见的焊缝几何形状和/或数据，
• 通过所获取的数据，优选地通过算法确定最佳测量位置，
• 传感器沿传感器轴线或围绕传感器轴线自动和/或自主接近最佳测量位置，
• 获取焊缝几何形状以确定焊缝的质量，
• 分析和判断在优化的测量位置处获取的焊缝几何形状的测量。
光学传感器相对于对接焊缝粗略地手动定位，该对接焊缝在焊接的管线部件、优选塑料管道之间延伸。光学传感器优选地直接布置在管道外直径上，例如通过紧固环或另一简单的紧固装置。传感器对准大致垂直于管道轴线对准，其中由传感器当然可以记录轻微位移和/或对轻微位移进行独立校正。
传感器沿传感器轴线和/或围绕传感器轴线自动地和/或自主地接近测量位置，在传感器轴线处传感器获取焊缝和/或焊缝宽度和/或K尺寸。
在优选经由控制器限定的测量位置处，传感器获得可见的焊缝几何形状。由于传感器相对于焊缝的粗略手动定位，为了能够准确分析质量和/或焊缝几何形状，传感器必须首先找到焊缝的最佳测量位置，在此传感器直接和/或垂直于焊缝定向而没有侧向位移和/或传感器相对于焊缝也没有倾斜。为此目的，接近至少三个测量位置并且获得相应的焊缝几何形状，优选地在每种情况下获得焊缝宽度和/或K尺寸。
然后优选地通过来自先前获取的数据的算法确定最佳测量位置。最佳测量位置在焊缝宽度最小或K尺寸也最小的点处，因为没有由于视差引起的加宽导致焊缝的正面顶视图，其中如果仅仅获取宽度或K尺寸来确定最佳测量位置是足够的。
基于确定的最佳测量位置，传感器沿着传感器轴线或围绕传感器轴线行进到该最佳测量位置中。
它再次获得那里的焊缝几何形状，然后用于分析和判断焊缝的质量和尺寸精度。分析和判断优选地通过控制器执行并且基于预定值，基于该预定值来比较记录的焊缝几何形状。
有利的是，在传感器沿传感器轴线或围绕传感器轴线自动和/或自主接近测量位置期间，接近至少三个测量位置以获得可见的焊缝几何形状。因此，最佳测量位置可以优选地通过算法确定。当然，沿传感器轴线或围绕传感器轴线的更多测量位置也是可能的。优选地，接近各自位于传感器轴线上的最外侧上的两个极限位置，并且获取那里的焊缝几何形状、优选焊缝宽度和/或K尺寸，以结合到最佳测量位置的计算中，以及传感器绕传感器轴线枢转时的外部极限位置也被接近。
已经示出有利的是，借助于传感器在每个接近的测量位置中获取焊缝宽度和/或K尺寸。然后使用这些测量数据来确定最佳测量位置，因为最佳测量位置对于确定用于质量确定的焊缝几何形状是决定性的，因为仅在该位置获得没有视差和/或图像失真的情况下的焊缝的正确记录，其中传感器线性地和/或垂直于焊缝定向。
根据一个优选实施例，算法通过所获取的可见焊缝几何形状和/或测量数据、特别是通过所获取的焊缝宽度和/或K尺寸来确定最佳测量位置，其中，最佳测量位置是存在最小焊缝宽度和/或最小K尺寸的位置，因为没有图像失真。在最佳测量位置处，传感器在中心和/或大致垂直于焊缝定向，这防止了图像失真并允许最佳记录焊缝几何形状以进行质量控制。
基于所获取的数据来确定最佳测量位置的算法优选地由多项式限定。多项式可以精确地延伸通过所确定的测量数据，并且也可以大致通过测量数据的范围。
最佳测量位置优选地由多项式的最低点或通过测量点形成，该测量点基于近似多项式形式定位成低于多项式的最低点和/或具有较低值。
有利的是，传感器自动接近测量位置沿着平行于管道轴线对准的传感器轴线延伸。因此，可以通过传感器和管道之间的已知距离以及孔径角来确定沿传感器的管道轴线相对于焊缝和/或相对于最佳测量位置、因此相对于焊缝的中心的偏移，所述孔径角存在于形成假想的直线的焊缝的一个边缘和传感器和形成另一假想的直线的另一个边缘和传感器之间。然而，为此目的需要至少三个测量点。
该方法的替代实施例是传感器轴线大致垂直于管道中心轴线延伸，其中传感器布置成使其可在传感器轴线上枢转。传感器优选地设计为具有远心物镜的照相机，该远心物镜具有圆柱形延伸的视场。对于这种类型的物镜，与具有锥形视场的标准物镜的不同之处在于它具有圆柱形延伸的视场。因此，与标准物镜一样，焊缝不一定必须布置在视场的中心，而是物镜必须垂直于焊缝和/或物镜的光轴定向，必须垂直于管道中心轴线定向。
根据本发明，该目的通过以下实现：传感器轴线平行于或垂直于管线轴线延伸，并且传感器可沿传感器轴线或围绕传感器轴线移动或枢转。
根据本发明的用于实施感测管线部件（优选塑料管道）之间的塑料对接焊缝的焊缝几何形状的方法的装置具有光学传感器和载体装置，其中载体装置具有驱动器和用于定位传感器的传感器轴线。传感器轴线平行于或垂直于管线轴线对准，并且传感器可沿传感器轴线或围绕传感器轴线移动或枢转和/或旋转。
已经证明有利的是，根据本发明的装置直接紧固在管道外直径上，例如，使用带或环，装置紧固在带或环上并且布置在管道上，其中独立于装置的管道设置的支撑件也可以想到，管道能够插入支撑件中。
已经证明有利的是，传感器设计为照相机并且具有普通或标准物镜或远心物镜。如果使用远心物镜，则有利的是使用垂直于管道中心轴线延伸的传感器轴线，传感器或具有远心物镜的照相机围绕该传感器轴线枢转，因为远心物镜仅具有线性延伸或者圆柱形视场，并且因此照相机和/或物镜必须对准，以便它可以相对于焊缝枢转，以达到最佳测量位置并避免图像失真。相比之下，对于具有锥形视场的标准物镜，为了避免图像失真，重要的是焊缝位于视场的中心，因此经由平行于管线延伸的传感器轴线执行对准。
有利的是，驱动器设计为具有主轴的步进马达，其中也可以想到线性马达。获得焊缝几何形状及其分析的完整程序持续几秒，优选在1和20秒之间，其中特别优选在1和12秒内发生执行。
驱动器优选地具有位置感测单元，其优选地连接到控制器。因此可以确定传感器位于哪个点，并且还可以通过计算和确定的测量数据来接近也经由位置感测运行的最佳测量位置。
所有可能的实施例可以彼此自由组合，并且方法特征也可以与装置特征组合。
附图说明
将基于附图描述本发明的示例性实施例，其中本发明不仅限于示例性实施例。在附图中：
图1示出了根据本发明的装置的布置的示意图，其用于在使用标准物镜接近测量位置期间执行根据本发明的方法，
图2示出了根据本发明的装置的布置的示意图，其用于使用标准物镜在最佳测量位置执行根据本发明的方法，
图3a示出了传感器在最佳测量位置的记录，
图3b示出了传感器在测量位置的记录，用于确定最佳测量位置，
图4示出了通过具有焊缝的管道的纵向截面，
图5示出了所获取的测量位置和由此确定的最佳测量位置的示意图，
图6示出了根据本发明的装置的三维视图，
图7示出了根据本发明的装置的布置的示意图，其用于在使用远心物镜接近测量位置期间执行根据本发明的方法，以及
图8示出了根据本发明的装置的布置的示意图，其用于使用远心物镜在最佳测量位置执行根据本发明的方法。
具体实施方式
图1中所示的附图示出了根据本发明的装置1的示意图。在传感器5的这个位置，沿传感器轴线7接近不同位置，以便获得焊缝几何形状，优选地是焊缝宽度B和/或K尺寸K。传感器5的记录图像之间的差异能够从图3a和图3b很好地看出。图3b示出了传感器5未定位在最佳测量位置opt.M（即在焊缝前方的中心）的记录，并且因此得到的宽度B和K尺寸K更大。这种记录沿着传感器轴线7记录在至少三个位置处，这是获取的测量数据的最小值，以确定和/或计算最佳测量位置。通过传感器5与管道11的已知距离和物镜的孔径角9以及焊缝3的两个获得的可见边缘2，焊缝宽度B和/或最佳测量位置opt.M的哪处可以记录而不会使宽度和/或K尺寸K结果失真，然后将其用于分析焊缝质量。
图2中示出传感器5位于最佳测量位置，用于记录焊缝几何形状，其用于分析和判断接缝。可以很好地看出，传感器5和/或光轴6在焊缝的中心定向，由此可以避免视差，这与焊缝质量的分析和判断相关。
图4示出了焊接管道11，其中焊缝3以截面示出，以便示出除了焊缝宽度B之外的尺寸，即K尺寸K，也用于确定最佳测量位置。该尺寸K可以单独代替宽度B确定，或者也可以组合确定。
图5示出了用于确定最佳测量位置的确定的测量点被示为十字形的图。这些是在沿着传感器轴线接近不同位置期间获得的，利用其最佳测量位置opt.M然后优选地基于算法确定。垂直轴线B / K示出焊缝B的宽度或焊缝的K尺寸K的测量尺寸，并且水平轴线示出传感器轴线上传感器的对应位置x或者传感器轴线上的角度设置。
在第一个图中，可以识别的是最佳测量位置opt.M也可以由两条直线的交点限定，这可以基于测量点来确定。
可替代地，该方法借助于多项式来表示，该多项式不精确地延伸通过测量点而是大致通过测量点。因此可以发生确定的测量点位于低于多项式曲线的最低点的位置。在这种情况下，较低的单点优选地用作最佳测量点opt.M，其中最低点位于图5中的第二图中的曲线上，并且单点布置得略高。最后一个图又示出了多项式曲线，该曲线精确地延伸通过测量点。
在图6中，三维地示出了根据本发明的装置1，其中在此独立于管道而示出了装置。装置1具有载体装置8，驱动器10布置在载体装置8上并且载体装置8具有用于精确定位传感器5的传感器轴线7。传感器5优选地设计为这里具有对应的标准物镜的照相机，其中也可以使用远心物镜，但是然后稍微改变驱动器的传感器轴线的布置。
图7和图8中所示的示意图对应于图1和图2，但是具有远心物镜而不是标准物镜。在这种情况下清楚地明显的是，在远心物镜中，视场以圆柱形延伸，并且因此通过传感器5在传感器轴线7上的枢转来校正偏移和/或图像失真，使得然后，光轴6在最佳测量位置opt.M中垂直于管道中心轴线4定向。然而，在该实施例中，焊缝不必位于传感器视场的中心。
附图标记列表：
1 用于感测塑料对接焊缝的焊缝几何形状的装置
2 焊缝边缘
3 焊缝
4 管道中心轴线
5 传感器
6 物镜的光轴，相对于带有标准物镜的焊缝居中，垂直于带有远心物镜的管道中心轴线（最佳测量位置）
7 传感器轴线
8 载体装置
9 孔径角
10 驱动器
11 管道
K 测量的K尺寸
B 测量焊缝宽度
Opt.M 最佳测量位置
X 传感器轴线上的位置

Claims (11)

1.一种用于感测管线部件、优选塑料管道（11）之间的塑料对接焊缝（3）的焊缝几何形状的方法，包括以下步骤：
相对于管线部件、优选塑料管道之间的对接焊缝（3）粗略手动定位光学传感器（5），优选地在管道外直径处，其中，传感器大致垂直于管道中心轴线（4）对准，
传感器沿传感器轴线（7）或围绕传感器轴线（7）自动接近测量位置，
在每个接近的测量位置通过传感器（5）获取可见的焊缝几何形状和/或数据，
通过所获取的数据，优选地通过算法确定最佳测量位置（opt.M），
传感器（5）沿传感器轴线（7）或围绕传感器轴线（7）自动接近最佳测量位置（opt.M），
获取焊缝几何形状以确定焊缝的质量，
分析和判断在优化的测量位置处获取的焊缝几何形状的测量。
2.根据权利要求1所述的方法，其特征在于，在传感器沿传感器轴线（7）或围绕传感器轴线（7）自动接近测量位置期间，接近至少三个测量位置以获得可见的焊缝几何形状。
3.根据权利要求1或2中任一项所述的方法，其特征在于，借助于传感器（5）在每个接近的测量位置中获取焊缝宽度（B）和/或K尺寸（K）。
4.根据权利要求1到3中任一项所述的方法，其特征在于，算法通过所获取的可见焊缝几何形状、特别是通过所获取的焊缝宽度（B）和/或K尺寸（K）来确定最佳测量位置（opt.M），其中，最佳测量位置（opt.M）是存在最小焊缝宽度（B）和/或最小K尺寸（K）并且不存在图像失真的位置。
5.根据权利要求1到4中任一项所述的方法，其特征在于，基于所获取的数据来确定最佳测量位置的算法由多项式限定。
6.根据前述权利要求中任一项所述的方法，其特征在于，传感器自动接近测量位置沿着平行于管道轴线对准的传感器轴线延伸。
7.根据前述权利要求中任一项所述的方法，其特征在于，传感器（5）自动接近测量位置围绕传感器轴线（7）延伸，其中，传感器轴线（7）用作传感器（5）的旋转轴线或枢轴点，并且大致垂直于管道中心轴线（4）延伸。
8.一种用于执行根据权利要求1到7中任一项所述的方法的装置，包括光学传感器（5）和载体装置（8），其中，载体装置（8）具有驱动器（10）和用于定位传感器（5）的传感器轴线（7），其特征在于，传感器轴线（5）平行于或垂直于管线轴线（4）延伸，并且传感器（5）可沿传感器轴线（7）移动或可沿传感器轴线（7）或围绕传感器轴线（7）旋转和/或枢转。
9.根据权利要求8所述的装置，其特征在于，传感器（5）设计为照相机并且具有普通或标准物镜或远心物镜。
10.根据权利要求8所述的装置，其特征在于，驱动器（10）设计成具有主轴的步进电动机。
11.根据权利要求8所述的装置，其特征在于，所述驱动器具有位置感测单元，并且优选地连接到控制器。
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