CN111176218A - Rolling shear quality monitoring system and method based on laser and visual detection - Google Patents
Rolling shear quality monitoring system and method based on laser and visual detection Download PDFInfo
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- CN111176218A CN111176218A CN202010007450.9A CN202010007450A CN111176218A CN 111176218 A CN111176218 A CN 111176218A CN 202010007450 A CN202010007450 A CN 202010007450A CN 111176218 A CN111176218 A CN 111176218A
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- shearing
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/414—Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
- G05B19/4147—Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller characterised by using a programmable interface controller [PIC]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D15/00—Shearing machines or shearing devices cutting by blades which move parallel to themselves
- B23D15/06—Sheet shears
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D33/00—Accessories for shearing machines or shearing devices
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/34—Director, elements to supervisory
- G05B2219/34013—Servocontroller
Abstract
The invention belongs to the technical field of metal material processing process control systems, and particularly relates to a rolling shear quality monitoring system and method based on laser and visual detection. The invention aims to improve the intelligent control level of the rolling shear and improve the shearing quality of a medium plate. The shear blade gap wedge adjusting mechanism is driven by a servo hydraulic cylinder, is adjusted and controlled through a servo valve, so that the adjustment of a shear blade gap is realized, the longitudinal linear motion of the hydraulic cylinder is converted into the horizontal transverse motion of a shear blade, the rigidity of the shear blade is ensured through a wedge block and a pressing mechanism, and the control of the shear blade gap of the hobbing shear is realized.
Description
Technical Field
The invention belongs to the technical field of metal material processing process control systems, and particularly relates to a rolling shear quality monitoring system and method based on laser and visual detection.
Background
The plate shearing machine is the important core equipment on the finishing line of medium plate, and along with the continuous bodiness of steel sheet thickness, the continuous improvement of steel sheet intensity, traditional shearing technology restriction medium plate cuts the improvement of size precision, section quality requirement, compares general oblique shear blade shearing technique, and the hobbing shearing technique has that it is of high quality to cut, cuts thickness big, shear blade fish tail and wearing and tearing little, cuts the steel sheet straight, cuts efficiently. Therefore, the method is widely applied to medium plate finishing lines. The shearing quality of the medium plate relates to the defects of uneven edges caused by 'wrong cutting' of the cut edge, collapse of the steel plate, burrs, long tearing fracture of a shearing fracture and the like, and the shearing length is also an important measurement index of the product.
But the problems existing at present are as follows: in the subsequent finishing process of the medium plate, the flatness, the sizing accuracy, the fracture tearing degree and the like of the cut steel plate need to be checked, the traditional method depends on meter ruler detection and manual visual inspection judgment, the detection precision and the judgment standard seriously depend on the responsibility and quality of workers, time and labor are wasted, and comprehensive, real-time, accurate and traceable recording and evaluation cannot be realized. With the improvement of the quality requirement of medium and thick plate blanks by downstream users, the automatic and intelligent judgment of the shearing quality is gradually emphasized. The Labview computer language of the American NI company adopts symbol programming, the upper computer interface is friendly, the building mode is simple, the Labview computer language is widely applied to building of a monitoring system, and the monitoring system with friendly interface and complete functions is built through a visual detection device, a laser ranging sensor, a roller speed regulating motor, a cutting edge wedge-shaped adjusting mechanism, an industrial storage server, a PLC (programmable logic controller), a Labview upper computer software platform and the like.
Disclosure of Invention
The invention aims to improve the intelligent control level of the rolling shear and improve the shearing quality of a medium plate. A system and a method for monitoring the quality of a rolling shear based on laser and visual detection are provided. The monitoring system can display the shearing quality of the on-line medium plate in real time, can also store and read historical records stored in a storage server, realizes traceability of process quality, adjusts the gap of the shearing blade through the wedge-shaped mechanism according to the quality of a shearing section and the sizing requirement, and adjusts the conveying motor to control the shearing sizing length. In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
a rolling shear quality monitoring system based on laser and visual detection comprises a system monitoring upper computer, a system detection device, a system regulation and control execution device and a control system, wherein the system monitoring upper computer is used for displaying, exporting and printing detection results of the quality of a medium and thick plate shearing fracture and the fixed-length actual shearing length in real time; the system detection device is used for detecting the quality and the fixed length of a medium plate shearing fracture and transmitting related data to the control system, and the control system determines whether to start the system regulation and control execution device or not according to a detection result and a system model; the system regulation and control execution device receives signals from a system controller to realize the adjustment of the position length of a shearing edge gap and a medium and heavy plate, the system monitors that an upper computer interface contains information of a plate blank number, a plate blank thickness, a plate blank width, a plate blank length and a plate blank weight, can record the starting time and the ending time of plate blank shearing operation, displays the length setting requirement of a client plate blank in a three-level management system, measures the length actually after shearing, can perform shearing quality analysis according to a shearing fracture monitoring result, calculates the shearing cutting section ratio and the shearing tearing section ratio, divides the quality grade of the shearing section according to the result, fits the contour straightness of the shearing fracture and draws a result, and the system can inquire historical data, print the data result and export the result storage data; the control system carries out model conversion through the secondary process control system according to a monitoring result, and then adjusts the frequency converter through the PLC to realize steering and speed control of the transport roller way driving motor, adjusts the servo hydraulic valve to control output displacement of the servo hydraulic cylinder rod, and further pushes the shear blade gap wedge adjusting mechanism to adjust and control the shear blade gap of the rolling shear. The system can improve the automatic and intelligent shearing level, realize the tracing and monitoring of the shearing quality of the medium and thick plates and improve the shearing quality of the medium and thick plates.
Further, the system monitoring upper computer is developed by adopting a Labview platform, and the system regulation and control execution device comprises a transportation roller way and a cutting edge gap wedge adjusting mechanism which are respectively used for adjusting the shearing length of the medium plate and controlling the quality of a shearing fracture; the conveying roller way power mechanism adopts a speed-adjustable alternating current motor and adopts a PLC (programmable logic controller) to control the speed of the motor so as to adjust the speed and the direction of the conveying roller way, the speed adjustment of the conveying roller way is mainly used for adjusting the feeding amount of a medium-thick plate according to the length of a fixed length so as to ensure the shearing precision, the conveying roller way is a common cylindrical billet conveying roller way and is respectively positioned in front of and behind a rolling cutting shearing machine, the conveying roller way is indirect 1m, and the number of single sides is more than or equal to 10; the shear blade gap wedge-shaped adjusting mechanism is driven by a servo hydraulic cylinder and is regulated and controlled by a servo valve, so that the adjustment of the shear blade gap is realized;
the control system comprises a PLC controller, an industrial Ethernet switch, an industrial memory, a secondary process control system and a tertiary management system, wherein the PLC controller controls the action of the execution device according to the relevant model control system; the industrial memory is used for storing data so that the system monitoring upper computer can conveniently read historical data from the industrial memory, and the secondary process control system sets the parameters of the blank shearing process according to the model database and transmits the parameters to the PLC; the three-level management system is used for issuing customer order specification information to the two-level process control system and the system monitoring upper computer, and the three-level management system, the two-level process control system, the system monitoring upper computer and the PLC are communicated through an industrial Ethernet switch; the three-level management system issues the specification of the medium plate blank of the client to the secondary process control system, the secondary process control system controls the feeding position of the medium plate blank according to the system requirements, the laser measuring and sizing system is adopted to accurately measure the length of the medium plate blank and feed the length back to the secondary process control system, the transportation roller way is controlled in real time through the basic automation level, and the cut of the fixed length of the medium plate blank is accurately realized. The sheared medium plate blank is conveyed forwards, when the sheared medium plate blank is conveyed to a fixed position, a visual identification device is adopted to visually identify a fracture after shearing, the fracture is compared with a medium plate blank section defect grading library stored in a secondary process control system, the quality of the section of the medium plate blank is graded and stored, a shear blade gap adjustment model or a shear blade replacement criterion is formulated according to the judgment of the quality of the section of the medium plate blank by combining experience, and the shear blade gap adjustment is realized by carrying out servo control on a shear blade gap wedge driving hydraulic cylinder;
the system detection device comprises a laser ranging sensor, a laser detection controller, a visual recognition device and a visual detection controller, wherein the laser ranging sensor and the visual recognition device respectively transmit a laser ranging sensor signal and an image signal to the PLC controller through the laser detection controller and the visual detection controller; the laser ranging sensor is arranged on a rack at the outlet of the rolling shear, the horizontal distance from the rolling shear main body is 3-5 m, the height from the rack to a roller surface is 2-4 m, the laser ranging sensor swings under the control of a motor with a photoelectric code, the incident angle of the laser ranging sensor to a vertical surface ranges from-60 degrees to 60 degrees, the position of an outlet roller way is scanned, reflected light of laser irradiation at three positions of a plate surface, a shear fracture and a transport roller way has certain difference, the position of the shear fracture is determined by judging the difference of the received reflected light, and the length of a shear plate is further obtained through measurement and conversion. By adding the laser ranging sensor and the visual recognition device, a foundation is laid for intelligent online control of the medium plate hobbing process, and the method is an important means for effectively improving the shearing precision and the shearing quality of the medium plate.
Still further, the vision recognition device includes camera and light source, the camera is arranged on the rack of roll-cutting shears export, the shearing section profile when camera objective aligns the cut-off profile of cut-off when medium plate exports this position, and the lens filter sees through the blue light, filters the colour of other frequencies, the light source is the LED lamp, the light source adopts the bar shape, and the colour is blue light source, light source and camera integrative installation, apart from roll-cutting shears horizontal distance 8 ~ 12m, rack apart from roll surface height 0.5 ~ 1 m. The vision recognition device can solve the problems of complex light and similar background of a medium plate finishing workshop, and the reasonable arrangement of the light source and the position is favorable for accurately recognizing the profile and the shape of the cross section.
Further, the shear blade clearance wedge-shaped adjusting mechanism comprises a hobbing shear blade, a horizontal guide plate, a vertical guide plate, an active wedge power device, a plurality of cooperation wedges, a plurality of active wedges and a plurality of pressing mechanisms, the hobbing shear blade comprises a hobbing shear upper shear blade and a hobbing shear lower shear blade, the hobbing shear upper shear blade does not move along the slab motion direction relative to the hobbing shear lower shear blade, the hobbing shear upper shear blade is driven by a plurality of motion connecting rods, rolling along the hobbing shear blade direction is guaranteed, the shear blade clearance wedge-shaped adjusting mechanism is arranged on the hobbing shear lower shear blade, the hobbing shear lower shear blade is driven to move along the direction perpendicular to the hobbing shear blade direction to realize clearance adjustment of the hobbing shear lower shear blade, a plurality of grooves are uniformly arranged on one side of the lower part of the hobbing shear lower shear blade, a counter bore is machined on the other side, the cooperation wedge is arranged in the groove, and the minimum thickness of the cooperation wedge is greater than the depth of the groove, the matched wedge block and the groove matched surface are provided with threaded holes, and the matched wedge block and the hobbing shear blade are connected through an inner hexagonal countersunk head screw; the horizontal guide plate is arranged at the bottom of the matched wedge block and the shearing edge of the rolling shear and is used for restricting the shearing edge of the rolling shear to move horizontally; initiative wedge and the vertical arrangement of cooperation wedge the bottom of every initiative wedge all is equipped with initiative wedge power device, roll and cut cutting edge, cooperation wedge, initiative wedge and vertical deflector and connect through a plurality of hold-down mechanism restrictions to keep the degree of freedom that the horizontal direction removed, cutting edge clearance wedge guiding mechanism has guaranteed the rigidity of cutting edge through wedge, hold-down mechanism through the horizontal transverse motion who turns into the cutting edge with the vertical linear motion of pneumatic cylinder, has realized the control in roll and cut cutting edge clearance.
Furthermore, the pressing mechanism comprises a spring frame, a gasket, a nut and a bolt pull rod; the bolt pull rod is the screw rod that one end has the bolt, the one end of bolt pull rod is cut with the hobbing and is cut down the cutting edge and be connected, and the other end runs through cooperation wedge, initiative wedge, vertical deflector to outside extending to vertical deflector the other end of bolt pull rod from left to right overlaps in proper order and establishes spring carrier, gasket and nut the outside of spring carrier is equipped with the spring, gasket and nut side contact, the spring carrier is established in the outside of spring carrier, and spring one end supports on the gasket, and one end supports in the spring carrier the inside to rely on the terminal surface hold-down spring and the gasket of nut, thereby adjusting spring's pretightning force. The requirement on the rigidity of the spring of the pressing mechanism is high, and the overall structure is simple.
Furthermore, initiative wedge power device includes servo cylinder, coupling nut and connecting plate, servo cylinder passes through output hydraulic cylinder pole anterior segment screw, nut and is connected with the connecting plate, the connecting plate passes through the screw and is connected with initiative wedge lower extreme surface, servo cylinder installs in the frame of hobbing shearing machine, is vertical arranging, servo cylinder's piston rod output processing screw thread links to each other through nut in the counter bore with the connecting plate.
A rolling shear quality monitoring method based on laser and visual detection comprises the following steps:
the method comprises the following steps that 1, a transport roller way is adopted to transport medium plate blanks to a shearing station, a medium plate rolling shearing quality monitoring system based on laser detection and visual identification is initialized, medium plate blank information is read in from a secondary process control system, medium plate blank length setting information is read in from a tertiary management system, and the medium plate blank length setting information is displayed on an upper computer;
and 5, when the quality of the shearing fracture is unqualified, according to a shearing quality model, a servo hydraulic cylinder is adopted to drive a shear blade gap wedge-shaped adjusting mechanism to adjust the shear blade gap, a conveying roller way is controlled to rotate, the medium plate blank is conveyed forwards, and next shearing preparation is carried out, wherein the shear blade gap is a gap between an upper shear blade and a lower shear blade in the direction perpendicular to the shear blade.
Compared with the prior art, the invention has the beneficial effects that:
1. the system monitoring upper computer interface comprises slab number, slab thickness, slab width, slab length and slab weight information, can record slab shearing operation starting time and ending time, display client slab length setting requirements in a three-level management system, actually measure the length after cutting, perform shearing quality analysis according to a shearing fracture monitoring result, calculate shearing cut-off section ratio and shearing tearing surface ratio, divide shearing section quality grades according to the results, fit the contour straightness of a shearing fracture and draw results, and can inquire historical data, print data results and export result storage data; the control system carries out model conversion through the secondary process control system according to a monitoring result, and then adjusts the frequency converter through the PLC to realize steering and speed control of the transport roller way driving motor, adjusts the servo hydraulic valve to control output displacement of the servo hydraulic cylinder rod, and further pushes the shear blade gap wedge adjusting mechanism to adjust and control the shear blade gap of the rolling shear. The system can improve the automatic and intelligent shearing level, realize the tracing and monitoring of the shearing quality of the medium and thick plates and improve the shearing quality of the medium and thick plates.
2. The shear blade gap wedge adjusting mechanism is driven by a servo hydraulic cylinder and is regulated and controlled by a servo valve, so that the adjustment of the shear blade gap is realized, the shear blade gap wedge adjusting mechanism converts the longitudinal linear motion of the hydraulic cylinder into the horizontal transverse motion of a shear blade, the rigidity of the shear blade is ensured by a wedge block and a pressing mechanism, and the control of the shear blade gap of the hobbing shear is realized.
3. The three-level management system sends the specification of the medium plate blank of a client to the two-level process control system, the two-level process control system controls the feeding position of the medium plate blank according to the system requirement, the laser measuring scale system is adopted to accurately measure the length of the medium plate blank and feed the length back to the two-level process control system, and the transportation roller way is controlled in real time through the basic automation level, so that the cut of the fixed-scale length of the medium plate blank is accurately realized. Cut back cut plate blank and transport forward, when transporting fixed position, adopt the vision recognition device to carry out vision recognition to the fracture after cutting, compare through the cut plate blank section defect hierarchical storehouse with the inside storage of second grade process control system, cut the cut plate blank section quality and grade and save, according to the judgement of cut plate blank section quality, combine experience to formulate cutting edge clearance adjustment model or cutting edge and change the criterion, carry out servo control through cutting edge clearance wedge drive pneumatic cylinder, realize cutting edge clearance adjustment.
4. The invention lays a foundation for intelligent online control of the medium plate hobbing process by adding the laser ranging sensor and the visual recognition device, is an important means for effectively improving the shearing precision and the shearing quality of the medium plate, solves the problems of complex light and similar background of a medium plate finishing workshop by the visual recognition device, and is beneficial to accurately recognizing the profile appearance of a section by reasonably setting the light source and the position.
5. The invention realizes the quality graph detection of the cut section and the high-precision measurement of the fixed length, can display the current measurement result in real time and stores the historical data; the method can define the evaluation standard of the rolling cutting quality of the medium plate, carry out product quality grading and print a product quality data report; the invention can realize the adjustment of the roller way speed and the shear blade gap according to the shearing length and the shearing section quality.
Drawings
FIG. 1 is a schematic diagram of a thick plate rolling shear quality monitoring system according to the present invention;
FIG. 2 is a monitoring interface of an upper computer of a rolling shear quality monitoring system of a medium plate based on Labview;
FIG. 3 is a flow chart of the operation of the thick plate blank shearing quality monitoring system according to the present invention;
FIG. 4 is a three-dimensional perspective view of a shear blade gap wedge adjustment mechanism of the present invention;
figure 5 is a cross-sectional view of a shear gap wedge adjustment mechanism of the present invention;
figure 6 is a side view of the shear blade gap wedge adjustment mechanism of the present invention;
FIG. 7 is a front view of the shear blade gap wedge adjustment mechanism of the present invention;
FIG. 8 is a front elevational view of the lower cutting edge of the roll shear of the present invention;
FIG. 9 is a rear view of the lower cutting edge of the roll shear of the present invention;
FIG. 10 is a schematic view of the connection between the active wedge power plant and the active wedge according to the present invention;
FIG. 11 is a schematic structural diagram of an active wedge of the present invention;
FIG. 12 is a front three-dimensional view of a mating wedge of the present invention;
fig. 13 is a rear plan view of a mating wedge block of the present invention;
in the figure: the device comprises 1-a rolling shear cutting edge, 101-a groove, 102-a rolling shear upper cutting edge, 103-a rolling shear lower cutting edge, 2-a horizontal guide plate, 3-a vertical guide plate, 4-an active wedge block power device, 401-a servo oil cylinder, 402-a connecting nut, 403-a connecting plate, 5-a plurality of matched wedge blocks, 6-a plurality of active wedge blocks, 7-a plurality of pressing mechanisms, 701-a spring frame, 702-a gasket, 703-a nut, 704-a bolt pull rod and 705-a spring.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Examples
Referring to fig. 1 and 3-12, a rolling shear quality monitoring system based on laser and visual detection comprises a system monitoring upper computer, a system detection device, a system regulation and control execution device and a control system, wherein the system monitoring upper computer is used for displaying, exporting and printing detection results of the quality of a medium and thick plate shearing fracture and the fixed-length actual shearing length in real time; the system detection device is used for detecting the quality and the fixed length of a medium plate shearing fracture and transmitting related data to the control system, the control system determines whether to start the system regulation and control execution device according to a detection result and a system model, and the control system regulation and control execution device regulates the steering and the speed of the speed-adjustable transportation roller way and the size of a shearing blade gap; the system regulating and controlling execution device receives signals from the system controller, and the regulation and control of the system regulating and controlling execution device, the regulation of the cutting edge gap and the position length of the medium and thick plates are realized.
The system regulation and control execution device comprises a conveying roller way and a shear blade gap wedge-shaped adjusting mechanism which are respectively used for adjusting the shearing length of the medium plate and controlling the quality of a shearing fracture; the conveying roller way power mechanism adopts a speed-adjustable alternating current motor and adopts a PLC (programmable logic controller) to control the speed of the motor so as to adjust the speed and the direction of the conveying roller way, the speed adjustment of the conveying roller way is mainly used for adjusting the feeding amount of a medium-thick plate according to the length of a fixed length so as to ensure the shearing precision, the conveying roller way is a common cylindrical billet conveying roller way and is respectively positioned in front of and behind a rolling cutting shearing machine, the conveying roller way is indirect 1m, and the number of single sides is more than or equal to 10; the shear blade gap wedge-shaped adjusting mechanism is driven by a servo hydraulic cylinder and is regulated and controlled by a servo valve, so that the adjustment of the shear blade gap is realized;
the control system comprises a PLC controller, an industrial Ethernet switch, an industrial memory, a secondary process control system and a tertiary management system, wherein the PLC controller controls the action of the execution device according to the relevant model control system; the industrial memory is used for storing data so that the system monitoring upper computer can conveniently read historical data from the industrial memory, and the secondary process control system sets the parameters of the blank shearing process according to the model database and transmits the parameters to the PLC; the three-level management system is used for issuing customer order specification information to the two-level process control system and the system monitoring upper computer, and the three-level management system, the two-level process control system, the system monitoring upper computer and the PLC are communicated through an industrial Ethernet switch;
the system detection device comprises a laser ranging sensor, a laser detection controller, a visual recognition device and a visual detection controller, wherein the laser ranging sensor and the visual recognition device respectively transmit a laser ranging sensor signal and an image signal to the PLC controller through the laser detection controller and the visual detection controller; the laser ranging sensor is arranged on a rack at the outlet of the rolling shear, the horizontal distance from the rolling shear main body is 3-5 m, the height from the rack to a roller surface is 2-4 m, the laser ranging sensor swings under the control of a motor with a photoelectric code, the incident angle of the laser ranging sensor to a vertical surface ranges from-60 degrees to 60 degrees, the position of an outlet roller way is scanned, reflected light of laser irradiation at three positions of a plate surface, a shear fracture and a transport roller way has certain difference, the position of the shear fracture is determined by judging the difference of the received reflected light, and the length of a shear plate is further obtained through measurement and conversion.
The shear blade clearance wedge-shaped adjusting mechanism comprises a rolling shear blade 1, a horizontal guide plate 2, a vertical guide plate 3, a driving wedge power device 4, a plurality of matching wedge blocks 5, a plurality of driving wedge blocks 6 and a plurality of pressing mechanisms 7, wherein the rolling shear blade 1 comprises a rolling shear upper shear blade 102 and a rolling shear lower shear blade 103, the rolling shear upper shear blade 102 is not moved along the slab motion direction relative to the rolling shear lower shear blade 103, and the rolling shear upper shear blade 102 is driven by a plurality of motion connecting rods to ensure rolling along the rolling shear blade 1 direction, the shear blade clearance wedge-shaped adjusting mechanism is arranged on the rolling shear lower shear blade 103 to drive the rolling shear lower shear blade 103 to move along the direction vertical to the rolling shear blade 1 direction to realize upper rolling shear lower shear blade clearance adjustment, a plurality of grooves 101 are uniformly arranged on one side of the lower part of the rolling shear lower shear blade 103, a counter bore is machined on the other side, the matching wedge block 5 is arranged in the groove 101, the minimum thickness of the matching wedge block 5 is larger than the depth of the groove 101, a threaded hole is machined in the matching surface of the matching wedge block 5 and the groove 101, and the matching wedge block 5 is connected with the hobbing shear blade 1 through an inner hexagonal countersunk head screw; the horizontal guide plate 2 is arranged at the bottom of the matched wedge block 5 and the hobbing shear blade 1 and is used for restricting the hobbing shear blade 1 from horizontally moving; the active wedge block 6 and the matched wedge block 7 are vertically arranged, the bottom of each active wedge block 6 is provided with an active wedge block power device 4, and the roll-cutting shear blade 1, the matched wedge block 5, the active wedge block 6 and the vertical guide plate 3 are connected in a constrained mode through a plurality of pressing mechanisms 7 and the degree of freedom of horizontal movement is reserved.
The active wedge block 6 of the core part of the shear blade gap wedge-shaped adjusting mechanism is provided with 2 flat long strip through holes, and the other end face of the active wedge block is provided with 2 threaded holes connected with the connecting plate 403; a connecting threaded hole and a bolt pull rod counter bore are processed on the connecting end face of the lower shear blade 103 of the rolling shear in cooperation with the wedge block 5, the connecting threaded hole is a non-through hole, the bolt pull rod counter bore is a through hole, and the number of the bolt pull rod counter bores is 2, which is equal to the number of the flat long strip through holes of the active wedge block 6; two counter bores connected with the active wedge-shaped blocks 6 are machined on one side of the connecting plate 403, the number of the counter bores corresponds to the number of the connecting threaded holes of the active wedge-shaped blocks 6, the number of the counter bores is 2, the number of the counter bores connected with the hydraulic cylinder rod is 1, and the counter bores on the two side faces are through holes; grooves are formed in the connecting surface of the vertical guide plate 3 and the active wedge block 6, the width of each groove is equal to the width of the active wedge block, the length of each groove is larger than or equal to the sum of the height of the active wedge block 6 and the moving stroke of the active wedge block 6, the number of the grooves 101 is 3 and is equal to the number of the active wedge blocks 6, counter bores for mounting the spring frame 701 are formed in the other side of the vertical guide plate 3, and the number of the counter bores is equal to the sum of the number of the counter bores of all bolt pull rods of the matched wedge blocks 5 (also equal to the sum of the number; processing recess 101 on shear blade 103 and the cooperation wedge 5 connection face under the hobbing shear, recess 101 width equals cooperation wedge 5 width, length more than or equal to cooperation wedge 5 height, quantity equals the quantity of cooperation wedge 5, for 3, the counter bore that has the connecting bolt of installation cooperation wedge 5 is processed to the opposite side of shear blade 103 under the hobbing shear, quantity equals the sum of all cooperation wedge 5 connection counter bores quantity (also equals the sum of the flat rectangular through-hole quantity of all initiative wedges 6).
The pressing mechanism 7 comprises a spring frame 701, a gasket 702, a nut 703 and a bolt pull rod 704; bolt pull rod 704 is the screw rod that one end has the bolt, bolt pull rod 704's one end and hobbing shear lower shear blade 103 are connected, and the other end runs through cooperation wedge 5, initiative wedge 6, vertical deflector 3 to outside extending to vertical deflector 3 the other end of bolt pull rod 704 from left to right overlaps in proper order and establishes spring holder 701, gasket 702 and nut 703 spring holder 701's the outside is equipped with spring 705, gasket 702 and nut 703 side contact, spring 705 cover is established in spring holder 701's the outside, and spring 705 one end supports on gasket 702, and one end supports in spring holder 701 the inside to the terminal surface pressure spring 705 and the gasket 702 that rely on nut 703, thereby adjust the pretightning force of spring 705.
Initiative wedge block power device 4 includes servo cylinder 401, coupling nut 402 and connecting plate 403, servo cylinder 401 is connected with connecting plate 403 through output hydraulic cylinder pole anterior segment screw thread, nut, connecting plate 403 passes through the screw and is connected with the terminal surface under the initiative wedge block 6, servo cylinder 401 installs in the frame of hobbing shearing machine, is vertical arranging, servo cylinder 401's piston rod output processing screw thread links to each other through nut in the counter bore with connecting plate 403.
A rolling shear quality monitoring method based on laser and visual detection comprises the following steps:
the method comprises the following steps that 1, a transport roller way is adopted to transport medium plate blanks to a shearing station, a medium plate rolling shearing quality monitoring system based on laser detection and visual identification is initialized, medium plate blank information is read in from a secondary process control system, medium plate blank length setting information is read in from a tertiary management system, and the medium plate blank length setting information is displayed on an upper computer;
and 5, when the quality of the shearing fracture is unqualified, according to a shearing quality model, a servo hydraulic cylinder is adopted to drive a shear blade gap wedge-shaped adjusting mechanism to adjust the shear blade gap, a conveying roller way is controlled to rotate, the medium plate blank is conveyed forwards, and next shearing preparation is carried out, wherein the shear blade gap is a gap between an upper shear blade and a lower shear blade in the direction perpendicular to the shear blade.
In the embodiment, a LabView platform shown in FIG. 2 is adopted to develop an upper computer interface of a rolling shear shearing quality monitoring system, and the upper computer interface can realize the functions of medium plate blank information and specification information display, medium plate blank fixed length and actual shearing length information, medium plate blank shearing fracture morphology, shearing fracture curve, medium plate blank shearing fracture contour quality evaluation, shearing fracture grade division, historical data query and printing and the like.
While there have been shown and described what are at present considered the fundamental principles and essential features of the invention and its advantages, it will be apparent to those skilled in the art that the invention is not limited to the details of the foregoing exemplary embodiments, but is capable of other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.
Claims (7)
1. The utility model provides a roll cutting cuts quality monitoring system based on laser and visual detection which characterized in that: the system monitoring upper computer is used for displaying, exporting and printing the detection results of the quality of the medium and thick plate shearing fracture and the fixed-length actual shearing length in real time; the system detection device is used for detecting the quality and the fixed length of a medium plate shearing fracture and transmitting related data to the control system, and the control system determines whether to start the system regulation and control execution device or not according to a detection result and a system model; the system regulating and controlling execution device receives signals from the system controller to realize the adjustment of the position and the length of the shear blade gap and the middle and thick plate.
2. The rolling shear quality monitoring system based on laser and visual detection as claimed in claim 1, wherein: the system monitoring upper computer is developed by adopting a Labview platform; the system regulation and control execution device comprises a conveying roller way and a shear blade gap wedge-shaped adjusting mechanism which are respectively used for adjusting the shearing length of the medium plate and controlling the quality of a shearing fracture; the conveying roller way power mechanism adopts a speed-adjustable alternating current motor and adopts a PLC (programmable logic controller) to control the speed of the motor so as to adjust the speed and the direction of the conveying roller way, the speed adjustment of the conveying roller way is mainly used for adjusting the feeding amount of a medium-thick plate according to the length of a fixed length so as to ensure the shearing precision, the conveying roller way is a common cylindrical billet conveying roller way and is respectively positioned in front of and behind a rolling cutting shearing machine, the conveying roller way is indirect 1m, and the number of single sides is more than or equal to 10; the shear blade gap wedge adjusting mechanism is driven by a servo hydraulic cylinder and is regulated and controlled by a servo valve, so that the adjustment of the rolling shear blade gap is realized;
the control system comprises a PLC controller, an industrial Ethernet switch, an industrial memory, a secondary process control system and a tertiary management system, wherein the PLC controller controls the action of the execution device according to the relevant model control system; the industrial memory is used for storing data so that the system monitoring upper computer can conveniently read historical data from the industrial memory, and the secondary process control system sets the parameters of the blank shearing process according to the model database and transmits the parameters to the PLC; the three-level management system is used for issuing customer order specification information to the two-level process control system and the system monitoring upper computer, and the three-level management system, the two-level process control system, the system monitoring upper computer and the PLC are communicated through an industrial Ethernet switch;
the system detection device comprises a laser ranging sensor, a laser detection controller, a visual recognition device and a visual detection controller, wherein the laser ranging sensor and the visual recognition device respectively transmit a laser ranging sensor signal and an image signal to the PLC controller through the laser detection controller and the visual detection controller; the laser ranging sensor is arranged on a rack at the outlet of the rolling shear, the horizontal distance from the rolling shear main body is 3-5 m, the height from the rack to a roller surface is 2-4 m, the laser ranging sensor swings under the control of a motor with a photoelectric code, the incident angle of the laser ranging sensor to a vertical surface ranges from-60 degrees to 60 degrees, the position of an outlet roller way is scanned, reflected light of laser irradiation at three positions of a plate surface, a shear fracture and a transport roller way has certain difference, the position of the shear fracture is determined by judging the difference of the received reflected light, and the length of a shear plate is further obtained through measurement and conversion.
3. The rolling shear quality monitoring system based on laser and visual detection as claimed in claim 2, wherein:
the vision recognition device comprises a camera and a light source, the camera is arranged on a rack of an outlet of the roll cutting shear, the camera objective is aligned to the shearing section outline when the medium plate is output to the position, a lens filter penetrates through blue light to filter the color of other frequencies, the light source is an LED lamp, the light source is in a strip shape, the color is a blue light source, the light source and the camera are integrally installed, the horizontal distance from the light source to the roll cutting shear is 8-12 m, and the height from the rack to a roller surface is 0.5-1 m.
4. The rolling shear quality monitoring system based on laser and visual detection as claimed in claim 2, wherein: the shear blade clearance wedge adjusting mechanism comprises a hobbing shear blade (1), a horizontal guide plate (2), a vertical guide plate (3), a driving wedge power device (4), a plurality of matching wedge blocks (5), a plurality of driving wedge blocks (6) and a plurality of pressing mechanisms (7), the hobbing shear blade (1) comprises an upper hobbing shear blade (102) and a lower hobbing shear blade (103), the upper hobbing shear blade (102) is not moved along the slab motion direction relative to the lower hobbing shear blade (103), the upper hobbing shear blade (102) is driven by a plurality of motion connecting rods, rolling is ensured along the direction of the hobbing shear blade (1), the shear blade clearance wedge adjusting mechanism is arranged on the lower hobbing shear blade (103), the lower hobbing shear blade (103) is driven to move along the direction perpendicular to the hobbing shear blade (1) to realize upper hobbing shear and lower hobbing shear blade clearance adjustment, and a plurality of grooves (101) are uniformly arranged on one side of the lower part of the hobbing shear blade (103), a counter bore is processed on the other side, the matching wedge block (5) is arranged in the groove (101), the minimum thickness of the matching wedge block (5) is larger than the depth of the groove (101), a threaded hole is processed on the matching surface of the matching wedge block (5) and the groove (101), and the matching wedge block (5) is connected with the hobbing shear blade (1) through an inner hexagonal counter bore screw; the horizontal guide plate (2) is arranged at the bottom of the matched wedge-shaped block (5) and the shearing edge (1) of the rolling shear and is used for restricting the shearing edge (1) of the rolling shear to move horizontally; initiative wedge (6) and cooperation wedge (7) are vertical to be arranged the bottom of every initiative wedge (6) all is equipped with initiative wedge power device (4), roll and cut shear blade (1), cooperation wedge (5), initiative wedge (6) and vertical deflector (3) and connect through a plurality of hold-down mechanism (7) restraint to remain the degree of freedom that the horizontal direction removed.
5. The rolling shear quality monitoring system based on laser and visual inspection as claimed in claim 4, wherein: the pressing mechanism (7) comprises a spring frame (701), a gasket (702), a nut (703) and a bolt pull rod (704); the bolt pull rod (704) is a screw rod with a bolt at one end, one end of the bolt pull rod (704) is connected with the lower shear blade (103) of the hobbing shear, the other end of the bolt pull rod (704) penetrates through the matched wedge block (5), the driving wedge block (6) and the vertical guide plate (3) and extends out of the vertical guide plate (3), a spring frame (701), a gasket (702) and a nut (703) are sequentially sleeved at the other end of the bolt pull rod (704) from left to right, a spring (705) is arranged on the outer side of the spring frame (701), the gasket (702) is in contact with the side surface of the nut (703), the spring (705) is sleeved on the outer side of the spring frame (701), one end of the spring (705) is propped against the gasket (702), the other end is propped against the inner side of the spring frame (701), and the end surface of the nut (703) presses the spring (705) and the gasket (702) so as to adjust the pretightening force of the spring (705).
6. The rolling shear quality monitoring system based on laser and visual inspection as claimed in claim 4, wherein: initiative wedge power device (4) include servo cylinder (401), coupling nut (402) and connecting plate (403), servo cylinder (401) are connected with connecting plate (403) through output hydraulic cylinder pole anterior segment screw thread, nut, terminal surface is connected under connecting plate (403) through screw and initiative wedge (6), servo cylinder (401) are installed in the frame of hobbing shearing machine, are vertical the arranging, the piston rod output processing screw thread of servo cylinder (401) links to each other through nut in the counter bore with connecting plate (403).
7. A rolling shear quality monitoring method based on laser and visual detection is characterized in that: the method comprises the following steps:
the method comprises the following steps that 1, a transport roller way is adopted to transport medium plate blanks to a shearing station, a medium plate rolling shearing quality monitoring system based on laser detection and visual identification is initialized, medium plate blank information is read in from a secondary process control system, medium plate blank length setting information is read in from a tertiary management system, and the medium plate blank length setting information is displayed on an upper computer;
step 2, controlling the transportation roller way to rotate, adjusting the shearing length of the medium plate blank, measuring the length of the medium plate blank by adopting laser sizing, and comparing the measured length with a set value of the length of the medium plate blank read by a three-level management system;
step 3, when the difference between the actually measured length of the medium plate blank and the set length of the medium plate blank is smaller than or equal to the fixed value upper limit, shearing is carried out, the medium plate blank is conveyed to the station of the visual recognition device after shearing, otherwise, the position of the medium plate blank is adjusted through a conveying roller way, and the difference between the detected length of the medium plate blank and the set value meets the control precision;
step 4, performing image recognition on the cut section of the medium plate blank meeting the control precision in the step 3 by using a visual recognition device to obtain the contour and the appearance of the cut section, comparing the quality of the cut section with a system defect classification library, judging the quality grade of the cut fracture, displaying related information on an upper computer, controlling a transport roller to rotate, transporting the medium plate blank forwards, and finishing the cutting;
and 5, when the quality of the shearing fracture is unqualified, according to a shearing quality model, a servo hydraulic cylinder is adopted to drive a shear blade gap wedge-shaped adjusting mechanism to adjust the shear blade gap, a conveying roller way is controlled to rotate, the medium plate blank is conveyed forwards to carry out next shearing preparation, and the shear blade gap is a gap between an upper shear blade of the rolling shear and a lower shear blade of the rolling shear along the direction perpendicular to the shear blade.
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