CN113103069A

CN113103069A - Efficient and accurate round steel automatic sizing system

Info

Publication number: CN113103069A
Application number: CN202110530756.7A
Authority: CN
Inventors: 陈守东; 方良伟
Original assignee: Tongling University
Current assignee: Tongling University
Priority date: 2021-05-15
Filing date: 2021-05-15
Publication date: 2021-07-13

Abstract

The invention discloses an efficient and accurate automatic round steel sizing system, and relates to the technical field of metal bar sizing. The method comprises the following specific steps: firstly, measuring distance by machine vision, namely measuring the length of a steel bar by adopting a machine vision system; step two, automatically sizing, namely setting calculation method compiling operation under the C language programming environment to meet the steel ball blank fixed length qualification rate and the yield; and step three, controlling a system, wherein the related production process and flow comprises length measurement, material turning, calculation and cutting, press breaking and alignment of a punch press, and the round steel automatic sizing system comprises a PLC unit (1), a machine vision detection unit (2), a display unit (3), a calculation unit (4), a power supply system, a production workshop logistics scheme, attention items and the like. By optimizing the steel bar length measurement and the steel bar automatic sizing control system, the invention has the advantages of high sizing precision, stability, simple calibration, simple installation, debugging, operation and maintenance, low operation cost and accurate cutting, improves the sizing rate and the yield, and reduces the rejection rate.

Description

Efficient and accurate round steel automatic sizing system

Technical Field

The invention relates to the technical field of sizing of forged wear-resistant steel ball and round steel blanks, in particular to an efficient and accurate automatic sizing and control system for steel bars.

Background

In the production process of the wear-resistant steel ball, the accuracy of the sizing precision of the round steel bar affects the yield, the product quality and the cost of the steel ball. Along with the change of the market and the improvement of the quality requirement of the steel ball, the cost pressure is higher and higher, the sizing specification is more and more, and the sizing precision and the efficiency are more and more important in the production of the wear-resistant steel ball. Currently, the existing automatic bar cutting machine generally utilizes infrared shooting sizing operation, but has the defects of poor anti-interference performance, too low environment temperature which cannot be identified by a blank, larger deviation when the sizing is changed, off-line sizing change caused by the fact that the sizing often does not meet the precision requirement, and unstable blank allowance, thereby seriously affecting the yield and the product quality.

Mechanical equipment baffles, contact measurement, infrared camera sizing and the like are the current main sizing and cutting methods. The pure mechanical method is that the mechanical baffle is sized, the processing technology is rough, the deviation of manual adjustment is large, the mechanical action reaction of the mechanical baffle is slow due to collision, and the deviation ratio after cutting is large; the contact type sizing has higher regulations on equipment maintenance management, such as damage of a measuring roller, slipping of the measuring roller, poor bearing lubrication, the service life of an encoder in an extreme environment and protection of a cable in the extreme environment, and the normal work of a sizing system is influenced, the operation cost is high, and the maintenance workload is large; compared with the two control methods, the infrared camera shooting belongs to image information identification processing control, has convenient operation and relatively high cutting precision, has extremely high regulation on installation precision, is easily influenced by external environmental factors such as sparks splashed when a bar is cut, environmental illumination conditions, temperature during cutting, shaking conditions of a camera support, resolution of a display and other uncontrollable factors, has troublesome manual regulation on the sizing, and basically cannot meet the use regulation if the production process involves a plurality of sizing specifications.

Therefore, an advanced image processing machine vision technology is required to be designed and applied, a mathematical analysis model of bar graphical characteristics is constructed according to the spectrum and shape characteristics of the steel bar, collected and monitored data are subjected to binarization and data preprocessing, edge detection is carried out by adopting operators, and efficient and accurate bar measurement and automatic sizing are realized.

Disclosure of Invention

The invention provides an efficient and accurate round steel automatic sizing system for solving the problems of low sizing precision, low efficiency and complex installation, debugging and operation and maintenance of the conventional wear-resistant steel ball and round steel blank sizing device.

In order to achieve the purpose, the technical scheme adopted by the system is as follows: the utility model provides a high-efficient accurate rod iron length measurement and automatic scale control system of rod iron, its concrete technical scheme is:

the 6m long diameter 80-120 mm round steel used by the sizing and control system is normal for 6m sizing. The round steel does not reach the standard length, short materials generally exist, 10% of the short materials exist in the round steel, and the maximum length deviation is 50 cm. The normal unloading diameter 80 ~ 120mm round steel is 200mm length (according to product specification change, unloading length can corresponding adjustment), and 6m length is just in time expect 30 absolutely, calculates every round steel average minute by the computer, and the steel bar stock blank of length 200mm can be 2 ~ 3mm or short 2 ~ 3mm in principle. The system optimizes the steel bar length measuring technology, designs program algorithm automatic sizing and control systems for different lengths of the steel bars, and realizes efficient and accurate sizing segmentation of the wear-resistant steel ball and round steel blanks. The method specifically comprises the following steps:

step one, measuring the actual total length, arranging a CCD camera at a material turning position after the billet is unfolded on a material unfolding table, and respectively measuring the distances L1 and L2 between the CCD camera and the billet. And calculating by a controller to obtain the billet length L which is L0-L1-L2. The length measurement adopts a camera to measure the length, the precision is high, and the repeat error of a single device is +/-0.5 mm.

And step two, sizing, and determining the integer variable cutting number num, the real variable length and averlen.

And step three, assigning an initial value to the operation variable. The value of length is entered, scanf _ s ("% f", & length) to get accurate bar total length data from the CCD camera.

Step four, the length of a single standard bar is 200mm, the error is 3mm, the length of the blank is judged to be divided by 197mm to obtain integer data num, when the length of the blank is larger than num multiplied by 203, the length of the blank is selected to be num multiplied by 203, and the single average value is the length of the blank. And step five, directly outputting the result if the length of the steel bar is less than num multiplied by 203 according to the result of the step three, and setting the length of the steel bar as num multiplied by 203 to output the result if the length of the steel bar is more than num multiplied by 203.

And step six, drawing an N-S flow chart.

And step seven, writing a program according to the N-S flow chart.

And step eight, checking the reasonability and accuracy of the program flow, and operating the computer to debug the program.

And step nine, completing automatic sizing and carrying out the next procedure.

Furthermore, the error of the steel bar blank is set to that each section of round steel with the diameter of 80mm is 200mm, and each round steel is 3mm long or short; each section of round steel with the diameter of 100mm is 200mm long, and a single round steel is 2.5mm long or short; each section of round steel with the diameter of 120mm is 200mm long, and a single round steel is 2mm long or short.

The invention has the beneficial effects that: the automatic remote automatic operation is automatically completed, the on-line steel bar and product size detection is adopted among groups, and a data basis is provided for a control system and the realization of full-line closed-loop automatic adjustment of the steel bar blank and the product size precision. Can avoid 1) the steel ball blank is not in accordance with the standard requirement because the steel bar is evenly distributed no matter how long the steel bar is; 2) the mechanical baffle plate brings a great amount of waste of steel ball blanks when being sized. And a machine vision system is adopted to measure the steel bar, so that the measuring efficiency and precision are improved. According to the specific lengths (fixed length) of steel billets and finished steel products specified by product standards, an algorithm is designed to cut steel ball blanks by steel rods with different lengths, the round steel with the algorithm is required to be designed to meet the qualification rate and the utilization rate of the steel ball blanks, a calculation method is designed to compile and run in a C language programming environment, and the reliability of results is verified. A programming method for structured programming of 'top-down, step-by-step refinement'. The system has the advantages of high sizing precision, stability, simple calibration, simple installation, debugging, operation and maintenance, low operation cost and accurate cutting, improves the sizing rate and the yield, and reduces the rejection rate.

Drawings

FIG. 1 is a steel ball blank measuring diagram of the high-efficiency and accurate round steel automatic sizing system of the invention;

FIG. 2 is a control system of the distance measuring device of the present invention;

FIG. 3 is a functional block diagram of the PC of the present invention;

FIG. 4 is a flow chart of the programming of the present invention;

FIG. 5 is a functional diagram of a control unit according to the present invention.

Detailed Description

As shown in fig. 1 to 5, an efficient and accurate automatic round steel sizing system comprises the following steps:

(1) length measuring part

After the billet is unfolded on the spreading table, a CCD camera is arranged at the material overturning position, and the distances L1 and L2 between the CCD camera and the billet are respectively measured. And calculating by a controller to obtain the billet length L which is L0-L1-L2. The length measurement adopts a camera to measure the length, the precision is high, and the repeat error of a single device is +/-0.5 mm.

(2) Upender part

When the material needs to be turned subsequently, the turning mechanism automatically turns the blanks with the measured lengths to the cutting position, the first group of roller ways rotate at the moment, the positioning stop block rises, when the blanks reach the position of the positioning stop block, the first roller ways delay for 500ms to stop, the blanks are prevented from rebounding, the lifting mechanism rises, and the blank rotating mechanism moves to drive the blanks to rotate.

(3) Sizing and cutting

After the blank is measured, the required cutting length Ls of each section of blank is calculated according to requirements, when the blank is lifted, the cutting trolley is driven by a stepping motor to position a first cutting device from an original position to a position of Ls (because the original position is not a blank zero point position, the trolley moving distance is set to be Lc1), and at the moment, a second cutting device is positioned from the zero point position to a position of 2Ls (the trolley moving distance is 2 Ls-the distance from the zero point of the second cutting to the first cutting knife) through a moving mechanism. After the cutting knife is in place, the cutting knife is controlled to work through the controller, after the first cutting is finished, the cutting knife is lifted, the trolley moves, the first cutting knife is controlled to reach the position of 3Ls, until the cutting is finished, the trolley returns to the zero position, and the second cutting knife returns to the respective zero position at the same time. And the positioning stop block returns, and the first group of roller ways starts to convey the material blanks to the material breaking position.

(4) Press-breaking and aligning of punch

And (3) the blank reaches the position detected by a material cutting position camera (or a detection device such as a proximity switch), the blank is firstly compressed and then cut, the action is repeated, and the cut blank is aligned through an alignment baffle.

The light source is fixed on the disk surface of the rotating chassis beside the through hole, the light source provides parallel light beams to the to-be-detected rod material passing through the middle of the through hole, a CCD camera is further arranged on the disk surface of the rotating chassis, the CCD camera receives the parallel light beams which are partially shielded by the to-be-detected rod material and then images, and image information captured by the CCD camera is transmitted to the signal processing controller.

The distance measuring device is arranged at the inlet end and the outlet end of the unit, the two CCD cameras are symmetrically arranged, namely the CCD cameras (3a) and (3b), and image data collected by the CCD cameras (3a) and (3b) are respectively transmitted to the transmitting modules (4a) and (4 b); the signal processing controller comprises a signal processing module (6), a comprehensive control board (7) and a PC (personal computer) machine (8), wherein the signal processing module (6) adopts an FPGA (field programmable gate array) high-speed signal processing module, and the signal processing module (6) receives the image data transmitted by the transmitting modules (4a) and (4b) through the receiving module (5) and carries out processing.

PC (8) among the signal processing controller transmits signal to main control unit, and the integrated control panel transmits state signal to PC (8), and PC (8) include three functional module, and one is receiving measured data module (81), raw data display module (82), parameter calculation module (83), data save module (84), and its second is receiving state data module (85), show state data module (86), real-time alarm module (87), and its third is control module (88). The signal processing module (6) is positioned in the case, and the signal processing module (6) is connected with a PC (8) outside the case through a serial port and a network interface. The device has the advantages of automatically completing remote automatic operation and detecting the sizes of the steel bars and products between groups by adopting on-line, and providing a data basis for controlling a system and realizing full-line closed-loop automatic adjustment of the size precision of the steel bar blanks and the products.

Aiming at the requirement of the system for automatic sizing after receiving the accurate rod length, the prior system and program do not meet the technical requirement, so the system sets calculation method compiling operation in the programming environment of C language in order to meet the qualification rate and the utilization rate of steel ball blanks, and verifies the reliability of results. A structured programming method of 'top-down, stepwise refinement' is applied.

An algorithm needs to be designed, the round steel meets the qualification rate and the utilization rate of steel ball blanks, a calculation method is designed and compiled to run in the C language programming environment, and the reliability of results is verified.

The method comprises the following specific steps:

step one, determining integer variable cutting number num, real variable length and averlen.

And step two, assigning an initial value to the operation variable. The value of length is entered, scanf _ s ("% f", & length) to get accurate bar total length data from the CCD camera.

And step three, the length of a single standard bar is 200mm, the error is 3mm, the length of the blank is judged to be divided by 197mm to obtain integer data num, when the length of the blank is greater than num multiplied by 203, the length of the blank is selected to be num multiplied by 203, and the single average value is the length of the blank.

And step four, according to the result of the step three, if the length of the steel bar is less than num multiplied by 203, directly outputting the result, and if the length of the steel bar is more than num multiplied by 203, setting the length of the steel bar as num multiplied by 203 and outputting the result.

And step five, drawing an N-S flow chart.

And step six, writing a program according to the N-S flow chart.

And seventhly, checking the reasonable and accurate program flow, and debugging the program on the computer.

The system realizes full-automatic control, real-time information transmission and real-time feedback regulation through a PLC electric control system. The system consists of (1) a material table; (2) a numerical control plasma cutting machine; (3) cutting off the material machine; (4) a bar conveying system; (5) a ventilation and dust removal system; (6) a safety and warning system; (7) and the production report, the fault record, the operator information, the printing system and the like are related and combined.

In the feeding process, the hydraulic control system controls the movable baffle and is combined with the inductor to realize the full-automatic control of blank feeding.

And determining the cutting size of the blank by combining a PLC control system and finite element analysis according to the distance measured in the previous step. And then the distance between the two plasma cutting guns is adjusted through computer analysis to carry out cutting.

The plasma cutting machine is provided with the flue gas dust removal system, so that the possibility of escaping flue gas dust is reduced, and the influence of the flue gas dust removal system on the environment is reduced.

After the cutting is finished, the blanks are conveyed through an automatic transfer roller way, the blanks are sent into a material breaking system, the blanks are broken through a hydraulic pressure breaking device, finished products are placed into a material collecting frame, and then the next step of processing is carried out.

For a further understanding of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings and examples.

According to the method, the maximum value and the minimum value of the allowable error of the steel ball blanks are utilized, 30 blanks can be cut according to the standard 6m steel bar when the lengths of the single steel ball blanks are different, on the premise that the minimum value of the blanks is 197mm, different blank numbers (num) can be calculated according to the length of the steel bar, and when the actual length of the steel bar is larger than the maximum value of the blanks (203mm multiplied by num) of the same blank number, the steel bar is designed to be segmented according to the newly obtained bar length. For example: the length of the steel bar is 5900mm, when the steel bar is mechanically cut into single pieces of 200mm, 100mm materials are finally remained, the steel bar is divided into 29 sections after the program compiled by the algorithm is adopted, each section is 203mm on average, the loss is obviously reduced, convenience is brought to subsequent processing, and the production line stably runs.

Example 1

In combination with the steel ball blank measuring diagram of fig. 1, in the existing non-sizing workshop steel bar, after the steel billet is unfolded in the material spreading table, a CCD camera is arranged at the material turning position, and the distances L1 and L2 between the CCD camera and the blank are respectively measured. And calculating by a controller to obtain the billet length L which is L0-L1-L2. The length measurement adopts a camera to measure the length, the precision is high, and the repeat error of a single device is +/-0.5 mm.

After the steel bar is measured by a machine vision system, the length of the steel bar is accurately measured to be 5600mm, the steel bar is sized, data are transmitted to a computer, a program runs, the steel bar is divided into 28 sections by the program calculation, and the average length of each section is 200 mm. The turning mechanism automatically turns the blanks with measured lengths to a cutting position, at the moment, the first group of roller ways rotate, the positioning stop blocks rise, when the blanks reach the positioning stop block positions, the first roller ways delay for 500ms to stop, the blanks are prevented from rebounding, the lifting mechanism rises, and the blank rotating mechanism moves to drive the blanks to rotate.

And (3) the blank reaches a material cutting position to reach a position detected by a camera (or a detection device such as a proximity switch), the blank is firstly compressed and then cut, the action is repeated, and the cut blank is aligned through an alignment baffle.

Example 2

After the steel bar is measured by a machine vision system, the length of the steel bar is accurately measured to be 6650mm, the steel bar is sized, data are transmitted to a computer, a program runs, the steel bar is divided into 33 sections by the program, and the average length of each section is 201.5 mm. The turning mechanism automatically turns the blanks with measured lengths to a cutting position, at the moment, the first group of roller ways rotate, the positioning stop blocks rise, when the blanks reach the positioning stop block positions, the first roller ways delay for 500ms to stop, the blanks are prevented from rebounding, the lifting mechanism rises, and the blank rotating mechanism moves to drive the blanks to rotate.

Example 3

After the steel bar is measured by a machine vision system, the length of the steel bar is accurately measured to be 5900mm, the steel bar is sized, data are transmitted to a computer, a program runs, the length of the steel bar is 5900mm, when a single steel bar is mechanically cut to be 200mm, 100mm materials are finally remained, the steel bar is divided into 29 sections after the program compiled by the algorithm is adopted, the average length of each steel bar is 203mm, loss is obviously reduced, and convenience is brought to subsequent processing. The turning mechanism automatically turns the blanks with measured lengths to a cutting position, at the moment, the first group of roller ways rotate, the positioning stop blocks rise, when the blanks reach the positioning stop block positions, the first roller ways delay for 500ms to stop, the blanks are prevented from rebounding, the lifting mechanism rises, and the blank rotating mechanism moves to drive the blanks to rotate.

Example 4

After the steel bar is measured by a machine vision system, the length of the steel bar is accurately measured to be 6300mm, the steel bar is sized, data are transmitted to a computer, a program runs, when a single steel bar is mechanically cut to be 200mm, 100mm materials are finally remained, the steel bar is divided into 31 sections after the program compiled by the algorithm is adopted, the average length of each steel bar is 203mm, loss is obviously reduced, and convenience is brought to subsequent processing. The turning mechanism automatically turns the blanks with measured lengths to a cutting position, at the moment, the first group of roller ways rotate, the positioning stop blocks rise, when the blanks reach the positioning stop block positions, the first roller ways delay for 500ms to stop, the blanks are prevented from rebounding, the lifting mechanism rises, and the blank rotating mechanism moves to drive the blanks to rotate.

The specific sizing execution procedure of each embodiment is as follows (the source procedure is modified according to the measured total length of the steel bar):

the foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to explain the principles of the invention, and that various modifications and alterations can be made by those skilled in the art without departing from the spirit and scope of the invention.

Claims

1. The utility model provides an automatic scale system of high-efficient accurate round steel which characterized in that includes following step:

step 1; in the side length part, after the billet is unfolded in the material unfolding table, a CCD camera is arranged at a material turning position, and distances L1 and L2 between the CCD camera and the billet are respectively measured; calculating by a controller to obtain the length L of the blank which is L0-L1-L2; the length measurement adopts a camera to measure the length, the precision is high, and the repeat error of single equipment is +/-0.5 mm;

step 2; when the material is required to be turned subsequently, the turning mechanism automatically turns the blank with the measured length to a cutting position, the first group of roller ways rotate, the positioning stop block rises, when the blank reaches the position of the positioning stop block, the first roller ways delay for 500ms to stop, the blank is prevented from rebounding, the lifting mechanism rises, and the blank rotating mechanism acts to drive the blank to rotate;

step 3; sizing and cutting; after the length of the material blank is measured, the cutting length Ls required by each section of the material blank is calculated according to the requirement, when the material blank is lifted, the cutting trolley is driven by a stepping motor to position the first cutting device to the position of Ls from the original position, and at the moment, the second cutting device is positioned to the position of 2Ls from the zero position through a moving mechanism; after the cutting is finished, the cutting knife is lifted, the trolley moves, the first cutting knife is controlled to reach the position of 3Ls, and the trolley returns to the zero position and the second cutting knife returns to the respective zero position at the same time; the positioning stop block returns, and the first group of roller ways starts to convey the material blanks to the material breaking position;

step 4; press-breaking and aligning the punch; and (3) when the blank reaches the position detected by the material cutting position camera, firstly pressing the blank, then cutting the blank, repeating the action, and aligning the cut blank by the alignment baffle.

2. The efficient and accurate automatic round steel sizing system as claimed in claim 1, which comprises a distance measuring device, wherein a light source is fixed on a disk surface of a rotating chassis beside the through hole, the light source provides parallel light beams to the to-be-measured rod material passing through the middle of the through hole, a CCD camera is further arranged on the disk surface of the rotating chassis, the CCD camera receives the parallel light beams which are partially shielded by the to-be-measured rod material and then images, and image information shot by the CCD camera is transmitted to a signal processing controller.

3. An efficient and accurate automatic round steel sizing system according to claim 2, wherein the distance measuring devices are arranged at the inlet end and the outlet end of the machine set, the two CCD cameras are symmetrically arranged, namely CCD cameras (3a) and (3b), and image data collected by the CCD cameras (3a) and (3b) are respectively transmitted to the transmitting modules (4a) and (4 b); the signal processing controller comprises a signal processing module (6), a comprehensive control board (7) and a PC (personal computer) machine (8), wherein the signal processing module (6) adopts an FPGA (field programmable gate array) high-speed signal processing module, and the signal processing module (6) receives the image data transmitted by the transmitting modules (4a) and (4b) through the receiving module (5) and carries out processing.

4. An efficient and accurate automatic round steel sizing system according to claim 3, wherein a PC (8) in the signal processing controller transmits signals to the main controller, the comprehensive control panel transmits state signals to the PC (8), the PC (8) comprises three functional modules, one of which is a measurement data receiving module (81), an original data display module (82), a parameter calculation module (83) and a data storage module (84), the other one of which is a state data receiving module (85), a state data display module (86) and a real-time alarm module (87), and the other one of which is a control module (88); the signal processing module (6) is positioned in the case, and the signal processing module (6) is connected with a PC (8) outside the case through a serial port and a network interface. The device has the advantages of automatically completing remote automatic operation and detecting the sizes of the steel bars and products between groups by adopting on-line, and providing a data basis for controlling a system and realizing full-line closed-loop automatic adjustment of the size precision of the steel bar blanks and the products.

5. The efficient and accurate automatic round steel sizing system according to claim 4, wherein aiming at the requirement of the system on automatic sizing after receiving the accurate rod length, the prior system and program do not meet the technical requirement, so the system is used for meeting the qualification rate and the utilization rate of steel ball blanks, and the compiling operation of a calculation method is set under the programming environment of C language, so that the reliability of the result is verified; a structured programming method of 'top-down, stepwise refinement' is applied.

6. The efficient and accurate automatic round steel sizing system according to claim 5, wherein an algorithm is required to be designed, the round steel meets the qualification rate and the utilization rate of a steel ball blank, calculation method compiling operation is designed under the programming environment of C language, and the reliability of a result is verified;

the method comprises the following specific steps:

And step two, assigning an initial value to the operation variable. Inputting a length value, and obtaining accurate total bar length data by using scanf _ s ("% f", & length) according to a CCD camera;

step three, the length of a single standard bar is 200mm, the error is 3mm, the length of the blank is judged to be divided by 197mm to obtain integer data num, when the length of the blank is greater than num multiplied by 203, the length of the blank is selected to be num multiplied by 203, and the single average value is the length of the blank;

step four, according to the result of the step three, if the length of the steel bar is less than num multiplied by 203, directly outputting the result, and if the length of the steel bar is more than num multiplied by 203, setting the length of the steel bar as num multiplied by 203 to output the result;

step five, drawing an N-S flow chart;

writing a program according to the N-S flow chart;

7. An efficient and accurate automatic round steel sizing system as claimed in claim 1, wherein the system realizes full-automatic control, real-time information transmission and real-time feedback adjustment through a PLC (programmable logic controller) electric control system. The system comprises a material table; a numerical control plasma cutting machine; cutting off the material machine; a bar conveying system; a ventilation and dust removal system; a safety and warning system; production report, fault record, operator information and printing system.

8. An efficient and accurate round steel automatic sizing system according to claim 1, characterized in that the cutting size of the blank is determined according to the distance measured in the previous step and by combining a PLC control system and finite element analysis; and then the distance between the two plasma cutting guns is adjusted through computer analysis to carry out cutting.