CN117907114A - High-efficient full-automatic multistation intelligent hydrostatic test machine - Google Patents

Abstract

The patent of the present invention discloses an efficient, fully automatic, multi-station intelligent water pressure testing machine, which relates to the field of pipe inspection, and includes an external control console, a closely spaced track, a synchronous conveyor, a cache track, and a pair of pipe pulling mechanisms. The synchronous conveyor is located between the closely spaced track and the cache track, and a centering station, a waiting station, a water test station, a water pouring station, and a weighing station are arranged from right to left above the synchronous conveyor. The multi-station water pressure testing machine overcomes the difficulty that manual operation can only operate two stations, which not only improves productivity, but also overcomes the process requiring manual intervention, greatly reduces the errors caused by manual judgment errors, and can automatically identify each cast pipe, and assign it water pressure test data and production management status, and set a fast-switching water inlet valve, which increases the service life and saves production time. A socket sealing plate sealed with a rubber strip is set, which saves time and meets the requirements of mixed pipes of different diameters.

Description

A highly efficient, fully automatic, multi-station intelligent water pressure testing machine

Technical Field

The invention relates to the field of pipe fitting detection, in particular to a high-efficiency, fully automatic, multi-station intelligent water pressure testing machine.

Background technique

The hydraulic testing machine is a device used to perform pressure tests on welded steel pipes produced. Its purpose is to inspect the welding quality of the welds, so as to determine whether the steel pipes meet the relevant standards and meet the needs of users. It is a quality inspection equipment suitable for all types of welded pipe manufacturers.

Traditionally, when conducting water pressure testing on pipe fittings, the workstations are single and scattered, and some require manual operation, resulting in low production efficiency and the risk of manual misjudgment. On the other hand, the water inlet control valve of the water pressure testing machine has a short life, which affects the production rhythm. The socket end face can meet the use of several specifications but not multiple specifications. When producing some specifications, the tooling needs to be replaced, which wastes time and cannot meet the current high-tempo production efficiency requirements as well as the market demand and intelligent development direction.

Summary of the invention

In order to solve the above problems, that is, to solve the problems raised by the above background technology, the present invention patent proposes an efficient, fully automatic, multi-station intelligent water pressure testing machine, which includes an external control console, a closely spaced track, a synchronous conveyor, a cache track, and a pair of pipe-pulling mechanisms. The synchronous conveyor is located between the closely spaced track and the cache track. A centering station, a waiting station, a water test station, a water pouring station, and a weighing station are arranged from right to left above the synchronous conveyor:

The centering station is composed of a centering machine and a centering roller, and the centering machine is provided with a pipe diameter and length detection device and a laser distance measuring device;

The water test station is composed of a hydraulic press, lifting rollers, a pressure wheel, a protective door, a sealing device and a correspondingly arranged oil cylinder component. The sealing device is provided with a socket sealing plate with a sealing strip. The water inlet valve connected to the hydraulic press and the pipe fitting is a quick switching valve, the quick switching valve is driven by an oil cylinder, and the seal is a mechanical seal.

The water pouring station is composed of an active rotary machine and a driven lifting rotary machine;

The weighing station is composed of a weighing sensor and corresponding transmission components;

The external control console is electrically connected to the centering station, the water testing station, the water pouring station, the weighing station, the close-packed track, the synchronous conveyor, the buffer track, and the pipe-pumping mechanism respectively.

The patent of the present invention is further configured as follows: one of the pair of pipe shifting mechanisms is located between the closely packed track and the centering station, for transporting the pipe fittings on the closely packed track to the centering station; the other is located between the centering station and the waiting station, for transporting the pipe fittings on the centering station to the waiting station.

The patent of the present invention is further configured as follows: the lifting roller is controlled by an oil cylinder plus a proportional servo valve, and has a built-in waterproof sensor.

The patent of the present invention is further configured as follows: the main sealing cylinder hydraulic system of the sealing device adopts a differential speed-increasing circuit and has two speeds, fast and slow.

The patent of the present invention is further configured as follows: the water testing station pipe fittings are filled with water using a centrifugal pump and a plunger water pump to conduct a water test.

The patent of the present invention is further configured as follows: a plurality of detection cameras are arranged on the upper and lower sides of the synchronous conveyor, and the detection cameras are industrial vision cameras.

The beneficial technical effects of the patent of this invention are: the multi-station water pressure testing machine overcomes the problem that manual operation can only operate two stations, not only improves productivity, but also overcomes the process that requires manual intervention, greatly reduces the mistakes caused by manual judgment errors, and can automatically identify each cast pipe and give it water pressure test data and production management status. The reliability of the water supply pipeline of the cast pipe product is improved, a fast-switching water inlet valve is set, the service life is increased, production time is saved, and a socket sealing plate sealed with a rubber strip is set, which saves time and meets the requirements of mixed pipes of different diameters.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a schematic diagram of the overall structure of the present invention;

FIG2 is a schematic diagram of a water inlet valve of a water test station according to the present invention;

FIG3 is a schematic diagram of the multi-station hydraulic differential hydraulic system of the present invention;

FIG4 is a schematic diagram of the hydraulic principle of the automatic pressure regulation of the multi-position proportional valve of the present invention;

FIG. 5 is a schematic diagram of the water system principle of the present invention.

Figure numerals: 1. Closely spaced track, 2. Centering station, 3. Pipe diameter and length detection device, 4. Synchronous conveyor, 5. Hydraulic press, 6. Lifting roller, 7. Pressing wheel, 8. Protective door, 9. Water pouring station, 10. Weighing station, 11. Detection camera, 12. Cache track, 13. Pipe shifting mechanism, 14. Centering roller, 15. Sealing device.

Detailed ways

The preferred implementations of the present invention are described below with reference to Figures 1 to 5. Those skilled in the art should understand that these implementations are only used to explain the technical principles of the present invention and are not intended to limit the protection scope of the present invention.

The present invention proposes a highly efficient, fully automatic, multi-station intelligent water pressure testing machine, which includes an external control console, a closely spaced track 1, a synchronous conveyor 4, a cache track 12, and a pair of pipe-pickup mechanisms 13. The synchronous conveyor 4 is located between the closely spaced track 1 and the cache track 12. Above the synchronous conveyor 4, a centering station 2, a waiting station, a water test station, a water pouring station 9, and a weighing station 10 are arranged from right to left; the centering station 2 is composed of a centering machine and a centering roller 14, and the centering machine is provided with a pipe diameter and length detection device 3 and a laser ranging device; the water test station is composed of a hydraulic press 5, a lifting roller 6, a pressure wheel 7, a protective door 8, a sealing device 15, and a correspondingly arranged oil cylinder component, and the sealing device 15 is provided with a socket sealing plate with a sealing strip, and the water inlet valve connected to the hydraulic press 5 and the pipe fitting is a quick switching valve, the quick switching valve is driven by an oil cylinder, and the seal is a mechanical seal; the water pouring station 9 is composed of an active rotary machine and a driven lifting rotary machine; The weighing station 10 is composed of a weighing sensor and corresponding transmission components; the external control console is electrically connected to the centering station 2, the water test station, the water pouring station 9, the weighing station 10, the close-packed track 1, the synchronous conveyor 4, the buffer track 12, and the pipe-shifting mechanism 13 respectively; one of the pair of pipe-shifting mechanisms 13 is located between the close-packed track 1 and the centering station 2, and is used to transport the pipe fittings on the close-packed track 1 to the centering station 2; the other is located between the centering station 2 and the waiting station, and is used to transport the pipe fittings on the centering station 2 to the waiting station; the lifting roller 6 is controlled by a cylinder plus a proportional servo valve, and has a built-in waterproof sensor; the main sealing cylinder hydraulic system of the sealing device adopts a differential speed increase circuit, and has two speeds, fast and slow; the water test station pipe fittings are filled with water using a centrifugal pump and a plunger water pump for water testing; a number of detection cameras 11 are arranged on the upper and lower sides of the synchronous conveyor 4, and the detection cameras are industrial vision cameras.

The pipe fittings are transported to the closely packed track 1, and are transported to the centering station 2 by the pipe shifting mechanism 13. The centering rollers 14 hold the pipe fittings, and the centering machine aligns the pipe fittings with the socket end faces. A laser distance meter is installed above the socket end face and connected to the centering machine. After centering, the pipe diameter is identified. The centering machine at the socket is equipped with a laser distance meter. The length of the pipe fitting is calculated by the travel of the centering machine at the socket, and then the data is transmitted to the PLC. The pipe shifting mechanism 13 works to transport the pipe fittings to the waiting station, and the pipe fittings at multiple stations are ready before the water pressure test.

The synchronous conveyor 4 transports the pipe fittings at the waiting station to the water test station, and at the same time, the lifting roller 6 lifts the pipe fittings to the preset position according to the pipe diameter. The pipe fittings of DN80-DN150 need to be pressed by the pressure wheel 7 to prevent the pipe fittings from bending after being pressed. The pressure wheel 7 is driven by the cylinder; the protective door 8 descends, and the clamping device of the water test station is driven by the oil cylinder to push the pipe fitting to clamp the pipe fitting between the socket and the plug seal. The quick switching valve can switch between low-pressure water inlet and high-pressure water inlet. The quick switching valve switches to the low-pressure water valve to open and inject low-pressure water into the pipe. When the exhaust valve discharges water, the exhaust valve is closed, the low-pressure water inlet valve is closed, and the high-pressure water is injected. After reaching the set rated pressure, the high-pressure water is turned off, and the pressure is maintained for 15 seconds. The exhaust valve is opened, the clamping device is pushed back, and the lifting roller 6 returns the pipe fitting to its original position. The protective door 8 rises, and the synchronous conveyor 4 transports the pipe fitting to the next station;

The synchronous conveyor 4 transports the pipe to the pouring station 9, which is composed of an active rotary machine and a driven lifting rotary machine. The active rotary machine rotates, and the driven lifting rotary machine lifts the pipe and pours out the remaining water in the pipe. After the pouring is completed, the synchronous conveyor 4 transports the pipe to the weighing station 10, and the sensor records the weight of the pipe. After completion, the synchronous conveyor 4 transports the pipe to the cache track 12.

The production speed of ordinary water pressure testing machine for DN80 pipe fittings is 120 pieces per hour. The production speed of efficient full-automatic multi-station water pressure testing machine for DN80 pipe fittings is 160 pieces per hour. The diameter of the water inlet valve is DN150. The ordinary water inlet valve needs to work at least 28,800 times in half a month. The service life is about half a month before the spare parts need to be replaced, which affects the production rhythm. The water inlet valve of the efficient full-automatic multi-station water pressure testing machine is driven by the oil cylinder and the seal is a mechanical seal, as shown in Figure 2. The service life is not less than 100,000 times. The mechanical seal is replaced during the monthly maintenance period. The exhaust valve uses a DN50 coaxial valve with a service life that meets the use requirements, thus saving production time.

When ordinary hydraulic presses seal DN80-400 pipe fittings, 2-3 socket and spigot sealing plates are needed for sealing. The efficient fully automatic multi-station hydraulic testing machine uses rubber strips for sealing. The sealing strips of DN80-400 pipe fittings are distributed on one board, which makes it unnecessary to replace the socket and spigot sealing plates, saving time and satisfying the mixed pipe passing requirements of all pipe diameters.

The lifting roller 6 adopts an oil cylinder with a waterproof built-in sensor and a proportional servo valve control. For pipes with different diameters, the center height of the pipes needs to be accurately adjusted. The socket and spigot sealing plates are common to all pipes.

The water test station is the core station, in which the main sealing cylinder is usually a piston cylinder with a large cylinder volume to ensure sufficient test clamping pressure. Therefore, in order to ensure that it can move quickly and effectively, a differential speed-increasing circuit is adopted, as shown in Figure 3, which greatly increases the extension speed of the cylinder and speeds up productivity. At the same time, in order to ensure that the speed is too fast when contacting the pipe fittings, causing impact and damaging the pipe fittings, this circuit has two speeds, fast and slow, which can be adjusted at will according to the actual production situation.

In order to meet the different clamping force requirements of different pipe types during water testing, different main cylinder clamping oil pressures need to be set according to different pipe types. The traditional method requires the operator to manually adjust the valve station pressure regulating valve, which is not only inconvenient, but also requires the operator to have certain hydraulic experience to adjust, which sometimes brings inconvenience. So we used a proportional servo valve to brake and adjust the pressure, as shown in Figure 4. After the pipe type is detected, the signal is transmitted to the PLC, and the test pressure of the pipe type is immediately adjusted through the proportional pressure reducing valve or the proportional overflow valve, which saves the manual link and can reduce the pressure on the rubber sealing ring, greatly improving the service life of the sealing ring.

The water filling process of the water test station is an indispensable link. As shown in Figure 5, for the rapid water filling of small-diameter pipes, a large-flow centrifugal pump is used to quickly replenish low-pressure water, and then a plunger-type high-pressure water pump is used to perform a water test in the form of pressure climbing. High efficiency, stable water pressure, and full automation are the main features of this system.

This equipment uses a Siemens programmable controller equipped with an industrial computer. During the production process of the equipment, it can record the pressure of each pipe in real time and display the pressure curve of the set value and the actual value, which is convenient for production personnel to find unqualified products. At the same time, the system also has the function of automatically identifying waste pipes. When the actual pressure value is less than a certain range of the set pressure value, the system automatically determines that the pipe is a waste pipe, and the automatic pressure process is terminated immediately. After a series of actions such as exhaust, the next cycle is carried out.

During the production process, pipes may see slight water seepage, which is difficult to detect through pressure changes. Therefore, after the pressure test, we use industrial visual cameras to analyze the outer surface of the pipes. The images of the places with water seepage are different from the images of the normal places next to them. We judge that the pipes are waste pipes and transmit the judgment information to the PLC. Through two judgments, we can basically ensure a 100% qualified rate of pipes.

After each pressure testing process is completed, the data of each pipe during the pressure testing process will be saved according to the pipe number. If water leakage occurs in the future application of the pipe fitting, the pipe number can be entered to call up the data and graphs during the pressure testing for analysis.

This control system uses IO-link sensors, which have self-diagnosis functions. When the sensor is disconnected or damaged, an alarm message will be generated, which is convenient for maintenance personnel to quickly deal with the problem and reduce maintenance time.

This system is divided into manual and automatic operation modes. In automatic mode, no manual labor is required and the equipment runs fully automatically, reducing human intervention and greatly improving production efficiency.

Although the present invention has been described with reference to the preferred embodiments, various modifications may be made thereto and parts thereof may be replaced with equivalents without departing from the scope of the present invention. In particular, the various technical features mentioned in the various embodiments may be combined in any manner as long as there is no structural conflict. The present invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

In the description of the present invention, the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicating directions or positions are based on the directions or positions shown in the drawings, which are only for the convenience of description, and do not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance.

In addition, it should be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "installation", "connection" and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal connection of two components. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

The term "comprise" or any other similar term is intended to cover a non-exclusive inclusion, such that a process, article, or apparatus/device that includes a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, article, or apparatus/device.

So far, the technical solution of the present invention has been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

Claims (6)

1. The utility model provides a high-efficient full-automatic multistation intelligent hydrostatic test machine, includes external control cabinet, closely arranged track (1), synchronous conveyor (4), buffer memory track (12) and a pair of driving mechanism (13) are constituteed, its characterized in that: the synchronous conveyor (4) is located between the close-packed track (1) and the cache track (12), and a centering station (2), a waiting station, a water test station, a water pouring station (9) and a weighing station (10) are sequentially arranged above the synchronous conveyor (4) from right to left:

the centering station (2) consists of a centering machine and a centering carrier roller (14), and the centering machine is provided with a pipe diameter and pipe length detection device (3) and a laser ranging device;

the water test station consists of a hydraulic press (5), a lifting carrier roller (6), a pressing wheel (7), a protective door (8), a sealing device (15) and oil cylinder components which are correspondingly arranged, wherein a faucet sealing plate with a sealing strip is arranged on the sealing device (15), a water inlet valve connected with a pipe fitting of the hydraulic press (5) is a quick switching valve, the quick switching valve is driven by an oil cylinder, and the sealing is mechanical sealing;

The water pouring station (9) consists of a driving rotary machine and a driven lifting rotary machine;

The weighing station (10) consists of a weighing sensor and a corresponding transmission part;

The external control console is electrically connected with the centering station (2), the water test station, the water pouring station (9), the weighing station (10), the close-packed track (1), the synchronous conveyor (4), the cache track (12) and the pipe pulling mechanism (13) respectively.

2. The efficient full-automatic multi-station intelligent hydrostatic testing machine according to claim 1, wherein: one of the pipe shifting mechanisms (13) is positioned between the close-packed rail (1) and the centering station (2) and is used for conveying pipe fittings on the close-packed rail (1) to the centering station (2); the other is positioned between the centering station (2) and the waiting station and is used for conveying the pipe fitting on the centering station (2) to the waiting station.

3. The efficient full-automatic multi-station intelligent hydrostatic testing machine according to claim 1, wherein: the lifting carrier roller (6) is controlled by an oil cylinder proportional servo valve, and a waterproof sensor is arranged in the lifting carrier roller.

4. The efficient full-automatic multi-station intelligent hydrostatic testing machine according to claim 1, wherein: the sealing device (15) adopts a differential speed increasing loop mode for a main sealing oil cylinder hydraulic system, and has two speeds of high speed and low speed.

5. The efficient full-automatic multi-station intelligent hydrostatic testing machine according to claim 1, wherein: the water test station pipe fitting fills water and adopts a centrifugal pump and a plunger type water pump to carry out water test.

6. The efficient full-automatic multi-station intelligent hydrostatic testing machine according to claim 1, wherein: a plurality of detection cameras (11) are arranged on the upper side and the lower side of the synchronous conveyor (4), and the detection cameras are industrial vision cameras.