JPS63165100A - Method for controlling supplying flux to flux cored wire - Google Patents

Abstract

PURPOSE:To permit continuous monitor and control of the amt. of the flux to be included by projecting slit shaped light to the transverse direction of a hoop before and after the supply of the flux from above, picking up the image thereof with a television camera from diagonally above and displaying the image on a CRT. CONSTITUTION:The slit shaped laser light 5 is first projected from a laser light generator 4 to the band-shaped hoop 3 prior to the supply of the flux 1 thereto and the bright line thereof on the hoop 3 is picked up by the television camera 6 from diagonally above so that the bright line 9 is projected on an image 7. The laser light 5a is similarly projected to the hoop 3 right after the supply of the flux 1 to the hoop 3 and the bright line 9a is projected on an image 7a in the same manner. These bright lines 9, 9a are subjected to image processing and the area of the part sandwiched by the lines 9 and 9a is determined. The supply rate of the flux 1 per unit time is calculated by a microcomputer from said area and the production line speed. The result thereof is fed back to a flux supplying device to control the flux supply.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to the production of flux-cored wire, and provides a flux supply control method for stabilizing the flux filling rate in the wire.

[Conventional technology]

A double flux-cored wire (Japanese Patent Publication No. 44-2336 ) is attracting attention.

The double-fault type double flux-cored wire whose cross section is shown in Fig.
This wire is characterized in that it is bent so as to have an inner envelope part, and different types of flux 1.2 are held in the outer envelope part and the inner envelope part, respectively. Such a flux-cored wire has an inner flux of 2 and an outer flux of 1.
The proportion of the total amount of welding is an important factor in determining the workability during welding and the mechanical performance of the welded part.

However, in the past, these factors could not be continuously checked during manufacturing, and the inclusion ratio of inner and outer fluxes in a predetermined length of wire sampled after the product was manufactured was measured. For this reason, a large number of rejected products were produced as a result of manufacturing, and since it was not possible to check all products, quality assurance was also extremely inadequate.

FIG. 6 shows the manufacturing process of a conventional double-layer flux-cored wire. Further, FIG. 7 shows changes in the cross-sectional shape of the flux-cored wire during the forming process.

In the process shown in FIG. 6(A), the band hoop 3 is formed into a U-shaped groove-like cross-sectional shape as shown in FIG. 7(A). Figure 6 (B
In step ), the outer flux 1 is supplied to the state shown in FIG. 7(b), and then in the step of FIG. 6(C), the state shown in FIGS. 7(c) and (d) is supplied.
It is sequentially bent into the shape shown in (E), and as shown in Fig. 6 (D).
In the process, the embedded flux 2 is supplied in the state shown in FIG. 7 (F), and in the FIG. 6 (E) process, it is formed into a circular shape as shown in FIG. The wire is drawn to a predetermined wire diameter as shown in FIG. 6(F), and the flux-cored wire is wound up in the step shown in FIG. 6(F).

Regarding the amount of fluxes 1 and 2 included during the above manufacturing process,
The amount of flux supplied is adjusted in advance according to the speed of the production line, but since it is not possible to monitor it on the hoop 3 immediately after supply, a prototype product is inspected and the amount of flux is adjusted based on the results. was being fine-tuned. Therefore, the amount of flux included should be determined in advance before manufacturing begins.
It took a very long time and effort to adjust.

It would be nice to be able to continuously measure the amount of flux contained in both the inner and outer packages of flux-cored wire products, but this has been difficult.

[Problem that the invention seeks to solve]

In view of the above circumstances, it is an object of the present invention to solve the following problems.

■ Capable of continuously controlling the amount of 7 lux contained in all products.

■ By monitoring the amount of flux included during manufacturing, ``reducing the time required to adjust the amount of flux supplied before manufacturing.

[Means for solving problems]

The present invention provides a flux supply method for supplying flux to a U-shaped groove in a cross section of the hoop during the process of continuously molding a flux-cored wire from a band-shaped hoop. A slit-shaped light is emitted from each hoop in the width direction of the hoop.

(2) The bright lines on the hoop caused by this irradiation slit light are each imaged from diagonally above with a television camera and imaged on a CRT.

(3) Calculate the area of the portion surrounded by each imaged bright line.

(4) Calculate the amount of flux supplied per unit time from the obtained area and the line speed of the production line.

(5) Control the flux supply device so that this calculated amount matches the flux supply amount setting value.

[Effect]

The method developed this time is a means of measuring the cross-sectional area and weight of flux during flux supply.

A slit-shaped light such as a laser beam or infrared light is applied to the width direction of the hoop before flux supply and after flux supply, and the reflected bright line is imaged with a television camera from diagonally above. is displayed on the CRT.

Use a computer to calculate the area between the bright line formed on the hoop before flux supply and the bright line formed on the flux after flux supply, and calculate the amount of flux supplied per unit time from the obtained area and production line speed. can be calculated.

By controlling the flux supply device so that this calculated value matches the predetermined flux supply amount setting value, online control of the flux supply amount in the flux-cored wire manufacturing process is possible, and the quality of the product wire can be stabilized. .

〔Example〕

FIG. 1 is a perspective explanatory view showing the state of flux supply of the outer envelope flux in the manufacturing method of the present invention. When the continuously formed strip hoop 3 is folded into a U-shaped groove, the flux l is supplied into the U-shaped groove.

First, before flux is supplied, a slit-shaped laser beam 5 is irradiated from a laser beam oscillator 4, and the bright line on the hoop is imaged from diagonally above with a television camera 6.
video. Immediately after supplying the flux 1 to the hoop 3, a slit-shaped laser beam 50 is similarly applied from the laser oscillator 4a to image a bright line 9a as shown in the image 7a. The images of these bright lines 9 and 9a are subjected to image processing using the system configuration shown in FIGS. 2, 3, and 4.
The area of the portion sandwiched between the bright lines 9 and 9a is determined, and the microcomputer calculates the flux supply amount per unit time from this and the manufacturing line speed. The results are fed back to the flux supply device IO.

The configuration of image processing and computer calculation will be explained in detail below.

First, image processing will be explained using FIGS. 2 and 3, taking as an example a case where image 7 is processed.

Bright line 9 captured by television camera 6 and displayed on CRT
is a set of pixels of the smallest size that can be captured by the camera (hereinafter referred to as pixels). First, the camera switching circuit 103 specifies that image 7 is to be captured, and the illuminance data of the pixels is sent to the A/D converter 104. The zero-order data to be converted into digital data is compared with a preset threshold register 105 and a comparator 106,
The data is converted into binary data and stored in the image memory 107. This binarization is performed as if the pixel digital data is larger than the set value of the threshold value, it is set as (bright), and when it is equal to or smaller than l1, it is set as O (dark).

Next, for the bright line 9a imaged by the television camera 6a, the camera switching circuit 103 similarly selects the image 7a for one image 7a.
After specifying that the image 7a is to be projected, the same process as above is performed to overwrite the processed image of image 7a on the image memory 107 in which the processed image of image 7 has already been stored. By this overwriting, the image shown in FIG. 3 is obtained. However, the third
The hatched areas in the figure are bright areas, and the other areas are dark areas.

Next, the necessary numerical values are determined by computer calculations, but before that, it is necessary to adjust and calibrate the optical system.

First, as for adjustment, when image 7 without flux and image 7a after flux are superimposed, 2
It is necessary to set the position of the optical system (laser light irradiator, television camera) so that there is no deviation between the two images. Only after making this adjustment can accurate values be obtained. This is due to the laser beam irradiation position and the camera 6.6.
This is achieved by arranging them so that the installation positions and imaging angles of a are the same.

The television camera 6.6a takes an image of the bright line reflected in the width direction on the hoop 3 from diagonally above in the line direction, in order to accurately grasp the uneven shape of the bright line.

After making the above adjustments, next it is necessary to clarify the relationship between the number of pixels in the vertical direction of the image memory, X, and the flux height, y. Actually, the following relationship holds between y and X.

y=kx ・・・・・・(1) Here k
is a positive constant determined by the arrangement of the optical system. Similarly, the relationship between the horizontal pixel number 2 of the image memory and the width W of the bottom of the hoop can be similarly expressed as follows using the statement as a constant.

w=iz ・・・・・・(2) Above x
, y, z, and w can be measured. Therefore, for the constant Jl
can be determined.

Next, an example of computer calculation in which the image shown in FIG. 3 is calculated by a microcomputer will be explained with reference to FIG.

In figure t53, when the horizontal coordinate alA of the left end of the bright line image 9 from image 7 on the image memory matches the horizontal coordinate alB of the bright line image 9a from image 7a, and the horizontal coordinates arA and arB of the right end match. think of.

In this case, the number of pixels in the horizontal direction is 2 (2 is from aaA to a
from are to alB). The case where this condition is not satisfied will be described later.

First, find the point at the left end and the lowest end of the bright line 9, and calculate the coordinates of this point on the image memory as (a (0),
b (0) ), in this case a (0)= az
It is A.

Next, the coordinates at the lowest end of the emission line 9a on a(0) are (a
(0) , c (0) ), then aO
The height of the flux at a(0), which is written as y(0) in the sense of the height of the flux at a(0) (the same applies hereinafter), is expressed as follows from equation (1).

y (0) = k (c (0) - b,
(0) )...(3) Next, in the image memory, do the same thing for a(1), which is the line of pixels to the right of a(0), to find y(1). The operation is continued in the same manner until a(z-1), which is the right end of the bright line 9. Since the number of operations at this time is two, assuming that the actual cross-sectional area of the flux is S, S is expressed by the following equation from equations (2) and (3).

(4) From equation (4), the flux cross-sectional area S can be easily determined by taking the sum of Vt and multiplying it by the product kJl.

In addition, whether alA and alB are different or arA and are
If they are different, the above calculation can be performed using the one that is not smaller between aot-aIA and alB, and the one that is not larger between arA and are as a(z-1). The difference in B or the difference between afA and arB is negligibly small compared to the number of pixels in the horizontal direction of the hoop, which is 2, so it has almost no effect on S.

FIG. 4 is a block diagram of the periphery of the microcomputer.0 Calculations are made as described above based on the input from the image memory 107, and the flux cross section obtained by the microcomputer 109 and the flux cross section previously stored in the operation data storage device 108 are shown. The amount of flux supplied per unit time is calculated from data on the specific gravity of the flux and the speed of the production line. This calculated value is compared with the supply amount set value 110 per predetermined time, and if it is outside the predetermined amount range, the rotational supply speed of the belt of the flux supply device 10 is adjusted, and control is performed to return the abnormal value to the normal value. By sending a signal, the flux supply amount is restored to normal. In this case, lamp 112
lights up and the buzzer 113 issues an alarm to notify the operator of an abnormality in the operation.

In addition, the microcomputer 109 is capable of displaying images from the image memory 107 on the display 114.
The printer 115 can print out operational information such as flux cross-sectional area, date and time, line speed, etc., making it easy for the operator to obtain this information and grasp the expected future operational status.

Above, we have described the supply control of the outer flux 1 in the process shown in FIG. 6 (B), but the supply control of the inner flux 2 in the process shown in FIG.
The same applies to supply control.

Although the processing time interval of the present invention depends on the manufacturing line speed, for example, when the manufacturing line speed is 60 m/min, the processing is measured, calculated, and controlled every 10 seconds.

Also, the amount of flux supplied per unit time is, for example, 1/
The supply amount for 100 seconds is measured and the supply device is controlled.

Next, Table 1 shows the results of investigating the flux inclusion ratio in the method of the present invention using the apparatus of the above embodiment and in the case where the method of the present invention was not carried out.

As is clear from the table, wires with a stable flux inclusion ratio can be obtained by the method of the present invention, and the quality can be improved.

〔Effect of the invention〕

According to the present invention, it has become possible to continuously monitor and control the amount of flux included in the flux-cored wire in both the outer envelope and the inner envelope. By being able to control the flux supply amount, the quality of the flux-cored wire is stabilized and the quality assurance level is improved.

In addition, the flux supply amount adjustment work, which previously took a long time, can be done in a short time, improving efficiency.

[Brief explanation of the drawing]

Fig. 1 is a partial schematic perspective view of the flux-cored wire manufacturing process explaining the method of the present invention, Fig. 2 is a block diagram of the image processing system, Fig. 3 is an explanatory diagram of image processing, and Fig. 4 is a block diagram around the computer. 5 is a cross-sectional view of the flux-cored wire, FIG. 6 is a manufacturing process diagram thereof, and FIG. 7 is a process diagram showing changes in the cross-sectional shape of the hoop during the forming process. 1.2...Furafukus 3...Hoop 4.4a・
...Laser light generator 5.5a...Slit-shaped laser light 6.6a...Television camera 7.7a...Image 9.9a-...Emission line lO.
...Flux supply device 103...Camera switching circuit 104...A/D converter 105...Threshold value register 106...Comparator 107...Image memory 108...Operation data storage device 109...・Microcomputer 110-・Setting value

Claims (1)

[Claims] 1. In a method of supplying flux to a U-shaped groove of a hoop during the process of continuously molding a flux-cored wire from a band-shaped hoop, A slit-shaped light is irradiated from above in the width direction of the hoop,
Each bright line of light is imaged from diagonally above with a television camera, the area of the area surrounded by each of the bright lines is calculated, and the amount of flux input per unit time is calculated from the obtained area and the manufacturing line speed. 1. A flux supply control method for a flux-cored wire, comprising: calculating the calculated amount, and controlling a flux supply device so that the calculated amount matches a flux supply amount setting value.