US20190201957A1 - Welding monitoring apparatus and welding monitoring method - Google Patents

Welding monitoring apparatus and welding monitoring method Download PDF

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Publication number
US20190201957A1
US20190201957A1 US16/331,067 US201616331067A US2019201957A1 US 20190201957 A1 US20190201957 A1 US 20190201957A1 US 201616331067 A US201616331067 A US 201616331067A US 2019201957 A1 US2019201957 A1 US 2019201957A1
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Prior art keywords
welding
image
monitoring method
welding monitoring
arcing
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Abandoned
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US16/331,067
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English (en)
Inventor
Noboru Hasegawa
Michitoshi Tanimoto
Michimasa Mukai
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Nippon Steel Corp
Nippon Steel Pipe Co Ltd
Original Assignee
Nippon Steel and Sumitomo Metal Corp
Nippon Steel and Sumikin Pipe Co Ltd
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Assigned to NIPPON STEEL & SUMITOMO METAL CORPORATION, NIPPON STEEL & SUMIKIN PIPE CO., LTD. reassignment NIPPON STEEL & SUMITOMO METAL CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HASEGAWA, NOBORU, MUKAI, MICHIMASA, TANIMOTO, MICHITOSHI
Assigned to NIPPON STEEL CORPORATION reassignment NIPPON STEEL CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: NIPPON STEEL & SUMITOMO METAL CORPORATION
Publication of US20190201957A1 publication Critical patent/US20190201957A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/08—Making tubes with welded or soldered seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/08—Making tubes with welded or soldered seams
    • B21C37/0818—Manufacture of tubes by drawing of strip material through dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/06—Resistance welding; Severing by resistance heating using roller electrodes
    • B23K11/061—Resistance welding; Severing by resistance heating using roller electrodes for welding rectilinear seams
    • B23K11/062—Resistance welding; Severing by resistance heating using roller electrodes for welding rectilinear seams for welding longitudinal seams of tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/08—Seam welding not restricted to one of the preceding subgroups
    • B23K11/087—Seam welding not restricted to one of the preceding subgroups for rectilinear seams
    • B23K11/0873—Seam welding not restricted to one of the preceding subgroups for rectilinear seams of the longitudinal seam of tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/24—Electric supply or control circuits therefor
    • B23K11/25—Monitoring devices
    • B23K11/252—Monitoring devices using digital means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K13/00—Welding by high-frequency current heating
    • B23K13/01—Welding by high-frequency current heating by induction heating
    • B23K13/02—Seam welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K13/00—Welding by high-frequency current heating
    • B23K13/08—Electric supply or control circuits therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/003—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to controlling of welding distortion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
    • G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/041—Analysing solids on the surface of the material, e.g. using Lamb, Rayleigh or shear waves
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04—Analysing solids
    • G01N29/043—Analysing solids in the interior, e.g. by shear waves
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
    • G01N21/952—Inspecting the exterior surface of cylindrical bodies or wires
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00—Indexing codes associated with group G01N29/00
    • G01N2291/26—Scanned objects
    • G01N2291/267—Welds

Definitions

  • the present invention relates to a welding monitoring apparatus and a welding monitoring method for an electric resistance welded steel pipe.
  • An electric resistance welded steel pipe is manufactured through the following step. That is, first, a strip-shaped metal sheet is continuously formed into a cylindrical shape by a roll group while being conveyed along its longitudinal direction. Then, while an upset is applied to the cylindrically formed metal sheet from its side by a pair of squeeze rolls, and while heat-input is controlled with respect to both side edges in a circumferential direction of the metal sheet converged in a V-shape, both the side edges are welded by being heated and melted through high-frequency resistance welding or induction heating welding and being butted each other. Since this step of welding an electric resistance welded steel pipe is an important step which directly affects the quality of an electric resistance welded steel pipe, various examinations have been performed in the related art.
  • Patent Document 1 discloses that the form of a welding spot changes into “a first kind”, “a second kind”, “a transition region”, or “a subordinate second kind” depending on the heat input amount applied at the time of welding (refer to FIG. 8 ).
  • This Patent Document 1 employs an electric resistance welding work management apparatus including “an arc detecting region extraction unit that extracts a narrow region including a welding slit generated between a V-convergence point (VI) that is an abutment point at which the steel sheet abuts and a welding point (W) in which a molten steel starts to be discharged from the inside of the steel sheet, as an arc detecting region; and an arc detecting unit that detects an arc generated in the arc detecting region”.
  • V-convergence point VI
  • W welding point
  • this electric resistance welding work management apparatus employs a constitution “including an arc generation frequency measuring unit that measures a frequency of generation of an arc, and a welding phenomenon determining unit that determines a welding phenomenon thereof based on whether or not the frequency of generation of an arc is equal to or greater than a predetermined value”.
  • the form of a steady state arc downstream of the V-convergence point is grasped based on the frequency of generation of the steady state arc, and thus an appropriate heat input amount is controlled.
  • Patent Document 1 Japanese Unexamined Patent Application, First Publication No. 2016-78056
  • Patent Document 1 it is possible to realize an appropriate welding state downstream of the V-convergence point. However, from the viewpoint of improving the quality of a welding spot, further amelioration is demanded.
  • high-frequency electric resistance welding is a technology in which currents are concentrated on a welding surface such that welding is efficiently performed by utilizing a proximity effect and a skin effect of steel edges in a weld.
  • a strong electromagnetic field is formed around the steel edges due to significant currents flowing in the steel edges. Since this electromagnetic field is maximized at a welding point (V point), if a magnetic substance is present around the steel edges, it is likely to be incorporated into the welding point.
  • a steel sheet to which scale generated at the time of hot rolling adheres is adopted, and the scale is peeled off from a surface layer through a forming process or by a fin pass roll.
  • the fin pass roll can form a newly formed surface by scraping a welding surface.
  • scale or iron powder may be generated.
  • iron powder may be similarly generated even in a pickled material in which scale seldom adheres to its surface layer. In this manner, a phenomenon, in which scale that has been peeled off or scale powder, iron powder, or the like that has been scraped is caught in a weld as a foreign substance, occurs sometimes.
  • the present invention has been made in consideration of the foregoing circumstances, and an object thereof is to provide a welding monitoring apparatus and a welding monitoring method, in which a relatively light caught-in defect caused by an incorporated foreign substance such as scale powder or iron powder can be detected in real time in a welding step of an electric resistance welded steel pipe.
  • FIG. 1A and FIG. 1B show a result obtained by installing an electric resistance welded steel pipe such that a weld of a defect-generated portion is at a 90° position in a vertical direction, and performing a flattening test for reduction in the vertical direction.
  • FIG. 1A shows an external appearance photograph of a fracture surface having a crack
  • FIG. 1B shows a secondary electron image captured by a scanning electron microscope (SEM). As shown in FIG.
  • a defect to be regarded as a target is characterized by a slender black streak pattern present in a central position of the crack while extending in the through-thickness direction and having a width of several millimeters or smaller present.
  • a boundary between a black streak part and the surrounding part is manifested, and a dimple fracture surface which is characteristically formed in the surrounding part at the time of a low heat input has been observed. From the results of the flattening test described above, it is speculated that the defect has been generated due to a caught-in foreign substance which has a lower temperature than a welding surface at the time of welding and causes a heat release of the surrounding part.
  • FIG. 2A and FIG. 2B show scanning electron microscope (SEM) analysis results of the black streak part.
  • SEM scanning electron microscope
  • the peaks of iron and oxygen are noticeable as shown in FIG. 2B .
  • compositions other than both the elements are at a substantially noise level, and thus it is ascertained that the composition of the black streak part is iron oxide.
  • fine ingots of such iron oxide are scattered inside the black streak part and are highly concentrated in their entirety. Therefore, it is determined that this defect is caused due to iron oxide (scale) which has been caught in or the welding surface in which iron powder is caught in and is oxidized.
  • the present invention provides the following aspects.
  • a welding monitoring apparatus that monitors a welding state of a V-convergence region in which a strip-shaped metal sheet is converged in a V-shape, when the metal sheet is cylindrically formed while being conveyed, and both side edges of the metal sheet are heated and melted in a manner of being butted each other while being converged in the V-shape, such that an electric resistance welded steel pipe is manufactured.
  • the welding monitoring apparatus includes: an image capturing unit that captures images of a region including the V-convergence region in time series; and an image processing unit that extracts a welding point based on the images captured in time series and detects the presence or absence and the position of irregular arcing at a welding point or on an upstream side of the welding point.
  • the aspect according to (1) may be constituted as follows.
  • the images captured by the image capturing unit are RGB images.
  • the image processing unit extracts at least one of a red image and a blue image from the RGB images, performs inverted binarization and labeling of the red image with respect to the red image, and detects a high-luminance portion in the blue image with respect to the blue image.
  • the image capturing unit may be a camera capturing 200 frames or more per second.
  • a welding monitoring method for monitoring a welding state of a V-convergence region in which a strip-shaped metal sheet is converged in a V-shape, when the metal sheet is cylindrically formed while being conveyed, and both side edges of the metal sheet are heated and melted in a manner of being butted each other while being converged in the V-shape, such that an electric resistance welded steel pipe is manufactured.
  • the welding monitoring method includes: an image capturing step of capturing images of a region including the V-convergence region in time series; and a detecting step of extracting a welding point based on the images captured in time series and detecting the presence or absence and a position of irregular arcing at the welding point or on an upstream side of the welding point.
  • the aspect according to (4) may be constituted as follows.
  • RGB images are used as the images.
  • the detecting step at least one of a red image and a blue image is extracted from the RGB images, inverted binarization and labeling of the red image are performed with respect to the red image, and a high-luminance portion in the blue image is detected with respect to the blue image.
  • images may be captured at a frame rate of 200 frames or more per second.
  • the aspect according to any one of (4) to (6) may further include a marking step of marking the position of the irregular arcing in a longitudinal direction in the electric resistance welded steel pipe.
  • the aspect may further include a defect presence-or-absence specifying step of performing an ultrasonic test with respect to a region to which the marking is applied.
  • the aspect according to any one of (4) to (6) may further include a tracking step of tracking the position of the irregular arcing in a longitudinal direction in the electric resistance welded steel pipe.
  • any of a monochrome camera and a color camera can be used.
  • a color camera which can perform color separation so as to distinguish light emission from a molten steel and irregular arcing from each other with high contrast.
  • the welding monitoring apparatus and the welding monitoring method of each of the aspects of the present invention it is possible to detect a defect which is generated due to a foreign substance caught on a welding surface, including a relatively light defect. Then, this detection information can be tracked in a step of manufacturing an electric resistance welded steel pipe, or marking can be performed on a steel pipe itself immediately after a defect is detected. In this case, a defect portion is unerringly eliminated from a product, so that only a normal portion having no caught-in defect can be shipped as a product.
  • FIG. 1A shows a photograph showing an external appearance of a target defect.
  • FIG. 1B is a photograph showing a secondary electron image of a target defect.
  • FIG. 2A is a view showing an example in which qualitative analysis is performed with respect to a target defect by using a scanning electron microscope (SEM), and it is a photograph of a backscattered electron image of a scanning electron microscope (SEM).
  • SEM scanning electron microscope
  • FIG. 2B is a view showing an example in which qualitative analysis is performed with respect to a target defect by using a scanning electron microscope (SEM), and it is a graph showing results of composition analysis of a portion 3 in FIG. 2A performed by using a scanning electron microscope (SEM).
  • SEM scanning electron microscope
  • FIG. 3 is a perspective view showing an electric resistance welded steel pipe welding apparatus in which a welding monitoring apparatus and a welding monitoring method according to an embodiment of the present invention are applied.
  • FIG. 4 is a flowchart of an image processing algorithm for detecting generation of a defect by using the same welding monitoring apparatus and the same welding monitoring method.
  • FIG. 5 is a photograph showing an example of an image of an image processing process for detecting generation of a defect.
  • FIG. 5( a ) shows a captured image
  • FIG. 5( b ) shows a detected welding point
  • FIG. 5( c ) shows a detected blue component
  • FIG. 5( d ) shows a detected high-luminance portion.
  • FIG. 6 is a photograph in which a state of a weld at the time of generation of a defect is image-captured.
  • FIG. 7 is a view showing an example in which a defect-generated position and a portion where a crack is generated through a flattening test are butted each other.
  • FIG. 7( a ) is a photograph showing an actual defect portion checked after the flattening test and the external appearance thereof, and
  • FIG. 7( b ) shows comparison between a portion where irregular arcing has occurred and an image.
  • FIG. 8 is a view describing an example of a welding monitoring method in the related art, and it is a view showing each of welding phenomena of “a first kind”, “a second kind”, “a transition region”, and “a subordinate second kind” in a welding spot.
  • FIG. 3 shows a perspective view of an electric resistance welded steel pipe welding apparatus in which the same welding monitoring apparatus and the same welding monitoring method are applied.
  • the same electric resistance welded steel pipe welding apparatus is an apparatus which manufactures an electric resistance welded steel pipe by cylindrically forming a strip-shaped metal sheet 1 while the strip-shaped metal sheet 1 is conveyed along its longitudinal direction, and heating and melting both side edges (edges) 1 a and 1 b of the metal sheet 1 in a manner of being butted each other while the side edges are converged in a V-shape in a plan view.
  • V-convergence point 3 is a V-convergence point at which both the side edges 1 a and 1 b converged in the V-shape are butted each other and are heated and melted.
  • the metal sheet (steel sheet) 1 proceeds from the front side on the paper toward the deep side on the paper along its longitudinal direction. Therefore, in a case where the V-convergence point 3 is taken as a reference, the front side on the paper becomes an upstream side, and the deep side on the paper becomes a downstream side.
  • the welding monitoring apparatus of the present embodiment monitors a welding state of a V-convergence region in which the metal sheet 1 is converged in a V-shape, when an electric resistance welded steel pipe is manufactured.
  • the reference signs 4 a and 4 b in FIG. 3 indicate a pair of contact tips disposed to come into contact with spots near both the side edges 1 a and 1 b of the metal sheet 1 in the circumferential direction, which travels toward the V-convergence point 3 .
  • the reference sign 5 in FIG. 3 indicates an impeder which is disposed in a central part of the cylindrically formed metal sheet 1
  • the reference sign 6 indicates a high-frequency power supply which is connected to each of the contact tips 4 a and 4 b .
  • High-frequency currents supplied through the contact tips 4 a and 4 b flow as indicated with arrows along the extending direction of both the side edges 1 a and 1 b in the circumferential direction of the metal sheet 1 , so that both the side edges 1 a and 1 b of the metal sheet 1 are heated and melted due to high-frequency resistance. Similar to that in the related art, a heat input is controlled by means of these high-frequency currents.
  • a pair of squeeze rolls 2 and 2 near the V-convergence point 3 apply an upset to both the side edges 1 a and 1 b of the metal sheet 1 which have been heated and melted such that both the side edges 1 a and 1 b are subjected to electric resistance welding.
  • an induction heating-type welding in which heating is performed by using an induction coil can also be employed.
  • the squeeze rolls 2 and 2 apply an upset to both the side edges 1 a and 1 b of the metal sheet 1 which have been heated and melted in this manner, so that oxide on a surface of the metal sheet 1 is extruded and discharged from a welding surface, and thereby excellent welding quality is achieved.
  • a foreign substance is caught on the welding surface, strength of the welding surface is degraded, and a possibility of a crack at the time of working of a steel pipe or when an internal pressure is applied to a steel pipe increases.
  • the welding monitoring apparatus of the present embodiment includes an image capturing unit 7 and an image processing unit 8 in order to monitor a caught-in defect in real time including a light defect which have not been able to be monitored in the related art.
  • irregular arcing arcing into which a foreign substance is incorporated
  • Irregular arcing differs from the steady state arcing described above in regard to the following points. That is, steady state arcing occurs on a downstream side of a weld (V-convergence point 3 ).
  • irregular arcing occurs in a weld (V-convergence point 3 ) and on an upstream side of a weld (V-convergence point 3 ).
  • steady state arcing occurs between a pair of end edges (edges) when an electric resistance welded steel pipe is formed. Therefore, the material of a welded portion generated as a result thereof is equivalent to the base material of the metal sheet 1 .
  • irregular arcing it occurs due to a foreign substance such as iron oxide (scale) or iron powder. Therefore, the material of a welded portion differs from the base material of the metal sheet 1 .
  • the image capturing unit 7 captures an image of a surface of a region including the V-convergence region in which both the side edges 1 a and 1 b of the metal sheet 1 are converged in a V-shape.
  • a CCD camera is used.
  • the image capturing apparatus is disposed above a weld (V-convergence point 3 ) such that a range including a weld (V-convergence point 3 ) and the upstream side of the weld (V-convergence point 3 ) can be captured from above thereof.
  • the image capturing apparatus can be installed without hardship and without interfering with other equipments (a nitrogen purge nozzle, a cooling water piping, and the like).
  • the image capturing unit 7 captures an image on a surface of the metal sheet 1 including red light.
  • FIG. 4 shows an image processing algorithm for automatically performing detection using the image capturing unit 7 and the image processing unit 8 .
  • (a) to (d) of FIG. 5 show examples of processed images.
  • At least one of a red component and a blue component is extracted from an RGB image (refer to (a) of FIG. 5 ) captured in Step S 1 of FIG. 4 ( FIG. 4 shows an example of a case where both are extracted).
  • Step S 2 When a red component shown in Step S 2 is extracted, inverted binarization (Step S 3 ) and labeling (Step S 4 ) are performed to obtain a welding point in a red image, and a downstream end point in a wedge-type region interposed between steel edges (both the side edges 1 a and 1 b ) is set as the welding point (Step S 5 , also refer to (b) of FIG. 5 ).
  • Step S 6 when a blue component shown in Step S 6 is extracted, a blue image is subjected to binarization (Step S 7 , also refer to (c) of FIG. 5 ) and labeling (Step S 8 ), and a high-luminance portion is detected (Step S 9 , also refer to (d) of FIG. 5 ).
  • the blue component In the present image in which a radiant pattern of a molten steel is captured, in a case where irregular arcing is present in spite of the low level of the blue component, the blue component exhibits high luminance and can be detected.
  • high luminance indicates a level of 200 or higher in 255 gradations, for example.
  • This high-luminance portion is subjected to labeling (the foregoing Step S 8 ), and positional information is derived out.
  • Labeling indicates processing in which the same label number is attached to one lump (blob) in a binary image, a particular blob is extracted, and the position (the maximum point and the minimum point of the X-coordinate, and the maximum point and the minimum point of the Y-coordinate), the width, the length, the area, and the like of the blob within the image are extracted. Even if a plurality of irregular arcing portions are present, the positional information of each thereof can be derived out.
  • Step S 10 The position of the welding point and the high-luminance portion obtained in this manner are compared to each other in Step S 10 . If the position of the high-luminance portion is not on a downstream side of the welding point (Step S 10 : YES), generation of an irregular arcing portion is determined as generation of a defect (Step S 11 ), and the processing returns to Step S 1 . On the other hand, if the position of the high-luminance portion is on a downstream side of the welding point (Step S 10 : NO), it is determined as normal (Step S 12 ), and the processing subsequently returns to Step S 1 .
  • a defect can be determined at all times.
  • a blue component image is extracted and processed in order to detect an irregular arcing portion with high contrast.
  • an irregular arcing portion is also saturated (Level 255 in 255 gradations) even in a red component image with high probability, only a red component can also be detected.
  • a camera capturing 200 frames or more per second is used when an image is captured, it is experimentally ascertained that there is no leakage in detection of an irregular arcing portion. Therefore, it is preferable to use a camera capturing 200 frames or more per second when an image is captured in Step S 1 .
  • the pipe adopted as a welding monitoring target was an actual pipe of ⁇ 100 mm ⁇ 4 mmt.
  • the frame rate was set to 200 frames/second, and the exposure time was set to 1/10,000 seconds.
  • FIG. 6 shows an example of welding monitoring.
  • the welding surfaces were short-circuited due to a foreign substance such as scale or iron powder having conductivity, and thus irregular arcing occurred.
  • a foreign substance such as scale or iron powder having conductivity
  • the welding monitoring apparatus of the present embodiment monitors the welding state of the V-convergence region in which the strip-shaped metal sheet 1 is converged in a V-shape, when the metal sheet 1 is cylindrically formed while being conveyed along its longitudinal direction, and both the side edges 1 a and 1 b of the metal sheet 1 are heated and melted in a manner of being butted each other while being converged in the V-shape, such that an electric resistance welded steel pipe is manufactured.
  • this welding monitoring apparatus includes: the image capturing unit 7 that captures images of a region including the V-convergence region in time series; and the image processing unit 8 that extracts a welding point based on the images captured in time series and detects the presence or absence and the position of irregular arcing at the welding point or on an upstream side of the welding point.
  • the welding monitoring apparatus is constituted as follows.
  • the images captured by the image capturing unit 7 are RGB images.
  • the image processing unit 8 extracts at least one of a red image and a blue image from the RGB images, performs inverted binarization and labeling of the red image with respect to the red image, and detects a high-luminance portion in the blue image with respect to the blue image.
  • the image capturing unit is a camera capturing 200 frames or more per second.
  • the welding monitoring method of the present embodiment is used for monitoring the welding state of the V-convergence region in which the strip-shaped metal sheet 1 is converged in a V-shape, when the metal sheet 1 is cylindrically formed while being conveyed along its longitudinal direction, and both the side edges 1 a and 1 b of the metal sheet 1 are heated and melted in a manner of being butted each other while being converged in the V-shape, such that an electric resistance welded steel pipe is manufactured.
  • This welding monitoring method includes: an image capturing step of capturing images of a region including the V-convergence region in time series; and a detecting step of extracting a welding point based on the images captured in time series and detecting the presence or absence and the position of irregular arcing at the welding point or on an upstream side of the welding point.
  • RGB images are used as the images.
  • the detecting step at least one of a red image and a blue image is extracted from the RGB images, inverted binarization and labeling of the red image are performed with respect to the red image, and a high-luminance portion in the blue image is detected with respect to the blue image.
  • images are captured at a frame rate of 200 frames or more per second.
  • the welding monitoring method further includes a marking step of marking the position of the irregular arcing in the longitudinal direction in the electric resistance welded steel pipe.
  • the welding monitoring method according to (7) further includes a defect presence-or-absence specifying step of performing an ultrasonic test with respect to a region to which the marking is applied.
  • the aspect according to any one of (4) to (6) further includes a tracking step of tracking the position of the irregular arcing in the longitudinal direction in the electric resistance welded steel pipe.
  • the presence or absence of a caught-in defect can be easily detected in real time by extracting a welding point and automatically determining the presence or absence of generation of irregular arcing in the vicinity of the welding point or on an upstream side of the welding point. Then, product-tracking is performed or a steel pipe is subjected to marking in the vicinity of the squeeze rolls 2 immediately after irregular arcing is detected, based on the information of the presence or absence of generation of irregular arcing, so that the position of a defect-generated portion is clarified, and thus the defect-generated portion can be easily eliminated in a refining step. Therefore, only a normal portion including no defect can be shipped as a product.
  • a welding monitoring apparatus and a welding monitoring method in which a relatively light caught-in defect caused by an incorporated foreign substance such as scale powder or iron powder can be detected in real time in a welding step of an electric resistance welded steel pipe.

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WO2018087818A1 (ja) 2018-05-17
US20240082900A1 (en) 2024-03-14
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EP3539683A4 (en) 2020-09-09

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