大型管件管端过弯矫圆工艺及智能化控制技术研究
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摘要
大型钢铁管件是基础设施建设中不可缺少的组成部分，相关研究表明：全球100％的天然气、85％以上的石油都依靠钢铁管道运输，而在核电和热电设施，城市的地下“大动脉”——城市管网中也需要相当可观的大型钢铁管件。近年来随着我国基础设施建设的不断推进，其中所需的大型管件的产量也在逐步增加。大型管件需求的激增促使了大型管件生产厂家之间竞争的日益残酷，从而使生产厂家对管件质量提出了新的要求。
管坯的椭圆度是衡量管件品质的重要标准之一。管端的椭圆度超差后将直接影响管件间的连接工艺，然而，在大型管件的生产过程中往往由于管件材料性能的波动和管件成形工序中一些不良因素的影响造成管件管端的椭圆度超差，因此需要对其进行矫圆处理。按照矫圆过程是否伴随有管件截面中性层周长尺寸的变化矫圆可分为整径矫圆和过弯矫圆。而后者虽然在生产厂家应用广泛但是技术却相对落后，因此急需改进。
首先，在工程应用精度的许可下，为简化过弯矫圆工艺的理论分析难度，本文采用物理实验的方法验证了曲梁纯弯等价原理，即曲梁纯弯曲过程等价与直梁纯弯曲过程叠加曲梁初始曲率的结果和过弯矫圆等价原理，即管坯矫圆与管坯压扁之间的等价关系。
其次，基于平面弯曲弹复方程和通过将管坯离散化，对管坯整体压扁过程进行了解析，确立了管坯卸载后椭圆度和相对压下量之间的线性关系，从而为过弯矫圆工艺的定量化提供了理论依据。
再次，通过物理实验对比得到了管端压扁过程和相同型号、相同材质的短管坯整体压扁之间的相似关系。并在此基础上建立了二步法过弯矫圆控制策略和三步法过弯矫圆控制策略。即首先通过两步或者三步对同批次首支管件进行压制从而获得管坯的压扁过程弹复规律，其次在后续管件的矫圆过程中利用该弹复规律直接预测管坯的最佳矫圆压下量，并根据矫圆结果对该弹复规律实时修正。这为管坯过弯矫圆智能化系统的搭建奠定了基础。
第四，为改变目前大型管件椭圆度测量主要依赖工作人员的手工完成的现状，基于CCD机器识别系统的特点，在VC++程序语言的基础上开发了管端椭圆度的自动识别系统，从而实现了管端椭圆度的非接触式的自动测量。该系统详细研究了管端图像预处理、图像内椭圆的最小二乘法识别与检测、三角形边线的识别与检测等算法，并提出了一种基于正三角形的标定方法。最终利用实验验证了椭圆度识别系统的可靠性。
最后，在控制策略和椭圆度识别系统的基础上建立了大型管件管端过弯矫圆智能化控制系统。通过物理实验表明该系统具有稳定性好、自动化程度高、矫圆效果理想等优点。
Large steel pipes are one of the indispensable parts in the construction ofinfrastructure. The relative research indicates that100％global gas and85%globalpetroleum rely steel pipeline transportation, there is also a considerable number of largesteel pipes in the nuclear power and thermoelectric facilities and municipal supplynetworks. In recent years, along with China’s infrastructure construction progresses, theneeded large pipes production is gradually increasing. However, the sharp rise of the pipesmakes increasingly brutal competition between manufacturers, thus to allowmanufacturers to put forward new requirements for the quality of the pipes.
Ovality of pipe is one of the main standard to measure the quality of the pipes. And ifthe ovality of the pipe-end is out of standard, it will directly affect the connection processbetween pipes. In the production process of the pipes, it is unavoidable to produce somepipe with ovality oversize because of the fluctuations of the material properties and manybad factors in production process. So the setting round process is needed. According towhether perimeter changes of the pipe section neutral layer, the setting round process canbe divided into “sizing and setting round” and “over-bending settiong round”. However,the latter is widely applied by the manufacturers although technological backwardness.Thus, the advanced methods are veritably needed.
Firstly, under the range of engineering applications accuracy, and to simplify thetheoretical analysis difficulty of the over-bending setting round, this paper proofsequivalence principle of curved beam pure bending, which means the pure bendingprocess of curved beam is equivalent to the addition of pure bending results of straightlybeam and the initial curvature of curved beam, and equivalence principle of over-bendingsetting round, which means the setting round process is equivalent to compressing ovalprocess.
Secondly, according to conventional bending theory and finite element meshing idea,the theoretical analysis for the compressing oval process of the whole pipe is finished, andthe relationship between the ovality after springback and the relative reduction is built. This lay the theoretical foundation for the over-bending setting round.
Thirdly, when the materials and the specifications are the same, the similarity relationbetween the pipe-end compressing oval process and the whole pipe compressing ovalprocess is given by experiment. Based on this, the “two steps” and “three steps”over-bending setting round control policy are built. Which means to obtain thespring-back law of the compressing oval process firstly by compressing the first pipetwice or three times, and then to set round the next pipe by the spring-back law, at last tomodify the spring-back law according to the setting round results. This lay the foundationfor the over-banding setting round intelligent control system.
Fourthly, for the purpose of changing the situation that the ovality measuring workare finished by handwork, according to the characteristic of CCD machine cognition, thepipe-end ovality recognition system is developed in the VC++program language. Thesystem researches into primary algorithms, such as the pipe-end image pre-processing, theoval recognition based least square method, the triangle foul line recognition and so on,and put forward a new camera calibration method. The final experiment proves thereliability of the system.
At last, base on the control policy and the pipe-end ovality recognition system, theover-bending setting round intelligent control system for pipe-end of large pipes is built.The system is proved to be good stability, high degree of automation and reaching idealeffect.
管坯的椭圆度是衡量管件品质的重要标准之一。管端的椭圆度超差后将直接影响管件间的连接工艺，然而，在大型管件的生产过程中往往由于管件材料性能的波动和管件成形工序中一些不良因素的影响造成管件管端的椭圆度超差，因此需要对其进行矫圆处理。按照矫圆过程是否伴随有管件截面中性层周长尺寸的变化矫圆可分为整径矫圆和过弯矫圆。而后者虽然在生产厂家应用广泛但是技术却相对落后，因此急需改进。
首先，在工程应用精度的许可下，为简化过弯矫圆工艺的理论分析难度，本文采用物理实验的方法验证了曲梁纯弯等价原理，即曲梁纯弯曲过程等价与直梁纯弯曲过程叠加曲梁初始曲率的结果和过弯矫圆等价原理，即管坯矫圆与管坯压扁之间的等价关系。
其次，基于平面弯曲弹复方程和通过将管坯离散化，对管坯整体压扁过程进行了解析，确立了管坯卸载后椭圆度和相对压下量之间的线性关系，从而为过弯矫圆工艺的定量化提供了理论依据。
再次，通过物理实验对比得到了管端压扁过程和相同型号、相同材质的短管坯整体压扁之间的相似关系。并在此基础上建立了二步法过弯矫圆控制策略和三步法过弯矫圆控制策略。即首先通过两步或者三步对同批次首支管件进行压制从而获得管坯的压扁过程弹复规律，其次在后续管件的矫圆过程中利用该弹复规律直接预测管坯的最佳矫圆压下量，并根据矫圆结果对该弹复规律实时修正。这为管坯过弯矫圆智能化系统的搭建奠定了基础。
第四，为改变目前大型管件椭圆度测量主要依赖工作人员的手工完成的现状，基于CCD机器识别系统的特点，在VC++程序语言的基础上开发了管端椭圆度的自动识别系统，从而实现了管端椭圆度的非接触式的自动测量。该系统详细研究了管端图像预处理、图像内椭圆的最小二乘法识别与检测、三角形边线的识别与检测等算法，并提出了一种基于正三角形的标定方法。最终利用实验验证了椭圆度识别系统的可靠性。
最后，在控制策略和椭圆度识别系统的基础上建立了大型管件管端过弯矫圆智能化控制系统。通过物理实验表明该系统具有稳定性好、自动化程度高、矫圆效果理想等优点。
Large steel pipes are one of the indispensable parts in the construction ofinfrastructure. The relative research indicates that100％global gas and85%globalpetroleum rely steel pipeline transportation, there is also a considerable number of largesteel pipes in the nuclear power and thermoelectric facilities and municipal supplynetworks. In recent years, along with China’s infrastructure construction progresses, theneeded large pipes production is gradually increasing. However, the sharp rise of the pipesmakes increasingly brutal competition between manufacturers, thus to allowmanufacturers to put forward new requirements for the quality of the pipes.
Ovality of pipe is one of the main standard to measure the quality of the pipes. And ifthe ovality of the pipe-end is out of standard, it will directly affect the connection processbetween pipes. In the production process of the pipes, it is unavoidable to produce somepipe with ovality oversize because of the fluctuations of the material properties and manybad factors in production process. So the setting round process is needed. According towhether perimeter changes of the pipe section neutral layer, the setting round process canbe divided into “sizing and setting round” and “over-bending settiong round”. However,the latter is widely applied by the manufacturers although technological backwardness.Thus, the advanced methods are veritably needed.
Firstly, under the range of engineering applications accuracy, and to simplify thetheoretical analysis difficulty of the over-bending setting round, this paper proofsequivalence principle of curved beam pure bending, which means the pure bendingprocess of curved beam is equivalent to the addition of pure bending results of straightlybeam and the initial curvature of curved beam, and equivalence principle of over-bendingsetting round, which means the setting round process is equivalent to compressing ovalprocess.
Secondly, according to conventional bending theory and finite element meshing idea,the theoretical analysis for the compressing oval process of the whole pipe is finished, andthe relationship between the ovality after springback and the relative reduction is built. This lay the theoretical foundation for the over-bending setting round.
Thirdly, when the materials and the specifications are the same, the similarity relationbetween the pipe-end compressing oval process and the whole pipe compressing ovalprocess is given by experiment. Based on this, the “two steps” and “three steps”over-bending setting round control policy are built. Which means to obtain thespring-back law of the compressing oval process firstly by compressing the first pipetwice or three times, and then to set round the next pipe by the spring-back law, at last tomodify the spring-back law according to the setting round results. This lay the foundationfor the over-banding setting round intelligent control system.
Fourthly, for the purpose of changing the situation that the ovality measuring workare finished by handwork, according to the characteristic of CCD machine cognition, thepipe-end ovality recognition system is developed in the VC++program language. Thesystem researches into primary algorithms, such as the pipe-end image pre-processing, theoval recognition based least square method, the triangle foul line recognition and so on,and put forward a new camera calibration method. The final experiment proves thereliability of the system.
At last, base on the control policy and the pipe-end ovality recognition system, theover-bending setting round intelligent control system for pipe-end of large pipes is built.The system is proved to be good stability, high degree of automation and reaching idealeffect.
引文
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