直縫焊(han)管自動超聲探傷(shang)系統(tong)設計

針(zhen)對直(zhi)縫焊管生(sheng)產中(zhong)傳統(tong)應用手工探(tan)傷(shang)效率低、故障(zhang)率高等(deng)問題，利用超聲(sheng)無損探(tan)傷(shang)精(jing)度高、速度快的(de)(de)優點，構(gou)建以可(ke)編程(cheng)(cheng)(cheng)控(kong)(kong)(kong)制(zhi)(zhi)器（PLC）為核心的(de)(de)直(zhi)縫焊管自動(dong)超聲(sheng)探(tan)傷(shang)系統(tong)．提出(chu)該系統(tong)的(de)(de)工藝參(can)數和系統(tong)機(ji)械構(gou)成，設計(ji)系統(tong)的(de)(de)PLC控(kong)(kong)(kong)制(zhi)(zhi)硬(ying)件(jian)(jian)、PLC程(cheng)(cheng)(cheng)序流程(cheng)(cheng)(cheng)及PLC控(kong)(kong)(kong)制(zhi)(zhi)程(cheng)(cheng)(cheng)序．系統(tong)的(de)(de)操作(zuo)監(jian)控(kong)(kong)(kong)硬(ying)件(jian)(jian)選用臺達觸摸屏，給出(chu)基于Windows系統(tong)觸摸屏編程(cheng)(cheng)(cheng)軟件(jian)(jian)設計(ji)的(de)(de)人機(ji)操作(zuo)監(jian)控(kong)(kong)(kong)畫(hua)面。

探傷系統原理

直縫(feng)焊管自動探傷工藝流程如下：上(shang)料→進料→壓料→探傷→打(da)標→松料→出料分(fen)選。

PLC控制流程

PLC程(cheng)(cheng)(cheng)(cheng)序(xu)(xu)(xu)采用西門子(zi)(zi)(zi)PLC編(bian)程(cheng)(cheng)(cheng)(cheng)軟件(jian)STEP7-MICRO/WINV 4.0SP8編(bian)制,程(cheng)(cheng)(cheng)(cheng)序(xu)(xu)(xu)編(bian)程(cheng)(cheng)(cheng)(cheng)為結構化(hua)編(bian)程(cheng)(cheng)(cheng)(cheng)模式，分為主程(cheng)(cheng)(cheng)(cheng)序(xu)(xu)(xu)、運管小(xiao)車(che)速(su)度(du)子(zi)(zi)(zi)程(cheng)(cheng)(cheng)(cheng)序(xu)(xu)(xu)、手(shou)(shou)動(dong)子(zi)(zi)(zi)程(cheng)(cheng)(cheng)(cheng)序(xu)(xu)(xu)、自動(dong)子(zi)(zi)(zi)程(cheng)(cheng)(cheng)(cheng)序(xu)(xu)(xu)、自動(dong)復位子(zi)(zi)(zi)程(cheng)(cheng)(cheng)(cheng)序(xu)(xu)(xu)、手(shou)(shou)動(dong)復位子(zi)(zi)(zi)程(cheng)(cheng)(cheng)(cheng)序(xu)(xu)(xu)、系統總停子(zi)(zi)(zi)程(cheng)(cheng)(cheng)(cheng)序(xu)(xu)(xu)、運管小(xiao)車(che)編(bian)碼器脈沖高速(su)計(ji)數子(zi)(zi)(zi)程(cheng)(cheng)(cheng)(cheng)序(xu)(xu)(xu)等，有自動(dong)、手(shou)(shou)動(dong)、單(dan)動(dong)控制功能

探傷系統操作監控界面設計

直縫焊管自(zi)動超聲(sheng)探傷系(xi)統操(cao)作監控(kong)硬件采用(yong)臺達(da)公司(si)的DOP-B系(xi)列觸摸(mo)屏(ping)，應用(yong)基于Windows系(xi)統編程軟件Screenedit設計(ji)觸摸(mo)屏(ping)操(cao)作監控(kong)界面(mian)(mian)，觸摸(mo)屏(ping)顯(xian)示畫面(mian)(mian)由系(xi)統主畫面(mian)(mian)、監控(kong)報警(jing)畫面(mian)(mian)、參數設置畫面(mian)(mian)等組成。

探傷系統優勢

(1)針對直縫焊管(guan)傳統人工探(tan)(tan)傷效率低、精度差等缺點，構建以西(xi)門子PLC為控(kong)制核心(xin)的(de)(de)(de)直縫焊管(guan)自(zi)動(dong)超(chao)聲探(tan)(tan)傷系統．應用西(xi)門子S-2000PLC的(de)(de)(de)高速(su)計(ji)數(shu)與比較功能實(shi)現(xian)超(chao)聲探(tan)(tan)頭的(de)(de)(de)自(zi)動(dong)下降和運管(guan)小(xiao)車定位(wei)(wei)控(kong)制，檢測速(su)度快(kuai)，精確度較高。系統調(diao)試中高速(su)計(ji)數(shu)脈沖當(dang)量的(de)(de)(de)選定與超(chao)聲探(tan)(tan)頭安裝位(wei)(wei)置(zhi)、小(xiao)車的(de)(de)(de)速(su)度、編碼器的(de)(de)(de)參數(shu)相關。

(2)觸(chu)摸屏(ping)(ping)具(ju)有人機交互、靈活的優點(dian)，減少了操(cao)作臺上的開關數(shu)量，使操(cao)作更加人性(xing)化。通過(guo)觸(chu)摸屏(ping)(ping)可實時顯示(shi)自動超聲(sheng)探(tan)傷(shang)系(xi)統參數(shu)，修(xiu)改系(xi)統參數(shu)便捷(jie)，系(xi)統柔性(xing)較(jiao)好．設計的觸(chu)摸屏(ping)(ping)監控畫面具(ju)有超聲(sheng)波傷(shang)波、失波等(deng)報警功能，確保了直(zhi)縫焊管(guan)檢測(ce)中的安全，避免了人工(gong)操(cao)作錯誤和生產(chan)故障的產(chan)生。

(3)自動超聲探傷系統(tong)設計方案簡潔，系統(tong)控制(zhi)硬件結構(gou)簡單，成本(ben)較低(di)，配(pei)合操作監控觸摸屏，使工作效(xiao)率得到提高，系統(tong)具有控制(zhi)穩定(ding)、可靠高的特點，具有良好的實際應用性。