| Shaped wire has been widely used in various fields because of its special shape characteristics and excellent mechanical properties.At present,our steel wire manufacturers are still using traditional manual measurement methods such as vernier calipers to detect shaped wires.This method has low detection efficiency,only part of the data can be measured for complex sections,and the wire section data cannot be obtained online,resulting in the inability to form real-time feedback on production,and further unable to achieve automatic production adjustment,process iteration and optimization.This thesis takes trapezoidal steel wire as the object,developed a set of online detection system of shaped wire size.It can detect the size of shaped wire quickly and accurately,laying the foundation for the analysis of production status and the realization of intelligent steel wire production.The main research contents of this paper are as follows:1.The commonly used measurement methods are investigated comprehensively,and line laser non-contact measurement is selected.Combined with the cross-sectional characteristics of the trapezoidal steel wire,this thesis proposed and designed a measurement scheme of a detection system composed of four sensors,and built an experimental test platform.2.The measurement error of the detection system is analyzed.The measurement error caused by the tilt of the sensor installation angle,which has the greatest influence on the measurement results,is mainly studied.A coordinate value error compensation model based on the inclination of α and β around the x and y axes is established.The results show that the error between the α and β values calculated by this method and the actual value is less than 0.15° under the condition that the measurement accuracy of the trapezoidal steel wire is satisfied,the influence on the measurement value is less than 0.001 mm,which can eliminate the influence of installation error on the measurement result.The practicability of the error compensation method is verified.3.Combined with the profile features of the trapezoidal steel wire,the measurement data are preprocessed,feature point identification and contour fitting are processed,and the dimension measurement of the trapezoidal steel wire is realized.The accuracy comparison test shows that the difference between the measured value of the vernier caliper before the angle compensation is not added is about 16 μm,and the difference is reduced to less than 4 μm after the angle compensation is added,which greatly reduces the measurement error caused by the angle installation of the sensor.The standard deviation of the measurement results of 40 repeated tests is about 2 μm,which verifies that the system not only meets the detection requirements of ±0.02 mm steel wire,but also has good feasibility and stability,and can well realize the online measurement of special-shaped steel wire.4.The software platform of the online detection system is designed and developed.Using C#,MATLAB and SQL Server database technology,the development of the online detection system for the section size of shaped steel wire is completed.The software system mainly includes six functional modules: login management,equipment connection,calibration and correction,dimension measurement,quality management,and information input,which makes the inspection system more operable,improves the factory’s management of steel wire quality,and lays a foundation for the data provenance of shaped steel wire size detection. |
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