基于激光位移传感器阵列的波纹板质量检测系统设计

Based on Laser Displacement Sensor Array Design of Corrugated Plate Quality Detection System

  • 摘要: 板式换热器的波纹板片作为换热核心组件,其质量直接影响设备性能。当前国内普遍采用的人工检测,并结合百分表测量及手持超声检测等离散方法,对制造过程中厚度减薄、微裂纹等高发缺陷缺乏系统性检测方案,存在效率低、精度差、抽样覆盖率不足的问题。为解决上述问题,设计高精度双激光位移传感器阵列及合理的机械随动机构,对称逐行扫描获取换热器板片数据,结合几何算法实现表面三维形貌重构与实际厚度计算,完成全板面质量检测。实验验证表明,该监测系统的波纹深度检测精度达±5 μm,实现100%全板面0.5 mm×0.5 mm点阵扫描,检测精度可达0.01 mm,能精准识别压制缺陷等问题,大幅提升检测效率与精度,推动换热器制造行业智能化检测转型,为过程工业装备质量管控提供创新方案。

     

    Abstract: As the core component of heat exchange, the quality of corrugated plate of plate heat exchanger directly affects the performance of the equipment. At present, the widely used manual detection in China, combined with the discrete methods such as dial indicator measurement and handheld ultrasonic detection, lacks a systematic detection scheme for the high incidence defects such as thickness thinning and microcracks in the manufacturing process, which has the problems of low efficiency, poor accuracy and insufficient sampling coverage. In order to solve the above problems, a high-precision double laser displacement sensor array and a reasonable mechanical follow-up mechanism were designed. The heat exchanger plate data were obtained by symmetrical progressive scanning. Combined with the geometric algorithm, the three-dimensional surface morphology reconstruction and the actual thickness calculation were realized, and the whole plate surface quality detection was completed. The experimental verification shows that the detection accuracy of the ripple depth of the monitoring system is±5μm, the detection accuracy can reach 0.01 mm, and the detection accuracy can reach 0.5 mm×0.5 mm dot matrix scanning of 100% of the whole plate surface. It can accurately identify pressing defects and other problems, significantly improve the detection efficiency and accuracy, promote the intelligent detection transformation of the heat exchanger manufacturing industry, and provide innovative solutions for the quality control of process industrial equipment.

     

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