CN111815286A - Welding process information system - Google Patents
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Abstract
The invention provides a welding process information system for welding process management and welding quality monitoring of ship manufacturing, which comprises: the device comprises a welding process database, a welding process expansion database, a condition query module, a neural network learning module, an input module and an output module; the neural network learning module is used for generating welding process information which is not stored in the welding process database and the welding process expansion database according to the input information of the condition query module; and the output module outputs the sequentially generated welding process planning book, the welding process test report and the welding process procedure so as to be butted with an enterprise production management system. The system realizes the digitization of ship production and manufacturing, and realizes the fitting and simulation of the welding process through the neural network learning module, so as to solve the technical problems of low paper process evaluation efficiency, high welding process evaluation cost and low utilization efficiency of welding process files.
Description
Technical Field
The invention relates to the field of welding process management, in particular to a welding process information system.
Background
The traditional digital welding process information system integrates welding specifications of different welding base metal materials and thicknesses under different welding methods, such as welding current, welding voltage and welding speed, and meanwhile, the welding process information system provides welding working hours and welding consumable consumption according to the welding specifications. The method is mainly used for data storage of welding production process, evaluation of welding process, welding working hours and statistics of welding production consumable cost. But has the following disadvantages: the traditional welding process information system is limited in the digital technical level at the time, and has limited interaction with data input/output of an upstream design end and an output end of downstream production application, so that an information isolated island is formed; the shipbuilding industry has large welding process information amount, various material types and multiple specifications, and lacks of professional welding process information system application of the ship industry; the welding process information relates to the contents of three procedures, namely a welding process planning book, a welding process test report and a welding process rule, and the procedures lack data correlation and are easy to make mistakes.
Disclosure of Invention
In view of the above defects in the prior art, the present invention aims to provide a welding process information system for welding process management and welding quality monitoring in the ship manufacturing industry, which realizes the digitization of ship production and manufacturing, and solves the technical problems of low paper process evaluation efficiency, high welding process evaluation cost and low utilization efficiency of welding process files.
In order to achieve the above object, the present invention provides a welding process information system, comprising: the device comprises a welding process database, a welding process expansion database, a condition query module, a neural network learning module, an input module and an output module;
the welding process database is used for storing welding process information which is certified by a classification society;
the welding process expansion database is used for storing welding process information which is based on the welding process database, learned through a neural network module and verified through a process test;
the condition query module is used for retrieving welding process information of a welding process database to output a welding process procedure file of a segmented structure project;
the neural network learning module is used for generating welding process information which is not stored in the welding process database and the welding process expansion database according to the input information of the condition query module;
the input module is used for butting a product data management system and a production design system to form a welding process procedure list of a segmented structure and a whole ship structure;
the output module is used for outputting welding process files of the segmented structure and the whole ship structure, the welding process files comprise a welding process planning book, a welding process test report and a welding process rule which are sequentially generated, and the welding specification in the welding process rule provides an enterprise production management system for monitoring production quality.
Further, the welding process database comprises parent metal information, a test item module and welding process information which pass classification society authentication, wherein the parent metal information comprises parent metal material and type and tube/plate thickness of parent metal; the content of the welding process information comprises: the welding method, the type and specification of welding materials, the welding current, the welding voltage, the welding speed, the type and flow of protective gas, the welding position, the groove form, the welding bead and welding seam arrangement form and the type and polarity of a welding power supply; the test item module includes a non-destructive inspection item module and a destructive test item module.
Further, the query condition of the condition query module includes: base material and type, pipe/plate thickness of base material, welding method, welding position, and applicable ship class.
Further, the content of the welding process plan includes: the material and the variety of the base metal, the application range of the welding process and the range of welding standard parameters; wherein the content of the first and second substances,
the welding process has the following application range: the method is suitable for ship grades, pipe/plate thickness ranges and welding position coverage ranges;
the weld specification parameter ranges include: the type and specification of welding material, welding method, welding position, groove form, weld bead and weld bead arrangement form.
Further, the contents of the welding process test report comprise an outline, a welding specification and a test item; the general content comprises a joint type, a groove form, a welding seam and welding bead arrangement form, the type and specification of welding materials, the type of parent metal materials, a welding position, pre-welding preheating and post-welding heat treatment and liner materials, and is directly generated by corresponding data in a welding process plan book, wherein the liner materials are manually input;
the welding standard is divided into three different welding work sequences of bottoming, filling and capping, and each data column is increased or decreased according to the process test condition; in the data column, the welding current of the welding specification generates data by the relation including the thickness of the pipe/plate and the welding current, and the data is used as a welding process test reference; updating according to the test result;
the test items of the welding process test report are subjected to menu-type designation through a welding process schedule book, and the test items in the welding process schedule book are selected from the test items in the welding process database.
Furthermore, the test items comprise one or more of a tensile test, a bending test, an impact toughness test, a hardness test, a metallographic test and a chemical composition test, and test data are manually input after the actual welding process test and are subjected to average calculation according to requirements.
Further, the welding process procedure file comprises basic information, a base metal, a filling metal module and welding parameters;
the joint type, the welding method, the groove form, the welding bead information and the gasket material in the basic information are directly obtained from the information reported by the welding process test;
the thickness range and the welding position of the pipe/plate in the basic information are automatically generated according to the requirements of welding specifications and the corresponding plate/pipe thickness and welding position in a welding process test report;
the information of the base metal and the filler metal modules is directly generated from the corresponding data in the welding process test report.
Further, the welding parameters comprise welding current, welding voltage, welding speed, gas flow, welding material grade, welding material specification and welding heat input quantity, and the welding parameters are calculated and generated by corresponding data in a welding process test report through a built-in formula. .
Further, the neural network learning module is used for generating welding specification data of a welding process database, when a newly generated welding process plan relates to the thickness which is not available in the established welding process database, the existing thickness in the welding process database is searched according to the type, the strength level and the welding method of the new material, the sigmoid function in the neural network is adopted to learn the corresponding relation between the existing thickness and the corresponding welding current, welding voltage and welding speed of the existing thickness under the condition of the new material thickness, the welding current, the welding voltage and the welding speed corresponding to the new material thickness are generated, and the welding current, the welding voltage and the welding speed are provided for reference of the welding specification parameters in the welding process plan.
Furthermore, the digital welding process information system is a welding process information system based on a Web server and a MySQL database management system, and operators perform operations such as query, addition, deletion and the like on the welding process database and the welding process expansion database through the database management system according to respective management authorities and output a welding process plan, a welding process test report and a welding process rule through an output module.
The invention realizes the following technical effects:
the invention provides a welding process information system for welding process design and management and welding quality monitoring in the ship manufacturing industry, which realizes ship production and manufacturing digitization and realizes fitting and simulation of a welding process through a neural network learning module, so as to solve the technical problems of low paper process evaluation efficiency, high welding process evaluation cost and low utilization efficiency of welding process files. The method has the advantages that the welding process design of the ship sectional product in the upstream of production, the welding quality monitoring data in the production process and the management work of the welding production cost data are connected, and the problem of isolated island of the welding process information is solved.
Drawings
FIG. 1 is a block diagram of a welding process information system of the present invention;
FIG. 2 is an integrated block diagram of a welding process information system of an embodiment of the present invention;
FIG. 3 is a query flow of the welding process information system of the present invention;
FIG. 4 is a query interface of a welding process database of the welding process information system of an embodiment of the present invention;
fig. 5 is a menu-type designation of a welding process experiment in a welding process schedule of an embodiment of the present invention.
Detailed Description
To further illustrate the various embodiments, the invention provides the accompanying drawings. The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the embodiments. With these references, one of ordinary skill in the art will appreciate other possible implementations and advantages of the present invention. Elements in the figures are not drawn to scale and like reference numerals are generally used to indicate like elements.
The invention will now be further described with reference to the accompanying drawings and detailed description.
The invention discloses a welding process information system based on a Web server and a MySQL database management system, which comprises a welding process database, a welding process expansion database, a condition query module, a neural network learning module, an authority management module, an input module and an output module, as shown in figure 1.
An operator inquires, adds, deletes and the like the welding process database and the welding process expansion database through the database management system according to respective management authority, and outputs welding process files of a segmented structure and a whole ship structure through an output module, wherein the welding process files comprise a welding process plan, a welding process test report and a welding process rule which are sequentially generated, the welding rule in the welding process rule is provided for an enterprise production management system MES for production quality monitoring, and simultaneously, the welding process database regulates the format and format conversion of each data module at an input module so as to butt joint a product data management system PDM and a production design system such as a Tribon/AM12 and the like to form a welding process rule list of the segmented structure and the whole ship structure, thereby realizing digital management of the welding process of the ship, realizing digital shipbuilding. As shown in fig. 2.
(1) Intelligent management of welding process database
The welding process database contains all shipyard certified welding processes. The database structure parameters of the welding process database include: the type and specification of welding materials, welding current, welding voltage, welding speed, type and flow of shielding gas, welding position, groove form, welding bead and welding seam arrangement form, type and polarity of welding power supply and the like.
The welding process database also comprises three sublibraries of ship and ocean engineering materials, welding methods, test projects and the like related to the specifications of the mainstream classification society (CCS of China classification society, DNV of Norwegian classification society and ABS of U.S. classification society).
In this embodiment, the present welding process information system accesses the data of the welding process database through Web queries.
(a) The conditional query of the welding process database typically includes: the material and the type of the base metal, the pipe/plate thickness of the base metal, the welding method, the welding position, the applicable ship class and other parameters.
When the input condition queries the database, if the welding process database has corresponding process data, the data columns or data blocks with the same pointer number are found in the output database through the pointer number, and the normative data records in the welding process database are output to form a welding process plan book. As shown in fig. 1.
When the welding process database does not have the required welding process, a neural network learning module is needed to establish a new welding process plan book, and then a process test is used for verification so as to perfect the welding specification in the welding process plan book, as shown in fig. 1.
(b) The welding process plan contains: material and type of parent metal, application range of welding process, welding specification parameter range and the like. Wherein:
the welding process has the following application range: the thickness range and the welding position coverage range of the tube/plate in the newly generated welding process plan can be automatically generated according to the welding specification of the applicable ship class.
The weld specification parameter ranges include: the model and specification of welding materials, a welding method, a welding position, a groove form, a welding seam, a welding bead arrangement form and other information are fitted and simulated according to the base metal material and type, the welding method and a neural grid learning module which is suitable for the ship class and the corresponding relation between the thickness of the base metal pipe/plate and the welding specification in a welding process database, and standard parameters corresponding to the thickness of the pipe/plate are output to a newly generated welding process plan book to form a new welding specification module. As shown in fig. 4.
And automatically generating the groove form, the welding seam and the welding bead arrangement form of the newly generated welding process plan according to the applicable ship-level welding specification.
And the welding process experiment items of the newly generated welding process plan book are specified in a menu mode. As shown in fig. 5. The menu-type designated welding process experimental items appear in the welding process experimental report. The menu items of the welding process experimental items are determined by the material and the type of the parent metal and the supply state thereof according to the applicable ship-level specification.
(c) The welding process test report contains an overview, welding specifications and three pieces of test content.
The contents of the profile include: the welding process comprises the following steps of (1) information such as a joint type, a groove diagram, a weld bead arrangement and welding sequence diagram, the type and specification of welding materials, the material and type of parent metal, a welding position, pre-welding preheating, post-welding heat treatment, a lining material and the like, wherein the content in the general diagram is directly generated from the corresponding content of a welding process plan, and the lining material is manually input.
The welding standard is divided into three different welding work sequences of bottoming, filling and capping, and each data column can be increased or decreased according to the process test condition; in the data column, the welding current of the welding specification can generate data by the relation between the thickness of the pipe/plate and the welding current, and the data is used as a welding process test reference; and then manually updating according to the test result.
The test items of the welding process test report are subjected to menu-type designation through a welding process schedule book, and the test items in the welding process schedule book are selected from the test items in the welding process database.
The test items in the welding process test report comprise: destructive test items such as a tensile test, a bending test, an impact toughness test, a hardness test and the like and non-destructive test items such as a visual inspection, a metallographic test, a chemical composition test and the like, wherein each test item has standard operation specifications and is set and called in a module mode, test data is manually input after an actual welding process test, and averaging calculation is carried out according to requirements.
(d) And after the new welding process passes simulation and test verification, forming a new welding process procedure file. The welding process procedure file comprises a basic information module, a base metal and filling metal module, a welding parameter module and other information modules. Wherein:
the joint type, welding method, groove form, welding bead information, liner material and other information in the basic information module are directly led out from a welding process test report; and the thickness range and the welding position of the pipe/plate in the basic information module are automatically generated according to the welding specification requirement and the corresponding pipe/plate thickness information in the welding process test report.
The information of the base metal and the filler metal modules is directly generated from the corresponding data in the welding process test report.
The welding parameter module information is automatically generated after formula calculation by combining the contents of welding current, voltage, advancing speed and the like of welding standard parameters in a welding process test report and the applicable ship-level standard requirements. The welding specification comprises welding current, welding voltage, welding speed, gas flow, welding material grade, welding material specification and welding heat input quantity, and the welding parameters are calculated and generated by a built-in formula according to corresponding data in a welding process test report.
The newly generated welding process procedure file is numbered and then directly stored in a welding process database, so that the complexity and errors of manual input operation are avoided.
And comparing the welding process data in the newly generated welding process procedure file with the inventory process data to avoid the coverage and loss of the inventory data.
The neural network learning module is used for generating welding specification data of the welding process database, when a newly generated welding process plan relates to the thickness which does not exist in the established welding process database, the existing thickness in the welding process database is searched according to the type, the strength level and the welding method of the new material, the sigmoid function in the neural network is adopted under the condition of the new material thickness, the corresponding relation between the existing thickness and the corresponding welding current, welding voltage and welding speed is learned, the welding current, the welding voltage and the welding speed which correspond to the new material thickness are generated, and the welding specification parameters are provided for reference in the welding process plan.
(e) Linking between three files
And (4) specifying the type of the welding process test by the welding process planning book, and generating a test sample and a test result to be recorded in a welding process test report.
The data in the welding process planning book is specified and relevant data columns in the welding process experimental report are generated.
(2) And (3) managing the authority of the operator:
for data security and responsibility attribution, the welding process information system is entitled to use according to different grading authorities through the authority management module.
The operators of the welding process information system comprise designers and production quality managers, the whole authority level adopts a project management mode with design authority, use authority, inquiry authority and management authority, and the operators related to the project are configured with different authority levels to respectively provide different authorities for inquiring, designing and calling the process database.
Wherein, the personnel with the design authority level export the data related to the current production and design in the welding process database, and establish a 'project management' module.
Related designers and production quality managers are set as personnel with use authority and inquiry authority. The personnel with the authority can view and use the welding process record in the module library through the 'project management' module. By adopting a project management mode, the management efficiency of the welding process library such as data query and export can be improved.
The welding process management personnel with the management authority has the authority of increasing, decreasing and maintaining the process record bars of the database, and can directly operate the welding process database.
(3) Manual capacity expansion of the new process procedure:
the data is based on the latest specifications of the three-great classification society. With the emergence of new materials and new welding methods, a welding process database can be expanded to adapt to the development of shipbuilding welding technology, and a welding process expansion database is additionally built based on a web server and a MySQL database management system. When the material major category is recorded in the welding process database and only lacks the material minor category and the new welding method, the welding method or the material minor category which is not in the welding process database is inquired, the welding method or the material minor category enters the material basic database in the welding process expansion database for searching, and the data confirmed by each classification society is found. If there is still no relevant data in the base data sub-library, it may be added to the sub-library and then added to the welding process database in the form of a new process after the process design is completed.
The advantages are that:
1) the work cost of the welding process of the shipyard is reduced, and when a new project is set, repeated welding test work can be avoided by quickly inquiring the welding process rules;
2) the work efficiency of the welding process of the shipyard is improved, the welding process plan book of the newly-built project, the welding process test report and the process data of the welding process procedure are correlated, the work efficiency is improved, and data entry errors are avoided;
3) the welding process data management program is standardized, the paper process data is changed into electronic records, and the welding process data is convenient to manage through authority distribution in the process of using the process data;
4) and the data information island is broken through, and the simulation software is communicated with upstream and downstream software, so that the data flow of enterprise production management MES, cost control PDM and production design Tribon/AM12 is communicated, and the digital shipbuilding is realized.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (10)
1. A welding process information system, comprising: the device comprises a welding process database, a welding process expansion database, a condition query module, a neural network learning module, an input module and an output module;
the welding process database is used for storing welding process information which is certified by a classification society;
the welding process expansion database is used for storing welding process information which is based on the welding process database, learned through a neural network module and verified through a process test;
the condition query module is used for retrieving welding process information of the welding process database to output a welding process procedure file of a segmented structure project;
the neural network learning module is used for generating welding process information which is not stored in the welding process database and the welding process expansion database according to the input information of the condition query module;
the input module is used for butting a product data management system and a production design system to form a welding process procedure list of a segmented structure and a whole ship structure;
the output module is used for outputting welding process files of the segmented structure and the whole ship structure, the welding process files comprise a welding process planning book, a welding process test report and a welding process rule which are sequentially generated, and the welding specification in the welding process rule is provided for an enterprise production management system to be used for monitoring the production quality.
2. The welding process information system of claim 1, wherein the welding process database comprises parent metal information including parent metal material and kind, pipe/plate thickness of parent metal, test item modules, and welding process information certified by classification society; the content of the welding process information comprises: the welding method, the type and specification of welding materials, welding current, welding voltage, welding speed, the type and flow of protective gas, welding position, groove form, welding bead and welding seam arrangement form and the type and polarity of a welding power supply; the test item module includes a non-destructive inspection item module and a destructive test item module.
3. The welding process information system of claim 2, wherein the query conditions of the condition query module comprise: base material and type, pipe/plate thickness of base material, welding method, welding position, and applicable ship class.
4. The welding process information system of claim 2, wherein the content of the welding process schedule comprises: the material and the variety of the base metal, the application range of the welding process and the range of welding standard parameters; wherein the content of the first and second substances,
the welding process has the following application range: the method is suitable for ship grades, pipe/plate thickness ranges and welding position coverage ranges;
the weld specification parameter ranges include: the type and specification of welding material, welding method, welding position, groove form, weld bead and weld bead arrangement form.
5. The welding process information system of claim 2, wherein the contents of the welding process test report comprise profiles, welding specifications, and test items; the general content comprises a joint type, a groove form, a welding seam and welding bead arrangement form, the type and specification of welding materials, the type of parent metal materials, a welding position, pre-welding preheating, post-welding heat treatment and a lining material, and is directly generated by corresponding data in a welding process plan book, wherein the lining material is manually input;
the welding standard is divided into three different welding work sequences of bottoming, filling and capping, and each data column is increased or decreased according to the process test condition; in the data column, the welding current of the welding specification generates data by the relation between the thickness of the pipe/plate and the welding current, and the data is used as a welding process test reference; updating according to the test result; and the test items of the welding process test report are subjected to menu-type designation through a welding process schedule book, and the test items in the welding process schedule book are selected from the test items in the welding process database.
6. The welding process information system of claim 5, wherein the test items comprise one or more of tensile tests, bending tests, impact toughness tests, hardness tests, metallographic tests and chemical composition tests, and test data is manually input after actual welding process tests and averaged as required.
7. The welding process information system of claim 2, wherein the welding process specification file comprises basic information, parent and filler metal modules, and welding parameters;
the joint type, the welding method, the groove form, the welding bead information and the gasket material in the basic information are directly obtained from the information reported by the welding process test;
the thickness range and the welding position of the pipe/plate in the basic information are automatically generated according to the welding specification requirement and the corresponding thickness range and welding position of the pipe/plate in the welding process test report;
the information of the base metal and the filler metal module is directly generated by corresponding data in a welding process test report.
8. The welding process information system of claim 7, wherein the welding parameters comprise welding current, welding voltage, welding speed, gas flow, grade of welding material, specification of welding material, and welding heat input, and wherein the welding parameters are calculated from corresponding data in a welding process test report by a built-in formula.
9. The welding process information system of claim 1, wherein the neural network learning module is configured to generate welding specification data for the welding process database, and when a newly generated welding process schedule relates to an absent thickness in the established welding process database, search for an existing thickness in the welding process database according to a type, an intensity level, and a welding method of a new material, and learn a correspondence between the existing thickness and a corresponding welding current, a corresponding welding voltage, and a corresponding welding speed using a sigmoid function in the neural network on the basis of the new material thickness to generate a welding current, a corresponding welding voltage, and a corresponding welding speed corresponding to the new material thickness, which are provided to the welding specification parameter reference in the welding process schedule.
10. The welding process information system according to any one of claims 2-9, wherein the welding process information system is a welding information management system based on a Web server and a MySQL database management system, and the operator performs operations such as query, addition, deletion, and the like on the welding process database and the welding process expansion database through the database management system according to the respective management authority, and outputs a welding process plan book, a welding process test report, and a welding process schedule through the output module.
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