CN112184473A - Intelligent forming workshop for multi-specification marine pipes and control method - Google Patents

Intelligent forming workshop for multi-specification marine pipes and control method Download PDF

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CN112184473A
CN112184473A CN202010883593.6A CN202010883593A CN112184473A CN 112184473 A CN112184473 A CN 112184473A CN 202010883593 A CN202010883593 A CN 202010883593A CN 112184473 A CN112184473 A CN 112184473A
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唐文献
王为民
林洪才
张建
苏世杰
杭世峰
陶志高
王月阳
郭胜
林剑波
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Jiangsu Hefeng Mechanical Making Co ltd
Zhenjiang Yucheng Intelligent Equipment Technology Co ltd
Jiangsu University of Science and Technology
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Jiangsu Hefeng Mechanical Making Co ltd
Zhenjiang Yucheng Intelligent Equipment Technology Co ltd
Jiangsu University of Science and Technology
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Abstract

The invention relates to an intelligent forming workshop for multi-specification marine pipes and a control method, wherein the intelligent forming workshop for multi-specification marine pipes comprises a pretreatment processing area and a processing station area which are sequentially arranged on a production line, a raw material storage area is arranged at the upstream of the production line, and a storage area for storing semi-finished pipe products, finished pipe products and flanges is arranged at one side of the production line; the intelligent control system sends control signals to the raw material storage area, the pretreatment processing area and the processing station area to realize the taking and processing of the multi-specification pipes, and simultaneously sends control signals to the transportation system to realize the transportation and the transfer of the multi-specification pipes on a transportation line; the invention can make an optimal scheduling strategy according to the order, monitor the fault of the whole workshop and is beneficial to the information management of the intelligent forming workshop of the marine pipes with multiple specifications.

Description

Intelligent forming workshop for multi-specification marine pipes and control method
Technical Field
The invention relates to an intelligent forming workshop for multi-specification marine pipes and a control method, and belongs to the field of pipe processing.
Background
The intelligent workshop is a workshop for realizing the self-organizing production of automatic decision and accurate execution commands by realizing interconnection and intercommunication of automatic equipment (production equipment, detection equipment, transportation equipment, mechanical arms and the like) through a network and software management system to achieve the sensing state (information of production requirements, equipment, production processes and the like) and real-time data analysis; in the process of shipbuilding, the processing and manufacturing of pipes are an important link in the production organization of a shipyard. According to statistics, the using amount of the steel ship pipes is huge, the using amount of 20 ten thousand tons of oil tanker pipes exceeds 2 ten thousand, so that the processing workload of the pipes is huge, especially when a plurality of ships are built simultaneously, the processing task of a pipe production workshop is aggravated, the pipe processing workshop is very easy to be in a disordered state, the pipe processing workshop becomes a development bottleneck of a shipbuilding enterprise, and the development of the shipbuilding enterprise towards an intelligent direction is restricted.
The ships are customized products, and the materials of the used pipes are different in different types, even for each ship, such as steel pipes, aluminum pipes, copper pipes, bimetallic pipes and the like, and meanwhile, the specifications of the pipes used by different ships are different, such as the nominal diameter of a seamless steel pipe is 10-300 mm, and the wall thickness is 2-8 mm; the nominal diameter of the welded steel pipe is 10-140 mm, and the wall thickness is 0.5-5.5 mm; the nominal diameter of the low-pressure fluid conveying pipe is 15-150 mm, and the wall thickness is 2.75-4.5 mm; the outer diameter of the aluminum pipe is 6-50 mm, and the wall thickness is 0.5-5 mm; the outer diameter of the bimetallic tube is 6-70 mm, and the wall thickness is 1.5-6 mm. The marine pipe has the characteristics of multiple forming size specifications, wide wall thickness range, multiple material varieties and large material difference.
The characteristics of the marine pipe enable the existing marine pipe forming workshop to have the following problems:
the method has the advantages that the types of the pipes in the order are numerous, and due to the fact that a reasonable and effective intelligent scheduling method is lacked in a pipe machining workshop, pipe machining consumes long time, the order cannot be completed according to the delivery date, and the order overstock is caused. The intelligent workshop-based mobile multi-agent real-time scheduling system disclosed in patent ZL201710282923.4 describes a general scheduling system and method for an intelligent workshop, and does not give an objective function to be optimized how to determine a scheduling strategy, and is not suitable for scheduling a complex pipe intelligent forming workshop; the intelligent factory workshop real-time dispatching system disclosed in patent ZL201610403522.5 also describes a dispatching system of a general factory workshop, and is not suitable for a marine pipe forming workshop with various pipe types and forming processes.
The existing marine pipe forming workshop lacks a necessary workshop fault monitoring system and a necessary workshop fault processing method, so that when a certain device breaks down, maintenance personnel are required to spend a large amount of time to confirm fault reasons and maintain, and further the processing progress of the workshop is influenced. The microinverter fault detection method based on the neural network expert system described in patent ZL103293415B describes a fault detection method of microinverters by the neural network expert system, but the method lacks a detailed construction process of the neural network expert system.
In addition, the existing pipe forming workshop for the ship in service also has the problems that the production workshop cannot realize information management, enterprise information integration is difficult and the like due to the lack of a relevant data acquisition and effective information management system in the machining process.
Disclosure of Invention
The invention provides an intelligent forming workshop for multi-specification marine pipes and a control method, which can make an optimal scheduling strategy according to an order, monitor faults of the whole workshop and facilitate information management of the intelligent forming workshop for the multi-specification marine pipes.
The technical scheme adopted by the invention for solving the technical problems is as follows:
an intelligent forming workshop for multi-specification marine pipes comprises a pretreatment processing area and a processing station area which are sequentially arranged on a production line, a raw material storage area is arranged at the upstream of the production line, and a storage area for storing semi-finished pipes, finished pipes and flanges is arranged at one side of the production line;
the intelligent control system sends control signals to the raw material storage area, the pretreatment processing area and the processing station area to realize the taking and processing of the multi-specification pipes, and simultaneously sends control signals to the transportation system to realize the transportation and the transfer of the multi-specification pipes on a transportation line;
as a further preferred aspect of the present invention, the raw material storage area is provided with a raw material storage area for storing the multi-specification pipes in a classified manner, and the raw material storage area transports the raw materials by a traveling crane;
the intelligent control system comprises a master control system, an MES system, a shared cloud and a monitoring system which are mutually communicated, wherein the master control system regulates and controls the MES system, the shared cloud and the monitoring system;
the general control system comprises an analysis and calculation module, an instruction sending module and a condition judgment module, wherein the analysis and calculation module acquires signals from a raw material storage area, a pretreatment processing area, a processing station area and a transportation system for analysis, the instruction sending module sends the received signals to the analysis and calculation module and sends an execution instruction to the raw material storage area, the pretreatment processing area, the processing station area and the transportation system, and the condition judgment module judges the quality of a product;
the MES system comprises a production scheduling module, a data acquisition module, a quality management module, a warehouse management module, an order management module and an equipment management module, wherein the production scheduling module is used for scheduling production programs in a workshop, the data acquisition module is used for collecting production information in the workshop, the quality management module is used for managing the quality of products, the warehouse management module is used for managing a raw material storage area and a warehousing system in the workshop, the order module is used for managing the order information of the products, and the equipment management module is used for managing equipment in the workshop;
the sharing cloud comprises an RFID information storage module, a processing data storage module, an equipment monitoring data storage module and a load data storage module, wherein the RFID information storage module is used for storing RFID scanning information, the processing data storage module is used for storing processing data in a workshop, the equipment monitoring data storage module is used for storing equipment monitoring data in the workshop, and the load data storage module is used for storing load data in the workshop;
the monitoring system is used for monitoring each part in the workshop;
as a further preferable aspect of the present invention, the pretreatment processing area includes a feeding conveyor line, a first straightening device, a second straightening device, a first cutting device, a second cutting device, a first detecting device, a second detecting device, a semi-finished product temporary storage area, and a first defective storage area, wherein the feeding conveying line is positioned at the upstream of the production line, a first straightening device, a first cutting device and a first detection device are sequentially arranged at one side of the production line, a second straightening device, a second cutting device and a second detection device are sequentially arranged at the other side of the production line, the first straightening device and the second straightening device, the first cutting device and the second cutting device, and the first detection device and the second detection device are symmetrically arranged, the feeding conveying line also comprises a first manipulator, the first manipulator clamps and transfers the detected unqualified products to a first unqualified storage area;
as a further preferred aspect of the present invention, the storage system includes a tray storage area, a first RFID scanner, a flange storage area, a semi-finished tube product storage area, and a finished tube product storage area, wherein a plurality of trays are placed in the tray storage area, the first RFID scanner is configured to scan and record information of the trays, a first buffer area is disposed at an entrance of the flange storage area, a second buffer area is disposed at an entrance of the semi-finished tube product storage area, a third buffer area is disposed at an entrance of the finished tube product storage area, the transport system transports the trays to the corresponding buffer areas, and transports corresponding products in the flange storage area, the semi-finished tube product storage area, and the finished tube product storage area to the corresponding buffer areas, a first tube material gripping device is disposed in the first buffer area, and grips and places the flange in the tray in the first buffer area, and a second tube material gripping device is disposed in the second buffer area, the pipe semi-finished product is grabbed and placed in the material tray positioned in the second cache area, and a third pipe grabbing device is arranged in the third cache area and used for grabbing the pipe finished product and placing the pipe finished product in the material tray of the third cache area;
as a further preferred aspect of the present invention, the machining station area includes a bending machining area, a groove machining area, a shrinking or flaring machining area, a welding machining area, and a two-dimensional code spraying area, and is further equipped with a second RFID scanner, and a tray containing products is scanned by the second RFID scanner and then distributed to each area in the machining station area by a transportation system;
the bending processing area comprises a first pipe bending device, a second pipe bending device, a first processing cache area and a first unqualified storage area, the conveying system conveys qualified products to the first processing cache area from the matching area, the second mechanical arm clamps the products to the first pipe bending device and the second pipe bending device from the first processing cache area for bending processing, and then clamps and places the unqualified products after bending processing into the second unqualified storage area;
the groove processing area comprises a first groove device, a second processing cache area and a second unqualified storage area, the transportation system conveys the qualified products to the second processing cache area from the matching area, and the third manipulator clamps the products to the first groove device and the second groove device from the second processing cache area for groove processing and then clamps and places the unqualified products subjected to groove processing into the third unqualified storage area;
the shrinking or flaring processing area comprises a first shrinking or flaring device, a second shrinking or flaring device, a third processing cache area and a third unqualified storage area, qualified products are conveyed to the third processing cache area from the storage system by the matching area, and after being clamped to the first shrinking or flaring device and the second shrinking or flaring device from the third processing cache area by the fourth mechanical hand for shrinking or flaring, the unqualified products after shrinking or flaring are clamped and conveyed to the fourth unqualified storage area;
the welding processing area comprises a first welding device, a second welding device, a fourth processing cache area and a fourth unqualified storage area, the conveying system conveys qualified products to the fourth processing cache area from the matching area, and the fifth manipulator clamps the products from the fourth processing cache area to the first welding device and the second welding device for welding treatment and then clamps and conveys unqualified products to the fifth unqualified storage area;
the two-dimensional code spraying area comprises a first two-dimensional code spraying device, a second two-dimensional code spraying device and a fifth worker cache area, the transportation system conveys the qualified products to the fifth worker cache area from the matching area, and the sixth manipulator clamps the products to the first two-dimensional code spraying device and the second two-dimensional code spraying device from the fifth worker cache area for spraying;
as a further preferred aspect of the present invention, the transportation system includes a first AGV cart and a second AGV cart, and further includes a charging area for charging the first AGV cart and the second AGV cart;
as a further preferable aspect of the present invention, a laser displacement sensor is mounted on the first detection device and the second detection device, an angle sensor, a torque sensor and a first scanner are mounted on the first pipe bending device and the second pipe bending device, a second scanner, a pressure sensor and a displacement sensor are mounted on the first reducing or flaring device and the second reducing or flaring device, a speed sensor, a third scanner and a surface roughness meter are mounted on the first beveling device and the second beveling device, and a voltage sensor, a current sensor and an ultrasonic nondestructive inspection instrument are mounted on the first welding device and the second welding device;
a control method for an intelligent forming workshop for multi-specification marine pipes based on any claim is divided into two parts, wherein the first part is a dispatching method, the second part is a fault detection method,
the scheduling method specifically comprises the following steps:
the first step is as follows: receiving order in workshop
Step 1.1, receiving an nth batch of pipe processing order by a multi-specification marine pipe intelligent forming workshop, wherein n is more than or equal to 2, and the content of the pipe processing order comprises an order, a delivery date, required pipe specifications, a processing procedure, welding flange information and required quantity;
step 1.2, the warehouse management module acquires addresses stored in an RFID chip of a material tray which is positioned in a storage system and is in an empty state through a first RFID scanner;
step 1.3, the order management module generates a processing technology file of each pipe according to the order content received by the workshop and writes the processing technology file into the acquired storage address;
the second step is that: obtaining workshop status information
The equipment management module acquires the state of each processing equipment in the workshop, wherein the state comprises the equipment type, the equipment performance, the current working state of the equipment and the current load capacity of the equipment;
the third step: scheduling order content according to processing equipment status
Step 3.1, determining the time required for processing the order content, acquiring the type of the specification of the order processed pipe by the master control system through the order management module, and calculating the time required for processing all types of pipes to finish all procedures by the analysis and calculation module;
step 3.2, determining the waiting time of the nth batch of order, and calculating the time required by the processing of all kinds of pipes in the order by an analysis and calculation module;
3.3, determining the pipe transportation time, acquiring the loading information of the processing equipment aiming at the pipes with different specifications from the loading data storage module by the master control system according to the pipe specifications, calculating the transportation distance, the required transportation times and the required transportation time of each specification of the pipe between each processing equipment and storage by the analysis and calculation module, and finally acquiring the transportation time required by all kinds of pipes in the order;
step 3.4, determining the total time required by order processing;
3.5, determining an optimal scheduling strategy, wherein the production scheduling module designates a plurality of different production scheduling plans, respectively calculates the total processing time of the different production scheduling plans, optimizes the total time required by the completion of the different scheduling processes by adopting an intelligent scheduling algorithm to obtain a scheduling scheme with the shortest total processing time, and sends the optimal scheduling strategy to a master control system;
the fourth step: semi-finished pipe transportation
Step 4.1, an instruction sending module sends a transportation instruction to a first AGV and a second AGV, and the first AGV and the second AGV feed back state information of the first AGV and the second AGV, wherein the state information comprises a transportation state and electric quantity information;
step 4.2, the analysis and calculation module selects a first AGV trolley or a second AGV trolley according to the feedback state information;
4.3, in the storage system, a transportation system in the pipe semi-finished product storage area conveys the required pipe semi-finished product to a second cache area, meanwhile, a first AGV trolley or a second AGV trolley conveys a material tray to the second cache area, a second pipe gripping device grips the pipe semi-finished product and puts the pipe into the material tray, and the first AGV trolley or the second AGV trolley transports the pipe semi-finished product to a processing station area;
the fifth step: semi-finished tube processing
Step 5.1, a first RFID scanner scans and acquires an RFID chip on a material tray, and a second RFID scanner accesses pipe processing information through a storage address of the RFID chip, wherein the pipe processing information comprises a pipe forming process and a forming requirement;
step 5.2, the analysis and calculation module selects a groove processing area, a bending processing area, a shrinking or flaring processing area or a welding processing area in the processing station area according to the acquired pipe processing process sequence, and the first AGV trolley or the second AGV trolley transports the material tray to the first processing cache area or the second processing cache area or the third processing cache area or the fourth processing cache area;
step 5.3, the instruction sending module sends a corresponding processing instruction and controls related processing equipment to complete processing of the pipe, and in the processing process, the data acquisition module acquires processing data and processing equipment monitoring data through a sensing device arranged on each equipment and respectively stores the processing data and the processing equipment monitoring data in the processing data storage module and the equipment monitoring data storage module;
step 5.4, the quality management module accesses the shared cloud according to the specification information of the pipe, acquires the pipe processing data, analyzes the data, completes the online quality detection of the pipe, and transmits the result to the master control system; the condition judgment module judges the product quality: if the product quality is qualified, the first manipulator, the second manipulator, the third manipulator or the fourth manipulator grabs the pipe and places the pipe in the related processing cache area; if the product quality is unqualified, the first manipulator or the second manipulator or the third manipulator or the fourth manipulator grabs the pipe and places the pipe in the unqualified second storage area or the unqualified third storage area or the unqualified fourth storage area or the unqualified fifth storage area;
and 5.5, the condition judgment module judges as follows: is the tube requires the machining process to be completed? If not, executing the 5.1 th step to the 5.5 th step; if so, executing the step 5.6;
and 5.6, the condition judgment module judges as follows: is the order completed? If the order is not finished, executing the fourth step to the fifth step; if the order is finished, executing the sixth step;
sixthly, spraying the two-dimensional code
Step 6.1, the first AGV trolley or the second AGV trolley transports the material tray for storing the qualified products to a fifth industrial cache area;
step 6.2, the first two-dimensional code spraying equipment or the second two-dimensional code spraying equipment accesses the shared cloud according to the specification information of the pipe, acquires the information of the pipe and generates a corresponding two-dimensional code;
6.3, the instruction sending module sends a two-dimensional code spraying instruction, controls a sixth mechanical arm to grab the pipe and places the pipe on the first two-dimensional code spraying equipment or the second two-dimensional code spraying equipment to finish code spraying operation; the sixth mechanical arm places the pipe in the material tray;
and 6.4, the condition judgment module judges as follows: is the code spraying operation for all tubes completed? If not, executing the 6.1 th step to the 6.4 th step; if yes, executing the seventh step;
the seventh step: warehousing the qualified products
Step 7.1, the instruction sending module sends a transportation instruction to the first AGV or the second AGV, and the first AGV or the second AGV feeds back state information of the first AGV or the second AGV, wherein the state information comprises a transportation state and electric quantity information;
7.2, selecting a proper AGV by the analysis and calculation module according to the state information fed back by the first AGV or the second AGV;
7.3, the first AGV trolley or the second AGV trolley transports the material tray to a third cache area, and a third pipe gripping device transfers the finished pipes to a specific material tray in a pipe finished product storage area to finish warehousing;
eighthly, judging whether the tube semi-finished product storage area needs to be supplemented by the warehouse management module, and executing the ninth step to the tenth step if the tube semi-finished product storage area needs to be supplemented by the material; otherwise, executing the twelfth step;
ninth, transporting the raw material of the pipe
9.1, the warehouse management module produces supplementary material files according to the specifications of the lacking pipe semi-finished products, wherein the supplementary material files comprise the specifications and the number of the needed pipe semi-finished products;
9.2, the instruction sending module sends a material taking signal, and the traveling crane in the raw material storage area takes out the corresponding raw material of the pipe from the raw material storage area and places the raw material on a material feeding conveying line;
the tenth step: processing of raw materials for pipes
Step 10.1, an analysis and calculation module selects processing equipment, namely first straightening equipment or second straightening equipment or first cutting equipment or second cutting equipment or first detection equipment or second detection equipment according to the state of the equipment, and an instruction sending module sends a raw material processing instruction and controls the raw material processing module to complete processing of the raw material of the pipe; in the processing process, the data acquisition module acquires related process processing data and related processing equipment monitoring data through the sensing devices arranged on the equipment, and the related process processing data and the related processing equipment monitoring data are respectively stored in the processing data storage module and the equipment monitoring data storage module;
step 10.2, the quality management module accesses the shared cloud according to the specification information of the pipe, acquires the pipe processing data, processes the data, performs online quality detection on the pipe, and transmits the result to the master control system; the condition judgment module judges the product quality: if the product quality is qualified, the first mechanical arm grabs the tubular product semi-finished product and places the tubular product semi-finished product in the semi-finished product temporary storage area; if the product quality is unqualified, the first mechanical arm grabs the tubular product semi-finished product and places the tubular product semi-finished product in a first unqualified storage area;
and step 10.3, the condition judgment module judges as follows: is the feed order complete? If the order is not finished, executing the ninth step to the tenth step; if the order is finished, executing the thirteenth step;
step ten, warehousing the tubular product semi-finished product
Step 11.1, an instruction sending module sends a transportation instruction to a first AGV or a second AGV, and the first AGV or the second AGV feeds back state information of the first AGV or the second AGV, wherein the state information comprises a transportation state and electric quantity information;
11.2, selecting a proper AGV by the analysis and calculation module according to the state information fed back by the first AGV or the second AGV;
step 11.3, the first AGV trolley or the second AGV trolley transports the material tray to a third cache area, and the third pipe gripping device transfers the semi-finished pipes to a specific material tray of the pipe semi-finished product storage area to finish warehousing;
twelfth, storage judgment of the storage system
12.1, the warehouse management module determines whether the flange storage area needs to be supplemented? If the material needs to be supplemented, an alarm is given out to prompt a manager to feed; otherwise, executing the step 12.2;
step 12.2, the warehouse management module determines whether the raw material storage area needs to be replenished? If the material needs to be supplemented, an alarm is given out to prompt a manager to feed; otherwise, executing the thirteenth step;
step thirteen, the master control system judges whether a new order is generated: if a new order is generated, executing the first step to the tenth step; if no new order is generated, ending;
the fault detection method specifically comprises the following steps:
step a, constructing a database
According to the fault type and reason of each device in the intelligent workshop in the working process and the suggestions of expert personnel, a fault database is constructed, and the database contains known fault types which are possible to generate and expression forms of corresponding faults;
step b, constructing a convolutional neural network expert system
Step c, data acquisition
The related data is acquired by each sensing device arranged on each device of the intelligent workshop, and the related data comprises three-phase current I of a motor of the pipe bending deviceu、Iv、IwAnd three phase voltage Uu、Uv、UwCorner theta of rocker arm of pipe bending equipment, torque T of rocker arm of pipe bending equipment and vibration dB of welding gun1Temperature t of welding gun1Temperature t of groove equipment2Working sound dB of groove equipment2The rising speed v of a blade of the cutting equipment and the sound dB of the cutting equipment3、AGV dolly movement distance s and AGV dolly lifting mechanism sound dB4；
D, analyzing and processing the data collected in the step c through the constructed convolutional neural network expert system;
step e, failure inquiry
The monitoring system outputs a result according to the convolutional neural network expert systemiAccessing a fault database; if the corresponding fault is inquired in the fault database, the fault is sent to a fault display module for displaying, and the fault display module is used for guiding maintenance workers to maintain and starting standby equipment; if the corresponding fault is not inquired in the database, executing the step f;
step f, updating the database
The expert judges the expression forms of the faults and the corresponding faults, if the expression forms of the faults and the corresponding faults are matched, the expression forms of the faults and the corresponding faults are brought into a database, and the faults are sent to a fault display module to be displayed, so that maintenance workers are guided to maintain, and standby equipment is started; simultaneously updating the convolutional neural network expert system; and if the expression forms of the faults are not matched with the expression forms of the corresponding faults, obtaining the faults corresponding to the corresponding expression forms according to the experience of expert personnel, bringing the faults into the database, and updating the convolutional neural network expert system.
Through the technical scheme, compared with the prior art, the invention has the following beneficial effects:
1. in the aspect of intelligent scheduling, the intelligent forming workshop for the multi-specification marine pipe can formulate different scheduling schemes by taking the delivery date as the deadline according to a pipe processing order, optimize each scheme by adopting an intelligent scheduling algorithm (such as a genetic algorithm), obtain an optimal scheduling strategy and guide the operation control of the whole workshop, thereby not only improving the processing efficiency of the whole workshop and avoiding the overdue phenomenon of the order, but also ensuring the ordered operation of the whole workshop, reducing manual intervention and improving the intelligence of the workshop;
2. in the aspect of fault detection of the intelligent forming workshop for the marine pipes with multiple specifications, the convolutional neural network expert system analyzes and processes detection data of each device in the intelligent forming workshop, compares and analyzes an analysis result with a fault database, acquires the fault type of each device in the intelligent forming workshop to guide maintenance operation of related personnel, and simultaneously starts standby equipment for reducing the influence of equipment faults on processing progress. The convolutional neural network expert system has the functions of continuous self-learning and updating, and perfects the database to improve the detection accuracy, and simultaneously can reduce the fault removal difficulty of maintenance personnel, thereby saving a large amount of time;
3. the data generated in the processing process are collected through the sensing devices arranged at the equipment positions and stored in the shared cloud, information integration of enterprises is facilitated, information management of workshops is achieved, and management and control capacity of the enterprises is improved.
Drawings
The invention is further illustrated with reference to the following figures and examples.
FIG. 1 is a layout diagram of an intelligent forming shop for multi-specification marine pipes according to a preferred embodiment of the present invention;
FIG. 2 is a flow chart of the intelligent scheduling of the intelligent forming shop for the multi-specification marine pipe according to the preferred embodiment of the invention;
FIG. 3 is a diagram of the intelligent process control and data acquisition for a multi-gauge marine tubular product according to a preferred embodiment of the present invention;
FIG. 4 shows the type and form of failure of the intelligent forming shop for multi-specification marine pipe according to the preferred embodiment of the present invention.
In the figure: in the raw material storage area, 1 is a raw material storage area, 10 is a raw material storage area, and 11 is a travelling crane;
in the intelligent control system, 2 is an intelligent control system, 20 is a master control system, 201 is an analysis calculation module, 202 is an instruction sending module, 203 is a condition judgment module, 21 is an MES system, 211 is a production scheduling module, 212 is a data acquisition module, 213 is a quality management module, 214 is a warehouse management module, 215 is an order management module, 216 is an equipment management module, 22 is a shared cloud, 221 is an RFID information storage module, 222 is a processing data storage module, 223 is an equipment monitoring data storage module, 224 is a load amount data storage module, and 23 is a monitoring system;
in the pretreatment processing area, 3 is a pretreatment processing area, 30 is a feeding conveying line, 31 is a first straightening device, 32 is a first cutting device, 33 is a first detection device, 34 is a first manipulator, 35 is a semi-finished product temporary storage area, 36 is a first unqualified storage area, 37 is a second straightening device, 38 is a second cutting device, and 39 is a second detection device;
in the transport system, 4 is the transport system, 40 is the first AGV, 41 is the second AGV, 42 is the charging area;
in the warehousing system, 5 is a warehousing system, 50 is a flange storage area, 51 is a pipe semi-finished product storage area, 52 is a pipe finished product storage area, 53 is a first cache area, 54 is a second cache area, 55 is a third cache area, 56 is a first RFID scanner, 57 is a first pipe gripping device, 58 is a second pipe gripping device, 59 is a third pipe gripping device, 510 is a material tray storage area, and 511 is a material tray;
in the machining station area, 6 is a machining station area, 60 is a bending machining area, 601 is a first pipe bending apparatus, 602 is a second pipe bending apparatus, 603 is a first machining buffer area, 604 is a second defective storage area, 605 is a second robot, 61 is a groove machining area, 611 is a first groove machining apparatus, 612 is a second groove machining apparatus, 613 is a second machining buffer area, 614 is a third defective storage area, 615 is a third robot, 62 is a shrinking or expanding machining area, 621 is a first shrinking or expanding machining apparatus, 622 is a second shrinking or expanding machining apparatus, 623 is a third machining buffer area, 624 is a fourth defective storage area, 625 is a fourth robot, 63 is a welding machining area, 631 is a first welding apparatus, 632 is a second welding apparatus, 633 is a fourth machining buffer area, 634 is a fifth storage area, 635 is a fifth robot, 64 is a second RFID scanner, 65 is a two-dimensional code spraying area, the manipulator is characterized in that 651 is first two-dimensional code spraying equipment, 652 is second two-dimensional code spraying equipment, 653 is an fifth manipulator buffer area, and 654 is a sixth manipulator;
a laser displacement sensor 701, a torque sensor 702, an angle sensor 703, a first scanner 704, a second scanner 705, a pressure sensor 706, a displacement sensor 707, a velocity sensor 708, a third scanner 709, a surface roughness meter 710, a voltage sensor 711, a current sensor 712, and an ultrasonic nondestructive inspection device 713.
Detailed Description
The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic views illustrating only the basic structure of the present invention in a schematic manner, and thus show only the constitution related to the present invention.
In the prior art, a ship pipe forming workshop has several problems pointed out in the background art, for example, the workshop is not suitable for the ship pipe forming workshop with various pipe types and forming processes, a large amount of time is needed to find fault reasons, related data acquisition of a processing process is lacked, and information is effectively managed.
Fig. 1 shows a specific structure of an intelligent forming workshop for multi-specification marine pipes, which can be clearly seen from the figure and specifically includes a raw material storage area 1, a pretreatment backbone area, a storage system 5 and a processing station area 6, wherein a control part of the whole workshop is an intelligent control system 2, a transportation channel of the whole workshop is a transportation system 4, the intelligent control system regulates and controls the whole workshop to realize straightening, cutting, bending and forming of multi-specification pipes, pipe end forming, end flange welding, two-dimensional code spraying, ex-warehouse and in-warehouse of pipe blanks, semi-finished products and the like, and products required by each area are transported and conveyed through the transportation system;
in particular, the method comprises the following steps of,
the raw material storage area is provided with a raw material storage area for classified storage of the multi-specification pipes, the raw materials are transported by the travelling crane 11, and the classification of the multi-specification pipes is based on the materials and the specifications (pipe diameter multiplied by wall thickness);
the intelligent control system comprises a master control system 20, an MES system 21, a shared cloud 22 and a monitoring system 23 which are communicated with each other, and the master control system carries out instruction regulation and control on the MES system, the shared cloud and the monitoring system;
the general control system comprises an analysis and calculation module 201, an instruction sending module 202 and a condition judgment module 203, wherein the analysis and calculation module acquires signals from the raw material storage area, the pretreatment processing area 3, the processing station area and the transportation system for analysis, the instruction sending module sends the received signals to the analysis and calculation module and sends execution instructions to the raw material storage area, the pretreatment processing area, the processing station area and the transportation system, and the condition judgment module judges the product quality;
the MES system comprises a production scheduling module 211, a data acquisition module 212, a quality management module 213, a warehouse management module 214, an order management module 215 and an equipment management module 216, wherein the production scheduling module is used for scheduling production programs in a workshop, the data acquisition module is used for collecting production information in the workshop, the quality management module is used for managing the quality of products, the warehouse management module is used for managing a raw material storage area and a warehousing system in the workshop, the order module is used for managing the order information of the products, and the equipment management module is used for managing equipment in the workshop;
the shared cloud comprises an RFID information storage module 221, a processing data storage module 222, an equipment monitoring data storage module 223 and a load data storage module 224, wherein the RFID information storage module is used for storing RFID scanning information, the processing data storage module is used for storing processing data in a workshop, the equipment monitoring data storage module is used for storing equipment monitoring data in the workshop, and the load data storage module is used for storing load data in the workshop;
the monitoring system is used for monitoring each part in the workshop;
the pretreatment processing area comprises a feeding conveying line 30, a first straightening device 31, a second straightening device 37, a first cutting device 32, a second cutting device 38, a first detection device 33, a second detection device 39, a semi-finished product temporary storage area 35 and a first unqualified storage area 36, wherein the feeding conveying line is positioned at the upstream of the production line, a first straightening device, a first cutting device and a first detection device are sequentially arranged at one side of the production line, a second straightening device, a second cutting device and a second detection device are sequentially arranged at the other side of the production line, the first straightening device and the second straightening device, the first cutting device and the second cutting device, and the first detection device and the second detection device are symmetrically arranged, the feeding conveying line also comprises a first manipulator 34, the first manipulator clamps and transfers the detected unqualified products to a first unqualified storage area; two devices are arranged for each equipment, so that the purpose of using one device for standby is achieved, and the production stop of a workshop caused by the fault of one device is avoided;
the warehousing system comprises a material tray storage area 510, a first RFID scanner 56, a flange storage area 50, a tubular product semi-finished product storage area 51 and a tubular product finished product storage area 52, wherein a plurality of material trays 511 are placed in the material tray storage area, the first RFID scanner is used for scanning and recording material tray information, a first cache area 53 is arranged at an inlet of the flange storage area, a second cache area 54 is arranged at an inlet of the tubular product semi-finished product storage area, a third cache area 55 is arranged at an inlet of the tubular product finished product storage area, a transport system transports the material trays to the corresponding cache areas, simultaneously transports the corresponding products in the flange storage area, the tubular product semi-finished product storage area and the tubular product storage area to the corresponding cache areas, a first tubular product grabbing device 57 is arranged in the first cache area and grabs and places the flanges in the material trays in the first cache area, and a second tubular product grabbing device 58 is arranged in the second cache area, the tube semi-finished product is grabbed and placed in the material tray positioned in the second cache area, and a third tube grabbing device 59 is arranged in the third cache area and used for grabbing and placing the tube finished product in the material tray of the third cache area;
the processing station area comprises a bending processing area 60, a groove processing area 61, a shrinking or flaring processing area 62, a welding processing area 63 and a two-dimensional code spraying area 65, and is also provided with a second RFID scanner 64, and a material tray containing products is scanned by the second RFID scanner and then distributed to each area in the processing station area through a transportation system;
the bending processing area comprises a first pipe bending device 601, a second pipe bending device 602, a first processing cache area 603 and a first unqualified storage area, the transportation system conveys qualified products to the first processing cache area from the matching area, the second manipulator 605 clamps the products from the first processing cache area to the first pipe bending device and the second pipe bending device for bending processing, and clamps and places the unqualified products after bending processing into the second unqualified storage area 604;
the groove processing area comprises a first groove device 611, a second groove device 612, a second processing cache area 613 and a second unqualified storage area, the transportation system conveys qualified products to the second processing cache area from the matching area, and the third manipulator 615 clamps the products from the second processing cache area to the first groove device and the second groove device for groove processing, and then clamps and places the unqualified products subjected to groove processing into the third unqualified storage area 614;
the shrinking or flaring processing area 621 comprises a first shrinking or flaring device, a second shrinking or flaring device 622, a third processing cache area 623 and a third unqualified storage area, the transportation system conveys qualified products to the third processing cache area from the matching area, the fourth manipulator 625 clamps the products from the third processing cache area to the first shrinking or flaring device and the second shrinking or flaring device for shrinking or flaring, and then clamps the unqualified products after shrinking or flaring to the fourth unqualified storage area 624;
the welding processing area comprises a first welding device 631, a second welding device 632, a fourth processing buffer area 633 and a fourth unqualified storage area, the transportation system conveys qualified products to the fourth processing buffer area from the matching area, the fifth manipulator 635 clamps the products from the fourth processing buffer area to the first welding device and the second welding device for welding treatment, and then clamps the unqualified products to the fifth unqualified storage area 634;
the two-dimensional code spraying area comprises a first two-dimensional code spraying device 651, a second two-dimensional code spraying device 652 and a fifth workpiece cache area 653, the transportation system conveys qualified products to the fifth workpiece cache area from the matching area, and the sixth manipulator 654 clamps the products from the fifth workpiece cache area to the first two-dimensional code spraying device and the second two-dimensional code spraying device for spraying;
it should be noted that the qualified products are transported to the designated area by the transportation system, and the matching area may be transported not only from the warehousing system, but also from other processing areas, such as the beveling area, the necking or flaring area, and the welding area in the processing station area.
The transport system comprises a first AGV trolley 40 and a second AGV trolley 41, and is also provided with a charging area 42 for charging the first AGV trolley and the second AGV trolley;
the laser displacement sensor 701 is installed on the first detection device and the second detection device, the angle sensor 703, the torque sensor 702 and the first scanner 704 are installed on the first pipe bending device and the second pipe bending device, the second scanner 705, the pressure sensor 706 and the displacement sensor 707 are installed on the first reducing or flaring device and the second reducing or flaring device, the speed sensor 708, the third scanner 709 and the surface roughness meter 710 are installed on the first beveling device and the second beveling device, and the voltage sensor 711, the current sensor 712 and the ultrasonic nondestructive inspection instrument 713 are installed on the first welding device and the second welding device, so that the collection and integration of the processing data of the devices in the pipe processing process can be realized.
Next, fig. 2 and fig. 3 show a usage of the intelligent forming shop for multi-specification marine pipes provided by the present application, fig. 2 is a method for performing intelligent scheduling by using the same, fig. 3 is a schematic diagram for performing control and data acquisition by using the same, and the following details are described in detail
The scheduling method specifically comprises the following steps:
the first step is as follows: receiving order in workshop
Step 1.1, receiving an nth batch of pipe processing order by a multi-specification marine pipe intelligent forming workshop, wherein n is more than or equal to 2, and the contents of the pipe processing order comprise an order supplier, a delivery date, required pipe specifications, a processing procedure, welding flange information, required quantity and the like;
step 1.2, the warehouse management module acquires addresses stored in an RFID chip of a material tray which is positioned in a storage system and is in an empty state through a first RFID scanner;
step 1.3, the order management module generates a processing technology file of each pipe according to the order content received by the workshop and writes the processing technology file into the acquired storage address;
the second step is that: obtaining workshop status information
The equipment management module acquires the state of each processing equipment in the workshop, wherein the state comprises the equipment type, the equipment performance, the current working state of the equipment and the current load capacity of the equipment;
the third step: scheduling order content according to processing equipment status
Step 3.1, determining the time required for processing the order content, acquiring the type of the specification of the order processed pipe by the master control system through the order management module, and calculating the time required for processing all types of pipes to finish all procedures by the analysis and calculation module; specifically, the master control system obtains the types of the specifications of the order-processed pipes as a (a is more than or equal to 1) through the order management module, obtains the required quantity of each pipe, and forms a quantity matrix N ═ N1，N2，...，Na]The types of the processing procedures of each pipe are b (b is more than or equal to 1 and less than or equal to 4),
the analysis and calculation module calculates the required processing time for finishing all the procedures of the pipe with the ith specification:
Figure BDA0002654899010000131
in the formula, tijThe processing time of the jth procedure of the ith specification of the pipe comprises the pipe processing time and auxiliary time, wherein the auxiliary time comprises the time (i is more than or equal to 1 and less than or equal to a, j is more than or equal to 1 and less than or equal to b) consumed by loading and unloading the pipe, starting equipment and the like, and NiThe number of pipes of the ith specification to be processed is shown;
the analysis and calculation module calculates the time required by the processing of all types of pipes of the order:
Figure BDA0002654899010000132
step 3.2, determining the waiting time of the nth batch of order, and calculating the time required by the processing of all kinds of pipes in the order by an analysis and calculation module; in particular, the method comprises the following steps of,
the analysis and calculation module calculates the processing time required by the tubes with unprocessed specifications in the (n-1) th batch to finish all the working procedures:
Figure BDA0002654899010000141
in the formula, tmjThe processing time of the jth procedure of the mth specification of the rest unprocessed tubes is shown (m is more than or equal to 0 and less than or equal to c, j is more than or equal to 1 and less than or equal to b), c is the type of the unprocessed specification of the nth-1 batch, EmjThe current load capacity of the pipe with the mth specification in the left unprocessed pipes on the jth processing equipment is shown and can be obtained through an equipment management module;
the analysis and calculation module calculates the time required by the processing of all types of pipes of the order:
Figure BDA0002654899010000142
and 3.3, determining the pipe transportation time, acquiring the load information of the processing equipment aiming at the pipes with different specifications (the pipe loads with different specifications are different) from the load data storage module according to the pipe specifications by the master control system, and forming a load matrix M (M is the load matrix M)1，M2，...，Ma](ii) a The analysis and calculation module calculates the transportation distance between each processing device and the storage, the required transportation times and the required transportation time of each specification of the pipe, and finally obtains the required transportation time of all kinds of pipes in the order, wherein the analysis and calculation module calculates the transportation distance between each processing device and the storage to form a distance matrix:
S＝[S1，S2，...，Sc](3≤c)
the analysis and calculation module calculates the required transportation times to form a time matrix:
Figure BDA0002654899010000143
the analysis and calculation module calculates the required transportation time of the pipe with the ith specification:
Figure BDA0002654899010000144
wherein v is the transport speed of the AGVeThe transport distance of the e-th section (e is more than or equal to 1 and less than or equal to c);
the analysis and calculation module calculates the required transportation time of all kinds of pipes of the order:
Figure BDA0002654899010000151
step 3.4, determining the total time required by order processing; in particular, the method comprises the following steps of,
the total time T required for the n-th order processing to complete comprises the time required for order processing, the waiting processing time and the transportation time, namely:
Figure BDA0002654899010000152
step 3.5, determining an optimal scheduling strategy, wherein a production scheduling module designates a plurality of different production scheduling plans, respectively calculating the total processing time of the different production scheduling plans, optimizing the total time required by finishing different scheduling processing by adopting an intelligent scheduling algorithm (such as a genetic algorithm) to obtain a scheduling scheme with the shortest total processing time, and sending the optimal scheduling strategy to a master control system;
the fourth step: semi-finished pipe transportation
Step 4.1, the instruction sending module sends a transportation instruction to the first AGV trolley and the second AGV trolley, and the first AGV trolley and the second AGV trolley feed back state information of the first AGV trolley and the second AGV trolley, wherein the state information comprises a transportation state (idle or on duty), electric quantity information (insufficient electric quantity, sufficient electric quantity) and the like;
step 4.2, the analysis and calculation module selects a first AGV or a second AGV according to the feedback state information, wherein in the provided embodiment, as shown in FIG. 2, the first AGV is selected;
4.3, in the storage system, a transportation system in the pipe semi-finished product storage area conveys the required pipe semi-finished product to a second cache area, meanwhile, a first AGV trolley conveys a material tray to the second cache area, a second pipe gripping device grips the pipe semi-finished product and puts the pipe semi-finished product into the material tray, and the first AGV trolley conveys the pipe semi-finished product to a processing station area;
the fifth step: semi-finished tube processing
Step 5.1, a first RFID scanner scans and acquires RFID chips on a material tray, and a second RFID scanner accesses pipe processing information through storage addresses of the RFID chips, wherein the pipe processing information comprises a pipe forming process (assuming that the pipe needs bending forming, beveling, necking and flange welding) and forming requirements;
step 5.2, the analysis and calculation module selects a groove processing area, a bending processing area, a shrinking or flaring processing area or a welding processing area in the processing station area according to the acquired tube processing process sequence, and the first AGV trolley transports the material tray to the first processing cache area or the second processing cache area or the third processing cache area or the fourth processing cache area;
step 5.3, the instruction sending module sends a corresponding processing instruction and controls related processing equipment to complete processing of the pipe, and in the processing process, the data acquisition module acquires processing data and processing equipment monitoring data through a sensing device arranged on each equipment and respectively stores the processing data and the processing equipment monitoring data in the processing data storage module and the equipment monitoring data storage module;
step 5.4, the quality management module accesses the shared cloud according to the specification information of the pipe, acquires the pipe processing data, analyzes the data, completes the online quality detection of the pipe, and transmits the result to the master control system; the condition judgment module judges the product quality: if the product quality is qualified, the first manipulator, the second manipulator, the third manipulator or the fourth manipulator grabs the pipe and places the pipe in the related processing cache area; if the product quality is unqualified, the first manipulator or the second manipulator or the third manipulator or the fourth manipulator grabs the pipe and places the pipe in the unqualified second storage area or the unqualified third storage area or the unqualified fourth storage area or the unqualified fifth storage area;
and 5.5, the condition judgment module judges as follows: is the tube requires the machining process to be completed? If not, executing the 5.1 th step to the 5.5 th step; if so, executing the step 5.6;
and 5.6, the condition judgment module judges as follows: is the order completed? If the order is not finished, executing the fourth step to the fifth step; if the order is finished, executing the sixth step;
sixthly, spraying the two-dimensional code
Step 6.1, the first AGV trolley or the second AGV trolley transports the material tray for storing the qualified products to a fifth industrial cache area;
step 6.2, the first two-dimensional code spraying equipment or the second two-dimensional code spraying equipment accesses the shared cloud according to the pipe specification information, acquires the information of the pipe (the pipe specification, the processing quality, the welding flange specification and the like), and generates a corresponding two-dimensional code;
6.3, the instruction sending module sends a two-dimensional code spraying instruction, controls a sixth mechanical arm to grab the pipe and places the pipe on the first two-dimensional code spraying equipment or the second two-dimensional code spraying equipment to finish code spraying operation; the sixth mechanical arm places the pipe in the material tray;
and 6.4, the condition judgment module judges as follows: is the code spraying operation for all tubes completed? If not, executing the 6.1 th step to the 6.4 th step; if yes, executing the seventh step;
the seventh step: warehousing the qualified products
Step 7.1, the instruction sending module sends a transportation instruction to the first AGV or the second AGV, and the first AGV or the second AGV feeds back state information of the first AGV or the second AGV, wherein the state information comprises a transportation state (idle or on duty), electric quantity information (insufficient electric quantity, sufficient electric quantity) and the like;
7.2, selecting a proper AGV by the analysis and calculation module according to the state information fed back by the first AGV or the second AGV, wherein the first AGV is still supposed to be selected;
7.3, the first AGV trolley or the second AGV trolley transports the material tray to a third cache area, and a third pipe gripping device transfers the finished pipes to a specific material tray in a pipe finished product storage area to finish warehousing;
eighthly, judging whether the tube semi-finished product storage area needs to be supplemented by the warehouse management module, and executing the ninth step to the tenth step if the tube semi-finished product storage area needs to be supplemented by the material; otherwise, executing the twelfth step;
ninth, transporting the raw material of the pipe
9.1, the warehouse management module produces supplementary material files according to the specifications of the lacking pipe semi-finished products, wherein the supplementary material files comprise the specifications and the number of the needed pipe semi-finished products;
9.2, the instruction sending module sends a material taking signal, and the travelling crane in the raw material storage area takes out the corresponding raw material of the pipe from the raw material storage area 10 and places the raw material on a feeding conveying line;
the tenth step: processing of raw materials for pipes
Step 10.1, an analysis and calculation module selects processing equipment, namely first straightening equipment or second straightening equipment or first cutting equipment or second cutting equipment or first detection equipment or second detection equipment according to the state of the equipment, and an instruction sending module sends a raw material processing instruction and controls the raw material processing module to complete processing of the raw material of the pipe; in the processing process, the data acquisition module acquires related process processing data and related processing equipment monitoring data through sensing devices (a laser displacement sensor, a torque sensor, a displacement sensor and the like) arranged on each piece of equipment, and the related process processing data and the related processing equipment monitoring data are respectively stored in the processing data storage module and the equipment monitoring data storage module;
step 10.2, the quality management module accesses the shared cloud according to the specification information of the pipe, acquires the pipe processing data, processes the data, performs online quality detection on the pipe, and transmits the result to the master control system; the condition judgment module judges the product quality: if the product quality is qualified, the first mechanical arm grabs the tubular product semi-finished product and places the tubular product semi-finished product in the semi-finished product temporary storage area; if the product quality is unqualified, the first mechanical arm grabs the tubular product semi-finished product and places the tubular product semi-finished product in a first unqualified storage area;
and step 10.3, the condition judgment module judges as follows: is the feed order (including processing of all kinds of pipes and the number of pipes required) completed? If the order is not finished, executing the ninth step to the tenth step; if the order is finished, executing the thirteenth step;
step ten, warehousing the tubular product semi-finished product
Step 11.1, the instruction sending module sends a transportation instruction to the first AGV or the second AGV, and the first AGV or the second AGV feeds back state information of the first AGV or the second AGV, wherein the state information comprises a transportation state (idle or on duty), electric quantity information (insufficient electric quantity, sufficient electric quantity) and the like;
11.2, selecting a proper AGV by the analysis and calculation module according to the state information fed back by the first AGV or the second AGV, wherein the first AGV is supposed to be selected;
step 11.3, the first AGV trolley or the second AGV trolley transports the material tray to a third cache area, and the third pipe gripping device transfers the semi-finished pipes to a specific material tray of the pipe semi-finished product storage area to finish warehousing;
twelfth, storage judgment of the storage system
12.1, the warehouse management module determines whether the flange storage area needs to be supplemented? If the material needs to be supplemented, an alarm is given out to prompt a manager to feed; otherwise, executing the step 12.2;
step 12.2, the warehouse management module determines whether the raw material storage area needs to be replenished? If the material needs to be supplemented, an alarm is given out to prompt a manager to feed; otherwise, executing the thirteenth step;
step thirteen, the master control system judges whether a new order is generated: if a new order is generated, executing the first step to the tenth step; if no new order is generated, ending;
the fault detection method specifically comprises the following steps:
step a, constructing a database
According to the fault type and reason of each device in the intelligent workshop in the working process and the suggestions of expert personnel, a fault database is constructed, and the database contains the fault dataThe type of possible faults and the corresponding form of representation of the faults are known, as shown in table 1 provided in fig. 4, for example when a three-phase current I of the motor of the pipe bending device (first pipe bending device or second pipe bending device) is monitoredu、Iv、IwWhen the height is too high, the corresponding fault type is motor coil interphase short circuit, and faults like bent pipe equipment rocker arm fault, welding gun fault, groove equipment gear fracture, groove equipment bearing damage, groove equipment rotating part damage, cutting equipment motor phase loss, cutting equipment air source under-voltage, code spraying equipment ink line splitting abnormity, AGV trolley optical coupling switch failure, AGV trolley screw rod hoister untimely lubrication and the like are also included; particularly, the database has a self-updating function, namely when the fault of each device of the intelligent workshop does not occur in the database, the database can automatically incorporate the fault into the database and continuously update and perfect;
and step b, constructing a convolutional neural network expert system, specifically,
step b.1, presetting the number M of convolution components of the convolutional neural network expert system, and initializing M to be 1;
step b.2, constructing input matrixes X (the number is N and is known) of the convolutional neural network expert system and corresponding fault matrixes Y based on the measured values and the fault types in the database:
X＝[dB3 t2 T … Iu Iv Iw]
y-short circuit between coils of cutting equipment air source under-pressure … motor
Step b.3, performing convolution calculation on the input matrix X, wherein the formula is as follows:
Figure BDA0002654899010000181
Figure BDA0002654899010000182
……
Figure BDA0002654899010000183
in the formula, XiIs the ith input map (1. ltoreq. i. ltoreq.N),
Figure BDA0002654899010000184
is the L-th convolution kernel, LiIs the total number of cores in the ith convolutional layer,
Figure BDA0002654899010000185
is the deviation of the measured value,
Figure BDA0002654899010000186
is the ith convolution output map and r represents the local region of shared weight.
Step b.4, add convolution output mapping by
Figure BDA0002654899010000191
The non-linear property of (2):
Figure BDA0002654899010000192
step b.5, through pooling layer calculation, the translation invariance of the data is increased and overfitting is prevented, and the formula is as follows:
Figure BDA0002654899010000193
in the formula, each neuron
Figure BDA0002654899010000194
All are converged at
Figure BDA0002654899010000195
On the 2 x 2 area in (1).
Step b.6, calculating the output size of the convolutional neural network expert system:
Figure BDA0002654899010000196
at step b.7, each neuron is calculated according to the following formula
Figure BDA0002654899010000197
Probability distribution of corresponding fault
Figure BDA0002654899010000198
Figure BDA0002654899010000199
In the formula, exp (θ)i) Is the ith neuron
Figure BDA00026548990100001910
The probability distribution of (a) is determined,
Figure BDA00026548990100001911
Figure BDA00026548990100001912
is a neuron
Figure BDA00026548990100001913
S is the number of elements contained in the output matrix;
step b.8, determining a final output matrix W according to the probability distribution of each fault; step b.9, the convolutional neural network expert system performs comparative analysis on the output matrix W and the known fault matrix Y:
if the fault type in the output matrix W calculated by the convolutional neural network expert system is not identical to the fault type in the known fault matrix Y, executing the steps b.10 to b.11;
if the fault type in the output matrix W calculated by the convolutional neural network expert system is the same as the fault type in the known fault matrix Y, executing the step b.12;
step b.10, the following calculation is carried out on the convolution component:
M＝M+1
step b.11, output sizeiConverting into an input matrix X, and executing the steps b.3 to b.9;
step b.12, determining the value of the number M of the convolution components and each scale factor
Figure BDA0002654899010000201
And constructing a convolutional neural network expert system;
step c, data acquisition
The related data is acquired by each sensing device arranged on each device of the intelligent workshop, and the related data comprises three-phase current I of a motor of the pipe bending deviceu、Iv、IwAnd three phase voltage Uu、Uv、UwCorner theta of rocker arm of pipe bending equipment, torque T of rocker arm of pipe bending equipment and vibration dB of welding gun1Temperature t of welding gun1Temperature t of groove equipment2Working sound dB of groove equipment2The rising speed v of a blade of the cutting equipment and the sound dB of the cutting equipment3AGV dolly movement distance s and AGV dolly lifting mechanism sound dB4；
D, analyzing and processing the data collected in the step c through the constructed convolutional neural network expert system; in particular, the method comprises the following steps of,
step d.1, initializing the execution times j of the convolutional neural network expert system to be 0;
step d.2, constructing an input matrix X of the convolutional neural network expert system:
X＝[t1 dB1 t2 v … Iw s]
d.3, analyzing the input matrix X by adopting the convolutional neural network expert system constructed in the step b;
step d.4, the convolution component is calculated as follows:
j＝j+1
step d.5, the convolutional neural network expert system judges whether j is less than or equal to M? If yes, outputting the output sizeiConverting into an input matrix X, and executing the steps d.3 to d.5; if notIf yes, outputting an output matrix W by the convolutional neural network expert system;
step e, failure inquiry
The monitoring system accesses a fault database according to an output result W of the convolutional neural network expert system; if the corresponding fault is inquired in the fault database, the fault is sent to a fault display module for displaying, and the fault display module is used for guiding maintenance workers to maintain and starting standby equipment; if the corresponding fault is not inquired in the database, executing the step f;
step f, updating the database
The expert judges the expression forms of the faults and the corresponding faults, if the expression forms of the faults and the corresponding faults are matched, the expression forms of the faults and the corresponding faults are brought into a database, and the faults are sent to a fault display module to be displayed, so that maintenance workers are guided to maintain, and standby equipment is started; simultaneously updating the convolutional neural network expert system; and if the expression forms of the faults are not matched with the expression forms of the corresponding faults, obtaining the faults corresponding to the corresponding expression forms according to the experience of expert personnel, bringing the faults into the database, and updating the convolutional neural network expert system.
It will be understood by those skilled in the art that, unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the prior art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
The meaning of "and/or" as used herein is intended to include both the individual components or both.
The term "connected" as used herein may mean either a direct connection between components or an indirect connection between components via other components.
In light of the foregoing description of the preferred embodiment of the present invention, many modifications and variations will be apparent to those skilled in the art without departing from the spirit and scope of the invention. The technical scope of the present invention is not limited to the content of the specification, and must be determined according to the scope of the claims.

Claims (8)

1. The utility model provides a many specifications marine tubular product intelligence workshop that takes shape which characterized in that: the production line comprises a pretreatment processing area and a processing station area which are sequentially arranged on the production line, a raw material storage area is arranged at the upstream of the production line, and a storage area for storing a semi-finished pipe, a finished pipe and a flange is arranged at one side of the production line;
still include conveying system and intelligent control system, intelligent control system sends control signal to raw and other materials storage area, pretreatment processing district and processing station district, realizes the processing of getting of many specifications tubular product, and intelligent control system sends control signal to conveying system simultaneously, realizes transporting the transportation of many specifications tubular product on the transfer line.
2. The intelligent multi-specification marine pipe forming plant according to claim 1, wherein: the raw material storage area is provided with a raw material storage area for classified storage of the pipes with various specifications, and transportation of the raw materials is realized;
the intelligent control system comprises a master control system, an MES system, a shared cloud and a monitoring system which are mutually communicated, wherein the master control system regulates and controls the MES system, the shared cloud and the monitoring system;
the general control system comprises an analysis and calculation module, an instruction sending module and a condition judgment module, wherein the analysis and calculation module acquires signals from a raw material storage area, a pretreatment processing area, a processing station area and a transportation system for analysis, the instruction sending module sends the received signals to the analysis and calculation module and sends an execution instruction to the raw material storage area, the pretreatment processing area, the processing station area and the transportation system, and the condition judgment module judges the quality of a product;
the MES system comprises a production scheduling module, a data acquisition module, a quality management module, a warehouse management module, an order management module and an equipment management module, wherein the production scheduling module is used for scheduling production programs in a workshop, the data acquisition module is used for collecting production information in the workshop, the quality management module is used for managing the quality of products, the warehouse management module is used for managing a raw material storage area and a warehousing system in the workshop, the order module is used for managing the order information of the products, and the equipment management module is used for managing equipment in the workshop;
the sharing cloud comprises an RFID information storage module, a processing data storage module, an equipment monitoring data storage module and a load data storage module, wherein the RFID information storage module is used for storing RFID scanning information, the processing data storage module is used for storing processing data in a workshop, the equipment monitoring data storage module is used for storing equipment monitoring data in the workshop, and the load data storage module is used for storing load data in the workshop;
the monitoring system is used for monitoring each part in the workshop.
3. The intelligent multi-specification marine pipe forming plant according to claim 2, wherein: the pretreatment processing area comprises a feeding conveying line, a first straightening device, a second straightening device, a first cutting device, a second cutting device, a first detection device, a second detection device, a semi-finished product temporary storage area and a first unqualified storage area, wherein the feeding conveying line is positioned at the upstream of the production line, a first straightening device, a first cutting device and a first detection device are sequentially arranged at one side of the production line, a second straightening device, a second cutting device and a second detection device are sequentially arranged at the other side of the production line, the first straightening device and the second straightening device, the first cutting device and the second cutting device, and the first detection device and the second detection device are symmetrically arranged, the feeding conveying line also comprises a first manipulator, the semi-finished product temporary storage area is used for clamping and transferring detected products to the semi-finished product temporary storage area, and the first mechanical arm is used for clamping and transferring detected unqualified products to the first unqualified storage area.
4. The intelligent multi-specification marine pipe forming plant according to claim 3, wherein: the storage system comprises a material tray storage area, a first RFID scanner, a flange storage area, a pipe semi-finished product storage area and a pipe finished product storage area, wherein a plurality of material trays are placed in the material tray storage area, the first RFID scanner is used for scanning and recording material tray information, a first cache area is arranged at an inlet of the flange storage area, a second cache area is arranged at an inlet of the pipe semi-finished product storage area, a third cache area is arranged at an inlet of the pipe finished product storage area, a material tray is conveyed to the corresponding cache area by a conveying system, the corresponding products in the flange storage area, the pipe semi-finished product storage area and the pipe finished product storage area are conveyed to the corresponding cache areas by the conveying system, a first pipe gripping device is arranged in the first cache area and is used for gripping and placing the flange in the material tray positioned in the first cache area, a second pipe gripping device is arranged in the second cache area and is used for gripping and placing the pipe semi-finished product in the material tray positioned in the second cache area, and a third pipe gripping device is arranged in the third cache area and is used for gripping the pipe finished product in a material tray placed in the third cache area.
5. The intelligent multi-specification marine pipe forming plant according to claim 4, wherein: the processing station area comprises a bending processing area, a groove processing area, a shrinking or flaring processing area, a welding processing area and a two-dimensional code spraying area, and is also provided with a second RFID scanner, and a material tray containing products is scanned by the second RFID scanner and then distributed to each area in the processing station area through a transportation system;
the bending processing area comprises a first pipe bending device, a second pipe bending device, a first processing cache area and a first unqualified storage area, the conveying system conveys qualified products to the first processing cache area from the matching area, the second mechanical arm clamps the products to the first pipe bending device and the second pipe bending device from the first processing cache area for bending processing, and then clamps and places the unqualified products after bending processing into the second unqualified storage area;
the groove processing area comprises a first groove device, a second processing cache area and a second unqualified storage area, the transportation system conveys the qualified products to the second processing cache area from the matching area, and the third manipulator clamps the products to the first groove device and the second groove device from the second processing cache area for groove processing and then clamps and places the unqualified products subjected to groove processing into the third unqualified storage area;
the shrinking or flaring processing area comprises a first shrinking or flaring device, a second shrinking or flaring device, a third processing cache area and a third unqualified storage area, the transportation system conveys the qualified products to the third processing cache area from the matching area, and the fourth manipulator clamps the products from the third processing cache area to the first shrinking or flaring device and the second shrinking or flaring device for shrinking or flaring processing, and then clamps the unqualified products after shrinking or flaring to the fourth unqualified storage area;
the welding processing area comprises a first welding device, a second welding device, a fourth processing cache area and a fourth unqualified storage area, the conveying system conveys qualified products to the fourth processing cache area from the matching area, and the fifth manipulator clamps the products from the fourth processing cache area to the first welding device and the second welding device for welding treatment and then clamps and conveys unqualified products to the fifth unqualified storage area;
the two-dimensional code spraying area comprises a first two-dimensional code spraying device, a second two-dimensional code spraying device and a fifth worker cache area, qualified products are conveyed to the fifth worker cache area from a matching area by the conveying system, and the products are clamped to the first two-dimensional code spraying device and the second two-dimensional code spraying device from the fifth worker cache area by the sixth manipulator for spraying processing.
6. The intelligent multi-specification marine pipe forming plant according to claim 5, wherein: the transporting system comprises a first AGV trolley, a second AGV trolley and a charging area for charging the first AGV trolley and the second AGV trolley.
7. The intelligent multi-specification marine pipe forming plant according to claim 6, wherein: the method comprises the steps that laser displacement sensors are installed on first detection equipment and second detection equipment, angle sensors, torque sensors and first scanners are installed on the first pipe bending equipment and the second pipe bending equipment, second scanners, pressure sensors and displacement sensors are installed on first beveling equipment and second beveling equipment, speed sensors, third scanners and surface roughness meters are installed on the first beveling equipment and the second beveling equipment, and voltage sensors, current sensors and ultrasonic nondestructive flaw detectors are installed on the first welding equipment and the second welding equipment.
8. The control method of the intelligent forming workshop for the multi-specification marine pipes is based on any claim, and is characterized in that: the method is divided into two parts, the first part is a scheduling method, the second part is a fault detection method,
the scheduling method specifically comprises the following steps:
the first step is as follows: receiving order in workshop
Step 1.1, receiving an nth batch of pipe processing order by a multi-specification marine pipe intelligent forming workshop, wherein n is more than or equal to 2, and the content of the pipe processing order comprises an order, a delivery date, required pipe specifications, a processing procedure, welding flange information and required quantity;
step 1.2, the warehouse management module acquires addresses stored in an RFID chip of a material tray which is positioned in a storage system and is in an empty state through a first RFID scanner;
step 1.3, the order management module generates a processing technology file of each pipe according to the order content received by the workshop and writes the processing technology file into the acquired storage address;
the second step is that: obtaining workshop status information
The equipment management module acquires the state of each processing equipment in the workshop, wherein the state comprises the equipment type, the equipment performance, the current working state of the equipment and the current load capacity of the equipment;
the third step: scheduling order content according to processing equipment status
Step 3.1, determining the time required for processing the order content, acquiring the type of the specification of the order processed pipe by the master control system through the order management module, and calculating the time required for processing all types of pipes to finish all procedures by the analysis and calculation module;
step 3.2, determining the waiting time of the nth batch of order, and calculating the time required by the processing of all kinds of pipes in the order by an analysis and calculation module;
3.3, determining the pipe transportation time, acquiring the loading information of the processing equipment aiming at the pipes with different specifications from the loading data storage module by the master control system according to the pipe specifications, calculating the transportation distance, the required transportation times and the required transportation time of each specification of the pipe between each processing equipment and storage by the analysis and calculation module, and finally acquiring the transportation time required by all kinds of pipes in the order;
step 3.4, determining the total time required by order processing;
3.5, determining an optimal scheduling strategy, wherein the production scheduling module designates a plurality of different production scheduling plans, respectively calculates the total processing time of the different production scheduling plans, optimizes the total time required by the completion of the different scheduling processes by adopting an intelligent scheduling algorithm to obtain a scheduling scheme with the shortest total processing time, and sends the optimal scheduling strategy to a master control system;
the fourth step: semi-finished pipe transportation
Step 4.1, an instruction sending module sends a transportation instruction to a first AGV and a second AGV, and the first AGV and the second AGV feed back state information of the first AGV and the second AGV, wherein the state information comprises a transportation state and electric quantity information;
step 4.2, the analysis and calculation module selects a first AGV trolley or a second AGV trolley according to the feedback state information;
4.3, in the storage system, a transportation system in the pipe semi-finished product storage area conveys the required pipe semi-finished product to a second cache area, meanwhile, a first AGV trolley or a second AGV trolley conveys a material tray to the second cache area, a second pipe gripping device grips the pipe semi-finished product and puts the pipe into the material tray, and the first AGV trolley or the second AGV trolley transports the pipe semi-finished product to a processing station area;
the fifth step: semi-finished tube processing
Step 5.1, a first RFID scanner scans and acquires an RFID chip on a material tray, and a second RFID scanner accesses pipe processing information through a storage address of the RFID chip, wherein the pipe processing information comprises a pipe forming process and a forming requirement;
step 5.2, the analysis and calculation module selects a groove processing area, a bending processing area, a shrinking or flaring processing area or a welding processing area in the processing station area according to the acquired pipe processing process sequence, and the first AGV trolley or the second AGV trolley transports the material tray to the first processing cache area or the second processing cache area or the third processing cache area or the fourth processing cache area;
step 5.3, the instruction sending module sends a corresponding processing instruction and controls related processing equipment to complete processing of the pipe, and in the processing process, the data acquisition module acquires processing data and processing equipment monitoring data through a sensing device arranged on each equipment and respectively stores the processing data and the processing equipment monitoring data in the processing data storage module and the equipment monitoring data storage module;
step 5.4, the quality management module accesses the shared cloud according to the specification information of the pipe, acquires the pipe processing data, analyzes the data, completes the online quality detection of the pipe, and transmits the result to the master control system; the condition judgment module judges the product quality: if the product quality is qualified, the first manipulator, the second manipulator, the third manipulator or the fourth manipulator grabs the pipe and places the pipe in the related processing cache area; if the product quality is unqualified, the first manipulator or the second manipulator or the third manipulator or the fourth manipulator grabs the pipe and places the pipe in the unqualified second storage area or the unqualified third storage area or the unqualified fourth storage area or the unqualified fifth storage area;
and 5.5, the condition judgment module judges as follows: is the tube requires the machining process to be completed? If not, executing the 5.1 th step to the 5.5 th step; if so, executing the step 5.6;
and 5.6, the condition judgment module judges as follows: is the order completed? If the order is not finished, executing the fourth step to the fifth step; if the order is finished, executing the sixth step;
sixthly, spraying the two-dimensional code
Step 6.1, the first AGV trolley or the second AGV trolley transports the material tray for storing the qualified products to a fifth industrial cache area;
step 6.2, the first two-dimensional code spraying equipment or the second two-dimensional code spraying equipment accesses the shared cloud according to the specification information of the pipe, acquires the information of the pipe and generates a corresponding two-dimensional code;
6.3, the instruction sending module sends a two-dimensional code spraying instruction, controls a sixth mechanical arm to grab the pipe and places the pipe on the first two-dimensional code spraying equipment or the second two-dimensional code spraying equipment to finish code spraying operation; the sixth mechanical arm places the pipe in the material tray;
and 6.4, the condition judgment module judges as follows: is the code spraying operation for all tubes completed? If not, executing the 6.1 th step to the 6.4 th step; if yes, executing the seventh step;
the seventh step: warehousing the qualified products
Step 7.1, the instruction sending module sends a transportation instruction to the first AGV or the second AGV, and the first AGV or the second AGV feeds back state information of the first AGV or the second AGV, wherein the state information comprises a transportation state and electric quantity information;
7.2, selecting a proper AGV by the analysis and calculation module according to the state information fed back by the first AGV or the second AGV;
7.3, the first AGV trolley or the second AGV trolley transports the material tray to a third cache area, and a third pipe gripping device transfers the finished pipes to a specific material tray in a pipe finished product storage area to finish warehousing;
eighthly, judging whether the tube semi-finished product storage area needs to be supplemented by the warehouse management module, and executing the ninth step to the tenth step if the tube semi-finished product storage area needs to be supplemented by the material; otherwise, executing the twelfth step;
ninth, transporting the raw material of the pipe
9.1, the warehouse management module produces supplementary material files according to the specifications of the lacking pipe semi-finished products, wherein the supplementary material files comprise the specifications and the number of the needed pipe semi-finished products;
9.2, the instruction sending module sends a material taking signal, and the traveling crane in the raw material storage area takes out the corresponding raw material of the pipe from the raw material storage area and places the raw material on a material feeding conveying line;
the tenth step: processing of raw materials for pipes
Step 10.1, an analysis and calculation module selects processing equipment, namely first straightening equipment or second straightening equipment or first cutting equipment or second cutting equipment or first detection equipment or second detection equipment according to the state of the equipment, and an instruction sending module sends a raw material processing instruction and controls the raw material processing module to complete processing of the raw material of the pipe; in the processing process, the data acquisition module acquires related process processing data and related processing equipment monitoring data through the sensing devices arranged on the equipment, and the related process processing data and the related processing equipment monitoring data are respectively stored in the processing data storage module and the equipment monitoring data storage module;
step 10.2, the quality management module accesses the shared cloud according to the specification information of the pipe, acquires the pipe processing data, processes the data, performs online quality detection on the pipe, and transmits the result to the master control system; the condition judgment module judges the product quality: if the product quality is qualified, the first mechanical arm grabs the tubular product semi-finished product and places the tubular product semi-finished product in the semi-finished product temporary storage area; if the product quality is unqualified, the first mechanical arm grabs the tubular product semi-finished product and places the tubular product semi-finished product in a first unqualified storage area;
and step 10.3, the condition judgment module judges as follows: is the feed order complete? If the order is not finished, executing the ninth step to the tenth step; if the order is finished, executing the thirteenth step;
step ten, warehousing the tubular product semi-finished product
Step 11.1, an instruction sending module sends a transportation instruction to a first AGV or a second AGV, and the first AGV or the second AGV feeds back state information of the first AGV or the second AGV, wherein the state information comprises a transportation state and electric quantity information;
11.2, selecting a proper AGV by the analysis and calculation module according to the state information fed back by the first AGV or the second AGV;
step 11.3, the first AGV trolley or the second AGV trolley transports the material tray to a third cache area, and the third pipe gripping device transfers the semi-finished pipes to a specific material tray of the pipe semi-finished product storage area to finish warehousing;
twelfth, storage judgment of the storage system
12.1, the warehouse management module determines whether the flange storage area needs to be supplemented? If the material needs to be supplemented, an alarm is given out to prompt a manager to feed; otherwise, executing the step 12.2;
step 12.2, the warehouse management module determines whether the raw material storage area needs to be replenished? If the material needs to be supplemented, an alarm is given out to prompt a manager to feed; otherwise, executing the thirteenth step;
step thirteen, the master control system judges whether a new order is generated: if a new order is generated, executing the first step to the tenth step; if no new order is generated, ending;
the fault detection method specifically comprises the following steps:
step a, constructing a database
According to the fault type and reason of each device in the intelligent workshop in the working process and the suggestions of expert personnel, a fault database is constructed, and the database contains known fault types which are possible to generate and expression forms of corresponding faults;
step b, constructing a convolutional neural network expert system
Step c, data acquisition
The related data is acquired by each sensing device arranged on each device of the intelligent workshop, and the related data comprises three-phase current I of a motor of the pipe bending deviceu、Iv、IwAnd three phase voltage Uu、Uv、UwCorner theta of rocker arm of pipe bending equipment, torque T of rocker arm of pipe bending equipment and vibration dB of welding gun1Temperature t of welding gun1Temperature t of groove equipment2Working sound dB of groove equipment2The rising speed v of a blade of the cutting equipment and the sound dB of the cutting equipment3AGV dolly movement distance s and AGV dolly lifting mechanism sound dB4；
D, analyzing and processing the data collected in the step c through the constructed convolutional neural network expert system;
step e, failure inquiry
The monitoring system outputs a result according to the convolutional neural network expert systemiAccessing a fault database; if the corresponding fault is inquired in the fault database, the fault is sent to a fault display module for displaying, and the fault display module is used for guiding maintenance workers to maintain and starting standby equipment; if the corresponding fault is not inquired in the database, executing the step f;
step f, updating the database
The expert judges the expression forms of the faults and the corresponding faults, if the expression forms of the faults and the corresponding faults are matched, the expression forms of the faults and the corresponding faults are brought into a database, and the faults are sent to a fault display module to be displayed, so that maintenance workers are guided to maintain, and standby equipment is started; simultaneously updating the convolutional neural network expert system; and if the expression forms of the faults are not matched with the expression forms of the corresponding faults, obtaining the faults corresponding to the corresponding expression forms according to the experience of expert personnel, bringing the faults into the database, and updating the convolutional neural network expert system.
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