CN112184473B - Intelligent forming workshop for multi-specification marine pipe and control method - Google Patents

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

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CN112184473B
CN112184473B CN202010883593.6A CN202010883593A CN112184473B CN 112184473 B CN112184473 B CN 112184473B CN 202010883593 A CN202010883593 A CN 202010883593A CN 112184473 B CN112184473 B CN 112184473B
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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 the 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 products, finished products and flanges of the pipes 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 conveying system to realize the conveying and transferring of the multi-specification pipes on a conveying line; according to the invention, an optimal scheduling strategy can be formulated according to the order, fault monitoring can be carried out on the whole workshop, and the intelligent forming workshop for the multi-specification marine pipe is beneficial to informationized management.

Description

Intelligent forming workshop for multi-specification marine pipe 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 machining.
Background
The intelligent workshop is a workshop for realizing self-organizing production of automatic equipment (production equipment, detection equipment, transportation equipment, manipulators and the like) through a network and a software management system, realizing perception states (information of production requirements, equipment, production processes and the like) and analyzing real-time data, so that automatic decision making and accurate command execution are realized; in the process of ship manufacturing, pipe processing and manufacturing are an important link in shipyard production organizations. According to statistics, the steel ship pipes are huge in use amount, and the use amount of one 20 ten thousand tons of oil ship pipes exceeds 2 ten thousand, so that the work load of pipe processing is huge, and particularly when a plurality of ships are simultaneously built, the processing tasks of a pipe production workshop are further aggravated, so that the pipe processing workshop is very easy to be in a chaotic state, the pipe processing workshop becomes a development bottleneck of shipbuilding enterprises, and the shipbuilding enterprises are restricted to develop towards an intelligent direction.
Because the ships are customized products, different types and even each ship are made of different materials, 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 bimetal 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 active marine pipe forming workshop to have the following problems:
⑴ The types of the pipes in the orders are numerous, and due to the fact that a reasonable and effective intelligent scheduling method is lacked in a pipe processing workshop, the pipe processing is long in time consumption, the orders cannot be completed according to the delivery period, and then the orders are backlogged. The intelligent shop-based mobile multi-agent real-time scheduling system described in patent ZL201710282923.4 describes a general scheduling system and method for intelligent shops, does not give any way to determine the objective function to be optimized for the scheduling strategy, and is not suitable for scheduling complex intelligent pipe forming workshops; the factory intelligent shop real-time scheduling system described in patent ZL201610403522.5 also describes a scheduling system for a general factory shop, and is not applicable to a marine pipe forming shop with a large variety of pipes and various forming processes.
⑵ The lack of a necessary workshop fault monitoring system and a processing method in the active marine pipe forming workshop leads to the fact that when a certain device fails, maintenance personnel are required to spend a great deal of time to confirm the fault cause and maintain, and further the processing progress of the workshop is affected. The neural network expert system-based fault detection method of the micro inverter described in patent ZL103293415B describes a fault detection method of the micro inverter by the neural network expert system, but the method lacks a detailed construction process of the neural network expert system.
In addition, the problems that the production workshop cannot realize informatization management and enterprise information integration is difficult and the like due to the lack of a processing process related data acquisition and effective information management system exist in the active marine pipe forming workshop.
Disclosure of Invention
The invention provides an intelligent forming workshop for multi-specification marine pipes and a control method thereof, which can formulate an optimal scheduling strategy according to orders, monitor faults of the whole workshop and are beneficial to informationized management of the intelligent forming workshop for the multi-specification marine pipes.
The technical scheme adopted 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, wherein a raw material storage area is arranged at the upstream of the production line, and a storage area for storing semi-finished products, finished products and flanges of the pipes 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 conveying system to realize the conveying and transferring of the multi-specification pipes on a conveying line;
as a further preferred aspect of the present invention, the raw material storage area is provided with a raw material storage area for classifying and storing the multi-specification pipes, and the raw material storage area is used for transporting raw materials by travelling 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 judging module, wherein the analysis and calculation module obtains 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 meanwhile, an execution instruction is sent to the raw material storage area, the pretreatment processing area, the processing station area and the transportation system, and the condition judging module judges the quality of products;
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 workshops, the data acquisition module is used for collecting production information in workshops, the quality management module is used for managing the quality of products, the warehouse management module is used for managing raw material storage areas and warehouse systems in workshops, the order management module is used for managing the order information of the products, and the equipment management module is used for managing equipment in workshops;
The shared cloud comprises an RFID information storage module, a processing data storage module, an equipment monitoring data storage module and a load capacity 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 capacity data storage module is used for storing load capacity data in the workshop;
The monitoring system is used for monitoring all parts in the workshop;
As a further preferred aspect of the present invention, the foregoing 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 reject storage area, wherein the feeding conveyor line is located upstream of the production line, the first straightening device, the first cutting device, and the first detecting device are sequentially arranged on one side of the production line, the second straightening device, the second cutting device, and the second detecting device are sequentially arranged on 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 detecting device and the second detecting device are symmetrically arranged, and further includes a first manipulator that clips and transfers the detected product to the semi-finished product temporary storage area, and the first manipulator clips and transfers the detected reject product to the first reject storage area;
As a further preferred aspect of the present invention, the foregoing warehousing system includes a stock disc storage area, a first RFID scanner, a flange storage area, a pipe semi-finished product storage area, and a pipe finished product storage area, in which a plurality of stock discs are placed, the first RFID scanner is configured to scan and record information of the stock discs, a first buffer area is provided at an entrance of the flange storage area, a second buffer area is provided at an entrance of the pipe semi-finished product storage area, a third buffer area is provided at an entrance of the pipe finished product storage area, a transport system transports the stock discs to the corresponding buffer areas, and simultaneously transports the flange storage area, the pipe semi-finished product storage area, and the corresponding products in the pipe finished product storage area to the corresponding buffer areas, a first pipe gripping device is provided in the first buffer area, in which the flange is gripped and placed in the stock discs in the first buffer area, a second pipe gripping device is provided in the second buffer area, in which the pipe semi-finished product is gripped and placed in the stock discs in the second buffer area, and a third pipe gripping device is provided in the third buffer area, in which the pipe gripping device is gripped and placed in the corresponding stock discs in the third buffer area;
As a further preferred aspect of the present invention, the aforementioned processing station area includes 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 a second RFID scanner is further installed, and a tray containing a product is distributed to each area in the processing station area through a transportation system after being scanned by the second RFID scanner;
the bending processing area comprises first pipe bending equipment, second pipe bending equipment, a first processing buffer area and a first disqualification storage area, the transportation system conveys qualified products from the matching area to the first processing buffer area, the second manipulator clamps the products from the first processing buffer area to the first pipe bending equipment and the second pipe bending equipment for bending treatment, and then clamps the disqualification products after bending treatment into the second disqualification storage area;
The groove processing area comprises first groove equipment, second groove equipment, a second processing buffer area and a second disqualification storage area, the transportation system conveys qualified products from the matching area to the second processing buffer area, the third manipulator clamps the products from the second processing buffer area to the first groove equipment and the second groove equipment for groove processing, and then clamps the disqualification products after groove processing into the third disqualification storage area;
The shrinkage or flaring processing area comprises first shrinkage or flaring equipment, second shrinkage or flaring equipment, a third processing buffer area and a third disqualification storage area, the matching area conveys qualified products from the storage system to the third processing buffer area, a fourth mechanical arm clamps the products from the third processing buffer area to the first shrinkage or flaring equipment and the second shrinkage or flaring equipment for shrinkage or flaring treatment, and then clamps the disqualification products after shrinkage or flaring to the fourth disqualification storage area;
The welding processing area comprises a first welding device, a second welding device, a fourth processing buffer area and a fourth disqualification storage area, the transportation system conveys qualified products from the matching area to the fourth processing buffer area, the fifth mechanical arm 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 and conveys the disqualification products to the fifth disqualification storage area;
The two-dimensional code spraying area comprises first two-dimensional code spraying equipment, second two-dimensional code spraying equipment and a fifth processing buffer area, the transportation system conveys qualified products from the matching area to the fifth processing buffer area, and the sixth manipulator clamps the products from the fifth processing buffer area to the first two-dimensional code spraying equipment and the second two-dimensional code spraying equipment for spraying treatment;
As a further preferred aspect of the present invention, the transport system includes a first AGV cart and a second AGV cart, and a charging area for charging the first AGV cart and the second AGV cart is installed;
As a further preferred aspect of the present invention, a laser displacement sensor is mounted on the first and second inspection apparatuses, an angle sensor, a torque sensor, and a first scanner are mounted on the first and second pipe bending apparatuses, a second scanner, a pressure sensor, and a displacement sensor are mounted on the first and second contraction or expansion apparatuses, a speed sensor, a third scanner, and a surface roughness meter are mounted on the first and second bevel apparatuses, and a voltage sensor, a current sensor, and an ultrasonic nondestructive inspection meter are mounted on the first and second welding apparatuses;
the control method for the intelligent forming workshop of the multi-specification marine pipe based on any claim is divided into two parts, wherein 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: the shop receives the order
1.1, Receiving an nth batch of pipe processing orders in an intelligent forming workshop of the multi-specification marine pipe, wherein n is more than or equal to 2, and the content of the pipe processing orders comprises an ordering party, a delivery period, required pipe specifications, processing procedures, welding flange information and required quantity;
Step 1.2, a warehouse management module obtains an address stored in an RFID chip of a material tray in a vacant state in a warehouse system through a first RFID scanner;
Step 1.3, an order management module generates a processing technology file of each pipe according to order content received by a workshop, and writes the processing technology file into the acquired storage address;
And a second step of: acquiring workshop status information
The equipment management module acquires the state of each processing equipment in the workshop, wherein the state comprises equipment type, equipment performance, the current working state of the equipment and the current load capacity of the equipment;
And a third step of: scheduling order content based on process equipment status
Step 3.1, determining the time required for processing the order content, wherein the master control system obtains the types of the specifications of the pipes processed by the order through the order management module, and the analysis calculation module calculates the time required for processing all the types of pipes to complete all the working procedures;
step 3.2, determining the waiting processing time of the nth batch of orders, and calculating the time required by the completion of the processing of all kinds of pipes in the orders by an analysis and calculation module;
Step 3.3, determining the pipe transportation time, and acquiring the load capacity information of the processing equipment for the pipes with different specifications from a load capacity data storage module according to the pipe specifications by a master control system, wherein an analysis and calculation module calculates the transportation distance between each processing equipment and the warehouse, the required transportation times and the required transportation time of the pipes with each specification, and finally acquires the required transportation time of all kinds of pipes in an order;
step 3.4, determining the total time required for finishing order processing;
step 3.5, determining an optimal scheduling strategy, designating a plurality of different production scheduling plans by a production scheduling module, respectively calculating the total processing time of the different production scheduling plans, optimizing the total time required by completing the different production processing by adopting an intelligent scheduling algorithm to obtain a scheduling scheme with the shortest total processing time, and transmitting the optimal scheduling strategy to a total control system;
fourth step: semi-finished pipe transportation
Step 4.1, a command transmitting module transmits a transport command to a first AGV trolley and a second AGV trolley, and the first AGV trolley and the second AGV trolley feed back state information of the transport command, wherein the state information comprises transport 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;
Step 4.3, in the warehouse system, a conveying system in the pipe semi-finished product storage area conveys the required pipe semi-finished product to a second buffer area, and meanwhile, a first AGV trolley or a second AGV trolley conveys a material tray to the second buffer area, a second pipe grabbing device grabs the pipe semi-finished product and puts the pipe semi-finished product into the material tray, and the first AGV trolley or the second AGV trolley conveys the pipe semi-finished product to a processing station area;
Fifth step: semi-finished pipe processing
Step 5.1, a first RFID scanner scans an RFID chip on the material obtaining disc, 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, an analysis and calculation module selects a groove processing area, a bending processing area, a shrinkage or flaring processing area or a welding processing area in a processing station area according to the acquired pipe processing process sequence, and a first AGV trolley or a second AGV trolley handle material tray is transported to a first processing buffer area or a second processing buffer area or a third processing buffer area or a fourth processing buffer area;
Step 5.3, the instruction sending module sends corresponding processing instructions and controls related processing equipment to finish processing the pipe, and in the processing process, the data acquisition module acquires processing data and processing equipment monitoring data through sensing devices arranged on the 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 pipe specification information, acquires pipe processing data, analyzes the data, completes online quality detection of the pipe, and transmits the result to the master control system; the condition judging module judges the product quality: if the product quality is qualified, the first manipulator or the second manipulator or the third manipulator or the fourth manipulator grabs the pipe and places the pipe in a relevant processing buffer 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 second unqualified storage area or the third unqualified storage area or the fourth unqualified storage area or the fifth unqualified storage area;
step 5.5, the condition judging module judges as follows: is the tubing required to complete the machining process? If not, executing the steps 5.1 to 5.5; if so, executing the step 5.6;
Step 5.6, the condition judging module judges as follows: is the order completed? If the order is not completed, executing the fourth step to the fifth step; if the order is completed, executing a sixth step;
Sixth, two-dimensional code spraying
Step 6.1, the first AGV trolley or the second AGV trolley conveys the trays for storing qualified products to a fifth processing buffer 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;
Step 6.3, the command sending module sends a two-dimensional code spraying command and controls the sixth manipulator to grasp the pipe and place the pipe on the first two-dimensional code spraying equipment or the second two-dimensional code spraying equipment so as to finish the code spraying operation; a sixth manipulator is used for placing the pipe in the material tray;
Step 6.4, the condition judging module judges as follows: is the code spraying operation of all the pipes complete? If not, executing the steps 6.1 to 6.4; if so, executing a seventh step;
Seventh step: warehousing of qualified products
Step 7.1, a command sending module sends a transport command to a first AGV trolley or a second AGV trolley, and the first AGV trolley or the second AGV trolley feeds back state information of the transport command, wherein the state information comprises transport state and electric quantity information;
Step 7.2, selecting a proper AGV according to the state information fed back by the first AGV or the second AGV by the analysis and calculation module;
Step 7.3, the first AGV trolley or the second AGV trolley conveys the material tray to a third buffer area, and the third pipe grabbing device transfers the finished pipe to a specific material tray in a pipe finished product storage area to finish warehousing;
Eighth, the warehouse management module judges whether the storage area of the semi-finished product of the pipe needs to be supplemented, if so, the ninth step to the eleventh step are executed; otherwise, executing a twelfth step;
ninth step, transporting the raw materials of the pipe
Step 9.1, a warehouse management module produces a feed supplement file according to the specifications of the semi-finished products of the pipe, wherein the feed supplement file comprises the specifications and the quantity of the required semi-finished products of the pipe;
step 9.2, the command transmitting module transmits a material taking signal, and the travelling crane of the raw material storage area takes out the corresponding raw material of the pipe from the raw material storage area and places the pipe on a material feeding conveying line;
Tenth step: pipe raw material processing
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 instruction to finish processing the raw material of the pipe; in the processing process, a data acquisition module acquires related process processing data and related processing equipment monitoring data through sensing devices arranged on all equipment and stores the processing data and the equipment monitoring data in a processing data storage module and an equipment monitoring data storage module respectively;
Step 10.2, the quality management module accesses the shared cloud according to the pipe specification information, acquires pipe processing data, processes the data, performs online quality detection on the pipe, and transmits the result to the master control system; the condition judging module judges the product quality: if the product quality is qualified, the first manipulator grabs the semi-finished product of the pipe and places the semi-finished product in a temporary storage area of the semi-finished product; if the product quality is unqualified, the first manipulator grabs the semi-finished product of the pipe and places the semi-finished product in a first unqualified storage area;
Step 10.3, the condition judging module judges as follows: is the feed order completed? If the order is not completed, executing the ninth step to the tenth step; if the order is completed, executing a thirteenth step;
eleventh step, the semi-finished products of the pipes are put in storage
11.1, A command sending module sends a transport command to a first AGV trolley or a second AGV trolley, and the first AGV trolley or the second AGV trolley feeds back state information of the transport command, wherein the state information comprises transport state and electric quantity information;
11.2, selecting a proper AGV according to the state information fed back by the first AGV or the second AGV by the analysis and calculation module;
11.3, conveying the first AGV trolley or the second AGV trolley to a third buffer area by using a material tray, and transferring the semi-finished pipe to a specific material tray in a pipe semi-finished storage area by using a third pipe grabbing device to finish warehousing;
Twelfth step, stock judgment of warehouse system
In step 12.1, the warehouse management module determines whether the flange storage area needs to be fed? If the feeding is needed, an alarm is sent to prompt a manager to feed; otherwise, executing the 12.2 th step;
In step 12.2, the warehouse management module determines whether the raw material storage area requires replenishment? If the feeding is needed, an alarm is sent to prompt a manager to feed; otherwise, executing a thirteenth step;
Thirteenth, the master control system judges whether a new order is generated: if a new order is generated, executing the first step to the thirteenth step; if no new order is generated, ending;
The fault detection method specifically comprises the following steps:
Step a, constructing a database
Constructing a fault database according to the fault types and reasons of each device of the intelligent workshop in the working process and combining with the suggestions of expert personnel, wherein the database contains known fault types possibly generated and the expression forms of corresponding faults;
Step b, constructing a convolutional neural network expert system
Step c, data acquisition
The method comprises the steps that related data are collected through sensing devices arranged on all devices of an intelligent workshop, wherein the sensing devices comprise a three-phase current I u、Iv、Iw and a three-phase voltage U u、Uv、Uw of a motor of the pipe bending device, a rocker angle theta of the pipe bending device, a rocker torque T of the pipe bending device, welding gun vibration dB 1, welding gun temperature T 1, groove device temperature T 2, groove device working sound dB 2, cutting device blade rising speed v, cutting device sound dB 3, AGV trolley moving distance s and AGV trolley lifting mechanism sound dB 4;
d, analyzing and processing the data acquired in the step c through a constructed convolutional neural network expert system;
Step e, fault inquiry
The monitoring system accesses a fault database according to an output result delta i of the convolutional neural network expert system; if the corresponding faults are inquired in the fault database, the faults are sent to a fault display module for display, so that maintenance workers are guided to maintain, and standby equipment is started; if no corresponding fault is queried in the database, executing the step f;
Step f, updating database
Expert personnel judge the expression forms of the faults and the corresponding faults, if the expression forms of the faults are matched with the expression forms of the corresponding faults, the expression forms of the faults and the corresponding faults are incorporated into a database, the faults are sent to a fault display module for display, and the fault display module is used for guiding maintenance workers to maintain and starting standby equipment; updating the convolutional neural network expert system at the same time; if the fault and the corresponding fault expression form are not matched, obtaining the fault corresponding to the corresponding expression form according to the experience of expert personnel, incorporating the fault into a 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 multi-specification marine pipe intelligent forming workshop can formulate different scheduling schemes according to pipe processing orders and taking delivery period as a period, adopts an intelligent scheduling algorithm (such as a genetic algorithm) to optimize each scheme, obtains an optimal scheduling strategy, guides the operation control of the whole workshop, improves the processing efficiency of the whole workshop, avoids the overdue phenomenon of orders, ensures that the whole workshop operates orderly, reduces manual intervention and improves the intellectualization of the workshop;
2. In the aspect of fault detection of the intelligent forming workshop of the multi-specification marine pipe, the convolutional neural network expert system disclosed by the invention is used for analyzing and processing detection data of all equipment in the intelligent forming workshop, comparing and analyzing an analysis result with a fault database to obtain fault types of all the equipment in the intelligent forming workshop so as to guide maintenance operation of related personnel, and simultaneously starting standby equipment for reducing the influence of equipment faults on the processing progress. The convolutional neural network expert system has the functions of continuous self-learning and updating, perfects the database to improve the detection accuracy, and can reduce the fault elimination difficulty of maintenance personnel so as to save a great amount of time;
3. The data generated in the processing process is collected through the sensing devices arranged at the equipment positions and stored in the shared cloud, so that the information integration of enterprises is facilitated, the informatization management of workshops is realized, and the management and control capacity of the enterprises is improved.
Drawings
The invention will be further described with reference to the drawings and examples.
FIG. 1 is a layout view of a multi-gauge marine pipe intelligent forming plant according to a preferred embodiment of the present invention;
FIG. 2 is a flow chart of intelligent scheduling of a multi-specification marine pipe intelligent forming shop according to a preferred embodiment provided by the invention;
FIG. 3 is a diagram of intelligent processing control and data acquisition of a multi-specification marine pipe according to a preferred embodiment of the present invention;
Fig. 4 is a fault type and manifestation of the intelligent forming shop for multi-specification marine pipe according to the preferred embodiment provided by 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 total control system, 201 is an analysis and calculation module, 202 is an instruction sending module, 203 is a condition judging 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 a device management module, 22 is a shared cloud, 221 is an RFID information storage module, 222 is a processing data storage module, 223 is a device monitoring data storage module, 224 is a load 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 first straightening equipment, 32 is first cutting equipment, 33 is first detection equipment, 34 is a first manipulator, 35 is a semi-finished product temporary storage area, 36 is a first disqualified storage area, 37 is second straightening equipment, 38is second cutting equipment, and 39 is second detection equipment;
in the transport system, 4 is a transport system, 40 is a first AGV trolley, 41 is a second AGV trolley, and 42 is a charging area;
in the warehouse system, 5 is the warehouse system, 50 is the flange storage area, 51 is the pipe semi-finished product storage area, 52 is the pipe finished product storage area, 53 is the first buffer area, 54 is the second buffer area, 55 is the third buffer area, 56 is the first RFID scanner, 57 is the first pipe grabbing device, 58 is the second pipe grabbing device, 59 is the third pipe grabbing device, 510 is the material disc storage area, 511 is the material disc;
Among the processing station areas, 6 is a processing station area, 60 is a bending processing area, 601 is a first pipe bending device, 602 is a second pipe bending device, 603 is a first processing buffer area, 604 is a second disqualification storage area, 605 is a second manipulator, 61 is a groove processing area, 611 is a first groove device, 612 is a second groove device, 613 is a second processing buffer area, 614 is a third disqualification storage area, 615 is a third manipulator, 62 is a shrinking or flaring processing area, 621 is a first shrinking or flaring device, 622 is a second shrinking or flaring device, 623 is a third processing buffer area, 624 is a fourth disqualification storage area, 625 is a fourth manipulator, 63 is a welding processing area, 631 is a first welding device, 632 is a second welding device, 633 is a fourth processing buffer area, 634 is a fifth disqualification storage area, 635 is a fifth manipulator, 64 is a second RFID scanner, 65 is a two-dimensional code spraying area, 651 is a first two-dimensional code device, 652 is a second two-dimensional code spraying device, 623 is a fifth two-dimensional spraying device, 653 is a sixth processing buffer area;
701 is a laser displacement sensor, 702 is a torque sensor, 703 is an angle sensor, 704 is a first scanner, 705 is a second scanner, 706 is a pressure sensor, 707 is a displacement sensor, 708 is a speed sensor, 709 is a third scanner, 710 is a surface roughness meter, 711 is a voltage sensor, 712 is a current sensor, 713 is an ultrasonic non-destructive inspection meter.
Detailed Description
The invention will now be described in further detail with reference to the accompanying drawings. The drawings are simplified schematic representations which merely illustrate the basic structure of the invention and therefore show only the structures which are relevant to the invention.
In the prior art, the marine pipe forming workshop has the problems as pointed out in the background art, such as inapplicability to the marine pipe forming workshop with various pipe types and various forming processes, a great deal of time is required to find out fault reasons, and the related data acquisition of the processing process and the effective management of information are lacked.
The application provides a specific structure of an intelligent forming workshop for multi-specification marine pipes, which is shown in the figure, and is clear from the figure, and particularly comprises a raw material storage area 1, a pretreatment river area, a storage system 5 and a processing station area 6, wherein the control part of the whole workshop is an intelligent control system 2, the 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 forming, pipe end forming, end flange welding, two-dimension code spraying, pipe blank, semi-finished products, finished product warehouse-in and the like of the multi-specification pipes, and the products required by each area are transported and conveyed through the transportation system;
In particular, the method comprises the steps of,
The raw material storage area is provided with a raw material storage area for classifying and storing the multi-specification pipes, the raw material storage area is used for realizing the transportation of raw materials through a travelling crane 11, and the multi-specification pipes are classified according to the materials and 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 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 201, an instruction sending module 202 and a condition judging module 203, wherein the analysis and calculation module obtains signals from a raw material storage area, a pretreatment processing area 3, 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 meanwhile, an execution instruction is sent to the raw material storage area, the pretreatment processing area, the processing station area and the transportation system, and the condition judging module judges the quality of products;
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 workshops, the data acquisition module is used for collecting production information in workshops, the quality management module is used for managing the quality of products, the warehouse management module is used for managing raw material storage areas and warehouse systems in workshops, the order management module is used for managing order information of the products, and the equipment management module is used for managing equipment in workshops;
The shared cloud comprises an RFID information storage module 221, a processing data storage module 222, a device monitoring data storage module 223 and a load capacity 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 device monitoring data storage module is used for storing device monitoring data in the workshop, and the load capacity data storage module is used for storing load capacity data in the workshop;
The monitoring system is used for monitoring all parts 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 disqualified storage area 36, wherein the feeding conveying line is positioned at the upstream of the production line, the first straightening device, the first cutting device and the first detection device are sequentially arranged at one side of the production line, the second straightening device, the second cutting device and the second detection device are sequentially arranged at the other side of the production line, the first straightening device, the second straightening device, the first cutting device, the second cutting device, the first detection device and the second detection device are symmetrically arranged, and the pretreatment processing area further comprises a first manipulator 34 which clamps and transfers detected products to the semi-finished product temporary storage area, and clamps and transfers detected disqualified products to the first disqualified storage area; two devices are arranged, so that the purpose of one standby is achieved, and the production of workshops is prevented from being stopped due to the occurrence of one fault;
The warehouse system comprises a stock disc storage area 510, a first RFID scanner 56, a flange storage area 50, a pipe semi-finished product storage area 51 and a pipe finished product storage area 52, wherein a plurality of stock discs 511 are placed in the stock disc storage area, the first RFID scanner is used for scanning and recording stock disc information, a first buffer area 53 is arranged at the inlet of the flange storage area, a second buffer area 54 is arranged at the inlet of the pipe semi-finished product storage area, a third buffer area 55 is arranged at the inlet of the pipe finished product storage area, the transport system transports the stock discs to the corresponding buffer areas, meanwhile, the transport system transports the flange storage area, the pipe semi-finished product storage area and the corresponding products in the pipe finished product storage area to the corresponding buffer areas, a first pipe grabbing device 57 is arranged in the first buffer area, the flange grabbing device is arranged in the stock disc of the first buffer area, a second pipe grabbing device 58 is arranged in the second buffer area, the pipe semi-finished product grabbing device is arranged in the stock disc of the second buffer area, and a third pipe grabbing device 59 is arranged in the third buffer area, and the pipe finished product grabbing device is arranged in the third buffer 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, a second RFID scanner 64 is also arranged, and a tray filled with products is distributed to each area in the processing station area through a conveying system after being scanned by the second RFID scanner;
The bending processing area comprises a first pipe bending device 601, a second pipe bending device 602, a first processing buffer area 603 and a first disqualification storage area, the transportation system conveys qualified products from the matching area to the first processing buffer area, the second mechanical arm 605 clamps the products from the first processing buffer area to the first pipe bending device and the second pipe bending device for bending processing, and clamps the disqualification products after bending processing into the second disqualification storage area 604;
the groove processing area comprises a first groove equipment 611, a second groove equipment 612, a second processing buffer area 613 and a second disqualification storage area, the transportation system conveys qualified products from the matching area to the second processing buffer area, a third manipulator 615 clamps the products from the second processing buffer area to the first groove equipment and the second groove equipment for groove processing, and then clamps the disqualification products after groove processing into a third disqualification 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 buffer area 623 and a third disqualification storage area, the transportation system conveys qualified products from the matching area to the third processing buffer area, the fourth manipulator 625 clamps the products from the third processing buffer area to the first shrinking or flaring device and the second shrinking or flaring device for shrinking or flaring treatment, and clamps and conveys the disqualification products after shrinking or flaring to the fourth disqualification 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 disqualification storage area, the transportation system conveys qualified products from the matching area to the fourth processing buffer 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 disqualification products to the fifth disqualification 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 processing cache area 653, the transportation system conveys qualified products to the fifth processing cache area from the matching area, and the sixth manipulator 654 clamps the products from the fifth processing cache area to the first two-dimensional code spraying device and the second two-dimensional code spraying device for spraying treatment;
The qualified products are transported to the designated area by the transport system, and the matching area is transported not only from the warehouse system, but also from other processing areas, such as a groove processing area, a shrink or flare processing area and a welding processing area in the processing station area.
The transport system includes a first AGV 40 and a second AGV 41, and a charging area 42 for charging the first AGV and the second AGV is also installed;
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 shrinking or expanding device and the second shrinking or expanding device, the speed sensor 708, the third scanner 709 and the surface roughness meter 710 are installed on the first groove device and the second groove device, and the voltage sensor 711, the current sensor 712 and the ultrasonic nondestructive flaw detector 713 are installed on the first welding device and the second welding device, so that the collection and integration of processing data of all devices in the pipe processing process can be realized.
Next, fig. 2 and3 show the usage of the intelligent forming shop for multi-specification marine pipes according to the present application, fig. 2 is a method for intelligent scheduling by using the intelligent forming shop, fig. 3 is a schematic diagram for controlling and collecting data by using the intelligent scheduling method, and the following description will be made specifically
The scheduling method specifically comprises the following steps:
The first step: the shop receives the order
1.1, Receiving an nth batch of pipe processing orders in an intelligent forming workshop of the multi-specification marine pipe, wherein n is more than or equal to 2, and the content of the pipe processing orders comprises an ordering party, a delivery period, required pipe specifications, processing procedures, welding flange information, required quantity and the like;
Step 1.2, a warehouse management module obtains an address stored in an RFID chip of a material tray in a vacant state in a warehouse system through a first RFID scanner;
Step 1.3, an order management module generates a processing technology file of each pipe according to order content received by a workshop, and writes the processing technology file into the acquired storage address;
And a second step of: acquiring workshop status information
The equipment management module acquires the state of each processing equipment in the workshop, wherein the state comprises equipment type, equipment performance, the current working state of the equipment and the current load capacity of the equipment;
And a third step of: scheduling order content based on process equipment status
Step 3.1, determining the time required for processing the order content, wherein the master control system obtains the types of the specifications of the pipes processed by the order through the order management module, and the analysis calculation module calculates the time required for processing all the types of pipes to complete all the working procedures; specifically, the master control system obtains the specification types of the pipes processed by the order form as a (a is more than or equal to 1) types through the order management module, obtains the required quantity of each pipe to form a quantity matrix N= [ N 1,N2,...,Na ], the processing procedure types of each pipe are b (b is more than or equal to 1 and less than or equal to 4) types,
The analysis and calculation module calculates the processing time required by the pipe with the i-th specification to complete all working procedures:
Wherein t ij represents the processing time of the jth procedure of the ith specification of the pipe, the processing time comprises pipe processing time and auxiliary time, the auxiliary time comprises the time required by pipe loading and unloading, equipment starting and the like (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), and N i represents the required processing quantity of the ith specification of the pipe;
the analysis and calculation module calculates the time required for completing the processing of all kinds of pipes in the order:
Step 3.2, determining the waiting processing time of the nth batch of orders, and calculating the time required by the completion of the processing of all kinds of pipes in the orders by an analysis and calculation module; in particular, the method comprises the steps of,
The analysis and calculation module calculates the processing time required by the raw-specification pipe in the n-1 batch to complete all the working procedures:
Wherein t mj represents the processing time (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) of the jth procedure of the m-th specification of the rest unprocessed pipes, c is the type of the unprocessed specification of the n-1 th batch, E mj represents the current load of the m-th specification of the rest unprocessed pipes on the jth processing equipment, and the load can be obtained through the equipment management module;
the analysis and calculation module calculates the time required for completing the processing of all kinds of pipes in the order:
Step 3.3, determining the pipe transportation time, and acquiring the load information of the processing equipment aiming at the pipes with different specifications (different pipe loads with different specifications) from a load data storage module according to the pipe specifications by a master control system to form a load matrix M= [ M 1,M2,...,Ma ]; the analysis and calculation module calculates the transportation distance between each processing device and the warehouse, the required transportation times and the required transportation time of each specification 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 warehouse 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:
the analysis and calculation module calculates the transportation time required by the pipe with the i-th specification:
/>
wherein v is the transport speed of the AGV trolley, and S e is the e-th transport distance (e is more than or equal to 1 and less than or equal to c);
the analysis and calculation module calculates the transportation time required by all kinds of pipes of the order:
Step 3.4, determining the total time required for finishing order processing; in particular, the method comprises the steps of,
The total time T required for completing the nth batch of order processing comprises the time required for order processing, the waiting processing time and the transportation time, namely:
Step 3.5, determining an optimal scheduling strategy, designating a plurality of different production scheduling plans by a production scheduling module, respectively calculating the total processing time of the different production scheduling plans, optimizing the total time required by completing the processing of the different production by adopting an intelligent scheduling algorithm (such as a genetic algorithm) to obtain a scheduling scheme with the shortest total processing time, and transmitting the optimal scheduling strategy to a total control system;
fourth step: semi-finished pipe transportation
Step 4.1, the command transmitting module transmits a transport command 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 transport command, wherein the state information comprises transport states (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 the first AGV trolley or the second AGV trolley according to the feedback state information, wherein in the provided embodiment, as shown in fig. 2, the first AGV trolley is selected;
Step 4.3, in the warehouse system, a conveying system in the pipe semi-finished product storage area conveys the required pipe semi-finished product to a second buffer area, meanwhile, a first AGV trolley conveys a material tray to the second buffer area, a second pipe grabbing device grabs 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;
Fifth step: semi-finished pipe processing
Step 5.1, a first RFID scanner scans an RFID chip on the material obtaining disc, 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 (assuming that the pipe needs to be bent, formed into a groove, reduced in mouth and welded into a flange) and a forming requirement;
step 5.2, an analysis and calculation module selects a groove processing area, a bending processing area, a shrinkage or flaring processing area or a welding processing area in a processing station area according to the acquired pipe processing process sequence, and a first AGV trolley handle material tray is transported to a first processing buffer area or a second processing buffer area or a third processing buffer area or a fourth processing buffer area;
Step 5.3, the instruction sending module sends corresponding processing instructions and controls related processing equipment to finish processing the pipe, and in the processing process, the data acquisition module acquires processing data and processing equipment monitoring data through sensing devices arranged on the 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 pipe specification information, acquires pipe processing data, analyzes the data, completes online quality detection of the pipe, and transmits the result to the master control system; the condition judging module judges the product quality: if the product quality is qualified, the first manipulator or the second manipulator or the third manipulator or the fourth manipulator grabs the pipe and places the pipe in a relevant processing buffer 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 second unqualified storage area or the third unqualified storage area or the fourth unqualified storage area or the fifth unqualified storage area;
step 5.5, the condition judging module judges as follows: is the tubing required to complete the machining process? If not, executing the steps 5.1 to 5.5; if so, executing the step 5.6;
Step 5.6, the condition judging module judges as follows: is the order completed? If the order is not completed, executing the fourth step to the fifth step; if the order is completed, executing a sixth step;
Sixth, two-dimensional code spraying
Step 6.1, the first AGV trolley or the second AGV trolley conveys the trays for storing qualified products to a fifth processing buffer 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 pipe information (pipe specification, processing quality, welding flange specification and the like) and generates a corresponding two-dimensional code;
Step 6.3, the command sending module sends a two-dimensional code spraying command and controls the sixth manipulator to grasp the pipe and place the pipe on the first two-dimensional code spraying equipment or the second two-dimensional code spraying equipment so as to finish the code spraying operation; a sixth manipulator is used for placing the pipe in the material tray;
Step 6.4, the condition judging module judges as follows: is the code spraying operation of all the pipes complete? If not, executing the steps 6.1 to 6.4; if so, executing a seventh step;
Seventh step: warehousing of qualified products
Step 7.1, a command sending module sends a transport command to a first AGV trolley or a second AGV trolley, and the first AGV trolley or the second AGV trolley feeds back state information of the first AGV trolley or the second AGV trolley, wherein the state information comprises transport states (idle or on duty), electric quantity information (insufficient electric quantity, sufficient electric quantity) and the like;
step 7.2, selecting a proper AGV trolley by the analysis and calculation module according to the state information fed back by the first AGV trolley or the second AGV trolley, and still assuming that the first AGV trolley is selected;
Step 7.3, the first AGV trolley or the second AGV trolley conveys the material tray to a third buffer area, and the third pipe grabbing device transfers the finished pipe to a specific material tray in a pipe finished product storage area to finish warehousing;
Eighth, the warehouse management module judges whether the storage area of the semi-finished product of the pipe needs to be supplemented, if so, the ninth step to the eleventh step are executed; otherwise, executing a twelfth step;
ninth step, transporting the raw materials of the pipe
Step 9.1, a warehouse management module produces a feed supplement file according to the specifications of the semi-finished products of the pipe, wherein the feed supplement file comprises the specifications and the quantity of the required semi-finished products of the pipe;
step 9.2, the command transmitting module transmits a material taking signal, and the travelling crane of the raw material storage area takes out the corresponding raw material of the pipe from the raw material storage area 10 and places the pipe on a material feeding conveying line;
Tenth step: pipe raw material processing
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 instruction to finish processing the raw material of the pipe; in the processing process, a 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 equipment, and the processing data and the processing equipment monitoring data are respectively stored in a processing data storage module and an equipment monitoring data storage module;
Step 10.2, the quality management module accesses the shared cloud according to the pipe specification information, acquires pipe processing data, processes the data, performs online quality detection on the pipe, and transmits the result to the master control system; the condition judging module judges the product quality: if the product quality is qualified, the first manipulator grabs the semi-finished product of the pipe and places the semi-finished product in a temporary storage area of the semi-finished product; if the product quality is unqualified, the first manipulator grabs the semi-finished product of the pipe and places the semi-finished product in a first unqualified storage area;
Step 10.3, the condition judging module judges as follows: is the feed order (including the processing of all kinds of tubing and the number of tubing required) complete? If the order is not completed, executing the ninth step to the tenth step; if the order is completed, executing a thirteenth step;
eleventh step, the semi-finished products of the pipes are put in storage
11.1, A command sending module sends a transport command to a first AGV trolley or a second AGV trolley, and the first AGV trolley or the second AGV trolley feeds back state information of the first AGV trolley or the second AGV trolley, wherein the state information comprises transport states (idle or on duty), electric quantity information (insufficient electric quantity, sufficient electric quantity) and the like;
Step 11.2, selecting a proper AGV according to the state information fed back by the first AGV or the second AGV by the analysis and calculation module, wherein the first AGV is assumed to be selected;
11.3, conveying the first AGV trolley or the second AGV trolley to a third buffer area by using a material tray, and transferring the semi-finished pipe to a specific material tray in a pipe semi-finished storage area by using a third pipe grabbing device to finish warehousing;
Twelfth step, stock judgment of warehouse system
In step 12.1, the warehouse management module determines whether the flange storage area needs to be fed? If the feeding is needed, an alarm is sent to prompt a manager to feed; otherwise, executing the 12.2 th step;
In step 12.2, the warehouse management module determines whether the raw material storage area requires replenishment? If the feeding is needed, an alarm is sent to prompt a manager to feed; otherwise, executing a thirteenth step;
Thirteenth, the master control system judges whether a new order is generated: if a new order is generated, executing the first step to the thirteenth 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 types and reasons of the equipment in the intelligent workshop in the working process, and by combining with the advice of expert personnel, constructing a fault database, wherein the database contains known fault types possibly generated and the expression forms of corresponding faults, as shown in a table 1 provided in fig. 4, for example, when the three-phase current I u、Iv、Iw of a motor of the pipe bending equipment (the first pipe bending equipment or the second pipe bending equipment) is monitored to be too high, the corresponding fault types are faults such as motor coil interphase short circuit, rocker arm faults of the pipe bending equipment, welding gun faults, gear breakage of groove equipment, bearing damage of the groove equipment, damage of rotating parts of the groove equipment, phase failure of a motor of the cutting equipment, gas source undervoltage of the cutting equipment, ink line splitting abnormality of a code spraying equipment, failure of an optical coupling switch of an AGV trolley wire rod lifter, and the like; particularly, the database has a self-updating function, namely when the faults of all the devices of the intelligent workshop are not occurred in the database, the database can automatically incorporate the faults into the database, and the continuous updating is completed;
Step b, constructing a convolutional neural network expert system, specifically,
Step b.1, presetting the number M of convolutional components of a convolutional neural network expert system, and initializing M=1;
Step b.2, based on the measured values in the database and the fault types, constructing an input matrix X (the number is N and known) of the convolutional neural network expert system and a corresponding fault matrix Y:
X＝[dB3 t2 T … Iu Iv Iw]
y= [ under-pressure air source … motor coil interphase short-circuit of cutting equipment ]
And b.3, carrying out convolution calculation on the input matrix X, wherein the formula is as follows:
/>
……
Where X i is the ith input map (1.ltoreq.i.ltoreq.N), Is the ith convolution kernel, L i is the total number of kernels in the ith convolution layer,/>Is deviation/>Is the first convolved output map, r represents the local region of shared weights.
Step b.4, increasing the convolution output map by the following formulaIs not limited by the non-linear properties of:
step b.5, adding translational invariance of the data and preventing overfitting through calculation of a pooling layer, wherein the formula is as follows:
In the formula, each neuron Are all collected at/>Is on the 2 x 2 area in (c).
Step b.6, calculating the output size of the convolutional neural network expert system:
Step b.7, calculating each neuron according to the following formula Probability distribution of corresponding faults/>
Wherein exp (θ i) is the ith neuronProbability distribution of/> Is neuron/>S is the number of elements contained in the output matrix;
step b.8, determining a final output matrix W according to probability distribution of each fault; step b.9, the convolutional neural network expert system performs a 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 types in the output matrix W calculated by the convolutional neural network expert system are all the same as those in the known fault matrix Y, executing the step b.12;
step b.10, the convolution component is calculated as follows:
M＝M+1
Step b.11, converting the output size delta i into an input matrix X, and performing steps b.3 to b.9;
step b.12, determining the value of the number M of convolution components and each scale factor Constructing a convolutional neural network expert system;
Step c, data acquisition
The method comprises the steps that related data are collected through sensing devices arranged on all devices of an intelligent workshop, wherein the sensing devices comprise a three-phase current I u、Iv、Iw and a three-phase voltage U u、Uv、Uw of a motor of the pipe bending device, a rocker angle theta of the pipe bending device, a rocker torque T of the pipe bending device, welding gun vibration dB 1, welding gun temperature T 1, groove device temperature T 2, groove device working sound dB 2, cutting device blade rising speed v, cutting device sound dB 3, AGV trolley moving distance s and AGV trolley lifting mechanism sound dB 4;
d, analyzing and processing the data acquired in the step c through a constructed convolutional neural network expert system; in particular, the method comprises the steps of,
Step d.1, initializing the execution times j=0 of the convolutional neural network expert system;
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, judging whether j is equal to or less than M is true or not by the convolutional neural network expert system? If so, converting the output size delta i into an input matrix X, and executing the steps d.3 to d.5; if not, outputting an output matrix W by the convolutional neural network expert system;
Step e, fault inquiry
The monitoring system accesses a fault database according to the output result W of the convolutional neural network expert system; if the corresponding faults are inquired in the fault database, the faults are sent to a fault display module for display, so that maintenance workers are guided to maintain, and standby equipment is started; if no corresponding fault is queried in the database, executing the step f;
Step f, updating database
Expert personnel judge the expression forms of the faults and the corresponding faults, if the expression forms of the faults are matched with the expression forms of the corresponding faults, the expression forms of the faults and the corresponding faults are incorporated into a database, the faults are sent to a fault display module for display, and the fault display module is used for guiding maintenance workers to maintain and starting standby equipment; updating the convolutional neural network expert system at the same time; if the fault and the corresponding fault expression form are not matched, obtaining the fault corresponding to the corresponding expression form according to the experience of expert personnel, incorporating the fault into a 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" in the present application means that each exists alone or both exist.
"Connected" as used herein means either a direct connection between components or an indirect connection between components via other components.
With the above-described preferred embodiments according to the present invention as an illustration, the above-described descriptions can be used by persons skilled in the relevant art to make various changes and modifications without departing from the scope of the technical idea of the present invention. The technical scope of the present invention is not limited to the description, but must be determined according to the scope of claims.

Claims (7)

1. A control method of an intelligent forming workshop for multi-specification marine pipes is characterized by comprising the following steps of: the intelligent forming workshop for the multi-specification marine pipe 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 products, finished products and flanges of the pipe 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 conveying system to realize the conveying and transferring of the multi-specification pipes on a conveying line;
Is divided into two parts, wherein 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: the shop receives the order
1.1, Receiving an nth batch of pipe processing orders in an intelligent forming workshop of the multi-specification marine pipe, wherein n is more than or equal to 2, and the content of the pipe processing orders comprises an ordering party, a delivery period, required pipe specifications, processing procedures, welding flange information and required quantity;
Step 1.2, a warehouse management module obtains an address stored in an RFID chip of a material tray in a vacant state in a warehouse system through a first RFID scanner;
Step 1.3, an order management module generates a processing technology file of each pipe according to order content received by a workshop, and writes the processing technology file into the acquired storage address;
And a second step of: acquiring workshop status information
The equipment management module acquires the state of each processing equipment in the workshop, wherein the state comprises equipment type, equipment performance, the current working state of the equipment and the current load capacity of the equipment;
And a third step of: scheduling order content based on process equipment status
Step 3.1, determining the time required for processing the order content, wherein the master control system obtains the types of the specifications of the pipes processed by the order through the order management module, and the analysis calculation module calculates the time required for processing all the types of pipes to complete all the working procedures;
step 3.2, determining the waiting processing time of the nth batch of orders, and calculating the time required by the completion of the processing of all kinds of pipes in the orders by an analysis and calculation module;
Step 3.3, determining the pipe transportation time, and acquiring the load capacity information of the processing equipment for the pipes with different specifications from a load capacity data storage module according to the pipe specifications by a master control system, wherein an analysis and calculation module calculates the transportation distance between each processing equipment and the warehouse, the required transportation times and the required transportation time of the pipes with each specification, and finally acquires the required transportation time of all kinds of pipes in an order;
step 3.4, determining the total time required for finishing order processing;
step 3.5, determining an optimal scheduling strategy, designating a plurality of different production scheduling plans by a production scheduling module, respectively calculating the total processing time of the different production scheduling plans, optimizing the total time required by completing the different production processing by adopting an intelligent scheduling algorithm to obtain a scheduling scheme with the shortest total processing time, and transmitting the optimal scheduling strategy to a total control system;
fourth step: semi-finished pipe transportation
Step 4.1, a command transmitting module transmits a transport command to a first AGV trolley and a second AGV trolley, and the first AGV trolley and the second AGV trolley feed back state information of the transport command, wherein the state information comprises transport 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;
Step 4.3, in the warehouse system, a conveying system in the pipe semi-finished product storage area conveys the required pipe semi-finished product to a second buffer area, and meanwhile, a first AGV trolley or a second AGV trolley conveys a material tray to the second buffer area, a second pipe grabbing device grabs the pipe semi-finished product and puts the pipe semi-finished product into the material tray, and the first AGV trolley or the second AGV trolley conveys the pipe semi-finished product to a processing station area;
Fifth step: semi-finished pipe processing
Step 5.1, a first RFID scanner scans an RFID chip on the material obtaining disc, 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, an analysis and calculation module selects a groove processing area, a bending processing area, a shrinkage or flaring processing area or a welding processing area in a processing station area according to the acquired pipe processing process sequence, and a first AGV trolley or a second AGV trolley handle material tray is transported to a first processing buffer area or a second processing buffer area or a third processing buffer area or a fourth processing buffer area;
Step 5.3, the instruction sending module sends corresponding processing instructions and controls related processing equipment to finish processing the pipe, and in the processing process, the data acquisition module acquires processing data and processing equipment monitoring data through sensing devices arranged on the 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 pipe specification information, acquires pipe processing data, analyzes the data, completes online quality detection of the pipe, and transmits the result to the master control system; the condition judging module judges the product quality: if the product quality is qualified, the first manipulator or the second manipulator or the third manipulator or the fourth manipulator grabs the pipe and places the pipe in a relevant processing buffer 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 second unqualified storage area or the third unqualified storage area or the fourth unqualified storage area or the fifth unqualified storage area;
Step 5.5, the condition judging module judges as follows: the pipe requires whether the processing procedure is finished or not, if not, the step 5.1 to the step 5.5 are executed; if so, executing the step 5.6;
Step 5.6, the condition judging module judges as follows: whether the order is completed or not, if the order is not completed, executing the fourth step to the fifth step; if the order is completed, executing a sixth step;
Sixth, two-dimensional code spraying
Step 6.1, the first AGV trolley or the second AGV trolley conveys the trays for storing qualified products to a fifth processing buffer 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;
Step 6.3, the command sending module sends a two-dimensional code spraying command and controls the sixth manipulator to grasp the pipe and place the pipe on the first two-dimensional code spraying equipment or the second two-dimensional code spraying equipment so as to finish the code spraying operation; a sixth manipulator is used for placing the pipe in the material tray;
step 6.4, the condition judging module judges as follows: whether the code spraying operation of all the pipes is finished or not, if not, executing the step 6.1 to the step 6.4; if so, executing a seventh step;
Seventh step: warehousing of qualified products
Step 7.1, a command sending module sends a transport command to a first AGV trolley or a second AGV trolley, and the first AGV trolley or the second AGV trolley feeds back state information of the transport command, wherein the state information comprises transport state and electric quantity information;
Step 7.2, selecting a proper AGV according to the state information fed back by the first AGV or the second AGV by the analysis and calculation module;
Step 7.3, the first AGV trolley or the second AGV trolley conveys the material tray to a third buffer area, and the third pipe grabbing device transfers the finished pipe to a specific material tray in a pipe finished product storage area to finish warehousing;
Eighth, the warehouse management module judges whether the storage area of the semi-finished product of the pipe needs to be supplemented, if so, the ninth step to the eleventh step are executed; otherwise, executing a twelfth step;
ninth step, transporting the raw materials of the pipe
Step 9.1, a warehouse management module produces a feed supplement file according to the specifications of the semi-finished products of the pipe, wherein the feed supplement file comprises the specifications and the quantity of the required semi-finished products of the pipe;
step 9.2, the command transmitting module transmits a material taking signal, and the travelling crane of the raw material storage area takes out the corresponding raw material of the pipe from the raw material storage area and places the pipe on a material feeding conveying line;
Tenth step: pipe raw material processing
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 instruction to finish processing the raw material of the pipe; in the processing process, a data acquisition module acquires related process processing data and related processing equipment monitoring data through sensing devices arranged on all equipment and stores the processing data and the equipment monitoring data in a processing data storage module and an equipment monitoring data storage module respectively;
Step 10.2, the quality management module accesses the shared cloud according to the pipe specification information, acquires pipe processing data, processes the data, performs online quality detection on the pipe, and transmits the result to the master control system; the condition judging module judges the product quality: if the product quality is qualified, the first manipulator grabs the semi-finished product of the pipe and places the semi-finished product in a temporary storage area of the semi-finished product; if the product quality is unqualified, the first manipulator grabs the semi-finished product of the pipe and places the semi-finished product in a first unqualified storage area;
Step 10.3, the condition judging module judges as follows: whether the feeding order is completed or not, if the order is not completed, executing the ninth step to the tenth step; if the order is completed, executing a thirteenth step;
eleventh step, the semi-finished products of the pipes are put in storage
11.1, A command sending module sends a transport command to a first AGV trolley or a second AGV trolley, and the first AGV trolley or the second AGV trolley feeds back state information of the transport command, wherein the state information comprises transport state and electric quantity information;
11.2, selecting a proper AGV according to the state information fed back by the first AGV or the second AGV by the analysis and calculation module;
11.3, conveying the first AGV trolley or the second AGV trolley to a third buffer area by using a material tray, and transferring the semi-finished pipe to a specific material tray in a pipe semi-finished storage area by using a third pipe grabbing device to finish warehousing;
Twelfth step, stock judgment of warehouse system
Step 12.1, the warehouse management module judges whether the flange storage area needs to be supplemented, and if so, an alarm is sent to prompt a manager to feed; otherwise, executing the 12.2 th step;
Step 12.2, the warehouse management module judges whether the raw material storage area needs to be supplemented, and if so, an alarm is sent to prompt a manager to feed; otherwise, executing a thirteenth step;
Thirteenth, the master control system judges whether a new order is generated: if a new order is generated, executing the first step to the thirteenth step; if no new order is generated, ending;
The fault detection method specifically comprises the following steps:
Step a, constructing a database
Constructing a fault database according to the fault types and reasons of each device of the intelligent workshop in the working process and combining with the suggestions of expert personnel, wherein the database contains known fault types possibly generated and the expression forms of corresponding faults;
Step b, constructing a convolutional neural network expert system
Step c, data acquisition
The method comprises the steps that related data are collected through sensing devices arranged on all devices of an intelligent workshop, wherein the sensing devices comprise a three-phase current I u、Iv、Iw and a three-phase voltage U u、Uv、Uw of a motor of the pipe bending device, a rocker angle theta of the pipe bending device, a rocker torque T of the pipe bending device, welding gun vibration dB 1, welding gun temperature T 1, groove device temperature T 2, groove device working sound dB 2, cutting device blade rising speed v, cutting device sound dB 3, AGV trolley moving distance s and AGV trolley lifting mechanism sound dB 4;
d, analyzing and processing the data acquired in the step c through a constructed convolutional neural network expert system;
Step e, fault inquiry
The monitoring system accesses a fault database according to an output result delta i of the convolutional neural network expert system; if the corresponding faults are inquired in the fault database, the faults are sent to a fault display module for display, so that maintenance workers are guided to maintain, and standby equipment is started; if no corresponding fault is queried in the database, executing the step f;
Step f, updating database
Expert personnel judge the expression forms of the faults and the corresponding faults, if the expression forms of the faults are matched with the expression forms of the corresponding faults, the expression forms of the faults and the corresponding faults are incorporated into a database, the faults are sent to a fault display module for display, and the fault display module is used for guiding maintenance workers to maintain and starting standby equipment; updating the convolutional neural network expert system at the same time; if the fault and the corresponding fault expression form are not matched, obtaining the fault corresponding to the corresponding expression form according to the experience of expert personnel, incorporating the fault into a database, and updating the convolutional neural network expert system.
2. A multi-gauge marine pipe intelligent forming shop for use in the control method of claim 1, characterized by: the raw material storage area is provided with a raw material storage area for classifying and storing the multi-specification pipes, and the raw material storage area is used for conveying raw materials;
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 judging module, wherein the analysis and calculation module obtains 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 meanwhile, an execution instruction is sent to the raw material storage area, the pretreatment processing area, the processing station area and the transportation system, and the condition judging module judges the quality of products;
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 workshops, the data acquisition module is used for collecting production information in workshops, the quality management module is used for managing the quality of products, the warehouse management module is used for managing raw material storage areas and warehouse systems in workshops, the order management module is used for managing the order information of the products, and the equipment management module is used for managing equipment in workshops;
The shared cloud comprises an RFID information storage module, a processing data storage module, an equipment monitoring data storage module and a load capacity 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 capacity data storage module is used for storing load capacity data in the workshop;
The monitoring system is used for monitoring all parts in the workshop.
3. The multi-gauge marine pipe intelligent forming shop according to claim 2, wherein: the pretreatment processing area comprises a feeding conveying line, first straightening equipment, second straightening equipment, first cutting equipment, second cutting equipment, first detecting equipment, second detecting equipment, a semi-finished product temporary storage area and a first disqualification storage area, wherein the feeding conveying line is located at the upstream of the production line, the first straightening equipment, the first cutting equipment and the first detecting equipment are sequentially arranged on one side of the production line, the second straightening equipment, the second cutting equipment and the second detecting equipment are sequentially arranged on the other side of the production line, the first straightening equipment, the second straightening equipment, the first cutting equipment, the second cutting equipment, the first detecting equipment and the second detecting equipment are symmetrically arranged, the pretreatment processing area further comprises a first manipulator which clamps and transfers detected products to the semi-finished product temporary storage area, and the first manipulator clamps and transfers detected disqualification products to the first disqualification storage area.
4. A multi-gauge marine pipe intelligent forming shop according to claim 3, wherein: the storage system comprises a material disc 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 discs are placed in the material disc storage area, the first RFID scanner is used for scanning and recording material disc information, a first buffer area is arranged at the inlet of the flange storage area, a second buffer area is arranged at the inlet of the pipe semi-finished product storage area, a third buffer area is arranged at the inlet of the pipe finished product storage area, the material discs are conveyed to the corresponding buffer areas by a conveying system, meanwhile, 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 buffer areas by the conveying system, a first pipe grabbing device is arranged in the first buffer area, the flange grabbing device is arranged in the material disc positioned in the first buffer area, a second pipe grabbing device is arranged in the second buffer area, a third pipe grabbing device is arranged in the third buffer area, and the pipe semi-finished product grabbing device is arranged in the material disc positioned in the third buffer area.
5. The multi-gauge marine pipe intelligent forming shop according to claim 4, wherein: the processing station area comprises a bending processing area, a groove processing area, a shrinkage or flaring processing area, a welding processing area and a two-dimensional code spraying area, a second RFID scanner is also arranged, and a material tray filled with products is distributed to each area in the processing station area through a conveying system after being scanned by the second RFID scanner;
the bending processing area comprises first pipe bending equipment, second pipe bending equipment, a first processing buffer area and a first disqualification storage area, the transportation system conveys qualified products from the matching area to the first processing buffer area, the second manipulator clamps the products from the first processing buffer area to the first pipe bending equipment and the second pipe bending equipment for bending treatment, and then clamps the disqualification products after bending treatment into the second disqualification storage area;
The groove processing area comprises first groove equipment, second groove equipment, a second processing buffer area and a second disqualification storage area, the transportation system conveys qualified products from the matching area to the second processing buffer area, the third manipulator clamps the products from the second processing buffer area to the first groove equipment and the second groove equipment for groove processing, and then clamps the disqualification products after groove processing into the third disqualification storage area;
The shrinkage or flaring processing area comprises first shrinkage or flaring equipment, second shrinkage or flaring equipment, a third processing buffer area and a third disqualification storage area, the transportation system conveys qualified products from the matching area to the third processing buffer area, the fourth mechanical arm clamps the products from the third processing buffer area to the first shrinkage or flaring equipment and the second shrinkage or flaring equipment for shrinkage or flaring treatment, and then clamps the disqualification products after shrinkage or flaring to the fourth disqualification storage area;
The welding processing area comprises a first welding device, a second welding device, a fourth processing buffer area and a fourth disqualification storage area, the transportation system conveys qualified products from the matching area to the fourth processing buffer area, the fifth mechanical arm 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 and conveys the disqualification products to the fifth disqualification storage area;
the two-dimensional code spraying area comprises first two-dimensional code spraying equipment, second two-dimensional code spraying equipment and a fifth processing buffer area, the transportation system conveys qualified products to the fifth processing buffer area from the matching area, and the sixth manipulator clamps the products from the fifth processing buffer area to the first two-dimensional code spraying equipment and the second two-dimensional code spraying equipment for spraying treatment.
6. The multi-gauge marine pipe intelligent forming shop according to claim 5, wherein: the transport system comprises a first AGV and a second AGV, and a charging area for charging the first AGV and the second AGV is further arranged.
7. The multi-gauge marine pipe intelligent forming shop according to claim 6, wherein: the method comprises the steps of installing laser displacement sensors on a first detection device and a second detection device, installing an angle sensor, a torque sensor and a first scanner on the first pipe bending device and the second pipe bending device, installing a second scanner, a pressure sensor and a displacement sensor on a first shrinking or expanding device and a second shrinking or expanding device, installing a speed sensor, a third scanner and a surface roughness meter on a first groove device and a second groove device, and installing a voltage sensor, a current sensor and an ultrasonic nondestructive inspection meter on a first welding device and a second welding device.
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