CN113001066A - Real-time monitoring system and monitoring method for pipeline welding working condition - Google Patents
Real-time monitoring system and monitoring method for pipeline welding working condition Download PDFInfo
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- CN113001066A CN113001066A CN202110169341.1A CN202110169341A CN113001066A CN 113001066 A CN113001066 A CN 113001066A CN 202110169341 A CN202110169341 A CN 202110169341A CN 113001066 A CN113001066 A CN 113001066A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
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- G06K17/0022—Methods or arrangements for effecting co-operative working between equipments covered by two or more of main groups G06K1/00 - G06K15/00, e.g. automatic card files incorporating conveying and reading operations arrangements or provisious for transferring data to distant stations, e.g. from a sensing device
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- G—PHYSICS
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- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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Abstract
The invention relates to a real-time monitoring system and a monitoring method for pipeline welding conditions. The real-time pipeline welding condition monitoring system comprises a welding parameter sensor, a welder two-dimensional code, a welded junction two-dimensional code, a code scanner, a welding condition acquisition terminal and a monitoring center server, wherein a pipeline engineering database, a welder group database, a full-automatic welding machine database and a welding process rule database are arranged in the welding condition acquisition terminal; the welding condition acquisition terminal is used for scanning the two-dimensional code of the welder and the two-dimensional code of the welding crater, determining a welding process rule adopted by the welding crater through database correlation query according to analysis information of the two-dimensional code, reading a welding parameter detected by the welding parameter sensor when the welding machine works in real time, sending alarm information when the welding parameter of the welding machine is in an abnormal working condition, and sending the analysis information of the two-dimensional code, the determined number information of the welding process rule, the welding parameter information when the welding machine works and the alarm information of the abnormal working condition to a monitoring center through a 4G network for service.
Description
Technical Field
The invention relates to a monitoring technology of welding conditions, in particular to a real-time monitoring system and a monitoring method of pipeline welding conditions.
Background
As a main link of natural gas pipeline installation and construction, the welding quality of the natural gas pipeline installation and construction method is directly related to the safe production operation capacity of the natural gas pipeline. At present, in the construction process of natural gas pipeline construction in China, the welding quality depends on the technical level and responsibility of welders to a great extent, welding process parameters are temporarily stored in a full-automatic welding machine, and then are manually copied into a computer end by field operators according to management requirements for manual data analysis. This approach is very labor intensive, data is inefficient, and data loss occurs at times. Because the platform management can not be timely and intuitively carried out, the middle process of pipeline welding is difficult to carry out real-time monitoring, and the change of welding parameters, the reduction of the number of welding layers and the number of channels can not be found through subsequent nondestructive testing in the welding operation process. The change of welding parameters and the reduction of the number of welding layers and welding tracks can often seriously reduce the performance of welding seams and the quality grade of welding, bring a plurality of uncertain factors to the control of welding quality, and bring great potential safety hazards to the safety construction of the natural gas pipeline. With the continuous improvement of the requirements of China on the construction quality of natural gas pipelines, the intelligent pipeline construction and the whole life cycle management of the pipelines become necessary trends.
Disclosure of Invention
The invention aims to provide a real-time pipeline welding condition monitoring system to solve the problem that the welding quality of a pipeline is influenced because the welding quality cannot be monitored in real time in the pipeline welding operation process.
The invention also aims to provide a real-time monitoring method for the welding condition of the pipeline, so as to realize intelligent pipeline construction, eliminate potential safety hazards caused by insufficient monitoring of pipeline welding construction and meet the working requirement of the construction quality requirement of the natural gas pipeline.
One of the objects of the invention is achieved by:
a real-time monitoring system for pipeline welding conditions comprises:
the welding parameter sensor is arranged on the full-automatic welding machine and used for collecting the working parameters of the welding machine, including welding current, welding voltage, wire feeding speed and environment temperature and humidity, generated during the working of the full-automatic welding machine;
the welder two-dimensional code is compiled by combining the two-dimensional code rule with comprehensive information including the number, name, telephone, job title and the welder team group where the welder is located, and is sealed and printed in a work hanging plate worn by each welder;
the crater two-dimensional code is compiled by combining the two-dimensional code rule and comprehensive information including engineering number, pile number, welding direction, crater number, crater form, full-automatic welding machine, required welding process rules and parameters of steel grade, wall thickness and pipe diameter of upstream steel pipes and downstream steel pipes of the crater, and is printed into pages and then adhered to the pipe wall of each steel pipe forming the butt-joint crater;
the code scanner is used for scanning the two-dimensional code of the welder and the two-dimensional code of the welding opening and transmitting scanning information to the welding condition acquisition terminal;
the system comprises a welding condition acquisition terminal, a pipeline engineering database, a welding crew group database, a full-automatic welding machine database and a welding process rule database, wherein the welding condition acquisition terminal is internally provided with a pipeline engineering database, a welding crew group database, a full-automatic welding machine database and a welding process rule database, is arranged at a pipeline welding operation point and is used for scanning a welding crew two-dimensional code and a welding crater two-dimensional code, determining a welding process rule to be adopted by the welding crater through database correlation query according to corresponding information obtained by analyzing the two-dimensional code, reading a welding parameter detected by a welding parameter sensor when a welding machine works in real time and storing the welding parameter into a real-time register, sending abnormal working condition alarm information when the welding parameter exceeds an abnormal working condition, and sending the two-dimensional code analysis information, the determined welding process rule number information, the welding parameter information when the welding machine; and
and the monitoring center server is used for receiving and storing two-dimensional code analysis information, determined welding process procedure number information, welding parameter information during the operation of the welding machine and abnormal working condition warning information which are sent by the welding working condition acquisition terminal through a 4G network, so that intelligent pipeline construction and pipeline full-life-cycle management are realized.
Welding condition acquisition terminal includes:
the data acquisition unit is used for carrying out reading type acquisition on the welding parameter information acquired by the welding parameter sensor;
the real-time register is used for storing corresponding information obtained by analyzing the two-dimensional code and welding parameter information collected by the data collector;
the 4G network is used for constructing an information transmission channel between the welding condition acquisition terminal and the monitoring center server; and
the data acquisition controller is used for analyzing the scanned two-dimensional code of the welder and the two-dimensional code of the welding crater, determining a welding process rule which is required by the welding crater according to the obtained corresponding information through database correlation query, controlling the data acquisition device to read welding parameters detected by the welding parameter sensor when the welder works and store the welding parameters into the real-time register, sending abnormal working condition alarm information when the welding parameters are in an abnormal working condition exceeding the limit, and sending the two-dimensional code analysis information, the determined welding process rule number information, the welding parameter information when the welder works and the abnormal working condition alarm information to the monitoring center server through the 4G network.
Welding condition acquisition terminal still includes:
the camera is used for acquiring crater information, interlayer temperature and protective gas flow and transmitting the acquired data information to the monitoring center server through the 4G network;
RJ45, 485 and I/O interfaces for communicating with environmental and status sensors; and
and the environment and state sensor is used for monitoring the running state and safety information of the welding condition acquisition terminal in real time.
The second purpose of the invention is realized by the following steps:
a real-time monitoring method for pipeline welding conditions comprises the following steps:
a. establishing a pipeline engineering database: the database content comprises geographic information of pipeline engineering, pipeline laying information, steel pipes and types used along the line, parameter information about the steel pipes, a weld crater form, a welding process procedure required by the weld crater, a weld crater number, an upstream steel pipe number and a downstream steel pipe number; the pipeline engineering database is respectively arranged in the welding condition acquisition terminal and the monitoring center server;
b. establishing a welding work group database: the database content comprises the number, name, telephone, job and welding machine set of each welder in each welder group; the welding work group database is respectively arranged in a welding work condition acquisition terminal and a monitoring center server;
c. establishing a full-automatic welding machine database: the database content comprises serial numbers of full-automatic welding machines configured in all pipeline projects and welding crew groups distributed for use; the full-automatic welding machine database is respectively arranged in the welding condition acquisition terminal and the monitoring center server;
d. compiling a welder two-dimensional code: the comprehensive information including the serial number, name, telephone, job and the welding team group of the welder is compiled into a two-dimensional code of the welder by combining with the two-dimensional code rule, and the two-dimensional code is sealed and printed in a work tag worn by each welder;
e. and (3) compiling a weld joint two-dimensional code: the method comprises the steps of compiling comprehensive information including engineering numbers, pile numbers, welding directions, crater numbers, crater forms, welding directions, full-automatic welding machines, required welding process procedures and parameters including steel grades, wall thicknesses and pipe diameters of upstream steel pipes and downstream steel pipes of craters into crater two-dimensional codes by combining with a two-dimensional code rule, and printing the crater two-dimensional codes into pages and then respectively sticking the pages to the pipe walls of the butt ends of the upstream steel pipes and the downstream steel pipes of each crater;
f. scanning the two-dimensional code of the welder by using a code scanner, performing database correlation query according to the number of the welder, and determining the identity of a welding operator and the number of the operated full-automatic welding machine;
g. scanning a two-dimensional code of a welded junction by using a code scanner, establishing a corresponding relation table of a full-automatic welding machine and a welding process rule and including steel pipe correlation information in a welding working condition acquisition terminal, and performing database correlation query according to the number of the full-automatic welding machine to obtain the welding process rule required by the welded junction and an information list relating to parameters such as steel grade, wall thickness and pipe diameter of an upstream steel pipe and a downstream steel pipe of the welded junction;
h. the welding condition acquisition terminal filters the information list obtained in the step g again according to the acquired steel grade, wall thickness and pipe diameter parameters of the steel pipe on the upstream and downstream of the welded junction, finally determines the number of the welding process procedure adopted by the welded junction, and inquires out the standard threshold range of the welding parameters including the welding current, the welding voltage, the wire feeding speed, the welding speed and the protective gas flow of the corresponding procedure from a welding process procedure library;
i. the method comprises the steps that a welding condition acquisition terminal acquires and stores welding parameter information detected by a welding parameter sensor in a full-automatic welding machine in real time when the welding machine works, stores the welding parameter information into a real-time register, sends abnormal condition alarm information when the welding parameter is in an abnormal condition exceeding the limit, and sends two-dimensional code analysis information, determined welding process procedure number information, welding parameter information when the welding machine works and the abnormal condition alarm information to a monitoring center server through a 4G network;
j. the monitoring center server receives and stores two-dimensional code analysis information, determined welding process procedure number information, welding parameter information during the operation of the welding machine and abnormal working condition warning information which are sent by the welding working condition acquisition terminal through a 4G network, and intelligent pipeline construction and pipeline full-life cycle management are realized through real-time monitoring of welding working conditions and inquiry and analysis of welding historical data.
The invention realizes the real-time collection of welding process parameters and the intelligent quality monitoring of a construction site by collecting, processing and analyzing the welding process parameters, forms big data of a welding construction process, and is used as a data base for carrying out the quality inspection work of the welding seam of the natural gas pipeline. Aiming at the characteristics of the current pipeline welding construction, the method can strengthen the process monitoring of the welding operation of the construction site, ensure that the welding working condition parameters meet the welding process rules and the quality of the welded junction meets the standards and requirements. The invention realizes real-time, accurate and reliable acquisition and uploading of core process parameters such as a welder number, a weld crater number, welding current, voltage, temperature, wire feeding speed, a welding layer and the like through the welding condition data acquisition terminal and the on-site wireless transmission system, can automatically match welding process rules according to two-dimensional code analysis information, alarms on abnormal welding conditions in real time, and meets the management requirements of on-line real-time monitoring of welding process parameters in a construction site and intelligent alarm on abnormal welding conditions.
The invention can carry out real-time acquisition, analysis and alarm on welding process parameters, realize real-time tracking on the welding process, discover the quality hidden danger as soon as possible, reduce the occurrence of major quality problems and further improve the welding quality control capability of the natural gas pipeline. By the arrangement of the welding working condition acquisition terminal, a large amount of work and data loss caused by manual copying and manual data analysis and the probability of errors in the manual data analysis are avoided, so that the timeliness of the welding working condition data is stronger, and the service requirement of a supervision department on the real-time monitoring of the welding construction quality can be well met; through the scientifically designed abnormal working condition monitoring process, system automatic analysis can be carried out on abnormal working condition parameters, alarm information can be generated on the generated abnormal working conditions, in-system alarm is carried out, and then short message sending, large-screen display and voice alarm are combined, so that the quality management effect can be further improved.
Drawings
FIG. 1 is a schematic diagram of the system of the present invention.
Fig. 2 is a structural block diagram of a welding condition acquisition terminal.
Detailed Description
As shown in FIG. 1, the real-time monitoring system for the pipeline welding condition comprises a welding parameter sensor, a welder two-dimensional code, a welded junction two-dimensional code, a code scanner, a welding condition acquisition terminal, a monitoring center server and the like. The welding condition acquisition terminal is connected with the code scanner and the welding parameter sensor in a wired mode, and the welding condition acquisition terminal is connected with the monitoring center server in a wireless mode through network transmission.
The welding parameter sensor is a component of the existing full-automatic welding machine, and can acquire the working parameters of the welding machine including welding current, welding voltage, wire feeding speed and environment temperature and humidity generated by the full-automatic welding machine during working in real time. The welder two-dimensional code is compiled by combining the two-dimensional code rule with comprehensive information including the number, name, telephone, job title and the welder team group where the welder is located, and is sealed and printed in a work tag worn by each welder. The crater two-dimensional code is compiled by combining the two-dimensional code rule and comprehensive information including engineering number, pile number, welding direction, crater number, crater form, full-automatic welding machine, required welding process rules and parameters of steel grade, wall thickness and pipe diameter of upstream steel pipes and downstream steel pipes of craters, and the two-dimensional code is printed into pages and then adhered to the pipe walls of the upstream steel pipes and the downstream steel pipes which form butt-joint craters at butt-joint ends. The code scanner can adopt a commercially available sizing product and is used for scanning a welder two-dimensional code worn by a welder and a welded junction two-dimensional code on the wall of a steel pipe on a construction site and transmitting scanning information to a welding condition acquisition terminal.
As shown in fig. 2, the welding condition acquisition terminal includes a data acquisition unit, a real-time register, a 4G network, a data acquisition controller, a camera, an environment and state sensor, and RJ45, 485 and I/O interfaces. The data acquisition controller is respectively connected with the data acquisition unit, the real-time register, the 4G network and the camera, and is connected with the environment and state sensor through RJ45, 485 and I/O interfaces.
And the data acquisition unit is used for carrying out reading type acquisition on the welding parameter information acquired by the welding parameter sensor. The real-time register is used for storing corresponding information obtained by analyzing the two-dimensional code and welding parameter information collected by the data collector. The 4G network is used for constructing an information transmission channel between the welding condition acquisition terminal and the monitoring center server.
The data acquisition controller analyzes the scanned two-dimensional code of the welder and the two-dimensional code of the crater, determines a welding process rule which is adopted by the crater of the scanned two-dimensional code according to the obtained analysis information of the two-dimensional code through database correlation query, controls the data acquisition unit to read welding parameters detected by a welding parameter sensor in the full-automatic welding machine for welding the crater when the welding machine works, and stores the welding parameter information into a real-time register; when the detected welding parameters are in an out-of-limit abnormal working condition, the data acquisition controller immediately sends out abnormal working condition warning information; the data acquisition controller also sends the two-dimensional code analysis information, the determined welding process procedure number information, the welding parameter information when the welding machine works, the abnormal working condition alarm information and the like to a monitoring center server through a 4G network.
The RJ45, 485 and I/O interfaces communicate with environmental and status sensors. The environment and state sensor monitors the running state and safety information of the welding condition acquisition terminal in real time, and the monitoring information is sent to the data acquisition controller through RJ45, 485 and I/O interfaces.
The camera is installed on a welding construction site, is connected with the welding working condition acquisition terminal and is used for acquiring crater information, interlayer temperature and protective gas flow and transmitting the acquired data information to the monitoring center server through the 4G network.
The working condition parameters which can be collected and monitored by the welding working condition collection terminal are shown in the following table:
the monitoring center server can be arranged in a monitoring center of a quality management department and can also be arranged in a cloud. The monitoring center server is used for receiving and storing two-dimensional code analysis information, determined welding process procedure number information, welding parameter information during the operation of the welding machine and abnormal working condition warning information which are sent by the welding working condition acquisition terminal through the 4G network, and intelligent pipeline construction and pipeline full-life-cycle management are achieved.
The invention discloses a real-time monitoring method for pipeline welding conditions, which comprises the following steps:
1. establishing a pipeline engineering database: the database content comprises geographic information of pipeline engineering, pipeline laying information, steel pipes and types used along the line, parameter information about the steel pipes, a weld crater form, a welding process procedure required by the weld crater, a weld crater number, an upstream steel pipe number and a downstream steel pipe number; the pipeline engineering database is respectively arranged in the welding condition acquisition terminal and the monitoring center server;
2. establishing a welding work group database: the database content comprises the number, name, telephone, job and welding machine set of each welder in each welder group; the welding work group database is respectively arranged in a welding work condition acquisition terminal and a monitoring center server;
3. establishing a full-automatic welding machine database: the database content comprises serial numbers of full-automatic welding machines configured in all pipeline projects and welding crew groups distributed for use; the full-automatic welding machine database is respectively arranged in the welding condition acquisition terminal and the monitoring center server;
4. compiling a welder two-dimensional code: the comprehensive information including the serial number, name, telephone, job and the welding team group of the welder is compiled into a two-dimensional code of the welder by combining with the two-dimensional code rule, and the two-dimensional code is sealed and printed in a work tag worn by each welder;
5. and (3) compiling a weld joint two-dimensional code: the method comprises the steps of compiling comprehensive information including engineering numbers, pile numbers, welding directions, crater numbers, crater forms, welding directions, full-automatic welding machines, required welding process procedures and parameters including steel grades, wall thicknesses and pipe diameters of upstream steel pipes and downstream steel pipes of craters into crater two-dimensional codes by combining with a two-dimensional code rule, and printing the crater two-dimensional codes into pages and then respectively sticking the pages to the pipe walls of the butt ends of the upstream steel pipes and the downstream steel pipes of each crater;
6. scanning the two-dimensional code of the welder by using a code scanner, performing database correlation query according to the number of the welder, and determining the identity of a welding operator and the number of the operated full-automatic welding machine;
7. scanning a two-dimensional code of a welded junction by using a code scanner, establishing a corresponding relation table of a full-automatic welding machine and a welding process rule and including steel pipe correlation information in a welding working condition acquisition terminal, and performing database correlation query according to the number of the full-automatic welding machine to obtain the welding process rule required by the welded junction and an information list relating to parameters such as steel grade, wall thickness and pipe diameter of an upstream steel pipe and a downstream steel pipe of the welded junction;
8. the welding condition acquisition terminal filters the information list obtained in the step 7 again according to the obtained steel grade, wall thickness and pipe diameter parameters of the steel pipe on the upstream and downstream of the welded junction, finally determines the number of the welding process procedure adopted by the welded junction, and inquires out the standard threshold range of the welding parameters including the welding current, the welding voltage, the wire feeding speed, the welding speed and the protective gas flow of the corresponding procedure from a welding process procedure library;
9. the method comprises the steps that a welding condition acquisition terminal acquires and stores welding parameter information detected by a welding parameter sensor in a full-automatic welding machine in real time when the welding machine works, stores the welding parameter information into a real-time register, sends abnormal condition alarm information when the welding parameter is in an abnormal condition exceeding the limit, and sends two-dimensional code analysis information, determined welding process procedure number information, welding parameter information when the welding machine works and the abnormal condition alarm information to a monitoring center server through a 4G network;
10. the monitoring center server receives and stores two-dimensional code analysis information, determined welding process procedure number information, welding parameter information during the operation of the welding machine and abnormal working condition warning information which are sent by the welding working condition acquisition terminal through a 4G network, and intelligent pipeline construction and pipeline full-life cycle management are realized through real-time monitoring of welding working conditions and inquiry and analysis of welding historical data.
Claims (6)
1. The utility model provides a pipeline welding condition real-time monitoring system, characterized by includes:
the welding parameter sensor is arranged on the full-automatic welding machine and used for collecting the working parameters of the welding machine, including welding current, welding voltage, wire feeding speed and environment temperature and humidity, generated during the working of the full-automatic welding machine;
the welder two-dimensional code is compiled by combining the two-dimensional code rule with comprehensive information including the number, name, telephone, job title and the welder team group where the welder is located, and is sealed and printed in a work hanging plate worn by each welder;
the crater two-dimensional code is compiled by combining the two-dimensional code rule and comprehensive information including engineering number, pile number, welding direction, crater number, crater form, full-automatic welding machine, required welding process rules and parameters of steel grade, wall thickness and pipe diameter of upstream steel pipes and downstream steel pipes of the crater, and is printed into pages and then adhered to the pipe wall of each steel pipe forming the butt-joint crater;
the code scanner is used for scanning the two-dimensional code of the welder and the two-dimensional code of the welding opening and transmitting scanning information to the welding condition acquisition terminal;
the system comprises a welding condition acquisition terminal, a pipeline engineering database, a welding crew group database, a full-automatic welding machine database and a welding process rule database, wherein the welding condition acquisition terminal is internally provided with a pipeline engineering database, a welding crew group database, a full-automatic welding machine database and a welding process rule database, is arranged at a pipeline welding operation point and is used for scanning a welding crew two-dimensional code and a welding crater two-dimensional code, determining a welding process rule to be adopted by the welding crater through database correlation query according to corresponding information obtained by analyzing the two-dimensional code, reading a welding parameter detected by a welding parameter sensor when a welding machine works in real time and storing the welding parameter into a real-time register, sending abnormal working condition alarm information when the welding parameter exceeds an abnormal working condition, and sending the two-dimensional code analysis information, the determined welding process rule number information, the welding parameter information when the welding machine; and
and the monitoring center server is used for receiving and storing two-dimensional code analysis information, determined welding process procedure number information, welding parameter information during the operation of the welding machine and abnormal working condition warning information which are sent by the welding working condition acquisition terminal through a 4G network, so that intelligent pipeline construction and pipeline full-life-cycle management are realized.
2. The real-time monitoring system for the welding condition of the pipeline according to claim 1, wherein the welding condition acquisition terminal comprises:
the data acquisition unit is used for carrying out reading type acquisition on the welding parameter information acquired by the welding parameter sensor;
the real-time register is used for storing corresponding information obtained by analyzing the two-dimensional code and welding parameter information collected by the data collector;
the 4G network is used for constructing an information transmission channel between the welding condition acquisition terminal and the monitoring center server; and
the data acquisition controller is used for analyzing the scanned two-dimensional code of the welder and the two-dimensional code of the welding crater, determining a welding process rule which is required by the welding crater according to the obtained corresponding information through database correlation query, controlling the data acquisition device to read welding parameters detected by the welding parameter sensor when the welder works and store the welding parameters into the real-time register, sending abnormal working condition alarm information when the welding parameters are in an abnormal working condition exceeding the limit, and sending the two-dimensional code analysis information, the determined welding process rule number information, the welding parameter information when the welder works and the abnormal working condition alarm information to the monitoring center server through the 4G network.
3. The real-time monitoring system for the welding condition of the pipeline according to claim 2, wherein the welding condition collecting terminal further comprises:
the camera is used for acquiring crater information, interlayer temperature and protective gas flow and transmitting the acquired data information to the monitoring center server through the 4G network;
RJ45, 485 and I/O interfaces for communicating with environmental and status sensors; and
and the environment and state sensor is used for monitoring the running state and safety information of the welding condition acquisition terminal in real time.
4. A real-time monitoring method for pipeline welding conditions is characterized by comprising the following steps:
a. establishing a pipeline engineering database: the database content comprises geographic information of pipeline engineering, pipeline laying information, steel pipes and types used along the line, parameter information about the steel pipes, a weld crater form, a welding process procedure required by the weld crater, a weld crater number, an upstream steel pipe number and a downstream steel pipe number; the pipeline engineering database is respectively arranged in the welding condition acquisition terminal and the monitoring center server;
b. establishing a welding work group database: the database content comprises the number, name, telephone, job and welding machine set of each welder in each welder group; the welding work group database is respectively arranged in a welding work condition acquisition terminal and a monitoring center server;
c. establishing a full-automatic welding machine database: the database content comprises serial numbers of full-automatic welding machines configured in all pipeline projects and welding crew groups distributed for use; the full-automatic welding machine database is respectively arranged in the welding condition acquisition terminal and the monitoring center server;
d. compiling a welder two-dimensional code: the comprehensive information including the serial number, name, telephone, job and the welding team group of the welder is compiled into a two-dimensional code of the welder by combining with the two-dimensional code rule, and the two-dimensional code is sealed and printed in a work tag worn by each welder;
e. and (3) compiling a weld joint two-dimensional code: the method comprises the steps of compiling comprehensive information including engineering numbers, pile numbers, welding directions, crater numbers, crater forms, welding directions, full-automatic welding machines, required welding process procedures and parameters including steel grades, wall thicknesses and pipe diameters of upstream steel pipes and downstream steel pipes of craters into crater two-dimensional codes by combining with a two-dimensional code rule, and printing the crater two-dimensional codes into pages and then respectively sticking the pages to the pipe walls of the butt ends of the upstream steel pipes and the downstream steel pipes of each crater;
f. scanning the two-dimensional code of the welder by using a code scanner, performing database correlation query according to the number of the welder, and determining the identity of a welding operator and the number of the operated full-automatic welding machine;
g. scanning a two-dimensional code of a welded junction by using a code scanner, establishing a corresponding relation table of a full-automatic welding machine and a welding process rule and including steel pipe correlation information in a welding working condition acquisition terminal, and performing database correlation query according to the number of the full-automatic welding machine to obtain the welding process rule required by the welded junction and an information list relating to parameters such as steel grade, wall thickness and pipe diameter of an upstream steel pipe and a downstream steel pipe of the welded junction;
h. the welding condition acquisition terminal filters the information list obtained in the step g again according to the acquired steel grade, wall thickness and pipe diameter parameters of the steel pipe on the upstream and downstream of the welded junction, finally determines the number of the welding process procedure adopted by the welded junction, and inquires out the standard threshold range of the welding parameters including the welding current, the welding voltage, the wire feeding speed, the welding speed and the protective gas flow of the corresponding procedure from a welding process procedure library;
i. the method comprises the steps that a welding condition acquisition terminal acquires and stores welding parameter information detected by a welding parameter sensor in a full-automatic welding machine in real time when the welding machine works, stores the welding parameter information into a real-time register, sends abnormal condition alarm information when the welding parameter is in an abnormal condition exceeding the limit, and sends two-dimensional code analysis information, determined welding process procedure number information, welding parameter information when the welding machine works and the abnormal condition alarm information to a monitoring center server through a 4G network;
j. the monitoring center server receives and stores two-dimensional code analysis information, determined welding process procedure number information, welding parameter information during the operation of the welding machine and abnormal working condition warning information which are sent by the welding working condition acquisition terminal through a 4G network, and intelligent pipeline construction and pipeline full-life cycle management are realized through real-time monitoring of welding working conditions and inquiry and analysis of welding historical data.
5. The method for monitoring the welding condition of the pipeline in real time as claimed in claim 4, wherein the welding condition acquisition terminal is provided with:
the data acquisition unit is used for carrying out reading type acquisition on the welding parameter information acquired by the welding parameter sensor;
the real-time register is used for storing corresponding information obtained by analyzing the two-dimensional code and welding parameter information collected by the data collector;
the 4G network is used for constructing an information transmission channel between the welding condition acquisition terminal and the monitoring center server; and
the data acquisition controller is used for analyzing the scanned two-dimensional code of the welder and the two-dimensional code of the welding crater, determining a welding process rule which is required by the welding crater according to the obtained corresponding information through database correlation query, controlling the data acquisition device to read welding parameters detected by the welding parameter sensor when the welder works and store the welding parameters into the real-time register, sending abnormal working condition alarm information when the welding parameters are in an abnormal working condition exceeding the limit, and sending the two-dimensional code analysis information, the determined welding process rule number information, the welding parameter information when the welder works and the abnormal working condition alarm information to the monitoring center server through the 4G network.
6. The method for monitoring the welding condition of the pipeline in real time as claimed in claim 5, wherein the welding condition acquisition terminal is further provided with:
the camera is used for acquiring crater information, interlayer temperature and protective gas flow and transmitting the acquired data information to the monitoring center server through the 4G network;
RJ45, 485 and I/O interfaces for communicating with environmental and status sensors; and
and the environment and state sensor is used for monitoring the running state and safety information of the welding condition acquisition terminal in real time.
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