CN116468187B - Green welding process decision method for large-diameter thick plate - Google Patents
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- 238000003466 welding Methods 0.000 title claims abstract description 171
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- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 12
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- 230000001988 toxicity Effects 0.000 claims description 5
- 231100000419 toxicity Toxicity 0.000 claims description 5
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- 239000002184 metal Substances 0.000 claims description 4
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- 210000001503 joint Anatomy 0.000 claims description 3
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- 229910000679 solder Inorganic materials 0.000 claims description 3
- 230000008901 benefit Effects 0.000 claims description 2
- 230000004907 flux Effects 0.000 claims description 2
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Abstract
The method can be flexibly applied to welding scenes of different large-diameter thick plates by focusing on different optimization targets, and provides a more suitable green welding process for welding large-diameter thick plates for welding personnel.
Description
Technical Field
The invention relates to the field of green welding process decision making, in particular to a green welding process decision making method for a large-diameter thick plate.
Background
The welding process is the most common basic manufacturing process in the metal manufacturing process, high pollution and high energy consumption are generated in the specific processing operation process, and certain harm is caused to human health when the welding process is in a welding environment for a long time.
Because the large-diameter thick plate is widely applied to engineering machinery such as a single pile pipe, a tower barrel of a wind generating set and the like, the unique V-shaped welding seam and the welding depth of the thick plate can meet the quality requirement of a weldment through multiple layers of welding. The uncomfortable welding process type can cause more energy consumption and environmental load, and the current green manufacturing large-environment requirement is violated, so that qualitative and quantitative decision analysis of the welding process is needed before welding. The research of the green welding process decision analysis method aiming at the large-diameter thick plate has not been significantly progressed. In order to be able to provide a green welding environment, it is highly desirable to build a green welding process decision model to evaluate the welding process employed, so as to obtain a welding process with low energy consumption and low environmental load.
Disclosure of Invention
Aiming at the defects of the large-diameter thick plate green welding process decision analysis model, the invention provides a large-diameter thick plate green welding process decision method, which adopts a decision model combining a hierarchical analysis method and an ideal point method to carry out green welding process decision evaluation, and decides a more green welding process based on the established decision model on the premise of ensuring the weld quality. In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:
a green welding process decision method for a large-diameter thick plate comprises the following steps:
the method comprises the following steps:
step one: summarizing various parameter data measured by various gas sensors and analysis instruments under different welding process working conditions of the same welding parent metal to establish a corresponding welding database, and obtaining various parameter data corresponding to a weld joint with unit length;
step two: aiming at actual working condition factors of welding of large-diameter thick plates, carrying out weld bead arrangement design of different welding processes, after determining the total length of a weld bead, combining various parameter data corresponding to the weld bead with unit length obtained in the step one to obtain various parameter expected data total amounts under different welding processes, and providing a bottom database for decision analysis in the step three;
step three: establishing a four-layer hierarchical analysis model comprising a measure layer, a sub-criterion layer, a criterion layer and a target layer according to different welding processes, and calculating elements of each contrast matrix according to the bottom database obtained in the step two so as to obtain each index weight from the target layer to the measure layer; and (3) carrying out standardization processing on the original data matrix after the same trend, then constructing a weighted standardization matrix, determining positive and negative ideal solutions and calculating the distance, and finally, determining to be suitable for the optimal green welding process under the current welding scene by calculating the relative proximity.
Further, the welding process mainly comprises five processes of argon arc welding, gas shielded welding, submerged arc welding and TLG welding.
Further, the actual working condition factors aiming at the welding of the large-diameter thick plate at least comprise a joint form and a groove form.
Further, the welding bead arrangement device is a multi-layer multi-channel laying welding device, and different designs are carried out according to actual welding processes on the premise of considering residual stress distribution and deformation amount so as to determine the total length of the welding seam.
Further, before the co-trend, the method further comprises the step of carrying out consistency test on the judgment matrix corresponding to all indexes of the criterion layer and the sub-criterion layer to confirm whether the judgment matrix scoring is reasonable or not
Further, the specific steps of the third step are as follows:
the first step: establishing a four-layer hierarchical analysis model according to five welding processes, wherein the four-layer hierarchical analysis model comprises a measure layer, a sub-criterion layer, a criterion layer and a target layer, and the measure layer comprises five welding processes of argon arc welding, gas shielded welding, submerged arc welding and TLG welding; the sub-standard layer comprises 14 parameter indexes of welding wire consumption, electric energy consumption, welding time, carbon dioxide emission, sulfur dioxide emission, dust content, noise decibels, waste residue quality, fresh water eutrophication, fresh water biotoxicity, marine eutrophication, marine biotoxicity, human toxicity and ionizing radiation; the criterion layer comprises five decision indexes including process energy consumption Q, solder consumption M, welding time T, environmental load degree E and human occupational health H; the target layer is the optimal green welding process; wherein, the parameter welding wire consumption corresponds to the welding flux consumption M, the welding time corresponds to the welding time T, the electric energy consumption corresponds to the process energy consumption Q, 7 parameters of carbon dioxide emission, sulfur dioxide emission, waste residue quality, fresh water eutrophication, fresh water biotoxicity, ocean eutrophication and ocean biotoxicity correspond to the environmental load degree E, and 4 parameters of dust content, noise decibel, human toxicity and ionizing radiation correspond to the human occupational health H;
and a second step of: respectively carrying out judgment scoring between every two of the parameter indexes of the sub-criterion layer and 5 decision indexes of the criterion layer by using a 1-9 scale method of the analysis-by-layer method, and constructing a judgment matrix of the criterion layer and the sub-criterion layer;
criterion layer judgment matrix:；
sub-criterion layer judgment matrix:
；
；
wherein ,；
and a third step of: performing hierarchical single sequencing on all the judgment matrixes, and respectively solving weights corresponding to each decision index of a criterion layer and each parameter index of a sub-criterion layer;
(1) Normalizing each column vector of the judgment matrix
Criterion layer:；
sub-criteria layer:；；
(2) Solving the product according to the row elements, and then opening the number of rows to the power;
criterion layer:；
sub-criteria layer:；；
(3) Will beIs->Normalized to->、Is->The method is the weight vector which is obtained, and is also the hierarchical single sequencing result of the judgment matrix;
criterion layer:；
sub-criteria layer:；
；
fourth step: consistency test is carried out on the judgment matrixes corresponding to all indexes of the criterion layer and the sub-criterion layer, and whether the judgment matrixes are reasonably scored or not is confirmed;
(1) Solving the maximum characteristic root of matrixAnd a consistency index CI value;
criterion layer:；/>；
sub-criteria layer:
；/>；
；/>；
(2) Solving the CR value of the check coefficient according to the CI value of the consistency index and the RI value of the random consistency index, wherein the RI value is taken from a random consistency index RI value table, the RI value of a criterion layer is 1.12, and the RI value of a sub-criterion layerRI value of 1.32>RI of 0.9; if CR is<0.1, judging that the consistency of the matrix is passed, namely, confirming that the target weight corresponding to the matrix is the weight required in the third step, if CR is more than or equal to 0.1, judging that the matrix is unreasonable, and returning to the second step of adjusting and scoring until CR is achieved<0.1；
Test coefficient:；
fifth step: after the weights corresponding to the targets of the criterion layer and the sub-criterion layer are determined by using the analytic hierarchy process, the ideal point method is combined for calculationThe corresponding scores of the process schemes, namely the relative proximity, are obtained, specifically, firstly, the welding processes in the bottom database are corresponding to the parameter dataCarrying out co-trend and standardization treatment on the composed original data matrix to obtain a standardized matrix Y;
(1) To ensure consistent direction of all index changes, the sub-criterion layer parameter data is requiredCarrying out co-trend treatment;
standard 0-1 transform:；
(2) The non-dimensionality adopts a method for carrying out standardization treatment on the original data matrix after the same trend;
standardization:；
normalization matrix:k=5, k is the number of welding process schemes, and n=14;
sixth step: calculating a weighted standardized matrix P by the target weights and the standardized matrix of the criterion layer and the sub-criterion layer;
，k=5，n=14；
seventh step: determining a positive ideal solutionNegative ideal solution->, wherein />Is an index of benefit, is->Is a cost index;
positive ideal solution:；
negative ideal solution:；
wherein ,；
eighth step: respectively calculating the total distance between various indexes of different welding processes and positive and negative ideal solutions and />；
；
；
Ninth step: calculating the relative proximity of different welding processesObtain a relative proximity vector +.>；
Relative proximity:；
relative proximity vector:；
tenth step: autonomous decision of the relative proximity vector according to the principle of maximum relative proximityThe welding process corresponding to the maximum value of the medium element is used as the optimal green welding process for the current welding.
Further, when constructing the criterion layer judgment matrix of the sub-criterion layer judgment matrix in the second step, the scale scores of the parameter indexes and the decision indexes are adjusted according to the specific welding scene.
Furthermore, the invention is particularly suitable for welding scenes of seaside factory welding, the thickness of a large-diameter thick plate is 30-50mm, and the butt joint is in a form of a V-shaped groove; and in the second step, when a criterion layer judgment matrix of the sub-criterion layer judgment matrix is constructed, adjusting the scale scores of 2 parameter indexes of ocean eutrophication and ocean biotoxicity and 1 decision index of environmental load degree to be 3-5.
The invention has the beneficial effects that:
the invention provides a green welding process decision method for large-diameter thick plates, which combines two comprehensive decision evaluation methods of an analytic hierarchy process and an ideal point method to analyze and decide an optimal green welding process.
Drawings
FIG. 1 is a flow diagram of a green welding process decision method for large diameter thick plates;
FIG. 2 is a schematic diagram of an analytical model of an analytic hierarchy process in a decision making process;
FIG. 3 is a schematic diagram of an analysis algorithm of the overall decision process.
Detailed Description
The invention will be further illustrated with reference to specific examples, but the invention is not limited to the examples.
Example 1: the thickness of the large-diameter thick plate is 30-50mm, the V-shaped groove is formed, the welding scene is the welding of a seaside factory, and at the moment, the welding environment load is large and two indexes of marine eutrophication and marine biotoxicity are required to be paid attention additionally. A green welding process decision method for a large-diameter thick plate comprises the following decision steps as shown in fig. 1:
step one: summarizing various parameter data measured by various gas sensors and analysis instruments under different welding process working conditions of the same welding parent metal to establish a corresponding welding database, and obtaining various parameter data corresponding to a weld joint with unit length;
step two: aiming at factors such as an actual butt joint form, a V-shaped groove and the like of large-diameter thick plate welding, carrying out weld bead arrangement design of different welding processes, determining the total length of a weld bead, and then obtaining the expected data total amount of various parameters under different welding processes by combining various parameter data corresponding to the weld bead with unit length obtained in the step one, so as to provide a bottom database for decision analysis in the step three;
step three: and (3) establishing four-level analytic hierarchy models according to different welding processes, establishing a hierarchical relation by the models as shown in figure 2, and calculating elements of each contrast matrix according to the bottom database obtained in the step two so as to obtain each index weight from a target layer to a scheme layer. And (3) carrying out standardization processing on the original data matrix after the same trend, then constructing a weighted standardization matrix, determining positive and negative ideal solutions and calculating the distance, and finally determining an optimal process suitable for the current green welding by calculating the relative proximity.
The welding process mainly comprises five processes of argon arc welding, gas shielded welding, submerged arc welding and TLG welding.
The welding bead arrangement design is generally multilayer multi-pass paving welding, and different designs are carried out according to the actual welding process on the premise of considering residual stress distribution, deformation and the like so as to determine the total length of the welding seam.
The specific calculation steps of the third step are as follows, as shown in fig. 3:
the first step: establishing four layers of analytic hierarchy models according to five welding processes, wherein the analytic hierarchy models comprise a measure layer, a sub-criterion layer, a criterion layer and a target layer, and the measure layer comprises five welding processes of argon arc welding, gas shielded welding, submerged arc welding and TLG welding; the sub-criterion layer comprises, but is not limited to, welding wire consumption, electric energy consumption, welding time, carbon dioxide emission, sulfur dioxide emission, dust content, noise decibels, waste residue quality, fresh water eutrophication, fresh water biotoxicity, marine eutrophication, marine biotoxicity, human toxicity, ionizing radiation and other parameters; the criterion layer comprises five decision indexes including process energy consumption Q, solder consumption M, welding time T, environmental load degree E and human occupational health H; the target layer is the optimal green welding process;
and a second step of: constructing a judgment matrix of a criterion layer and a sub-criterion layer by using a 1-9 scale method of the analysis-by-layer Santy, wherein in the welding scene, when constructing the judgment matrix of the sub-criterion layer, the scale scores of two indexes of marine eutrophication and marine biotoxicity are required to be improved compared with other indexes; when constructing a criterion layer judgment matrix, the scale score of the environmental load degree is improved compared with other indexes;
in order to embody the implementation process of the decision method of the invention, two scoring methods are adopted to carry out calculation decision.
(1) Constructing a judgment matrix under a common scene, and taking special cases that the weights of all indexes are the same
Criterion layer:；
sub-criteria layer:；/>；
(2) Constructing a judging matrix of a welding scene of a seaside factory, and focusing on improving the weights of two indexes of marine eutrophication and marine biotoxicity and the weights of environmental load degree indexes
Criterion layer:；
sub-criteria layer:；/>；
and a third step of: ordering the sheets;
(1) Common scene
Criterion layer:；
sub-criteria layer:
；
；
(2) Seaside welding scene
Criterion layer:；
sub-criteria layer:
；
；
fourth step: consistency test;
(1) Common scene
Criterion layer:ci=0, ri=1.12, cr=0 < 0.1, the judgment matrix is reasonable in scoring, and the confirmation weight vector is:
；
sub-criteria layer:
：/>ci=0, ri=1.12, cr=0 < 0.1, the judgment matrix is reasonable in scoring, and the confirmation weight vector is:
；
the judgment matrix is reasonable in scoring, and the confirmation weight vector is as follows:
；
(2) Seaside welding scene
Criterion layer:ci=0, ri=1.12, cr=0 < 0.1, the judgment matrix is reasonable in scoring, and the confirmation weight vector is:
；
：/>ci=0.011, ri=1.32, cr=0.008 < 0.1, the judgment matrix is reasonable in scoring, and the confirmation weight vector is:
；
the judgment matrix is reasonable in scoring, and the confirmation weight vector is as follows:
；
fifth step: carrying out co-trend and normalization on the original data matrix;
extracting an original data matrix from a welding database:
；
normalizing the transformed normalized matrix:
；
sixth step: weighting the standardized matrix;
(1) Common scene
；
(2) Seaside welding scene
；
Seventh step: determining positive and negative ideal solutions;
(1) Common scene
Positive ideal solution:
；
negative ideal solution:
；
(2) Seaside welding scene
Positive ideal solution:
；
negative ideal solution:
；
eighth step and ninth step: calculating the total distance between various indexes of different welding processes and positive and negative ideal solutions and />Relative proximity +.>；
(1) Common scene
(2) Seaside welding scene
Tenth step: selecting an optimal welding process
(1) Common scene
Relative proximity vector:from the principle of maximum relative proximity, it is known that +.>The corresponding gas shielded welding is used as the optimal welding process in the current scene.
(2) Seaside welding scene
Relative proximity vector:from the principle of maximum relative proximity, it is known that +.>The corresponding submerged arc welding is used as the optimal green welding process in the current scene.
In the embodiment, two welding scenes of a common scene and a seaside welding scene are used as comparison, and the effectiveness and feasibility of the comprehensive decision evaluation method provided by the invention are verified through actual data calculation.
The foregoing description of the preferred embodiments of the present invention has been presented only in terms of those specific and detailed descriptions, and is not, therefore, to be construed as limiting the scope of the invention. In different welding scenes, the weights of the sub-criterion layers and the scale fractions of the corresponding indexes of the criterion layers compared with other indexes of the layer are adjusted according to the focused optimization targets, so that the decision making method can be flexibly applied to the decision making process of the green welding process of the welding scene of the thick plate with different large diameters. In addition, it is intended that all such equivalents and modifications not be included in the scope of the invention.
Claims (6)
1. The green welding process decision-making method for the large-diameter thick plate is characterized by comprising the following steps of:
step one: summarizing various parameter data measured by various gas sensors and analysis instruments under different welding process working conditions of the same welding parent metal to establish a corresponding welding database, and obtaining various parameter data corresponding to a weld joint with unit length;
step two: aiming at actual working condition factors of welding of large-diameter thick plates, carrying out weld bead arrangement design of different welding processes, after determining the total length of a weld bead, combining various parameter data corresponding to the weld bead with unit length obtained in the step one to obtain the expected data total amount of various parameters under different welding processes, and providing a bottom database for decision analysis in the step three;
step three: establishing a four-layer hierarchical analysis model comprising a measure layer, a sub-criterion layer, a criterion layer and a target layer according to different welding processes, and calculating elements of each contrast matrix according to the bottom database obtained in the step two so as to obtain each index weight from the target layer to the measure layer; carrying out standardization processing on the original data matrix after the same trend, then constructing a weighted standardization matrix, determining positive and negative ideal solutions and calculating the distance, and finally, determining to be suitable for the optimal green welding process under the current welding scene by calculating the relative proximity;
before the co-trend is carried out, consistency test is carried out on the judgment matrixes corresponding to all indexes of the criterion layer and the sub-criterion layer, and whether the judgment matrixes are scored reasonably or not is confirmed;
the specific steps of the third step are as follows:
the first step: establishing a four-layer hierarchical analysis model according to five welding processes, wherein the four-layer hierarchical analysis model comprises a measure layer, a sub-criterion layer, a criterion layer and a target layer, and the measure layer comprises five welding processes of argon arc welding, gas shielded welding, submerged arc welding and TLG welding; the sub-standard layer comprises 14 parameter indexes of welding wire consumption, electric energy consumption, welding time, carbon dioxide emission, sulfur dioxide emission, dust content, noise decibels, waste residue quality, fresh water eutrophication, fresh water biotoxicity, marine eutrophication, marine biotoxicity, human toxicity and ionizing radiation; the criterion layer comprises five decision indexes including process energy consumption Q, solder consumption M, welding time T, environmental load degree E and human occupational health H; the target layer is the optimal green welding process; wherein, the parameter welding wire consumption corresponds to the welding flux consumption M, the welding time corresponds to the welding time T, the electric energy consumption corresponds to the process energy consumption Q, 7 parameters of carbon dioxide emission, sulfur dioxide emission, waste residue quality, fresh water eutrophication, fresh water biotoxicity, ocean eutrophication and ocean biotoxicity correspond to the environmental load degree E, and 4 parameters of dust content, noise decibel, human toxicity and ionizing radiation correspond to the human occupational health H;
and a second step of: respectively carrying out judgment scoring between every two of the parameter indexes of the sub-criterion layer and 5 decision indexes of the criterion layer by using a 1-9 scale method of the analysis-by-layer method, and constructing a judgment matrix of the criterion layer and the sub-criterion layer;
criterion layer judgment matrix:;
sub-criterion layer judgment matrix:
;
;
wherein ,;
and a third step of: performing hierarchical single sequencing on all the judgment matrixes, and respectively solving weights corresponding to each decision index of a criterion layer and each parameter index of a sub-criterion layer;
(1) Normalizing each column vector of the judgment matrix
Criterion layer:;
sub-criteria layer:；;
(2) Solving the product according to the row elements, and then opening the number of rows to the power;
criterion layer:;
sub-criteria layer:；;
(3) Will beIs->Normalized to->、Is->The method is the weight vector which is obtained, and is also the hierarchical single sequencing result of the judgment matrix;
criterion layer:;
sub-criteria layer:；/>;
fourth step: consistency test is carried out on the judgment matrixes corresponding to all indexes of the criterion layer and the sub-criterion layer, and whether the judgment matrixes are reasonably scored or not is confirmed;
(1) Solving the maximum characteristic root of matrixAnd a consistency index CI value;
criterion layer:；/>;
sub-criteria layer:；/>;
；/>;
(2) Solving the CR value of the check coefficient according to the CI value of the consistency index and the RI value of the random consistency index, wherein the RI value is taken from a random consistency index RI value table, the RI value of a criterion layer is 1.12, and the RI value of a sub-criterion layerRI value of 1.32>RI of 0.9; if CR is<0.1, judging that the consistency of the matrix is passed, namely, confirming that the target weight corresponding to the matrix is the weight required in the third step, if CR is more than or equal to 0.1, judging that the matrix is unreasonable, and returning to the second step of adjusting and scoring until CR is achieved<0.1；
Test coefficient:；
fifth step: after the weights corresponding to the targets of the criterion layer and the sub-criterion layer are determined by using an analytic hierarchy process, calculating the corresponding scores of the process schemes, namely the relative proximity by combining an ideal point method, specifically, firstly, carrying out co-trend and standardization treatment on an original data matrix formed by the parameter data corresponding to the welding processes in the bottom database to obtain a standardized matrix Y;
(1) To ensure consistent direction of all index changes, the sub-criterion layer parameter data is requiredCarrying out co-trend treatment;
standard 0-1 transform:;
(2) The non-dimensionality adopts a method for carrying out standardization treatment on the original data matrix after the same trend;
standardization:;
normalization matrix:k=5, k is the number of welding process schemes, and n=14;
sixth step: calculating a weighted standardized matrix P by the target weights and the standardized matrix of the criterion layer and the sub-criterion layer;
，k=5，n=14；
seventh step: determining a positive ideal solutionNegative ideal solution->, wherein />Is an index of benefit, is->Is a cost index;
positive ideal solution:;
negative ideal solution:;
wherein ,;
eighth step: respectively calculating the total distance between various indexes of different welding processes and positive and negative ideal solutions and />；
;
;
Ninth step: calculating the relative proximity of different welding processes to obtain a relative proximity vector；
Relative proximity:;
relative proximity vector:;
tenth step: and according to the principle of maximum relative proximity, independently deciding a welding process corresponding to the maximum value of the element in the relative proximity vector as the optimal green welding process of the current welding.
2. The green welding process decision method for the large-diameter thick plate according to claim 1, wherein the welding process mainly comprises five processes of argon arc welding, gas shielded welding, submerged arc welding and TLG welding.
3. The green welding process decision method for large-diameter thick plates according to claim 1, wherein the actual working condition factors for welding the large-diameter thick plates at least comprise a joint form and a groove form.
4. The green welding process decision method for the large-diameter thick plate according to claim 1, wherein the weld bead arrangement is a multi-layer and multi-channel spread welding, and the residual stress distribution and the deformation are considered as the premise, and different designs are carried out according to the actual welding process so as to determine the total length of the weld joint.
5. The green welding process decision method for large-diameter thick plates according to claim 1, wherein when constructing the sub-criterion layer judgment matrix in the second step, the scale scores of each parameter index and decision index are adjusted according to the specific welding scene.
6. The green welding process decision method for the large-diameter thick plate according to claim 1, wherein the welding scene is seaside factory welding, the thickness of the large-diameter thick plate is 30-50mm, the butt joint is in a form of a V-shaped groove; and in the second step, when a criterion layer judgment matrix of the sub-criterion layer judgment matrix is constructed, adjusting the scale scores of 2 parameter indexes of ocean eutrophication and ocean biotoxicity and 1 decision index of environmental load degree to be 3-5.
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