CN116787019B - Digital management method and system for pipeline welding - Google Patents
Digital management method and system for pipeline welding Download PDFInfo
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- CN116787019B CN116787019B CN202311060898.7A CN202311060898A CN116787019B CN 116787019 B CN116787019 B CN 116787019B CN 202311060898 A CN202311060898 A CN 202311060898A CN 116787019 B CN116787019 B CN 116787019B
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- 238000003466 welding Methods 0.000 title claims abstract description 140
- 238000007726 management method Methods 0.000 title claims abstract description 25
- 230000007246 mechanism Effects 0.000 claims abstract description 84
- 238000012795 verification Methods 0.000 claims abstract description 18
- 238000004364 calculation method Methods 0.000 claims description 41
- 238000000034 method Methods 0.000 claims description 40
- 230000002093 peripheral effect Effects 0.000 claims description 33
- 238000012216 screening Methods 0.000 claims description 31
- 230000008569 process Effects 0.000 claims description 13
- 230000008859 change Effects 0.000 claims description 6
- 229910000831 Steel Inorganic materials 0.000 description 9
- 239000010959 steel Substances 0.000 description 9
- 210000001503 joint Anatomy 0.000 description 7
- 238000001514 detection method Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000035772 mutation Effects 0.000 description 2
- 238000005452 bending Methods 0.000 description 1
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Classifications
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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
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
- B23K31/027—Making tubes with soldering or welding
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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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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/70—Determining position or orientation of objects or cameras
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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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
- B23K2101/06—Tubes
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/10—Image acquisition modality
- G06T2207/10028—Range image; Depth image; 3D point clouds
Abstract
The invention discloses a digital management method and a digital management system for pipeline welding, which relate to the technical field of digital welding and comprise the following steps: collecting point cloud data in a pipeline, calculating the inner diameter of each part of the pipeline based on the point cloud data in the pipeline, and obtaining pipeline inner diameter data; determining a position to be welded of the pipeline based on the pipeline inner diameter data; acquiring alignment data of the pipeline based on point cloud data of two ends of a position to be welded of the pipeline; judging whether welding alignment of the pipeline meets the pipeline welding positioning requirement or not based on the historical alignment data of the pipeline; and judging whether the positioning mechanism meets the stable alignment requirement or not based on the alignment data of the plurality of welded pipelines. The invention has the advantages that: according to the scheme, the multi-dimensional management for pipeline welding can be effectively realized by means of the welding position determination, the welding alignment accuracy verification and the stable alignment verification, and the stability and the welding yield of pipeline welding are guaranteed.
Description
Technical Field
The invention relates to the technical field of digital welding, in particular to a pipeline welding digital management method and a pipeline welding digital management system.
Background
The welded pipeline is a steel pipe which is formed by bending and deforming a steel belt or a steel plate into a round shape, a square shape and the like and then welding the steel pipe with seams on the surface, a blank adopted by the welded pipeline is the steel plate or the steel plate, the quality of the welding seam is continuously improved along with the rapid development of high-quality steel strip continuous rolling production and the progress of welding and inspection technology, the variety and the specification of the welded pipeline are increased, and seamless steel pipes are replaced in more fields. The welded pipeline has lower cost and higher production efficiency than a seamless steel pipe.
For some pipelines with larger pipe wall thickness, the single-sided welding is easy to generate poor welding impermeability, so that double-sided welding is needed at the butt joint position of the pipelines, however, the welding in the pipelines is difficult to observe, the problem that the welding butt joint position is not aligned is easy to generate, the large deviation generated in the butt joint of the welding position in the prior art is difficult to discover in time, the welding can directly influence the quality of welding seams in the pipelines, the quality of the welding of the pipelines is further influenced, the operation faults of the positioning mechanism of the welding equipment are difficult to identify in advance, and the positioning mechanism of the welding equipment cannot be calibrated in time.
Disclosure of Invention
In order to solve the technical problems, the technical scheme provides a digital management method and a digital management system for pipeline welding, which solve the problems that in the prior art, large deviation in butt joint at a welding position is difficult to find in time, welding can affect the quality of welding seams in a pipe directly, further the quality of pipeline welding is affected, the operation faults of a positioning mechanism of welding equipment are difficult to identify in advance, and the positioning mechanism of the welding equipment cannot be calibrated in time.
In order to achieve the above purpose, the invention adopts the following technical scheme:
a method for digitally managing pipeline welding, comprising:
collecting point cloud data in a pipeline, calculating the inner diameter of each part of the pipeline based on the point cloud data in the pipeline, and obtaining pipeline inner diameter data;
determining a position to be welded of the pipeline based on the pipeline inner diameter data;
acquiring alignment data of the pipeline based on point cloud data of two ends of a position to be welded of the pipeline;
judging whether welding alignment of the pipeline meets the pipeline welding positioning requirement or not based on the historical alignment data of the pipeline, if so, outputting a positioning qualified signal to a welding mechanism, welding the interior of the pipeline by the welding mechanism, and if not, outputting a positioning unqualified signal to an alarm mechanism, and outputting warning information by the alarm mechanism;
judging whether the positioning mechanism meets the stable alignment requirement based on the alignment data of a plurality of welded pipelines, if so, not outputting, if not, judging that the positioning mechanism has positioning fault hidden danger, outputting early warning signals to the alarm mechanism, and outputting early warning information by the alarm mechanism.
Preferably, the collecting the point cloud data inside the pipeline, and calculating the inner diameter of each part of the pipeline based on the point cloud data inside the pipeline, the obtaining the pipeline inner diameter data specifically includes:
the method comprises the steps of establishing a space rectangular coordinate system by taking the circle center position of the edge of a welding extension end of a pipeline as an origin, taking the axial direction of the pipeline as a Y axis, taking a horizontal plane as an XOY plane, and taking the space rectangular coordinate system as a reference coordinate system;
inputting the point cloud data in the pipeline into a reference coordinate system, and acquiring the coordinates of the point cloud of the inner peripheral surface of the pipeline in the reference coordinate system;
calculating the average value of the distance from the point on the inner peripheral surface of the pipeline to the Y axis according to an inner diameter calculation formula, and taking the average value as the inner diameter of the pipeline;
wherein, the internal diameter calculation formula specifically comprises:
in the method, in the process of the invention,for the inner diameter of the pipe at Y-coordinate Y, < >>For the total number of inner peripheral surface point clouds at Y coordinate +.>X-axis coordinates of the ith inner peripheral surface point cloud at Y-coordinate Y,/-Y>Is the Z-axis coordinate of the i-th inner peripheral surface point cloud at Y-coordinate.
Preferably, determining the position to be welded of the pipe based on the pipe inner diameter data specifically includes:
determining a verification level value based on the roughness of the inner diameter of the pipeline, wherein the larger the roughness of the inner diameter of the pipeline is, the larger the verification level value is;
searching a pipeline screening critical standard from a Grabbs table based on the verification level value;
calculating Y-axis coordinates of a position to be welded of the pipeline based on a screening formula;
wherein, the screening formula specifically comprises:
in the method, in the process of the invention,for Y coordinate +.>The inner diameter of the pipeline at the position is>For the average of all the pipe inside diameter data, +.>Standard deviation of all pipe inner diameter data +.>Screening critical standards for the pipeline;
if the screening formula is satisfied, thenIs the Y-axis coordinate of the position of the pipe to be welded.
Preferably, the obtaining the alignment data of the pipe based on the point cloud data of two ends of the to-be-welded position of the pipe specifically includes:
the Y-axis coordinate of the position to be welded of the pipeline is recorded as Y0, and the Y-axis coordinate of the nearest point cloud of the inner peripheral surface of the pipeline at the two ends of the position to be welded of the pipeline is recorded as Y1 and Y2 respectively;
calculating a pipeline alignment deviation index through an alignment deviation calculation formula;
screening out the maximum value of the alignment deviation index of the pipeline as alignment data of the pipeline;
the alignment deviation calculation formula specifically comprises:
in the method, in the process of the invention,is the index of the alignment deviation of the ith pipeline, +.>X-axis coordinates of the ith inner peripheral surface point cloud at Y-coordinate Y1,/-Y>Z-axis coordinate of the ith inner peripheral surface point cloud at Y-coordinate Y1,/for the Y-coordinate>X-axis coordinates of the ith inner peripheral surface point cloud at Y2 as Y-coordinates,/-, and>is the Z-axis coordinate of the i-th inner peripheral surface point cloud at Y2.
Preferably, the judging whether the welding alignment of the pipeline meets the pipeline welding positioning requirement based on the historical alignment data of the pipeline specifically comprises:
judging whether the alignment data of the pipeline is larger than a standard deviation preset value or not;
if yes, judging that the welding alignment of the pipeline does not meet the welding positioning requirement of the pipeline;
if not, judging that the welding alignment of the pipeline meets the pipeline welding positioning requirement.
Preferably, the determining whether the positioning mechanism meets the stable alignment requirement based on the alignment data of the welded pipelines specifically includes:
numbering the alignment data of a plurality of welded pipelines sequentially from front to back according to the time sequence, and obtaining the one-to-one correspondence of the alignment data and the numbers of the welded pipelines;
calculating the linear variation trend value of the alignment data of the welded pipeline according to a trend index calculation formula based on the one-to-one correspondence of the alignment data and the numbers of the welded pipeline;
judging whether the linear variation trend value of the alignment data is larger than a preset trend critical value, if so, indicating that the positioning mechanism does not meet the stable alignment requirement, and if not, indicating that the positioning mechanism meets the stable alignment requirement;
the trend index calculation formula specifically comprises:
in the method, in the process of the invention,for the linear trend value of the alignment data of the welded pipe,/->For the total number of contraposition data of welded pipes, +.>Is numbered->Corresponding alignment data.
Furthermore, a pipeline welding digital management system is provided, which is used for implementing the pipeline welding digital management method, and includes:
the point cloud acquisition module is used for acquiring point cloud data in the pipeline;
the inner diameter calculation module is electrically connected with the point cloud acquisition module and is used for calculating the inner diameter of each part of the pipeline based on the point cloud data in the pipeline to acquire pipeline inner diameter data;
the position determining module is electrically connected with the inner diameter calculating module and is used for determining the position to be welded of the pipeline based on the inner diameter data of the pipeline;
the positioning accurate module is electrically connected with the inner diameter calculation module and the position determination module and is used for judging whether welding alignment of the pipeline meets the pipeline welding positioning requirement or not based on historical alignment data of the pipeline, if so, a positioning qualified signal is output to the welding mechanism, the welding mechanism performs pipeline internal welding, if not, a positioning unqualified signal is output to the alarm mechanism, and warning information is output by the alarm mechanism;
the stability module is electrically connected with the alignment precision module, and is used for judging whether the positioning mechanism meets the stable alignment requirement based on alignment data of a plurality of welded pipelines, if so, the positioning mechanism is not output, if not, the positioning mechanism is judged to have positioning fault hidden danger, an early warning signal is output to the warning mechanism, and early warning information is output by the warning mechanism.
Optionally, the location determining module specifically includes:
a data unit for storing a glabros table;
and the position determining unit is used for calculating Y-axis coordinates of the position to be welded of the pipeline based on the screening formula.
Optionally, the alignment precision module specifically includes:
the deviation index calculation unit is used for calculating the pipeline alignment deviation index through an alignment deviation calculation formula;
and the screening unit is used for screening out the maximum value of the alignment deviation index of the pipeline and taking the maximum value as the alignment data of the pipeline.
Optionally, the alignment precision module specifically includes;
the trend calculation unit is used for numbering the alignment data of a plurality of welded pipelines sequentially from front to back according to time sequence, obtaining a one-to-one correspondence of the alignment data of the welded pipelines and the numbers, and calculating a linear variation trend value of the alignment data of the welded pipelines according to a trend index calculation formula based on the one-to-one correspondence of the alignment data of the welded pipelines;
the judging unit is used for judging whether the linear change trend value of the alignment data is larger than a preset trend critical value, if so, the positioning mechanism is not satisfied with the stable alignment requirement, and if not, the positioning mechanism is satisfied with the stable alignment requirement.
Compared with the prior art, the invention has the beneficial effects that:
according to the invention, the inner diameter of each part of the pipeline is calculated by analyzing the point cloud data in the pipeline, and the position with abrupt change in the inner diameter of each part of the pipeline is used as a welding position, so that the welding position of the pipeline can be rapidly and accurately determined, the positioning efficiency of the welding position in the pipeline can be effectively improved, and the efficiency and yield of pipeline welding are further improved;
according to the invention, the maximum value of pipe diameter difference values at two ends of a pipeline welding position is calculated and used as alignment data of the pipelines, so that the alignment accuracy of the interiors of the two pipelines after the pipelines are butted can be intuitively reflected, and for the condition of large alignment deviation, warning information is timely output, welding is stopped, the pipeline welding quality can be effectively ensured, and the occurrence of defective pipeline welding products is prevented;
according to the invention, whether the positioning mechanism meets the stable positioning requirement is judged through the change trend of the positioning data of the welded pipelines relative to time, and in this way, when the positioning mechanism of the welding equipment is deteriorated in positioning inaccuracy, the positioning mechanism of the welding equipment can be quickly and timely identified, so that the positioning mechanism of the welding equipment can be conveniently and timely calibrated, and the positioning stability of the positioning mechanism of the welding equipment is improved.
Drawings
FIG. 1 is a flow chart of a digital management method for pipeline welding provided by the invention;
FIG. 2 is a flow chart of a method of calculating the inner diameter of a pipe throughout the present invention;
FIG. 3 is a flow chart of a method of determining a position of a pipe to be welded in accordance with the present invention;
FIG. 4 is a flow chart of a method for obtaining alignment data of a pipeline according to the present invention;
FIG. 5 is a flow chart of a method for determining whether the welding alignment of a pipeline meets the welding alignment requirement of the pipeline in the invention;
FIG. 6 is a flowchart of a method for determining whether a positioning mechanism meets a stable alignment requirement in the present invention;
fig. 7 is a block diagram of a digital management system for pipeline welding according to the present invention.
Detailed Description
The following description is presented to enable one of ordinary skill in the art to make and use the invention. The preferred embodiments in the following description are by way of example only and other obvious variations will occur to those skilled in the art.
Referring to fig. 1, a method for digitally managing pipe welding includes:
collecting point cloud data in a pipeline, calculating the inner diameter of each part of the pipeline based on the point cloud data in the pipeline, and obtaining pipeline inner diameter data;
determining a position to be welded of the pipeline based on the pipeline inner diameter data;
acquiring alignment data of the pipeline based on point cloud data of two ends of a position to be welded of the pipeline;
judging whether welding alignment of the pipeline meets the pipeline welding positioning requirement or not based on the historical alignment data of the pipeline, if so, outputting a positioning qualified signal to a welding mechanism, welding the interior of the pipeline by the welding mechanism, and if not, outputting a positioning unqualified signal to an alarm mechanism, and outputting warning information by the alarm mechanism;
judging whether the positioning mechanism meets the stable alignment requirement based on the alignment data of a plurality of welded pipelines, if so, not outputting, if not, judging that the positioning mechanism has positioning fault hidden danger, outputting early warning signals to the alarm mechanism, and outputting early warning information by the alarm mechanism.
According to the scheme, the inner diameter of each part of the pipeline is calculated by analyzing the point cloud data inside the pipeline, the position where the mutation occurs in the inner diameter of each part of the pipeline is used as a welding position, in this way, the welding position of the pipeline can be rapidly and accurately determined, meanwhile, the welding alignment accuracy verification and the stable alignment verification are carried out, the multidimensional management for the pipeline welding can be effectively realized, and the stability and the welding yield of the pipeline welding are ensured.
Referring to fig. 2, the collecting point cloud data inside the pipeline, and calculating the inner diameter of each part of the pipeline based on the point cloud data inside the pipeline, the obtaining the pipeline inner diameter data specifically includes:
the method comprises the steps of establishing a space rectangular coordinate system by taking the circle center position of the edge of a welding extension end of a pipeline as an origin, taking the axial direction of the pipeline as a Y axis, taking a horizontal plane as an XOY plane, and taking the space rectangular coordinate system as a reference coordinate system;
inputting the point cloud data in the pipeline into a reference coordinate system, and acquiring the coordinates of the point cloud of the inner peripheral surface of the pipeline in the reference coordinate system;
calculating the average value of the distance from the point on the inner peripheral surface of the pipeline to the Y axis according to an inner diameter calculation formula, and taking the average value as the inner diameter of the pipeline;
wherein, the internal diameter calculation formula specifically comprises:
in the method, in the process of the invention,for the inner diameter of the pipe at Y-coordinate Y, < >>For the total number of inner peripheral surface point clouds at Y coordinate +.>X-axis coordinates of the ith inner peripheral surface point cloud at Y-coordinate Y,/-Y>Is the Z-axis coordinate of the i-th inner peripheral surface point cloud at Y-coordinate.
It should be understood that the above method for establishing the reference coordinate system is merely an exemplary embodiment, in other embodiments, other positioning methods may be used to establish the reference coordinate system, and the inner diameter calculation formula is correspondingly deformed according to the method for establishing the reference coordinate system, so that the technical scheme is not listed for the general knowledge of the mathematics in other embodiments obtained after the coordinate system is converted.
Referring to fig. 3, the determining, based on the inner diameter data of the pipe, a position to be welded of the pipe specifically includes:
determining a verification level value based on the roughness of the inner diameter of the pipeline, wherein the larger the roughness of the inner diameter of the pipeline is, the larger the verification level value is;
searching a pipeline screening critical standard from a Grabbs table based on the verification level value;
calculating Y-axis coordinates of a position to be welded of the pipeline based on a screening formula;
wherein, the screening formula specifically comprises:
in the method, in the process of the invention,for Y coordinate +.>The inner diameter of the pipeline at the position is>For the average of all the pipe inside diameter data, +.>Standard deviation of all pipe inner diameter data +.>Screening critical standards for the pipeline;
if the screening formula is satisfied, thenIs the Y-axis coordinate of the position of the pipe to be welded.
In the scheme, a screening formula is established based on the principle of the Grabbs criterion, and it is understood that under the normal condition, the fluctuation of the data of the inner diameter of the pipeline accords with the normal distribution rule, firstly, the detection level value is determined through the roughness of the inner diameter of the pipeline, and the larger the roughness of the inner diameter of the pipeline is, the larger the fluctuation of the data of the inner diameter of the pipeline is, the value range of the detection level value is 0.05-0.1, the larger the value of the detection level value is, the larger the fluctuation tolerance of the data is, and the pipe diameter mutation is obvious at the butt joint position of the pipeline.
Referring to fig. 4, the obtaining the alignment data of the pipe based on the point cloud data of two ends of the to-be-welded position of the pipe specifically includes:
the Y-axis coordinate of the position to be welded of the pipeline is recorded as Y0, and the Y-axis coordinate of the nearest point cloud of the inner peripheral surface of the pipeline at the two ends of the position to be welded of the pipeline is recorded as Y1 and Y2 respectively;
calculating a pipeline alignment deviation index through an alignment deviation calculation formula;
screening out the maximum value of the alignment deviation index of the pipeline as alignment data of the pipeline;
the alignment deviation calculation formula specifically comprises:
in the method, in the process of the invention,is the index of the alignment deviation of the ith pipeline, +.>X-axis coordinates of the ith inner peripheral surface point cloud at Y-coordinate Y1,/-Y>Z-axis coordinate of the ith inner peripheral surface point cloud at Y-coordinate Y1,/for the Y-coordinate>X-axis coordinates of the ith inner peripheral surface point cloud at Y2 as Y-coordinates,/-, and>is the Z-axis coordinate of the i-th inner peripheral surface point cloud at Y2.
Referring to fig. 5, the determining whether the welding alignment of the pipeline meets the welding positioning requirement of the pipeline based on the historical alignment data of the pipeline specifically includes:
judging whether the alignment data of the pipeline is larger than a standard deviation preset value or not;
if yes, judging that the welding alignment of the pipeline does not meet the welding positioning requirement of the pipeline;
if not, judging that the welding alignment of the pipeline meets the pipeline welding positioning requirement.
Through calculating the pipe diameter difference maximum value at both ends of the pipeline welding position, as the counterpoint data of pipeline, can audio-visually reflect the pipeline butt joint after, the inside counterpoint precision of two pipelines, can effectually guarantee when appearing the butt joint and appear the deviation, carry out timely detection and output warning signal, stop welding, can effectually guarantee pipeline welding quality, prevent the poor condition of welding.
Referring to fig. 6, the determining whether the positioning mechanism meets the stable alignment requirement based on the alignment data of the plurality of welded pipes specifically includes:
numbering the alignment data of a plurality of welded pipelines sequentially from front to back according to the time sequence, and obtaining the one-to-one correspondence of the alignment data and the numbers of the welded pipelines;
calculating the linear variation trend value of the alignment data of the welded pipeline according to a trend index calculation formula based on the one-to-one correspondence of the alignment data and the numbers of the welded pipeline;
judging whether the linear variation trend value of the alignment data is larger than a preset trend critical value, if so, indicating that the positioning mechanism does not meet the stable alignment requirement, and if not, indicating that the positioning mechanism meets the stable alignment requirement;
the trend index calculation formula specifically comprises:
in the method, in the process of the invention,for the linear trend value of the alignment data of the welded pipe,/->Is a welded pipeIs>Is numbered->Corresponding alignment data.
Through the change trend of the alignment data of a plurality of welded pipelines relative to time, whether the positioning mechanism meets the stable alignment requirement is judged, and in this way, when the positioning mechanism of the welding equipment is deteriorated due to inaccurate positioning, the positioning mechanism of the welding equipment can be rapidly and timely identified, workers are reminded to timely calibrate the positioning mechanism of the welding equipment, and the positioning stability of the positioning mechanism of the welding equipment is improved.
Further, referring to fig. 7, the present disclosure further proposes a digital management system for pipe welding based on the same inventive concept as the digital management method for pipe welding, including:
the point cloud acquisition module is used for acquiring point cloud data in the pipeline;
the inner diameter calculation module is electrically connected with the point cloud acquisition module and is used for calculating the inner diameter of each part of the pipeline based on the point cloud data in the pipeline to acquire pipeline inner diameter data;
the position determining module is electrically connected with the inner diameter calculating module and is used for determining the position to be welded of the pipeline based on the inner diameter data of the pipeline;
the positioning accurate module is electrically connected with the inner diameter calculation module and the position determination module and is used for judging whether welding alignment of the pipeline meets the pipeline welding positioning requirement or not based on historical alignment data of the pipeline, if so, a positioning qualified signal is output to the welding mechanism, the welding mechanism performs pipeline internal welding, if not, a positioning unqualified signal is output to the alarm mechanism, and warning information is output by the alarm mechanism;
the stability module is electrically connected with the alignment precision module, and is used for judging whether the positioning mechanism meets the stable alignment requirement based on alignment data of a plurality of welded pipelines, if so, the positioning mechanism is not output, if not, the positioning mechanism is judged to have positioning fault hidden danger, an early warning signal is output to the warning mechanism, and early warning information is output by the warning mechanism.
The position determining module specifically comprises:
a data unit for storing a glabros table;
and the position determining unit is used for calculating Y-axis coordinates of the position to be welded of the pipeline based on the screening formula.
The accurate module of counterpointing specifically includes:
the deviation index calculation unit is used for calculating the pipeline alignment deviation index through an alignment deviation calculation formula;
and the screening unit is used for screening out the maximum value of the alignment deviation index of the pipeline and taking the maximum value as the alignment data of the pipeline.
The alignment precision module specifically comprises;
the trend calculation unit is used for numbering the alignment data of a plurality of welded pipelines sequentially from front to back according to time sequence, obtaining a one-to-one correspondence of the alignment data of the welded pipelines and the numbers, and calculating a linear variation trend value of the alignment data of the welded pipelines according to a trend index calculation formula based on the one-to-one correspondence of the alignment data of the welded pipelines;
the judging unit is used for judging whether the linear change trend value of the alignment data is larger than a preset trend critical value, if so, the positioning mechanism is not satisfied with the stable alignment requirement, and if not, the positioning mechanism is satisfied with the stable alignment requirement.
The use process of the pipeline welding digital management system comprises the following steps:
step one: the point cloud acquisition module acquires point cloud data in the pipeline;
step two: the inner diameter calculation module takes the center position of the edge circle of the welding extension end of the pipeline as an origin, takes the axial direction of the pipeline as a Y axis, takes a horizontal plane as an XOY plane, and establishes a space rectangular coordinate system as a reference coordinate system; inputting the point cloud data in the pipeline into a reference coordinate system, and acquiring the coordinates of the point cloud of the inner peripheral surface of the pipeline in the reference coordinate system; calculating the average value of the distance from the point on the inner peripheral surface of the pipeline to the Y axis according to an inner diameter calculation formula, and taking the average value as the inner diameter of the pipeline;
step three: determining a verification level value based on the roughness of the inner diameter of the pipeline, inputting the verification level value into a position determining module, checking a storage Grabbs table from a data unit by a position determining unit based on the verification level value, obtaining a pipeline screening critical standard, and calculating Y-axis coordinates of a position to be welded of the pipeline based on a screening formula;
step four: the deviation index calculating unit records the Y-axis coordinate of the position to be welded of the pipeline as Y0, records the Y-axis coordinate of the nearest point cloud of the inner peripheral surface of the pipeline at the two ends of the position to be welded of the pipeline as Y1 and Y2 respectively, and calculates the pipeline alignment deviation index through an alignment deviation calculating formula;
step five: the screening unit screens out the maximum value of the alignment deviation index of the pipeline as alignment data of the pipeline;
step six: the alignment precision module judges whether alignment data of the pipeline is larger than a standard deviation preset value or not; if yes, judging that the welding alignment of the pipeline does not meet the welding positioning requirement of the pipeline; if not, judging that the welding alignment of the pipeline meets the pipeline welding positioning requirement;
step seven: the trend calculation unit sequentially numbers the alignment data of a plurality of welded pipelines from front to back according to the time sequence, acquires the one-to-one correspondence of the alignment data and the numbers of the welded pipelines, and calculates the linear variation trend value of the alignment data of the welded pipelines according to a trend index calculation formula based on the one-to-one correspondence of the alignment data and the numbers of the welded pipelines;
step eight: the judging unit judges whether the linear variation trend value of the alignment data is larger than a preset trend critical value, if so, the positioning mechanism is not satisfied with the stable alignment requirement, and if not, the positioning mechanism is satisfied with the stable alignment requirement.
In summary, the invention has the advantages that: according to the scheme, the multi-dimensional management for pipeline welding can be effectively realized by means of the welding position determination, the welding alignment accuracy verification and the stable alignment verification, and the stability and the welding yield of pipeline welding are guaranteed.
The foregoing has shown and described the basic principles, principal features and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, and that the above embodiments and descriptions are merely illustrative of the principles of the present invention, and various changes and modifications may be made therein without departing from the spirit and scope of the invention, which is defined by the appended claims. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (7)
1. A method for digitally managing pipeline welding, comprising:
collecting point cloud data in a pipeline, calculating the inner diameter of each part of the pipeline based on the point cloud data in the pipeline, and obtaining pipeline inner diameter data;
determining a position to be welded of the pipeline based on the pipeline inner diameter data;
acquiring alignment data of the pipeline based on point cloud data of two ends of a position to be welded of the pipeline;
judging whether welding alignment of the pipeline meets the pipeline welding positioning requirement or not based on the historical alignment data of the pipeline, if so, outputting a positioning qualified signal to a welding mechanism, welding the interior of the pipeline by the welding mechanism, and if not, outputting a positioning unqualified signal to an alarm mechanism, and outputting warning information by the alarm mechanism;
judging whether the positioning mechanism meets the stable alignment requirement or not based on alignment data of a plurality of welded pipelines, if so, not outputting, if not, judging that the positioning mechanism has positioning fault hidden danger, outputting early warning signals to the warning mechanism, and outputting early warning information by the warning mechanism;
the method for acquiring the pipeline inner diameter data comprises the steps of acquiring the pipeline inner diameter data, calculating the inner diameters of all the positions of the pipeline based on the pipeline inner point cloud data, and specifically comprises the following steps:
the method comprises the steps of establishing a space rectangular coordinate system by taking the circle center position of the edge of a welding extension end of a pipeline as an origin, taking the axial direction of the pipeline as a Y axis, taking a horizontal plane as an XOY plane, and taking the space rectangular coordinate system as a reference coordinate system;
inputting the point cloud data in the pipeline into a reference coordinate system, and acquiring the coordinates of the point cloud of the inner peripheral surface of the pipeline in the reference coordinate system;
calculating the average value of the distance from the point on the inner peripheral surface of the pipeline to the Y axis according to an inner diameter calculation formula, and taking the average value as the inner diameter of the pipeline;
wherein, the internal diameter calculation formula specifically comprises:
in the method, in the process of the invention,for the inner diameter of the pipe at Y-coordinate Y, < >>For the total number of inner peripheral surface point clouds at Y coordinate +.>X-axis coordinates of the ith inner peripheral surface point cloud at Y-coordinate Y,/-Y>A Z-axis coordinate of an ith inner peripheral surface point cloud at a Y-coordinate of Y;
the determining the position to be welded of the pipeline based on the pipeline inner diameter data specifically comprises the following steps:
determining a verification level value based on the roughness of the inner diameter of the pipeline, wherein the larger the roughness of the inner diameter of the pipeline is, the larger the verification level value is;
searching a pipeline screening critical standard from a Grabbs table based on the verification level value;
calculating Y-axis coordinates of a position to be welded of the pipeline based on a screening formula;
wherein, the screening formula specifically comprises:
in the method, in the process of the invention,for Y coordinate +.>The inner diameter of the pipeline at the position is>For the average of all the pipe inside diameter data, +.>Standard deviation of all pipe inner diameter data +.>Screening critical standards for the pipeline;
if the screening formula is satisfied, thenThe Y-axis coordinate of the position to be welded of the pipeline;
the obtaining of the alignment data of the pipeline based on the point cloud data of the two ends of the to-be-welded position of the pipeline specifically comprises the following steps:
the Y-axis coordinate of the position to be welded of the pipeline is recorded as Y0, and the Y-axis coordinate of the nearest point cloud of the inner peripheral surface of the pipeline at the two ends of the position to be welded of the pipeline is recorded as Y1 and Y2 respectively;
calculating a pipeline alignment deviation index through an alignment deviation calculation formula;
screening out the maximum value of the alignment deviation index of the pipeline as alignment data of the pipeline;
the alignment deviation calculation formula specifically comprises:
in the method, in the process of the invention,is the index of the alignment deviation of the ith pipeline, +.>X-axis coordinates of the ith inner peripheral surface point cloud at Y-coordinate Y1,/-Y>Z-axis coordinate of the ith inner peripheral surface point cloud at Y-coordinate Y1,/for the Y-coordinate>X-axis coordinates of the ith inner peripheral surface point cloud at Y2 as Y-coordinates,/-, and>is the Z-axis coordinate of the i-th inner peripheral surface point cloud at Y2.
2. The digitized management method for pipeline welding according to claim 1, wherein the determining whether the welding alignment of the pipeline meets the pipeline welding positioning requirement based on the historical alignment data of the pipeline specifically comprises:
judging whether the alignment data of the pipeline is larger than a standard deviation preset value or not;
if yes, judging that the welding alignment of the pipeline does not meet the welding positioning requirement of the pipeline;
if not, judging that the welding alignment of the pipeline meets the pipeline welding positioning requirement.
3. The digitized management method for pipeline welding according to claim 2, wherein the determining whether the positioning mechanism meets the stable alignment requirement based on the alignment data of the plurality of welded pipelines specifically comprises:
numbering the alignment data of a plurality of welded pipelines sequentially from front to back according to the time sequence, and obtaining the one-to-one correspondence of the alignment data and the numbers of the welded pipelines;
calculating the linear variation trend value of the alignment data of the welded pipeline according to a trend index calculation formula based on the one-to-one correspondence of the alignment data and the numbers of the welded pipeline;
judging whether the linear variation trend value of the alignment data is larger than a preset trend critical value, if so, indicating that the positioning mechanism does not meet the stable alignment requirement, and if not, indicating that the positioning mechanism meets the stable alignment requirement;
the trend index calculation formula specifically comprises:
in the method, in the process of the invention,for the linear trend value of the alignment data of the welded pipe,/->For the total number of contraposition data of welded pipes, +.>Is numbered->Corresponding alignment data.
4. A pipeline welding digital management system, for implementing the pipeline welding digital management method according to any one of claims 1-3, comprising:
the point cloud acquisition module is used for acquiring point cloud data in the pipeline;
the inner diameter calculation module is electrically connected with the point cloud acquisition module and is used for calculating the inner diameter of each part of the pipeline based on the point cloud data in the pipeline to acquire pipeline inner diameter data;
the position determining module is electrically connected with the inner diameter calculating module and is used for determining the position to be welded of the pipeline based on the inner diameter data of the pipeline;
the positioning accurate module is electrically connected with the inner diameter calculation module and the position determination module and is used for judging whether welding alignment of the pipeline meets the pipeline welding positioning requirement or not based on historical alignment data of the pipeline, if so, a positioning qualified signal is output to the welding mechanism, the welding mechanism performs pipeline internal welding, if not, a positioning unqualified signal is output to the alarm mechanism, and warning information is output by the alarm mechanism;
the stability module is electrically connected with the alignment precision module, and is used for judging whether the positioning mechanism meets the stable alignment requirement based on alignment data of a plurality of welded pipelines, if so, the positioning mechanism is not output, if not, the positioning mechanism is judged to have positioning fault hidden danger, an early warning signal is output to the warning mechanism, and early warning information is output by the warning mechanism.
5. The digitized management system for pipe welding of claim 4 wherein said location determination module comprises:
a data unit for storing a glabros table;
and the position determining unit is used for calculating Y-axis coordinates of the position to be welded of the pipeline based on the screening formula.
6. The digitized management system of claim 5 wherein said alignment precision module comprises:
the deviation index calculation unit is used for calculating the pipeline alignment deviation index through an alignment deviation calculation formula;
and the screening unit is used for screening out the maximum value of the alignment deviation index of the pipeline and taking the maximum value as the alignment data of the pipeline.
7. The digitized management system for pipe welding of claim 6 wherein said alignment precision module comprises;
the trend calculation unit is used for numbering the alignment data of a plurality of welded pipelines sequentially from front to back according to time sequence, obtaining a one-to-one correspondence of the alignment data of the welded pipelines and the numbers, and calculating a linear variation trend value of the alignment data of the welded pipelines according to a trend index calculation formula based on the one-to-one correspondence of the alignment data of the welded pipelines;
the judging unit is used for judging whether the linear change trend value of the alignment data is larger than a preset trend critical value, if so, the positioning mechanism is not satisfied with the stable alignment requirement, and if not, the positioning mechanism is satisfied with the stable alignment requirement.
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