CN117391295A - Intelligent pipe network management system and method - Google Patents
Intelligent pipe network management system and method Download PDFInfo
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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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- 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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Abstract
The invention discloses an intelligent pipe network management system and method, comprising the following steps: the intelligent welding machine, a welding machine terminal, a marking device and a mapping terminal, and the server collects welding information through the intelligent welding machine; engineering information is acquired through a welding machine terminal, welding information and the engineering information are transmitted to a server for storage, and a welded junction label corresponding to a marker device is generated according to the welding information; marking the welding port through a marking device; the method comprises the steps of scanning a weld neck label of a marker device through a mapping terminal, obtaining position information corresponding to the weld neck label, and transmitting the weld neck label and the position information to a server; the position information, the welding information and the engineering information are associated, integrated and stored through the server according to the crater tag, and a mapping map is generated according to the position information and the crater tag; through the technical scheme, the invention simplifies the existing data acquisition mapping mode and realizes the association of mapping data and welding data.
Description
Technical Field
The invention relates to the technical field of engineering management, in particular to an intelligent pipe network management system and method.
Background
The welding interface of the gas pipeline is the current most main leakage point during construction and operation, most of the gas pipeline is buried in pipe network construction, and in the later data mapping and searching work of the pipeline, related personnel are generally required to conduct repeated mapping and searching on the pipe network buried for a long time in an acoustic mode, a magnetic mode and the like, and the gas pipeline belongs to a post detection method, but the data acquired by the post detection method and the data in the construction process generally have larger errors, and the effective detection can be conducted only by conducting the mapping and searching for a long time and multiple times. The use of relevant data in the construction process is of great importance for later detection.
At present, the data acquisition in the welding and mapping processes all require constructors to manually input a large amount of data. In the welding construction process, welder numbers, engineering numbers and material information are required to be input, wherein the material information comprises manufacturers, type pipe diameters, SDR values, material grades, production batch numbers, material brands, production places and the like; the mapping stage describes information of mapping points, such as type, characteristics, wall thickness, pipe diameter, welding mode, materials and the like, which need to be input. The manual mode input is not only tedious and low in efficiency, but also is easy to cause input errors, so that data acquisition is inaccurate. Meanwhile, pipe network construction and mapping work are mutually independent and are completed by two different teams, data among different teams cannot be communicated and shared, and certain isolation exists among data in different stages. Meanwhile, mapping is generally performed after pipe network welding is completed, mapping and acquisition are mostly performed according to the trend of a pipe ditch, only the positions of inflection points and the positions of two ends of a straight line are measured, the acquisition density is low, all acquisition of each welded junction cannot be performed, and further each key node and each key position cannot be accurately acquired.
The welded junction information in the pipe network construction process and the acquisition point information in the mapping have no associated attribute, are uploaded to a system and are mutually independent and stored in a background database, and data among different background databases are mutually independent. When abnormality occurs due to no correlation between mapping data and construction data, operation and maintenance personnel cannot find corresponding pipeline construction data, so that problems cannot be solved in time, and quality cannot be traced permanently.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides an intelligent pipe network management system and method, which simplify a data acquisition mode, realize the association of mapping data and welding data, quickly locate a welded junction position in a GIS system, determine information such as personnel, materials, equipment, process, environment, photos and the like in construction, realize abnormal quick response and follow-up responsibility for quality life.
In order to achieve the technical purpose, the invention provides the following technical scheme: an intelligent pipe network system, comprising:
An intelligent welding machine, a welding machine terminal, a marking device, a mapping terminal, a server,
collecting welding information through an intelligent welding machine;
engineering information is acquired through a welding machine terminal, welding information and the engineering information are transmitted to a server for storage, and a welded junction label corresponding to a marker device is generated according to the welding information;
marking the welding port through a marking device;
scanning a crater tag of a marker device through a mapping terminal, acquiring position information corresponding to the crater tag, and transmitting the crater tag and the position information to a server;
and carrying out association integration and storage on the position information, the welding information and the engineering information according to the crater tag by the server, and generating a mapping map according to the position information and the crater tag.
Optionally, the welding information includes voltage, current, resistance, temperature, welder information, welding time, date and longitude and latitude.
Optionally, the engineering information includes personnel information, material information, project information, process parameters and key node images.
Optionally, the welding machine terminal is further used for acquiring verification information, and performing authentication login according to the verification information to acquire personnel information of a welder; the authentication login comprises bar code or two-dimensional code scanning, account password login and face recognition.
Optionally, the survey and drawing terminal is connected with the RTK measuring apparatu, the RTK measuring apparatu is connected with CORS base station and big dipper satellite.
Optionally, the server includes a database and a database, wherein the database is used for storing information and mapping maps integrated by the server; the database is used for storing personnel information, welding machine information and engineering information of different projects; and generating an engineering number on the engineering information card through the database, and collecting engineering information by scanning the engineering number through a welding machine terminal.
Optionally, the marking device adopts an ultrahigh frequency RFID chip, and the crater tag is a unique ID number of the crater.
Optionally, the key node images include images of milled end faces, centered inspection, and flanging conditions.
Optionally, a MySQL database is used to store data in the intelligent network, wherein in a specific storage structure of the MySQL database, 7 attribute tables are built in total, and are a unit table, a welder table, an engineering project table, a construction data table, a mapping point table and a pipeline table respectively.
In order to better achieve the technical purpose, the invention also provides a corresponding method of the intelligent pipe network system, which comprises the following steps:
Before welding operation, engineering information is acquired through a welding machine terminal and login authentication is carried out;
in the welding operation process, welding information is acquired through an intelligent welding machine and is transmitted to a welding machine terminal, and the welding machine terminal stores engineering information and welding information;
after the welding operation is finished, engineering information and welding information are transmitted to a server through a welding machine terminal, a welding junction label is generated according to a welding machine number and a time stamp in the welding information, the welding junction label is written into a mark device, and the mark device is stuck beside the welding junction;
before the pipeline is covered with soil and in the mapping process, measuring the position information of the welded junction through an RTK measuring instrument, transmitting the position information to a mapping terminal, collecting the position information and a welded junction label corresponding to a marking device through the mapping terminal, and transmitting the position information and the welded junction label to a server;
and carrying out association integration on the position information, the engineering information and the welding information through a server according to the weld junction label, marking a GIS map according to the position information, generating mapping points of different weld junctions, carrying out connection processing on the mapping points through the position information, and generating a mapping map and a pipe network dotted line table.
The invention has the following technical effects:
according to the technical scheme, the external data acquisition is performed in the construction stage in a scanning or sensing mode through the intelligent welding machine and the welding machine terminal, so that human input errors are avoided, and the data accuracy is ensured. In the welding process, photographing verification is added to the key nodes, so that the method has standardization and ensures the construction quality. The marking device adopts an ultrahigh frequency RFID electronic chip, is convenient to read and write, and is remotely sensitive, and construction data and mapping data are associated. In the mapping stage, the RFID chip is identified, so that the attribute of a mapping point is not required to be manually input, and the mapping time is saved. The system and the method have the advantages that the material information during pipe network generation is quickly searched in the rush repair stage after mapping and mapping is finished, response is timely made, secondary disasters are reduced, meanwhile, the data stored by the server are one-stop retrieval full life cycle data, and quality is traceable throughout the life.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions of the prior art, the drawings that are needed in the embodiments will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a system according to an embodiment of the present invention;
FIG. 2 is a diagram of an engineering information data structure provided by an embodiment of the present invention;
fig. 3 is a diagram of a relational database according to an embodiment of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In order to solve the problems existing in the prior art, the invention provides the following scheme:
as shown in fig. 1, the present invention provides an intelligent pipe network system, which comprises an intelligent welder, a welder terminal, a marking device, a mapping terminal, a server,
collecting welding information through an intelligent welding machine; engineering information is acquired through a welding machine terminal, welding information and the engineering information are transmitted to a server for storage, and a welded junction label corresponding to a marker device is generated according to the welding information; marking the welding port through a marking device; scanning a crater tag of a marker device through a mapping terminal, acquiring position information corresponding to the crater tag, and transmitting the crater tag and the position information to a server; and carrying out association integration and storage on the position information, the welding information and the engineering information according to the crater tag by the server, and generating a mapping map according to the position information and the crater tag.
According to the technical scheme, the external data acquisition is performed in the construction stage in a scanning or sensing mode through the intelligent welding machine and the welding machine terminal, so that human input errors are avoided, and the data accuracy is ensured. In the welding process, photographing verification is added to the key nodes, so that the method has standardization and ensures the construction quality. The marking device adopts an ultrahigh frequency RFID electronic chip, is convenient to read and write, and is remotely sensitive, and construction data and mapping data are associated. In the mapping stage, the RFID chip is identified, so that the attribute of a mapping point is not required to be manually input, and the mapping time is saved. The system and the method have the advantages that the material information during pipe network generation is quickly searched in the rush repair stage after mapping and mapping is finished, response is timely made, secondary disasters are reduced, meanwhile, the data stored by the server are one-stop retrieval full life cycle data, and quality is traceable throughout the life.
And all information of engineering and materials is acquired by scanning a two-dimensional code or an induction chip during welding, so that inaccurate data caused by artificial reasons is avoided, and time is saved. After welding is finished, the weld junction information is written into the ultrahigh frequency RFID electronic tag by generating a unique ID number, and welding data and the weld junction tag are synchronously uploaded to a server. When mapping, the ID number of the electronic tag is directly read, a large number of measuring and drawing point attributes are not required to be recorded, the three-dimensional coordinates drawn and drawn by the measurement are bound, the three-dimensional coordinates are uploaded to a server to form a GIS map, and the server side automatically completes the binding of mapping data and welding data through the welding junction ID number. And in the operation and maintenance management stage, all information in the crater generation stage can be directly traced through a GIS map.
The intelligent welding machine is provided with various sensors, can monitor information such as voltage, current, ambient temperature and the like in real time, and sends welding machine information and acquired sensor data to the handheld terminal in a Bluetooth communication mode.
In the server management system, personnel, welding machines and engineering information databases are established and used for verifying personnel and welding machines in the construction process and acquiring engineering information. The personnel information comprises information such as name, number, certificate, qualification, validity period, account number, password, unit, face library and the like. The device information includes brands, numbers, models, units, annual inspection validity periods, and the like. The engineering information base comprises an engineering number, an engineering name, a construction address, a construction unit, a supervision unit, a project manager and the like.
On the basis of the original welding machine, a Bluetooth communication module is added. After the intelligent welding system APP is installed on the handheld terminal and Bluetooth connection is established between the intelligent welding system APP and the welding machine, data collected by the welding machine and information of the welding machine can be obtained in real time, at the moment, the welding machine serves as an executing mechanism, and all user operations are transferred to the handheld terminal APP.
The handheld terminal is internally provided with the Internet of things card, and the intelligent welding system APP can achieve login authentication of a welder, so that welder information is obtained. 3 welder authentication modes are provided, namely, authentication login is completed by scanning a personnel information bar code or a two-dimensional code; secondly, logging in through an account number password; thirdly, authentication login can be performed through face recognition. The system does not allow personnel with expired annual inspection or no construction qualification to perform welding operations.
The engineering information collection utilizes the handheld terminal to scan the engineering number two-dimensional code on the engineering information card, the system obtains all engineering information issued by the record from the server through the engineering number, and the engineering information database structure is shown in figure 2. When the pipe fitting and pipe tracing information is recorded, the handheld terminal can collect and store the pipe fitting and pipe tracing information in a mode of scanning and tracing the two-dimensional code or identifying the RFID label.
In the construction flow, the electric fusion welding oxide skin scraping, the clamp use and the appearance after welding are key nodes for guaranteeing the welding quality, and the butt welding key nodes comprise end face milling, centering checking, flanging and the like. At the key nodes, a photographing function is designed, so that operators are required to clearly photograph the site operation conditions, and the construction specification is ensured.
In the welding heating process, the welding machine acquires welding parameters in real time, and performs data interaction with an intelligent welding system in the handheld terminal in real time in a Bluetooth mode, and the data is updated and stored in the handheld terminal in real time.
After welding is finished, automatically generating a crater unique ID number through a welding machine number and a welding time stamp according to the crater data information, writing the crater unique ID number into the ultrahigh frequency RFID electronic chip tag, sticking the ultrahigh frequency RFID electronic chip tag beside the crater, and finishing the operation.
After the welding operation is finished, the welding port data is automatically uploaded to the server in real time in a background mode, and personnel operation is not needed. The manager can monitor the site construction condition through the computer or the mobile equipment at any time and any place, and timely learn the site condition and quickly make feedback aiming at the failure weld junction error code.
After the pipeline falls into the ditch, before earthing, survey staff carries survey and drawing terminal and RTK, carries out welded junction survey and drawing work. The RTK is connected with the CORS base station through a network, and meanwhile, beidou positioning information is obtained, and the precision can reach the centimeter level. The mapping terminal is automatically connected with the RTK in a Bluetooth mode, and the centimeter-level three-dimensional coordinate of the RTK equipment is obtained in real time. And a mapping personnel stands outside the pipe ditch, places the RTK above the weld junction, and performs acquisition to obtain a precise three-dimensional positioning point when a fixed solution of the display position on the interface of the mapping terminal is obtained. Meanwhile, the RFID electronic chip is of an ultrahigh frequency type, the identification distance is long, the mapping terminal can remotely read information (a weld junction unique ID number) written in the chip, and the two information are automatically bound to form a precise weld junction position point without manually inputting any attribute parameters.
The related technical structure of engineering management software of a server mainly comprises a view layer, a service layer and a data layer, wherein the view layer comprises Bootstrap, thymeleaf, and the service layer comprises Spring MVC, spring Boot, spring Security, spring Framework, mybatis, hibernate and Alibaba Druid. The view layer adopts a Bootstrap framework supporting responsive layout, so that the user can conveniently use the Bootstrap framework at the PC end and the mobile end. By using the Thymeleaf template, front and back end engineers can directly view the page effect, and the coordination and development are convenient. The server adopts an SSM framework: the SSM framework is short for SpringMVC, spring, mybatis three frameworks, and the design is mainly based on the MVC framework, so that the development speed of web applications can be increased, the application development cost can be reduced, and meanwhile, the coupling between different application layers can be reduced, so that the applications have good expansibility and portability. The SSM architecture is used, so that the huge system has good expansibility and portability, meanwhile, the coupling between different layers can be reduced, the later development and maintenance are facilitated, the code readability is improved, the code practicability is improved, and the processing capacity of related data is improved. The data layer adopts MySql and Redis, and the database adopts MySQL database: the relational database management system stores related data such as welding, engineering, personnel, mapping and the like in a database, performs scientific organization, and interfaces with various application programs or application systems by taking the relational database management system as an intermediary so as to enable the relational database management system to conveniently use the data in the database. The system uses MySQL to manage the database, and uses MySQL as an intermediary to interface with various application programs or application systems, so that the system can conveniently use the data in the database due to the huge number of data interfaces under the server. More convenient access to the data while reducing the time consumed for accessing the data. Redis: the key value pair storage system based on the memory is mainly used as a high-performance cache middleware, and because Redis is based on the memory, the influence of the disk I/O speed is avoided, so that the read-write performance is extremely high, and the data processing and reading performance of the terminal is improved.
The MySQL database is used to store construction mapping data.
In a concrete storage structure of the database, 7 attribute tables are built in total, namely a unit table, a welder table, an engineering project table, a construction data table, a mapping point table and a pipeline table. After the attribute tables are constructed, different data are stored according to the corresponding attribute tables after the data are collected, all the attribute tables are linked through the set related unique identifiers, meanwhile, the image files are stored independently, and the association is established with the corresponding data in the data tables, so that the image files can be checked according to the association when the data are checked. The data are stored in a separated address mode through different attribute tables, a certain connection is established, the ordering and the relevance of the stored data are guaranteed, and effective checking of subsequent related personnel is facilitated.
As shown in fig. 3, a relational database is provided with unique IDs of data such as a unit (dept_id), a welder (welder_id), a welder (device_id), an engineering project (project_id), data (data_id), a mapping point (point_id), and a pipeline (line_id), and a relational index is established. The system adopts a multi-tenant mode, and multi-tenant means that a single instance can serve a plurality of organizations. Multi-tenant technology provides the same or even customizable services as most clients with a single system architecture and services within a common data center, and still can guarantee data isolation. A system supporting multi-tenant technology requires virtual partitioning of its data and configuration in design, so that each tenant or organization of the system can use a single system instance, and each tenant can individually configure the rented system instance according to its own needs. The method realizes that users of different units can only check related personnel, equipment and engineering project related construction mapping data information of the unit. Compared with the traditional test, after mapping and construction data are associated through the identification device, mapping point table attributes are greatly reduced, table structures are simplified, occupied content is reduced, and multiplexing of the data is achieved.
And after the measurement and drawing of all the welded junction points are completed, automatically connecting the welded junction points into lines according to the sequence of the measurement and drawing to form pipe network point line table data, and uploading the pipe network point line table data to a server GIS system to complete the measurement and drawing work. The server side automatically correlates the data collected in the construction stage with the data collected in the mapping stage through the unique ID number of the welded junction, and stores the correlated data in a database, so that the inquiry of related personnel is facilitated.
The MySQL database is used to store construction mapping data.
In a concrete storage structure of the database, 7 attribute tables are built in total, namely a unit table, a welder table, an engineering project table, a construction data table, a mapping point table and a pipeline table. After the attribute tables are constructed, different data are stored according to the corresponding attribute tables after the data are collected, all the attribute tables are linked through the set related unique identifiers, meanwhile, the image files are stored independently, and the association is established with the corresponding data in the data tables, so that the image files can be checked according to the association when the data are checked.
As shown in fig. 3, a relational database is provided with unique IDs of data such as a unit (dept_id), a welder (welder_id), a welder (device_id), an engineering project (project_id), data (data_id), a mapping point (point_id), and a pipeline (line_id), and a relational index is established. The system adopts a multi-tenant mode, and multi-tenant means that a single instance can serve a plurality of organizations. Multi-tenant technology provides the same or even customizable services as most clients with a single system architecture and services within a common data center, and still can guarantee data isolation. A system supporting multi-tenant technology requires virtual partitioning of its data and configuration in design, so that each tenant or organization of the system can use a single system instance, and each tenant can individually configure the rented system instance according to its own needs. The method realizes that users of different units can only check related personnel, equipment and engineering project related construction mapping data information of the unit. Compared with the traditional test, after mapping and construction data are associated through the identification device, mapping point table attributes are greatly reduced, table structures are simplified, occupied content is reduced, and multiplexing of the data is achieved.
At this time, the mapping point in the GIS system is not just a position point, but a weld junction with rich information. When an emergency occurs, the traditional mapping mode cannot accurately know the material information of the on-site pipeline, and emergency repair personnel need to prepare various specifications of materials, welding machines and tools, which is time-consuming and labor-consuming.
When a road overhauls and has problems or abnormal leakage occurs, the position with the problems is checked through the GIS map, the corresponding position point is derived, the position of a nearby welded junction and welding records formed during construction can be accurately inquired, the welding records comprise welding data and personnel engineering information, and the corresponding data can be rapidly derived through checking the welding data. The invention can quickly know what material is used in the position and accurately prepare the consumable of the rush repair tool. Quality problems occur, and operators of construction units can be found accurately. And a data support is provided for the later inspection, leak detection and quality tracing.
Example 1
Collecting welding information through an intelligent welding machine; engineering information is acquired through a welding machine terminal, welding information and the engineering information are transmitted to a server for storage, and a welded junction label corresponding to a marker device is generated according to the welding information; marking the welding port through a marking device; scanning a crater tag of a marker device through a mapping terminal, acquiring position information corresponding to the crater tag, and transmitting the crater tag and the position information to a server; and carrying out association integration and storage on the position information, the welding information and the engineering information according to the crater tag by the server, and generating a mapping map according to the position information and the crater tag.
The intelligent welder can adopt a related intelligent welder, and the handheld welder terminal mainly comprises a touch display screen, a two-dimension code scanning probe, a camera, an RFID reader-writer and a high-performance processor, wherein the high-performance processor is respectively connected with the touch display screen, the two-dimension code scanning probe, the camera and the RFID reader-writer, performs related data processing, and is connected with the processor by carrying a Bluetooth module at the same time so as to perform Bluetooth communication. The handheld mapping terminal can also adopt the device, and mainly uses an RFID reader-writer, a high-performance processor, a touch display screen and a Bluetooth module.
Taking an intelligent welding machine as an example, an intelligent full-automatic butt welding machine and an intelligent full-automatic electric fusion welding machine are adopted.
The hand-held terminal is synchronous to uploading of data acquisition of intelligent full-automatic butt welding machine:
login and information verification of handheld terminal
The Bluetooth module of the intelligent welding machine is connected with the handheld terminal; the hand-held terminal is internally provided with an Internet of things card and a related scanning and shooting probe, and carries out login verification through an intelligent welding system APP, and can select three modes of code scanning, face recognition or account password input to carry out system login. The logging users are welding personnel with relevant qualification, at the moment, the welder information of the relevant personnel is recorded, and after logging, the logging-out button can be selected to log out;
After logging in, scanning Bluetooth equipment of the welding machine, selecting a corresponding welding machine according to the number of the welding machine, and controlling a handheld welding machine terminal to be connected with the welding machine through the Bluetooth equipment; after connection is completed, relevant information of the welding machine is collected, and the relevant information of the welding machine is as follows: number of welding machine: AGU2501812001, can realize the disconnection of welding machine through "disconnection" button subsequently;
control and data acquisition for a handheld terminal
After the welding machine is connected, the engineering information card is scanned manually or by using a two-dimensional code or an induction chip, and the engineering number is recorded. The project number is like CP001, the project number is stored in the database of the server in advance, and the number corresponds to the relevant project information in the database, after collecting the project number, the welding machine terminal can search and record the project information in the server through the project number when searching the relevant project information later.
In the process of executing a welding task, firstly, relevant content of pipe information is collected, and the pipe information is directly scanned and input by two-dimensional codes or manually input through a traceability information traceability code provided by a pipe fitting manufacturer. Aiming at pipe information needed by two ends of welding, after the first pipe information is input, entering a second pipe information input next, wherein the pipe information comprises manufacturer and PE material grade, such as 80, standard size ratio, such as 11.0, pipe diameter, production scheme number, material number and manufacturer.
And after the pipe information is acquired, performing interface jump, executing the next step, and entering the clamping positioning related data acquisition.
At the moment, related personnel control the welding machine frame to start moving, and close to the position for clamping the pipe, and the pipe can be installed. And (5) installing the pipes at the two ends on the rack in an aligned manner, and clamping the clamp. In the process, the hand-held welding machine terminal records real-time pressure (bar), real-time displacement (mm), hot plate temperature (DEG C) and environment temperature (DEG C) through the sensors of the welding machine, such as 'real-time pressure 0.0, real-time displacement 80.0, hot plate temperature 215 and environment temperature 20', displays an indication image of the installation process, and determines that the installation is completed in the hand-held welding machine terminal after the installation is completed.
After the clamping and positioning are determined to be installed, interface jumping is carried out, a reminding interface for placing the milling cutter is displayed, after the milling cutter of related personnel is placed in the frame, a pump station in the welding machine can send out alarm sound, then the welding machine receives related alarm signals, the milling cutter is started by itself, after the frame is folded, the terminal of the handheld welding machine is switched to a milling pipe section interface.
And the welding machine enters a milling stage, and a screen of the handheld terminal is automatically switched to a milling pipe section page. The terminal of the handheld welding machine records milling pressure in real time through relevant sensors arranged in the welding machine, for example, 100.0bar, and the intelligent welding machine can be controlled to increase and decrease the milling pressure by outputting corresponding signals through control keys of "+" and "-" in a touch screen of the handheld terminal, and relevant personnel stop milling after milling to a satisfactory position, and the milling cutter is stopped after finishing the milling process by turning a plurality of circles. At the moment, a screen of the handheld terminal enters a milling completion information prompt, the end face of the pipe can be checked to click for milling again if the end face is unsatisfactory, the previous milling step is repeated, if the milling requirement is met, the next step is carried out, and a photo of the milling end face is taken through a high-definition camera of the handheld welding machine terminal.
During the milling stage, real-time pressure, real-time displacement, hot plate temperature and environmental temperature during the milling process are recorded in real time through a terminal of the handheld welding machine, such as: real time pressure 5.0, real time displacement 10.0, hotplate temperature 215, ambient temperature 20.
After milling, interface jumping is carried out through the terminal of the handheld welding machine, alignment checking is carried out, a touch screen on the terminal of the handheld welding machine is clicked, a folding button is clicked, a frame of the welding machine is wirelessly controlled to be folded until pipe sections at two ends are contacted by output signals, a stop button is clicked to stop, and related personnel observe whether the pipe sections are in gaps or overlarge in staggered edge. Judging whether the alignment is qualified or not according to the conditions, returning to a milling pipe section page through a disqualification button if the alignment is disqualified, re-milling, updating wrong data, and taking a centering photo if the alignment is qualified.
In the process of folding, the relevant information is recorded in real time, for example: the implementation pressure is 0.0, the real-time displacement is 80.0, the hot plate temperature is 215, the ambient temperature is 20,
after the step of photographing the positive check is completed, the page automatically turns to the dragging pressure measurement page. After the alignment inspection is finished, after the interface is turned to, the handheld terminal outputs a signal to control the rack to open to the maximum automatically, then the rack is slowly pressurized until sliding and propping up, and in the process, the system automatically detects the dragging pressure of the rack. After the frames at the two sides are propped together, the pump station continues to boost pressure, and at the moment, the terminal picture of the welding machine automatically jumps to the clamping judgment page.
In the process of measuring the dragging pressure, the parameters are detected in real time, such as: real time pressure 10.0, real time displacement 30.0, hotplate temperature 215, ambient temperature 20, and alert to drag pressure, such as drag pressure 10.0, real time pressure 10.0.
In the clamping judging process, after the pipe orifice is closed, the welding pressure is continuously applied for 5 seconds, the force is detected, and if the displacement variation exceeds 5mm, the pipe orifice is considered to be not clamped.
The parameters were recorded in real time as real time pressure 10.0, real time displacement 80.0, hotplate temperature 215, ambient temperature 20.
After the clamping judgment is passed, the page automatically jumps to a cleaning end face page, a relevant cleaning mode is displayed, and relevant personnel clean the welding end faces at the two ends by using absolute alcohol.
And the parameters described above during the process were recorded as real time pressure 0.0, real time displacement 0.0, hotplate temperature 215, ambient temperature 20.
After the cleaning end face is finished, clicking a next button on the terminal of the handheld welding machine, and entering a prompt page for putting the hot plate. The page automatically detects whether the temperature of the hot plate reaches a set value, and after the temperature reaches the set value, a hot plate in-place button is displayed. The relevant personnel put in the hot plate and pull out the mechanism according to the prompt in the handheld terminal, click the hot plate to be in place, and start automatic welding work.
Recording the parameters, such as real-time pressure 0.0, real-time displacement 25.0, hot plate temperature 215, ambient temperature 20, when the set value is 215, the hot plate temperature reaches the set value, a hot plate in place button can be displayed,
the hot plate page is put down, the hot plate is put in place, the welding page is started, the terminal automatically interacts with the welding machine in real time, the pressure, time, temperature and displacement of the welding process are obtained, real-time records are made, the work of each welding stage is automatically completed, human intervention is not needed, the pressure-time curve is recorded, the real-time values of heat absorption and cooling are recorded, and the threshold value is set.
During the welding process, the parameters are recorded in real time, such as: in welding, the real-time pressure is 5.0, the real-time displacement is 80.0, the hot plate temperature is 215, and the ambient temperature is 20; the end of the weld, the real-time pressure 12.0, the real-time displacement 80.0, the hot plate temperature 215, the ambient temperature 20,
during the welding process, the welding can be finished in advance by a 'forced stop' button.
After welding, the high-definition camera arranged on the handheld terminal shoots a flanging condition image of the welded junction.
After the welding junction is photographed, the handheld terminal automatically enters a GPS positioning page, and the current position is displayed by default. If the position deviation is larger, the related key can acquire the position information again. Clicking the storage position, displaying positioning specific information, selecting the embedded depth information for storage, simply recording the relevant position at the moment, and updating the position information according to positioning equipment at the later stage.
After the crater is positioned and stored, a page for filling in welding information is entered, a user can set the crater number and remark information, and meanwhile, the crater information can be written into the electronic tag.
Generating a corresponding weld neck label set weld neck number through the welding machine number and the welding time stamp, for example, welding time: 20190730172909 welder number AGU2501812001, weld neck number: 201907300002.
when the electronic tag is written, the RFID electronic tag is close to the position of the RFID reader-writer on the back surface of the handheld terminal, the 'determination' button is clicked, the information of the weld junction is written into the tag, and the tag is stuck beside the weld junction.
After the sticking is finished, relevant personnel remove the pipe, and the handheld terminal completes relevant control and data acquisition of the whole welding process.
Storage and uploading of welding record data for handheld terminals
And recording and storing related contents in the whole welding process, selecting 'welding record', and entering a welding record page. The page displays a list of all weld records. A record search screening may be performed, with search conditions including "welding date", "upload result" (uploaded/not uploaded). For example, welding time: 20190730172909, 201912240001, the date is marked with information, and the back end is indexed with the relevant welding information under the welding date.
And selecting a record of a certain date standard information, and clicking the index to enter a welding data detail interface. The page displays all data information of the weld junction, the detail of the weld junction can be exported to a PDF file through a document generation button at the upper right corner, and the related data of the weld junction data is uploaded to a server side.
The information includes welding information: for example, welding results: "welding failed: forced termination ", general rule: "engineering number: CP001, welder id card S666, weld crater number 201907300002, welding time 20190730172909, end time: 18:43:57, welding standard TSG, welding remarks: no "welding data: "ambient temperature: 20, drag pressure: 10.0, hotplate temperature: 215, crimping stage set pressure: 6.09, the actual pressure of the hemming stage is 6.1, and the hemming stage setting time is as follows: 7, actual time of hemming stage: 7, setting pressure in the endothermic stage: 5.0, the actual pressure of the heat absorption stage is 6.09, the set time of the heat absorption stage is 68, the actual time of the heat absorption stage is 68, the switching time is 5.0', etc.
The hand-held terminal is synchronous to uploading of data acquisition of intelligent full-automatic electric fusion welding machine:
login and information verification of handheld terminal
The Bluetooth module of the intelligent welding machine is connected with the handheld terminal; the hand-held terminal is internally provided with an Internet of things card and a related scanning and shooting probe, and carries out login verification through an intelligent welding system APP, and can select three modes of code scanning, face recognition or account password input to carry out system login. The logging users are welding personnel with relevant qualification, at the moment, the welder information of the relevant personnel is recorded, and after logging, the logging-out button can be selected to log out;
after logging in, carrying out Bluetooth equipment scanning of the welding machine, selecting a corresponding welding machine according to the number of the welding machine, and carrying out 'connection start', wherein the welding machine is connected with the welding machine through the Bluetooth equipment; the welder number is for example: PFS3501912003 can check relevant information of the welding machine after connection, such as manufacturer, welding machine model, factory number, verification date and the like. The disconnection of the welding machine can be realized through a key for disconnecting;
control and data acquisition for a handheld terminal
After the welding machine is connected, the engineering information card is scanned manually or by using a two-dimensional code or an induction chip through an input box of the engineering information card, and the engineering number is recorded. Engineering information cards such as "HR190417".
In the process of executing the welding task, firstly, a page of 'material traceability information' is carried out, the aimed weld neck number can be generated in advance, or can be generated automatically according to the number of the welding machine and the welding time, or can be generated in a mode of gradually adding 1 after successful welding, the corresponding mode can be selected to generate the weld neck number, namely the weld neck label,
The pipe information is directly input by two-dimension code scanning or manual input through a traceability information traceability code provided by a pipe fitting manufacturer. After outputting, displaying and recording the pipe related information, wherein the pipe related information comprises the following steps: manufacturer, type of pipe fitting: 90 elbow, specification size: 040mm, material grade: PE100, SDR:11, production lot number: 193191.
after the material traceability information is checked, executing the next step, and entering a key node photographing and pre-welding preparation page. And performing photographing operation of the corresponding node by using the camera. The photographing content is that the skin is scraped and cleaned, and the photographing is clamped and fixed.
After all photographing nodes complete photographing, the 'next' button is changed from the original non-clickable state to the clickable state. Focusing can be performed when the image is unclear in the photographing process.
The shot page is prepared before welding to execute the next step, and the welding information page is entered. By clicking the "welding information" input box, scanning the pipe welding code or manually entering the welding code information is performed. And after the identification welding code is finished, automatically entering a pipe fitting welding information page, and displaying the identified pipe fitting welding information.
The pipe fitting welding information comprises a pipe fitting manufacturer, a set resistor, such as 1.89QHM, welding time 50s, welding voltage 39.5v, cooling time 10min, pipe fitting specification 40mm and pipe fitting type: sleeve, temperature compensation: -1s.
And controlling the intelligent full-automatic electric fusion welding machine to carry out welding treatment through the pipe welding information, executing 'confirm and start welding' on a pipe welding information page, and entering a welding page. Welding information recorded during welding is as follows: total welding time: 3 minutes 15 seconds, heating value: 302.803kj, count down; after the welding is finished, the page which is being cooled is automatically entered, and relevant parameters such as the weld neck cooling time 15 minutes and countdown are recorded in the cooling process.
After the countdown is finished, namely the automatic welding is finished, the welding process is finished, the handheld terminal prompts that the welding is successful, and a post-welding photographing page is entered after the welding is confirmed. In the welding page or the cooling page, the end welding can be terminated in advance by a 'forced stop' button.
And after the welding is finished, automatically entering a post-welding photographing page. Photographing through the welding completion condition of the high-definition camera arranged on the handheld terminal, prompting appearance inspection after photographing is completed, and judging whether abnormality exists or not through related personnel. And recording the relevant image data.
After the welding is completed without abnormality, the handheld terminal writes tag information, related personnel determine the RFID electronic tag to be close to the position of the RFID reader-writer on the back of the handheld terminal, write the crater number, the welding machine label and the welding time corresponding to the crater information into the tag, and paste the tag to the side of the crater, wherein the crater number is generated by generating related content in the crater number after the completion of login. Data written to the tag such as weld number: d001, welder number 2005350931, welding time 20180813100037.
After the writing of the weld neck label is finished, the current position is determined through GPS positioning, and the current position is displayed by default. If the positional deviation is large, the positioning can be performed again to acquire positional information again.
The positioning information comprises displaying positioning specific information, and selecting 'burial depth' information for input. So far, the whole welding process is completed. At this time, only simple positioning is performed, the positioning information has larger error, and fine positioning is performed later through an RTK system.
And recording and storing related contents in the whole welding process, selecting 'welding record', and entering a welding record page. The page displays a list of all weld records. A record search screening may be performed, with search conditions including "welding date", "upload result" (uploaded/not uploaded). For example, welding time: 20180813100037, 201912240001, the date is marked with information, and the back end is indexed with the relevant welding information under the welding date.
And selecting a record of a certain date standard information, and clicking the index to enter a welding data detail interface. The page displays all data information of the weld junction, the detail of the weld junction can be exported to a PDF file through a document generation button at the upper right corner, and the related data of the weld junction data is uploaded to a server side.
The information includes welding information such as: welding results: "welding success", general rule: "engineering number: HR190417 welder identification card S666, weld neck number: d001, construction date 2018/08/13, welding time 10:00:37, end time: 10:00:41, welding standard CJJ63, welding remarks: none "; pipe fitting information: "manufacturer, tube type: current bushing, size: 40mm, set resistance: 4.89OHM, measured resistance: 4.9OHM, post-weld resistance: 4.90OHM, welding code: 952504310403994896050422 "welding data: welding voltage: 39.5V, welding time: 49s ", etc.
The welding machine is connected with the handheld terminal to collect the related data, the related data are uploaded to the server, the server stores the data, and after the data are stored, the welding mouth number, namely the welding mouth label, is used as related associated information corresponding to the positioning information of the later mapping map. After the positioning information is acquired, marking is carried out on the map through the positioning information, and after marking, the corresponding weld neck label is used as a data index, so that corresponding welding data are generated.
Position information of a welded junction is acquired through an RTK connection mapping terminal:
The related content of the mapping terminal for position acquisition is as follows:
the mapping terminal logs in through login verification, wherein the login verification comprises account password login.
After logging in, the corresponding RTK instrument is selected to be connected in a Bluetooth mode, related settings are carried out on the mapped engineering name and attribute, meanwhile, the frequency of the detector is selected to be positioned, the frequency of the detector can be set to be 128/640 in double frequencies, and a corresponding coordinate system, such as CGCS2000, is set.
Under the coordinate system, the RTK is connected with the CORS base station through a network and is combined with the Beidou satellite to acquire the position information of the current weld leg, and acquire a fixed solution to finally generate the position information of the weld leg, such as: latitude 31.1400141287, longitude: 121.1221373516, north coordinates: 3479334.976, east coordinates: 1187357.970, elevation 16.53. The RFID tag is scanned through the mapping terminal, after scanning, the content related to the weld opening number, the welding machine number and the welding time in the current RFID tag is determined, and the node type, such as a non-node and a node/tee, corresponding to the weld opening number of the current RFID tag is searched through the server; this information is retained.
And uploading the corresponding information to a server platform, searching corresponding welding data by the server platform through the position information, the corresponding weld neck label, the welding machine number and the welding time, marking the position information, and after marking, displaying the position information in a GPS map as index information of the welding data and clicking the position information to check the corresponding welding information.
The server platform is pre-stored with relevant personnel of welder, engineering information and relevant record information data of welder information, and the relevant record information data is stored through a relevant database;
the welder terminal login mode is corresponding to welder related identity information, when welder related identity information is insufficient in qualification, the welder terminal login mode is unavailable, wherein the welder related identity information comprises name, number, unit, identity verification information, certificate time and qualification validity period, the information can generate two-dimension codes to carry out login verification, the welder related identity information is verified for a certain time, the validity time is determined, historical annual inspection records are stored, and when welder terminal needs related identity information, the welder terminal is transmitted to the welder terminal to be used and checked through the association relation of the login information and the identity information.
The welding machine number is used as a label of welding machine related information, the welding machine number corresponds to the welding machine information, the welding machine information comprises a factory number, a welding machine number, a management number, a welding machine type, a welding machine brand, a welding machine model, the unit, a factory date and an arrival date, the welding machine related information can be searched out through related search conditions, the welding machine related information is mainly searched through the welding machine number, and the service time and the position information of the welding machine are determined through rough positioning information of a handheld welding machine terminal.
The project number corresponds to project information including a project type, a project number, a project name, a project address, a management unit, a construction unit, a project manager, a site manager, a project date, a project completion date, and related remarks. By deriving the information, an engineering information card can be derived, the engineering information card contains the related information and the corresponding two-dimensional code and bar code, and engineering information is input through the two-dimensional code and the bar code through the handheld welding machine terminal.
After receiving the related contents of the handheld welding machine terminal and the handheld mapping terminal, marking position information on a GPS map, wherein different position points represent a welding point, and marking modes of different position points, such as hollow or solid, represent different welding modes, and solid position points represent hot-melt welding. When the position point is anchored, the weld junction number and the engineering number can be directly displayed, the relevance of the position information-weld junction number-engineering number/welding data represented by the position point can be used for opening the position information, the image information, the welding type, the engineering information, the weld junction number, the detailed information, the evaluation and the like corresponding to the subsequent weld junction through the position point 。
In the evaluation, aiming at the abnormal welded junction of the system alarm, a manager can evaluate the welded junction according to the actual construction condition and parameter information on site, and when the related data accords with the construction requirement and related parameter information, whether the welded junction can be put through is evaluated. For example, if the cooling time is not over, the cooling time can be judged according to the parameters, and whether the pipe is moved after the cooling is over can be judged.
There is a lower description for the position information, the image information, the detailed information, and the evaluation, wherein the position information stores a corresponding position map and a corresponding detailed position information, such as longitude and latitude altitude.
The detailed information includes all of welding data, engineering data, personnel data, and location information.
The image information contains different image data, and the butt welding comprises three photos, namely: photographing a pipe port after milling, and proving a milled flat image; shooting the misalignment situation after centering inspection, and proving that the pipe is well aligned; and shooting the curling condition after welding to prove an image with normal appearance of the welded junction curling.
The electrofusion welding comprises three photos, namely: after the oxide skin is scraped, the scraping of the complete qualified image is proved; the assembly is fixed and centered, and the good alignment image of the electrofusion welding clamp or the pipe is proved to be used; and shooting the condition of the observation hole after welding to prove that the welding electrode has no flash, smoke and normal appearance.
The foregoing is merely a preferred embodiment of the present application, but the scope of the present application is not limited thereto, and any changes or substitutions easily conceivable by those skilled in the art within the technical scope of the present application should be covered in the scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.
Claims (10)
1. An intelligent pipe network system, comprising:
an intelligent welding machine, a welding machine terminal, a marking device, a mapping terminal, a server,
collecting welding information through an intelligent welding machine;
engineering information is acquired through a welding machine terminal, welding information and the engineering information are transmitted to a server for storage, and a welded junction label corresponding to a marker device is generated according to the welding information;
marking the welding port through a marking device;
scanning a crater tag of a marker device through a mapping terminal, acquiring position information corresponding to the crater tag, and transmitting the crater tag and the position information to a server;
and carrying out association integration and storage on the position information, the welding information and the engineering information according to the crater tag by the server, and generating a mapping map according to the position information and the crater tag.
2. The intelligent pipe network system of claim 1, wherein:
the welding information comprises voltage, current, resistance, temperature, welding machine information, welding time, date and longitude and latitude.
3. The intelligent pipe network system of claim 1, wherein:
the engineering information comprises personnel information, material information, project information, process parameters and key node images.
4. The intelligent pipe network system of claim 1, wherein:
the welding machine terminal is also used for acquiring verification information, and performing authentication login according to the verification information to acquire personnel information of a welder; the authentication login comprises bar code or two-dimensional code scanning, account password login and face recognition.
5. The intelligent pipe network system of claim 1, wherein:
the surveying and mapping terminal is connected with an RTK measuring instrument, and the RTK measuring instrument is connected with a CORS base station and a Beidou satellite.
6. The intelligent pipe network system of claim 1, wherein:
the server comprises a database and a database, wherein the database is used for storing information integrated by the server and a mapping map; the database is used for storing personnel information, welding machine information and engineering information of different projects; and generating an engineering number on the engineering information card through the database, scanning the engineering number through a welding machine terminal, and collecting engineering information.
7. The intelligent pipe network system of claim 1, wherein:
the marker device adopts an ultrahigh frequency RFID chip, and a welded junction label is a unique ID number of the welded junction.
8. The intelligent pipe network system of claim 3, wherein:
the key node images include images of milled end faces, centered inspection, and flanging conditions.
9. The intelligent pipe network system of claim 3, wherein:
the MySQL database is used for storing data in the intelligent pipe network, wherein in a specific storage structure of the MySQL database, 7 attribute tables are built, namely a unit table, a welder table, an engineering project table, a construction data table, a mapping point table and a pipeline table.
10. The method based on the intelligent pipe network system according to claims 1-9, characterized in that:
before welding operation, engineering information is acquired through a welding machine terminal and login authentication is carried out;
in the welding operation process, welding information is acquired through an intelligent welding machine and is transmitted to a welding machine terminal, and the welding machine terminal stores engineering information and welding information;
after the welding operation is finished, engineering information and welding information are transmitted to a server through a welding machine terminal, a welding junction label is generated according to a welding machine number and a time stamp in the welding information, the welding junction label is written into a mark device, and the mark device is stuck beside the welding junction;
Before the pipeline is covered with soil and in the mapping process, measuring the position information of the welded junction through an RTK measuring instrument, transmitting the position information to a mapping terminal, collecting the position information and a welded junction label corresponding to a marking device through the mapping terminal, and transmitting the position information and the welded junction label to a server;
and carrying out association integration on the position information, the engineering information and the welding information through a server according to the weld junction label, marking a GIS map according to the position information, generating mapping points of different weld junctions, carrying out connection processing on the mapping points through the position information, and generating a mapping map and a pipe network dotted line table.
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| JP2008059116A (en) * | 2006-08-30 | 2008-03-13 | Hitachi-Ge Nuclear Energy Ltd | Welding work management and recording system using rfid tag |
| CN109787844A (en) * | 2019-03-22 | 2019-05-21 | 国网上海市电力公司 | A kind of distribution master station communication fault fast positioning system |
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