Method and system for intelligent identification and automatic correction of piping set-up deviation in petrochemical processes

Abstract

The application provides a method for intelligent identification and automatic correction of deviation of petrochemical process pipeline pairs, which comprises the following steps: setting a deviation range of a pipe material test piece pair; acquiring size data of an end surface of at least one pipe material test piece by a visual sensing system and transmitting the size data to a deviation data identification system; comparing the size data of the pipe material test piece with a pipe material standard size database to obtain the deviation of the pipe material test piece by the deviation data identification system; or forming a virtual pair by two different pipe material test pieces, comparing the end surface sizes of the different pipe material test pieces in the pair; analyzing and judging whether the deviation of the pipe material test piece or the virtual pair is within the set range, recording the deviation data and repeatedly calculating the deviation processing correction amount; and automatically processing the end surface of the pipe material test piece by a deviation processing correction system until the deviation is within the set range of the pipe material test piece.

Description

Technical Field

[0001] This invention belongs to the field of materials engineering technology, specifically relating to a method and system for intelligent identification and automatic correction of deviations in petrochemical process pipeline assembly. Background Technology

[0002] Petrochemicals are a pillar industry of the national economy. Petrochemical plants are the core units for cracking and refining petroleum to produce various fuels and chemical raw materials. Process pipelines are the bridges connecting petrochemical plants, their "lifeblood," and are numerous and play a crucial role. Petrochemical process pipelines often operate in high-temperature, high-pressure, and highly corrosive environments, containing flammable and explosive substances. Depending on the specific service environment, petrochemical process pipelines can be made of various materials such as carbon steel, stainless steel, and heat-resistant steel.

[0003] Welding is a primary forming process for petrochemical process pipelines and plays a crucial role in the petrochemical construction industry. In recent years, with the continuous development of welding technology, automated welding technology has been widely applied across various industries. However, in the petrochemical construction industry, especially for petrochemical process pipelines, welding production is mostly carried out on-site or in prefabrication workshops. The variety of welded products and the harsh on-site environment make it difficult to promote automated welding technology. Automated welding technology has high requirements for pipe assembly tolerances. Welding of petrochemical process pipelines includes the connection of pipes to pipes and pipes to fittings (elbows, flanges, etc.), involving a wide variety of pipe materials. Especially for the welding of pipes to fittings, differences in factory specifications, manufacturers, and applicable standards result in significant thickness deviations between pipe materials. Currently, on-site petrochemical prefabrication uses manual methods to grind away these thickness deviations, which is not only labor-intensive but also difficult to accurately control. While modern precision machining technology can perfectly solve the problem of pipe assembly tolerances, the expensive precision machining equipment, complex operating procedures, and the need for dedicated personnel increase equipment and labor costs and extend the project construction period. Finding a simple, accurate, and quick way to resolve assembly deviations in petrochemical process pipelines is the first problem that needs to be solved in promoting automated welding technology for petrochemical process pipelines. Significant pipeline assembly deviations are a major obstacle to the widespread application of automated welding technology in petrochemical process pipelines. Summary of the Invention

[0004] In view of this, to solve the problem of assembly deviation in petrochemical process pipelines in a simple, accurate, and quick manner, and to promote the application of automated welding technology in the welding of process pipelines in prefabrication workshops at petrochemical project sites, this invention provides a method for intelligent identification and automatic correction of assembly deviation in petrochemical process pipelines, including:

[0005] Step 1: Set the deviation range for the assembly of pipe test specimens;

[0006] Step 2: The visual sensing system acquires dimensional data of the end face of at least one pipe specimen and transmits it to the deviation data recognition system.

[0007] Step 3: The deviation data identification system forms a virtual pair of at least two identical pipe specimens and compares the dimensional data of the pipe specimens with the standard pipe size database to obtain the deviation of the pipe specimens; or forms a virtual pair of two different pipe specimens and compares the end face dimensions between the different types of pipes in the pair; analyzes and determines whether the deviation of the pipe specimens or the virtual pair is within the set range;

[0008] Step 4: If the deviation of the virtual pair exceeds the set range, the deviation data identification system records the deviation data and automatically calculates the deviation processing correction amount;

[0009] Step 5: The end face of the pipe specimen is automatically processed by the deviation processing correction system according to the deviation processing correction amount;

[0010] Step 6: The deviation data identification system performs a second check on the processed pipe specimen. For the pipe specimen whose deviation still exceeds the set range, a second correction is performed. Steps 2-5 are repeated until the deviation is within the set range of the pipe specimen.

[0011] Specifically, at least two identical pipe specimens are paired virtually, and the deviation of the pipe specimens is obtained by comparing the dimensional data of the pipe specimens with the standard pipe size database. This includes comparing the maximum and minimum radial dimensions of each of the pipe specimens with the corresponding standard pipe size in the standard pipe size database.

[0012] Specifically, two different pipe specimens are paired virtually, and the end face dimensions between the different types of pipes in the pair are compared. The deviation of the virtual pair is analyzed and determined to be within a set range. This includes: the virtual pair includes a first pipe and a second pipe, and the maximum deviation size of the first pipe and the second pipe in the virtual pair is determined respectively; the minimum pair deviation between the first pipe and the second pipe is automatically calculated through the virtual pair, and it is determined whether the minimum pair deviation is within the set pair deviation range.

[0013] Specifically, the first pipe is selected as the reference, and the deviation processing correction amount of the second pipe is automatically calculated; or the second pipe is selected as the reference, and the deviation processing correction amount of the first pipe is automatically calculated.

[0014] Specifically, the calculation method for the deviation processing correction includes: the end face dimension deviation D at a specific position x of the pipe specimen. x The calculation formula is as follows:

[0015]

[0016]

[0017] Where R xo R is the outer diameter of the pipe end face at point x after lattice reconstruction. xi R is the inner diameter of the pipe end face at point x after lattice reconstruction. b Let D be the reference radius of the ideal pipe end face, Ro be the outer diameter of the ideal pipe end face, and Ri be the inner diameter of the ideal pipe end face; when D x When D > 0, the deviation at x is positive; when D x When D = 0, the deviation at x is zero; when D = 0, the deviation at x is zero. x When < 0, the deviation at x is negative;

[0018] The deviation processing correction amount D a The calculation formula is as follows:

[0019]

[0020] Where D pmax For the maximum positive deviation, D nmin For the minimum negative deviation, D t The tolerance for deviation is set.

[0021] Specifically, the calculation of the deviation processing correction includes: through virtual pairing in the system, keeping the first type of pipe specimen stationary, rotating the second type of pipe, and automatically calculating the maximum pairing deviation D between the first type of pipe specimen and the second type of pipe specimen within the rotation angle β of the second type of pipe specimen in the range [0°, 359°). βmax It automatically identifies the minimum value among them, which is the smallest pairwise deviation between the first type of pipe and the second type of pipe.

[0022] D min =MIN[D βmax ];

[0023] The deviation machining correction amount Da is calculated using the following formula:

[0024] D t The tolerance for deviation is set;

[0025] Alternatively, the system can virtually pair the two types of pipe specimens, keeping the second type stationary while rotating the first type. The maximum pairing deviation D between the first and second pipe specimens is automatically calculated within the rotation angle β of the first type (0°, 359°). βmax It automatically identifies the minimum value among them, which is the smallest pairwise deviation between the first type of pipe and the second type of pipe.

[0026] D min =MIN[Dβmax ];

[0027] The deviation machining correction amount Da is calculated using the following formula:

[0028] D t The tolerance for deviation is set.

[0029] Specifically, the visual sensing system includes a 3D scanner, a microcomputer, supporting software, and a supporting structure; the visual sensing system is used to acquire dimensional data of the end face of the pipe specimen, wherein the 3D scanner is used to collect visual signals of the pipe end face, and the microcomputer is used to reconstruct a 3D dot matrix model using the supporting software and calculate the end face dimensions of the pipe specimen.

[0030] Specifically, the machining correction system includes a cutting system, and the vision sensing system, deviation data recognition system, and deviation machining correction system are all mounted on the mechanical motion control system.

[0031] Specifically, the pipe specimens include at least steel pipes, flanges, or elbows.

[0032] This invention also proposes an intelligent identification and automatic correction system for deviations in petrochemical process pipeline assembly, which includes a visual sensing system, a deviation data identification system, and a deviation processing correction system.

[0033] The visual sensing system is used to acquire the dimensional data of the end face of at least one pipe specimen, and transmit the end face dimensional data to the deviation data recognition system;

[0034] The deviation data identification system is used to form a virtual pair of at least two identical pipe specimens, compare the dimensional data of the pipe specimens with the standard pipe dimension database to obtain the deviation of the pipe specimens; or form a virtual pair of two different pipe specimens, compare the end face dimensions between the different types of pipes in the pair; analyze and determine whether the deviation of the pipe specimens or the virtual pair is within a set range; if the deviation of the virtual pair exceeds the set range, the deviation data identification system is used to record the deviation data and automatically calculate the deviation processing correction amount; transmit the deviation processing correction amount to the deviation processing correction system; the deviation data identification system also performs a secondary check on the processed pipe specimens, and performs a secondary correction on the pipe specimens whose deviation still exceeds the set range, until the deviation is within the set range of the pipe specimens.

[0035] The deviation machining correction system is used to automatically machine the end face of the pipe specimen.

[0036] Beneficial effects:

[0037] 1. This invention addresses the existing pipeline assembly technology, which primarily relies on manual assembly, rough estimation of deviations, and manual or semi-automatic grinding. It achieves intelligent identification and automatic processing correction of deviations, providing a simple, accurate, and quick solution to the problem of pipeline assembly deviations in petrochemical processes, and promoting the application of automated welding technology in the welding of process pipelines in prefabrication workshops at petrochemical project sites.

[0038] 2. The intelligent pipeline assembly deviation identification and correction system of the present invention has three working modes, which can be flexibly changed according to different welding application scenarios.

[0039] 3. The pipe specimens in this invention include at least steel pipes, flanges or elbows. Through virtual assembly, various connection methods for multiple pipe specimens can be flexibly addressed in various welding scenarios.

[0040] 4. In calculating the deviation tolerance, this invention fully considers the errors caused by different rotation angles between different pipe specimens, and can be adapted to different pipes, thus balancing accuracy and flexibility.

[0041] 5. The machining correction system in this invention includes a cutting system. The vision sensing system, deviation data recognition system, and deviation machining correction system are all integrated on the mechanical motion control system. The entire machining correction system is realized through integration, which can save space and improve operating efficiency.

[0042] 6. The visual sensing system of this invention includes a 3D scanner, a microcomputer, supporting software, and a supporting structure; the visual sensing system is used to acquire the dimensional data of the end face of the pipe specimen; wherein the 3D scanner is used to collect visual signals of the pipe end face, and the microcomputer is used to reconstruct a 3D dot matrix model using the supporting software and calculate the end face dimensions of the pipe specimen. Through the above-mentioned combined structure, various dimensional data of the pipe specimen can be acquired quickly and accurately. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of the intelligent identification and automatic correction method for deviations in petrochemical process pipeline groups in this invention;

[0044] Figure 2 This is a schematic diagram of the commonly used steel pipe structure in petrochemical process pipelines in this invention;

[0045] Figure 3 This is a schematic diagram of a commonly used flange structure in petrochemical process pipelines in this invention;

[0046] Figure 4 This is a structural diagram of the intelligent identification and automatic correction system for deviations in petrochemical process pipelines in this invention;

[0047] Figure 5 This is a schematic diagram illustrating the calculation of the pipe end face dimensional deviation in this invention. Detailed Implementation

[0048] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0049] Example 1: Identification and Correction of Dimensional Deviations in Pipe Material 1 - Steel Pipe

[0050] This invention provides a method for intelligent identification and automatic correction of deviations in petrochemical process piping assembly, the process of which is as follows: Figure 1 As shown.

[0051] like Figure 2 The image shows commonly used steel pipe materials in petrochemical process pipelines. A large amount of welding is involved in the installation and construction of petrochemical process pipelines. Due to differences in steel pipe manufacturers and applicable standards, even steel pipes of the same specification can still exhibit certain deviations after assembly, making it difficult to meet the requirements of automated welding.

[0052] This invention provides a method for intelligent identification and automatic correction of deviations in petrochemical process pipeline assembly, comprising:

[0053] Step 1.1: Set the deviation range for the pipe specimens;

[0054] Before scanning the pipe end face, an acceptable deviation range for the pipe specimen is first set. In this embodiment, the pipe specimen includes at least steel pipes. The following uses a steel pipe as an example, and a schematic diagram of the steel pipe is shown below. Figure 2 As shown;

[0055] Step 1.2: The visual sensing system acquires the dimensional data of the end face of at least one steel pipe and transmits the end face dimensional data to the deviation data recognition system.

[0056] The aforementioned visual sensing system comprises a 3D scanner, a microcomputer, supporting software, and a supporting structure. It is mainly used for visual signal acquisition of pipe end faces, reconstruction of 3D dot matrix models, calculation of pipe end face dimensions, and transmission of dimensional data to the pipe deviation identification system.

[0057] Step 1.3: The deviation data identification system compares the dimensional data of the at least one type of steel pipe with the standard pipe size database to obtain the deviation of the pipe specimen;

[0058] The extreme value (maximum and minimum value) method of radial dimension of steel pipe is used here to determine the maximum deviation dimension of steel pipe; by comparing with the standard dimension database of pipe materials, the assembly deviation of pipe materials is automatically calculated and it is determined whether the deviation is within the set assembly deviation range (tolerance range);

[0059] Step 1.4: If the deviation of the pipe specimen exceeds the set range, the deviation data identification system records the deviation data and automatically calculates the deviation processing correction amount;

[0060] By comparing with the standard pipe size database, the deviation of the pipe specimen is automatically calculated and it is determined whether the deviation is within the set assembly deviation range. For pipes with deviations within the range, the operation is terminated; for pipes with deviations outside the range, the deviation processing correction amount is automatically calculated.

[0061] The functions of the aforementioned deviation data identification system include setting deviation range, calling built-in database data, deviation data identification and recording, and correction dimension calculation, and are mainly used for the identification of deviation data and the calculation of correction data;

[0062] The calculation of the pipe end face dimensional deviation is as follows: Figure 4 The following explanation is provided:

[0063] The formula for calculating the end face dimensional deviation Dx at a specific location x of the pipe is as follows:

[0064]

[0065]

[0066] Where R xo R is the outer diameter of the pipe end face at point x after lattice reconstruction. xi R is the inner diameter of the pipe end face at point x after lattice reconstruction. b R is the reference radius for the ideal pipe end face. o R is the outer diameter of the ideal pipe end face. i The inner diameter of the ideal pipe end face.

[0067] When D x When x > 0, the deviation is positive.

[0068] When D x When = 0, the deviation at x is zero;

[0069] When D x When < 0, the deviation at x is negative;

[0070] The deviation machining correction amount Da is calculated using the following formula:

[0071]

[0072] Where D pmax For the maximum positive deviation, D nmax For the minimum negative deviation, D t The tolerance for deviation is set.

[0073] Step 1.5: The deviation data identification system transmits the deviation processing correction amount to the deviation processing correction system, and the deviation processing correction system automatically processes the end face of the pipe specimen.

[0074] For pipes with deviations outside the acceptable range, the deviation processing correction amount is automatically calculated; then the deviation correction system is activated to process and correct the pipes that exceed the tolerance.

[0075] The aforementioned mechanical motion control system is equipped with a vision sensing system, a deviation data recognition system, and a deviation processing correction system, and receives signals from the vision sensing system and the deviation processing correction system to realize data acquisition and processing correction of the end face.

[0076] Step 1.6: The deviation data identification system performs a second check on the processed pipe specimen, i.e., the steel pipe in this embodiment. For the pipe specimen whose deviation still exceeds the set range, a second correction is performed until the deviation is within the set range of the pipe specimen.

[0077] Figure 4 This is a structural diagram of a petrochemical process pipeline assembly deviation intelligent identification and automatic correction system, including motor 1, support shaft 2, transmission shaft 3, microcomputer and display 4, 3D scanner 5, cutting system 6, internal support mechanism 7, pipeline clamping mechanism 8, and pipeline to be processed 9.

[0078] Example 2: Identification and Correction of Dimensional Deviations in Pipe 2-Flange

[0079] like Figure 3 The image shows flanges commonly used in petrochemical process pipelines. A large amount of steel pipe material is welded during the installation and construction of petrochemical process pipelines. Due to differences in manufacturers and applicable standards, flanges of the same specification still exhibit certain deviations after assembly, making it difficult to meet the requirements of automated welding.

[0080] This invention provides a method for intelligent identification and automatic correction of deviations in petrochemical process piping assembly, the process of which is as follows: Figure 1As shown. Its main process is similar to the processing of pipe 1 (steel pipe) in Example 1. Using the system of this invention, a 3D scanner is used to scan the end face of the steel pipe. A built-in microcomputer and supporting software are used to reconstruct the 3D dot matrix of the pipe end face, and the end face dimensions of the pipe are automatically calculated. Here, the extreme value (maximum and minimum value) method of the radial dimension of the steel pipe is used to determine the maximum deviation dimension of the steel pipe. By comparing with the standard pipe size database, the pipe assembly deviation is automatically calculated, and it is determined whether the deviation is within the set assembly deviation range (tolerance range). For pipes with deviations within the range, the operation is terminated; for pipes with deviations outside the range, the deviation processing correction amount is automatically calculated. Then, the deviation correction system is activated to process and correct the out-of-tolerance pipes. A second deviation check is performed on the processed and corrected pipes. For pipes with deviations within the range, the operation is terminated; for pipes with deviations outside the range, the above steps are repeated until the set deviation range is met.

[0081] In addition to the common pipe specimens mentioned above, such as steel pipes and flanges, this method can also be used to process other pipe specimens, such as elbows, etc., which will not be described in detail in this embodiment.

[0082] Example 3: Identification of assembly deviations between Pipe 1 (steel pipe) and Pipe 2 (flange) and correction of Pipe 2 (flange)

[0083] For petrochemical process pipelines, steel pipes and flanges awaiting assembly may still exhibit certain deviations after assembly due to differences in manufacturers and applicable standards. This makes it difficult to meet the requirements of automated welding.

[0084] Step 3.1: Set the deviation range for the pipe specimens;

[0085] Before scanning the pipe end face, an acceptable deviation range for the pipe specimen is first set. In this embodiment, the pipe specimen includes at least steel pipes and flanges.

[0086] Step 3.2: The vision sensing system acquires the dimensional data of the end faces of at least one steel pipe and flange, and transmits the end face dimensional data to the deviation data recognition system;

[0087] The aforementioned visual sensing system comprises a 3D scanner, a microcomputer, supporting software, and a supporting structure. It is mainly used for visual signal acquisition of pipe end faces, reconstruction of 3D dot matrix models, calculation of pipe end face dimensions, and transmission of dimensional data to the pipe deviation identification system.

[0088] A 3D scanner was used to scan the end face of pipe 1 (steel pipe) and pipe 2 (flange). The built-in microcomputer and supporting software, such as data processing and image forming software, were used to reconstruct the 3D dot matrix of the pipe end face and automatically calculate the end face dimensions of pipe 1 (steel pipe) and pipe 2 (flange). The extreme value (maximum value and minimum value) method of the radial dimension of the pipe was used to determine the maximum deviation dimension of pipe 1 (steel pipe) and pipe 2 (flange).

[0089] Step 3.3: Form a virtual pair of two different pipe specimens, compare the end face dimensions between the different types of pipes in the pair, and analyze and determine whether the deviation of the pipe specimens or the virtual pair is within the set range.

[0090] Here, the extreme value (maximum value, minimum value) method of radial dimension of pipe is used to determine the maximum deviation dimension of pipe 1-steel pipe and pipe 2-flange respectively; through virtual pairing, the minimum pairing deviation of pipe 1-steel pipe and pipe 2-flange is automatically calculated;

[0091] The automatic virtual pairing and deviation calculation process is as follows:

[0092] Using the steel pipe as a reference, keep the steel pipe stationary;

[0093] First, the flange is virtually assembled with the reference steel pipe at an arbitrary angle, and the rotation angle β between the steel pipe and the flange is defined as 0° at this time.

[0094] The maximum assembly deviation between the steel pipe and the flange at this time is calculated using the following formula.

[0095] D βmax =|D αpipe -D αflange |

[0096] Where D βmax D represents the maximum assembly deviation when the rotation angle between the steel pipe and the flange is β, where β ranges from [0°, 359°]. αpipe This indicates the deviation of the steel pipe at angle α when the rotation angle between the steel pipe and the flange assembly is β; D αflange This represents the deviation of the flange at angle α when the rotation angle between the steel pipe and the flange assembly is β (α ranges from [0°, 359°)). αflange D αpipe The calculation formula is consistent with the formula for calculating the end face dimension deviation Dx at a specific location x of the pipe. Here, x is synonymous with α, as shown below:

[0097]

[0098]

[0099] Where R xo R is the outer diameter of the pipe end face at point x after lattice reconstruction.xi R is the inner diameter of the pipe end face at point x after lattice reconstruction. b R is the reference radius for the ideal pipe end face. o R is the outer diameter of the ideal pipe end face. i The inner diameter of the ideal pipe end face.

[0100] When D x When x > 0, the deviation is positive.

[0101] When D x When = 0, the deviation at x is zero;

[0102] When D x When < 0, the deviation at x is negative;

[0103] Step 3.4: If the deviation of the pipe specimen exceeds the set range, the deviation data identification system records the deviation data and automatically calculates the deviation processing correction amount;

[0104] Determine whether the deviation is within the set pairing deviation range (tolerance range); terminate the operation for pipes with deviations within the range, and automatically calculate the deviation processing correction amount for pipes with deviations outside the range;

[0105] By virtually assembling the system, keeping the steel pipe stationary and rotating the flange, the maximum assembly deviation D between the steel pipe and the flange within the range of [0°, 359°] is automatically calculated. βmax It automatically identifies the minimum value among them, which is the smallest pairwise deviation between the steel pipe and the flange.

[0106] D min =MIN[D βmax ]

[0107] The deviation machining correction amount Da is calculated using the following formula:

[0108] D t The tolerance for deviation is set.

[0109] Step 3.5: The deviation data identification system transmits the deviation processing correction amount to the deviation processing correction system, and the deviation processing correction system automatically processes the end face of the pipe specimen.

[0110] For pipes with deviations outside the acceptable range, the deviation processing correction amount is automatically calculated; then the deviation correction system is activated to process and correct the pipes that exceed the tolerance.

[0111] In this embodiment, pipe 1 - steel pipe is selected as the benchmark, and the deviation processing correction amount of pipe 2 - flange is automatically calculated;

[0112] The pipe 2-flange is processed and corrected; the mechanical motion control system is used to carry a vision sensing system, a deviation data recognition system, and a deviation processing correction system for the processed and corrected pipe 2-flange, and receives signals from the vision sensing system and the deviation processing correction system to realize data acquisition and processing correction of the end face.

[0113] Step 3.6: The visual sensing system and deviation data recognition system perform secondary scanning and dot matrix reconstruction on the processed pipe specimens, namely the steel pipe and flange in this embodiment, and perform secondary virtual assembly and deviation verification. For pipes with deviations within the range, the operation is terminated. For pipe specimens whose deviations still exceed the set range, the reference pipe is replaced, and pipe 2-flange is selected as the reference. The steel pipe is rotated, and the minimum assembly deviation and the deviation correction amount of pipe 1-steel pipe are automatically calculated. The above steps are repeated until the assembly deviation is within the set range.

[0114] Example 4: Identification of assembly deviations between Pipe 1 (steel pipe) and Pipe 2 (flange) and correction of Pipe 1 (steel pipe)

[0115] like Figure 2 , Figure 3 The image shows steel pipes and flanges to be assembled in a petrochemical process pipeline. Due to differences in the manufacturers and standards used for the steel pipes and flanges, even steel pipes and flanges of the same specifications will still have certain deviations after assembly, making it difficult to meet the requirements of automated welding.

[0116] Step 4.1: Set the deviation range for the pipe specimens;

[0117] Before scanning the pipe end face, an acceptable deviation range for the pipe specimen is first set. In this embodiment, the pipe specimen includes at least steel pipes and flanges.

[0118] Step 4.2: The vision sensing system acquires the dimensional data of the end faces of at least one steel pipe and flange, and transmits the end face dimensional data to the deviation data recognition system;

[0119] The aforementioned visual sensing system comprises a 3D scanner, a microcomputer, supporting software, and a supporting structure. It is mainly used for visual signal acquisition of pipe end faces, reconstruction of 3D dot matrix models, calculation of pipe end face dimensions, and transmission of dimensional data to the pipe deviation identification system.

[0120] A 3D scanner was used to scan the end face of pipe 1 (steel pipe) and pipe 2 (flange) respectively. The built-in microcomputer and supporting software were used to reconstruct the 3D dot matrix of the pipe end face and automatically calculate the end face dimensions of pipe 1 (steel pipe) and pipe 2 (flange). The extreme value (maximum value and minimum value) method of the radial dimension of the pipe was used to determine the maximum deviation dimension of pipe 1 (steel pipe) and pipe 2 (flange) respectively.

[0121] Step 4.3: Assemble two different pipe specimens into a virtual pair, compare the end face dimensions between the different types of pipes in the pair, and analyze and determine whether the deviation of the pipe specimens or the virtual pair is within the set range.

[0122] Here, the extreme value (maximum value, minimum value) method of radial dimension of pipe is used to determine the maximum deviation dimension of pipe 1-steel pipe and pipe 2-flange respectively; through virtual pairing, the minimum pairing deviation of pipe 1-steel pipe and pipe 2-flange is automatically calculated;

[0123] The automatic virtual pairing and deviation calculation process is as follows:

[0124] This example uses the flange as a reference, keeping the flange stationary;

[0125] First, the steel pipe is virtually assembled with the reference flange at an arbitrary angle, and the rotation angle β between the steel pipe and the flange is defined as 0° at this time.

[0126] The maximum assembly deviation between the steel pipe and the flange at this time is calculated using the following formula.

[0127] D βmax =|D αpipe -D αflange |

[0128] Where D βmax D represents the maximum assembly deviation when the rotation angle between the steel pipe and the flange is β, where β ranges from [0°, 359°]. αpipe D represents the deviation of the steel pipe at angle α when the rotation angle between the steel pipe and the flange assembly is β. αflange This represents the deviation of the flange at angle α when the rotation angle between the steel pipe and the flange assembly is β (α ranges from [0°, 359°)). αflange D αpipe The calculation formula is consistent with the formula for calculating the end face dimension deviation Dx at a specific location x of the pipe. Here, x is synonymous with α, as shown below:

[0129]

[0130]

[0131] Where R xo R is the outer diameter of the pipe end face at point x after lattice reconstruction. xi R is the inner diameter of the pipe end face at point x after lattice reconstruction. b R is the reference radius for the ideal pipe end face. o R is the outer diameter of the ideal pipe end face. i The inner diameter of the ideal pipe end face.

[0132] When D x When x > 0, the deviation is positive.

[0133] When D x When = 0, the deviation at x is zero;

[0134] When D x When < 0, the deviation at x is negative;

[0135] Step 4.4: If the deviation of the pipe specimen exceeds the set range, the deviation data identification system records the deviation data and automatically calculates the deviation processing correction amount;

[0136] Determine whether the deviation is within the set pairing deviation range (tolerance range); terminate the operation for pipes with deviations within the range, and automatically calculate the deviation processing correction amount for pipes with deviations outside the range;

[0137] By virtually assembling the system, keeping the flange stationary and rotating the steel pipe, the maximum assembly deviation D between the steel pipe and the flange within the rotation angle β of the steel pipe in the range of [0°, 359°) is automatically calculated. βmax It automatically identifies the minimum value among them, which is the smallest pairwise deviation between the steel pipe and the flange.

[0138] D min =MIN[D βmax ]

[0139] The deviation machining correction amount Da is calculated using the following formula:

[0140] D t The tolerance for deviation is set;

[0141] Step 4.5: The deviation data identification system transmits the deviation processing correction amount to the deviation processing correction system, and the deviation processing correction system automatically processes the end face of the pipe specimen.

[0142] For pipes with deviations outside the acceptable range, the deviation processing correction amount is automatically calculated; then the deviation correction system is activated to process and correct the pipes that exceed the tolerance.

[0143] In this embodiment, the pipe 1 is processed and corrected; the mechanical motion control system is equipped with a vision sensing system, a deviation data recognition system, and a deviation processing correction system, and receives signals from the vision sensing system and the deviation processing correction system to realize data acquisition and processing correction of the end face.

[0144] Step 4.6: The visual sensing system and the deviation data recognition system perform secondary scanning and dot matrix reconstruction on the processed pipe specimens, namely the steel pipes and flanges in this embodiment, and perform secondary virtual assembly and deviation verification. For pipes with deviations within the range, the operation is terminated. For pipe specimens whose deviations still exceed the set range, the reference pipe is replaced, and the above steps are repeated until the assembly deviation is within the set range.

[0145] Examples 1 and 2 above identify and correct batch assembly deviations for pipe material 1 (steel pipe) and pipe material 2 (flange), respectively, and verify them by comparing with a pipe deviation database. The advantage is that the corrected pipe materials can be assembled with each other, and it also serves as a way to establish and enrich the pipe deviation database. Examples 3 and 4 identify and correct assembly deviations for specific pipe material 1 (steel pipe) and pipe material 2 (flange), respectively. They do not require comparison with a pipe deviation database; as long as the set deviation range is met, assembly can be completed, exhibiting strong targeting and high efficiency. In current petrochemical process pipeline installation, Example 3 is more commonly used, namely, identifying deviations for specific pipe material 1 (steel pipe) and pipe material 2 (flange), and then processing and correcting pipe material 2 (flange).

[0146] Example 5: This invention also proposes an intelligent identification and automatic correction system for deviations in petrochemical process pipeline assembly. This system includes a visual sensing system, a deviation data identification system, and a deviation processing correction system, characterized in that:

[0147] The visual sensing system is used to acquire the dimensional data of the end face of at least one pipe specimen, and transmit the end face dimensional data to the deviation data recognition system;

[0148] The deviation data identification system is used to form a virtual pair of at least two identical pipe specimens, compare the dimensional data of the pipe specimens with the standard pipe dimension database to obtain the deviation of the pipe specimens; or form a virtual pair of two different pipe specimens, compare the end face dimensions between the different types of pipes in the pair; analyze and determine whether the deviation of the pipe specimens or the virtual pair is within a set range; if the deviation of the virtual pair exceeds the set range, the deviation data identification system is used to record the deviation data and automatically calculate the deviation processing correction amount; transmit the deviation processing correction amount to the deviation processing correction system; the deviation data identification system also performs a secondary check on the processed pipe specimens, and performs a secondary correction on the pipe specimens whose deviation still exceeds the set range, until the deviation is within the set range of the pipe specimens.

[0149] The deviation machining correction system is used to automatically machine the end face of the pipe specimen.

[0150] Using the system of this invention, a 3D scanner is used to scan the end face of the steel pipe. A built-in microcomputer and accompanying software are used to reconstruct the 3D dot matrix of the pipe end face and automatically calculate the end face dimensions. Here, the extreme values ​​(maximum and minimum values) of the radial dimensions of the steel pipe are used to determine the maximum deviation dimension. By comparing with a standard pipe size database, the system automatically calculates the pipe assembly deviation and determines whether the deviation is within the set assembly deviation range (tolerance range). For pipes with deviations within the range, the operation is terminated; for pipes with deviations outside the range, the deviation processing correction amount is automatically calculated. Then, the deviation correction system is activated to process and correct the out-of-tolerance pipes. A second deviation check is performed on the corrected pipes. For pipes with deviations within the range, the operation is terminated; for pipes with deviations outside the range, the above steps are repeated until the set deviation range is met.

[0151] In summary, the above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

[0152] It will be apparent to those skilled in the art that the embodiments of the present invention are not limited to the details of the exemplary embodiments described above, and that the embodiments of the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the embodiments of the present invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the embodiments of the present invention is defined by the appended claims rather than the foregoing description. Therefore, all variations falling within the meaning and scope of equivalents of the claims are intended to be encompassed within the embodiments of the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims. Furthermore, it is clear that the word "comprising" does not exclude other units or steps, and the singular does not exclude the plural. Multiple units, modules, or devices recited in the system, apparatus, or terminal claims may also be implemented by the same unit, module, or device through software or hardware. The terms "first," "second," etc., are used to indicate names and do not indicate any particular order.

[0153] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the embodiments of the present invention and are not intended to limit them. Although the embodiments of the present invention have been described in detail with reference to the above preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions to the technical solutions of the embodiments of the present invention should not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for intelligent identification and automatic correction of deviations in petrochemical process pipeline assembly, characterized in that, include: Step 1: Set the deviation range for the assembly of pipe test specimens; Step 2: The visual sensing system acquires dimensional data of the end face of at least one pipe specimen and transmits it to the deviation data recognition system. The visual sensing system includes a 3D scanner, a microcomputer, supporting software, and a support structure. The visual sensing system is used to acquire dimensional data of the end face of the pipe specimen. The 3D scanner is used to collect visual signals of the pipe end face, and the microcomputer is used to reconstruct a 3D dot matrix model using the supporting software and calculate the end face dimensions of the pipe specimen. Step 3: The deviation data identification system forms a virtual pair of at least two identical pipe specimens, compares the dimensional data of the pipe specimens with the pipe standard size database to obtain the deviation of the pipe specimens; and compares the maximum and minimum values ​​of the radial dimensions of each of the pipe specimens with the corresponding pipe standard dimensions in the pipe standard size database. Alternatively, two different pipe specimens can be paired virtually, and the end face dimensions of the different pipes in the pair can be compared; the calculation method for the deviation processing correction specifically includes: the end face dimension deviation D at a specific position x of the pipe specimen. x The calculation formula is as follows: Where R xo R is the outer diameter of the pipe end face at point x after lattice reconstruction. xi R is the inner diameter of the pipe end face at point x after lattice reconstruction. b Let D be the reference radius of the ideal pipe end face, Ro be the outer diameter of the ideal pipe end face, and Ri be the inner diameter of the ideal pipe end face; when D x When D > 0, the deviation at x is positive; when D x When D = 0, the deviation at x is zero; when D = 0, the deviation at x is zero. x When < 0, the deviation at x is negative; The deviation processing correction amount D a The calculation formula is as follows: Where D pmax For the maximum positive deviation, D nmin For the minimum negative deviation, D t The system sets a tolerance for deviation; analyzes and judges whether the deviation of the pipe specimen or the virtual pair is within the set range; the virtual pair includes a first pipe and a second pipe, and determines the maximum deviation size of the first pipe and the second pipe in the virtual pair respectively; automatically calculates the smallest pairing deviation between the first pipe and the second pipe through the virtual pairing, and judges whether the smallest pairing deviation is within the set pairing deviation range; selects the first pipe as the reference and automatically calculates the deviation processing correction amount of the second pipe; through the system virtual pairing, keeping the first type of pipe specimen stationary, rotates the second type of pipe, and automatically calculates the maximum pairing deviation D between the first type of pipe specimen and the second type of pipe when the rotation angle β of the second type of pipe specimen is in the range of [0°, 359°). βmax It automatically identifies the minimum value among them, which is the smallest pairwise deviation between the first type of pipe and the second type of pipe. D min =MIN[D βmax ]; The deviation machining correction amount Da is calculated using the following formula: D t The tolerance for deviation is set; Step 4: If the deviation of the virtual pair exceeds the set range, the deviation data identification system records the deviation data and automatically calculates the deviation processing correction amount; Step 5: The end face of the pipe specimen is automatically processed by the deviation processing correction system according to the deviation processing correction amount; the processing correction system includes a cutting system, and the vision sensing system, deviation data recognition system, and deviation processing correction system are all mounted on the mechanical motion control system; the pipe specimen includes at least a steel pipe, flange, or elbow. Step 6: The deviation data identification system performs a second check on the processed pipe specimen. For the pipe specimen whose deviation still exceeds the set range, a second correction is performed. Steps 2-5 are repeated until the deviation is within the set range of the pipe specimen.

2. The method for intelligent identification and automatic correction of deviations in petrochemical process pipeline assembly as described in claim 1, characterized in that: Alternatively, you can choose to use the second pipe as a reference and automatically calculate the deviation processing correction amount for the first pipe.

3. The method for intelligent identification and automatic correction of deviations in petrochemical process pipeline assembly as described in claim 2, characterized in that: The calculation of the deviation processing correction amount includes: Alternatively, the system can virtually pair the two types of pipe specimens, keeping the second type stationary while rotating the first type. The maximum pairing deviation D between the first and second pipe specimens is automatically calculated within the rotation angle β of the first type (0°, 359°). βmax It automatically identifies the minimum value among them, which is the smallest pairwise deviation between the first type of pipe and the second type of pipe. D min =MIN[D βmax ]; The deviation machining correction amount Da is calculated using the following formula: D t The tolerance for deviation is set.

4. A petrochemical process pipeline assembly deviation intelligent identification and automatic correction system, the system comprising a vision sensing system, a deviation data identification system, and a deviation processing correction system, characterized in that: The visual sensing system is used to acquire dimensional data of the end face of at least one pipe specimen and transmits the end face dimensional data to a deviation data recognition system. The visual sensing system includes a 3D scanner, a microcomputer, supporting software, and a support structure. The visual sensing system is used to acquire dimensional data of the end face of the pipe specimen, wherein the 3D scanner is used to collect visual signals of the pipe end face, and the microcomputer is used to reconstruct a 3D dot matrix model using the supporting software and calculate the end face dimensions of the pipe specimen. The deviation data identification system is used to form a virtual pair of at least two identical pipe specimens, compare the dimensional data of the pipe specimens with a pipe standard size database to obtain the deviation of the pipe specimens; compare the maximum and minimum values ​​of the radial dimensions of each pipe specimen with the corresponding pipe standard dimensions in the pipe standard size database; or form a virtual pair of two different pipe specimens and compare the end face dimensions between the different types of pipes in the pair; the calculation method of the deviation processing correction amount specifically includes: the end face dimension deviation D at a specific position x of the pipe specimen. x The calculation formula is as follows: Where R xo R is the outer diameter of the pipe end face at point x after lattice reconstruction. xi R is the inner diameter of the pipe end face at point x after lattice reconstruction. b Let D be the reference radius of the ideal pipe end face, Ro be the outer diameter of the ideal pipe end face, and Ri be the inner diameter of the ideal pipe end face; when D x When D > 0, the deviation at x is positive; when D x When D = 0, the deviation at x is zero; when D = 0, the deviation at x is zero. x When < 0, the deviation at x is negative; The deviation processing correction amount D a The calculation formula is as follows: Where D pmax For the maximum positive deviation, D nmin For the minimum negative deviation, D t The system sets a tolerance for deviation; analyzes and determines whether the deviation of the pipe specimen or the virtual assembly is within a set range; if the deviation of the virtual assembly exceeds the set range, the deviation data identification system records the deviation data and automatically calculates the deviation processing correction amount; the deviation data identification system also performs a secondary check on the processed pipe specimen, and performs a secondary correction on the pipe specimen whose deviation still exceeds the set range until the deviation is within the set range of the pipe specimen; the virtual assembly includes a first pipe and a second pipe, and the virtual assembly is determined respectively. The system calculates the maximum deviation dimensions of the first and second pipes respectively; automatically calculates the minimum pairing deviation between the first and second pipes through virtual pairing, and determines whether the minimum pairing deviation is within the set pairing deviation range; selects the first pipe as the reference and automatically calculates the deviation processing correction amount of the second pipe; through virtual pairing, keeping the first pipe specimen stationary and rotating the second pipe, the system automatically calculates the maximum pairing deviation D between the first and second pipe specimens with a rotation angle β of [0°, 359°). βmax It automatically identifies the minimum value among them, which is the smallest pairwise deviation between the first type of pipe and the second type of pipe. D min =MIN[D βmax ]; The deviation machining correction amount Da is calculated using the following formula: D t The tolerance for deviation is set; The deviation processing correction system is used to automatically process the end face of the pipe specimen according to the deviation processing correction amount; the processing correction system includes a cutting system, and the vision sensing system, deviation data recognition system, and deviation processing correction system are all mounted on the mechanical motion control system; the pipe specimen includes at least a steel pipe, flange, or elbow.

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