Ship curved plate forming method and forming equipment based on digital twin

Abstract

The present application relates to the field of ship processing and manufacturing technology, and specifically, to a ship curved plate forming method and forming equipment based on digital twins. The ship curved plate forming method of the present application adopts a digital twin, and after obtaining the physical property information of the curved plate, the curved plate can be directly and quickly processed when there is a one-time forming scheme. When there is no curved plate forming scheme, a three-dimensional simulation analysis system is used to simulate the forming process of the mold, and the bending machine uses the simulated mold shape to form the curved plate. The formed curved plate shape is compared with the target shape through the data comparison system. If it does not meet the requirements, the nonlinear finite element calculation and analysis parameters are updated, and the mold shape is adjusted to continue processing until it meets the requirements. The present application continuously improves and optimizes the forming process of the curved plate through three-dimensional simulation analysis in conjunction with the bending machine, and stores the optimization results in a database, thereby improving the forming speed of the curved plate.

Description

Technical Field

[0001] The present application relates to the field of ship processing and manufacturing technology, and specifically to a ship curved plate forming method and forming equipment based on digital twins. Background Art

[0002] The description in this section merely provides background information related to the present disclosure and may not constitute prior art.

[0003] In the shipbuilding process, the forming of the hull outer plate is one of the most complicated processes. The outer plate with single curvature is generally bent by three-core rollers or hydraulic presses, while the outer plate with double curvature needs to be formed by water and fire bending. With the development of processing technology, three-dimensional CNC bending technology based on multi-point forming has also emerged. The use of bending machines can quickly roll out complex curved plates that meet the requirements of the profile. However, for the cold rolling of curved plates, a certain rebound phenomenon will occur. Therefore, it is difficult to achieve precise control of the downward rolling scale of the bending machine. It is often necessary to carry out multiple rolling processes to bend the curved plate into a specified shape. With the development of numerical simulation technology, the rolling process can be numerically simulated based on nonlinear finite element simulation, but the simulation process is not based on real-time data, and the calculation results are easily affected by the setting of calculation and analysis parameters, resulting in deviations from the actual situation. Summary of the Invention

[0004] The purpose of the embodiments of the present application is to provide a ship curved plate forming method based on digital twinning, which is used to increase the forming speed of the curved plate.

[0005] Another purpose of an embodiment of the present application is to provide a digital twin-based ship curved plate forming device that implements the above-mentioned forming method.

[0006] In a first aspect, a method for forming a curved plate of a ship based on digital twin is provided, comprising the following steps:

[0007] Step 1: Construct a digital twin architecture for the curved plate forming process. The digital twin architecture includes a plate bending machine, a data acquisition system, and a data processing and storage system. The plate bending machine is used to bend the plate to be processed and form it into a curved plate. The data acquisition system is used to collect deformation data of the curved plate and transmit the collected data to the data processing and storage system. The data processing and storage system includes an experience database, a three-dimensional simulation analysis system, and a data comparison system. The experience database is used to store the mold shape corresponding to the curved plate during the forming process and the finite element simulation calculation parameters used to calculate the mold shape. The three-dimensional simulation analysis system is used to perform nonlinear finite element simulation on the curved plate forming process. The data comparison system is used to compare the actual processing results of the curved plate collected by the data acquisition system with the target shape, and is also used to compare the finite element analysis results with the theoretical target results to determine whether the error between the two meets the requirements.

[0008] Step 2: Obtain the physical property information of the curved plate to be formed, and search the corresponding forming information from the experience database based on the physical property information of the curved plate. If there is a result of one-time forming of the curved plate, select the mold shape corresponding to the result, and directly submit the mold shape to the plate bending machine for processing. After the processing is completed, the operation ends.

[0009] If there is no curved plate forming result in the experience database, the mold shape is initialized based on the physical properties of the curved plate and combined with experience, and step 3 is performed;

[0010] Step 3: Submit the mold shape to the 3D simulation analysis system and update the nonlinear finite element analysis parameters;

[0011] Step 4: Perform finite element simulation of the curved plate forming process to determine whether the curved plate simulation result is consistent with the target shape. If not, continue to adjust the mold shape until the curved plate forming result is consistent with the target shape, and obtain a mold shape that meets the requirements. Save the finite element calculation and analysis parameters at this time to the experience database, and submit the mold shape to the bending machine;

[0012] Step 5: Control the plate bending machine operation, obtain the forming results of the bent plate through the data acquisition system, and feed the forming results back to the data comparison system;

[0013] In step 6, the actual formed curved plate shape is compared with the target shape. If the error between the two meets the requirements, the operation is terminated, the curved plate forming operation is completed, and the data generated by the curved plate forming process is saved to the experience database; otherwise, the curved plate state is used as the initial condition, and steps 2 to 5 are repeated until the curved plate forming operation is completed.

[0014] In one possible implementation scheme, in step 2, if there is only the result of multiple forming of the bent plate, based on the result of the minimum forming steps, adjustments are made on the basis of the mold shape used in the first forming step to obtain the mold shape, and the obtained mold shape is submitted to the bending machine to proceed to step 3.

[0015] In a possible implementation, the empirical database stores the mold shape corresponding to the curved plate during the forming process, as well as finite element simulation calculation parameters for calculating the mold shape.

[0016] In one possible implementation scheme, the data comparison system sets a standard threshold and compares the actual processing results of the curved plate with the target shape in step 6 to determine whether the error between the two meets the requirements; in step 4, the finite element analysis results are compared with the theoretical target results to determine whether the error between the two meets the requirements.

[0017] In one possible implementation, the data acquisition system includes a strain sensor for acquiring deformation data of the curved plate, and the strain sensor is communicatively connected to the data processing and storage system.

[0018] In one possible implementation, the plate bending machine is a three-dimensional CNC plate bending machine.

[0019] In one possible implementation, in step 5, the plate bending machine operation is controlled, and the rebound result of the bent plate is obtained through the data acquisition system, and the rebound result is fed back to the data comparison system.

[0020] In the second aspect, a ship curved plate forming equipment based on digital twin is provided, including a plate bending machine, a data acquisition system, and a data processing and storage system;

[0021] The plate bending machine is used to bend the plate to be processed to form a curved plate;

[0022] The data acquisition system is used to collect the deformation data of the curved plate and transmit the collected data to the data processing and storage system;

[0023] The data processing and storage system includes an experience database, a three-dimensional simulation analysis system, and a data comparison system;

[0024] The 3D simulation analysis system is used to perform nonlinear finite element simulation on the curved plate forming process to obtain the mold shape that meets the requirements;

[0025] The experience database is used to store the mold shape corresponding to the curved plate during the forming process, and the finite element simulation calculation parameters used to calculate the mold shape;

[0026] The data comparison system is used to compare the actual processing results of the curved plate collected by the data acquisition system with the target shape, and is also used to compare the finite element analysis results with the theoretical target results to determine whether the error between the two meets the requirements.

[0027] In one possible implementation, the plate bending machine is a three-dimensional CNC plate bending machine.

[0028] In one possible implementation, the data acquisition system includes a strain sensor for acquiring deformation data of the curved plate, and the strain sensor is communicatively connected to the data processing and storage system.

[0029] In one possible implementation, the strain sensor is connected to the data processing and storage system via a cable.

[0030] The beneficial effects of the present application: The ship curved plate forming method of the present application adopts a digital twin. After obtaining the physical property information of the curved plate, it first searches the database to see if there is a one-time forming solution. If there is a one-time forming solution, the curved plate can be directly and quickly processed. When there is no curved plate forming solution, a three-dimensional simulation analysis system is used to simulate the forming process of the mold, and the mold shape is obtained according to the simulation results. The bending machine uses the simulated mold shape to form the curved plate, and then collects the curved plate data through data. The formed curved plate shape is compared with the target shape through the data comparison system. If it does not meet the requirements, the nonlinear finite element calculation and analysis parameters are updated, and the mold shape is adjusted to continue processing until it meets the requirements. The present application continuously improves and optimizes the forming process of the curved plate through three-dimensional simulation analysis in conjunction with the bending machine, and stores the optimization results in the database, thereby improving the forming speed of the curved plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following is a brief introduction to the drawings required for use in the embodiments. It should be understood that the following drawings only show certain embodiments of the present application and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without creative work.

[0032] Figure 1 This is a flow chart of a ship curved plate forming method based on digital twinning in this application.

[0033] Figure 2 This is the main architecture diagram of the digital twin of this application.

[0034] Figure 3 This is a flow chart of the digital twin improvement and curved plate forming process for this application. DETAILED DESCRIPTION

[0035] To make the objectives, technical solutions, and advantages of the embodiments of the present application more clear, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Generally, the components of the embodiments of the present application described and shown in the drawings herein can be arranged and designed in various different configurations.

[0036] Therefore, the following detailed description of the embodiments of the present application provided in the accompanying drawings is not intended to limit the scope of the present application for protection, but merely represents selected embodiments of the present application. All other embodiments obtained by persons of ordinary skill in the art based on the embodiments in the present application without creative work are within the scope of protection of the present application.

[0037] In the description of this application, it should be noted that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inside," "outside," and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended only to facilitate the description of this application and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore should not be construed as limiting this application. In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0038] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on specific circumstances.

[0039] According to the first aspect of the present application, a ship curved plate forming method based on digital twin is first provided. In this embodiment, a ship curved plate forming device based on digital twin is used to implement the method. First, the forming device is introduced. Figure 1 and Figure 2 As shown in the figure, the ship curved plate forming equipment based on digital twin includes a plate bending machine, a data acquisition system, and a data processing and storage system. The plate bending machine is used to bend the plate to be processed to form a curved plate.

[0040] The data acquisition system is used to collect the deformation data of the curved plate and transmit the collected data to the data processing and storage system; the data processing and storage system includes an experience database, a three-dimensional simulation analysis system and a data comparison system.

[0041] The 3D simulation analysis system is used to perform nonlinear finite element simulation of the curved plate forming process to obtain the required mold shape. The empirical database is used to store the corresponding mold shape of the curved plate during the forming process, as well as the finite element simulation calculation parameters for calculating the mold shape.

[0042] The data comparison system is used to compare the actual processing results of the curved plate collected by the data acquisition system with the target shape, and is also used to compare the finite element analysis results with the theoretical target results to determine whether the error between the two meets the requirements.

[0043] In this embodiment, the plate bending machine is a three-dimensional CNC plate bending machine. The data acquisition system includes a strain sensor for collecting plate deformation data. The strain sensor is communicatively connected to the data processing and storage system. Specifically, the strain sensor and the data processing and storage system are connected via a cable. The cable connection provides good stability and is less susceptible to interference.

[0044] like Figure 3 As shown in the figure, the ship curved plate forming method based on digital twin includes:

[0045] Step 1, construct the digital twin architecture of the curved plate forming process. The digital twin of the curved plate forming process includes a bending machine, a data acquisition system, and a data processing and storage system. The bending machine is used to bend the plate to be processed and form it into a curved plate. The data acquisition system is used to collect the deformation data of the curved plate and transmit the collected data to the data processing and storage system. The data processing and storage system includes an experience database, a three-dimensional simulation analysis system, and a data comparison system. The three-dimensional simulation analysis system is used to perform nonlinear finite element simulation on the curved plate forming process. The experience database stores the mold shape corresponding to the curved plate during the forming process, as well as the finite element simulation calculation parameters for calculating the mold shape. The data comparison system is used to compare the actual processing results of the curved plate collected by the data acquisition system with the target shape, and is also used to compare the finite element analysis results with the theoretical target results to determine whether the error between the two meets the requirements.

[0046] Step 2: Obtain the physical property information of the curved plate to be formed. Based on this information, the corresponding forming information is searched from the empirical database. If a single-shot forming result for the curved plate exists, the corresponding mold shape is selected. Simulation is not required for this forming process; the mold shape is directly submitted to the plate bending machine for processing. Once the processing is complete, the process ends. In this embodiment, the physical property information of the curved plate includes size, shape, material, etc.

[0047] If there is only the result of multiple bending forming, based on the result of the minimum forming step, the mold shape used in the first forming step is adjusted to obtain the mold shape, and the obtained mold shape is submitted to the bending machine to proceed to step 3. Multiple bending forming refers to forming the plate more than twice to complete the bending forming.

[0048] If there is no one-step forming result of the curved plate in the experience database, the mold shape is initialized according to the physical properties of the curved plate and combined with experience, and step 3 is performed.

[0049] In step 3, the initialized mold shape is submitted to the data processing and storage system. A 3D simulation of the obtained mold shape is performed, and the nonlinear finite element analysis parameters are updated. Nonlinear finite element analysis parameters can cause discrepancies between simulation analysis and actual molding results. The digital twin refinement process involves continuously optimizing these parameters in different simulation scenarios to ensure that the final simulation results are completely consistent with the actual results.

[0050] Step 4: Perform finite element simulation of the curved plate forming process to determine whether the curved plate simulation results are consistent with the target shape. If not, continue to adjust the mold shape until the curved plate forming results are consistent with the target shape to obtain a mold shape that meets the requirements. Save the finite element calculation and analysis parameters at this time to the experience database and submit the mold shape to the bending machine.

[0051] Step 5: Control the plate bending machine operation, obtain the forming results of the bent plate through the data acquisition system, and feed the forming results back to the data comparison system.

[0052] In step 6, the actual formed curved plate shape is compared with the target shape. If the error between the two meets the requirements, the operation is terminated, the curved plate forming operation is completed, and the data generated by the curved plate forming process is saved to the experience database; otherwise, the curved plate state is used as the initial condition, and steps 2 to 5 are repeated until the curved plate forming operation is completed.

[0053] Specifically, the data comparison system in step 1 sets a standard threshold, and in step 6 compares the actual processing result of the curved plate with the target shape to determine whether the error between the two meets the requirements; in step 4, the finite element analysis result is compared with the theoretical target result to determine whether the error between the two meets the requirements.

[0054] Specifically, in step 5, the plate bending machine operation is controlled, and the rebound result of the bent plate is obtained through the data acquisition system, and the rebound result is fed back to the data comparison system.

[0055] The three-dimensional simulation analysis model is based on the three-dimensional modeling software CATIA V6 to build the geometric model of the mold and plate, and the finite element pre-processing software ABAQUS is used for meshing and boundary condition setting to finally obtain the three-dimensional simulation analysis model.

[0056] The data acquisition module also includes a data interaction interface, which is used to transmit the bending plate deformation data collected by the strain sensor to the data processing and storage system for the next step of mold shape setting and simulation analysis verification, and at the same time feed back the final confirmed mold shape data to the operating system of the 3D CNC bending machine.

[0057] This digital twin-based ship curved plate forming method can quickly initialize the shape of the curved plate forming mold, continuously optimize the digital twin solution parameters, and achieve efficient curved plate forming.

[0058] It should be noted that the division of the experience database, 3D simulation analysis system, and data comparison system within the data processing and storage system is merely a logical functional division; in actual implementation, they can be fully or partially integrated into one or more physical entities. Furthermore, these modules can be implemented entirely as software invoked by processing elements, entirely as hardware, or partially as software invoked by processing elements and partially as hardware.

[0059] According to the second aspect of the present application, a digital twin-based ship curved plate forming device is also provided, which adopts the digital twin-based ship curved plate forming device as described in the embodiment of the first aspect and will not be described in detail.

[0060] The above description is merely a preferred embodiment of the present application and is not intended to limit the present application. Various modifications and variations are possible for those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present application shall be included within the scope of protection of the present application.

Claims

1. A ship curved plate forming method based on digital twin, characterized in that: The following steps are involved: Step 1: Construct a digital twin architecture for the curved plate forming process. The digital twin architecture includes a plate bending machine, a data acquisition system, and a data processing and storage system. The plate bending machine is used to bend the plate to be processed and form it into a curved plate. The data acquisition system is used to collect deformation data of the curved plate and transmit the collected data to the data processing and storage system. The data processing and storage system includes an experience database, a three-dimensional simulation analysis system, and a data comparison system. The experience database is used to store the mold shape corresponding to the curved plate during the forming process and the finite element simulation calculation parameters used to calculate the mold shape. The three-dimensional simulation analysis system is used to perform nonlinear finite element simulation on the curved plate forming process. The data comparison system is used to compare the actual processing results of the curved plate collected by the data acquisition system with the target shape, and is also used to compare the finite element analysis results with the theoretical target results to determine whether the error between the two meets the requirements. Step 2: Obtain the physical property information of the curved plate to be formed, and search the corresponding forming information from the experience database based on the physical property information of the curved plate. If there is a result of one-time forming of the curved plate, select the mold shape corresponding to the result, and directly submit the mold shape to the plate bending machine for processing. After the processing is completed, the operation ends. If there is no curved plate forming result in the experience database, the mold shape is initialized based on the physical properties of the curved plate and combined with experience, and step 3 is performed; Step 3: Submit the mold shape to the 3D simulation analysis system and update the nonlinear finite element analysis parameters; Step 4: Perform finite element simulation of the curved plate forming process to determine whether the curved plate simulation result is consistent with the target shape. If not, continue to adjust the mold shape until the curved plate forming result is consistent with the target shape, and obtain a mold shape that meets the requirements. Save the finite element calculation and analysis parameters at this time to the experience database, and submit the mold shape to the bending machine; Step 5: Control the plate bending machine operation, obtain the forming results of the bent plate through the data acquisition system, and feed the forming results back to the data comparison system; In step 6, the actual formed curved plate shape is compared with the target shape. If the error between the two meets the requirements, the operation is terminated, the curved plate forming operation is completed, and the data generated by the curved plate forming process is saved to the experience database; otherwise, the curved plate state is used as the initial condition, and steps 2 to 5 are repeated until the curved plate forming operation is completed.

2. The ship curved plate forming method based on digital twinning according to claim 1 is characterized in that: In step 2, if there is only the result of multiple forming of the bent plate, based on the result of the minimum forming steps, adjustments are made on the basis of the mold shape used in the first forming step to obtain the mold shape, and the obtained mold shape is submitted to the bending machine to proceed to step 3.

3. The ship curved plate forming method based on digital twinning according to claim 1 or 2, characterized in that: The empirical database stores the mold shape corresponding to the curved plate during the forming process, as well as the finite element simulation calculation parameters for calculating the mold shape; Alternatively, the data comparison system sets a standard threshold and compares the actual processing result of the curved plate with the target shape in step 6 to determine whether the error between the two meets the requirements; and compares the finite element analysis result with the theoretical target result in step 4 to determine whether the error between the two meets the requirements.

4. The ship curved plate forming method based on digital twinning according to claim 1 or 2, characterized in that: The data acquisition system includes a strain sensor for acquiring deformation data of the curved plate, and the strain sensor is communicatively connected to the data processing and storage system.

5. The ship curved plate forming method based on digital twinning according to claim 1 or 2, characterized in that: The plate bending machine is a three-dimensional CNC plate bending machine.

6. The ship curved plate forming method based on digital twinning according to claim 1 or 2, characterized in that: In step 5, the plate bending machine operation is controlled, and the rebound result of the bent plate is obtained through the data acquisition system, and the rebound result is fed back to the data comparison system.

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