Method for field pipe welding and sorting and distributing device for intermediate products thereof

Abstract

The application discloses a kind of inner field pipe welding processing method and intermediate product sorting and distributing device thereof, comprising the following steps: pipe model data extraction and pipe segment splitting;Pipe segment working hour calculation based on process planning;Cutting and pipe accessory processing;Processing station distribution and pipe segment distributing;The pipe segment tray obtained by sorting and collecting the above steps is processed;Pipe segments with assembly relationship are assembled to obtain complete pipe products.The application can improve the parallel degree of intermediate links, reduce the size of intermediate products and reduce the difficulty of intermediate logistics;The sorting device of the application solves the problem of large workload and low efficiency in the process of sorting and distributing on-site pipes and pipe accessories, and with the intervention of the sorting device, the rationality of tray division is greatly improved, which avoids the task accumulation problem of individual stations to the greatest extent, improves the efficiency of inner field pipe processing and shortens the length of the entire pipe processing process.

Description

Technical Field

[0001] This invention relates to a pipe assembly and welding process and an intermediate product sorting and traying device, and more particularly to an indoor pipe assembly and welding process and an intermediate product sorting and traying device. Background Technology

[0002] Pipe fabrication is a crucial step in the construction of ships and marine engineering equipment. For example, a typical 20-ton bulk carrier has approximately 11,000 pipes. However, for high-value-added products like luxury cruise ships and offshore platforms, the number of pipes is far greater due to their functional complexity, exceeding that of conventional ships of similar tonnage. Pipe fabrication directly impacts the overall construction schedule. In-workshop pipe processing accounts for about 35% of the total pipe fabrication and installation time, making it a key area for reducing overall pipe outfitting and installation time.

[0003] Currently, the in-house operations for shipbuilding pipe processing typically include several processes: material preparation, pipe bending, pipe alignment, welding, grinding, and pressure testing. Among these, the alignment and welding processes suffer from poor parallelism due to the large number of managed objects and significant differences in shape parameters, often resulting in material accumulation at individual workstations. Most shipyards currently employ a sequential operation method, where after material preparation, the pipe materials and fittings required for a single pipe are placed in the same outfitting pallet and transferred to the alignment and welding workstations to complete the relevant manufacturing processes. This model typically only allows for sequential alignment and welding of weld seams, resulting in poor parallelism in the assembly and welding stages. The large size of intermediate products often leads to significant material accumulation, disrupting the production rhythm. A few related companies have made relevant improvements to their existing processes due to the introduction of automated welding equipment. For example, they have introduced a "weld first, bend later" model, which shifts the bending operation to the completion of the straight pipe and accessories welding, thereby increasing the speed of the pipe straightening and welding process. However, the problems of poor parallelism in this process and increased difficulty in the bending process still exist. In addition, the intermediate products made before bending have a large external dimension, which places high demands on the space of the pipe processing site and the load-bearing capacity of the transportation equipment. Summary of the Invention

[0004] Purpose of the invention: The purpose of this invention is to provide a method for welding and assembling internal pipes and an intermediate product sorting and traying device, so as to improve the efficiency of internal pipe processing and shorten the overall construction cycle of ships and marine engineering products.

[0005] Technical solution: This invention includes the following steps:

[0006] S1. Extraction of pipe model data and pipe segment splitting;

[0007] S2. Pipeline segment time calculation based on process planning;

[0008] S3. Material cutting and pipe fitting processing;

[0009] S4. Allocation of processing stations and pipe section distribution;

[0010] S5. Process the pipe segment pallets obtained from the sorting and distribution in step S4.

[0011] S6. Assemble pipe sections that have assembly relationships to obtain complete pipe products.

[0012] An intermediate product sorting and traying device for indoor pipes includes a pipe sorting device, a pipe accessory sorting device, and a tray. The pipe sorting device and the pipe accessory sorting device are both connected to the tray. The pipe sorting device and the pipe accessory sorting device each include a feeding mechanism, a sorting mechanism, and a buffering mechanism. The sorting mechanism has a feeding mechanism on one side and a buffering mechanism on the other side.

[0013] The pipe sorting device includes a pipe feeding mechanism, a pipe sorting mechanism, and a pipe buffering mechanism. The pipe sorting mechanism has a pipe feeding mechanism on one side and a pipe buffering mechanism on the other side.

[0014] The pipe sorting mechanism is equipped with an identification device on top, and one end of the pipe sorting mechanism is connected to the pallet through a pipe output slide.

[0015] The pipe sorting mechanism includes a track with multiple slide rails. A first clamping device is provided at the end of the slide rail away from the pallet, and a second clamping device is rotatably connected at the end closer to the pallet.

[0016] The pipe buffer mechanism is equipped with multiple guide rails, each with a pipe fixing device. The bottom of the pipe buffer mechanism is connected to a vertical drive device and a horizontal drive device.

[0017] The pipeline accessory sorting device includes a pipeline accessory feeding mechanism, a pipeline accessory sorting mechanism, and a pipeline accessory buffering mechanism. One end of the pipeline accessory sorting mechanism is connected to the pipeline accessory feeding mechanism via a slide, and the other end is equipped with the pipeline accessory buffering mechanism.

[0018] The pipeline accessory sorting mechanism includes a ring conveyor belt, a pipeline accessory identification device is provided diagonally above the ring conveyor belt, and several pipeline accessory storage spaces are provided on the ring conveyor belt.

[0019] The pipeline accessory sorting mechanism is connected to the pallet via a guiding device and a guide slide.

[0020] A first ejection device is installed on the inner side of the annular conveyor track near the guide device, and a second ejection device is installed on the inner side of the track near the pipeline accessory buffer mechanism.

[0021] Beneficial effects: This invention can improve the parallelism of intermediate links, reduce the size of intermediate products, and reduce the difficulty of intermediate logistics; the sorting device of this invention solves the problem of large workload and low efficiency in material finding during the on-site pipe and pipe accessory tray matching process. At the same time, with the help of the sorting device, the rationality of tray division is greatly improved, which avoids the problem of task accumulation at individual workstations to the greatest extent, improves the efficiency of pipe processing in the field, and shortens the time of the entire pipe processing process. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0023] Figure 2 This is a schematic diagram of the pipe sorting mechanism of the present invention;

[0024] Figure 3 This is a schematic diagram of the first clamping device of the pipe sorting mechanism in this invention;

[0025] Figure 4 This is a schematic diagram of the second clamping device of the pipe sorting mechanism in this invention;

[0026] Figure 5 This is a schematic diagram of the second clamping device of the present invention in the released state;

[0027] Figure 6 This is a schematic diagram of the pipe buffer mechanism of the present invention;

[0028] Figure 7 This is a schematic diagram of the pipeline accessory sorting device of the present invention;

[0029] Figure 8 This is a schematic diagram of the pipeline accessory feeding mechanism of the present invention;

[0030] Figure 9 This is a schematic diagram of the pipeline accessory guiding device of the present invention;

[0031] Figure 10 This is a schematic diagram of the pipeline accessory buffer mechanism of the present invention;

[0032] Figure 11 This is a flowchart of pipe processing in this invention, where pipe segments are used as intermediate products. Detailed Implementation

[0033] The invention will now be further described with reference to the accompanying drawings.

[0034] The assembly and welding process of the present invention includes the following steps:

[0035] S1: Extraction of pipe model data and pipe segment decomposition

[0036] Currently, mainstream shipyards primarily use software such as Aveva Marine and Intergraph to create 3D models of piping systems. However, the 3D model data cannot directly guide on-site pipe fabrication. This step mainly involves extracting key data from the 3D model, such as pipe length, wall thickness, diameter, and the shape parameters of pipe fittings, to directly guide on-site pipe fabrication. The complete piping system is then broken down into smaller pipe sections based on the equipment and site conditions, such as... Figure 11 As shown, this is used as an intermediate product for pipe processing, which improves the parallelism of the entire processing flow.

[0037] S2: Pipeline segment time calculation based on process planning

[0038] After disassembling the pipeline system, the pipe segment to be worked on was obtained. The pipe segment is assembled and welded from several pipe materials and pipe fittings. This step mainly calculates the assembly and welding lengths during the pipe segment manufacturing process based on the model data extracted in step S1, obtaining relevant dimensional data. Then, based on equipment data (such as welding speed) and process data (such as the assembly time for pipes of specific shapes) from the pipe processing workshop, the dimensional data is processed to obtain the estimated pipe segment manufacturing time.

[0039] S3: Material cutting and pipe fitting processing

[0040] Based on the dimensional data of the pipes and pipe fittings disassembled in step S1, surface treatment, bending, and beveling are performed on the fixed-length pipes and pipe fittings purchased from the steel mill to form the pipes and pipe fitting parts required for pipe segment welding. This invention is designed for processing specific types of pipes, and the pipe bending structure is made by welding straight pipe elbows, without including straight pipe bending operations.

[0041] S4: Processing station allocation and pipe section distribution based on work hour load balancing

[0042] Step S3 yields the pipes and pipe fittings required for pipe segment fabrication, but these raw materials are often processed in batches. This step primarily involves sorting and grouping the processed pipes and pipe fittings according to the pipe segment divisions, facilitating subsequent processes. To achieve efficient grouping of intermediate products, this invention also provides a sorting and palletizing device for pipe segment grouping. This device uses visual recognition to screen pipes and pipe fittings and makes decisions about which processing station to assign them to based on the accumulated processing time, thereby improving the parallelism of the entire processing flow.

[0043] like Figures 1 to 10As shown, the sorting and palletizing device of the present invention includes a pipe sorting device, a pipe accessory sorting device and a pallet 35, wherein the pipe accessory sorting device is provided below the pipe sorting device, and both the pipe sorting device and the pipe accessory sorting device are connected to the pallet 35.

[0044] like Figure 1 As shown, the pipe sorting device includes a pipe feeding mechanism 5, a pipe sorting mechanism 8, and a pipe buffer mechanism 31. The pipe feeding mechanism 5 is located on one side of the pipe sorting mechanism 8, and the pipe buffer mechanism 31 is located on the other side. The pipe feeding mechanism 5 uses a roller-driven track for conveying the pipes processed in S3 to the pipe sorting mechanism 8. Several anti-slip strips with triangular cross sections are arranged on the track to fix the pipes.

[0045] The pipe sorting mechanism 8 is used to sort and output pipes, such as... Figure 2 As shown, the pipe sorting mechanism 8 adopts a roller-driven track structure. An identification device 13 is installed above the track, which can visually identify the contour of the input pipes, match material information, and, based on this, determine the processing station by referring to the task accumulation situation at the welding station, guiding the next step of sorting to the corresponding pallet. One side of the track is connected to the pallet 35 via a pipe output slide 16, used to guide the pushed-out pipes into the corresponding distribution pallet.

[0046] The track is equipped with multiple guide rails 9. A first clamping device 11 is located at the end of the guide rail 9 furthest from the pallet, and a second clamping device 14 is located at the end closer to the pallet. Figure 3 As shown, the first clamping device 11 can slide along the slide rail 9 to match pipes of different lengths. The first clamping device 11 is pushed by the first push rod 12 to apply pressure from the inner wall of the pipe to clamp it. Figure 4 and Figure 5 As shown, the second clamping device 14 is pushed by the second push rod 15 to the concave clamping block at its bottom, clamping the pipe from the outside, and working together with the first clamping device 11 to fix the pipe.

[0047] When the pipe needs to be pushed out, the second clamping device 14 can rotate along the bottom, such as Figure 5 As shown, the first clamping device 11 can slide from the end of the slide rail 9 to push the pipe forward, thereby sliding from the second clamping device 14 and the pipe output slide 16 into the tray 35.

[0048] like Figure 6As shown, the pipe buffer mechanism 31 is equipped with multiple guide rails 30, each with a pipe fixing device 32. The opening angle of the fixing device 32 is adjustable to accommodate pipes of different diameters. The fixing device 32 can move horizontally along the guide rail 30 to match pipes of different lengths. A vertical drive device 33 and a horizontal drive device 34 are connected to the bottom of the pipe buffer mechanism 31. The horizontal drive device 34 drives the fixing device 32 to move horizontally, adjusting its distance from the sorting conveyor belt to facilitate pipe transfer and avoid collisions between machines. The vertical drive device 33 drives the fixing device 32 to move vertically, enabling alternation of the pipe buffering stations.

[0049] like Figure 7 As shown, the pipeline accessory sorting device includes a pipeline accessory feeding mechanism, a pipeline accessory sorting mechanism, and a pipeline accessory buffering mechanism. The pipeline accessory feeding mechanism has the same structure as the pipe feeding mechanism 5 and is used to transfer the processed pipeline accessories from S3 to the pipeline accessory sorting mechanism. Triangular cross-section anti-slip strips are arranged on the track to secure the pipeline accessories. One end of the pipeline accessory sorting mechanism is connected to the pipeline accessory feeding mechanism via a slide 4, and the other end is equipped with the pipeline accessory buffering mechanism. The slide 4 guides the pipeline accessories from the feeding mechanism to the sorting mechanism. The pipeline accessory sorting mechanism is connected to the pallet 35 via a guide device 24 and a guide slide 26.

[0050] like Figure 8 As shown, the pipe fitting sorting mechanism is used to sort and output pipe fittings. It includes a circular conveyor belt 17, with a pipe fitting identification device 36 located diagonally above the conveyor belt 17. This device visually identifies the contours of the input pipe fittings, matches them with material information, and, based on this, determines the processing station by referring to the task accumulation at the welding station, guiding the next step of sorting to the corresponding pallet. The circular conveyor belt 17 has several recessed pipe fitting storage spaces 18, which can limit the sliding of the pipe fittings arranged on the belt to a certain extent.

[0051] A first ejection device 19 is installed on the inner side of the track near the guide device 24. The first ejection device 19 is driven by a third push rod 20, which pushes the pipe accessories placed in the pipe accessory storage space 18 into the pipe accessory output slide 23, and then into the guide device 24. The guide device 24 includes a disc with multiple guide wheels 25. The guide device 24 is connected to multiple pallets 35 one by one through multiple guide slides 26. The disc can be rotated to adjust the orientation of the guide wheels 25 towards different track directions. The rotation of the guide wheels 25 can guide the pipe accessories to slide to different guide slides 26, and the guide slides 26 can guide the pipe accessories to fall into the corresponding collection pallets.

[0052] A second ejection device 21 is installed on the inner side of the track near the pipeline accessory buffer mechanism. The second ejection device 21 is pushed by a fourth push rod 22, which pushes the pipeline accessories placed in the pipeline accessory storage space 18 into the pipeline accessory buffer mechanism. In this invention, four second ejection devices are provided, each with an independent push rod, which can be controlled individually as needed.

[0053] like Figure 10 As shown, the pipeline accessory buffer mechanism is used to store pipeline accessories that cannot be temporarily palletized on the pipeline accessory sorting mechanism, thereby reducing the ineffective occupation of sorting stations on the sorting mechanism. It includes a pipeline accessory buffer space 27 and a pushing device 28. The pipeline accessory buffer space 27 is used to store the corresponding pipeline accessories, and the pushing device 28 is driven by a fifth push rod 29 to push the pipeline accessories in the buffer space 27 back onto the annular conveyor belt 17. This invention provides four buffer spaces, each equipped with an independent push rod, which can be individually controlled as needed.

[0054] Pallet 35 is used to store the selected pipes and pipe fittings. Pallet 35 is divided into left and right sections, each corresponding to a different slide inlet for storing the corresponding pipes and pipe fittings. Once the pallets are assembled, they can be transferred to the corresponding processing station for the assembly and welding work in step S5.

[0055] S5: One-time welding

[0056] This step mainly involves processing the pipe segment pallets obtained from the sorting and distribution in step S4. The automatic welding equipment at the processing station is used to assemble and weld the pipes and pipe fittings in the pallets to obtain the assembled and welded pipe segment products and affix material codes.

[0057] S6: Secondary welding

[0058] After step S5, an intermediate product consisting mainly of pipe segments is obtained. Based on the material codes affixed in step S5, the pipe segments with assembly relationships are assembled and welded to obtain a complete pipe product.

Claims

1. An intermediate product sorting tray device for an internal field tube, characterized in that, The application relates to a pipe and pipe fitting sorting device, which comprises a pipe sorting device, a pipe fitting sorting device and a tray (35), the pipe sorting device and the pipe fitting sorting device are connected with the tray (35), the pipe sorting device comprises a pipe feeding mechanism (5), a pipe sorting mechanism (8) and a pipe buffer mechanism (31), one side of the pipe sorting mechanism (8) is provided with the pipe feeding mechanism (5), and the other side is provided with the pipe buffer mechanism (31), the pipe sorting mechanism (8) comprises a track belt, a plurality of slide rails (9) are arranged on the track belt, a first clamping device (11) is slidably connected to one end of the slide rail (9) away from the tray (35), and a second clamping device (14) is rotatably connected to one end of the slide rail close to the tray, the pipe fitting sorting device comprises a pipe fitting feeding mechanism, a pipe fitting sorting mechanism and a pipe fitting buffer mechanism, one end of the pipe fitting sorting mechanism is connected with the pipe fitting feeding mechanism through a slide (4), and the other end is provided with the pipe fitting buffer mechanism, the pipe fitting sorting mechanism comprises a ring-shaped conveying track belt (17), a pipe fitting identification device (36) is arranged on the obliquely upper side of the ring-shaped conveying track belt (17), a plurality of pipe fitting storage spaces (18) are arranged on the ring-shaped conveying track belt (17), a first ejecting device (19) is arranged on the inner side of the track belt close to a guide device (24) of the ring-shaped conveying track belt (17), and a second ejecting device (21) is arranged on the inner side of the track belt close to the pipe fitting buffer mechanism.

2. An apparatus for sorting and dispensing intermediate products of an inner field tube according to claim 1, characterized in that The pipe sorting mechanism (8) is provided with an identification device (13) above, and one end of the pipe sorting mechanism (8) is connected with the tray (35) through a pipe output slide (16).

3. An apparatus for sorting and dispensing intermediate products of an inner field tube according to claim 1, characterized in that, The pipe buffer mechanism (31) is provided with a plurality of guide rails (30), and pipe fixing devices (32) are arranged on each guide rail (30), and the pipe buffer mechanism (31) is connected with a vertical driving device (33) and a horizontal driving device (34) at the bottom.

4. An apparatus for sorting and dispensing intermediate products of an inner field tube according to claim 1, characterized in that, The pipe fitting sorting mechanism is connected with the tray (35) through a guide device (24) and a guide slide (26).

5. A method of field welding a pipe, comprising: The application further discloses a pipe sorting and distributing method, which comprises the following steps: S1, extraction of pipe model data and pipe segment splitting; S2, pipe segment working hour calculation based on process planning; S3, pipe cutting and pipe fitting processing; S4, processing station distribution and pipe segment tray distribution: the intermediate product sorting and distributing device of the field pipe according to any one of claims 1-4 is used to screen the pipe and the pipe fitting, the processing station is decided according to the existing working hour accumulation of the processing station, and the pipe segment is distributed to the corresponding tray; S5, processing of the pipe segment tray obtained by the sorting and distributing of step S4; S6, assembling of the pipe segments with an assembly relationship to obtain a complete pipe product.

Images