Digital manufacturing method for pccp pipe

Abstract

The application discloses a PCCP pipe digital manufacturing method, which comprises the following steps: accepting a manufacturing order; modeling a PCCP pipe according to the manufacturing order to obtain a first three-dimensional model, and verifying the first three-dimensional model; determining manufacturing materials and manufacturing processes according to the verified first three-dimensional model, and issuing the manufacturing materials and the manufacturing processes to each manufacturing unit, so that each manufacturing unit performs manufacturing work according to the manufacturing materials and the manufacturing processes; obtaining manufacturing monitoring data of each manufacturing unit, establishing a second three-dimensional model, and comparing the second three-dimensional model with the first three-dimensional model, and issuing an alarm signal or not issuing an alarm signal according to a comparison result. The application can improve the manufacturing quality and the standardization degree of the PCCP pipe.

Description

Technical Field

[0001] This invention relates to the technical field of PCCP pipes. More specifically, this invention relates to a digital manufacturing method for PCCP pipes. Background Technology

[0002] PCCP pipe (prestressed concrete cylinder pipe) is a composite pipe made by rolling thin steel plates into a cylinder, pouring concrete inside and outside the cylinder, then applying high-strength steel wire to the outside of the concrete core, and finally spraying a coating on the outer layer. The manufacturing of PCCP pipes relies heavily on skilled workers' use of materials and machinery, as well as their selection of manufacturing processes. The manufacturing process is difficult to monitor, and manufacturing quality cannot be guaranteed. Therefore, it is necessary to design a technical solution that can overcome these shortcomings to a certain extent. Summary of the Invention

[0003] One objective of this invention is to provide a digital manufacturing method for PCCP pipes, which can improve the manufacturing quality and standardization of PCCP pipes.

[0004] To achieve these objectives and other advantages of the present invention, according to one aspect of the present invention, a digital manufacturing method for PCCP pipes is provided, comprising: receiving a manufacturing order; modeling the PCCP pipe according to the manufacturing order to obtain a first three-dimensional model, and verifying the first three-dimensional model; determining manufacturing materials and manufacturing processes according to the verified first three-dimensional model, and distributing them to each manufacturing unit so that each manufacturing unit performs manufacturing operations according to the manufacturing materials and manufacturing processes; acquiring manufacturing monitoring data of each manufacturing unit, establishing a second three-dimensional model, comparing it with the first three-dimensional model, and issuing an alarm signal or not issuing an alarm signal according to the comparison result.

[0005] Furthermore, it also includes: obtaining the test parameters of historically manufactured PCCP pipes and the corresponding first three-dimensional model, establishing a training set and a test set, inputting the training set into the neural network model, training and testing with the test set to obtain a verification model, inputting the parameters of the first three-dimensional model corresponding to the current manufacturing order into the verification model to obtain predicted test parameters, and if the predicted test parameters do not conform to the manufacturing order, then re-establishing the first three-dimensional model.

[0006] Furthermore, the manufacturing order includes at least the size and performance information of the PCCP pipe.

[0007] Furthermore, the manufacturing materials include at least steel plates, spigot rings, socket rings, concrete, steel wire, and coating materials, and the manufacturing process includes at least steel plate cutting parameters, steel plate, spigot ring, and socket ring welding parameters, concrete curing parameters, wire winding parameters, and coating parameters.

[0008] Furthermore, the manufacturing unit includes a cutting unit, a welding unit, a casting unit, a curing unit, a wire winding unit, and a coating unit.

[0009] Furthermore, the monitoring data includes image data, manufacturing material usage, and manufacturing process parameter values.

[0010] Furthermore, the image data, the amount of manufacturing materials used, and the manufacturing process parameter values ​​are obtained sequentially from the cutting unit, the welding unit, the casting unit, the curing unit, the wire winding unit, and the coating unit to gradually build the second three-dimensional model. The second three-dimensional model is compared with the corresponding part in the first three-dimensional model in real time, and the error is calculated. If the error is greater than a predetermined value, an alarm signal is issued.

[0011] Furthermore, the image data includes images from multiple angles, and the images contain a standard object. The dimensions of each part of the PCCP pipe during manufacturing are estimated based on the actual size of the standard object and its size within the image. Combined with the amount of manufacturing materials used and the manufacturing process parameter values, a second three-dimensional model is established.

[0012] The present invention has at least the following beneficial effects:

[0013] This invention models the PCCP pipe according to the manufacturing order to obtain a first three-dimensional model. Based on the first three-dimensional model, the manufacturing materials and manufacturing processes are determined and distributed to each manufacturing unit so that each manufacturing unit can perform manufacturing operations according to the manufacturing materials and manufacturing processes. The manufacturing monitoring data of each manufacturing unit is obtained, a second three-dimensional model is established, and compared with the first three-dimensional model. This invention enables precise management of the manufacturing materials and manufacturing processes used in PCCP pipes and real-time monitoring of the manufacturing operation process, thereby improving manufacturing quality and efficiency.

[0014] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0015] Figure 1 A flowchart of one embodiment of this application;

[0016] Figure 2 This is a manufacturing process according to one embodiment of the present application. Detailed Implementation

[0017] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0018] It should be understood that terms such as “having,” “comprising,” and “including” as used herein do not exclude the presence or addition of one or more other elements or combinations thereof.

[0019] like Figure 1 As shown, embodiments of this application provide a digital manufacturing method for PCCP pipes, including:

[0020] S1: Accept manufacturing orders; the manufacturing orders contain the user's requirements for PCCP pipes. Optionally, the manufacturing orders include at least the size information and performance information of the PCCP pipes. The size information includes the inner diameter, outer diameter, length, concrete layer thickness, coating thickness, etc., and the performance information includes tensile strength, compressive strength, impermeability, etc.

[0021] S2: Model the PCCP pipe according to the manufacturing order to obtain the first three-dimensional model, and verify the first three-dimensional model; the first three-dimensional model is a virtual model obtained according to user requirements, which includes not only size information, but also all materials used in the actual manufacturing operation and their operation level. After the first three-dimensional model is established, it needs to be continuously verified until the performance information can meet the user requirements before proceeding to the next step.

[0022] S3: Based on the verified first 3D model, determine the manufacturing materials and manufacturing process, and distribute them to each manufacturing unit so that each manufacturing unit performs manufacturing operations according to the manufacturing materials and manufacturing process; optionally, the manufacturing materials include at least steel plates, spigot rings, socket rings, concrete, steel wire, and coating materials; the manufacturing process includes at least steel plate cutting parameters, such as the length and width of the steel plate; welding parameters for the steel plate, spigot ring, and socket ring, such as welding consumables, welding temperature, and welding time; concrete curing parameters, such as curing time, curing temperature, and curing humidity; wire winding parameters, such as wire stress and wire spacing; and coating parameters, such as coating material and coating thickness; optionally, see [reference needed]. Figure 2 The manufacturing unit includes a cutting unit, a welding unit, a casting unit, a curing unit, a wire winding unit, and a coating unit. Each manufacturing unit is connected by a conveying or transfer device, which transfers the PCCP pipes under manufacturing between the manufacturing units to complete the manufacturing operation.

[0023] S4: Obtain manufacturing monitoring data from each manufacturing unit, establish a second three-dimensional model, and compare it with the first three-dimensional model. Based on the comparison result, issue an alarm signal or not issue an alarm signal. Optionally, the monitoring data includes image data, manufacturing material usage, and manufacturing process parameter values, which can be obtained by setting up cameras and other monitoring devices in each manufacturing unit. Based on the monitoring data, the shape of the PCCP pipe during the manufacturing process can be determined for three-dimensional reconstruction to obtain the second three-dimensional model. The second three-dimensional model is superimposed and compared with the first three-dimensional model. When the difference is large, an alarm signal is issued. If it can be repaired, it is repaired; if it cannot be repaired, it is remanufactured. It can be seen that the present invention accurately manages the manufacturing materials and manufacturing processes used for PCCP pipes and monitors the manufacturing process in real time, promptly alarming when abnormalities are detected, thereby improving manufacturing quality, standardization, and manufacturing efficiency.

[0024] In another embodiment, the method further includes: acquiring test parameters of historically manufactured PCCP pipes and the corresponding first three-dimensional model; establishing a training set and a test set; inputting the training set into a neural network model; training and testing with the test set to obtain a verification model; inputting the parameters of the first three-dimensional model corresponding to the current manufacturing order into the verification model to obtain predicted test parameters; if the predicted test parameters do not conform to the manufacturing order, then re-establishing the first three-dimensional model; the training set includes test parameters of manufactured PCCP pipes and various design parameters of the corresponding first three-dimensional model, including dimensional information, manufacturing materials, and manufacturing processes; and test parameters including tensile strength, compressive strength, and impermeability. The design parameters and test parameters are input into a neural network, such as a BP neural network, to train and obtain a verification model, which can be put into use after verification with the verification set; inputting the design parameters of the first three-dimensional model constructed in S2 into the verification model to obtain predicted test parameters; only when the predicted test parameters meet the user's requirements can they be used to determine the manufacturing materials and manufacturing processes; otherwise, the design parameters need to be continuously modified.

[0025] In another embodiment, the image data, manufacturing material usage, and manufacturing process parameter values ​​are sequentially acquired from the cutting unit, welding unit, casting unit, curing unit, wire winding unit, and coating unit to gradually build the second three-dimensional model. The second three-dimensional model is compared with the corresponding parts of the first three-dimensional model in real time, and the error is calculated. If the error is greater than a predetermined value, an alarm signal is issued. The size information of each part of the PCCP pipe during manufacturing can be estimated based on the image data. The level of operation of casting, wire winding, and coating of the PCCP pipe during manufacturing can be estimated based on the material usage and manufacturing process parameter values. Based on this real-time collected information, the second three-dimensional model is constructed and compared with the corresponding parts of the first three-dimensional model to determine the error. If the error is large, a warning is issued.

[0026] In another embodiment, the image data includes images from multiple angles, each containing a standard object. The dimensions of each part of the PCCP pipe during manufacturing are estimated based on the actual dimensions of the standard object and its dimensions within the image. Combined with the amount of manufacturing materials used and manufacturing process parameters, a second three-dimensional model is established. Optionally, the standard object is a pipe fitting coaxially arranged with the PCCP pipe. The dimensions and diameter of the standard object are known. By comparing the PCCP pipe in the image with the standard object, information such as the dimensions and diameter of each part of the PCCP pipe can be obtained. Then, combined with the amount of manufacturing materials used and manufacturing process parameters for the corresponding part, the second three-dimensional model can be constructed.

[0027] The number of devices and processing scale described herein are for the purpose of simplifying the description of this invention. Applications, modifications, and variations of the digital manufacturing method for PCCP pipes of this invention will be readily apparent to those skilled in the art.

[0028] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. A digital manufacturing method for PCCP pipes, characterized in that, include: Accept manufacturing orders; The PCCP pipe is modeled according to the manufacturing order to obtain a first three-dimensional model, and the first three-dimensional model is verified. Based on the verified first three-dimensional model, the manufacturing materials and manufacturing processes are determined and distributed to each manufacturing unit so that each manufacturing unit can perform manufacturing operations according to the manufacturing materials and manufacturing processes. Acquire manufacturing monitoring data of each manufacturing unit, establish a second three-dimensional model, compare it with the first three-dimensional model, and issue an alarm signal or not issue an alarm signal based on the comparison result; Also includes: Obtain the test parameters of the PCCP pipes manufactured in the past and the corresponding first three-dimensional model, establish a training set and a test set, input the training set into the neural network model, train and test with the test set to obtain a verification model, input the parameters of the first three-dimensional model corresponding to the current manufacturing order into the verification model to obtain the predicted test parameters, if the predicted test parameters do not conform to the manufacturing order, then re-establish the first three-dimensional model; The manufacturing unit includes a cutting unit, a welding unit, a casting unit, a curing unit, a wire winding unit, and a coating unit; The monitoring data includes image data, manufacturing material usage, and manufacturing process parameter values. The image data, manufacturing material usage, and manufacturing process parameter values ​​are sequentially obtained from the cutting unit, welding unit, casting unit, curing unit, wire winding unit, and coating unit to gradually build the second three-dimensional model. The second three-dimensional model is compared with the corresponding part in the first three-dimensional model in real time, and the error is calculated. If the error is greater than a predetermined value, an alarm signal is issued. The image data includes images from multiple angles, and each image contains a standard object. The dimensions of each part of the PCCP pipe during manufacturing are estimated based on the actual size of the standard object and its dimensions within the image. Combined with the amount of manufacturing materials used and the manufacturing process parameters, a second three-dimensional model is established.

2. The digital manufacturing method for PCCP pipes as described in claim 1, characterized in that, The manufacturing order shall include at least the size and performance information of the PCCP pipe.

3. The digital manufacturing method for PCCP pipes as described in claim 1, characterized in that, The manufacturing materials include at least steel plates, spigot rings, socket rings, concrete, steel wire, and coating materials. The manufacturing process includes at least steel plate cutting parameters, steel plate, spigot ring, and socket ring welding parameters, concrete curing parameters, wire winding parameters, and coating parameters.

Images