Automatic deck plate laying process
Through the automated process flow, including drawing analysis, coding and cutting and the use of QR code RFID tags, the problems of low efficiency and poor accuracy of deck laying are solved, efficient and accurate deck laying is achieved, and manual dependence and construction are reduced. cost.
Patent Information
- Application Number
- CN202411097246.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-12
- Publication Date
- 2024-12-13
AI Technical Summary
In marine engineering, the laying efficiency of deck slabs is low and the accuracy is poor, resulting in high construction costs and long cycles. The existing technology relies on manual operation of large gantry cranes, making it difficult to ensure the accuracy of laying.
Design a deck automatic laying process, including origin calibration, drawing analysis, coding and cutting, deck sorting, transportation, identification and positioning, automatic laying, precise calibration and spot welding positioning, and use QR codes and RFID tags to achieve information matching With the delivery, the sequential-area slabing mode and partition calibration scheme are adopted to reduce the dependence of manual decision-making and improve the degree of automation and accuracy.
It realizes automatic analysis, automatic cutting, automatic transportation and automatic laying of deck information, improves production efficiency and laying accuracy, reduces randomness, enhances the controllability and traceability of production, and reduces manpower and material consumption.
Smart Images
Figure CN119117212A_ABST
Abstract
Description
Technical Field
[0001] The invention belongs to the technical field of marine engineering manufacturing, and in particular relates to an automatic deck plate laying process. Background Art
[0002] As my country continues to advance its efforts to build a strong maritime nation, the demand for marine engineering equipment related to marine infrastructure construction, resource development, space development, etc. has become more prominent, which has put forward higher requirements for the development of my country's marine engineering equipment. In the process of deck prefabrication, the accuracy control of deck plate laying is a difficult problem. The laying accuracy directly affects the quality of the deck, and then affects the construction cost and construction period of marine engineering equipment.
[0003] At present, the deep integration of information technology and manufacturing has become the core of my country's manufacturing industry upgrade and transformation. The digitalization, intelligence and networking of manufacturing models have become the key link in the transformation of manufacturing from high speed to high quality. Deck plate laying is mainly completed by manually operated large gantry cranes. The construction process requires the cooperation and participation of ground staff, which consumes a lot of manpower and material resources, and the transportation and laying accuracy of deck plates are difficult to guarantee.
[0004] Therefore, it is urgent to design an automatic deck board laying process to solve the above-mentioned problems of low deck board laying efficiency and poor deck board laying accuracy. Summary of the invention
[0005] In order to solve the technical problems of low planking efficiency and poor planking accuracy mentioned in the background technology, an automatic planking process for deck boards is provided to solve the above problems.
[0006] To achieve the above-mentioned purpose, the specific technical scheme of the automatic deck board laying process of the present invention is as follows: An automatic deck board laying process, characterized by comprising the following steps: S1, origin calibration; S2, drawing analysis; S3, coding and cutting; S4, deck board sorting; S5. Deck plate transportation; S6, identification and positioning; S7, automatic planking; S8, precise calibration; S9, spot welding positioning.
[0007] Furthermore, in S1, by unifying the coordinates of the tire frame, the door frame, and the planking diagram, the relative laying position of the deck plate on the tire frame is determined according to the shape and size of the planking diagram, and the appropriate origin coordinates are selected to complete the origin calibration.
[0008] Further, in S2, the deck plate laying diagram is read by a drawing parsing device to obtain the number, specification, size, shape of the deck plate, the relative coordinates of the deck plate laying, and the specific information of the QR code position, and a laying plan is generated based on the information.
[0009] Further, the planking scheme includes a planking sequence, a cutting sequence, and a pallet transportation sequence; The order of planking adopts the sequential-regional planking mode, that is, the tire frame is divided into six areas, and the six areas are planked in sequence. The area where the origin coordinate is located is marked as area a, and the two areas in the same column are marked as area b and area c in sequence. The three symmetrical areas of the tire frame are marked according to the same logic, and are marked as area d, area e and area f in sequence. Cutting sequence: according to the information of the drawing, follow the principle of making full use of raw materials and give a plan of cutting sequence; The order of pallet transportation is based on the area number, that is, the deck boards stacked on each pallet belong to the same area. The pallet with deck boards from area a is transported first, and then the pallets from area b, area c, area d, area e, and area f are transported in sequence.
[0010] Further, in S3, after the cut deck plate is cooled, an etcher is used to etch a QR code on the cut deck plate using black and white color etching technology.
[0011] Furthermore, in S4, the QR code on the deck plate is identified by a manual handheld PDA, and the deck plate is stacked onto a pallet with a corresponding serial number according to the displayed area information, and the information is entered into the pallet RFID tag.
[0012] Further, in S5, the pallets are transported from the buffer area to the material preparation area by the AGV according to the pallet transportation sequence in S2.
[0013] Furthermore, in S6, the gantry and the moving device are used to move the spreader to one end of the pallet and then to the other end opposite to the pallet. During the movement, the RFID receiver identifies the RFID tag information on the pallet; the laser rangefinder measures and records the vertical distance between the top deck plate and the spreader; the linear array camera obtains the image of the deck plate on the top layer of the pallet. After the scanning is completed, the gantry and the moving device are moved again to position the spreader directly above the suction position.
[0014] Furthermore, in S7, the automatic planking includes lowering of the spreader into position, lifting of the deck panels, transportation of the deck panels, and laying of the deck panels. During the automatic planking process, the monitoring device monitors the state of the spreader in real time.
[0015] Furthermore, in S8, the zoning laying and zoning calibration are adopted, that is, after each area is paved, precise positioning is performed and the position of the deck plate is manually adjusted using a handheld electromagnetic suction cup device. The automatic deck board laying process of the present invention has the following advantages: 1. The present invention integrates various links in the deck plate laying process into a complete process, from origin calibration, drawing analysis, coding and cutting, deck plate sorting, deck plate transportation, identification and positioning, automatic plate laying, precise positioning to the final spot welding positioning, forming a closely connected production chain, realizing the functions of automatic analysis of deck plate information, automatic cutting, automatic transportation, automatic identification and positioning, automatic plate laying, etc., reducing the dependence on manual decision-making, improving the degree of automation of the process flow, and improving production efficiency.
[0016] 2. The present invention adopts a sequential-regional planking mode and a zoning calibration scheme, standardizes the specific positions of QR codes and RFID tags, clarifies the process sequence of cutting and coding, reduces the randomness in the deck planking process, and effectively improves the deck planking accuracy.
[0017] 3. The present invention simultaneously introduces QR codes and RFID tags, realizes information matching and transmission between various processes, effectively connects the planking process, improves the controllability and traceability of the production process, and is beneficial to production management and quality control. BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Figure 1 The present invention is a process flow chart of the automatic laying of deck boards.
[0019] Figure 2 It is a schematic diagram of deck board laying according to the present invention.
[0020] Figure 3 It is a schematic diagram of the spatial position of the equipment of the present invention.
[0021] Figure 4 It is a schematic diagram of the division of the deck board planking area of the present invention.
[0022] Explanation of the markings in the figure: 1. tire frame; 2. lifting device; 3. gantry; 4. moving device; 5. pallet; 6. RFID receiver; 7. laser rangefinder; 8. linear array camera; 9. lifting device; 10. deck plate; 11. QR code; 12. RFID tag. DETAILED DESCRIPTION
[0023] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.
[0024] Those skilled in the art will appreciate that, although some embodiments herein include certain features included in other embodiments but not other features, the combination of features of different embodiments is meant to be within the scope of the present invention and form different embodiments. For example, in the claims, any one of the claimed embodiments may be used in any combination.
[0025] Please refer to the attached Figure 1 To Attachment Figure 4 The automated deck board planking process of the present invention is described.
[0026] The existing deck plate 10 is mainly laid by manually operating a large gantry crane. The construction process requires the cooperation and participation of ground workers, which consumes a lot of manpower and material resources. In addition, the transportation and laying accuracy of the deck plate 10 are difficult to guarantee.
[0027] Therefore, the present invention provides a deck board 10 automatic planking process, such as Figure 1-Figure 4 As shown, the following steps are included: The equipment used includes a frame 1 for laying a deck plate 10, a sling 2 for lifting the deck plate 10, a gantry 3 supporting the sling 2 and being movable along the length direction of the frame 1, a drawing parsing device for reading the information of the planking drawing, a moving device 4 for moving the sling 2 on the gantry 3, a cutting room for cutting plates, an etching machine for coding plates, a PDA for entering information of the deck plate 10, a pallet 5 and an AGV trolley for transporting the deck plate 10, an RFID receiver 6 for identifying an RFID tag 12, a laser rangefinder 7 for measuring vertical distance, a linear array camera 8 for scanning the image of the deck plate 10, a lifting device 9 for lifting the sling 2, a monitoring device for monitoring the process flow, and a handheld electromagnetic suction cup device for adjusting the position of the deck plate 10, wherein the plate cut to meet the size is the deck plate 10, a buffer area is provided at the discharge port of the cutting room, a material preparation area is provided at the front side of the frame 1, and a database for storing the lifting information of the deck plate 10 is also required.
[0028] S1, origin calibration; by unifying the coordinates of the tire frame 1, the gantry 3, and the planking diagram, determine the relative position of the deck plate 10 on the tire frame 1 according to the shape and size of the planking diagram, and select the appropriate origin coordinates to complete the origin calibration.
[0029] S2, drawing analysis; reading the deck plate 10 planking drawing through the drawing analysis device, obtaining the number, specification, size, shape of the deck plate 10, the relative coordinates of the deck plate 10 planking, and the specific information of the position of the QR code 11, and generating a planking plan based on the information; The planking scheme includes the planking sequence, cutting sequence and pallet 5 transportation sequence; The planking sequence adopts a sequential-region planking mode, that is, the tire frame 1 is divided into six regions, and the six regions are planked in sequence. The region where the origin coordinate is located is marked as region a, and the two regions in the same column are marked as region b and region c in sequence. The three symmetrical regions of the tire frame 1 are marked according to the same logic, and are marked as region d, region e and region f in sequence. Cutting sequence: according to the information of the drawing, follow the principle of making full use of raw materials and give a plan of cutting sequence; The transportation order of pallets 5 is based on the area serial number, that is, the deck boards 10 stacked on each pallet 5 belong to the same area. The pallet 5 stacked with the deck boards 10 of area a is transported first, and then the pallets 5 of area b, area c, area d, area e, and area f are transported in sequence.
[0030] S3, coding and cutting; after the cut deck plate 10 is cooled, a two-dimensional code 11 is etched on the cut deck plate 10 using an etcher with black and white color etching technology. After etching, a person holds a spray can of anti-rust paint and sprays anti-rust paint on the two-dimensional code 11 to extend the effective use time of the two-dimensional code 11. The etching position of the two-dimensional code 11 is fixed at 1m in both the vertical and horizontal directions of the deck plate 10 away from the alignment corner point to ensure the consistency of the etching position of the two-dimensional code 11 and the recognition accuracy of the two-dimensional code 11.
[0031] S4, sorting of deck boards 10; using a manual handheld PDA to identify the QR code 11 on the deck board 10, stacking the deck boards 10 onto the pallets 5 of the corresponding serial numbers according to the displayed area information, and entering the information into the RFID tag 12 of the pallet 5. Specifically, six pallets 5 need to be parked in the buffer area in advance, corresponding to the six planking areas respectively. After the deck boards 10 are coded and cut, a manual handheld PDA identifies the QR code 11 on the deck board 10, stacking the deck boards 10 onto the pallets 5 of the corresponding serial numbers according to the displayed area information, and entering the information into the RFID tag 12 on the pallet 5. The RFID tag 12 is attached to the lower left corner of the pallet 5, 500 mm away from the leftmost edge of the pallet 5.
[0032] S5, transport of deck plate 10; by AGV trolley according to the transport sequence of pallet 5 in S2, the pallet 5 is transported from the buffer area to the preparation area, the preparation area is provided with a fixed placement point for the pallet 5, and the coordinates of the placement point have been determined in S1.
[0033] S6, identification and positioning; the sling 2 is moved to one end of the pallet 5 and to the other end opposite to the pallet 5 by means of the gantry 3 and the moving device 4. During the movement, the RFID receiver 6 identifies the information of the RFID tag 12 on the pallet 5; the laser rangefinder 7 measures and records the vertical distance between the top deck plate 10 and the sling 2; the line array camera 8 obtains the image of the deck plate 10 on the top layer of the pallet 5. After the scanning is completed, the gantry 3 and the moving device 4 are moved again to position the sling 2 directly above the suction position.
[0034] S7, automatic planking; the automatic planking includes lowering the spreader 2 into position, lifting the deck plate 10, transporting the deck plate 10, and laying the deck plate 10. During the automatic planking process, the monitoring device monitors the status of the spreader 2 in real time; Specifically, the spreader 2 is lowered into position, that is, according to the actual height, position and angle of the deck plate 10, the lifting device 9 is lowered, and at the same time, the spreader 2 automatically adjusts the extension and contraction of the suction cup according to the command to compensate for the deformation of the deck plate 10, and the monitoring device monitors the operating status of the spreader 2 in real time. If the compensation limit is exceeded, the spreader 2 will stop descending immediately and alarm to notify manual processing; The deck plate 10 is lifted, and after the sling 2 is lowered into place, a small suction force is first used to suck up the deck plate 10, and the lifting device 9 lifts the sling 2 to a height of 0.1 meters. The monitoring device detects that the sling 2 is in normal working condition and confirms that the lower deck plate 10 is not stuck. If everything is normal, a normal signal is transmitted to the sling 2, and the sling 2 increases the suction force to prepare for transportation; otherwise, an alarm is sounded and the lifted deck plate 10 is slowly lowered, and the identification and positioning are returned to make a new plan.
[0035] After the deck plate 10 is transported and lifted successfully, the gantry 3 and the moving device 4 automatically calculate the transportation vector according to the current position of the hoist 2 and the target position of the deck plate 10 on the tire frame 1, and transport the deck plate 10 to the designated position.
[0036] After the deck plate 10 is laid and reaches the designated position, the sling 2 slowly lowers the deck plate 10. The monitoring device monitors whether the deck plate 10 is completely placed on the tire frame 1. If it is completely placed, the sling 2 eliminates the magnetic force, the deck plate 10 is laid, and the sling 2 returns to the top of the pallet 5 to start the next lifting; otherwise, the sling 2 continues to descend.
[0037] S8, precise calibration: To ensure that the laying accuracy of the deck plate 10 is within 2mm, the deck plate 10 is laid and calibrated in different areas, that is, after each area is laid, precise positioning is performed, and the position of the deck plate 10 is adjusted manually using a handheld electromagnetic suction cup device to align the joints. At the same time, considering that the subsequent spot welding positioning will cause certain loss to the plate, it is necessary to leave a welding margin.
[0038] S9, spot welding positioning; after all deck plates 10 are laid, spot welding positioning is completed manually to complete the deck plates 10 laying.
[0039] The present invention integrates various links in the deck board 10 planking process into a complete process, from origin calibration, drawing analysis, coding and cutting, deck board 10 sorting, deck board 10 transportation, identification and positioning, automatic planking, precise positioning to the final spot welding positioning, forming a closely connected production chain, realizing the functions of automatic analysis of deck board 10 information, automatic cutting, automatic transportation, automatic identification and positioning, automatic planking, etc., reducing dependence on manual decision-making, improving the degree of automation of the process flow, and improving production efficiency.
[0040] The present invention adopts a sequential-regional planking mode and a zoning calibration scheme, standardizes the specific positions of the QR code 11 and the RFID tag 12, clarifies the process sequence of cutting, coding, etc., reduces the randomness in the planking process of the deck board 10, and effectively improves the planking accuracy of the deck board 10.
[0041] The present invention simultaneously introduces the QR code 11 and the RFID tag 12, realizes the information matching and transmission between each process, effectively connects the planking process, improves the controllability and traceability of the production process, and is beneficial to production management and quality control.
[0042] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.
Claims
1. A deck board automatic planking process, characterized in that: The following steps are involved: S1, origin calibration; S2, drawing analysis; S3, coding and cutting; S4, deck board sorting; S5. Deck plate transportation; S6, identification and positioning; S7, automatic planking; S8, precise calibration; S9, spot welding positioning.
2. The automatic deck board laying process according to claim 1, characterized in that: In S1, the coordinates of the tire frame, the door frame and the planking diagram are unified, and the relative laying position of the deck plate on the tire frame is determined according to the shape and size of the planking diagram, and the appropriate origin coordinates are selected to complete the origin calibration.
3. The automatic deck board laying process according to claim 1, characterized in that: In S2, the deck plate laying diagram is read by a drawing parsing device to obtain the number, specification, size, shape of the deck plate, the relative coordinates of the deck plate laying, and the specific information of the QR code position, and a laying plan is generated based on the information.
4. The automatic deck board laying process according to claim 3 is characterized in that: The planking plan includes the planking sequence, cutting sequence and pallet transportation sequence; The order of planking adopts the sequential-regional planking mode, that is, the tire frame is divided into six areas, and the six areas are planked in sequence. The area where the origin coordinate is located is marked as area a, and the two areas in the same column are marked as area b and area c in sequence. The three symmetrical areas of the tire frame are marked according to the same logic, and are marked as area d, area e and area f in sequence. Cutting sequence: according to the information of the drawing, follow the principle of making full use of raw materials and give a plan of cutting sequence; The order of pallet transportation is based on the area number, that is, the deck boards stacked on each pallet belong to the same area. The pallet with deck boards from area a is transported first, and then the pallets from area b, area c, area d, area e, and area f are transported in sequence.
5. The automatic deck board laying process according to claim 1, characterized in that: In S3, after the cut deck plate is cooled, an etcher is used to etch a QR code on the cut deck plate using black and white color etching technology.
6. The automatic deck board laying process according to claim 5, characterized in that: In S4, the QR code on the deck plate is identified by a manual handheld PDA, and the deck plate is stacked onto a pallet with a corresponding serial number according to the displayed area information, and the information is entered into the pallet RFID tag.
7. The automatic deck board laying process according to claim 4, characterized in that: In S5, the pallets are transported from the buffer area to the material preparation area by the AGV according to the pallet transportation sequence in S2.
8. The automatic deck board laying process according to claim 6, characterized in that: In S6, the gantry and the moving device move the spreader to one end of the pallet and then to the other end of the pallet. During the movement, the RFID receiver identifies the RFID tag information on the pallet; the laser rangefinder measures and records the vertical distance between the top deck plate and the spreader; the linear array camera obtains the image of the deck plate on the top layer of the pallet. After the scanning is completed, the gantry and the moving device move again to position the spreader directly above the suction position.
9. The automatic deck board laying process according to claim 1, characterized in that: In S7, automatic planking includes lowering of the spreader into position, lifting of the deck panels, transportation of the deck panels, and laying of the deck panels. During the automatic planking process, the monitoring device monitors the status of the spreader in real time.
10. The automatic deck board laying process according to claim 1, characterized in that: In S8, zoned laying and zoned calibration are adopted, that is, precise positioning is carried out after each area is laid, and the position of the deck plate is manually adjusted using a handheld electromagnetic suction cup device.