A control system and control method for automatic welding equipment for corrugated plates of LNG ships

Abstract

An automatic welding equipment control system for LNG ship corrugated plates includes a welding system, a motion actuator, a control system, and a sensing system. The control system includes a PLC industrial computer, a coupler, and a communication module. The PLC industrial computer is connected to the communication module via the coupler, and a remote controller is also connected to the communication module. The motion actuator includes a reducer, a servo motor, and a servo controller. The sensing system includes a first-point laser sensor, a second-point laser sensor, a tilt sensor, a contact displacement sensor, and a proximity sensor. The welding system includes a transformer, a water chiller, and a welding power source. Based on the rapid, accurate, and multi-directional sensing capabilities of the sensing system, the collected data signals are transmitted to the industrial computer. The industrial computer processes the relevant data and transmits control signals to the welding system and the motion actuator in real time. During the process of traversing the corrugated plates, the system monitors the process through sensors and automatically adjusts the corresponding process parameters and mechanism actions, reducing manual intervention and achieving fully automatic welding of the corrugated plates.

Description

Technical Field

[0001] This invention relates to the field of ship welding technology, and in particular to an automatic welding equipment control system and control method for LNG ship corrugated plates. Background Technology

[0002] The Mark III type cargo containment system is one of the mainstream forms of LNG carrier cargo tanks. Its main shielding layer uses corrugated plates made of 304L low-temperature stainless steel, mostly 1.2 mm thick. The plates are stamped into cross-shaped corrugated pleats, consisting of corrugated sections and straight sections. The corrugated sections are available in two sizes. The corrugated plates are treated with shoulder pressing and require lap welding. Due to the large size of the cargo containment system and the large number of corrugated plates used, the welding process is difficult. Using manual welding requires a lot of time for related training, resulting in low welding efficiency, low welding quality, and high cost.

[0003] The current corrugated plate welding equipment has a low automation rate. When welding the corrugated section, it requires manual control by workers, which has a high operating threshold, is difficult to maintain, and the equipment motor and mechanical structure cannot provide timely feedback and adjustment, which can easily lead to operational errors and rework, resulting in high operating costs.

[0004] Therefore, in order to solve the above-mentioned technical problems, a new automatic welding equipment control system for the corrugated plates of Mark III LNG ships is provided to improve the automation rate of the equipment and reduce the equipment quality control cost and manual training cost. Summary of the Invention

[0005] The purpose of this invention is to provide a control system and control method for an automatic welding equipment for corrugated plates of LNG ships.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows:

[0007] An automatic welding equipment control system for LNG ship corrugated plates, characterized in that it includes a welding system, a motion actuator, a control system, and a sensing system.

[0008] The control system includes a PLC industrial computer, a coupler, and a communication module. The PLC industrial computer is electrically connected to the communication module via the coupler.

[0009] The motion actuator includes a speed reducer, a servo motor, and a servo controller. The servo controller is electrically connected to the servo motor and to a communication module.

[0010] The sensing system includes a first-point laser sensor, a second-point laser sensor, a tilt sensor, a contact displacement sensor, and a proximity sensor. All four sensors are electrically connected to a communication module. The first-point laser sensor is positioned at the front end of the motion actuator along its direction of motion. The second-point laser sensor is positioned between the first-point laser sensor and the motion actuator. The contact displacement sensor includes a sensor head and a tail amplifier. The tilt sensor is mounted on the motion actuator.

[0011] The welding system includes a transformer, a water chiller, and a welding power source, which is electrically connected to a communication module.

[0012] Furthermore, the servo motor includes an X-axis servo motor, a Y-axis servo motor, a Z-axis servo motor, an S-axis servo motor, and an R-axis servo motor.

[0013] Furthermore, the communication module includes an analog signal input / output module and a digital signal input / output module.

[0014] Furthermore, the control system also includes a touch screen and a remote controller, both of which are electrically connected to the PLC industrial computer.

[0015] The control method of the automatic welding equipment control system for corrugated plates of LNG ships is characterized in that when the sensor head at the top of the contact displacement sensor contacts the corrugated plate, the change in height is used to determine the corrugation and the plane and to track the error. The starting position of the corrugation is distinguished by the change in height between the two points before and after.

[0016] The first point laser sensor measures the distance between the first point laser sensor and the corrugated plate in real time, and senses the corrugated structure in the direction of equipment movement. When the first point laser sensor measures the corrugated structure, the PLC industrial control computer transmits control signals to the motion actuator according to the identified corrugated characteristics, and executes preset action commands such as overturning the corrugated plate.

[0017] The second laser sensor swings left and right, sampling at 50ms intervals and 2ms intervals to collect the distance between the second laser sensor and the corrugated plate in real time. Based on the 1.2mm height difference at the lap weld of the corrugated plate, the PLC industrial control computer converts the collected data into digital data and sets the parameter judgment conditions. When the midpoint deviates from the weld, a control signal is sent to the motion actuator, and the motion actuator adjusts the motion direction according to the signal.

[0018] The tilt sensor monitors the equipment position and the state of the ripples in real time, and transmits the collected tilt information to the PLC industrial control computer in real time. After calculation, the industrial control computer sends control commands to the motion actuator to adjust the posture of the equipment in real time.

[0019] This invention is based on the rapid, accurate, and multi-directional sensing capabilities of the sensing system. The collected data signals are transmitted to the industrial control computer, which processes the relevant data and transmits the control signals to the welding system and motion actuators in real time. During the process of traversing the corrugations, the sensors monitor and automatically adjust the corresponding process parameters and mechanism actions, reducing the need for manual intervention and realizing fully automated welding of corrugated plates. Attached Figure Description

[0020] Figure 1 This is a system structure block diagram of the present invention.

[0021] Figure label:

[0022] 1. Control system

[0023] 101 PLC industrial computer, 102 Touch screen, 103 Remote control, 104 Coupler, 105 Communication module.

[0024] 2. Sensing system

[0025] 201 First laser sensor, 202 Second laser sensor, 203 Tilt sensor,

[0026] 204 Contact Displacement Sensor, 205 Proximity Sensor

[0027] 3 Welding system

[0028] 301 Transformer, 302 Water Chiller, 303 Welding Power Supply

[0029] 4. Motion execution mechanism

[0030] 401 Gearbox, 402 Servo Motor, 403 Servo Controller. Detailed Implementation

[0031] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] This invention discloses an automatic welding equipment control system 1 for LNG ship corrugated plates, as follows: Figure 1As shown, it includes a welding system 3, a motion actuator 4, a control system 1, and a sensing system 2. The control system 1 is electrically connected to the welding system 3, the motion actuator 4, and the sensing system 2 respectively. During operation, the control system 1 sends a start signal to first start the motion control mechanism and the sensing system 2, and then receives the sensing information sent by the sensing system 2. After the sensing information is processed, the production control signal is transmitted to the motion actuator 4 and the welding system 3, and finally the motion control and welding control are performed.

[0033] like Figure 1 As shown, the control system 1 includes a PLC industrial computer 101, a touch screen 102, a remote controller 103, a coupler 104, and a communication module 105. The touch screen 102 is electrically connected to the PLC industrial computer 101. The PLC industrial computer 101 is electrically connected to the communication module 105 through the coupler 104. The remote controller 103 is electrically connected to the communication module 105. The industrial computer is a Codesys PLC system. The coupler 104 is an Ethercat coupler. The communication module 105 includes an analog signal input / output module and a digital signal input / output module, and has digital-to-analog conversion function.

[0034] The motion actuator 4 includes a reducer 401, a servo motor 402, and a servo controller 403. The servo controller 403 is electrically connected to the servo motor 402 and to the communication module 105. The servo motor 402 includes an X-axis servo motor 402, a Y-axis servo motor 402, a Z-axis servo motor 402, an S-axis servo motor 402, and an R-axis servo motor 402.

[0035] The sensing system 2 includes a first point laser sensor 201, a second point laser sensor 202, a tilt sensor 203, a contact displacement sensor 204, and a proximity sensor 205. The first point laser sensor 201, the second point laser sensor 202, the contact displacement sensor 204, and the proximity sensor 205 are all electrically connected to the communication module 105.

[0036] The welding system 3 includes a transformer 301, a water chiller 302, and a welding power source 303, which is electrically connected to the communication module 105.

[0037] The control method using the automatic welding equipment control system 1 for LNG ship corrugated plates includes the following steps:

[0038] The contact displacement sensor 204 includes a sensor head and a tail amplifier. When the sensor head at the top of the contact displacement sensor 204 contacts the corrugated plate, it judges the corrugation and the plane by the change in height and uses it as an error tracker. The starting position of the corrugation is distinguished by the change in height between the two points.

[0039] The first point laser sensor 201 is set at the front end of the motion actuator 4 in the motion direction. The first point laser sensor 201 measures the distance between the point laser sensor and the corrugated plate in real time and senses the corrugated structure in the motion direction of the equipment. When the first point laser sensor 201 measures the corrugated structure, the PLC industrial control computer 101 transmits control signals to the motion actuator 4 according to the identified corrugated features and executes preset action commands such as flipping over the corrugated plate.

[0040] The second laser sensor 202 is positioned between the first laser sensor 201 and the motion actuator 4. The second laser sensor 202 swings left and right, sampling at 50ms intervals and 2ms intervals to collect the distance between the second laser sensor 202 and the corrugated plate in real time. Based on the 1.2mm height difference at the lap weld of the corrugated plate, the PLC industrial control computer 101 performs digital-to-analog conversion on the collected data and sets parameter judgment conditions. When the midpoint deviates from the weld, a control signal is sent to the motion actuator 4, and the motion actuator 4 adjusts the motion direction according to the signal.

[0041] The tilt sensor 203 is installed on the motion actuator 4. The tilt sensor 203 monitors the position of the equipment and the state of the ripple in real time, and transmits the collected tilt information of the mechanism to the PLC industrial computer 101 in real time. After calculation, the industrial computer sends control commands to the motion actuator 4 to adjust the posture of the equipment in real time.

[0042] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method of controlling an automatic welding equipment for LNG ship corrugated plate, characterized by, When the sensor head on the top of the contact displacement sensor (204) is in contact with the corrugated plate, the height change amount is used to determine the corrugation and the plane as the tracking of errors, and the height change of the front and back two points is used to distinguish the starting position of the corrugation; The first point laser sensor (201) measures the distance between the first point laser sensor (201) and the corrugated plate in real time, senses the corrugated structure in the equipment movement direction, and when the first point laser sensor (201) measures the corrugated structure, the PLC industrial computer (101) transmits a control signal to the motion execution mechanism (4) according to the recognized corrugated feature, and executes a preset action instruction such as rolling over the corrugation. The second point laser sensor (202) swings left and right, samples at a period of 50ms and an interval of 2ms, and collects the distance between the second point laser sensor (202) and the corrugated plate in real time. Based on the 1.2mm height difference at the lap weld of the corrugated plate, the PLC industrial computer (101) performs digital-to-analog conversion on the collected data, sets the parameter judgment condition, and when the midpoint deviates from the weld, sends a control signal to the motion execution mechanism (4), and the motion execution mechanism (4) adjusts the movement direction according to the signal. The inclination sensor (203) monitors the equipment position and the state of rolling over the corrugation in real time, and transmits the collected mechanism inclination information to the PLC industrial computer (101) in real time. The industrial computer issues a control instruction to the motion execution mechanism (4) after calculation, and adjusts the equipment posture in real time.

2. The LNG ship corrugated plate automatic welding equipment control system applied to the LNG ship corrugated plate automatic welding equipment control method of claim 1, characterized in that, It comprises a welding system (3), a motion execution mechanism (4), a control system (1) and a sensing system (2), The control system (1) comprises a PLC industrial computer (101), a coupler (104) and a communication module (105), and the PLC industrial computer (101) is electrically connected with the communication module (105) through the coupler (104), The motion execution mechanism (4) comprises a speed reducer (401), a servo motor (402) and a servo controller (403), the servo controller (403) is electrically connected with the servo motor (402), and the servo controller (403) is electrically connected with the communication module (105), The sensing system (2) comprises a first point laser sensor (201), a second point laser sensor (202), an inclination sensor (203), a contact displacement sensor (204) and a proximity sensor (205), the first point laser sensor (201), the second point laser sensor (202), the contact displacement sensor (204) and the proximity sensor (205) are all electrically connected with the communication module (105), the first point laser sensor (201) is arranged at the front end of the motion direction of the motion execution mechanism (4), the second point laser sensor (202) is arranged between the first point laser sensor (201) and the motion execution mechanism (4), the contact displacement sensor (204) comprises a sensor head and a tail amplifier, and the inclination sensor (203) is arranged on the motion execution mechanism (4). The welding system (3) comprises a transformer (301), a water cooling machine (302) and a welding power supply (303), wherein the welding power supply (303) is electrically connected with the communication module (105).

3. The LNG carrier corrugated plate automatic welding equipment control system according to claim 2, characterized by, The servo motor (402) comprises an X-axis servo motor, a Y-axis servo motor, a Z-axis servo motor, an S-axis servo motor and an R-axis servo motor.

4. The LNG carrier corrugated plate automatic welding equipment control system according to claim 2, characterized by, The communication module (105) comprises an analog signal input and output module and a digital signal input and output module.

5. The LNG carrier corrugated plate automatic welding equipment control system according to claim 2, characterized by, The control system (1) further comprises a touch screen (102) and a remote controller (103), wherein the touch screen (102) and the remote controller (103) are electrically connected with the PLC industrial computer (101).

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