Intelligent manufacturing method and system for complex special-shaped guardrail columns

Abstract

The present invention discloses an intelligent manufacturing method and system for complex-shaped guardrail columns. By using advanced equipment and processes such as numerical control laser cutting, digital bending, portable machining, special-purpose groove assembly tooling, laser rust removal, robotic welding, mechanized hydraulic assembly, correction devices, and information platforms, the geometric dimensions of complex-shaped guardrail columns can be controlled, and the welds and overall appearance are well formed. It successfully solves the problem of mass production of complex-shaped guardrail column steel structures. The design and use of digital, mechanized, and proprietary equipment and tooling also improve the overall intelligent manufacturing level of steel guardrails. The welding path of the welding robot is optimized through AI scanning and positioning tracking algorithms to accurately weld the welds. After welding, the laser scanner is used to obtain the weld reinforcement height, and the PID control algorithm is used to control the grinding robot to perform reinforcement height grinding, which can effectively improve the efficiency and accuracy of welding and grinding.

Description

Technical Field

[0001] The present invention relates to the technical field of guardrail post manufacturing, and particularly to an intelligent manufacturing method and system for complex special-shaped guardrail posts. Background Art

[0002] With the rapid development of modern transportation infrastructure, bridge engineering has been widely applied at home and abroad. As an important part of a bridge, the bridge guardrail not only plays a protective role but also affects the overall aesthetics and safety of the bridge. In recent years, with the continuous innovation of bridge design and the progress of technology, the guardrail structure has become increasingly complex, especially for special-shaped and multi-joint guardrail posts, and the manufacturing difficulty has increased significantly. The traditional manufacturing methods for guardrail posts have been difficult to meet the current engineering requirements for precision and quality. Therefore, it is particularly important to develop an efficient intelligent manufacturing method for complex special-shaped guardrail posts.

[0003] At present, the manufacturing of the main structural plate units of bridge steel structures has gradually achieved industrialization, standardization, automation, and intelligence, especially in major engineering projects such as the Hong Kong-Zhuhai-Macao Bridge, the Shenzhen-Zhongshan Link, and the Huangmaohai Cross-sea Channel, remarkable results have been achieved. However, as a bridge deck accessory structure, the manufacturing level of steel guardrails still remains at the traditional manual operation stage. The existing technologies mainly rely on manual operations, and there are a large number of manual marking, manual cutting, and welding processes in the production process, resulting in low production efficiency and unstable product quality. In addition, it is difficult to accurately control the geometric dimensions of complex special-shaped guardrail posts by traditional manufacturing methods, especially in structures such as multi-joints and inner-folded types, and the problems of welding deformation and dimensional deviation are particularly prominent.

[0004] The deficiencies of the existing technologies are mainly reflected in the following aspects: First, the traditional manufacturing methods have low automation and low production efficiency, and it is difficult to meet the requirements of large-scale production and high quality; Second, human errors are prone to occur during manual operations, resulting in unstable product quality, especially for guardrail posts with complex special-shaped structures, and it is difficult to guarantee the geometric dimension accuracy; Third, the existing technologies lack effective information management means, and production data is difficult to monitor and adjust in real time, which is not conducive to the optimization and improvement of the production process. These problems seriously restrict the further development of the steel guardrail manufacturing industry. Summary of the Invention

[0005] In view of the above deficiencies or improvement requirements of the prior art, the purpose of the present invention is to provide a smart manufacturing method and system for complex-shaped guardrail columns. By designing and building the first domestic streamlined smart manufacturing system for guardrail columns, and using advanced equipment and processes such as numerical control laser cutting, digital bending, portable machining, special-purpose groove-assembling tooling, laser rust removal, robotic welding, mechanized hydraulic assembly, correction devices, and information platforms, the geometric dimensions of complex-shaped guardrail columns can be controlled, the welds and the overall appearance can be formed excellently, successfully solving the problem of streamlined manufacturing of complex-shaped guardrail column steel structures. The design and use of digital, mechanized, and proprietary equipment and tooling also improve the overall intelligent manufacturing level of steel guardrails, achieving stable and reliable product quality, a significant increase in output, cost reduction, and the intelligent and information level entering a new stage.

[0006] According to the first aspect of the present invention, a smart manufacturing method for complex-shaped guardrail columns is provided, including:

[0007] S100. Establish a solid model of the complex-shaped guardrail column and its components, and generate the geometric dimensions for part processing; the parts include the column body U plate, web plate, internal stiffener, bracket, and flange seat plate, external stiffener, and the column body U plate includes the outer column body U plate, the upper inner column body U plate, and the lower inner column body U plate;

[0008] S200. Perform precise cutting and marking on the column body U plate, web plate, internal stiffener, bracket, and base plate, machine-process the column body U plate using a portable mobile beveling device, and digitally bend the column body U plate and the bracket using a high-precision digital bending device;

[0009] S300. Design a special positioning fixture to assemble the outer column body U plate, web plate, and internal stiffener to form a first structure, and use a multi-axis welding robot to weld the first structure through an AI scanning and position-finding tracking algorithm, and integrally combine the first structure with the upper inner column body U plate and the lower inner column body U plate through a digital hydraulic device to form a second structure;

[0010] S400. Use a multi-axis welding robot to weld the butt welds of the column body U plate on the second structure through an AI scanning and position-finding tracking algorithm, and use a special gantry workstation to grind the excess height of the butt welds of the column body U plate on the second structure;

[0011] S500. Design a special column body total assembly device to assemble the second structure with the flange seat plate and the bracket to form a third structure, and design a special 360° rotary position welding workstation to weld the weld between the column body and the flange plate on the third structure, and use a digital hydraulic correction device to correct the angle between the column body and the flange on the third structure to complete the manufacturing of the column.

[0012] Further, the welding objective function of the AI scanning and positioning tracking algorithm includes:

[0013]

[0014] In the formula, d error (t) represents the torch offset; υ torch (t) represents the welding speed; Θ(t) represents the torch angle; λ1, λ2, λ3 represent the weight coefficients.

[0015] Further, it also includes: after the welding robot completes welding, the weld reinforcement is collected through a sensor, and the PID control algorithm is used to control the grinding tool to grind the weld reinforcement.

[0016] Further, the AI scanning and positioning tracking algorithm also includes: during welding or grinding, the offset of the key mating parts is detected in real time, and the position of the torch or grinding head is adjusted according to the offset:

[0017] ε t = f sensor(t) - f expected(t)

[0018] P i+1 = P i - k2·ε t

[0019] In the formula, k2 represents the adjustment coefficient; P i represents the position of the torch or grinding head at the i - th adjustment; P i+1 represents the position of the torch or grinding head at the (i + 1)-th adjustment; ε i represents the offset; f sensor(t) represents the actual position of the part detected in real time by the sensor at time t; f expected(t) represents the ideal position where the part should be according to the design requirements and the preset path at time t.

[0020] Further, the dedicated 360° rotary positioning welding station constantly controls the rotation speed of the motor to ensure continuous welding of the circumferential flat - position welds, optimizing the traditional welding method of "the person rotates around the object for welding" to the welding method of "the object rotates and the person is fixed" at the station. Before welding, the rotation speed is adjusted to match the welding speed, and the welding of the weld between the column body and the flange plate is completed along with the rotation of the column.

[0021] Further, the dedicated column total assembly device described in step S500, which assembles the second structure with the flange seat plate and the bracket to form a third structure, includes: placing the bracket and the second structure column in a vertical state on a support platform having three reference lines, namely a horizontal baseline, a transverse baseline, and a vertical baseline, and a bracket spiral positioning device for adjustment and assembly. Based on the bracket spiral positioning device, the height of the bracket and the flange seat plate is adjusted through the horizontal baseline, the left and right of the bracket and the flange seat plate are adjusted through the vertical baseline, and the front and back of the bracket and the flange seat plate are adjusted through the transverse baseline.

[0022] According to a second aspect of the present invention, there is provided an intelligent manufacturing system for complex-shaped guardrail columns, which is used for the above-mentioned intelligent manufacturing method of complex-shaped guardrail columns, and includes: a control center, a material preparation area, a part processing area, an assembly area, an intelligent welding area, a grinding area, a correction area, and a semi-finished product area. The control center further includes a control system, which grasps production data through the control system, monitors and adjusts welding parameters, conducts real-time video monitoring, and controls the production sites of other functional areas, so as to realize the dynamic management and control of the intelligent system for complex-shaped columns.

[0023] Further, the realization of the dynamic management and control of the intelligent system for complex-shaped columns includes: controlling the numerical control laser cutting equipment to realize cutting programs, cutting statistics, and process reporting; controlling the digital bending device to realize real-time adjustment of bending parameters, bending angles, and dimensions; controlling the multi-axis welding robot to adaptively adjust and group-control and group-weld according to the welding parameters of the gap and the programmed position; controlling the digital hydraulic correction device to realize the quantification of the correction pressure of the angle between the column body and the flange.

[0024] Further, the control system further includes a vision-assisted programming module, which is used to take pictures and identify weld seams through an industrial camera installed on the multi-axis welding robot, quickly generate welding programs, and control the multi-axis welding robot to accurately complete welding;

[0025] The control system further includes a laser position-finding and tracking module, which is used to accurately measure, position, and track weld seams through a high-precision laser profile sensor.

[0026] Further, the control system further includes an error prediction module, which is used to collect real-time data of each functional area through sensors and generate an error vector:

[0027] e i =Q i -S i

[0028]

[0029] In the formula, e i represents the error vector of the i-th measurement point; Q iThe design model of the guardrail post part representing the i-th measurement point; S i The actual machining data point cloud representing the i-th measurement point; E total Represents the overall error vector.

[0030] Advantages of the present invention:

[0031] 1. The intelligent manufacturing method for complex-shaped guardrail posts in the present invention builds a streamlined intelligent manufacturing system for guardrail posts through design. By using advanced numerically controlled laser cutting, digital bending, portable machining, special-purpose groove-assembling tooling, laser rust removal, robotic welding, mechanical hydraulic assembly, straightening devices, information platforms and other equipment and control algorithms, the geometric dimensions of complex-shaped guardrail posts can be controlled, the welds and the overall appearance are well formed. It successfully solves the problem of streamlined manufacturing of complex-shaped guardrail post steel structures. The design and use of digital, mechanical and proprietary equipment and tooling also improve the overall intelligent manufacturing level of steel guardrails, achieving stable and reliable product quality, a significant increase in output, cost reduction, and the intelligent and information levels entering a new stage.

[0032] 2. The intelligent manufacturing method for complex-shaped guardrail posts in the present invention uses a welding robot to optimize the welding path of the welding robot through AI scanning and position-finding tracking algorithms for precise welding of the welds. After welding is completed, the laser scanner is also used to obtain the weld reinforcement height, and the PID control algorithm is used to control the grinding robot for reinforcement height grinding, which can effectively improve the efficiency and accuracy of welding and grinding.

[0033] 3. The intelligent manufacturing system for complex-shaped guardrail posts in the present invention integrates advanced numerically controlled laser cutting, digital bending, portable machining, special-purpose groove-assembling tooling, laser rust removal, robotic welding, mechanical hydraulic assembly, straightening devices and information platforms and other equipment and processes, and successfully solves the problem of streamlined manufacturing of complex-shaped guardrail post steel structures. The system realizes precise control of the geometric dimensions of guardrail posts and excellent quality of welds and overall appearance, greatly improving the intelligent manufacturing level of steel guardrails. The system uses AI scanning and position-finding tracking algorithms to optimize the welding path, ensuring the accuracy and efficiency of welding, and realizes precise grinding of the weld reinforcement height through the PID control algorithm. In addition, the system also establishes a feedback closed-loop system for real-time data collection and error prediction, and uses a recurrent neural network to optimize the processing path and process parameters in advance, ensuring high precision in processing and welding. The visual-aided programming module, laser position-finding tracking module and welding process database included in the control system further enhance the flexibility and adaptability of the system, making the product quality more stable and reliable, the production efficiency significantly improved, and the cost significantly reduced, thus pushing the intelligent and information levels of the steel guardrail manufacturing industry to a new stage.

[0034] Additional aspects and advantages of the present application will be given in part in the following description, will become apparent from the following description, or will be learned through the practice of the present application. Description of the Drawings

[0035] The above-mentioned and / or additional aspects and advantages of the present application will become apparent and be readily understood from the following description of embodiments in conjunction with the drawings, where:

[0036] Figure 1 is a flowchart of the intelligent manufacturing method for complex special-shaped guardrail columns in an embodiment of the present invention

[0037] Figure 2 is a schematic diagram of the structure of a complex special-shaped column in an embodiment of the present invention;

[0038] Figure 3 is a schematic diagram of laser precision cutting and scribing of parts in an embodiment of the present invention;

[0039] Figure 4 is a schematic diagram of bevel processing of U-shaped plate parts in an embodiment of the present invention;

[0040] Figure 5 is a schematic diagram of bending of U-shaped plates / brackets in an embodiment of the present invention;

[0041] Figure 6 is a schematic diagram of the assembly of a special positioning tooling for a single groove in an embodiment of the present invention;

[0042] Figure 7 is a schematic diagram of laser rust removal in a small space in an embodiment of the present invention;

[0043] Figure 8 is a schematic diagram of multi-position robotic welding with stiffeners in an embodiment of the present invention;

[0044] Figure 9 is a schematic diagram of column body assembly in an embodiment of the present invention;

[0045] Figure 10 is a schematic diagram of multi-axis robotic welding in an embodiment of the present invention;

[0046] Figure 11 is a schematic diagram of grinding at a special welding position in an embodiment of the present invention;

[0047] Figure 12 is a schematic diagram of the overall assembly station in an embodiment of the present invention;

[0048] Figure 13 is a schematic diagram of 360° rotation and variable-position welding in an embodiment of the present invention;

[0049] Figure 14 is a schematic diagram of digital hydraulic correction of the included angle in an embodiment of the present invention;

[0050] Figure 15 It is the layout diagram of the intelligent manufacturing system for complex-shaped guardrail columns in the embodiment of the present invention;

[0051] Figure 16 It is the schematic diagram of laser position searching and tracking in the embodiment of the present invention. Detailed implementation manners

[0052] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It can be understood that the specific embodiments described herein are only used to explain the present invention, rather than limiting the present invention. Additionally, it should be noted that for the sake of description, only the parts related to the present invention rather than all the structures are shown in the drawings.

[0053] In the description of the present invention, unless otherwise clearly defined and limited, the terms "connected", "connected to", and "fixed" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication of two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0054] Those skilled in the art of the present technology can understand that unless specifically stated, the singular forms "a", "an", "the", and "said" used herein may also include the plural forms. It should be further understood that the term "comprising" used in the specification of the present application means the presence of the described features, integers, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or their combinations.

[0055] Those skilled in the art of the present technology can understand that unless otherwise defined, all terms (including technical terms and scientific terms) used herein have the same meaning as the general understanding of those of ordinary skill in the art to which the present application belongs. It should also be understood that terms such as those defined in a general dictionary should be understood to have a meaning consistent with the meaning in the context of the prior art, and will not be interpreted in an idealized or overly formal sense unless specifically defined as in the embodiments of the present application.

[0056] The present invention provides a method and system for intelligent manufacturing of complex-shaped guardrail columns. By designing and building the first domestic intelligent manufacturing system for guardrail columns in a streamlined manner, and using advanced equipment and processes such as numerical control laser cutting, digital bending, portable machining, special-purpose grooving tooling, laser rust removal, robotic welding, mechanized hydraulic assembly, correction devices, and information platforms, the geometric dimensions of complex-shaped guardrail columns can be controlled, the welds and the overall appearance are well formed, successfully solving the problem of streamlined manufacturing of complex-shaped guardrail column steel structures. The design and use of digital, mechanized, and proprietary equipment and tooling also improve the overall intelligent manufacturing level of steel guardrails, achieving stable and reliable product quality, a significant increase in production, cost reduction, and entering a new stage in the level of intelligence and informatization.

[0057] Example 1:

[0058] As Figure 1 shown, the embodiment of the present invention provides a method for intelligent manufacturing of complex-shaped guardrail columns, including:

[0059] S100. Use digital modeling software to complete the solid modeling of the guardrail column and its components, and generate the geometric dimensions for part processing. The parts include the column body U-plate, web plate, internal stiffeners, brackets, flange seat plates, and external stiffeners. The column body U-plate includes the outer column body U-plate, the upper inner column body U-plate, and the lower inner column body U-plate;

[0060] As Figure 2 shown, first use digital modeling software to complete the solid modeling, generate the geometric dimensions for part processing, accurately add process machining allowances to ensure the accuracy of machining dimensions. The generated parts include: the outer column body U-plate 101, the upper inner column body U-plate 102, and the lower inner column body U-plate 103; the web plate 201; the internal stiffeners 301 - 305; the first bracket 401, the second bracket 402, the third bracket 403, and the fourth bracket 404; the flange seat plate 501; and the external stiffener 601.

[0061] S200. Use numerical control laser cutting equipment to accurately cut and mark the column body U-plate, web plate, internal stiffeners, brackets, and base plates, then use a portable mobile beveling device to machine the column body U-plate, and finally use a high-precision digital bending device to digitally bend the column body U-plate and the brackets;

[0062] Specifically, as Figure 3As shown in the figure, the outer U-plate 101 of the column body, the upper inner U-plate 102 of the column body, the lower inner U-plate 103 of the column body, the web plate 201, the first internal stiffener 301, the second internal stiffener 302, the third internal stiffener 303, the fourth internal stiffener 304, and the fifth internal stiffener 305, the first bracket 401, the second bracket 402, the third bracket 403, the fourth bracket 404, and the flange seat plate 501 are automatically programmed and the processing allowance is added, and then directly imported into the current most advanced numerical control laser cutting equipment to complete precise cutting and marking. The cutting efficiency is high, the deviation accuracy of cutting and marking reaches 0.5 mm, the cutting surface and roughness are good, and the cutting workload statistics and work reporting can be completed in real time in the information system, reducing repeated cutting errors and improving the efficiency of manual statistics and work reporting.

[0063] As Figure 4 shown, the butt joint groove of the column body U-plate is machined by a portable mobile groove equipment. The equipment processing accuracy reaches 0.5 mm, the efficiency is high, and the machining deformation is small, solving the problem of difficult control of the thermal cutting groove deformation.

[0064] As Figure 5 shown, after the groove machining of the outer U-plate 101 of the column body, the upper inner U-plate 102 of the column body, and the lower inner U-plate 103 of the column body is completed, and after the first bracket 401, the second bracket 402, the third bracket 403, and the fourth bracket 404 are laser precision cut and marked, a high-precision digital bending machine is used to quantitatively control the bending angle and bending size, so as to accurately control the geometric dimensions of the subsequent column body splicing size and gap.

[0065] S300. Design a special positioning fixture to assemble the outer U-plate, web plate and internal stiffener of the column body to form a first structure, and use a multi-axis welding robot to weld the first structure through the AI scanning and positioning tracking algorithm. Finally, the first structure is integrally assembled with the upper inner U-plate and the lower inner U-plate of the column body through a digital hydraulic device to form a second structure;

[0066] Among them, the welding objective function of the AI scanning and positioning tracking algorithm includes:

[0067]

[0068] In the formula, d error (t) represents the welding torch offset; υ torch (t) represents the welding speed; Θ(t) represents the welding torch angle; λ1, λ2, λ3 represent the weight coefficients. After the welding robot completes the welding, it is also necessary to collect the weld reinforcement height through a sensor and use the PID control algorithm to control the grinding tool to grind the weld reinforcement.

[0069] Specifically, as Figure 6As shown, a special positioning fixture is designed for the assembly of the U-shaped plate 101, web plate 201, first internal stiffener 301, second internal stiffener 302, third internal stiffener 303, fourth internal stiffener 304, and fifth internal stiffener 305 on the outer side of the column body. By relying on the fixed dimensions of the column body support and the positioning reference of the stiffener distance of the positioning plate, the assembly accuracy and efficiency are improved, and the deviation is controlled within 0.5 mm to ensure the force requirement. Compared with the traditional scribing assembly process, the work efficiency is increased by 3 times.

[0070] As Figure 7 shown, for the welds of the U-shaped plate 101, web plate 201, first internal stiffener 301, second internal stiffener 302, third internal stiffener 303, fourth internal stiffener 304, and fifth internal stiffener 305 on the column body, a handheld laser rust removal device is used to complete the grinding of the weld parts, solving the problem that conventional grinding equipment cannot complete the rust removal of the weld parts in a confined small space. At the same time, the rust removal cleanliness quality is improved, and the rust removal efficiency is increased by at least 2 times compared with ordinary manual work.

[0071] As Figure 8 shown, the U-shaped plate 101, web plate 201, first internal stiffener 301, second internal stiffener 302, third internal stiffener 303, fourth internal stiffener 304, and fifth internal stiffener 305 on the column body are welded by a multi-axis robot. The multi-axis robot forms a welding path through AI scanning and realizes a smooth transition of the flat and vertical welds 701 through laser position finding and tracking. The deviation of the weld leg size is 1 mm, the appearance of the weld is excellent, and the welding efficiency is increased by 1.5 times.

[0072] As Figure 9 shown, after the U-shaped plate 101 on the column body is welded with the web plate 201, first internal stiffener 301, second internal stiffener 302, third internal stiffener 303, fourth internal stiffener 304, and fifth internal stiffener 305 to form a groove shape, a digital hydraulic device is designed for the column body assembly station to integrally combine the completed primary groove shape with the U-shaped plates 102 and 103 of the column body into a hexagonal variable cross-section internally folded column body. The assembly angle of the column body is less than 0.1°, and the gap is controlled within 1 mm.

[0073] S400. A multi-axis welding robot is used to weld the butt weld of the U-shaped plate on the column body of the second structure through AI scanning and position finding and tracking algorithms, and a special gantry type station is used to grind the excess height of the butt weld of the U-shaped plate on the column body of the second structure;

[0074] As Figure 10 shown, the butt weld 801 of the U-shaped plate on the column body is welded by a multi-axis robot. The welding is completed through AI scanning and position finding and tracking. The penetration depth and weld leg size both reach a deviation of 1 mm. The appearance of the weld is good, and the qualified rate of the first flaw detection is high. The welding efficiency is increased by more than 2 times compared with traditional manual welding.

[0075] As Figure 11As shown in the figure, the reinforcement of the weld 801 between the U-shaped plate of the column body is polished by a special gantry-type work station. The polishing equipment is placed on the gantry and can be moved. The polishing is mechanized. 50 columns can be completed every day, and the work efficiency is more than 3 times higher than that of manual polishing, reducing the labor intensity. The deviation of the weld reinforcement is as high as 0.2 mm. The hexagonal arc part is smooth and uniform, which is easy to paint beautifully.

[0076] Design a special total assembly device for the column body, assemble the second structure with the flange seat plate and the bracket to form the third structure, and design a special 360° rotary positioning welding station to weld the weld between the column body and the flange plate on the third structure. Finally, use a digital hydraulic correction device to correct the included angle between the column body and the flange on the third structure to complete the production of the column.

[0077] As Figure 12 shown, design a special total assembly equipment for the column body, and place the bracket and the column body in a vertical state on a support platform with three types of reference lines. Among them, the horizontal baseline is used to control the height of the bracket hole and the flange bottom plate, the vertical baseline controls the left and right of the bracket and the flange, and the horizontal baseline is used to control the front and back of the bracket and the flange bottom plate; the height, front and back position relationships are controlled by the positioning rods 5, the rotating shaft 4 and the positioning shaft 6 at different positions. This equipment realizes a deviation of 1 mm in the included angle, size and connection relationship, and the number of columns assembled in a single day is increased by 2 times.

[0078] As Figure 13 shown, design a special 360° rotary positioning welding station for the weld 801 between the column body and the flange plate. The rotation speed of the motor is controlled at 6° / second to ensure the continuous welding of the circumferential flat-position weld. Optimize the traditional welding method of "the person rotates around the object for welding" to the welding method of "the object rotates and the person is fixed" at the work station. Before welding, adjust the rotation speed of the positioning welding equipment to match the welding speed, and set a fixed welding station. Along with the rotation of the column, complete the welding of the column body and the flange weld. The foot size deviation is 0.5 mm, and the appearance forming is uniform, continuous and excellent.

[0079] As Figure 14 shown, there is deformation after welding the weld between the column body and the flange bottom plate 501. Design a special digital hydraulic correction device. According to the inclination angle and the size deviation value, digitally control the hydraulic adjustment device to ensure that the included angle deviation between the seat plate and the column body is controlled within 1 mm.

[0080] Example 2:

[0081] As Figure 15As shown in the figure, based on Embodiment 1, the embodiment of the present invention provides an intelligent manufacturing system for complex special-shaped guardrail columns, including: a control center, a stock preparation area, a part processing area, an assembly area, an intelligent welding area, a grinding area, a straightening area, and a semi-finished product area. The control center includes a control system, which masters production data through the control system, monitors and adjusts welding parameters, conducts real-time video monitoring, and controls the production sites of other functional areas, realizing dynamic management and control of the intelligent system for complex special-shaped columns, including: controlling the numerical control laser cutting equipment to realize cutting procedures, cutting statistics, and process reporting; controlling the digital bending device to realize real-time adjustment of bending parameters, bending angles, and dimensions; controlling the multi-axis welding robot to adaptively adjust and group control and group weld according to the welding parameters of the gap and programming positions; controlling the digital hydraulic straightening device to realize quantification of the straightening pressure of the column body and flange angle.

[0082] Furthermore, the control system also includes a visual-aided programming module, which is used to identify weld seams by taking pictures with an industrial camera installed on the multi-axis welding robot, quickly generate welding programs, and control the multi-axis welding robot to accurately complete welding. The visual-aided programming function is a function of quickly generating programs by identifying weld seams through camera photography. This system consists of an industrial camera, a visual recognition module, and a program generation module. An industrial camera is used for taking pictures. The camera is installed on the robot cantilever. The operator selects the weld seam position according to the picture-taking result to complete the identification of the weld seam position, and then generates a welding program. Compared with traditional teaching programming, this function has the advantages of more convenient programming operation, less workload, and can quickly generate programs; it is more suitable for weld programming of small-batch and multi-specification steel structure parts; and it is not affected by the workshop lighting and the surface state of the workpiece.

[0083] As Figure 16 shown, the control system also includes a laser seam tracking module, which is used to accurately measure, position, and track weld seams through a high-precision laser profile sensor. The laser module uses a high-precision laser profile sensor to accurately measure, position, and track weld seams. The laser module has the advantages of high tracking accuracy, up to ±0.5mm; good anti-interference ability, using a variety of filtering and anti-reflection means, suitable for various weld surface grinding and processing states; the installation position of the laser can be arbitrarily changed to facilitate welding and avoid interference; and it has multiple functions such as positioning and tracking.

[0084] Furthermore, the control system also includes an error prediction module, which is used to collect real-time data of each functional area through sensors and generate an error vector:

[0085] e i =Q i -S i

[0086]

[0087] In the formula, e i represents the error vector of the i-th measurement point; Q i represents the design model of the guardrail post part at the i-th measurement point; S i represents the actual processed data point cloud at the i-th measurement point; E total represents the overall error vector. Finally, the error distribution of the subsequent process is predicted through a recurrent neural network to optimize the machining path and process parameters in advance.

[0088] Furthermore, the control system also includes a welding process package and a welding process database. The welding process package provides a complete welding process solution for the welding robot, including welding process flow, welding sequence, multi-layer and multi-pass welding process parameter planning, torch posture, torch position, welding machine process mode, welding parameters at different positions, etc. And the results of the welding decision are generated into a complete welding program and sent to the robot and the welding machine to control their precise execution of the welding program, and adjust the welding process, torch posture, and torch position in real time to adapt to the actual weld state and achieve high-quality welding. The welding process database is the basis for realizing intelligent welding, providing complete welding process parameters for welding decision-making, including the basic welding process parameters of different standard weld specifications and the welding process parameters of different weld errors. The welding process database in this system has the characteristics of a wide range of process parameters covering various materials; applicable to various joint forms; the process parameters fully consider the workpiece structure, microstructure of the welded joint, mechanical properties, and internal quality; including multi-layer and multi-pass welding processes, automatically planning the number of welding layers and passes; supporting the pulsed process mode, which can obtain a lower heat input; and having a large compatible error range. The welding process library provides precise welding process parameters for the robot equipment to realize the intelligent welding of the target workpiece. The welding process library supports the process call of the intelligent welding robot to realize the welding of standard welds, and also supports the adaptive welding function, providing real-time process adjustment with an accuracy of 0.5 mm.

[0089] Furthermore, the control system can also perform adaptive adjustment on the welding process. The adaptive adjustment of the welding process is aimed at actual situations such as irregular welding trajectories, and adjusts the welding process parameters and torch position in real time. In contrast, the trajectories, postures, and welding process specifications of traditional robots using teaching programming are too single to adapt to the changes in the weld, and it is easy to have process defects such as welding deviation, burn-through, lack of fusion, and lack of penetration during welding. To adapt to a larger gap, a large current is used to cover it, resulting in an excessive heat input and a decrease in the mechanical properties of the joint.

[0090] It should be understood that although the steps in the flowchart of the accompanying drawings are shown sequentially as indicated by the arrows, these steps are not necessarily executed sequentially in the order indicated by the arrows. Unless there is a clear indication in this document, there is no strict order restriction for the execution of these steps, and they can be executed in other orders. Moreover, at least a part of the steps in the flowchart of the accompanying drawings may include multiple sub-steps or multiple stages. These sub-steps or stages are not necessarily completed at the same moment, but can be executed at different moments, and their execution order is not necessarily sequential, but can be executed alternately or in turn with at least a part of other steps or sub-steps or stages of other steps.

[0091] The above are only some embodiments of the present application. It should be noted that for those of ordinary skill in the art, without departing from the principle of the present application, several improvements and refinements can be made, and these improvements and refinements should also be regarded as the protection scope of the present application.

Claims

1. A method for intelligent manufacturing of complex and special-shaped guardrail columns, characterized in that: include: S100, establishing a solid model of a complex special-shaped guardrail column and its components, and generating geometric dimensions of parts processing; the parts include a column shaft U-plate, a web, an inner stiffener, a bracket, a flange seat plate, and an outer stiffener; the column shaft U-plate includes an outer column shaft U-plate, an inner column shaft upper U-plate, and an inner column shaft lower U-plate; S200, accurately cutting and marking the column U-plate, web, inner stiffener, bracket and base plate, machining the column U-plate with a portable mobile groove equipment, and digitally bending the column U-plate and the bracket with a high-precision digital bending device; S300, designing a special positioning fixture to assemble the outer U-plate, the web and the inner stiffener of the column to form a first structure, and using a multi-axis welding robot to weld the first structure through AI scanning and position tracking algorithm, and using a digital hydraulic device to assemble the first structure with the inner upper U-plate and the inner lower U-plate of the column to form a second structure; S400, using a multi-axis welding robot to weld the column shaft U-plate butt weld on the second structure through AI scanning and position tracking algorithm, and using a special gantry workstation to grind the excess height of the column shaft U-plate butt weld on the second structure; S500. Design a special column assembly device to assemble the second structure with the flange seat plate and the bracket to form a third structure, and design a special 360° rotating displacement welding station to weld the column body and the flange plate weld on the third structure, use a digital hydraulic correction device to correct the angle between the column body and the flange on the third structure, and complete the column manufacturing.

2. According to claim 1, a complex and special-shaped guardrail column intelligent manufacturing method is characterized in that: The welding objective function of the AI ​​scanning and position tracking algorithm includes: J=∫0 T [λ1·d error (t)+λ2·υ torch (t)+λ3·Θ(t)]dt Where, d error (t) represents the welding gun offset; ν torch (t) represents the welding speed; Θ(t) represents the welding gun angle; λ1, λ2, λ3 represent the weight coefficients.

3. A method for intelligently manufacturing complex and special-shaped guardrail posts according to claim 2, characterized in that: Also includes: After the welding robot completes welding, the weld excess height is collected through the sensor, and the PID control algorithm is used to control the grinding tool to grind the weld excess height.

4. According to claim 2, a method for intelligently manufacturing complex and special-shaped guardrail columns is characterized in that: The AI ​​scanning and position tracking algorithm also includes: real-time detection of the offset of key matching parts during welding or grinding, and adjustment of the position of the welding gun or grinding head according to the offset: e t =f sensor(t) -f expected(t) P i+1 =P i -k2·e t Where, k2 represents the adjustment coefficient; P i Indicates the position of the welding gun or grinding head at the i-th adjustment; P i+1 Indicates the position of the welding gun or grinding head at the i+1th adjustment; ε i Indicates the offset; f sensor(t) represents the actual position of the part detected by the sensor in real time at time t; f expected(t) Represents the ideal position that the expected part should be in at time t according to the design requirements and preset path.

5. The intelligent manufacturing method of complex and special-shaped guardrail columns according to claim 1 is characterized in that: The special 360° rotating position welding station constantly controls the motor rotation speed to ensure continuous welding of circumferential flat welds, optimizes the traditional welding method of "people rotating around objects" to a welding method of "objects rotating and people fixed". Before welding, the rotation speed is adjusted to match the welding speed, and the welding of the column body and the flange plate weld is completed as the column rotates.

6. A method for intelligently manufacturing complex and special-shaped guardrail posts according to any one of claims 1 to 5, characterized in that: The special column assembly device designed in step S500 assembles the second structure with the flange seat plate and the bracket to form a third structure, including: placing the bracket and the second structure column in a vertical state on a supporting platform having three baselines, namely, a horizontal baseline, a transverse baseline and a vertical baseline, and a bracket spiral positioning device for adjustment and assembly; based on the bracket spiral positioning device, the height of the bracket and the flange seat plate is adjusted through the horizontal baseline, the left and right of the bracket and the flange seat plate are adjusted through the vertical baseline, and the front and back of the bracket and the flange seat plate are adjusted through the transverse baseline.

7. An intelligent manufacturing system for complex and special-shaped guardrail columns, used in an intelligent manufacturing method for complex and special-shaped guardrail columns according to any one of claims 1 to 6, characterized in that: include: Control center, material preparation area, parts processing area, assembly area, intelligent welding area, grinding area, correction area, semi-finished product area and CNC laser cutting equipment. The control center also includes a control system, which can grasp production data, monitor and adjust welding parameters, conduct real-time video monitoring and control of production sites in other functional areas, and realize dynamic management and control of complex special-shaped column intelligent systems.

8. The complex and special-shaped guardrail column intelligent manufacturing system according to claim 7 is characterized in that: The dynamic control of the intelligent system for complex special-shaped columns includes: controlling the CNC laser cutting equipment to realize the cutting program, cutting statistics and process reporting; controlling the digital bending device to realize real-time adjustment of bending parameters, bending angles and dimensions; controlling the multi-axis welding robot to adaptively adjust and group-control the welding parameters according to the gap and programmed position; controlling the digital hydraulic correction device to realize the quantification of the correction pressure of the angle between the column body and the flange.

9. A complex and special-shaped guardrail column intelligent manufacturing system according to any one of claims 7 or 8, characterized in that: The control system also includes a visually assisted programming module for identifying welds by taking photos with an industrial camera provided on the multi-axis welding robot, quickly generating a welding program, and controlling the multi-axis welding robot to accurately complete welding; The control system also includes a laser positioning and tracking module, which is used to accurately measure, locate and track the weld through a high-precision laser profile sensor.

10. An intelligent manufacturing system for complex special-shaped guardrail columns according to any one of claims 7 or 8, characterized in that: The control system also includes an error prediction module, which is used to collect real-time data of each functional area through sensors and generate an error vector: e i =Q i -S i In the formula, e i represents the error vector of the i-th measurement point; Q i represents the guardrail column part design model of the i-th measurement point; S i Represents the actual processing data point cloud of the i-th measurement point; E total represents the overall error vector.

Images