Efficient pipe section intersecting line cutting, positioning and detecting method

Abstract

The invention discloses an efficient pipe section intersecting line cutting positioning and inspection method which comprises the following steps: firstly, accurately collecting data such as the size, the shape and the material of a pipe section, and making cross quadrant lineation before the pipe section is hoisted; thirdly, accurately inputting information according to an intersecting line cutting pipe section positioning data table, and performing accurate positioning calculation according to different pipe section types, such as double ends, double ends of short pipe sections smaller than 9 meters, single ends, sub-factories and the like; and then, the cutting equipment is controlled strictly according to the positioning data, and original point identification and alignment are made before and after cutting. After cutting is completed, according to a project pipe section production design drawing and a cutting model, a high-precision inspection method is applied, key data are input, an intersecting line inspection data table is output, and quality inspection is completed. According to the method, full-table programming is adopted, a complete working program is constructed, programming efficiency and accuracy are greatly improved, cost is reduced, design changes can be coped with conveniently, data management and sharing are facilitated, universality is high, and powerful support is provided for heavy industry pipe section intersecting line machining.

Description

Technical Field

[0001] The invention relates to the technical field of heavy industry, in particular to an efficient cutting positioning and inspection method for intersecting lines of pipe sections. Background Art

[0002] As the domestic wind power market approaches saturation, domestic wind power companies have been laying out overseas markets. In overseas wind power projects, such as the Saipem NFPS offshore platform steel pipe pile processing project, the pipe segment production presents a variety of specifications, thickness ranging from 25mm to 150mm, pipe diameter ranging from 1100mm to 3640mm, large span, large quantity and complexity. Among them, 148 pipe segments need to be cut by intersecting lines. The project has a long acceptance cycle and tight delivery time. The intersecting line cutting machine is a newly purchased KR-HG1600 intelligent marine engineering double-head groove robot. It is used for the first time by the production base and lacks operating experience.

[0003] When traditional manual cutting instructions for pipe segment intersection lines are produced, omissions and mistakes are very likely to occur, which greatly increases the workload of review and proofreading. Not only can it not meet the requirements of the project production cycle, but it can also easily lead to cost losses, seriously hindering the company's development of overseas wind power foundation steel structure markets. At the same time, in the manufacturing process of large-scale structural parts such as offshore wind power pipe racks, the cutting accuracy of pipe segment intersection lines is directly related to the overall quality and safety of the structure, and an efficient and accurate method for positioning and inspecting the cutting of pipe segment intersection lines is urgently needed. Summary of the invention

[0004] The purpose of the present invention is to provide an efficient method for cutting, positioning and inspecting intersection lines of pipe sections, to solve the problems of cutting, positioning and high-precision inspection of intersection lines of offshore wind power pipe sections, to improve the cutting accuracy and inspection efficiency of intersection lines of pipe sections, to ensure the overall quality of pipe sections, to meet the production needs under complex working conditions such as overseas wind power projects, and to help wind power companies expand their overseas markets.

[0005] In order to achieve the above object, the present invention is implemented by the following technical solution: an efficient pipe segment intersection line cutting positioning and inspection method, comprising the following steps:

[0006] Data preparation steps: Before cutting, collect the size, shape, and material information of the pipe segment to form basic data records. By recording the various parameters of the pipe segment in detail, a reliable basis is provided for subsequent precise operations, avoiding cutting deviations due to missing or inaccurate basic data, and effectively ensuring the scientific nature of the start of cutting.

[0007] Pipe section preparation steps: Before the pipe section is hoisted onto the intersecting line cutting machine bracket, use a marking tool to mark the cross quadrant at the end of the pipe section so that the lines of the shortest point and the longest point are clearly presented. This step helps the operator to quickly find the positioning reference in the subsequent cutting process, intuitively understand the geometric characteristics of the pipe section, reduce cutting errors caused by inaccurate positioning, and improve the accuracy and efficiency of initial positioning.

[0008] Data input steps: According to the intersecting line cutting pipe segment positioning data table, accurately fill in the pipe segment name, pipe specifications at both ends of the pipe segment, the angle of the through-mouth axis and the positioning value, and refer to the drawing to select the end with a larger pipe diameter as the main cutting end, and adjust the pipe segment so that the shortest point of the intersecting line of the main cutting end faces directly upward. Accurate data input and reasonable selection of the main cutting end, combined with standardized pipe segment orientation adjustment, ensure that the cutting instructions can accurately correspond to the actual pipe segment status, making the cutting process orderly and accurate, reducing human judgment errors, and improving the rationality of cutting planning.

[0009] Positioning calculation steps:

[0010] For the double-end intersecting line cut pipe section, the main cutting origin positioning value L1 of the double-end cut pipe section is determined according to the position of the first annular seam at the main cutting end. This positioning method based on actual structural characteristics fully considers the connection requirements of the pipe section during assembly, so that the cut pipe section can be accurately connected, ensuring the smoothness of subsequent assembly and reducing assembly difficulty and errors.

[0011] For double-end cutting of short pipe sections less than 9 meters, after the main cutting end is cut, the pipe is moved to the secondary cutting end using a hoisting device. Before cutting the secondary cutting end, the secondary cutting origin is repositioned by a measuring tool based on the main cutting origin and the L2 value, where the main cutting origin positioning value L1 is also determined based on the first annular seam position of the main cutting end. The operation process for short pipe sections of special specifications not only meets the processing requirements of pipe sections of different lengths, but also ensures the accuracy consistency of the cutting at both ends of the short pipe section through rigorous origin repositioning, thereby improving the yield rate of short pipe section processing.

[0012] For single-head intersecting line cutting pipe sections, the main cutting origin positioning value L1 of the single-head intersecting line cutting pipe section is determined based on the secondary head end of the pipe section. The origin is determined based on the structural characteristics of the pipe section itself, making the single-head cutting more targeted, reducing unnecessary operation links, optimizing the single-head cutting process, improving cutting efficiency, and ensuring that the cutting quality meets the requirements.

[0013] For the intersecting line cutting pipe section in the sub-factory area, when the intersecting line of the secondary cutting end has been cut and formed in the external factory area, the main cutting origin is determined by measuring the inner diameter endpoint of the secondary cutting end in the same quadrant and combining it with the positioning value L2. When collaborating across factories, this method ensures the compatibility and precise docking of parts processed in different factories, avoids the accumulation of processing errors caused by differences in factories, and ensures the continuity and accuracy of the pipe section processing of the entire project.

[0014] Cutting operation steps: After positioning and calculation are completed, the cutting equipment is controlled according to the positioning data and preset cutting parameters to perform the pipe segment cutting operation. Before cutting, the cutting origin is marked with a marking tool at the main cutting end of the pipe segment. Before formal cutting, the calibration tool is used to ensure that the origin mark is aligned. Strictly follow the positioning and parameters for cutting, cooperate with accurate origin marking and calibration, give full play to the advantages of the preliminary preparation work, minimize the deviation in the cutting process, ensure the flatness and dimensional accuracy of the cutting surface, and improve the quality of pipe segment cutting.

[0015] Quality inspection steps: After cutting is completed, a high-precision pipe segment intersection line inspection method is used for quality inspection. According to the project pipe segment production design drawings, the theoretical distances of the four quadrants of the pipe segment, namely the upper, middle (south), middle (north), and lower inner diameter endpoints, are accurately entered. According to the data obtained by querying the cutting model, the theoretical value of the groove is accurately filled in, and the intersection line inspection data table is output. The cutting of the pipe segment intersection line is inspected based on the table. Through the inspection process closely integrated with the design drawings and the introduction of multi-dimensional data comparison, cutting defects can be discovered in a timely and accurate manner to ensure that the quality of the pipe segments leaving the factory meets the standards, prevent unqualified products from entering the subsequent processes, and ensure the quality foundation of the entire project.

[0016] Optimization and improvement steps: In actual applications, feedback information and test results are collected, and the positioning and inspection methods are adjusted and optimized based on this information. The continuous optimization mechanism enables the method to adapt to the complex changes of different projects and continuously improve its performance. With the accumulation of practice, it is more and more in line with actual production needs, extending the effective use cycle of the method and providing technical support for the long-term stable production of enterprises.

[0017] As a further improvement of the technical solution of the present invention, the intersecting line cutting pipe segment positioning data table adopts a full table compilation form, and the pipe segment number, main cutting end data, main cutting end data, auxiliary cutting end data and remarks are filled in as required, so as to complete the establishment of the intersecting line cutting positioning rules, and the pipe segment intersecting line cutting instructions produced by the software are combined to realize the pipe segment intersecting line cutting. The full table compilation form simplifies the operation process. The operator only needs to fill in the key information as required to quickly generate the positioning rules, and automatically drive the cutting in combination with the software instructions, which greatly improves the work efficiency, reduces the uncertainty caused by manual intervention, and makes the cutting process more standardized and intelligent.

[0018] As a further improvement of the technical solution of the present invention, the intersection line inspection data table output by the high-precision pipe segment intersection line inspection method is used for accuracy verification and quality control of the pipe segment before it leaves the factory. The inspection data table provides a visual and standardized basis for judging the quality of the pipe segment. The quality inspector can quickly judge whether the pipe segment is qualified based on the table data, accurately locate the problem part, and facilitate timely rework and repair, thereby ensuring the product's factory qualification rate and improving the company's product reputation.

[0019] As a further improvement of the technical solution of the present invention, the method constructs a complete technical work procedure for cutting the intersecting line of the pipe segment, and generates a data file for the positioning of the cutting of the intersecting line of the pipe segment, a cutting instruction, and a cutting inspection file. The complete technical work procedure covers the entire process from data preparation to inspection, and each link is closely connected. The various files generated provide clear records and guidance for the entire production process, which is convenient for traceability management. When problems occur, the causes can be quickly identified, the production process can be optimized, and the production efficiency and stability can be guaranteed.

[0020] As a further improvement of the technical solution of the present invention, the method includes a set of general classification positioning data tables and positioning precautions, as well as a general inspection and testing table compiled according to the requirements of the later inspection and testing. The above two tables are compiled into an automatically generated general table using Excel tools, so that it is applicable to all projects of the same type. The design of the general table greatly enhances the applicability of the method. Regardless of the size of the project and how the pipe section specifications change, the company only needs to fill in the table according to the actual situation to quickly start the cutting and inspection process, reduce the cost of re-developing methods for different projects, and improve the company's market competitiveness.

[0021] As a further improvement of the technical solution of the present invention, for projects with multiple physical quantity specifications, the method can improve the speed and accuracy of compiling the location data and inspection tables of the pipe segment intersection lines. In large-scale, multi-specification projects, traditional methods often fall into confusion due to the complexity of data, resulting in low compilation efficiency and frequent errors. However, this method, with scientific processes and intelligent table design, can quickly sort out massive data and accurately generate the required tables, saving valuable time for the project and reducing quality risks caused by data problems.

[0022] As a further improvement of the technical solution of the present invention, the efficient pipe segment intersection line cutting positioning and inspection method can reduce the time spent on pipe segment cutting data proofreading, reduce labor costs, and ensure that the pipe segment production meets the accuracy requirements. The precise data preparation, positioning and inspection process greatly reduces the workload of data proofreading, saves a lot of man-hours, and reduces labor costs. At the same time, since the manual operation links are reduced, the risk of precision reduction due to human errors is also reduced, ensuring that the pipe segment processing accuracy is stable and reliable, saving costs for enterprises while improving product quality.

[0023] As a further improvement of the technical solution of the present invention, in the face of design changes and production adjustments, the method can make the modification of the pipe segment intersection line positioning data and the inspection table fast and convenient. In actual production, design changes are inevitable. This method is based on tabular design. It only needs to modify the corresponding table data to quickly adapt to new design requirements without re-planning the entire process, which greatly shortens the downtime caused by design changes and ensures that the project progress is not greatly affected.

[0024] As a further improvement of the technical solution of the present invention, the method is convenient for data management and sharing, and is conducive to the orderly development of on-site production. By generating standardized positioning data files, cutting instructions and inspection files, staff at all links can easily obtain the required information, realize real-time data sharing, avoid information islands, make the entire production site coordinated, improve production efficiency, and ensure the smooth progress of the project.

[0025] As a further improvement of the technical solution of the present invention, the method is applicable to all projects of the same type and has strong versatility. The wide applicability means that no matter what kind of projects the enterprise undertakes, the method can be adopted, without having to re-explore the cutting and inspection methods for each project, which reduces the cost of technology research and development, improves the ability of enterprises to cope with diversified market demands, and lays a solid foundation for enterprises to expand the market.

[0026] The present invention has the following beneficial effects:

[0027] For projects with complex material quantity specifications, the present invention can increase the efficiency of compiling pipe section intersection line positioning data and inspection tables by several times by relying on full table compilation and precise algorithms, and the accuracy rate approaches 100%. The traditional manual compilation method is not only inefficient, but also prone to errors.

[0028] The time for proofreading the pipe cutting data is greatly reduced. The proofreading work that originally required a lot of man-hours can be completed in a short time with the help of the present invention, which significantly reduces the labor cost. At the same time, it ensures that the pipe segment production accuracy is stable at a high standard. Traditional manual proofreading is prone to loss of accuracy due to fatigue, negligence, etc.

[0029] In the face of design changes and production adjustments, the present invention relies on a flexible table structure and intelligent algorithms, and the pipe section intersection line positioning data and inspection tables can be modified simply and quickly, and can quickly adapt to new working conditions. The traditional method requires recalculating a large amount of data, which is time-consuming and labor-intensive.

[0030] The present invention uses digital tables and software to facilitate data management and sharing. Personnel at all levels of the construction site can obtain accurate data in real time, promoting smooth production. In the traditional mode, data circulation is not smooth and is easily lost, delaying production.

[0031] The present invention has excellent versatility. Through well-designed universal forms and standardized processes, it is applicable to all projects of the same type and can operate efficiently regardless of changes in project scale and pipe section specifications. Traditional methods are often limited to specific projects and have poor adaptability. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Other features, objects and advantages of the present invention will become more apparent from the detailed description of non-limiting embodiments made with reference to the following drawings:

[0033] Figure 1 It is a schematic diagram of a typical intersecting line pipe section;

[0034] Figure 2 Positioning data table for double-end intersecting line cutting pipe section;

[0035] Figure 3 Double-end cutting positioning data table for short pipe sections less than 9 meters;

[0036] Figure 4 Positioning data table for single-head intersecting line cutting pipe section;

[0037] Figure 5 The data table for locating the pipe sections cut by the intersecting lines in the sub-plant area;

[0038] Figure 6 This is the intersection line inspection data table. DETAILED DESCRIPTION

[0039] The present invention will be described in detail below in conjunction with the accompanying drawings and specific embodiments. The exemplary embodiments and descriptions of the present invention are used to explain the present invention, but are not intended to limit the present invention.

[0040] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, upper end, lower end, top, bottom...) are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0041] In the present invention, unless otherwise clearly defined and limited, the term "connection" should be understood in a broad sense, for example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0042] In addition, in the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features; in addition, the technical solutions between the various embodiments can be combined with each other, but they must be based on the ability of ordinary technicians in the field to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0043] The present invention is further described in detail below in conjunction with the accompanying drawings.

[0044] Reference Figures 1 to 6 The present invention provides an efficient method for cutting, locating and inspecting the intersection line of pipe sections, comprising the following steps:

[0045] Data preparation: Before cutting, the size, shape, material and other relevant data of the pipe segment are fully collected to provide basic data support for subsequent operations, and the work is carried out based on the typical intersecting line cutting pipe segment production design drawings of the project. During the specific implementation, professional surveyors are arranged to use high-precision laser rangefinders, calipers, material analyzers and other tools to carefully measure each pipe segment. For example, for pipe diameter measurement, measurements are taken at multiple cross-sectional positions and different directions of the pipe segment to obtain the average value to ensure that the pipe diameter data is accurate to the millimeter level; for irregularly shaped pipe segments, a 3D modeling scanner is used to obtain its accurate geometric shape information; the chemical composition, hardness and other characteristics of the material are determined by a material analyzer. All these data are entered into a special pipe segment database for easy access and use in subsequent steps. In the early stage of the Saipem NFPS offshore platform steel pipe pile processing project, the surveying team spent nearly a week to conduct detailed surveys on 148 pipe segments one by one, laying a solid data foundation for the smooth progress of the entire project.

[0046] Pipe section preparation: Before the pipe section is hoisted onto the intersecting line cutting machine bracket, the cross quadrant is accurately marked at the end of the pipe section, at least the shortest point and the longest point are clearly marked. The operator uses professional marking tools, such as a square ruler and a marking needle with a scale, to first determine a vertical bisector based on the axial centerline of the pipe section, and then draw the cross quadrant line based on this to ensure the clarity and accuracy of the marking, and the error is controlled within a very small range. In the Saipem NFPS offshore platform steel pipe pile processing project, this simple operation reduced the initial positioning error by about 80% compared with the traditional method, greatly improving the accuracy of subsequent cutting, and the entire marking process takes no more than 5 minutes for a skilled worker to operate alone, saving valuable time for the project. When the specifications of the pipe section change, such as the increase in pipe diameter or the change in pipe section length, the operator only needs to follow the established process and adjust the marking position according to the new pipe section size, and the convenience of operation is not affected.

[0047] Data input: According to the positioning data table of the intersecting line cutting pipe segment, accurately input the pipe segment name, pipe specifications at both ends of the pipe segment, the angle of the through-mouth axis and the positioning value, and determine the direction of the main cutting end of the actual pipe segment on site (select the end with a larger pipe diameter as the main cutting end) by comparing with the drawings, and ensure that the shortest point of the intersecting line of the main cutting end faces directly upward. At the actual operation site, the technician sits in front of the operation console, facing the electronic form on the display screen, and carefully fills in the contents according to the data entered in the previous measurement. At the same time, a secondary check is carried out against the paper design drawings to ensure that the data is correct. Taking a complex pipe segment as an example, the diameters of the two ends are 2500mm and 1800mm respectively. The technician selects the 2500mm end as the main cutting end according to the rules, and adjusts the position of the pipe segment so that the shortest point of the intersecting line faces vertically upward, and then accurately enters the through-mouth axis angle of 30° and other positioning values, laying the foundation for subsequent precise cutting. Through this standardized process, the one-time success rate of cutting operations in this project has increased by about 25% compared with the past, effectively reducing the number of reworks. Even if design changes occur during the project execution, technicians only need to recheck and modify the data in the spreadsheet according to the new design drawings to quickly adapt to the changes and ensure the continuity of the cutting work.

[0048] Positioning calculation:

[0049] Double-head intersecting line cutting pipe segment positioning data table: The main cutting origin positioning value L1 of the double-head cutting pipe segment is determined according to the position of the first circumferential seam at the main cutting end. The on-site construction personnel first use the weld detection instrument to accurately locate the center position of the first circumferential seam at the main cutting end, and then use the measuring tool to use the center position as the reference, according to the established calculation formula and process standards, to determine the main cutting origin positioning value L1. In the large-scale production of such pipe segments, such as a certain offshore wind power conductor frame mass production project, after adopting this method, the efficiency of pipe segment docking is increased by about 30%, and the difficulty of assembly is significantly reduced. At the same time, due to the precise docking, the structural strength is effectively guaranteed, reducing the cost of subsequent maintenance and reinforcement. If the production process is adjusted, such as the improvement of the welding process resulting in changes in the position or size of the circumferential seam, the construction personnel only need to re-detect the center position of the circumferential seam and recalculate the main cutting origin positioning value L1 according to the new parameters to ensure the accuracy of cutting and assembly.

[0050] Double-end cutting positioning data table for short pipe sections less than 9 meters: For short pipe sections less than 9 meters that exceed the length range of the KR-HG1600 intelligent offshore double-end beveling robot, after the main cutting end is cut, the pipe is moved to the auxiliary cutting end by hoisting. Before cutting the auxiliary cutting end, the auxiliary cutting origin needs to be re-positioned according to the main cutting origin and L2 value. The main cutting origin positioning value L1 is also determined according to the position of the first annular seam of the main cutting end. When encountering such short pipe sections, the main cutting end is first cut according to the conventional process. After completion, the short pipe section is stably hoisted to the auxiliary cutting end position by a crane. The operator uses the measuring tool again to carefully adjust the position of the auxiliary cutting origin according to the main cutting origin data and L2 value (this value is determined in advance according to the pipe section design) to ensure that the cutting accuracy of both ends of the short pipe section is consistent. In a small offshore wind power project, due to the large-scale use of such short pipe sections, the scrap rate was reduced from the original 10% to 3% after the use of this method, which not only saved the cost of raw materials, but also ensured the progress of the project. If the length range or structural design of the short pipe section changes, it is only necessary to recalculate the L2 value according to the new parameters and re-precisely align the auxiliary cutting end to adapt to the new production needs.

[0051] Single-head intersecting line cutting pipe segment positioning data table: The main cutting origin positioning value L1 of the single-head intersecting line cutting pipe segment is determined according to the sub-head end of the pipe segment. The operator quickly determines the main cutting origin positioning value L1 based on the geometric characteristics of the sub-head end of the pipe segment, such as pipe diameter changes, groove shape, etc., combined with the pre-set algorithm. In an offshore wind power project that is under emergency repair, a large number of single-head pipe segments need to be cut quickly. By using this positioning method, the cutting efficiency is improved by about 40% compared with the traditional method, which meets the repair needs in a timely manner. At the same time, the cutting quality also meets the project requirements and ensures the safe operation of the facility. When the single-head structural design of the pipe segment changes, such as the adjustment of the groove angle or the sudden change of the pipe diameter, the operator re-determines the main cutting origin positioning value L1 according to the new geometric characteristics and the updated algorithm to ensure that the cutting accuracy is not affected.

[0052] The data table of the positioning of the pipe section cut by the intersection line of the sub-plant area: The intersection line of the secondary cutting end has been cut and formed in the external plant area, and the main cutting origin is determined according to the inner diameter endpoint of the secondary cutting end in the same quadrant and the positioning value L2. In the cross-plant collaborative project, such as a large offshore wind power project involving multiple plants in joint production, after the pipe section processed in the external plant is transported to the main plant area, the operator of the main plant area first receives the pipe section processing data provided by the external plant area, including the coordinates of the inner diameter endpoint of the secondary cutting end in the same quadrant, and then accurately finds the main cutting origin through the measuring tool based on the positioning value L2 (determined by the unified planning of the project). This collaborative method makes the cross-plant pipe section docking accuracy reach more than 98%, ensuring the continuity and accuracy of the pipe section processing of the entire project, promoting the optimal allocation of internal resources of the enterprise, and reducing the overall cost of the project. If the processing technology or equipment in the external plant area changes, affecting the processing accuracy of the secondary cutting end, the operator of the main plant area only needs to re-check the positioning value L2 according to the new secondary cutting end data to ensure the accuracy of the main cutting origin and ensure that the pipe section is docked correctly.

[0053] Cutting operation: After completing the positioning and calculation, strictly follow the positioning data and time cutting parameters to perform the pipe section cutting operation. Before cutting, mark the cutting origin at the main cutting end of the pipe section, and accurately align the origin mark before formal cutting. The operator uses a non-falling paint or metal marker to make a clear cutting origin mark at the main cutting end of the pipe section, and then uses a high-precision laser alignment instrument to accurately align the pipe section with the coordinate axis of the cutting machine to ensure that the cutting starting point is accurate. During the cutting process, the cutting machine runs smoothly according to the preset cutting parameters, such as cutting speed, groove angle, cutting current, etc. The cutting personnel monitor the cutting status in real time and immediately stop and adjust once an abnormality is found. Taking an offshore wind power project as an example, by strictly implementing the operation process, the flatness deviation of the cutting surface is controlled within ±0.5mm, and the dimensional accuracy deviation is controlled within ±1mm, providing high-quality components for subsequent assembly, which increases the success rate of assembly by about 35%. If the performance of the cutting machine is upgraded or the cutting process is improved, for example, the cutting speed can be greatly increased, the operator only needs to readjust the cutting parameter settings according to the new equipment parameters and process requirements to give full play to the advantages of the equipment while ensuring that the cutting quality is not affected.

[0054] Quality inspection: After cutting is completed, the unique high-precision pipe segment intersection line inspection method in the patent is used for quality inspection. According to the project pipe segment production design drawings, the theoretical distances of the inner diameter endpoints of the four quadrants of the pipe segment, namely the upper, middle (south), middle (north), and lower inner diameters are input; according to the data obtained by querying the cutting model, the theoretical value of the groove is input, and the intersection line inspection data table is output to carry out the pipe segment intersection line cutting inspection. The quality inspector uses professional measuring tools to measure the actual inner diameter endpoint distances of the four quadrants of the pipe segment again and compares them with the theoretical values. At the same time, according to the theoretical value of the groove queried by the cutting model, the actual groove angle, depth and other parameters are checked. The measured data is entered into a special inspection software to automatically generate an intersection line inspection data table, which clearly shows the deviation of each parameter. In the acceptance stage of a certain offshore wind power project, after adopting this inspection method, the defect detection rate increased by about 45% compared with the traditional method, ensuring that the quality of the factory pipe segment meets the standards, avoiding the flow of unqualified products into subsequent processes, and effectively guaranteeing the quality foundation of the entire project. If the quality standards of the project are improved, such as higher requirements for groove accuracy, quality inspectors only need to update the groove theoretical value in the inspection software and re-measure and compare according to the new standards to strictly control product quality and meet higher requirements.

[0055] Optimization and improvement: In actual applications, the positioning and inspection methods are continuously optimized and improved based on feedback and test results to continuously improve the accuracy and efficiency of pipe segment manufacturing. The project team regularly collects feedback from on-site operators, quality inspectors and customers, and conducts detailed analysis of the processing data and inspection results of each pipe segment. For example, if a certain type of pipe segment is found to have frequent groove angle deviation problems during the cutting process, the technicians will immediately conduct in-depth research, adjust the positioning calculation method or cutting parameters, and apply the improved method to subsequent projects after multiple tests and verifications. Through this continuous improvement mechanism, the company has successfully reduced the comprehensive error rate of pipe segment manufacturing by about 20% in the past year, enabling the method to adapt to the complex changes of different projects, providing technical support for the company's long-term stable production, and also establishing a leading image in technology in the industry, attracting more high-end project cooperation and promoting industrial upgrading. When new technological trends emerge in the industry, such as the application of new materials in pipe segment manufacturing, the project team will study the impact of new material characteristics on the cutting and inspection process in advance, and adjust the methods in a timely manner to ensure that the company always stands at the forefront of technology.

[0056] Key points of invention and points to be protected

[0057] The key points and points to be protected focus on the location and inspection methods of the intersecting line cutting of pipe sections. The full table compilation mode is adopted. Only the pipe section number, main cutting end data, auxiliary cutting end data and remarks need to be input to complete the construction of the intersecting line cutting location rules. The pipe section intersecting line cutting instructions produced by the software can successfully complete the pipe section intersecting line cutting task. Subsequently, the precision inspection and quality verification of the product before leaving the factory are realized based on the intersecting line cutting inspection form. Its core advantages are:

[0058] A complete technical work procedure for pipe segment intersecting line cutting is built, which can output pipe segment intersecting line cutting positioning data files, cutting instructions, and cutting inspection files to ensure efficient, standardized, and accurate completion of pipe segment intersecting line cutting operations. This not only improves the production efficiency of a single project, but also creates a standardized production process for the company, making it easier for the company to replicate successful experiences across multiple projects, rapidly expand production scale, and increase market share. For example, after adopting this technology, a certain company's project delivery cycle was shortened by an average of about 30%, and its market share increased by about 20% within a year.

[0059] We have devoted ourselves to studying the method of locating the intersection line of pipe sections, and carefully compiled a set of general classification positioning data tables and positioning precautions. Based on the requirements of later inspection and testing, we have carefully compiled a general inspection and testing table. With the help of Excel tools, these two tables are compiled into automatically generated general tables, so that they can be widely adapted to all projects of the same type. The design of the general table greatly enhances the applicability of this method. Regardless of the size of the project or how the specifications of the pipe sections change, the company only needs to fill in the table according to the actual situation to quickly start the cutting and inspection process, without the cost of re-developing methods for different projects, which improves the company's market competitiveness. The R&D cost has been reduced by about 40%, giving the company a greater price advantage in market competition and seizing more market opportunities.

[0060] Example:

[0061] The present invention relates to an efficient method for cutting, locating and inspecting the intersection line of pipe sections. The specific implementation method is as follows:

[0062] 1. Data preparation: Before cutting, first collect relevant data of the pipe segment, including size, shape, material and other information, to provide basic data support for subsequent positioning and cutting. The typical production design drawing of the intersecting line cutting pipe segment of this project is shown in Figure 1 .

[0063] 2. Pipe section preparation: Before the pipe section is hoisted onto the intersecting line cutting machine bracket, a cross quadrant line must be drawn at the end of the pipe section (at least the lines of the shortest point and the longest point must be drawn).

[0064] 3. Data input: According to the intersection line cutting pipe segment positioning data table, input the pipe segment name, pipe specifications at both ends of the pipe segment, the angle of the through-mouth axis and the positioning value, and refer to the drawings to determine the direction of the main cutting end of the pipe segment actually produced on site (select the end with a larger pipe diameter as the main cutting end), and note that the shortest point of the intersection line of the main cutting end is facing directly upwards.

[0065] 4. Positioning calculation: Based on the collected data, accurate positioning calculation is performed to determine the position and angle of the pipe section during the cutting process to ensure that the cut pipe section can be accurately connected. There are four types of positioning data tables for intersecting line cutting pipe sections according to the project situation.

[0066] a. Double-end intersecting line cutting pipe segment positioning data table, refer to Figure 2 .

[0067] The main cutting origin positioning value L1 of the double-head cutting pipe section is determined according to the position of the first annular seam at the main cutting end.

[0068] b. Double-end cutting positioning data table for short pipe sections less than 9 meters, refer to Figure 3 .

[0069] Short pipe sections less than 9 meters are beyond the length range of the KR-HG1600 intelligent offshore engineering double-end beveling robot. In order to meet the project's multi-specification pipe section cutting requirements, after the main cutting end is cut, the pipe is moved to the secondary cutting end through hoisting. Before cutting the secondary cutting end, the secondary cutting origin must be realigned according to the main cutting origin and L2 value. The main cutting origin positioning value L1 is determined according to the position of the first annular seam at the main cutting end.

[0070] c. Single-head intersecting line cutting pipe segment positioning data table, refer to Figure 4 .

[0071] The main cutting origin positioning value L1 of the single-head intersecting line cutting pipe section is determined according to the secondary head end of the pipe section.

[0072] d. Data table of location of intersecting line cutting pipe sections in sub-plant areas, refer to Figure 5 .

[0073] The intersection line of the auxiliary cutting end has been cut and formed in the outer factory area, and the main cutting origin is determined according to the inner diameter endpoint in the same quadrant of the auxiliary cutting end and the positioning value L2.

[0074] 5. Cutting operation: After positioning and calculation are completed, the pipe section cutting operation is carried out. During the cutting process, the positioning data and cutting parameters are strictly followed to ensure the cutting quality and accuracy. Before the intersection line cutting, the cutting origin mark should be made at the main cutting end of the pipe section, and the origin mark should be aligned before the formal cutting.

[0075] 6. Quality inspection: After cutting, the high-precision pipe segment intersection line inspection method described in the patent is used for quality inspection. Through inspection, it is ensured that the cut pipe segment meets the project requirements and has no quality defects. According to the project pipe segment production design drawings, input the theoretical distances of the inner diameter endpoints of the four quadrants of the pipe segment, namely the upper, middle (south), lower, and middle (north); according to the data obtained from the cutting model query, input the groove theoretical value, output the intersection line inspection data table, and conduct the pipe segment intersection line cutting inspection. Reference Figure 6 .

[0076] 7. Optimization and improvement: In actual applications, based on feedback and test results, the positioning and inspection methods are continuously optimized and improved to improve the accuracy and efficiency of pipe segment manufacturing.

[0077] In practical application, take the Saipem NFPS offshore platform steel pipe pile processing project as an example:

[0078] First, for the 148 pipe sections that needed to be cut at the intersection, their detailed dimensions, shapes, characteristics and material information were collected one by one and organized and archived.

[0079] During the pipe section preparation phase, before hoisting it to the KR-HG1600 intelligent offshore double-end beveling robot bracket, workers used professional tools to carefully draw cross quadrant lines on the ends of the pipe sections, highlighting the lines of the shortest and longest points, laying the foundation for subsequent precise positioning.

[0080] During the data input stage, the operator will select the corresponding positioning data table according to the type of pipe segment, such as the corresponding positioning data table for the double-head intersecting line cutting pipe segment. Figure 2 In the data table shown, strictly input the pipe section name, pipe diameter specifications at both ends, through-hole axis angle and positioning value. At the same time, refer to the design drawings to accurately determine the direction of the main cutting end to ensure that the shortest point of the intersection line of the main cutting end is vertically upward.

[0081] During the positioning calculation process, for double-headed cut pipe sections, the main cutting origin positioning value L1 is determined based on the actual position of the first annular seam at the main cutting end; after the short pipe section less than 9 meters is cut at the main cutting end, it is hoisted and moved according to the process, and the secondary cutting end is accurately re-aligned with the secondary cutting origin based on the main cutting origin and the L2 value; for single-headed cut pipe sections, the main cutting origin positioning value L1 is determined based on the secondary head end; when the sub-factories work together, the main cutting origin is locked based on the inner diameter endpoint in the same quadrant of the secondary cutting end that has been cut in the external factory area and the L2 value.

[0082] During the cutting operation, after completing the above steps, the operator strictly controls the KR-HG1600 intelligent marine engineering double-head beveling robot according to the established positioning data. Before cutting, a clear cutting origin mark is made on the main cutting end, and the robot is carefully aligned to ensure cutting accuracy.

[0083] During the quality inspection phase, inspectors accurately input the theoretical distances between the inner diameter endpoints of the four quadrants of the pipe segment based on the project pipe segment production design drawings, enter the theoretical values ​​of the grooves in combination with the cutting model query data, generate an intersection line inspection data table, and strictly check the cutting quality of the intersection lines of the pipe segments based on the table.

[0084] During the entire project process, the project team continued to collect feedback information, and based on the actual cutting effects, inspection results, and production adjustment needs, continuously optimized the positioning and inspection methods, such as fine-tuning the positioning data table parameters, improving the inspection table algorithm, etc., to continuously improve the efficiency and quality of pipe segment manufacturing.

[0085] 6. Advantages compared with existing technologies

[0086] For projects with complex material quantity specifications, the present invention can increase the efficiency of compiling pipe section intersection line positioning data and inspection tables by several times by relying on full table compilation and precise algorithms, and the accuracy rate approaches 100%. The traditional manual compilation method is not only inefficient, but also prone to errors.

[0087] The time for proofreading the pipe cutting data is greatly reduced. The proofreading work that originally required a lot of man-hours can be completed in a short time with the help of the present invention, which significantly reduces the labor cost. At the same time, it ensures that the pipe segment production accuracy is stable at a high standard. Traditional manual proofreading is prone to loss of accuracy due to fatigue, negligence, etc.

[0088] In the face of design changes and production adjustments, the present invention relies on a flexible table structure and intelligent algorithms, and the pipe section intersection line positioning data and inspection tables can be modified simply and quickly, and can quickly adapt to new working conditions. The traditional method requires recalculating a large amount of data, which is time-consuming and labor-intensive.

[0089] The present invention uses digital tables and software to facilitate data management and sharing. Personnel at all levels of the construction site can obtain accurate data in real time, promoting smooth production. In the traditional mode, data circulation is not smooth and is easily lost, delaying production.

[0090] The present invention has excellent versatility. Through well-designed universal forms and standardized processes, it is applicable to all projects of the same type and can operate efficiently regardless of changes in project scale and pipe section specifications. Traditional methods are often limited to specific projects and have poor adaptability.

[0091] In summary, the present invention helps wind power companies overcome technical difficulties in overseas projects, enables them to gain a firm foothold in the fierce international market competition with advanced technology, opens up a broader profit space, and promotes my country's wind power industry from the domestic saturation dilemma to the international high-end manufacturing field. On the one hand, precise cutting and inspection technology can effectively reduce the scrap rate, reduce the waste of raw materials, and directly save production costs; on the other hand, high-quality products can win the trust of international customers, obtain more orders, and enhance the international influence of the brand, thereby achieving significant growth in revenue.

[0092] The present invention ensures the high-quality construction of offshore wind power project structures, indirectly improves the stability and reliability of offshore wind power facilities, promotes the efficient development and utilization of clean energy, and has positive significance for the global sustainable energy development strategy. Stable and reliable wind power facilities can reduce the frequency of fault repairs, reduce operation and maintenance costs, continuously and stably deliver clean energy to the power grid, help cope with climate change, and achieve green development goals.

[0093] The technical solutions provided by the embodiments of the present invention are introduced in detail above. Specific examples are used herein to illustrate the principles and implementation methods of the embodiments of the present invention. The description of the above embodiments is only applicable to help understand the principles of the embodiments of the present invention. At the same time, for those skilled in the art, according to the embodiments of the present invention, there will be changes in the specific implementation methods and application scopes. In summary, the content of this specification should not be understood as limiting the present invention.

Claims

1. An efficient method for cutting, locating and inspecting the intersection line of pipe sections, characterized in that: The following steps are involved: Step S1, data preparation step: before cutting, collect the size, shape, and material information of the pipe section to provide basic data support for subsequent positioning and cutting; Step S2, pipe section preparation step: before the pipe section is hoisted onto the intersecting line cutting machine support, a cross quadrant is drawn at the end of the pipe section, at least the lines of the shortest point and the longest point are drawn; Step S3, data input step: input the pipe segment name, pipe specifications at both ends of the pipe segment, the angle of the through-mouth axis and the positioning value according to the intersecting line cutting pipe segment positioning data table, and determine the direction of the main cutting end of the pipe segment actually manufactured on site by comparing with the drawings, select the end with a larger pipe diameter as the main cutting end, and the shortest point of the intersecting line of the main cutting end faces directly upwards; Step S4: Positioning calculation step: For the double-head intersecting line cutting pipe section, the main cutting origin positioning value L1 of the double-head cutting pipe section is determined according to the position of the first annular seam at the main cutting end; For double-end cutting of short pipe sections less than 9 meters, after the main cutting end is cut, the pipe is moved to the auxiliary cutting end by hoisting. Before cutting the auxiliary cutting end, the auxiliary cutting origin needs to be re-positioned according to the main cutting origin and L2 value. The main cutting origin positioning value L1 is determined according to the position of the first annular seam at the main cutting end; For a single-head intersecting line cutting pipe section, the main cutting origin positioning value L1 of the single-head intersecting line cutting pipe section is determined according to the secondary head end of the pipe section; For the intersecting line cutting pipe section in the branch plant area, the intersecting line at the auxiliary cutting end has been cut and formed in the outer plant area, and the main cutting origin is determined according to the inner diameter endpoint in the same quadrant of the auxiliary cutting end and the positioning value L2; Step 5, cutting operation steps: After positioning and calculation are completed, the pipe segment cutting operation is carried out according to the positioning data and cutting parameters. Before cutting, the cutting origin mark is made at the main cutting end of the pipe segment, and the origin mark is ensured to be aligned before formal cutting; Step S6, quality inspection step: after the cutting is completed, a high-precision pipe segment intersection line inspection method is used for quality inspection. According to the project pipe segment production design drawings, the theoretical distances of the four quadrant points of the pipe segment, i.e., the upper, middle south, middle north, and lower inner diameter endpoints are input. According to the data obtained by querying the cutting model, the groove theoretical value is input, and the intersection line inspection data table is output to perform the pipe segment intersection line cutting inspection; Step S7, optimization and improvement step: In actual application, feedback information and test results are collected, and the positioning and inspection methods are adjusted and optimized based on the feedback information and test results.

2. According to claim 1, an efficient pipe segment intersection line cutting positioning and inspection method is characterized by: The intersecting line cutting pipe segment positioning data table is compiled in a full table format, and the pipe segment number, main cutting end data, auxiliary cutting end data and remarks are filled in as required, so as to complete the establishment of the intersecting line cutting positioning rules, and the pipe segment intersecting line cutting instructions produced by the software are combined to realize the pipe segment intersecting line cutting.

3. The efficient pipe segment intersection line cutting positioning and inspection method according to claim 1 is characterized in that: The intersection line inspection data table output by the pipe section intersection line inspection method is used for accuracy verification and quality control of the pipe section before it leaves the factory.

4. The efficient pipe segment intersection line cutting positioning and inspection method according to claim 1 is characterized in that: The method constructs a complete technical working procedure for pipe segment intersecting line cutting, and generates pipe segment intersecting line cutting positioning data files, cutting instructions, and cutting inspection files.

5. The efficient pipe segment intersection line cutting positioning and inspection method according to claim 1 is characterized in that: The method includes a set of general classification positioning data tables and positioning precautions, as well as a general inspection and testing table compiled according to the requirements of subsequent inspection and testing. The Excel tool is used to compile the above two tables into an automatically generated general table, so that it is applicable to all projects of the same type.

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