Ball valve end face automatic surfacing method based on AB PLC

Abstract

The invention provides an AB PLC-based ball valve end face automatic surfacing method, which relates to the technical field of automatic welding, and comprises the steps of performing three-dimensional modeling, geometric feature analysis and surfacing path planning on a ball valve by using an AB PLC system, controlling the motion trail of surfacing equipment, and monitoring and adjusting the position and posture of a welding gun at the same time. The modeling precision, the angle deviation threshold value and the like are strictly set, and control over parameters such as the wire feeding speed, the welding current and the temperature in the surfacing welding process is elaborated in detail. The invention further relates to quality detection after surfacing, communication with an upper computer, cooperative work of multiple devices and the like. The surfacing precision is improved, and it is guaranteed that surfacing layers are uniform and consistent; the efficiency is remarkably improved, and the large-scale production requirement is met; surfacing quality is ensured, and cost is reduced; the device adapts to different ball valve specifications; and intelligent management and data security are realized. And many problems of a traditional surfacing method are effectively solved, and the method has wide application value and remarkable economic and social benefits.

Description

Technical Field

[0001] The present invention belongs to the technical field of automated welding, and more specifically, particularly relates to a method for automatic surfacing of the end face of a ball valve based on an AB PLC. Background Art

[0002] In modern industry, as an important control component, the ball valve is widely used in many fields such as petroleum, chemical industry, and natural gas. The end face quality of the ball valve directly affects its sealing performance and service life. Therefore, the surfacing process of the ball valve end face is crucial.

[0003] Traditional methods for surfacing the end face of a ball valve mainly rely on manual operation, and there are many problems with this approach. First of all, it is difficult to ensure the accuracy and consistency of surfacing by manual operation. Due to the subjectivity and uncertainty of manual operation, it is very difficult to precisely control the position, posture, and welding parameters of the welding torch, resulting in uneven thickness of the surfacing layer, poor flatness, and easy occurrence of defects such as pores and slag inclusions, thereby affecting the sealing performance and service life of the ball valve.

[0004] Secondly, the efficiency of manual surfacing is extremely low. Workers need to concentrate for a long time to operate, which not only has a high labor intensity but also a slow working speed, and it is difficult to meet the requirements of large-scale production in modern industry. When faced with a large number of ball valve production tasks, manual surfacing often becomes a bottleneck in the production process, severely restricting the improvement of production efficiency.

[0005] Furthermore, it is difficult to control the quality in manual surfacing. Due to the lack of real-time and precise monitoring means, it is difficult to detect and correct problems in a timely manner during the surfacing process. Defects are often only discovered during the inspection after surfacing is completed, resulting in a large amount of rework and material waste, increasing production costs.

[0006] In addition, traditional surfacing processes have poor adaptability when dealing with ball valves of different materials, sizes, and hardness requirements. It is often necessary to redesign the surfacing plan and adjust the process parameters for different ball valve specifications and requirements, which is a cumbersome process and prone to errors.

[0007] At the same time, for the data generated during the surfacing process, there are no effective means of recording and analyzing it, and it is impossible to form a valuable process database, making it difficult to optimize and improve the process, and it is also not conducive to the quality traceability and problem troubleshooting of subsequent products.

[0008] In terms of data security, traditional surfacing processes usually do not have perfect data encryption and protection measures, and there is a risk of leakage of key data during the surfacing process, such as process parameters and product information, which may cause potential losses to the enterprise.

[0009] With the continuous development of industrial automation technology, the traditional surfacing method for the end face of ball valves can no longer meet the increasingly high production requirements and quality standards. To solve these problems, improve the accuracy, efficiency, and quality of the end face surfacing of ball valves, reduce costs, enhance process adaptability, achieve intelligent management, and ensure data security, it has become an urgent task to develop an automatic end face surfacing method for ball valves based on AB PLC. Summary of the Invention

[0010] To solve the above technical problems, the present invention provides an automatic end face surfacing method for ball valves based on AB PLC to solve the above problems.

[0011] An automatic end face surfacing method for ball valves based on AB PLC includes the following steps:

[0012] S1: Use the AB PLC system to perform three-dimensional modeling on the ball valve. The radius of the ball valve is R and the thickness is H. The modeling formula is M = f(R, H), where f(R, H) = 0.5R 2 H + 0.2RH 2 ;

[0013] S2: Analyze the geometric features of the end face of the ball valve, where the angle deviation threshold α ≤ 3°;

[0014] S3: According to the geometric features, plan the surfacing path, and the path interval L = 0.4R - 0.08R;

[0015] S4: Control the movement trajectory of the surfacing equipment through AB PLC, so that the welding torch moves along the planned surfacing path. At the same time, monitor and adjust the position and posture of the welding torch in real time. The position deviation X ≤ 0.15 mm, and the posture deviation θ ≤ 2°.

[0016] Preferably, in S1, the three-dimensional modeling of the ball valve is specifically as follows:

[0017] A1: By collecting the dimensional parameters of the ball valve, the radius measurement accuracy is ±0.08 mm, and the thickness measurement accuracy is ±0.03 mm;

[0018] A2: Build a three-dimensional model of the ball valve in the AB PLC system and optimize the model. The number of optimization iterations N ≥ 5 times, and the optimization function is G(N) = N 2 -2N + 3.

[0019] Preferably, the planning of the surfacing path in S3 is specifically as follows:

[0020] B1: Consider the material of the end face of the ball valve, and the material hardness range is HRC[45, 55];

[0021] B2: Combine the thickness and welding process requirements to generate the optimal surfacing path. The welding speed V = 6 - 7 mm / s, and the welding speed adjustment formula is V' = V + 0.2(T - T0), where T is the real-time temperature and T0 is the preset reference temperature.

[0022] Preferably, during the surfacing process, use an AB PLC to control the wire feeding speed. The wire feeding speed S = 3.5 - 4.5 m / min;

[0023] Control the welding current. The current range I = 180 - 220 A, and the current adjustment formula is I' = I + 10log(P - P0), where P is the real-time power and P0 is the preset reference power.

[0024] Preferably, during the surfacing process, use a temperature sensor in the AB PLC system to monitor the temperature of the surfacing area in real time. The accuracy of the temperature sensor is ±0.5 °C;

[0025] When the temperature exceeds the preset threshold T = 750 °C, automatically pause the surfacing and start the cooling system. After the temperature drops to the safe range T' = 450 °C, continue the surfacing. The cooling rate is controlled at 10 - 15 °C / s.

[0026] Preferably, when controlling the movement of the surfacing equipment, use an AB PLC to control the movement speed of the surfacing equipment. The speed range V' = 0.6 - 0.9 m / min;

[0027] Control the acceleration. The acceleration range a = 0.15 - 0.25 m / s 2 , and the acceleration adjustment formula is a' = a + 0.05sin(ωt), where ω is the angular frequency and t is the time.

[0028] Preferably, during data recording and analysis:

[0029] Use an AB PLC to record and analyze various parameters during the surfacing process;

[0030] Form a surfacing process database. The storage capacity of the database is not less than 200 GB. Use a data compression algorithm C. The data compression algorithm C can be an improved version of the LZ77 algorithm based on dictionary coding. This algorithm first creates a dynamically updated dictionary that stores previously appeared string fragments. When compressing data, the algorithm searches for string fragments that match those in the dictionary in the current input data and uses pointers and lengths to represent these matches instead of directly storing the repeated string content. At the same time, for new string fragments that have not appeared in the dictionary, they are directly stored in their original form. In this way, while ensuring a high compression ratio, the computational complexity is reduced, and the compression and decompression speeds are increased. The compression ratio is not less than 3:1, providing a reference for subsequent surfacing of similar ball valves.

[0031] Preferably, after surfacing is completed, an AB PLC is used to control a detection device to automatically detect the quality of the surfacing layer, and the detection accuracy is not less than 0.005 mm;

[0032] Defect recognition algorithm D is adopted. Defect recognition algorithm D is a convolutional neural network (CNN) algorithm based on deep learning. First, a large number of surfacing layer images containing various types of defects are collected as training data, and the defects in these images are labeled. Then, a CNN model with multiple convolutional layers and pooling layers is constructed, and the model is trained through the backpropagation algorithm to learn the characteristic patterns of different defects;

[0033] In practical applications, the surfacing layer image to be detected is input into the trained model, and the model will automatically extract the image features and output information such as the type, location, and size of the defects. To improve the recognition accuracy, data augmentation techniques can also be used to increase the diversity of the training data, and an attention mechanism can be introduced to focus on the key areas in the image. The recognition accuracy is not less than 95%. If the detection is unqualified, surfacing repair is carried out again.

[0034] Preferably, the AB PLC system communicates with a host computer, the communication baud rate is 38400 bps, and encryption algorithm E is used to encrypt the communication data. Encryption algorithm E is the Advanced Encryption Standard (AES) algorithm. AES is a symmetric encryption algorithm, usually using a key length of 128 bits, 192 bits, or 256 bits, and the encryption strength is not less than 128 bits, realizing remote monitoring and operation, and being able to receive external instructions to adjust the surfacing process in real time. The process of AES encryption can be expressed as:

[0035] C = E(K, P), where C represents the ciphertext, K represents the key, P represents the plaintext, and E represents the encryption operation.

[0036] Preferably, multiple sets of surfacing devices work simultaneously, and the number of devices is not less than 3 sets. They are uniformly coordinated and controlled by an AB PLC to improve the surfacing efficiency. The efficiency improvement ratio is not less than 50%, and the response time of device cooperative control algorithm F does not exceed 50 ms.

[0037] Compared with the prior art, the present invention has the following beneficial effects:

[0038] In the present invention, through precise three-dimensional modeling and geometric feature analysis, the surfacing path can be accurately planned, and the position and attitude deviation of the welding torch can be controlled within a very small range (such as the position deviation X ≤ 0.15 mm, the attitude deviation θ ≤ 2°), thereby ensuring the uniformity and consistency of the surfacing layer. The significant improvement in the flatness of the surfacing layer and the substantial reduction in the number of defects in the examples have both proved the improvement of the surfacing accuracy.

[0039] In the present invention, an AB PLC system is adopted to achieve full automation control, reducing the time for manual intervention and adjustment. In multiple embodiments, the time required to complete the surfacing of a single ball valve is significantly shortened compared to traditional methods, and the efficiency improvement ratio is not less than 50%. The collaborative work of multiple surfacing devices and optimized process parameters further accelerate the surfacing process.

[0040] In the present invention, key parameters during the welding process, such as welding speed, wire feeding speed, welding current, and temperature, are monitored and adjusted in real time to ensure the stability and reliability of the surfacing process. High-precision quality inspection means can timely detect and repair defects, improving the quality and performance of the surfacing layer.

[0041] In the present invention, high-efficiency surfacing reduces labor costs and time costs. Precise parameter control reduces material waste, thereby reducing material costs. Fewer defects and rework reduce equipment maintenance costs.

[0042] In the present invention, it is capable of adapting to the surfacing of ball valve end faces with different material, size, and hardness requirements, and can meet diverse production needs by flexibly adjusting process parameters.

[0043] In the present invention, various parameters during the surfacing process are recorded and analyzed to form a process database, providing a reference and optimization basis for subsequent production, and realizing intelligent process management and quality traceability.

[0044] In the present invention, the communication with the host computer adopts an encryption algorithm to ensure the security and confidentiality of production data and prevent the leakage of important information. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Figure 1 is the main process schematic diagram of the present invention;

[0046] Figure 2 is the content schematic diagram of each main process in the present invention;

[0047] Figure 3 is the schematic diagram of S1 in the present invention;

[0048] Figure 4 is the schematic diagram of S3 in the present invention;

[0049] Figure 5 is the numerical schematic diagram of wire feeding speed and current during the surfacing process in the present invention;

[0050] Figure 6 is the schematic diagram of the temperature sensor during the surfacing process in the present invention;

[0051] Figure 7 is the schematic diagram of the speed relationship during the surfacing process in the present invention;

[0052] Figure 8 It is a schematic diagram of data recording and analysis in the present invention;

[0053] Figure 9 It is a schematic diagram of automatic detection after surfacing welding in the present invention;

[0054] Figure 10 It is a schematic diagram of parameters for communication between the AB PLC system and the host computer in the present invention. Specific embodiments

[0055] Ball valves have wide applications in the industrial field, and the quality and performance of their end faces are crucial for the overall performance and service life of the ball valves. Traditional surfacing welding methods for ball valve end faces often rely on manual operations, which are not only inefficient but also difficult to guarantee the quality. The automatic surfacing welding method for ball valve end faces based on AB PLC proposed by the present invention aims to improve the precision, efficiency, and quality of surfacing welding, and realize the automation and intelligence of ball valve end face surfacing welding. The following further describes the implementation manners of the present invention in detail with reference to the accompanying drawings and embodiments. The following embodiments are used to illustrate the present invention, but cannot be used to limit the scope of the present invention.

[0056] An automatic surfacing welding method for ball valve end faces based on AB PLC includes the following steps:

[0057] S1: Use the AB PLC system to perform three-dimensional modeling on the ball valve. The radius of the ball valve is R, and the thickness is H. The modeling formula is M = f(R, H), where f(R, H) = 0.5R 2 H + 0.2RH 2 ;

[0058] S2: Analyze the geometric features of the ball valve end face, where the angle deviation threshold α ≤ 3°;

[0059] S3: According to the geometric features, plan the surfacing welding path, and the path interval L = 0.4R - 0.08R;

[0060] S4: Control the movement trajectory of the surfacing welding equipment through AB PLC, so that the welding torch moves along the planned surfacing welding path, and at the same time, the position and attitude of the welding torch are monitored and adjusted in real time. The position deviation X ≤ 0.15 mm, and the attitude deviation θ ≤ 2°.

[0061] In S1, performing three-dimensional modeling on the ball valve specifically includes:

[0062] A1: Collect the size parameters of the ball valve. The radius measurement accuracy is ±0.08 mm, and the thickness measurement accuracy is ±0.03 mm;

[0063] A2: Build a three-dimensional model of the ball valve in the AB PLC system and optimize the model. The number of optimization iterations N ≥ 5 times, and the optimization function is G(N) = N 2-2N + 3

[0064] The planned surfacing path in S3 is specifically as follows:

[0065] B1: Consider the material of the ball valve end face, and the material hardness range is HRC[45, 55];

[0066] B2: Combine the thickness and welding process requirements to generate the optimal surfacing path. The welding speed V = 6 - 7 mm / s, and the welding speed adjustment formula is V' = V + 0.2(T - T0), where T is the real-time temperature and T0 is the preset reference temperature.

[0067] During the surfacing process, use an AB PLC to control the wire feeding speed. The wire feeding speed S = 3.5 - 4.5 m / min, control the welding current, and the current range I = 180 - 220 A. The current adjustment formula is I' = I + 10log(P - P0), where P is the real-time power and P0 is the preset reference power.

[0068] Example 1:

[0069] Parameters of the ball valve to be surfaced:

[0070] Radius R = 50 mm;

[0071] Thickness H = 20 mm.

[0072] 3D modeling:

[0073] Use high-precision measuring tools to collect the dimensional parameters of the ball valve. The measured radius is 50.02 mm (accuracy of ±0.08 mm), and the measured thickness is 19.98 mm (accuracy of ±0.03 mm).

[0074] According to the modeling formula M = 0.5×50 2 ×20 + 0.2×50×20 2 = 250000 + 40000 = 290000, and build a 3D model of the ball valve in the AB PLC system.

[0075] Geometric feature analysis:

[0076] Analyze the geometric features of the ball valve end face. The angle deviation threshold α is set to 3°, and the actual measured angle deviation is 2°, meeting the requirements.

[0077] Surfacing path planning:

[0078] Consider the material of the ball valve end face to be stainless steel with a hardness of HRC50.

[0079] Combine the thickness and welding process requirements to generate the optimal surfacing path. The path interval L = 0.4×50 - 0.08×50 = 16 mm.

[0080] The welding speed is set at 6.5 mm / s.

[0081] Surfacing process control:

[0082] The wire feeding speed is set at 4 m / min.

[0083] The welding current is set at 200 A.

[0084] The temperature of the surfacing area is monitored in real time by a temperature sensor. The accuracy of the temperature sensor is ±0.5 °C. The real-time temperature is 700 °C, which does not exceed the preset threshold of 750 °C, and surfacing continues.

[0085] Surfacing equipment motion control:

[0086] The motion speed is controlled at 0.8 m / min.

[0087] The acceleration is controlled at 0.2 m / s 2 .

[0088] Data recording and analysis:

[0089] Use AB PLC to record and analyze various parameters during the surfacing process.

[0090] A surfacing process database is formed. The surfacing data this time is successfully stored, and the current storage capacity of the database is 50 GB.

[0091] Surfacing quality inspection:

[0092] After surfacing is completed, use inspection equipment to automatically inspect the surfacing layer. The inspection accuracy is 0.005 mm, and no defects are found.

[0093] Communication and control:

[0094] The AB PLC system communicates with the host computer at a baud rate of 38400 bps, and the data transmission is stable.

[0095] Use the AES encryption algorithm to encrypt the communication data. The encryption strength is 128 bits to ensure data security.

[0096] Efficiency evaluation:

[0097] Using this automatic surfacing method, the time required to complete the surfacing of a single ball valve end face is 30 minutes. Compared with the traditional manual surfacing method (60 minutes), the efficiency is increased by 50%.

[0098] Example 2:

[0099] Ball valve parameters to be surfaced:

[0100] Radius R = 80 mm;

[0101] The thickness H = 30 mm.

[0102] 3D modeling:

[0103] Collect the size parameters of the ball valve. The measured radius is 80.05 mm (accuracy of ±0.08 mm), and the measured thickness is 29.97 mm (accuracy of ±0.03 mm).

[0104] Modeling formula calculation: M = 0.5 × 80 2 × 30 + 0.2 × 80 × 30 2 = 960000 + 144000 = 1104000, and a 3D model is constructed.

[0105] Geometric feature analysis:

[0106] The angle deviation threshold α is 3°, and the actual angle deviation is 2.5°, meeting the requirements.

[0107] Surfacing path planning:

[0108] The material of the ball valve end face is alloy steel with a hardness of HRC48.

[0109] The surfacing path interval L = 0.4 × 80 - 0.08 × 80 = 25.6 mm, and the welding speed is 6 mm / s. Surfacing process control:

[0110] The wire feeding speed is 3.8 m / min, and the welding current is 190 A.

[0111] The real-time monitored temperature is 680 °C, which does not exceed the threshold, and surfacing continues.

[0112] Surfacing equipment motion control:

[0113] The motion speed is 0.7 m / min, and the acceleration is 0.18 m / s 2 .

[0114] Data recording and analysis:

[0115] Record and analyze the surfacing parameters, and the storage capacity of the database is increased to 80 GB.

[0116] Surfacing quality inspection:

[0117] The inspection accuracy is 0.005 mm, and no defects are found.

[0118] Communication and control:

[0119] The communication is normal, and the encryption is effective.

[0120] Efficiency evaluation:

[0121] It takes 45 minutes to complete surfacing, while the traditional method takes 90 minutes, with a 50% efficiency improvement.

[0122] Example 3:

[0123] Parameters of the ball valve to be surfacing welded:

[0124] Radius R = 60 mm;

[0125] Thickness H = 25 mm.

[0126] Three-dimensional modeling:

[0127] The measured radius is 59.96 mm (accuracy ±0.08 mm), and the measured thickness is 25.01 mm (accuracy ±0.03 mm).

[0128] Modeling: M = 0.5×60 2 ×25 + 0.2×60×25 2 = 450000 + 75000 = 525000.

[0129] Geometric feature analysis:

[0130] The angle deviation threshold α is 3°, and the actual deviation is 1.8°.

[0131] Surfacing welding path planning:

[0132] The material is cast iron, and the hardness is HRC52.

[0133] Path interval L = 0.4×60 - 0.08×60 = 19.2 mm, and the welding speed is 7 mm / s.

[0134] Surfacing welding process control:

[0135] Wire feeding speed is 4.2 m / min, and the welding current is 210 A.

[0136] The real-time temperature is 720 °C, not exceeding the threshold.

[0137] Surfacing welding equipment motion control:

[0138] Motion speed is 0.85 m / min, and the acceleration is 0.22 m / s 2 .

[0139] Data recording and analysis:

[0140] The data recording is complete, and the database storage capacity reaches 120 GB.

[0141] Surfacing welding quality inspection:

[0142] The inspection accuracy is 0.005 mm, and there are no defects.

[0143] Communication and control:

[0144] The communication is good, and the encryption is reliable.

[0145] Efficiency evaluation:

[0146] This method takes 35 minutes, while the traditional method takes 70 minutes, with a 50% increase in efficiency.

[0147] To further highlight the advantages of the present invention, the following comparative examples are set:

[0148] Comparative Example 1: Traditional manual surfacing method:

[0149] The parameters of the ball valve to be surfaced are the same as those in Example 1, with a radius R = 50 mm and a thickness H = 20 mm. Surfacing process:

[0150] The surfacing operation is carried out relying on manual experience, and the surfacing path planning is not precise enough.

[0151] Parameters such as welding speed, wire feeding speed, and current are difficult to control precisely.

[0152] Surfacing result:

[0153] The quality of the surfacing layer is uneven, with local defects.

[0154] It takes 60 minutes to complete the surfacing.

[0155] Comparative Example 2: Surfacing method using simple automation equipment but without AB PLC control: The ball valve parameters are the same as those in Example 2, with a radius R = 80 mm and a thickness H = 30 mm.

[0156] Surfacing process:

[0157] The control accuracy of the automation equipment is relatively low, and the parameters cannot be adjusted in real time.

[0158] The temperature monitoring is not accurate enough, and overheating or overcooling is likely to occur.

[0159] Surfacing result:

[0160] The quality stability of the surfacing layer is poor.

[0161] It takes 75 minutes to complete the surfacing.

[0162] Experimental example:

[0163] To more intuitively show the effect of the present invention, the following experimental examples are carried out, and comparative analysis is carried out through detailed data and tables:

[0164] Experimental Example 1: Comparison of surfacing quality:

[0165]

[0166] Experimental Example 2: Comparison of efficiency:

[0167]

[0168] Experimental Example 3: Cost Comparison:

[0169]

[0170]

[0171] As can be seen from the above-mentioned multiple embodiments, comparative examples and experimental examples, the automatic surfacing method for the end face of the ball valve based on AB PLC of the present invention has significant advantages in terms of surfacing quality, efficiency and cost, and can effectively meet the high-quality and high-efficiency requirements of ball valve production.

[0172] The differences between Embodiments 1, 2 and 3 are as follows:

[0173] The parameters of the ball valve to be surfaced are different:

[0174] In Embodiment 1, the radius of the ball valve is 50 mm and the thickness is 20 mm.

[0175] In Embodiment 2, the radius of the ball valve is 80 mm and the thickness is 30 mm.

[0176] In Embodiment 3, the radius of the ball valve is 60 mm and the thickness is 25 mm.

[0177] There are differences in the specific parameters during the surfacing process: for example, the surfacing path interval, welding speed, wire feeding speed, welding current, movement speed and acceleration of the surfacing equipment, etc.;

[0178] Through the embodiments of ball valves with different sizes and parameters, it is proved that the automatic surfacing method for the end face of the ball valve based on AB PLC of the present invention can be effectively applied to ball valves of different specifications, is not limited by the size of the ball valve, demonstrates the wide applicability of the method, and different combinations of ball valve parameters and surfacing parameters represent various actual working conditions that may be encountered. Through these embodiments, the performance of the present invention under various conditions, such as the stability and reliability in terms of surfacing quality, efficiency, cost, etc., can be understood. By comparing and analyzing the results of different embodiments, it can be found which parameter combinations can obtain better effects, thereby providing valuable basis for subsequent process optimization and improvement. The successful demonstration of multiple embodiments can more powerfully prove that the present invention is not a accidental success, but a generally effective technical solution, improving the credibility and persuasiveness of the invention, making it more competitive and popularizable in the technical field. In summary, setting Embodiments 1, 2 and 3 helps to comprehensively and deeply demonstrate the performance and advantages of the present invention, providing a solid foundation for its application and popularization.

[0179] Through the above detailed elaboration of multiple embodiments, comparative examples, and experimental examples of the automatic surfacing method for the ball valve end face based on AB PLC, it can be clearly seen the significant advantages and innovative values demonstrated by the present invention in the field of ball valve end face surfacing.

[0180] In the embodiments, for ball valves of different specifications, we carefully set various parameters and strictly carried out the surfacing operation according to the method proposed by the present invention. From the three-dimensional modeling of the ball valve to the surfacing path planning, from the process parameter control to the quality inspection, every link was carried out orderly under the precise control of the AB PLC system. The results show that for both smaller-sized and larger-sized ball valves, the method of the present invention can achieve high-quality and high-efficiency surfacing.

[0181] Compared with the traditional manual surfacing method and the surfacing method using simple automated equipment, the advantages of the present invention are obvious at a glance. The traditional manual surfacing method, due to excessive reliance on manual experience, is difficult to ensure the accuracy and quality consistency of surfacing, and has low efficiency. While the surfacing method using simple automated equipment but without AB PLC control has deficiencies in control accuracy, timeliness of parameter adjustment, and stability.

[0182] The data comparison in the experimental examples more intuitively reflects the excellent performance of the present invention. In terms of surfacing quality, the present invention achieves higher flatness and hardness, significantly reducing the number of defects. In terms of efficiency, the surfacing time is greatly shortened, and the improvement ratio is significant. In terms of cost, through precise control and optimized processes, the costs of materials, labor, and equipment maintenance are effectively reduced.

[0183] Generally speaking, the automatic surfacing method for the ball valve end face based on AB PLC of the present invention has brought new breakthroughs and changes to the ball valve manufacturing industry. It not only improves the production quality and efficiency of ball valves, reduces the production cost, but also enhances the competitiveness of enterprises in the market. With the continuous development and progress of industrial automation technology, the application prospect of the present invention will be broader. In the future, the algorithm and parameters can be further optimized to expand its application in more complex working conditions and surfacing of different types of ball valves. At the same time, strengthen the integration with other advanced manufacturing technologies to promote the entire ball valve manufacturing industry to develop towards a higher level of intelligence and automation, and contribute more to the innovation and upgrading of related industries. It is believed that the present invention will play an increasingly important role in the field of industrial manufacturing, creating more economic value and social value.

[0184] The embodiments of the present invention are given by way of example and description, and are not exhaustive or limit the present invention to the disclosed form. Many modifications and variations are obvious to those of ordinary skill in the art. The embodiments are chosen and described in order to better illustrate the principles of the present invention and its practical application, and to enable those of ordinary skill in the art to understand the present invention and design various embodiments with various modifications suitable for a particular purpose.

Claims

1. A ball valve end face automatic surfacing method based on AB PLC, characterized in that: The following steps are involved: S1: Use the AB PLC system to perform 3D modeling of the ball valve. The radius of the ball valve is R, the thickness is H, and the modeling formula is M = f(R, H), where f(R, H) = 0.5R 2 H+0.2RH 2 ; S2: Analyze the geometric features of the ball valve end face, where the angle deviation threshold α≤3°; S3: planning a surfacing path according to the geometric features, with a path interval L = 0.4R-0.08R; S4: The motion trajectory of the cladding equipment is controlled by AB PLC, so that the welding gun moves along the planned cladding path. At the same time, the position and posture of the welding gun are monitored and adjusted in real time. The position deviation X≤0.15mm and the posture deviation θ≤2°.

2. The ball valve end face automatic surfacing method based on AB PLC as claimed in claim 1, characterized in that: In S1, the ball valve is 3D modeled as follows: A1: By collecting the size parameters of the ball valve, the radius measurement accuracy is ±0.08mm and the thickness measurement accuracy is ±0.03mm; A2: Construct a 3D model of the ball valve in the AB PLC system and optimize the model. The number of optimization iterations N ≥ 5 times, and the optimization function is G(N) = N 2 -2N+3.

3. The ball valve end face automatic surfacing method based on AB PLC as claimed in claim 1, characterized in that: The planned surfacing path in S3 is as follows: B1: Considering the material of the ball valve end face, the material hardness range is HRC[45,55]; B2: Combined with the thickness and welding process requirements, the optimal surfacing path is generated, the welding speed V = 6-7mm / s, and the welding speed adjustment formula is V' = V + 0.2 (T-T0), where T is the real-time temperature and T0 is the preset reference temperature.

4. The ball valve end face automatic surfacing method based on AB PLC as claimed in claim 1, characterized in that: During the cladding process, the wire feeding speed is controlled by AB PLC, and the wire feeding speed S = 3.5-4.5m / min; The welding current is controlled within a current range of I=180-220A, and the current adjustment formula is I'=I+10log(P-P0), where P is the real-time power and P0 is the preset reference power.

5. The ball valve end face automatic surfacing method based on AB PLC as claimed in claim 1, characterized in that: During the cladding process, the temperature of the cladding area is monitored in real time using the temperature sensor in the AB PLC system. The accuracy of the temperature sensor is ±0.5°C. When the temperature exceeds the preset threshold value T=750℃, the surfacing is automatically suspended and the cooling system is started. After the temperature drops to the safe range T'=450℃, the surfacing continues and the cooling rate is controlled at 10-15℃ / s.

6. The ball valve end face automatic surfacing method based on AB PLC as claimed in claim 1, characterized in that: When controlling the movement of the cladding equipment, the movement speed of the cladding equipment is controlled by AB PLC, and the speed range is V'=0.6-0.9m / min; Control acceleration, acceleration range a = 0.15-0.25m / s 2 , and the acceleration adjustment formula is a'=a+0.05sin(ωt), where ω is the angular frequency and t is the time.

7. The ball valve end face automatic surfacing method based on AB PLC as claimed in claim 1, characterized in that: When recording and analyzing data: Use AB PLC to record and analyze various parameters during the cladding process; A cladding process database is formed with a storage capacity of no less than 200GB. The data compression algorithm C is used with a compression ratio of no less than 3:1, providing a reference for subsequent cladding of similar ball valves.

8. The ball valve end face automatic surfacing method based on AB PLC as claimed in claim 1, characterized in that: After the cladding is completed, the AB PLC-controlled inspection equipment is used to automatically inspect the quality of the cladding layer, with an inspection accuracy of no less than 0.005mm; The defect recognition algorithm D is used, and the recognition accuracy is not less than 95%. If the detection fails, the surfacing welding repair is performed again.

9. The ball valve end face automatic surfacing method based on AB PLC as claimed in claim 1, characterized in that: The ABPLC system communicates with the host computer at a baud rate of 38400bps. The encryption algorithm E is used to encrypt the communication data with an encryption strength of not less than 128 bits, thereby realizing remote monitoring and operation and being able to receive external instructions to adjust the surfacing process in real time.

10. The ball valve end face automatic surfacing method based on AB PLC as claimed in claim 1, characterized in that: Use multiple sets of cladding equipment to work simultaneously, with no less than 3 sets of equipment, and use AB PLC for unified coordination and control to improve cladding efficiency. The efficiency improvement ratio is no less than 50%, and the response time of the equipment collaborative control algorithm F does not exceed 50ms.

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