Real-time quality monitoring and feedback system for intelligent production process of steel structure

Abstract

The invention discloses a steel structure intelligent production process quality real-time monitoring and feedback system, which relates to the technical field of steel structure production monitoring and comprises a control group setting module, a data acquisition module, a positioning height reference table acquisition module, a standard dislocation coefficient reference table acquisition module and a monitoring module, the real-time positioning height and the real-time dislocation of each layer of plate in the production process of the composite steel plate are compared and analyzed with the positioning height reference table and the standard dislocation coefficient reference table to generate a deviation signal, and once a height deviation signal or a dislocation deviation signal occurs, a management end can be notified in time, so that an operator can conveniently and quickly adjust production parameters, and the production efficiency is improved. When a plurality of continuous real-time production layers are marked as defective layers, the system automatically outputs a shutdown signal and immediately cuts off power supply of a power device in production equipment, so that batch production of defective products is effectively prevented, and the production quality is timely and effectively monitored and fed back in the production process of composite steel plates.

Description

Technical Field

[0001] The present invention belongs to the technical field of steel structure production monitoring, and specifically relates to a real-time quality monitoring and feedback system for the intelligent production process of steel structures. Background Art

[0002] In the fields of modern architecture, bridges, ships, and container manufacturing, the requirements for material strength and reliability are becoming increasingly stringent. As a widely used structural system, steel structures, among which composite steel plates formed by stacking multiple steel plates through welding, bolt connection, or bonding, play a key role in scenarios with high strength requirements due to their excellent mechanical properties. For example, in bridge construction, the composite steel plates need to have sufficient compressive strength to bear huge vehicle loads; in shipbuilding, the impact resistance of the composite steel plates is crucial for the safe navigation of ships in complex sea conditions; in container manufacturing, the composite steel plates need to meet specific compressive and sealing requirements.

[0003] Since in the manufacturing process of composite steel plates, the performance and quality requirements of each layer of steel plate are very strict, if problems such as processing accuracy and position deviation occur in a certain layer during the production process, it will directly affect the performance of the overall composite steel plate and may even lead to structural failure.

[0004] However, in the production process of composite steel plates, due to the lack of effective real-time monitoring means, it is difficult to obtain key data of each layer plate at different production stages in a timely manner, such as the actual positioning height of each layer plate during production and the misalignment situation between layers, resulting in the inability to analyze these data in a timely manner, the inability to quickly judge whether the composite steel plate is in a normal state during the production process, and it is even more difficult to conduct effective monitoring and feedback on the production process of the composite steel plate, resulting in potential quality problems in the produced composite steel plates, affecting their safety and reliability in various high-strength application scenarios. Based on this, a real-time quality monitoring and feedback system for the intelligent production process of steel structures is proposed. Summary of the Invention

[0005] The purpose of the present invention is to provide a real-time quality monitoring and feedback system for the intelligent production process of steel structures, which solves the technical problem of being difficult to conduct effective monitoring and feedback on the production process of composite steel plates.

[0006] The real-time quality monitoring and feedback system for the intelligent production process of steel structures includes: A control group setting module, which uses multiple qualified composite steel plates of the same specification as the composite steel plate to be monitored as the control group; A data acquisition module, which acquires the production data corresponding to each layer plate of each composite steel plate in the control group during the production of the composite steel plate; A positioning height reference table acquisition module generates the calibrated positioning height of each layer plate by analyzing the production data corresponding to each layer plate of each composite steel plate, and constructs a positioning height reference table; A standard misalignment coefficient reference table acquisition module calculates the standard misalignment coefficient of each layer plate by analyzing the production data corresponding to each layer plate of each composite steel plate, and constructs a standard misalignment coefficient reference table; A monitoring module obtains the real-time positioning height and real-time misalignment coefficient of the real-time production layer, generates a deviation signal by comparing with the reference table, and outputs a shutdown signal when preset conditions are met.

[0007] As a further solution of the present invention: The specific method for constructing the positioning height reference table is as follows: A1: Randomly select one composite steel plate without replacement as the analysis steel plate, perform contour extraction on the analysis steel plate according to the front view contour diagram of the analysis steel plate, and mark the corresponding side lines of each layer plate of the analysis steel plate according to the bottom edge lines of each layer plate of the analysis steel plate; A3: Establish a two-dimensional coordinate system of the front view contour according to the front view contour diagram of the analysis steel plate, and obtain the central point coordinates Dn1 (D1Xn, D1Yn) corresponding to the side lines of each layer plate of the analysis steel plate. Here, n represents different side lines, and at the same time, n is marked as the layer number corresponding to each layer plate. n = 1, 2,..., a, where a represents the number of layer plates of the analysis steel plate, a is a positive integer, and a satisfies a ≥ 2; A4: Repeat steps A1 - A3 to obtain the height values DYnd corresponding to each layer plate of each composite steel plate at each layer plate. Analyze the height values DYnd to generate the calibrated positioning height Wn of each layer plate. Bind the calibrated positioning height Wn to the layer number corresponding to each layer plate to construct a positioning height reference table. Here, d represents different composite steel plates, d = 1, 2,..., b, where b represents the number of composite steel plates, b is a positive integer, and b satisfies b ≥ 2; The specific method for generating the calibrated positioning height of each layer plate is as follows: A41: Randomly select one layer without replacement from each layer plate as the analysis layer; A42: Obtain the number of values y that meet the preset screening condition Q among the height values DY1d of each composite steel plate at the analysis layer. When the number y is greater than or equal to the preset threshold Z1, define the mean value DY1p of DY1d as the positioning height G1 corresponding to the monitoring composite steel plate at the analysis layer. When the number y is less than the preset threshold Z1, define the mean value of the maximum and minimum values in DY1d as the positioning height G1 corresponding to the composite steel plate to be monitored at the analysis layer. Mark the mean value of the absolute value of the difference between the height value DY1d and its mean value DY1p as the domain value R1. Take the sum of the positioning height G1 and the domain value R1 as the calibrated positioning height W1 of the analysis layer: A43: Repeat steps A41 - A42, and the calibrated positioning height Wn of each layer board can be obtained. The preset threshold Z1 is a positive integer and its value is greater than or equal to 2.

[0008] As a further solution of the present invention: The specific method for marking the side lines corresponding to each layer board of the analysis steel plate is as follows: Within the front view contour diagram of the analysis steel plate, mark the connection line between the right - hand end points of the bottom side lines of every two adjacent layer boards as the side lines corresponding to each layer board of the analysis steel plate; The specific method for establishing a two - dimensional front - view contour coordinate system according to the front - view contour diagram of the analysis steel plate is as follows: Take the right - hand end point of the bottom side line of the bottom - most layer of the analysis steel plate as the origin, the bottom side line of the bottom - most layer as the horizontal coordinate axis, and at the same time take the side line of the bottom - most layer board as the vertical coordinate axis, and then establish a two - dimensional front - view contour coordinate system.

[0009] As a further solution of the present invention: The specific method for constructing a standard misalignment coefficient reference table is as follows: A01: Randomly select one layer as the target layer from the layer boards of the composite steel plate after removing the bottom - most layer board without replacement; A02: Randomly select one from each composite steel plate without replacement as the target steel plate; Obtain the center - point coordinates of the side line and the intersection coordinates between the side line and the bottom side line of the target layer at the target layer of the target steel plate. Mark the corresponding layer at the bottom of the target layer as the comparison layer, obtain the right - hand end - point coordinates of the top side line of the comparison layer, take the absolute value of the difference in the ordinates between the intersection coordinates and the comparison - point coordinates as the vertical elevation C1 corresponding to the target layer, take the distance between the center point and the comparison point as the hypotenuse length C2 corresponding to the target layer, and take the ratio between the vertical elevation C1 and the hypotenuse length C2 of the target layer as the inclination coefficient K1 corresponding to the target steel at the target layer; A03: Repeat steps A01 - A02, and then obtain the inclination coefficients Kd corresponding to each composite steel plate at the target layer respectively, and analyze the inclination coefficients Kd to obtain the standard misalignment coefficient M1 corresponding to the target layer; A04: Repeat steps A01 - A03, and the standard misalignment coefficients Me of each layer board can be obtained. Bind the standard misalignment coefficients Me with the layer - number numbers of each layer board to construct and generate a standard misalignment coefficient reference table, where e is the layer - number number corresponding to each layer board after removing the bottom - most layer board in the composite steel plate, e = 1, 2, ……, a - 1; The specific method for obtaining the standard misalignment coefficient corresponding to the target layer is as follows: Calculate the standard deviation U of the inclination coefficient Kd. When the standard deviation U is less than or equal to the preset value Z3, take the mean value Kp of the inclination coefficient Kd as the standard misalignment coefficient M1 corresponding to the target layer of the composite steel plate to be monitored. When the standard deviation U is greater than the standard deviation U, take the mean value of the maximum and minimum values in the inclination coefficient Kd as the standard misalignment coefficient M1 of the target layer.

[0010] As a further solution of the present invention: The specific way to generate the deviation signal is as follows: During the production process of the composite steel plate, take the composite steel plate being produced as the composite steel plate to be monitored, obtain the real-time positioning height and real-time misalignment coefficient corresponding to the real-time production layer of the composite steel plate to be monitored, and obtain the calibrated positioning height and standard misalignment coefficient corresponding to the real-time production layer from the positioning height reference table and the standard misalignment coefficient reference table. When the real-time positioning height of the real-time production layer is greater than its corresponding calibrated positioning height, generate a height deviation signal, otherwise do nothing. When the real-time misalignment coefficient of the real-time production layer is greater than its corresponding standard misalignment coefficient, generate a misalignment deviation signal, otherwise do nothing.

[0011] Generate a stop signal and output it when i consecutive real-time production layers are marked as defective layers. Generate a stop signal and output it when the real-time production layer simultaneously generates a height deviation signal and a misalignment deviation signal; where i is a positive integer and satisfies a≥i≥2.

[0012] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) In the present invention, analyze the production data of each layer of the composite steel plate layer by layer later to obtain the calibrated positioning height of each layer of the composite steel plate to be monitored, and generate a positioning height reference table, which enables the positioning height that each layer of the laminate should be in under normal production conditions to be clarified, providing a basis for judging the height deviation during the production process. At the same time, analyze the production data layer by layer to obtain the standard misalignment coefficient of each layer of the laminate, and generate a standard misalignment coefficient reference table, providing a standard for judging whether the misalignment between layers is normal; (2) In the present invention, by obtaining the real-time positioning height and real-time misalignment coefficient at each layer of the composite steel plate during the production process, comparing and analyzing them with the positioning height reference table and the standard misalignment coefficient reference table, generating a deviation signal. Once a height deviation signal or a misalignment deviation signal appears, it can notify the management end in time, facilitating the operator to quickly adjust the production parameters. When multiple consecutive real-time production layers are marked as defective layers, the system automatically outputs a stop signal and immediately cuts off the power supply of the power device in the production equipment, effectively preventing the mass production of defective products, significantly improving the overall quality of the composite steel plate, and providing timely and effective monitoring and feedback on the production quality during the production process of the composite steel plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 Schematic diagram of the system framework structure of the present invention; Figure 2 Schematic diagram of the structure of the two-dimensional coordinate system of the front view contour of the present invention; Figure 3 Schematic diagram of the comparison points and intersection points of the present invention; Figure 4 Schematic diagram of the hypotenuse length and vertical elevation of the present invention. Specific implementation manners

[0014] The technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0015] Embodiment 1: Please refer to Figures 1-4 , the present application provides a real-time quality monitoring and feedback system for the intelligent production process of steel structures, including; A control group setting module, configured to obtain a plurality of qualified composite steel plates of the same specification as the composite steel plate to be monitored according to the specification of the composite steel plate to be monitored, and use them as the control group; By selecting a plurality of qualified composite steel plates of the same specification and constructing a control group based on the specification of the composite steel plate to be monitored, this operation ensures that the subsequent analysis data has a reliable reference standard and provides a basis for accurately judging the quality of the composite steel plate to be monitored.

[0016] A data acquisition module, configured to read hierarchical data of each composite steel plate in the control group during the production process of each composite steel plate, and thus obtain control group data. The specific method is: The specific method for reading hierarchical data of each composite steel plate in the control group is: During the production of the composite steel plate, accurately collect the production data corresponding to each layer plate, record and organize it in detail to form a complete control group data set, providing a rich data sample for subsequent analysis.

[0017] A positioning height reference table acquisition module, configured to perform layer-by-layer analysis on the production data corresponding to each layer plate of each composite steel plate, obtain the calibrated positioning height corresponding to each layer plate of the composite steel plate to be monitored according to the analysis result, and generate a positioning height reference table for the composite steel plate to be monitored according to the calibrated positioning height corresponding to each layer plate of the monitored composite steel plate. The specific method is: A1: Randomly select one from each composite steel plate without replacement as the analysis steel plate; A2: Obtain the front view contour diagram of the analysis steel plate, perform contour extraction on the analysis steel plate in the front view contour diagram, and then obtain the front view contour line of the analysis steel plate; Obtain and mark the bottom edge lines of each layer plate of the analysis steel plate within the front view contour diagram of the analysis steel plate. Mark the connection line between the right end points of the bottom edge lines of every two adjacent layer plates within the front view contour diagram of the analysis steel plate as the side line corresponding to each layer plate of the analysis steel plate. And mark each side line as L1n in the order from the bottom layer to the upper layer of each layer plate, where n represents different side lines. At the same time, mark n as the layer number corresponding to each layer plate respectively. n = 1, 2, ……, a, where a represents the number of layer plates of the analysis steel plate, a is a positive integer, and a satisfies a ≥ 2; It should be noted that the specifications of each composite steel plate are the same, so the total number of layer plates is the same; A3: Establish a front view contour two-dimensional coordinate system based on the front view contour diagram of the analysis steel plate, analyze each side line of the analysis steel plate, obtain the positioning height corresponding to each side line of the analysis steel plate according to the analysis result, and then analyze the positioning height corresponding to each side line respectively, so as to obtain the calibrated positioning height corresponding to each layer plate of the analysis steel plate. The specific method is as follows: Take the right end point of the bottom edge line of the bottom layer of the analysis steel plate as the origin, the bottom edge line of the bottom layer as the horizontal coordinate axis, and at the same time take the side line of the bottom layer plate as the vertical coordinate axis, and then establish a front view contour two-dimensional coordinate system. At the same time, mark the center point Dn1 of each side line, and output the center point coordinates Dn1 (D1Xn, D1Yn) of each side line; According to the center point coordinates D1n (DXn1, DYn1) of each side line, extract the height value D1Yn corresponding to each center point; Extract the front view contour diagram of the analysis steel plate through an edge detection algorithm (such as Canny edge detection). Extracting the contour diagram through the edge detection algorithm is an existing and mature technology, so it will not be elaborated here.

[0018] A4: Repeat steps A1 - A3, and then obtain the height value DYnd corresponding to each layer plate of each composite steel plate, where d represents different composite steel plates, d = 1, 2, ……, b, b represents the number of composite steel plates, b is a positive integer, and b satisfies b ≥ 2; Analyze the height value DYnd corresponding to each layer plate of each composite steel plate, and then obtain the calibrated positioning height corresponding to each layer plate of the composite steel plate to be monitored. At the same time, the specific method for generating the positioning height reference table of the composite steel plate to be monitored is as follows: A41: Randomly select one layer from each layer plate without replacement as the analysis layer; A42: Obtain the corresponding height value DY1d of each composite steel plate at the analysis layer; Obtain the number y of values in the height value DY1d that meet the preset screening condition Q1, where b≥y≥1. Compare the number y with the preset threshold Z1. When the number y is greater than or equal to the preset threshold Z1, it indicates that the number of values in DY1d that meet the preset screening condition A1 is relatively large, and the mean value of DY1d is representative. Furthermore, define the mean value DY1p of DY1d as the positioning height G1 corresponding to the monitored composite steel plate at the analysis layer. When the number y is less than the preset threshold Z1, it indicates that the number of values in DY1d that meet the preset screening condition A1 is relatively small, and the mean value of DY1d is not representative. Furthermore, define the mean value of the maximum and minimum values in DY1d as the positioning height G1 corresponding to the monitored composite steel plate at the analysis layer, that is, G1 = (DY1min + DY1max) / 2, where DY1max and DY1min are the maximum and minimum values in DY1d respectively; It should be noted here that the preset condition Q1 is specifically: |DY1d - DY1p| < Z2, where Z2 is a preset value, the preset threshold Z1 is a positive integer, and its value is greater than or equal to 2. The specific values of Z1 and Z2 are determined by relevant personnel according to actual needs; Analyze the degree of dispersion of the data in the height value DY1d through the preset condition Q. The more the number of values that satisfy |DY1d - DY1p| < Z2, the smaller the difference between the values in DY1d and its mean value DY1p, the more concentrated the data, and the smaller the degree of dispersion. On the contrary, the degree of dispersion is larger; Obtain the mean value of the absolute values of the differences between the corresponding height values DY1d of each composite steel plate at the analysis layer and its mean value DY1p respectively, and mark it as the domain value R1. Take the sum of the positioning height G1 corresponding to the monitored composite steel plate at the analysis layer and the domain value R1 as the calibrated positioning height W1 corresponding to the monitored composite steel plate at the analysis layer; A43: Repeat steps A41 - A42 to obtain the calibrated positioning heights Wn corresponding to the monitored composite steel plate at each layer board respectively. Bind the calibrated positioning heights Wn with the layer numbers of each layer board of the monitored composite steel plate to generate a positioning height reference table BW of the monitored composite steel plate; The positioning height reference table acquisition module analyzes the production data of each layer board of each composite steel plate layer by layer, and obtains the calibrated positioning heights of each layer board of the monitored composite steel plate through a complex calculation process, and generates a positioning height reference table, which enables the positioning height that each layer board should be at under normal production conditions to be determined, providing a basis for judging the height deviation during the production process.

[0019] A standard misalignment coefficient reference table acquisition module is used to analyze the production data corresponding to each layer of each composite steel plate layer by layer. According to the analysis results, the standard misalignment coefficients corresponding to each layer of the composite steel plate to be monitored are obtained, and a standard misalignment coefficient reference table for the composite steel plate to be monitored is generated. The specific method is as follows: A01: Randomly select one layer as the target layer from the layers of the composite steel plate after removing the bottom layer without replacement; A02: Randomly select one composite steel plate without replacement as the target steel plate; Obtain the coordinates of the center point of the side line corresponding to the target layer of the target steel plate, and at the same time obtain the coordinates of the intersection point between the side line and the bottom side line of the target layer. Output the center point coordinates FA (FAX, FAY) and the intersection point coordinates FB (FBX, FBY) at the same time. Mark the corresponding layer at the bottom of the target layer as the comparison layer, and obtain the comparison point coordinates FC (FCX, FCY) corresponding to the right end point of the top side line of the comparison layer; Take the absolute value of the difference in the vertical coordinates between the intersection point coordinates FB (FBX, FBY) and the comparison point coordinates FC (FCX, FCY) as the vertical elevation C1 corresponding to the target layer, that is, C1 = |FBY - FCY|. Calculate the hypotenuse length C2 corresponding to the target layer through the center point coordinates FA (FAX, FAY) and the comparison point coordinates FC (FCX, FCY); That is, through , calculate the hypotenuse length C2 corresponding to the target layer; Take the ratio between the vertical elevation C1 and the hypotenuse length C2 corresponding to the target layer as the inclination coefficient K1 corresponding to the target steel at the target layer; A03: Repeat steps A01 - A02 to obtain the inclination coefficients Kd corresponding to each composite steel plate at the target layer respectively; Calculate the standard deviation U of the inclination coefficient Kd. When the standard deviation U is less than or equal to the preset value Z3, take the mean value Kp of the inclination coefficient Kd as the standard misalignment coefficient M1 corresponding to the target layer of the composite steel plate to be monitored. When the standard deviation U is greater than the standard deviation U, take the mean value of the maximum and minimum values of the inclination coefficient Kd as the standard misalignment coefficient M1 corresponding to the target layer of the composite steel plate to be monitored. The specific value of the preset value Z3 is determined by relevant personnel according to actual needs; A04: Repeat steps A01 - A03 to obtain the standard dislocation coefficients Me corresponding to each layer plate of the composite steel plate to be monitored. Bind the standard dislocation coefficients Me with the layer numbers of each layer plate to generate a standard dislocation coefficient reference table AM for the composite steel plate to be monitored. Here, e is the layer number corresponding to each layer plate after removing the bottom - most layer plate in the composite steel plate, e = 1, 2, ……, a - 1, and n > e, where e corresponds one - to - one with the layer number n of each remaining layer plate after removing the bottom - most layer plate in the composite steel plate; The standard dislocation coefficient reference table acquisition module also analyzes the production data layer by layer, obtains the standard dislocation coefficients of each layer plate of the composite steel plate to be monitored, and generates a standard dislocation coefficient reference table, providing a standard for judging whether the dislocation between layers is normal.

[0020] Monitoring module: During the production of the composite steel plate, regard the composite steel plate being produced as the composite steel plate to be monitored. During the production of the composite steel plate to be monitored, obtain the real - time positioning height and real - time dislocation coefficient corresponding to each layer plate of the composite steel plate to be monitored in real - time, and compare and analyze the real - time positioning height and real - time dislocation coefficient corresponding to each layer plate with the calibrated positioning height and standard dislocation coefficient corresponding to each layer plate respectively. Obtain and output the height deviation signal and dislocation deviation signal according to the analysis results. The specific method is as follows: During the production of the composite steel plate, regard the composite steel plate being produced as the composite steel plate to be monitored, obtain the real - time positioning height and real - time dislocation coefficient corresponding to the real - time production layer of the composite steel plate to be monitored, and obtain the calibrated positioning height and standard dislocation coefficient corresponding to the real - time production layer from the positioning height reference table and the standard dislocation coefficient reference table. When the real - time positioning height of the real - time production layer is greater than its corresponding calibrated positioning height, generate a height deviation signal; otherwise, do nothing. When the real - time dislocation coefficient of the real - time production layer is greater than its corresponding standard dislocation coefficient, generate a dislocation deviation signal; otherwise, do nothing. When the real - time production layer generates both a height deviation signal and a dislocation deviation signal simultaneously, output a stop signal, and output it to the management end together with the height deviation signal and the dislocation deviation signal; When the real - time production layer generates one of the height deviation signal or the dislocation deviation signal, mark the real - time production layer as a defective layer, and at the same time bind the corresponding deviation signal with its corresponding layer to generate defect information. At the same time, continue to monitor the composite steel plate to be monitored. When i consecutive real - time production layers are marked as defective layers, output a stop signal, and output it to the management end together with the defect information corresponding to the real - time production layer; Where i is a preset threshold, i is the number of defective layers, i is a positive integer, and i satisfies a ≥ i ≥ 2; Through the communication protocol preset within the system, the shutdown signal is transmitted to the control unit of the production equipment in the form of a digital electrical signal. After receiving the shutdown signal, the control unit immediately cuts off the power supply to the power device in the production equipment, causing the production equipment to stop running. At the same time, the shutdown signal and related deviation signals or defect information are sent to the monitoring platform at the management end via wireless communication and displayed in the form of a prominent prompt box on the monitoring platform to remind the management personnel to handle it in a timely manner.

[0021] By obtaining the real-time positioning height and real-time misalignment coefficient at each layer of the composite steel plate during the production process in real time and accurately, the timeliness and accuracy of data acquisition are greatly improved. Potential quality problems can be detected at an early stage, a large number of unqualified products can be avoided, and the production cost can be effectively reduced.

[0022] The real-time positioning height and real-time misalignment coefficient are compared and analyzed with the positioning height reference table and the standard misalignment coefficient reference table to generate deviation signals. Once a height deviation signal or a misalignment deviation signal appears, the system can promptly send a notice to the management end. The operator can quickly adjust production parameters such as hot pressing temperature and cold pressing pressure based on this feedback information to ensure that the production process resumes normal as soon as possible and improve production efficiency and product quality.

[0023] By comparing and analyzing with the positioning height reference table and the standard misalignment coefficient reference table, once a height deviation signal or a misalignment deviation signal appears, the management end can be promptly notified to facilitate the operator to quickly adjust production parameters. When multiple consecutive real-time production layers are marked as defective layers, the system automatically outputs a shutdown signal and immediately cuts off the power supply to the power device in the production equipment. This function effectively prevents the batch production of defective products and significantly improves the overall quality of the composite steel plate.

[0024] The above formulas are all dimensionless and take their numerical values for calculation. The formulas are obtained by collecting a large amount of data and performing software simulation to obtain a formula that is closest to the real situation. The preset parameters and threshold selection in the formulas are set by those skilled in the art according to the actual situation.

[0025] The above is only the specific implementation manner of this application, but the protection scope of this application is not limited thereto. Any person skilled in the art within the technical scope disclosed in this application can easily think of changes or substitutions, which should all be covered within the protection scope of this application. Therefore, the protection scope of this application should be subject to the protection scope of the claims.

Claims

1. Real-time monitoring and feedback system for quality of intelligent steel structure production process, characterized by: include: A control group setting module is used to set a plurality of qualified composite steel plates of the same specification as the composite steel plate to be monitored as a control group; A data acquisition module, during the production of the composite steel plate, acquires the production data corresponding to each composite steel plate at each layer in the control group; The positioning height reference table acquisition module generates the calibrated positioning height of each layer of the plate and constructs a positioning height reference table by analyzing the production data corresponding to each composite steel plate at each layer of the plate; A standard misalignment coefficient reference table acquisition module calculates the standard misalignment coefficient of each layer of the plate and constructs a standard misalignment coefficient reference table by analyzing the production data corresponding to each composite steel plate at each layer of the plate; The monitoring module obtains the real-time positioning height and real-time misalignment coefficient of the real-time production layer, generates a deviation signal by comparing it with the reference table, and outputs a shutdown signal when the preset conditions are met.

2. The real-time monitoring and feedback system for quality of intelligent production process of steel structure according to claim 1 is characterized in that: The specific method of constructing the positioning height reference table is: A1: Randomly select one of the composite steel plates as the analysis steel plate without replacement, extract the contour of the analysis steel plate according to the front view contour map of the analysis steel plate, and mark the side edge lines corresponding to each layer of the analysis steel plate according to the bottom edge lines of each layer of the analysis steel plate; A3: According to the front view contour drawing of the analyzed steel plate, a front view contour two-dimensional coordinate system is established, and the center point coordinates Dn1 (D1Xn, D1Yn) corresponding to the side lines of each layer of the analyzed steel plate are obtained, where n refers to different side lines, and n is marked as the layer number corresponding to each layer of the analyzed steel plate, n=1, 2, ..., a, a refers to the number of layers of the analyzed steel plate, a is a positive integer, and a satisfies a≥2; A4: Repeat steps A1-A3 to obtain the height values ​​DYnd corresponding to each composite steel plate at each layer of the plate, analyze the height values ​​DYnd to generate the calibrated positioning height Wn of each layer of the plate, bind the calibrated positioning height Wn with the layer number of each layer of the plate, and then construct a positioning height reference table, wherein d refers to different composite steel plates, d=1, 2, ..., b, b refers to the number of composite steel plates, b is a positive integer, and b satisfies b≥2.

3. The real-time monitoring and feedback system for quality of intelligent production process of steel structure according to claim 2 is characterized in that: The specific method for generating the calibrated positioning height of each layer is: A41: Randomly select one layer from each layer without replacement as the analysis layer; A42: The number of values ​​y that meet the preset screening condition Q is obtained from the height values ​​DY1d of each composite steel plate at the analysis layer. When the number y is greater than or equal to the preset threshold value Z1, the mean value DY1p of DY1d is defined as the positioning height G1 corresponding to the monitored composite steel plate at the analysis layer. When the number y is less than the preset threshold value Z1, the mean of the maximum and minimum values ​​in DY1d is defined as the positioning height G1 corresponding to the composite steel plate to be monitored at the analysis layer. The mean of the absolute values ​​of the differences between the height values ​​DY1d and their mean values ​​DY1p is marked as the domain value R1. The sum of the positioning height G1 and the domain value R1 is used as the calibrated positioning height W1 of the analysis layer: A43: Repeat steps A41-A42 to obtain the calibrated positioning height Wn of each layer of the board. The preset threshold Z1 is a positive integer and its value is greater than or equal to 2.

4. The real-time monitoring and feedback system for quality of intelligent production process of steel structure according to claim 3 is characterized in that: The preset condition Q1 is specifically: |DY1d-DY1p|<Z2, where Z2 is a preset value.

5. The real-time monitoring and feedback system for quality of intelligent production process of steel structure according to claim 2 is characterized in that: The specific method for marking the side lines corresponding to each layer of the analyzed steel plate is: In the front view contour diagram of the analyzed steel plate, the connecting line between the right end points of the bottom edge lines of each two adjacent layers of the plate is marked as the side edge lines corresponding to each layer of the analyzed steel plate.

6. The real-time monitoring and feedback system for quality of intelligent production process of steel structure according to claim 5 is characterized in that: The specific method of establishing the two-dimensional coordinate system of the front view contour according to the analysis of the front view contour of the steel plate is: The right end point of the bottom edge of the bottom layer of the analyzed steel plate is taken as the origin, the bottom edge of the bottom layer is taken as the horizontal axis, and the side edge of the bottom layer is taken as the vertical axis, thereby establishing a two-dimensional coordinate system for the front view contour.

7. The real-time monitoring and feedback system for quality of intelligent production process of steel structure according to claim 6 is characterized in that: The specific method of constructing the standard misalignment coefficient reference table is: A01: After removing the bottom layer from each layer of the composite steel plate, a layer is randomly selected as the target layer without replacement; A02: Randomly select one of the composite steel plates without replacement as the target steel plate; Obtain the coordinates of the center point of the side line of the target steel plate at the target layer and the coordinates of the intersection point between the side line and the side line at the bottom of the target layer, mark the corresponding layer at the bottom of the target layer as the comparison layer, obtain the coordinates of the right end point of the top side line of the comparison layer, take the absolute value of the difference between the ordinates in the intersection coordinates and the comparison point coordinates as the vertical elevation C1 corresponding to the target layer, take the distance between the center point and the comparison point as the hypotenuse length C2 corresponding to the target layer, and take the ratio between the vertical elevation C1 of the target layer and the hypotenuse length C2 as the inclination coefficient K1 corresponding to the target steel at the target layer; A03: Repeat steps A01-A02 to obtain the inclination coefficient Kd corresponding to each composite steel plate at the target layer, and analyze the inclination coefficient Kd to obtain the standard misalignment coefficient M1 corresponding to the target layer; A04: Repeat steps A01-A03 to obtain the standard misalignment coefficient Me of each layer of plywood, and bind the standard misalignment coefficient Me with the layer number of each layer of plywood to generate a reference table of standard misalignment coefficients, where e is the layer number corresponding to each layer of plywood in the composite steel plate after removing the bottom layer of plywood, and e=1, 2, ..., a-1.

8. The real-time monitoring and feedback system for quality of intelligent production process of steel structure according to claim 7 is characterized in that: The specific method of obtaining the standard misalignment coefficient corresponding to the target layer is: Calculate the standard deviation U of the inclination coefficient Kd. When the standard deviation U is less than or equal to the preset value Z3, the mean Kp of the inclination coefficient Kd is used as the standard misalignment coefficient M1 corresponding to the monitored composite steel plate at the target layer. When the standard deviation U is greater than the standard deviation U, the mean of the maximum and minimum values ​​of the inclination coefficient Kd is used as the standard misalignment coefficient M1 of the target layer.

9. The real-time monitoring and feedback system for quality of intelligent production process of steel structure according to claim 8 is characterized in that: The specific way to generate the deviation signal is: During the production process of composite steel plates, the composite steel plates being produced are used as the composite steel plates to be monitored, and the real-time positioning height and real-time misalignment coefficient corresponding to the real-time production layer of the composite steel plates to be monitored are obtained, and the calibrated positioning height and standard misalignment coefficient corresponding to the real-time production layer are obtained from the positioning height reference table and the standard misalignment coefficient reference table. When the real-time positioning height of the real-time production layer is greater than the corresponding calibrated positioning height, a height deviation signal is generated, otherwise no processing is performed; when the real-time misalignment coefficient of the real-time production layer is greater than the corresponding standard misalignment coefficient, a misalignment deviation signal is generated, otherwise no processing is performed.

10. The real-time monitoring and feedback system for quality of intelligent production process of steel structure according to claim 9 is characterized in that: The specific method of outputting the stop signal is: When i consecutive real-time production layers are marked as defective layers, a stop signal is generated and output; when the real-time production layer generates a height deviation signal and a misalignment deviation signal at the same time, a stop signal is generated and output; wherein i is a positive integer and satisfies a≥i≥2.

Images