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

Abstract

This invention discloses a real-time monitoring and feedback system for the intelligent production process of steel structures, relating to the field of steel structure production monitoring technology. It includes a control group setting module, a data acquisition module, a positioning height reference table acquisition module, a standard misalignment coefficient reference table acquisition module, and a monitoring module. By comparing and analyzing the real-time positioning height and real-time misalignment at each layer of the composite steel plate during production with the positioning height reference table and the standard misalignment coefficient reference table, deviation signals are generated. Once a height deviation signal or misalignment deviation signal appears, the system can promptly notify the management end, facilitating operators to quickly adjust 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 to the power unit in the production equipment, effectively preventing the mass production of defective products. This system provides timely and effective monitoring and feedback of production quality during the composite steel plate production process.

Description

Technical Field

[0001] This invention belongs to the field of steel structure production monitoring technology, specifically a real-time monitoring and feedback system for the quality of intelligent steel structure production processes. Background Technology

[0002] In modern architecture, bridge construction, shipbuilding, and container manufacturing, the requirements for material strength and reliability are becoming increasingly stringent. Steel structures, as a widely used structural system, utilize composite steel plates formed by welding, bolting, or bonding multiple steel plates. These composite plates, with their excellent mechanical properties, play a crucial role in high-strength applications. For example, in bridge construction, composite steel plates need sufficient compressive strength to withstand massive vehicle loads; in shipbuilding, the impact resistance of composite steel plates is essential for the safe navigation of ships in complex sea conditions; and in container manufacturing, composite steel plates must meet specific compressive strength and sealing requirements.

[0003] Because the performance and quality requirements of each layer of steel plate are very strict during the manufacturing process of composite steel plates, if there are problems with the processing accuracy or positional deviation of 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 methods, it is difficult to obtain key data of each layer at different production stages in a timely manner, such as the actual positioning height of each layer during production and the misalignment between layers. This makes it impossible to analyze this data in a timely manner, to quickly determine whether the composite steel plate is in a normal state during the production process, and even more difficult to effectively monitor and provide feedback on the composite steel plate production process. As a result, the produced composite steel plates have potential quality hazards, affecting their safety and reliability in various high-strength application scenarios. Based on this, a real-time monitoring and feedback system for the quality of intelligent steel structure production process is proposed. Summary of the Invention

[0005] The purpose of this invention is to provide a real-time monitoring and feedback system for the quality of intelligent steel structure production processes, which solves the technical problem of difficulty in effectively monitoring and providing feedback on the production process of composite steel plates.

[0006] A real-time quality monitoring and feedback system for the intelligent production process of steel structures, including:

[0007] The control group setting module uses multiple qualified composite steel plates of the same specifications as the composite steel plate to be monitored as the control group.

[0008] The data acquisition module acquires production data corresponding to each layer of the composite steel plate in the control group during the production of the composite steel plate.

[0009] The positioning height reference table acquisition module analyzes the production data corresponding to each composite steel plate at each layer, generates the calibrated positioning height of each layer, and constructs a positioning height reference table.

[0010] The standard misalignment coefficient reference table acquisition module calculates the standard misalignment coefficient of each layer of composite steel plate and constructs a standard misalignment coefficient reference table by analyzing the production data corresponding to each layer of the composite steel plate.

[0011] The monitoring module acquires the real-time positioning height and misalignment coefficient of the production layer, compares them with a reference table to generate a deviation signal, and outputs a stop signal when preset conditions are met.

[0012] As a further aspect of the present invention, the specific method for constructing the positioning height reference table is as follows:

[0013] A1: Randomly select one composite steel plate without replacement as the analysis steel plate. Extract the outline of the analysis steel plate based on the front view outline of the analysis steel plate. Mark the side edge lines of each layer of the analysis steel plate according to the bottom edge line of each layer of the analysis steel plate.

[0014] A3: Based on the frontal profile of the steel plate, establish a two-dimensional coordinate system for the frontal profile and obtain the center point coordinates Dn1 (D1Xn, D1Yn) corresponding to the side edge lines of each layer of the steel plate. Here, n represents different side edge lines, and n is marked as the layer number corresponding to each layer of the steel plate, n=1, 2, ..., a, where a represents the number of layers of the steel plate, a is a positive integer, and a satisfies a≥2;

[0015] A4: Repeat steps A1-A3 to obtain the height value DYnd of each composite steel plate at each layer plate. Analyze the height value DYnd to generate the calibration positioning height Wn of each layer plate. Bind the calibration positioning height Wn with the layer number of each layer plate to construct a positioning height reference table. Here, 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.

[0016] The specific method for generating the calibration and positioning height of each layer plate is as follows:

[0017] A41: Randomly select one layer from each layer without replacement as the analysis layer;

[0018] A42: Obtain the number y of the height values ​​DY1d of each composite steel plate at the analysis layer that meet the preset screening condition Q. 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 of the monitored composite steel plate at the analysis layer. When the number y is less than the preset threshold Z1, define the mean of the maximum and minimum values ​​in DY1d as the positioning height G1 of the monitored composite steel plate at the analysis layer. Mark the mean of the absolute values ​​of the differences between the height values ​​DY1d and their mean values ​​DY1p as the domain value R1. Use the sum of the positioning height G1 and the domain value R1 as the calibration positioning height W1 of the analysis layer.

[0019] A43: Repeat steps A41-A42 to obtain the calibration positioning height Wn of each layer plate. The preset threshold Z1 is a positive integer and its value is greater than or equal to 2.

[0020] As a further aspect of the present invention, the specific method for marking the side lines corresponding to each layer of the analytical steel plate is as follows:

[0021] In the frontal outline drawing of the steel plate, the line connecting the right endpoints of the bottom edge lines of each two adjacent layers is marked as the side edge lines corresponding to each layer of the steel plate.

[0022] The specific method for establishing a two-dimensional coordinate system for the front view contour of the steel plate, based on the analysis, is as follows:

[0023] The origin is taken as the right end point of the bottom edge of the bottom layer of the steel plate, 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, thus establishing a two-dimensional coordinate system for the frontal contour.

[0024] As a further aspect of the present invention, the specific method for constructing the standard misalignment coefficient reference table is as follows:

[0025] A01: Randomly select one layer as the target layer without replacement after removing the bottom layer from each layer of the composite steel plate;

[0026] A02: Randomly select one of the composite steel plates without replacement as the target steel plate;

[0027] 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 bottom edge line 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 edge line of the comparison layer. Take the absolute value of the difference between the vertical coordinates of the intersection point and the comparison point as the vertical elevation C1 of the target layer. Take the distance between the center point and the comparison point as the hypotenuse length C2 of the target layer. Take the ratio between the vertical elevation C1 and the hypotenuse length C2 of the target layer as the inclination coefficient K1 of the target steel at the target layer.

[0028] A03: Repeat steps A01-A02 to obtain the tilt coefficient Kd of each composite steel plate at the target layer, and analyze the tilt coefficient Kd to obtain the standard misalignment coefficient M1 corresponding to the target layer.

[0029] A04: Repeat steps A01-A03 to obtain the standard misalignment coefficient Me for each layer plate. Bind the standard misalignment coefficient Me with the layer number of each layer plate to generate a standard misalignment coefficient reference table. Here, e is the layer number of each layer plate after removing the bottom layer plate in the composite steel plate, e=1, 2, ..., a-1.

[0030] The specific method for obtaining the standard misalignment coefficient corresponding to the target layer is as follows:

[0031] Calculate the standard deviation U of the tilt coefficient Kd. When the standard deviation U is less than or equal to the preset value Z3, the mean value Kp of the tilt coefficient Kd is taken as the standard misalignment coefficient M1 of the composite steel plate to be monitored at the target layer. When the standard deviation U is greater than the standard deviation U, the mean value of the maximum and minimum values ​​of the tilt coefficient Kd is taken as the standard misalignment coefficient M1 of the target layer.

[0032] As a further aspect of the present invention, the specific method for generating the deviation signal is as follows:

[0033] During the production of composite steel plates, the composite steel plates currently in production are used as the composite steel plates to be monitored. 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 are obtained. 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 its 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 its corresponding standard misalignment coefficient, a misalignment deviation signal is generated; otherwise, no processing is performed.

[0034] A stop signal is generated and output when i consecutive real-time production layers are marked as defective layers; a stop signal is generated and output when a real-time production layer generates both height deviation signal and misalignment deviation signal simultaneously; where i is a positive integer and satisfies a≥i≥2.

[0035] Compared with the prior art, the beneficial effects of the present invention are:

[0036] (1) In this invention, the production data of each composite steel plate layer is analyzed layer by layer to obtain the calibrated positioning height of each layer of the composite steel plate to be monitored, and a positioning height reference table is generated. This makes it possible to clarify the positioning height of each layer under normal production conditions, providing a basis for judging the height deviation in the production process. At the same time, the production data is analyzed layer by layer to obtain the standard misalignment coefficient of each layer, and a standard misalignment coefficient reference table is generated, providing a standard for judging whether the misalignment between layers is normal.

[0037] (2) In this invention, by obtaining the real-time positioning height and real-time misalignment coefficient of each layer of composite steel plate during the production process, and comparing and analyzing them with the positioning height reference table and the standard misalignment coefficient reference table, a deviation signal is generated. Once a height deviation signal or misalignment deviation signal appears, the management end can be notified in time, so that the operators can quickly adjust the production parameters. When multiple 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 and significantly improving the overall quality of composite steel plates. In the process of composite steel plate production, timely and effective monitoring and feedback of production quality are carried out. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the system framework structure of the present invention;

[0039] Figure 2 This is a schematic diagram of the two-dimensional coordinate system of the frontal contour of the present invention;

[0040] Figure 3 This is a schematic diagram of the comparison points and intersection points of the present invention;

[0041] Figure 4 This is a structural schematic diagram of the hypotenuse length and vertical elevation of the present invention. Detailed Implementation

[0042] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0043] Example 1: Please refer to Figures 1-4 This application provides a real-time quality monitoring and feedback system for the intelligent production process of steel structures, including:

[0044] The control group setting module is used to obtain multiple qualified composite steel plates with the same specifications as the composite steel plate to be monitored, and use them as the control group.

[0045] This module selects multiple qualified composite steel plates of the same specification and constructs a control group based on the specifications of the composite steel plate to be monitored. This operation ensures that the subsequent analysis data has a reliable reference standard, providing a basis for accurately judging the quality of the composite steel plate to be monitored.

[0046] The data acquisition module is used to read layered data from each composite steel plate in the control group during the production process of each composite steel plate, thereby obtaining the control group data. The specific method is as follows:

[0047] The specific method for reading layered data from each composite steel plate in the control group is as follows:

[0048] During the production of composite steel plates, production data corresponding to each layer of the plate are accurately collected, recorded and organized in detail to form a complete control group data set, providing rich data samples for subsequent analysis.

[0049] The positioning height reference table acquisition module is used to analyze the production data corresponding to each layer of the composite steel plate layer by layer. Based on the analysis results, it obtains the calibrated positioning height of the composite steel plate to be monitored at each layer. Based on the calibrated positioning height of the composite steel plate to be monitored at each layer, it generates a positioning height reference table for the composite steel plate to be monitored. The specific method is as follows:

[0050] A1: Randomly select one composite steel plate without replacement from each composite steel plate as the steel plate for analysis;

[0051] A2: Obtain the front view contour of the steel plate to be analyzed, and extract the contour of the steel plate to obtain the front view contour line of the steel plate.

[0052] Within the frontal contour drawing of the steel plate, the bottom edge lines of each layer of the steel plate are obtained and marked. Within the frontal contour drawing of the steel plate, the line connecting the right endpoints of the bottom edge lines of each two adjacent layers is marked as the side edge line corresponding to each layer of the steel plate. Each side edge line is marked as L1n according to the order of each layer from bottom to top, where n represents a different side edge line. At the same time, n is marked as the layer number corresponding to each layer of the steel plate, n=1, 2, ..., a, where a represents the number of layers of the steel plate, a is a positive integer, and a satisfies a≥2.

[0053] It should be noted that all composite steel plates have the same specifications, therefore the total number of layers is the same.

[0054] A3: Based on the establishment of a two-dimensional coordinate system for the frontal contour of the analyzed steel plate, the side lines of the analyzed steel plate are analyzed. The positioning heights corresponding to each side line of the analyzed steel plate are obtained based on the analysis results. Then, the positioning heights corresponding to each side line are analyzed to obtain the calibration positioning heights corresponding to each layer of the analyzed steel plate. The specific method is as follows:

[0055] The origin is taken as the right end point of the bottom edge line of the bottom layer of the steel plate, the bottom edge line is taken as the horizontal axis, and the side edge line of the bottom layer plate is taken as the vertical axis. Thus, a two-dimensional coordinate system of the frontal contour is established. At the same time, the center point Dn1 of each side edge line is marked, and the coordinates Dn1 (D1Xn, D1Yn) of the center point of each side edge line are output.

[0056] Based on the center point coordinates D1n(DXn1, DYn1) of each side line, extract the height value D1Yn corresponding to each center point.

[0057] The frontal contour of the steel plate is extracted using edge detection algorithms (such as Canny edge detection). Since extracting the contour using edge detection algorithms is an existing and mature technology, it will not be elaborated on here.

[0058] A4: Repeat steps A1-A3 to obtain the height values ​​DYnd of each composite steel plate at each layer, 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.

[0059] The height values ​​DYnd of each composite steel plate at each layer are analyzed to obtain the calibrated positioning height of the composite steel plate to be monitored at each layer. The specific method for generating a positioning height reference table for the composite steel plate to be monitored is as follows:

[0060] A41: Randomly select one layer from each layer without replacement as the analysis layer;

[0061] A42: Obtain the height value DY1d of each composite steel plate at the analysis layer;

[0062] The number of values ​​y in height value DY1d that meet the preset screening condition Q1 is obtained, b≥y≥1. The number y is compared with the preset threshold Z1. When the number y is greater than or equal to the preset threshold Z1, it means that there are more values ​​in DY1d that meet the preset screening condition A1, and the mean of DY1d is representative. Then the mean value DY1p of DY1d is defined as the positioning height G1 of the composite steel plate at the analysis layer. When the number y is less than the preset threshold Z1, it means that there are fewer values ​​in DY1d that meet the preset screening condition A1, and the mean of DY1d is not representative. Then the mean of the maximum and minimum values ​​in DY1d is defined as the positioning height G1 of the composite steel plate to be monitored at the analysis layer, that is, G1=(DY1min +DY1max) / 2, where DY1max and DY1min are the maximum and minimum values ​​in DY1d, respectively.

[0063] It should be noted here that the preset condition Q1 is: |DY1d-DY1p|<Z2, where Z2 is a preset value, the preset threshold Z1 is a positive integer and takes a value greater than or equal to 2, and the specific values ​​of Z1 and Z2 are determined by relevant personnel according to actual needs;

[0064] The dispersion of the height value DY1d is analyzed by using the preset condition Q. The more times |DY1d-DY1p|<Z2 there are, the smaller the difference between the values ​​in DY1d and their mean DY1p, the more concentrated the data is and the less dispersion it is. Conversely, the less dispersion it is, the more dispersion it is.

[0065] The mean of the absolute values ​​of the differences between the height values ​​DY1d of each composite steel plate at the analysis layer and their mean values ​​DY1p is obtained and marked as the domain value R1. The sum of the positioning height G1 of the composite steel plate to be monitored at the analysis layer and the domain value R1 is taken as the calibration positioning height W1 of the composite steel plate to be monitored at the analysis layer.

[0066] A43: Repeat steps A41-A42 to obtain the calibrated positioning height Wn corresponding to each layer of the composite steel plate to be monitored. Bind the calibrated positioning height Wn to the layer number of each layer of the composite steel plate to be monitored to generate the positioning height reference table BW of the composite steel plate to be monitored.

[0067] The positioning height reference table acquisition module analyzes the production data of each layer of composite steel plate layer by layer. Through a complex calculation process, it obtains the calibrated positioning height of each layer of the composite steel plate to be monitored and generates a positioning height reference table. This makes it possible to clarify the positioning height that each layer should be at under normal production conditions, providing a basis for judging the height deviation in the production process.

[0068] The standard misalignment coefficient reference table acquisition module is used to analyze the production data corresponding to each layer of the composite steel plate layer by layer. Based on the analysis results, it obtains the standard misalignment coefficient corresponding to each layer of the composite steel plate to be monitored. Based on the standard misalignment coefficients corresponding to each layer of the composite steel plate to be monitored, it generates a standard misalignment coefficient reference table for the composite steel plate to be monitored. The specific method is as follows:

[0069] A01: Randomly select one layer as the target layer without replacement after removing the bottom layer from each layer of the composite steel plate;

[0070] A02: Randomly select one of the composite steel plates without replacement as the target steel plate;

[0071] Obtain the coordinates of the center point of the side edge line corresponding to the target steel plate at the target layer, and at the same time obtain the coordinates of the intersection point between the side edge line and the bottom edge line of the target layer. Output the center point coordinates FA(FAX,FAY) and the intersection point coordinates FB(FBX,FBY) simultaneously. 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 edge line of the comparison layer.

[0072] The absolute value of the difference between the ordinates of the intersection point FB(FBX,FBY) and the comparison point FC(FCX,FCY) is taken as the vertical elevation C1 corresponding to the target layer, i.e., C1=|FBY-FCY|. The hypotenuse length C2 corresponding to the target layer is calculated using the center point coordinates FA(FAX,FAY) and the comparison point coordinates FC(FCX,FCY).

[0073] That is, through Calculate the hypotenuse length C2 corresponding to the target layer;

[0074] The ratio between the vertical elevation C1 corresponding to the target layer and the side length C2 of the hypotenuse is taken as the inclination coefficient K1 of the target steel at the target layer;

[0075] A03: Repeat steps A01-A02 to obtain the tilt coefficient Kd of each composite steel plate at the target layer;

[0076] Calculate the standard deviation U of the tilt coefficient Kd. When the standard deviation U is less than or equal to the preset value Z3, the mean value Kp of the tilt coefficient Kd is used as the standard misalignment coefficient M1 of the composite steel plate to be monitored 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 tilt coefficient Kd is used as the standard misalignment coefficient M1 of the composite steel plate to be monitored at the target layer. The specific value of the preset value Z3 is determined by relevant personnel according to actual needs.

[0077] A04: Repeat steps A01-A03 to obtain the standard misalignment coefficient Me corresponding to each layer of the composite steel plate to be monitored. Bind the standard misalignment coefficient Me to the layer number of each layer to generate the standard misalignment coefficient reference table AM ​​of the composite steel plate to be monitored. Here, e is the layer number corresponding to each layer of the composite steel plate after removing the bottom layer, e=1, 2, ..., a-1, satisfying n>e. e is one-to-one with the layer number n corresponding to each layer of the composite steel plate after removing the bottom layer.

[0078] The standard misalignment coefficient reference table acquisition module also analyzes the production data layer by layer to obtain the standard misalignment coefficient of each layer of the composite steel plate to be monitored, and generates a standard misalignment coefficient reference table, which provides a standard for judging whether the misalignment between layers is normal.

[0079] The monitoring module, during the production of composite steel plates, uses the composite steel plates currently in production as the monitoring plates. During the production process, it acquires the real-time positioning height and misalignment coefficient of each layer of the monitoring plate. It then compares these real-time positioning height and misalignment coefficient with the calibrated positioning height and standard misalignment coefficient of each layer. Based on the analysis results, it obtains and outputs height deviation signals and misalignment deviation signals. Specifically:

[0080] During the production of composite steel plates, the composite steel plates currently in production are used as the composite steel plates to be monitored. The real-time positioning height and real-time misalignment coefficient of the real-time production layer of the composite steel plate to be monitored are obtained. The calibrated positioning height and standard misalignment coefficient of 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 its 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 its corresponding standard misalignment coefficient, a misalignment deviation signal is generated; otherwise, no processing is performed. When the real-time production layer generates both a height deviation signal and a misalignment deviation signal, a stop signal is output and simultaneously output to the management terminal along with the height deviation signal and the misalignment deviation signal.

[0081] When the real-time production layer generates either a height deviation signal or a misalignment deviation signal, the real-time production layer is marked as a defect layer. At the same time, the corresponding deviation signal is bound to its corresponding layer to generate defect information. Meanwhile, the monitoring of the composite steel plate to be monitored continues. When i consecutive real-time production layers are marked as defect layers, a stop signal is output, and the signal and the corresponding defect information of the real-time production layer are simultaneously output to the management terminal.

[0082] Where i is a preset threshold, i is the number of defect layers, i is a positive integer, and i satisfies a≥i≥2;

[0083] The system transmits the shutdown signal as a digital electrical signal to the control unit of the production equipment through a pre-set communication protocol. Upon receiving the shutdown signal, the control unit immediately cuts off the power supply to the power unit 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 wirelessly to the monitoring platform at the management end, where they are displayed in a prominent prompt box to remind the management personnel to handle the situation in a timely manner.

[0084] By acquiring real-time positioning height and misalignment coefficient of each layer of composite steel plate during the production process, the timeliness and accuracy of data acquisition are greatly improved. Potential quality problems can be detected early, avoiding the production of a large number of unqualified products and effectively reducing production costs.

[0085] By comparing and analyzing the real-time positioning height and real-time misalignment coefficient with the positioning height reference table and the standard misalignment coefficient reference table, deviation signals are generated. Once a height deviation signal or misalignment deviation signal appears, the system can promptly send a notification to the management terminal. Operators 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 returns to normal as soon as possible, thereby improving production efficiency and product quality.

[0086] By comparing and analyzing the positioning height reference table and the standard misalignment coefficient reference table, the system can promptly notify the management end once a height deviation signal or misalignment deviation signal is detected, allowing operators 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 unit in the production equipment. This function effectively prevents the mass production of defective products and significantly improves the overall quality of the composite steel plate.

[0087] The above formulas are all dimensionless calculations. The formulas are derived from software simulations based on a large amount of collected data to obtain the most recent real-world results. The preset parameters and thresholds in the formulas are set by those skilled in the art according to the actual situation.

[0088] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A real-time monitoring and feedback system for the quality of intelligent steel structure production processes, characterized in that, include: The control group setting module uses multiple qualified composite steel plates of the same specifications as the composite steel plate to be monitored as the control group. The data acquisition module acquires production data corresponding to each layer of the composite steel plate in the control group during the production of the composite steel plate. The positioning height reference table acquisition module generates the calibrated positioning height of each layer of composite steel plate and constructs a positioning height reference table by analyzing the production data corresponding to each layer of composite steel plate at each layer. Standard misalignment coefficient reference table acquisition module, A01: Randomly select one layer as the target layer without replacement after removing the bottom layer from each layer of the composite steel plate; 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 bottom edge line 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 edge line of the comparison layer. Take the absolute value of the difference between the vertical coordinates of the intersection point and the comparison point as the vertical elevation C1 of the target layer. Take the distance between the center point and the comparison point as the hypotenuse length C2 of the target layer. Take the ratio between the vertical elevation C1 and the hypotenuse length C2 of the target layer as the inclination coefficient K1 of the target steel at the target layer. A03: Repeat steps A01-A02 to obtain the tilt coefficient Kd corresponding to each composite steel plate at the target layer. Calculate the standard deviation U of the tilt coefficient Kd. When the standard deviation U is less than or equal to the preset value Z3, the mean value Kp of the tilt coefficient Kd is used as the standard misalignment coefficient M1 corresponding to the composite steel plate to be monitored at the target layer. When the standard deviation U is greater than the standard deviation U, the mean value of the maximum and minimum values ​​of the tilt coefficient Kd is used as the standard misalignment coefficient M1 of the target layer. Here, 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. A04: Repeat steps A01-A03 to obtain the standard misalignment coefficient Me for each layer plate. Bind the standard misalignment coefficient Me with the layer number of each layer plate to generate a standard misalignment coefficient reference table. Here, e is the layer number of each layer plate after removing the bottom layer plate in the composite steel plate, e=1, 2, ..., a-1, where a refers to the number of layers of the steel plate being analyzed. The monitoring module acquires the real-time positioning height and misalignment coefficient of the production layer, compares them with a reference table to generate a deviation signal, and outputs a stop signal when preset conditions are met.

2. The intelligent steel structure production process quality real-time monitoring and feedback system according to claim 1, characterized in that, 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. Extract the outline of the analysis steel plate based on the front view outline of the analysis steel plate. Mark the side edge lines of each layer of the analysis steel plate according to the bottom edge line of each layer of the analysis steel plate. A3: Based on the frontal profile of the steel plate, establish a two-dimensional coordinate system for the frontal profile and obtain the center point coordinates Dn1 (D1Xn, D1Yn) corresponding to the side edge lines of each layer of the steel plate. Here, n represents different side edge lines, and n is marked as the layer number corresponding to each layer of the steel plate, n=1, 2, ..., a, where a represents the number of layers of the steel plate, a is a positive integer, and a satisfies a≥2; A4: Repeat steps A1-A3 to obtain the height value DYnd of each composite steel plate at each layer plate. Analyze the height value DYnd to generate the calibrated positioning height Wn of each layer plate. Bind the calibrated positioning height Wn with the layer number of each layer plate to construct a positioning height reference table.

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

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

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

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

7. The intelligent steel structure production process quality real-time monitoring and feedback system according to claim 6, characterized in that, The specific method for generating the deviation signal is as follows: During the production of composite steel plates, the composite steel plates currently in production are used as the composite steel plates to be monitored. 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 are obtained. 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 its 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 its corresponding standard misalignment coefficient, a misalignment deviation signal is generated; otherwise, no processing is performed.

8. The intelligent steel structure production process quality real-time monitoring and feedback system according to claim 7, characterized in that, The specific method for outputting the stop signal is as follows: A stop signal is generated and output when i consecutive real-time production layers are marked as defective layers; a stop signal is generated and output when a real-time production layer generates both height deviation signal and misalignment deviation signal simultaneously; where i is a positive integer and satisfies a≥i≥2.

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