Structural design and manufacturing method of transportation anti-shaking liquid tank assembly

Abstract

The invention discloses a structural design and manufacturing method of a transportation anti-shake liquid tank assembly, and relates to the technical field of liquid tank manufacturing, the area of an adjusted swash plate is calculated through an adjusted swash plate area algorithm unit, the swash plate is welded in the manufacturing process of an anti-shake liquid tank, and the anti-shake liquid tank assembly can be manufactured on the premise that the anti-shake effect is guaranteed. The area of the swash plate is reduced to the maximum extent, so that the manufactured liquid tank can release more storage space, the area of the swash plate can be compensated according to structural strength reduction caused by weld defects during welding of the liquid tank, and it is ensured that the anti-shaking effect of the liquid tank is not affected by the welding defects; meanwhile, the influence of the length-diameter ratio on liquid inertia force can be considered, the area of the swash plate is increased when the length-diameter ratio is large, it is guaranteed that the manufactured liquid tank has the excellent anti-shaking performance in subsequent transportation and use, meanwhile, the space utilization rate of the liquid tank is optimized, and a more efficient and more economical liquid tank manufacturing method is provided for the liquid tank manufacturing industry.

Description

Technical Field

[0001] The present invention relates to the technical field of liquid tank manufacturing, and in particular to a structural design and manufacturing method of a transport anti-sway liquid tank assembly. Background Art

[0002] Liquid tanks are containers used to transport liquid goods such as alcohol, oil, liquid food, and chemicals. They are oval or nearly spherical in shape and can be categorized into different types based on their purpose and shape. Common types include petrochemical storage tanks, food storage tanks, pharmaceutical storage tanks, and liquid oxygen storage tanks.

[0003] The current structural design and manufacturing methods for liquid tank assemblies in existing calculations make it difficult to monitor and adjust the welding process during the welding steps of liquid tank manufacturing. Relying solely on worker experience or trial-and-error methods to determine welding parameters can result in excessive or insufficient heat input, leading to energy waste and weld defects such as lack of fusion, incomplete penetration, and welds that are too narrow or too wide.

[0004] In addition, in order to improve the anti-sway effect of the liquid tank during transportation, the liquid tank in the current existing technology usually has a wave-breaking plate installed in the liquid tank. In the structural design and manufacturing method of the liquid tank assembly in the existing technology, the area of the wave-breaking plate is usually fixed at the beginning of the structural design and manufacturing of the liquid tank assembly. If the area of the wave-breaking plate set in the liquid tank is too large, it will occupy the storage space of the liquid tank and cause waste of materials. If the area of the wave-breaking plate is insufficient, it will not have a good anti-sway effect in the subsequent transportation of the liquid tank. It is difficult to adjust the area of the wave-breaking plate in the liquid tank according to the welding state of the liquid tank during production and the initial aspect ratio of the liquid tank (the ratio of the height to the width of the tank body). It is difficult to control the wave-breaking plate in the liquid tank to reduce the area of the wave-breaking plate as much as possible while having a good anti-sway effect.

[0005] Therefore, there is an urgent need for a structural design and manufacturing method of a transport anti-sway liquid tank assembly to solve the above problems. Summary of the invention

[0006] The purpose of the present invention is to provide a structural design and manufacturing method for a transport anti-sway liquid tank assembly to solve the problems raised in the above background technology.

[0007] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a structural design and manufacturing method for a transport anti-sloshing liquid tank assembly, the structural design and manufacturing method specifically comprising;

[0008] The data collection module is used to obtain the design data of the anti-sloshing tank and the welding information data during the manufacturing process of the anti-sloshing tank;

[0009] The design data of the anti-sloshing tank include: base material density, base material specific heat capacity, base material melting point, preset height of the tank, preset width of the tank;

[0010] The welding information data includes: welding current, welding voltage, welding speed, welding time, initial temperature, and the actual temperature and ideal temperature during the welding process;

[0011] Through the data preprocessing module, the welding information data and the design data of the anti-slosh tank are decoded and preprocessed to obtain the calculation parameters in the calculation processing module;

[0012] By multiplying the welding current by the welding voltage and then multiplying by the welding heat efficiency factor η in the welding heat input value algorithm unit of the calculation processing module, the actual welding power is obtained, and the welding heat input value Whi is calculated based on the deviation influence term between the actual temperature and the ideal temperature;

[0013] The welding heat input value Whi is input into the weld formation value algorithm unit in the calculation processing module and combined with the difference between the base metal density ρ, base metal specific heat capacity Cp, base metal melting point Tm and the initial temperature T0 to calculate the weld formation value Wsf, providing a quantitative digital index for the geometric characteristics of the anti-slosh tank weld;

[0014] The weld formation value Wsf is input into the adjusted anti-wave plate area algorithm unit in the calculation processing module and combined with the aspect ratio obtained by dividing the preset height of the liquid tank by the preset width of the liquid tank to calculate the adjusted anti-wave plate area Spf;

[0015] According to the adjusted anti-wave plate area Spf, the anti-wave plate is welded during the manufacturing process of the anti-slosh tank.

[0016] Optionally, obtaining the design data of the anti-slosh tank and the welding information data during welding specifically includes:

[0017] Obtaining the welding current Iw, welding voltage Uw, and welding speed Vw through real-time monitoring of a digital welding machine;

[0018] Obtaining the actual temperature Ta of the welding environment through a temperature sensor in real time;

[0019] Obtaining the base metal density ρ, base metal specific heat capacity Cp, base metal melting point Tm, preset height Lcs of the liquid tank, and preset width Ltw of the liquid tank from the design material manual for transporting the anti-slosh tank assembly;

[0020] Obtaining the initial temperature T0 of the base metal for manufacturing the anti-slosh tank before processing through measurement with a K-type thermocouple.

[0021] Optionally, the calculation logic of the welding heat input value algorithm unit includes:

[0022] S11, by multiplying the welding current Iw by the welding voltage Uw and then multiplying by the welding heat efficiency factor η, the actual welding power is obtained;

[0023] S12. Divide the actual welding power by the welding speed Vw to obtain the energy input per unit length of the weld, which is the basic value of the welding heat input value Whi when the influence of the deviation of the welding environment temperature is not considered.

[0024] Optionally, the calculation logic of the welding heat input value algorithm unit further includes:

[0025] S13. Standardize the absolute difference between the actual temperature Ta and the ideal temperature Tr through the ideal temperature Tr, and add 1 to this standardized value as the logarithmic part of the logarithmic function to obtain the temperature deviation influence term in the calculation of the welding heat input value Whi;

[0026] S14. Compress a large temperature change range into a small numerical range through the logarithmic function, so that the correction effect of this standardized difference on the welding heat input value Whi is smooth and controllable. Even if the temperature deviates greatly from the reference temperature, the temperature influence term will not increase infinitely, avoiding overcorrection.

[0027] Optionally, the calculation logic of the weld formation value algorithm unit includes:

[0028] S21. Multiply the base metal density ρ by the specific heat capacity Cp of the base metal and the difference between the melting point Tm of the base metal and the initial temperature T0 to represent the total heat required for the unit volume of the base metal to be heated from the initial temperature to the melting point, reflecting the heat absorption capacity of the material during welding;

[0029] S22. Divide the total heat required for the unit volume of the base metal to be heated from the initial temperature to the melting point by the welding heat input value Whi, and the resulting fraction represents the volume of the base metal that can be melted by the unit welding heat input, reflecting the matching relationship between the welding heat input and the thermophysical properties of the material.

[0030] Optionally, the calculation logic of the weld formation value algorithm unit further includes:

[0031] S23. Multiply the welding time Wt by the welding cooling coefficient k, and use it as the exponential part of the exponential function with the natural constant e as the base, and reflect the attenuation characteristics of the weld cooling process through the characteristics of the exponential function. Specifically:

[0032] When Wt = 0, it means that at the beginning of welding, the weld has not yet formed, and the calculated weld formation value Wsf is 0;

[0033] As the welding time Wt increases, the calculated weld formation value Wsf increases, but due to the characteristics of the negative exponential function with the natural constant e as the base, the growth rate will slow down to avoid mutations and discontinuities during the increase of the welding time Wt.

[0034] Optionally, the calculation logic of the adjusted wave-breaking plate area algorithm unit includes:

[0035] S31, multiplying the preset height Lcs of the liquid tank by the preset width Ltw of the liquid tank to obtain the cross-sectional area of the liquid tank, and multiplying this cross-sectional area by 0.4 to represent the initial design value of the wave-breaking plate area;

[0036] S32, using the Sigmoid function, maps the influence value of the weld seam forming value Wsf on the wave-breaking plate area to a numerical range of (0,1), thereby realizing a dynamic association between the weld seam forming value Wsf and the wave-breaking plate area.

[0037] Optionally, the calculation logic of the adjusted wave-breaking plate area algorithm unit further includes:

[0038] S33, dividing the preset height Lcs of the liquid tank by the preset width Ltw of the liquid tank to obtain the aspect ratio of the liquid tank, and limiting the aspect ratio to [1.5, 3];

[0039] S34, using a linear function to map the effect of the aspect ratio on the adjusted wave-breaking plate area to a numerical range of [1, 1.5]. Specifically:

[0040] When the aspect ratio is 1.5, it means that the aspect ratio of the liquid tank is the optimal state for anti-sloshing. At this time, the aspect ratio has no effect on the calculation of the adjusted wave-breaking plate area Spf. As the aspect ratio increases by 1, the impact value increases by 0.33.

[0041] Compared with the prior art, the present invention has the following beneficial effects:

[0042] 1. The present invention calculates the adjusted wave-breaking plate area algorithm unit using 0.4 times the cross-sectional area of the liquid tank as the basic value for calculating the wave-breaking plate area, and takes into account the weld formation value and the aspect ratio of the liquid tank to obtain the adjusted wave-breaking plate area. The wave-breaking plate is welded during the manufacturing process of the anti-sway liquid tank based on this value. Under the premise of ensuring the anti-sway effect, the wave-breaking plate area can be minimized to the maximum extent, so that the manufactured liquid tank can release more storage space and improve the liquid storage efficiency. The wave-breaking plate area can also be compensated according to the structural strength reduction caused by the weld defects during welding of the liquid tank, ensuring that the anti-sway effect of the liquid tank is not affected by the welding defects. By incorporating the aspect ratio of the liquid tank into the calculation of the adjusted wave-breaking plate area algorithm unit, the influence of the aspect ratio on the inertia force of the liquid can also be considered. When the aspect ratio is large, the wave-breaking plate area is increased, ensuring that the manufactured liquid tank has excellent anti-sway performance in subsequent transportation and use while optimizing the space utilization rate of the liquid tank. This intelligent design concept provides a more efficient and economical liquid tank manufacturing method for the liquid tank manufacturing industry.

[0043] II. By comprehensively considering the welding current, welding voltage, welding speed, and the deviation value of the designed temperature during welding from the ideal temperature through the welding heat input value algorithm unit, the welding heat input value Whi is calculated, which can avoid abnormal metallographic structures caused by insufficient heat input, such as increased brittleness, reduced impact resistance, and the risk of cold cracks. At the same time, it can prevent problems such as overheating of the weld and grain coarsening caused by excessive heat input, so as to ensure that the anti-slosh liquid tank after welding has excellent mechanical properties and corrosion resistance. By considering the influence of the ambient temperature in real time through the welding heat input value algorithm unit and dynamically adjusting the welding parameters, it solves the problem that in the current manufacturing of anti-slosh liquid tanks, relying on workers' experience or the trial-and-error method to determine welding parameters easily leads to excessive or insufficient heat input, resulting in energy waste and weld defects such as lack of fusion, incomplete penetration, too narrow or too wide weld seams, improving the finished product quality of the manufactured anti-slosh liquid tank and enhancing the stability of the liquid tank during transportation and use. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 It is a schematic diagram of the overall structure of a structural design and manufacturing method for a transportation anti-slosh liquid tank assembly. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0045] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all 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.

[0046] Example 1, please refer to Figure 1 , the present invention provides a structural design and manufacturing method for a transportation anti-slosh liquid tank assembly, and the structural design and manufacturing method specifically includes;

[0047] During the manufacturing process of the anti-slosh liquid tank, the design data of the anti-slosh liquid tank and the welding information data during welding are obtained through the data collection module, specifically including:

[0048] The welding current Iw, welding voltage Uw, and welding speed Vw are obtained through real-time monitoring by a digital welding machine;

[0049] The actual temperature Ta of the welding environment is obtained in real time through a temperature sensor;

[0050] The base metal density ρ, base metal specific heat capacity Cp, base metal melting point Tm, preset height Lcs of the liquid tank, and preset width Ltw of the liquid tank are obtained from the design material manual of the transportation anti-slosh liquid tank assembly;

[0051] The initial temperature T0 of the base metal for manufacturing the anti-slosh liquid tank before processing is measured by a K-type thermocouple;

[0052] Through the data preprocessing module, the welding information data and the design data of the anti-slosh tank are decoded and preprocessed to obtain the calculation parameters in the calculation processing module;

[0053] Through the welding heat input value algorithm unit in the calculation processing module, the welding current is multiplied by the welding voltage and then multiplied by the welding heat efficiency factor η to obtain the actual welding power, and the welding heat input value Whi is calculated based on the deviation influence term between the actual temperature and the ideal temperature;

[0054] The welding heat input value Whi is input into the weld forming value algorithm unit in the calculation processing module and combined with the difference between the base metal density ρ, the base metal specific heat capacity Cp, the base metal melting point Tm and the initial temperature T0 to calculate the weld forming value Wsf, providing a quantitative digital index for the geometric characteristics of the anti-slosh tank weld;

[0055] The weld forming value Wsf is input into the adjusted anti-wave plate area algorithm unit in the calculation processing module and combined with the aspect ratio obtained by dividing the preset height of the liquid tank by the preset width of the liquid tank to calculate the adjusted anti-wave plate area Spf;

[0056] According to the adjusted anti-wave plate area Spf, the anti-wave plate is welded during the manufacturing process of the anti-slosh tank.

[0057] In this embodiment:

[0058] Through the cooperation of the welding heat input value algorithm unit, the weld forming value algorithm unit and the adjusted anti-wave plate area algorithm unit, the present invention jointly constitutes the core architecture of a structural design and manufacturing method for a transportation anti-slosh tank assembly. The adjusted anti-wave plate area algorithm unit takes 0.4 times the cross-sectional area of the liquid tank as the basic value for calculating the anti-wave plate area, comprehensively considering the weld forming value Wsf and the aspect ratio of the liquid tank, and calculates the adjusted anti-wave plate area Spf. On the premise of ensuring the anti-slosh effect, reducing the anti-wave plate area can release more internal space of the liquid tank, improve the liquid storage efficiency, and thus maximize the storage capacity of the liquid tank. By incorporating the weld forming value Wsf into the calculation of the adjusted anti-wave plate area algorithm unit, compensation can be made for the structural strength decline caused by weld defects (such as lack of fusion, porosity) during the welding of the liquid tank. The worse the weld quality, the adjusted anti-wave plate area algorithm unit will automatically increase the anti-wave plate area to ensure that the anti-slosh effect of the liquid tank is not affected by welding defects. And by incorporating the aspect ratio of the liquid tank into the calculation of the adjusted anti-wave plate area algorithm unit, in view of the influence of the aspect ratio on the liquid inertia force, the anti-wave plate area is increased when the aspect ratio is relatively large, effectively suppressing violent sloshing and improving transportation safety.

[0059] By adjusting the rear wave-breaking plate area algorithm unit, accurate calculation of the wave-breaking plate area is achieved. During the structural design and manufacturing process of the anti-sway liquid tank assembly for transport, it is ensured that the manufactured liquid tank has excellent anti-sway performance while optimizing the liquid tank space utilization, reducing material costs, and improving the safety and reliability of the liquid tank. This intelligent design concept provides the liquid tank manufacturing industry with a more efficient and economical liquid tank manufacturing method.

[0060] See also Figure 1 , the welding heat input value algorithm unit is as follows:

[0061]

[0062] in:

[0063] Whi represents the welding heat input value;

[0064] Iw represents the welding current, which is obtained through real-time monitoring of the digital welding machine;

[0065] Uw represents the welding voltage, which is obtained through real-time monitoring of the digital welding machine;

[0066] Vw represents the welding speed, which indicates the length of the weld completed per unit time and is obtained through real-time monitoring of the digital welding machine;

[0067] Ta represents the actual temperature, which is the actual temperature during the welding process of the anti-sloshing tank and is obtained in real time by the temperature sensor;

[0068] η represents the welding thermal efficiency factor, and the default value is 0.85;

[0069] Tr stands for ideal temperature, which is the ideal temperature for the anti-sloshing tank welding environment. The preset value is 25. Specifically:

[0070] When the actual temperature during the welding of anti-sway liquid tanks is low, the cooling rate during welding of the liquid tanks is accelerated, which will lead to abnormal metallographic structure and deteriorate the mechanical properties of the weld, manifesting as increased brittleness, reduced impact resistance, and even cold cracks. When the environment is too high, the weld is prone to overheating, causing excessive growth of metal grains, reducing the strength and toughness of the weld. In addition, excessively high temperatures may cause grain boundary migration and phase change of the material, affecting the mechanical properties and corrosion resistance of the material, and increasing the discomfort of workers in operation, indirectly affecting the operation accuracy.

[0071] The actual welding power is obtained by multiplying the welding current Iw by the welding voltage Uw and then by the welding thermal efficiency factor η. Specifically:

[0072] Not all the energy provided by the power supply is directly used for welding the anti-slosh liquid tank. A part of the energy will be lost in the forms of heat radiation, spatter, etc. The welding thermal efficiency η represents the proportion of the effective energy actually used for welding, and its value is less than 1. Therefore, the energy actually used for welding, that is, the actual welding power, is the welding current Iw multiplied by the welding voltage Uw and then multiplied by the welding thermal efficiency factor η;

[0073] By dividing this part of the actual welding power Iw×Uw×μ by the welding speed Vw, the energy input per unit length of the weld can be obtained, which is the basic value of the welding heat input value Whi when the influence of the deviation of the welding environment temperature is not considered;

[0074] This part passes through the ideal temperature Tr to standardize the absolute difference between the actual temperature Ta and the ideal temperature Tr, that is, the deviation value of the actual temperature Ta from the ideal temperature Tr. The value after standardization is added by 1 and used as the logarithmic part of the logarithmic function to obtain the temperature deviation influence term in the calculation of the welding heat input value Whi. The logarithmic function can compress a large temperature change range into a small numerical range, so that the correction effect of the difference after this part of standardization on the welding heat input value Whi is smoother and more controllable. Even if the temperature deviates greatly from the reference temperature, the temperature influence term will not increase infinitely, avoiding overcorrection. Specifically:

[0075] As |Ta - Tr| increases, it represents that the deviation degree between the actual temperature Ta and the ideal temperature Tr is greater. The value of this part of the logarithmic influence is greater, but due to the characteristics of the logarithmic function, the growth rate will slow down.

[0076] In this embodiment, in the production of the anti-slosh liquid tank, the quality of the anti-slosh liquid tank weld is directly related to the pressure-bearing capacity and impact resistance of the liquid tank. The welding heat input value algorithm unit comprehensively considers the welding current, welding voltage, welding speed, and the deviation value of the designed temperature during welding relative to the ideal temperature, and calculates the welding heat input value Whi, which can avoid abnormal metallographic structures caused by insufficient heat input (when the actual temperature is too low), such as increased brittleness, reduced impact resistance, and cold crack risk. At the same time, it can also prevent problems such as weld overheating and grain coarsening caused by excessive heat input (when the actual temperature is too high), ensuring that the weld metal has excellent mechanical properties and corrosion resistance. By the welding heat input value algorithm unit considering the influence of the ambient temperature in real time and dynamically adjusting the welding parameters, it can effectively prevent welding defects caused by temperature fluctuations, such as pores, slag inclusions, and lack of fusion, etc., thereby improving the first-pass rate of the weld and reducing the repair cost.

[0077] Moreover, the required welding heat input value \(W_{hi}\) is accurately calculated by the welding heat input value algorithm unit in the control system, avoiding the problems of excessive or insufficient heat input that may exist in the traditional empirical method, reducing energy waste, which helps to reduce the energy consumption of the anti-slosh tank during welding and improve energy utilization efficiency.

[0078] Please refer to Figure 1 , the weld formation value algorithm unit is as follows:

[0079]

[0080] Where:

[0081] \(W_{sf}\) represents the weld formation value;

[0082] \(W_{hi}\) represents the welding heat input value, which is calculated by the welding heat input value algorithm unit;

[0083] \(\rho\) represents the base metal density, which is the density of the base metal for manufacturing the anti-slosh tank and is obtained from the design material manual for transporting the anti-slosh tank assembly;

[0084] \(C_p\) represents the specific heat capacity of the base metal, which is the specific heat capacity of the base metal for manufacturing the anti-slosh tank and is obtained from the design material manual for transporting the anti-slosh tank assembly;

[0085] \(T_m\) represents the melting point of the base metal, which is the melting point of the base metal for manufacturing the anti-slosh tank and is obtained from the design material manual for transporting the anti-slosh tank assembly;

[0086] \(T_0\) represents the initial temperature, which is the initial temperature of the base metal for manufacturing the anti-slosh tank before processing and is measured and calculated by a K-type thermocouple. Specifically:

[0087] The K-type thermocouple is composed of two different metal materials (usually nickel-chromium alloy and nickel-silicon alloy). When the temperatures of the two junctions are different, a thermoelectromotive force will be generated. The magnitude of this voltage is proportional to the temperature difference between the junctions. By measuring this voltage, the temperature value can be calculated. This is a relatively mature existing technology in the field of thermocouples and will not be elaborated here;

[0088] \(W_t\) represents the welding time, which is obtained by real-time recording with a timer;

[0089] \(k\) represents the welding cooling coefficient, \(k\in[0.1,0.5]\), and the preset value is 0.3. Specifically:

[0090] When the thickness of the tank body of the welded anti-slosh tank is relatively large, the heat dissipation during welding is slow, and the value of \(k\) is low, between 0.1 and 0.3;

[0091] When the thickness of the tank body of the welded anti-slosh tank is relatively small, the heat dissipation during welding is fast, and the value of \(k\) is high, between 0.3 and 0.5;

[0092] The numerator part ρ×Cp×(Tm - T0) represents the total heat required for the base material per unit volume to be heated from the initial temperature to the melting point by multiplying the density ρ of the base material, the specific heat capacity Cp of the base material, and the difference between the melting point Tm of the base material and the initial temperature T0, reflecting the heat absorption capacity of the material during welding:

[0093] As the density ρ of the base material, the specific heat capacity Cp of the base material, and the difference between the melting point Tm of the base material and the initial temperature T0 increase, the calculated weld formation value Wsf becomes larger;

[0094] The welding heat input value Whi in the denominator represents the actual heat input into the weld per unit length considering the temperature deviation effect during welding. By dividing the numerator part ρ×Cp×(Tm - T0) by the denominator, the resulting fraction represents the volume of the base material that can be melted by unit welding heat input, reflecting the matching relationship between the welding heat input and the thermophysical properties of the material. Specifically:

[0095] As the welding heat input value Whi decreases, the volume of the base material melted by unit heat input decreases, the weld will be narrower or shallower, and the calculated weld formation value Wsf decreases;

[0096] The part exp(-k×Wt) reflects the attenuation characteristics of the weld cooling process by taking the product of the welding time Wt and the welding cooling coefficient k as the exponent part of the exponential function with the natural constant e as the base, and through the characteristics of the exponential function. Specifically:

[0097] When Wt = 0, the part 1 - exp(-k×Wt) is 0, indicating that at the beginning of welding, the weld has not been formed and the calculated weld formation value Wsf is 0.

[0098] As the welding time Wt increases, the value of the part exp(-k×Wt) approaches 0, and the part 1 - exp(-k×Wt) gradually approaches 1, indicating that the weld gradually cools and stabilizes.

[0099] Due to the characteristics of the negative exponential function with the natural constant e as the base, as the welding time Wt increases, the part 1 - exp(-k×Wt) gradually approaches 1, but the growth rate will slow down to avoid sudden changes or discontinuities during the increase of the welding time Wt.

[0100] In this embodiment:

[0101] The weld formation value algorithm unit comprehensively considers the base material density ρ, base material specific heat capacity Cp, welding time Wt, and the difference between the base material melting point Tm and the initial temperature T0, and calculates the weld formation value Wsf, which provides a quantitative digital indicator for the geometric characteristics of the anti-sway liquid tank weld in the production of the anti-sway liquid tank. By real-time monitoring of the weld formation value Wsf and adjusting the welding parameters, it helps to reduce weld defects (such as lack of fusion, incomplete penetration, welds that are too narrow or too wide, etc.), ensure that the weld has excellent geometric morphology, improve the one-time pass rate of the weld, and enhance the structural strength and sealing performance of the transport anti-sway liquid tank assembly.

[0102] Traditional welding processes often rely on experience or trial and error to determine welding parameters, which may result in excessive or insufficient heat input, resulting in energy waste or weld defects. The weld shape value algorithm unit provides a scientific basis for optimizing welding parameters by calculating the weld shape value Wsf, so that the welding heat input can accurately match the material's thermophysical properties and weld morphology requirements, thereby reducing energy waste and lowering production costs.

[0103] See also Figure 1 , the algorithm unit of the wave-breaking plate area after adjustment is as follows:

[0104]

[0105] in:

[0106] Spf represents the area of the wave-breaking plate after adjustment;

[0107] Lcs represents the preset height of the tank, which can be obtained from the design material manual of the transport anti-sloshing tank assembly;

[0108] Ltw represents the preset width of the tank, which is obtained from the design material manual of the transport anti-sloshing tank assembly;

[0109] Wsf represents the weld profile value;

[0110] Wgt represents the good threshold value of weld formation value, and the preset value is 0.8;

[0111] The Lth×Lt portion is calculated by multiplying the tank's preset height Lcs by the tank's preset width Ltw to obtain the tank's cross-sectional area. This cross-sectional area is then multiplied by 0.4 to represent the initial design value of the breakwater area. This is determined based on a fixed ratio of 40% of the tank's cross-sectional area. This determination of the breakwater area based on 40% of the tank's cross-sectional area is a well-known technical benchmark in the tank manufacturing field and will not be discussed in detail here.

[0112] This part represents the weld quality correction term. By using the Sigmoid function, the influence value of the weld forming value Wsf on the wave baffle area is mapped to the numerical interval of (0, 1), realizing the dynamic association between the weld forming value Wsf and the wave baffle area. Specifically:

[0113] When Wsf < Wgt, it means that the weld quality does not meet the standard. It is necessary to increase the wave baffle area to compensate for the insufficient structural strength of the tank body caused by the liquid sloshing during transportation, and increase the calculated adjusted wave baffle area Spf;

[0114] This part divides the preset height Lcs of the liquid tank by the preset width Ltw of the liquid tank to obtain the aspect ratio of the liquid tank, and limits the aspect ratio ∈ [1.5, 3]. This part represents the aspect ratio correction term. By using a linear function, the influence value of the aspect ratio on the adjusted wave baffle area is mapped to the numerical interval of [1, 1.5]. Specifically:

[0115] In this part represents the slope of the linear function, and 0.5 represents the intercept. When the value of this part is 1.5, it means that the aspect ratio of the liquid tank is in the optimal state for anti-slosh at this time. The numerical value of the influence value of this part is 1, and for every 1 increase in the aspect ratio, the influence value increases by 0.33;

[0116] In this embodiment:

[0117] The adjusted wave baffle area algorithm unit takes 0.4 times of the cross-sectional area of the liquid tank as the basic value for calculating the wave baffle area, and comprehensively considers the weld forming value Wsf and the aspect ratio of the liquid tank to calculate the adjusted wave baffle area Spf. It can minimize the wave baffle area as much as possible while ensuring the anti-slosh effect, release more internal space of the liquid tank, improve the liquid storage efficiency, and maximize the storage capacity of the liquid tank. By incorporating the weld forming value Wsf into the calculation of the adjusted wave baffle area algorithm unit, it can compensate for the structural strength decline caused by weld defects (such as lack of fusion, porosity) during the welding of the liquid tank. The worse the weld quality, the adjusted wave baffle area algorithm unit will automatically increase the wave baffle area to ensure that the anti-slosh effect of the liquid tank is not affected by welding defects. By incorporating the aspect ratio of the liquid tank into the calculation of the adjusted wave baffle area algorithm unit, it can address the influence of the aspect ratio (the ratio of the tank height to the width) on the liquid inertia force, increase the wave baffle area when the aspect ratio is relatively large, effectively suppress violent sloshing, and improve the transportation safety.

[0118] By adjusting the rear wave-breaking plate area algorithm unit, accurate calculation of the wave-breaking plate area is achieved. In the structural design and manufacturing of the anti-sway liquid tank assembly for transport, it is ensured that the liquid tank has excellent anti-sway performance while maximizing the utilization of the liquid tank space, reducing material costs, and improving the safety and reliability of the liquid tank. This intelligent design concept provides a more efficient and economical solution for the liquid tank manufacturing industry.

[0119] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A structural design and manufacturing method of a transport anti-slosh liquid tank assembly, characterized in that, Specifically, it includes: During the manufacturing process of the anti-slosh liquid tank, the design data of the anti-slosh liquid tank and the welding information data during welding are obtained through the data collection module; The actual welding power is obtained by multiplying the welding current by the welding voltage and then multiplying by the welding thermal efficiency factor η in the welding heat input value algorithm unit of the calculation and processing module, and the welding heat input value Whi is calculated based on the deviation influence term between the actual temperature and the ideal temperature; The welding heat input value Whi is input into the weld formation value algorithm unit in the calculation and processing module, and the weld formation value Wsf is calculated in combination with the difference between the base metal density ρ, the base metal specific heat capacity Cp, the base metal melting point Tm and the initial temperature T0, providing a quantitative digital index for the geometric characteristics of the anti-slosh liquid tank weld; The weld formation value Wsf is input into the adjusted anti-wave plate area algorithm unit in the calculation and processing module, and the adjusted anti-wave plate area Spf is calculated in combination with the aspect ratio obtained by dividing the preset height of the liquid tank by the preset width of the liquid tank; According to the adjusted anti-wave plate area Spf, the anti-wave plate is welded during the manufacturing process of the anti-slosh liquid tank.

2. The structural design and manufacturing method of a transport anti-slosh liquid tank assembly according to claim 1, characterized in that: The design data of the anti-slosh liquid tank includes the base metal density, the base metal specific heat capacity, the base metal melting point, the preset height of the liquid tank, and the preset width of the liquid tank; The welding information data includes the welding current, the welding voltage, the welding speed, the welding time, the initial temperature, and the actual temperature and the ideal temperature during the welding process.

3. The structural design and manufacturing method of a transport anti-slosh liquid tank assembly according to claim 2, characterized in that: The obtaining of the design data of the anti-slosh liquid tank and the welding information data during welding specifically includes: The welding current Iw, the welding voltage Uw, and the welding speed Vw are obtained through real-time monitoring by a digital welding machine; The actual temperature Ta of the welding environment is obtained through a temperature sensor in real time; The base metal density ρ, the base metal specific heat capacity Cp, the base metal melting point Tm, the preset height Lcs of the liquid tank, and the preset width Ltw of the liquid tank are obtained from the design material manual for transporting the anti-slosh liquid tank assembly; The initial temperature T0 of the base metal for manufacturing the anti-slosh liquid tank before processing is measured by a K-type thermocouple.

4. The structural design and manufacturing method of a transport anti-slosh liquid tank assembly according to claim 3, characterized in that: The calculation logic of the welding heat input value algorithm unit includes: S11, the actual welding power is obtained by multiplying the welding current Iw by the welding voltage Uw and then multiplying by the welding thermal efficiency factor η; S12, the actual welding power is divided by the welding speed Vw to obtain the energy input per unit length of the weld, which is the basic value of the welding heat input value Whi without considering the influence of the welding environment temperature deviation; S13, the absolute difference between the actual temperature Ta and the ideal temperature Tr is normalized by the ideal temperature Tr, and the value after this normalization is added by 1 and used as the logarithmic part of the logarithmic function to obtain the temperature deviation influence term in the calculation of the welding heat input value Whi; S14, the large temperature change range is compressed into a small numerical range through the logarithmic function, making the correction effect of the difference after this standard processing on the welding heat input value Whi smooth and controllable, that is, even if the temperature deviates greatly from the reference temperature, the temperature influence term will not increase infinitely, avoiding overcorrection.

5. The structural design and manufacturing method of a transport anti-slosh liquid tank assembly according to claim 4, characterized in that: The calculation logic of the weld formation value algorithm unit includes: S21. The total heat required for the base material per unit volume to be heated from the initial temperature to the melting point is represented by multiplying the density ρ of the base material by the specific heat capacity Cp of the base material and the difference between the melting point Tm of the base material and the initial temperature T0, which reflects the heat absorption capacity of the material during welding. S22. By dividing the total heat required for the base material per unit volume to be heated from the initial temperature to the melting point by the welding heat input value Whi, the resulting fraction represents the volume of the base material that can be melted by a unit of welding heat input, reflecting the matching relationship between the welding heat input and the thermophysical properties of the material.

6. The structural design and manufacturing method of a transport anti-slosh liquid tank assembly according to claim 5, characterized in that: The calculation logic of the weld formation value algorithm unit further includes: S23. After multiplying the welding time Wt by the welding cooling coefficient k, it is used as the exponential part of the exponential function with the natural constant e as the base, and the decay characteristics of the weld cooling process are reflected through the characteristics of the exponential function. Specifically: When Wt = 0, it means that at the beginning of welding, the weld has not been formed, and the calculated weld formation value Wsf is 0. As the welding time Wt increases, the calculated weld formation value Wsf increases, but due to the characteristics of the negative exponential function with the natural constant e as the base, the growth rate slows down to avoid sudden changes and discontinuities during the increase of the welding time Wt.

7. The structural design and manufacturing method of a transport anti-slosh liquid tank assembly according to claim 1, characterized in that: The calculation logic of the adjusted anti-sway baffle area algorithm unit includes: S31. By multiplying the preset height Lcs of the liquid tank by the preset width Ltw of the liquid tank, the cross-sectional area of the liquid tank is obtained, and multiplying this part of the cross-sectional area by 0.4 represents the initial design value of the anti-sway baffle area. S32. The influence value of the weld formation value Wsf on the anti-sway baffle area is mapped to the numerical interval of (0, 1) through the Sigmoid function to achieve the dynamic association between the weld formation value Wsf and the anti-sway baffle area. S33. By dividing the preset height Lcs of the liquid tank by the preset width Ltw of the liquid tank, the aspect ratio of the liquid tank is obtained, and the aspect ratio is limited to ∈[1.5, 3]. S34. The influence value of the aspect ratio on the adjusted anti-sway baffle area is mapped to the numerical interval of [1, 1.5] through a linear function. Specifically: When the aspect ratio takes the value of 1.5, it represents that the aspect ratio of the liquid tank is in the optimal state for anti-sway at this time, and at this time, the calculation of the aspect ratio has no influence on the adjusted anti-sway baffle area Spf, and the influence value increases by 0.33 for each increase of 1 in the aspect ratio.

8. The structural design and manufacturing method of a transport anti-slosh liquid tank assembly according to claim 1, characterized in that, The structure design and manufacturing method further includes decoding and preprocessing the welding information data and the design data of the anti-sway liquid tank through a data preprocessing module to obtain the calculation parameters in the calculation processing module.

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