Large-span water conservancy gate and manufacturing process thereof

Abstract

The application belongs to the technical field of hydraulic engineering manufacturing, and provides a large-span water conservancy gate and a manufacturing process thereof; in a historical symmetry welding period, a visual sensor is used to simultaneously monitor welding tracks of welding joints in symmetric directions to obtain A welding sub-track and B welding sub-track; the welding seams on both sides of the A welding sub-track and the B welding sub-track are analyzed from the space X axis, the space Y axis and the space Z axis, respectively; the overall fitting degree of the A welding sub-track and the B welding sub-track in the three-dimensional space is reflected, that is, the consistency comprehensive performance of the welding seams on both sides in each dimension, so as to help reduce the vibration and shaking of the gate in the running process due to the inconsistent welding seam positions, make the structure stress of the gate more uniform, enable the gate to bear greater external force, effectively reduce the gap at the welding seam, improve the sealing performance of the gate, and prevent the occurrence of problems such as water leakage.

Description

Technical Field

[0001] This invention belongs to the field of water conservancy engineering manufacturing technology, specifically a large-span water conservancy gate and its manufacturing process. Background Technology

[0002] In the field of water conservancy engineering, the manufacturing quality of large-span gates is directly related to the safe and stable operation of water conservancy projects. Among them, the welding process is a key link in the gate manufacturing process, and its quality has a decisive impact on the overall performance of the gate. Symmetrical welding, as a commonly used welding method, has certain advantages in improving welding efficiency and ensuring welding quality, and is especially suitable for welding large structures such as large-span gates.

[0003] In existing technologies, there are certain limitations to addressing the issue of inconsistent welding trajectories during symmetrical welding. Firstly, when analyzing welding trajectories, only deviations in a single dimension are typically considered, lacking a comprehensive assessment of the overall consistency of the welding trajectories in three-dimensional space (X-axis, Y-axis, and Z-axis).

[0004] On the other hand, existing technologies lack a systematic and in-depth analysis of track deviations that occur during welding. Even when track deviations are detected during welding, it is difficult to determine whether these deviations are occasional or regular. There is a lack of effective assessment methods for whether track deviations are stable during certain periods, making it impossible to accurately determine the severity and scope of the problem during welding. Due to the lack of stability analysis of track deviation periods, it is difficult to implement precise measures during subsequent welding adjustments.

[0005] Therefore, the present invention provides a large-span hydraulic gate and its manufacturing process. Summary of the Invention

[0006] In order to overcome the shortcomings of the prior art, at least one technical problem raised in the background art is solved.

[0007] The technical solution adopted by this invention to solve its technical problem is:

[0008] A large-span hydraulic gate and its manufacturing process, comprising the following steps:

[0009] Within a historical symmetrical welding cycle, the welding trajectory of the welding head in the symmetrical direction is monitored simultaneously by a visual sensor to obtain the A-weld track separation and the B-weld track separation.

[0010] Within the historical symmetrical welding cycle, the welds on both sides of the A and B rails were analyzed to assess whether the welds on both sides of the A and B rails were consistent.

[0011] If there is no consistency, a stability analysis is performed on the track deviation periods within multiple historical symmetrical welding cycles to assess whether the track deviation periods are stable and obtain the stability analysis results.

[0012] If the deviation of the rails during the time period is stable, the adjustment amount of the rail welding gap is obtained, and the welding adjustment of rails A and B is performed. If the deviation of the rails during the time period is unstable, the adjustment range of the rail welding gap is obtained, and the welding adjustment of rails A and B is performed.

[0013] As a further aspect of the present invention, the method for obtaining the A-welding rail and the B-welding rail is as follows:

[0014] The historical symmetrical welding cycle is equally divided into several historical symmetrical welding periods;

[0015] Using a vision sensor, the weld trajectories along directions A and B are converted into a three-dimensional coordinate model. The historical symmetrical welding period is equally divided into several historical measurement nodes. The coordinates of the weld joints within each historical measurement node on the three-dimensional coordinate model are obtained, thus obtaining the A measurement coordinate point. The A measurement coordinate points corresponding to all historical measurement nodes within the historical symmetrical welding period are then connected according to the time sequence to obtain the A weld track.

[0016] The historical symmetrical welding period is equally divided into several measured nodes. The coordinates of the weld joint in each historical measured node on the three-dimensional coordinate model are obtained to obtain the measured coordinate point B.

[0017] Connect the B-measured coordinate points corresponding to all historical measured nodes within the historical symmetrical welding period according to the time sequence to obtain the B-welding track.

[0018] A further aspect of this invention is as follows: The welds on both sides of the A and B rail sections are analyzed separately, as follows:

[0019] During the historical symmetrical welding period, the measured coordinates of weld A and B at each historical measured node were obtained. and B measured coordinate points And and The groups were combined separately to obtain the X-axis alignment group, the Y-axis alignment group, and the Z-axis alignment group;

[0020] Using the Pearson distance formula, the differences in X-axis, Y-axis and Z-axis were calculated for all the comparison groups.

[0021] A further aspect of this invention is as follows: The process for evaluating whether the welds on both sides of the A and B rails are consistent is as follows:

[0022] Input the X-axis difference value, Y-axis difference value, and Z-axis difference value into the coordinate distance formula, and the output will be the track alignment value;

[0023] If the rail alignment value is greater than the rail alignment threshold, a rail welding deviation signal is generated. The historical symmetrical welding time periods corresponding to the generated rail welding deviation signal are statistically analyzed and marked as rail deviation time periods.

[0024] A further aspect of this invention is as follows: Stability analysis is performed on the track deviation periods within multiple historical symmetrical welding cycles to obtain the ratio of key track numbers. The process is as follows:

[0025] Arbitrarily select a historical symmetrical welding cycle as the target analysis cycle, and obtain the ranking of all track deviation periods within the target analysis cycle as the target deviation ranking;

[0026] The remaining historical symmetrical welding cycles are used as the comparison and analysis cycles. The comparison deviation rankings corresponding to the track deviation periods within all comparison and analysis cycles are extracted.

[0027] If the comparison deviation ranking in at least one comparison analysis period overlaps with the target deviation ranking in the target analysis period, it is recorded as the overlap deviation ranking. The deviation time periods of the overlap deviation ranking are counted, and the corresponding welding rails are obtained and marked as key welding rails. The total number of key welding rails in multiple historical symmetrical welding periods is counted, and the proportion of the key rails in the total number of historical symmetrical welding periods in multiple historical symmetrical welding periods is calculated to obtain the key rail quantity ratio.

[0028] A further aspect of this invention is as follows: Stability analysis is performed on the track deviation periods within multiple historical symmetrical welding cycles to obtain the standard deviation of the track deviation. The process is as follows:

[0029] Within each track deviation period of the overlap deviation ranking, obtain the corresponding track alignment value, perform difference processing with the track alignment threshold, take the absolute value, and calculate the ratio with the track alignment threshold to output the track deviation ratio.

[0030] Calculate the standard deviation of all track deviation ratios and output the standard deviation of track deviation.

[0031] A further aspect of this invention is the evaluation of whether the track deviation period is stable, the process of which is as follows:

[0032] The ratio of the number of key track segments to the standard deviation of track segment deviation is processed to output the deviation stability value;

[0033] If the deviation from the stable value is greater than or equal to the deviation from the stable threshold, a deviation from the stable signal is generated.

[0034] A further aspect of this invention is as follows: if the deviation of the rails during the time period is stable, the adjustment amount of the rail welding gap is obtained, and the process is as follows:

[0035] If a deviation from the stable signal is generated, the deviation ratio of the key welded rails is extracted and averaged to output the adjustment amount of the rail welding gap. The key welded rails are then adjusted according to the adjustment amount of the rail welding gap.

[0036] A further aspect of this invention is as follows: If the track deviation time period is unstable, the lower warning limit for track welding and the upper warning limit for track welding are obtained, and the process is as follows:

[0037] If a deviation fluctuation signal is generated, the deviation stability values ​​corresponding to key welding tracks within multiple historical symmetrical welding cycles are compared, and the key welding tracks corresponding to the maximum and minimum deviation stability values ​​are extracted respectively as the lower and upper warning limit welding tracks.

[0038] As a further aspect of the present invention, the process for obtaining the adjustment range of the rail welding gap is as follows:

[0039] The lower limit welding rail deviation ratio is obtained within multiple historical symmetrical welding cycles, and then averaged to output the lower limit adjustment value.

[0040] The upper limit welding rail deviation ratio is obtained within multiple historical symmetrical welding cycles, and then averaged to output the upper limit adjustment value.

[0041] The adjustment range for the rail welding gap is constructed based on the lower and upper limit adjustment values.

[0042] The beneficial effects of this invention are as follows:

[0043] 1. This invention monitors the welding trajectory of the welding head in the symmetrical direction simultaneously using a visual sensor within a historical symmetrical welding cycle, obtaining welding track A and welding track B. The weld seams on both sides of welding track A and B are analyzed from the X, Y, and Z axes in space, reflecting the overall degree of conformity of welding track A and B in three-dimensional space, that is, the overall consistency of the weld seams on both sides in various dimensions. This helps to reduce the vibration and shaking of the gate caused by inconsistent weld seam positions during operation, making the gate structure more uniformly stressed, able to withstand greater external forces, and effectively reducing the gap at the weld seam, improving the sealing performance of the gate, and preventing problems such as water leakage.

[0044] 2. This invention performs stability analysis on track deviation periods within multiple historical symmetrical welding cycles to obtain stable deviation values. These stable deviation values ​​reflect the stability of the proportion of track deviation periods with overlapping deviation rankings within multiple historical symmetrical welding cycles, as well as the stability of the track deviation degree within each overlapping deviation ranking period. This not only identifies the periods of recurring track deviation during welding and the corresponding welded tracks, but also analyzes the stability of the track deviation degree in each welding process. Subsequently, targeted adjustments to the symmetrical welding parameters are made. If the track deviation periods are stable, the adjustment amount of the track weld gap is obtained. Welding adjustments are made to the A and B rail sections. If the deviation of the rail sections is unstable during certain periods, the adjustment range of the rail section weld gap is obtained. Welding adjustments to the A and B rail sections are made not only to optimize the deviation of symmetrical welding by adjusting welding parameters when the deviation of the rail sections is stable during certain periods, reducing weld defects caused by welding deviation, but also to specifically adjust the rail sections with key welds, improving the efficiency of adjustment and optimization. Furthermore, for the fluctuation of the rail section deviation during certain periods, the lower limit adjustment value and the upper limit adjustment value are used as the basis to construct the adjustment range of the rail section weld gap, ensuring that the welding adjustment is not excessive or insufficient, avoiding new welding quality problems caused by improper adjustment, and ensuring that the welding quality is stable within a certain range. Attached Figure Description

[0045] The invention will now be further described with reference to the accompanying drawings.

[0046] Figure 1 This is a flowchart illustrating the manufacturing process of a large-span hydraulic gate according to the present invention. Detailed Implementation

[0047] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0048] Example 1

[0049] The present invention provides a large-span hydraulic gate and its manufacturing process, comprising the following steps:

[0050] S1. Based on the design drawings, virtual layout is carried out using 3D modeling software to determine the assembly position and bevel form of each component of the gate;

[0051] S2, pre-treatment of steel plates, including mechanical leveling or flame leveling of steel plates, removal of oxide scale and rust by shot blasting or sandblasting to achieve Sa2.5 grade standard (near white level cleanliness), cutting steel plate shape (such as door leaf panel, beam structure), milling or planing the edges of the cut steel plate, and processing welding bevels.

[0052] S3. Position the door leaf panel, main beam, secondary beam, side beam and other components on the assembly platform and fix them with clamps to ensure the relative position accuracy of each component (e.g., diagonal error ≤3mm).

[0053] S4. Submerged arc welding is used to weld the connection between the main beam and the panel according to the principle of "symmetrical welding and segmented back welding", and defect detection is performed on the weld.

[0054] S5, the supporting and traveling mechanism of the gate (such as the shaft hole at the end of the support arm of the arc gate) is bored and then painted.

[0055] Example 2

[0056] Please see Figure 1 As shown in the embodiment of the present invention, a manufacturing process for a large-span hydraulic gate involves submerged arc automatic welding using symmetrical welding rules. However, during real-time welding of the two weld joints in the symmetrical welding process, localized stress concentration is prone to occur in the symmetrical welding direction, leading to misalignment or incomplete fusion of the weld seam. This necessitates manual repair welding, increasing the welding time and consequently affecting the manufacturing cycle of the large-span hydraulic gate. The process includes the following steps:

[0057] Step 1: Within the historical symmetrical welding cycle, the welding trajectory of the welding head in the symmetrical direction is monitored simultaneously by a vision sensor to obtain the A-weld track separation and the B-weld track separation.

[0058] It should be noted that the symmetrical directions are directions A and B, respectively;

[0059] In some embodiments, the historical symmetrical welding cycle is equally divided into several historical symmetrical welding periods;

[0060] It should be noted that the symmetrical welding duration is equal for each historical symmetrical welding period;

[0061] The A-rail and B-rail separations within each historical symmetrical welding period were acquired using a visual sensor, as follows:

[0062] The process of obtaining the A-weld rail segmentation during the historical symmetrical welding period is as follows:

[0063] For example, a vision sensor is used to convert the weld trajectory in direction A into a three-dimensional coordinate model, where the X-axis is the weld trajectory length, the Y-axis is the weld trajectory width, and the Z-axis is the weld trajectory depth.

[0064] The historical symmetrical welding period is equally divided into several historical measurement nodes. The coordinates of the welded joint in the three-dimensional coordinate model within each historical measurement node are obtained to obtain the A measurement coordinate point.

[0065] Connect the A-measured coordinate points corresponding to all historical measured nodes within the historical symmetrical welding period according to the time sequence to obtain the A-weld track.

[0066] A2, the process of obtaining the B-weld rail during the historical symmetrical welding period is as follows:

[0067] For example, a vision sensor is used to convert the weld trajectory in the B direction into a three-dimensional coordinate model, where the X-axis is the weld trajectory length, the Y-axis is the weld trajectory width, and the Z-axis is the weld trajectory depth.

[0068] The historical symmetrical welding period is equally divided into several measured nodes. The coordinates of the weld joint in each historical measured node on the three-dimensional coordinate model are obtained to obtain the measured coordinate point B.

[0069] Connect the B-measured coordinate points corresponding to all historical measured nodes within the historical symmetrical welding period according to the time sequence to obtain the B-welding track.

[0070] It should be noted that the obtained A and B welded rails are all within the same historical symmetrical welding period, and each measured coordinate point of A and B within the same historical symmetrical welding period corresponds to the same historical measured node.

[0071] Welded rails A and B are on the same three-dimensional coordinate model, and welded rails A and B are axisymmetric welded rails formed with the plane about the ZY axis as the reference plane.

[0072] Step 2: Within the historical symmetrical welding cycle, analyze the welds on both sides of the A and B rails respectively, and evaluate whether the welds on both sides of the A and B rails are consistent.

[0073] In some embodiments, during the historical symmetrical welding period, the measured coordinate points of weld A and weld B at each historical measured node are obtained respectively. and B measured coordinate points And and The groups were combined separately to obtain the X-axis alignment group, the Y-axis alignment group, and the Z-axis alignment group;

[0074] Where i represents the i-th measured node within the historical symmetrical welding period;

[0075] Statistically analyze all X-axis comparison groups, Y-axis comparison groups, and Z-axis comparison groups corresponding to the A and B welding rails;

[0076] For example, inputting the coordinates of all X-axis comparison groups into the Pearson distance formula (Equation 1) outputs the X-axis difference value D. x ;

[0077] Specifically: Formula 1: in, This represents the X-axis coordinate of weld rail A at the i-th measured node within the historical symmetrical welding period. This represents the X-axis coordinate of the B-weld sub-rail at the i-th measured node within the historical symmetrical welding period. This is expressed as the average of all X-axis coordinates on weld rail A within the X-axis comparison group. It is expressed as the average value of all X-axis coordinates on the B-welding rail within the X-axis comparison group;

[0078] Input the coordinates of all Y-axis comparison groups into the Pearson distance formula (Equation 2) to output the Y-axis difference value D. Y ;

[0079] Specifically: Formula Two: in, This represents the Y-axis coordinate of weld rail A at the i-th measured node within the historical symmetrical welding period. This represents the Y-axis coordinate of weld B on the measured node during the historical symmetrical welding period. This is expressed as the average of all Y-axis coordinates on the A-weld sub-rail within the group, compared to the Y-axis. It is expressed as the average value of all Y-axis coordinates on the B-welding rail within the group;

[0080] Input the coordinates of all Z-axis comparison groups into the Pearson distance formula (Equation 3) to obtain the Z-axis difference value D. Z ;

[0081] Specifically: Formula 3: in, This represents the Z-axis coordinate on weld rail A at the i-th measured node within the historical symmetrical welding period. This represents the Z-axis coordinate on the B-weld track at the i-th measured node within the historical symmetrical welding period. This is expressed as the average value of all Z-axis coordinates on the A-weld sub-rail within the Z-axis comparison group. It is expressed as the average value of all Z-axis coordinates on the B-welding rail within the Z-axis comparison group;

[0082] As will be understood by those skilled in the art, the purpose of using the Pearson distance formula is:

[0083] Objective 1: By calculating the Pearson distance of the X-axis comparison group, we can understand whether the weld positions of the A and B welded rails are relatively consistent in the horizontal direction (X-axis direction) and whether there is any significant offset or misalignment in the smooth operation of the gate. This allows us to promptly detect and adjust horizontal deviations during the welding process to ensure the normal operation of the gate.

[0084] Objective 2: By calculating the Pearson distance of the Y-axis comparison group, we can understand the structural stability and load-bearing capacity of the gate in the vertical direction (wel positions in the Y-axis direction) of the A and B welded rails. This allows us to promptly detect and adjust vertical deviations during the welding process, ensuring the structural safety of the gate.

[0085] Objective 3: By calculating the Pearson distance of the Y-axis comparison group, we can understand the sealing performance and waterproof leakage performance of the gate in terms of weld depth (wel position in the Z-axis direction) of the A and B welded rails. This allows us to promptly detect and adjust depth deviations during the welding process to ensure the sealing performance of the gate.

[0086] Input the X-axis, Y-axis, and Z-axis difference values ​​into the coordinate distance formula to obtain the track alignment value D. w ;

[0087] Specifically: Coordinate distance formula: The calculated track alignment value D w , where D x Represented as the difference value on the X-axis, D Y Represented as the difference value along the Y-axis, D Z Represented as the Z-axis difference value;

[0088] It can be explained that the purpose of using the coordinate distance formula to obtain the track alignment value is that the coordinate distance formula quantifies the difference values ​​in three dimensions in a unified manner, making the track alignment values ​​under different welding conditions comparable. This facilitates horizontal and vertical comparative analysis by technicians, thereby reflecting the deviation of welding quality in different dimensions, providing technicians with clear directions for improvement, and helping to improve welding quality and production efficiency, and shorten the manufacturing cycle of large-span hydraulic gates.

[0089] It is understandable that the meaning of the track alignment value is: a comprehensive index calculated by using the coordinate distance formula based on the difference values ​​of the X-axis, Y-axis and Z-axis. It reflects the overall degree of alignment of the A and B welded tracks in three-dimensional space (X-axis, Y-axis and Z-axis), that is, the overall consistency of the welds on both sides in various dimensions. This helps to reduce the vibration and shaking caused by the inconsistent position of the welds during the operation of the gate, making the gate structure more uniformly stressed, able to withstand greater external forces, and effectively reducing the gap at the weld, improving the sealing performance of the gate, and preventing problems such as water leakage.

[0090] The track alignment value is compared with the track alignment threshold, as follows:

[0091] If the track alignment value is greater than the track alignment threshold, it indicates that when welding the same weld seam in different spatial directions, the consistency of the welding trajectory in different spatial directions is low, generating a track deviation signal. Then, the historical symmetrical welding time period corresponding to the generated track deviation signal is statistically analyzed and marked as the track deviation time period.

[0092] If the track alignment value is less than or equal to the track alignment threshold, it indicates that when welding the same weld seam in different spatial directions, the consistency of the welding trajectory in different spatial directions is high, generating a track welding consistency signal.

[0093] The specific solution in this embodiment is as follows: During the historical symmetrical welding cycle, the welding trajectory of the welding head in the symmetrical direction is monitored simultaneously by a visual sensor to obtain the A-weld rail and the B-weld rail. The weld seams on both sides of the A and B rails are analyzed from the spatial X-axis, Y-axis and Z-axis to reflect the overall degree of conformity of the A and B rails in three-dimensional space (X-axis, Y-axis and Z-axis), that is, the overall consistency of the weld seams on both sides in various dimensions. This helps to reduce the vibration and shaking of the gate caused by inconsistent weld seam positions during operation, making the gate structure more uniformly stressed, able to withstand greater external forces, and effectively reducing the gap at the weld seam, improving the sealing performance of the gate and preventing problems such as water leakage.

[0094] Example 3

[0095] Please see Figure 1 As shown in the figure, the manufacturing process of a large-span hydraulic gate according to an embodiment of the present invention includes the following steps:

[0096] Step 3: If there is no consistency, perform stability analysis on the track deviation periods within multiple historical symmetrical welding cycles to evaluate whether the track deviation periods are stable and obtain the stability analysis results.

[0097] In some embodiments, an arbitrary historical symmetrical welding cycle is selected as the target analysis cycle;

[0098] Extract the ranking of all track deviation periods within the target analysis period to obtain the target deviation ranking;

[0099] The remaining historical symmetrical welding cycles will be used as the comparison and analysis cycles.

[0100] Extract all track deviation periods within the comparison analysis period and obtain the corresponding comparison deviation ranking;

[0101] The target deviation ranking within the target analysis period is compared with the comparison deviation ranking within multiple comparison analysis periods. The process is as follows:

[0102] If at least one comparison deviation ranking in the comparison analysis period overlaps with the target deviation ranking in the target analysis period, it is recorded as an overlap deviation ranking.

[0103] If the comparison deviation rankings in multiple comparison analysis periods do not overlap with the target deviation rankings in the target analysis period, they are recorded as non-overlapping deviation rankings.

[0104] The time periods of track deviation for ranking overlapping deviations are statistically analyzed, and the corresponding welding tracks are marked as key welding tracks.

[0105] The total number of key welded rail sections in multiple historical symmetrical welding cycles is statistically analyzed, and the proportion of the key welded rail sections in the total number of historical symmetrical welding periods in multiple historical symmetrical welding cycles is calculated to obtain the key rail section number ratio.

[0106] Within each track deviation period of the overlap deviation ranking, obtain the corresponding track alignment value, perform difference processing with the track alignment threshold, take the absolute value, and calculate the ratio with the track alignment threshold to output the track deviation ratio.

[0107] Calculate the standard deviation of all track deviation ratios and output the standard deviation of track deviation.

[0108] The ratio of the number of key track segments to the standard deviation of track segment deviation is processed to output the deviation stability value;

[0109] Those skilled in the art will understand that the deviation stability value means: combining the key track deviation ratio (reflecting the repetition of track deviation periods in multiple historical cycles) and the standard deviation of track deviation (reflecting the consistency or volatility of track deviation), to assess the stability of track deviation periods during welding. Specifically, on the one hand, the key track deviation ratio reflects the stability of the proportion of track deviation periods with overlapping deviation rankings in multiple historical symmetrical welding cycles. On the other hand, the standard deviation of track deviation reflects the stability of track deviation within each overlapping deviation ranking period. Thus, it is possible not only to identify the periods of repeated track deviation and the corresponding welding tracks during welding, but also to analyze the stability of track deviation in each welding process, and subsequently make targeted adjustments to the symmetrical welding parameters.

[0110] The deviation from the stable value is compared with the deviation from the stable threshold, as follows:

[0111] If the deviation from the stable value is greater than or equal to the deviation from the stable threshold, it indicates that the location of the track deviation period is relatively stable in multiple historical symmetrical welding cycles. This reflects that the welding position corresponding to the key welding track is prone to welding deviation, and the degree of deviation in each welding is also relatively stable, generating a deviation stability signal.

[0112] If the deviation from the stable value is less than the deviation from the stable threshold, it indicates that the location of the track deviation period in multiple historical symmetrical welding cycles is relatively unstable. This reflects that the welding position corresponding to the key welding track is relatively unstable, and the degree of deviation in each welding is also relatively unstable, generating a deviation fluctuation signal.

[0113] Step 4: If the deviation of the rails during the time period is stable, obtain the adjustment amount of the rail welding gap and adjust the welding of rails A and B. If the deviation of the rails during the time period is unstable, obtain the adjustment range of the rail welding gap and adjust the welding of rails A and B.

[0114] In some embodiments, if a deviation from the stable signal is generated, the deviation ratio of the rails corresponding to the key welded rails is extracted and averaged, and the rail welding gap adjustment amount is output. The key welded rails are then welded and adjusted according to the rail welding gap adjustment amount.

[0115] If a deviation fluctuation signal is generated, the deviation stability values ​​corresponding to key welding tracks within multiple historical symmetrical welding cycles are compared, and the key welding tracks corresponding to the maximum and minimum deviation stability values ​​are extracted respectively as the lower and upper warning limit welding tracks.

[0116] The lower limit welding rail deviation ratio is obtained within multiple historical symmetrical welding cycles, and then averaged to output the lower limit adjustment value.

[0117] The upper limit welding rail deviation ratio is obtained within multiple historical symmetrical welding cycles, and then averaged to output the upper limit adjustment value.

[0118] The adjustment range for the rail welding gap is constructed based on the lower and upper limit adjustment values.

[0119] The specific solution in this embodiment is as follows: Stability analysis is performed on the track deviation periods within multiple historical symmetrical welding cycles to obtain stable deviation values. These stable deviation values ​​reflect the stability of the proportion of track deviation periods with overlapping deviation rankings within multiple historical symmetrical welding cycles, and also reflect the stability of the track deviation degree within each overlapping deviation ranking period. This not only identifies the periods of repeated track deviation during the welding process and the corresponding weld tracks, but also analyzes the stability of the track deviation degree during each welding process. Subsequently, targeted adjustments are made to the symmetrical welding parameters. If the track deviation periods are stable, the track weld gap adjustment is obtained. The process involves adjusting the welding gaps of rails A and B. If the deviation of the rails during a given period is unstable, the adjustment range of the rail welding gaps is determined. This adjustment not only addresses the stable deviation during the time period by optimizing symmetrical welding through parameter adjustments to reduce weld defects caused by deviation, but also specifically targets key rails, improving optimization efficiency. Furthermore, it establishes a rail welding gap adjustment range based on lower and upper limit adjustment values ​​to prevent excessive or insufficient adjustments, thus avoiding new welding quality problems and ensuring stable welding quality within a certain range.

[0120] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for a large-span hydraulic gate, characterized in that: include: Within the historical symmetrical welding cycle, the welding trajectory of the welding head in the symmetrical direction is monitored to obtain the A-weld track division and the B-weld track division. A consistency analysis was performed on the welds on both sides of the A and B rails. If the welds on both sides of the A and B rails are inconsistent, a stability analysis is performed on the rail deviation periods within multiple historical symmetrical welding cycles to assess whether the rail deviation periods are stable. If the deviation of the rails from the time period is stable, the adjustment amount of the rail welding gap is obtained, and the welding adjustment of rails A and B is carried out. If the deviation of the rails from the time period is unstable, the adjustment range of the rail welding gap is obtained, and the welding adjustment of rails A and B is carried out. Stability analysis was performed on the track deviation periods within multiple historical symmetrical welding cycles to obtain the key track quantity ratio. The process is as follows: Arbitrarily select a historical symmetrical welding cycle as the target analysis cycle, and obtain the ranking of all track deviation periods within the target analysis cycle as the target deviation ranking; The remaining historical symmetrical welding cycles are used as the comparison and analysis cycles. The comparison deviation rankings corresponding to the track deviation periods within all comparison and analysis cycles are extracted. If the comparison deviation ranking in at least one comparison analysis period overlaps with the target deviation ranking in the target analysis period, it is recorded as the overlap deviation ranking. The deviation time periods of the overlap deviation ranking are counted, and the corresponding welding rails are obtained and marked as key welding rails. The total number of key welding rails in multiple historical symmetrical welding periods is counted, and the proportion of the key rails in the total number of historical symmetrical welding periods in multiple historical symmetrical welding periods is calculated to obtain the key rail quantity ratio. Stability analysis was performed on the track deviation periods within multiple historical symmetrical welding cycles to obtain the standard deviation of the track deviation. The process is as follows: Within each track deviation period of the overlap deviation ranking, obtain the corresponding track alignment value and compare it with the track alignment threshold. The difference is processed, the absolute value is taken, and the ratio is calculated with the track deviation threshold. The output is the track deviation ratio. Calculate the standard deviation of all track deviation ratios and output the standard deviation of track deviation. The process for assessing whether track deviation is stable during the time period is as follows: The ratio of the number of key track segments to the standard deviation of track segment deviation is processed to output the deviation stability value; If the deviation from the stable value is greater than or equal to the deviation from the stable threshold, a deviation from the stable signal is generated; If the deviation of the rails from the time period is stable, the adjustment amount of the rail welding gap is obtained, and the process is as follows: If a deviation from the stable signal is generated, the deviation ratio of the rails corresponding to the key welded rails is extracted and averaged to output the rail welding gap adjustment amount. The key welded rails are then welded and adjusted according to the rail welding gap adjustment amount. If the deviation of the rail section during the time period is unstable, the lower warning limit for rail section welding and the upper warning limit for rail section welding are obtained. The process is as follows: If a deviation fluctuation signal is generated, the deviation stability values ​​corresponding to key welding tracks within multiple historical symmetrical welding cycles are compared, and the key welding tracks corresponding to the maximum and minimum deviation stability values ​​are extracted respectively as the lower and upper warning limit welding tracks. The process for obtaining the adjustment range of the rail welding gap is as follows: The lower limit welding rail deviation ratio is obtained within multiple historical symmetrical welding cycles, and then averaged to output the lower limit adjustment value. The upper limit welding rail deviation ratio is obtained within multiple historical symmetrical welding cycles, and then averaged to output the upper limit adjustment value. The adjustment range for the rail welding gap is constructed based on the lower and upper limit adjustment values.

2. The manufacturing process of a large-span hydraulic gate according to claim 1, characterized in that: The methods for obtaining welded rail A and welded rail B are as follows: The historical symmetrical welding cycle is equally divided into several historical symmetrical welding periods; Using a visual sensor, the weld trajectories in directions A and B are converted into a three-dimensional coordinate model. The historical symmetrical welding period is equally divided into several historical measurement nodes. The coordinates of the weld joint in each historical measurement node on the three-dimensional coordinate model are obtained to obtain the A measurement coordinate point. The A measurement coordinate points corresponding to all historical measurement nodes in the historical symmetrical welding period are connected according to the time sequence to obtain the A weld track. The historical symmetrical welding period is equally divided into several measured nodes. The coordinates of the weld joint in each historical measured node on the three-dimensional coordinate model are obtained to obtain the measured coordinate point B. Connect the B-measured coordinate points corresponding to all historical measured nodes within the historical symmetrical welding period according to the time sequence to obtain the B-welding track.

3. The manufacturing process of a large-span hydraulic gate according to claim 1, characterized in that: The welds on both sides of rails A and B were analyzed separately, and the process is as follows: During the historical symmetrical welding period, the A measured coordinate points corresponding to each historical measured node of the A and B weld rails were obtained and combined to obtain the X-axis comparison group, Y-axis comparison group and Z-axis comparison group. Using the Pearson distance formula, the differences in X-axis, Y-axis and Z-axis were calculated for all the comparison groups.

4. The manufacturing process of a large-span hydraulic gate according to claim 3, characterized in that: The process for assessing the consistency of the welds on both sides of rails A and B is as follows: Input the X-axis difference value, Y-axis difference value, and Z-axis difference value into the coordinate distance formula to output the track alignment value; if the track alignment value is greater than the track alignment threshold, a track welding deviation signal is generated to obtain the track deviation time period.

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