A smart manufacturing system and process for corrugated steel cylinder fiber reinforced tube structure

Abstract

This invention discloses an intelligent manufacturing system and process for corrugated steel cylinder fiber reinforced pipe structures, belonging to the field of industrial automatic control technology. The system includes: a real-time monitoring module for monitoring the processing quality of multiple processes; and a central processing module for instantaneously analyzing the data from the real-time monitoring module and generating control commands to regulate the processing parameters of the production equipment. Based on the data collected by the real-time monitoring module and the output of the central processing module, this invention achieves closed-loop control of the entire process from data acquisition and analysis to equipment adjustment, ensuring that the quality parameters of each process remain stable within the qualified range. This achieves precision, efficiency, and intelligence in the pipe manufacturing process, effectively avoiding the problem that manual control dominates the production process, and that each manufacturing process is relatively independent, lacking effective integration and coordination.

Description

Technical Field

[0001] This invention relates to the field of industrial automatic control technology, and in particular to an intelligent manufacturing system and process for corrugated steel cylinder fiber reinforced pipe structure. Background Technology

[0002] In numerous fields such as infrastructure construction and water conservancy projects, corrugated steel cylinder fiber-reinforced pipes are widely used in drainage, water supply, and underground pipeline projects due to their unique structural and performance advantages, such as high strength, corrosion resistance, and good flexibility. However, traditional manufacturing methods for corrugated steel cylinder fiber-reinforced pipes have many problems that urgently need to be solved. In the production process, manual control plays a dominant role, with each manufacturing step relatively independent and lacking effective integration and coordination.

[0003] Chinese Patent Application No. 2024119499458 discloses an improved corrugated steel cylinder fiber-reinforced pipe and its manufacturing method. This method improves the traditional corrugated steel cylinder fiber-reinforced pipe by replacing the annular corrugated steel cylinder with a spiral corrugated steel cylinder, processing the corrugation valleys, and improving the wire winding process. Subsequently, circumferential and longitudinal reinforcing bars are welded onto the steel cylinder, resulting in a novel corrugated steel cylinder composite pipe structure with less prestress loss and stronger steel cylinder constraint. The aforementioned improved corrugated steel cylinder fiber-reinforced pipe improves the prestress retention capacity and anti-fiber breakage performance of the pipe by using a spiral corrugated steel cylinder and a prestressed fiber winding method. However, in the prestressed fiber winding process of the above invention, the difficulty in accurately and stably controlling the winding tension leads to inconsistent pipe quality. Unstable winding tension can cause uneven prestress distribution in different parts of the pipe, easily leading to localized stress concentration, which in turn affects the overall strength and service life of the pipe. Furthermore, traditional methods cannot accurately control prestress loss, resulting in a significant deviation between the actual performance of the pipe and the design requirements.

[0004] Similar to the existing technologies described above, quality monitoring of finished corrugated steel cylinder fiber-reinforced pipes primarily relies on manual sampling or partial inspection. Manual sampling is not only inefficient but also has blind spots, failing to ensure comprehensive inspection of every product. Partial inspection only obtains partial information and cannot reflect the quality status of the entire manufacturing process. Therefore, real-time monitoring of the entire manufacturing process is difficult to achieve, and adjustments to the production process based on monitoring results are not possible in a timely manner. Quality problems often only become apparent after the product is completed, resulting in wasted resources and increased production costs. In the production process, manual control dominates, with each manufacturing step relatively independent and lacking effective integration and coordination.

[0005] Therefore, there is an urgent need for an advanced production system and process that can integrate and optimize the manufacturing process of corrugated steel cylinder fiber reinforced pipes, achieve intelligent quality control at each stage, thereby improving the overall production level and product reliability, and meeting the market demand for high-quality pipes. Summary of the Invention

[0006] The purpose of this invention is to provide an intelligent manufacturing system and process for corrugated steel cylinder fiber reinforced pipe structures to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: an intelligent manufacturing system for corrugated steel cylinder fiber reinforced pipe structure, including a real-time quality monitoring system. The system includes: a real-time monitoring module for monitoring the processing quality of multiple processes. The real-time monitoring module also includes a laser scanning module applied in the steel cylinder forming process, which acquires the corrugated shape and size parameters by scanning in all directions multiple times per second.

[0008] The tension acquisition module is used in the winding process to capture fiber winding tension data in real time at millisecond-level frequency.

[0009] The fluorescence detection module is located after the tension acquisition module and is used in the winding process to detect the number and density of fiber winding layers.

[0010] The central processing module is used to perform instantaneous analysis of the data from the real-time monitoring module and generate control commands to regulate the processing parameters of the production equipment, thereby achieving closed-loop control of the entire process from data acquisition and analysis to equipment adjustment, and ensuring that the quality parameters of each process remain stable within the qualified range.

[0011] Preferably, the real-time monitoring module further includes a visual recognition module and a mortar thickness detection module. The visual recognition module is applied in the welding process to identify the appearance quality by capturing images of the welding points in real time. The mortar thickness detection module is applied in the spraying process to monitor the mortar spraying thickness and crack defects in real time.

[0012] Preferably, the system also includes a steel cylinder hydraulic forming equipment, a wire winding equipment, a resin spraying equipment, a welding equipment, and a mortar spraying equipment. The above equipment corresponds to the steel cylinder forming process, the wire winding process, the welding process, and the spraying process, respectively. The tension acquisition module and the fluorescence detection module are both applied in the wire winding process.

[0013] Preferably, the laser scanning module includes multiple laser scanners arranged around the steel cylinder, which can perform all-round three-dimensional laser scanning on the formed corrugated steel cylinder according to a preset scanning path and frequency, and transmit the data to the central processing module. The central processing module can compare and analyze the real-time data with the preset data to determine whether the corrugated steel cylinder meets the standards, and adjust the processing parameters of the steel cylinder hydraulic forming equipment according to the frequency of substandard corrugated grooves.

[0014] Preferably, the tension acquisition module includes a tension sensor, which can capture the tension changes of the fiber filament in real time during the winding process and transmit the data to the central processing module. The central processing module can predict the winding tension of the fiber filament based on the depth of each corrugated groove acquired by the laser scanning module, and adjust the winding equipment in advance according to the prediction results.

[0015] Preferably, the winding equipment includes fibers impregnated with fluorescent agents and a fiber feeding mechanism. The fluorescence detection module includes an ultraviolet fluorescence detection device, which can detect the uniformity of the distribution of special fluorescent marks on the fibers and determine whether the number and density of the winding layers of the fibers meet the standards through a central processing module, and control the winding equipment to rewind the areas that do not meet the standards.

[0016] Preferably, the winding equipment further includes a resin coating containing a fluorescent agent and a resin spraying mechanism. The fluorescence detection module also includes a timing module, which can time the solidification of the resin after the resin spraying mechanism completes the spraying operation. The central processing module can perform secondary detection of the degree of resin solidification based on the timing of the timing module in conjunction with the tension acquisition module and the fluorescence detection module.

[0017] Preferably, the system further includes a pushing mechanism and a rotating mechanism. The pushing mechanism can drive the steel cylinder to move within multiple processes, and the rotating mechanism can drive the steel cylinder to rotate to assist the real-time monitoring module in monitoring and processing the steel cylinder.

[0018] This invention also provides an intelligent manufacturing method for corrugated steel cylinder fiber-reinforced tube structures. The method utilizes the aforementioned intelligent system to manufacture the corrugated steel cylinder fiber-reinforced tube structures, and includes the following steps:

[0019] S100, Hydraulic forming and inspection: The forming process of corrugated grooves on the steel cylinder is completed by the steel cylinder hydraulic forming equipment, and the forming parameters of each corrugated groove are detected and recorded by the laser scanning module, and the processing parameters of the steel cylinder hydraulic forming equipment are adjusted by the central processing module.

[0020] S200, Steel cylinder winding and tension detection: The winding equipment winds the steel cylinder with wire, and the tension acquisition module monitors the change of fiber tension in real time. Combined with the data obtained by the laser scanning module, the processing parameters of the winding equipment are pre-adjusted by the central processing module to reduce the response time.

[0021] S300, Resin Spraying and Fluorescence Detection: The resin spraying mechanism sprays a resin coating containing a fluorescent agent onto the corrugated part of the steel cylinder after the wire winding operation, and the central processing module performs secondary detection on the degree of resin solidification based on the timing of the timing module, the tension acquisition module and the fluorescence detection module.

[0022] S400, Rebar Welding and Visual Recognition: The welding process of longitudinal and circumferential reinforcing bars is carried out through the welding equipment, and the welding point image is captured in real time by the visual recognition module and the appearance quality is identified by the central processing module.

[0023] S500, Sandblasting and Inspection Inside the Steel Cylinder: The inside of the steel cylinder is sandblasted using a mortar spraying device, and the sandblasting thickness is detected by a mortar thickness detection module. At the same time, the central processing module determines whether the sandblasting thickness meets the standard.

[0024] Preferably, S200 includes the following steps:

[0025] S210. The tension data of the fiber filament is collected in real time through the tension acquisition module, and the data is processed and transmitted to the central processing module.

[0026] S220. The central processing module analyzes and judges the tension using data from the tension acquisition module and the laser scanning module to determine whether the tension meets the standard. If it does, the current parameters are maintained and the operation continues. If not, the process proceeds to S230.

[0027] S230. By calculating and analyzing the difference between the current tension and the preset tension, a control command is generated to control the winding equipment for adjustment, and then proceed to step S210.

[0028] Preferably, step S300 includes the following steps:

[0029] S310. The fluorescence data on the fiber filament is collected through the fluorescence detection module;

[0030] S320, and the central processing module judges whether the number of winding layers and density of the fiber filaments meet the standards. If not, the winding equipment is controlled to rewind and proceed to S310; if yes, proceed to S330.

[0031] S330: Maintain the current parameters and continue operation. When the number of winding layers reaches the preset number, control the resin spraying mechanism to spray resin and use the timing module to keep track of the time.

[0032] S340. The central processing module determines whether the solidification time is met based on the data from the timing module. If not, solidification continues; if so, proceed to S350.

[0033] S350. The central processing module detects the solidification degree of the resin layer through the tension acquisition module and the fluorescence detection module to determine whether the solidification degree of the resin meets the standard. If yes, proceed to S400; otherwise, wait for solidification.

[0034] The technical effects and advantages of this invention are as follows:

[0035] 1. Based on the data collected by the real-time monitoring module and the output of the central processing module, this invention immediately generates an early warning message and sends a real-time feedback instruction to the corresponding process equipment once the quality data exceeds the preset threshold. This achieves closed-loop control of the entire process from data collection and analysis to equipment adjustment, ensuring that the quality parameters of each process remain stable within the qualified range. This enables the pipe manufacturing process to be precise, efficient, and intelligent, effectively avoiding the problems of manual control dominating the production process, each manufacturing process being relatively independent, lacking effective integration and coordination, and the quality monitoring of the completed corrugated steel cylinder fiber reinforced pipe mainly relying on manual sampling or local inspection. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the overall layout of the intelligent production system of the present invention.

[0037] Figure 2 This is a schematic diagram of the control process of the intelligent production system of the present invention.

[0038] Figure 3 This is a flowchart illustrating the real-time quality monitoring module and central control module of the present invention.

[0039] Figure 4 This is a schematic diagram of the steel cylinder forming and inspection process of the present invention.

[0040] Figure 5 This is a schematic diagram of the winding tension and detection process of the present invention.

[0041] Figure 6 This is a schematic diagram of the process flow for determining the number of winding layers and fluorescence detection in this invention.

[0042] Figure 7 This is a schematic diagram of the intelligent production method of the present invention.

[0043] Figure 8 This is a schematic diagram of the S200 sub-step in the intelligent production method of the present invention.

[0044] Figure 9This is a flowchart illustrating step S300 in the intelligent production method of the present invention.

[0045] In the diagram: 1. Laser scanning module; 2. Tension acquisition module; 3. Fluorescence detection module; 4. Central processing module; 5. Visual recognition module; 6. Mortar thickness detection module. Detailed Implementation

[0046] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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.

[0047] First Embodiment

[0048] To address the issues that in the production process, manual control dominates, each manufacturing step is relatively independent, lacks effective integration and coordination, and the quality monitoring of finished corrugated steel cylinder fiber reinforced pipes mainly relies on manual sampling or local inspection.

[0049] like Figures 1-9 As shown, the present invention provides an intelligent manufacturing system for corrugated steel cylinder fiber reinforced pipe structure to solve the above problems. The system includes a real-time quality monitoring system and supporting equipment for steel cylinder hydraulic forming, wire winding, resin spraying, welding, and mortar spraying.

[0050] It should be noted that the above-mentioned equipment together constitutes the production equipment mentioned in the accompanying drawings of this application, and all of the above-mentioned equipment is prior art, so it will not be described in detail here.

[0051] In this embodiment, the intelligent manufacturing system for the corrugated steel cylinder fiber reinforced tube structure specifically includes the following processes: steel cylinder forming process, wire winding process, welding process, and spraying process. The above-mentioned equipment corresponds to the above-mentioned processes, wherein the wire winding process includes two processes: wire winding and resin spraying.

[0052] In this embodiment, the real-time quality monitoring system includes a real-time monitoring module, which is used to monitor the processing quality of multiple processes.

[0053] In this embodiment, the system also includes a central processing module 4, which is used to perform instantaneous analysis of the data from the real-time monitoring module and generate control commands to regulate the processing parameters of the production equipment, thereby achieving closed-loop control of the entire process from data acquisition and analysis to equipment adjustment, and ensuring that the quality parameters of each process are stable within the qualified range.

[0054] In this embodiment, the real-time monitoring module also includes a laser scanning module 1 applied in the steel cylinder forming process. It scans the corrugated shape and size parameters multiple times per second in all directions. Through high-precision three-dimensional laser scanning, it accurately obtains the shape and size data of the corrugations, including key parameters such as crest height, trough depth, and pitch, and immediately transmits them to the central processing module 4. When it is detected that the processed corrugated groove is not up to standard, the central processing module 4 can issue a control command to the steel cylinder hydraulic forming equipment in a timely manner to adjust the processing parameters, thereby avoiding the problem that the subsequent steel cylinder corrugated grooves are all substandard.

[0055] In this embodiment, the laser scanning module 1 includes multiple laser scanners arranged around the steel cylinder. It can perform all-round three-dimensional laser scanning on the formed corrugated steel cylinder according to a preset scanning path and frequency, and transmit the data to the central processing module 4 to adjust the processing parameters of the steel cylinder hydraulic forming equipment.

[0056] It should be noted that the system also includes a pushing mechanism that can move the steel cylinder, and a rotating mechanism that can rotate the steel cylinder.

[0057] In this embodiment, the real-time monitoring module also includes a tension acquisition module 2, which is used in the winding process to capture fiber winding tension data in real time at a millisecond frequency. By installing high-precision tension sensors at key positions of the winding equipment, the tension change data during the fiber winding process is captured in real time and transmitted to the central control unit at a millisecond frequency.

[0058] It should be noted that the central processing module 4 has a built-in tension prediction and control model trained based on deep learning algorithms. This model can perform instantaneous analysis of the real-time tension data transmitted by the sensor based on preset winding process parameters (such as the design tension value range, tension attenuation compensation coefficient at different winding stages, etc.), and the fiber used in the above process is basalt fiber.

[0059] In this embodiment, the wire winding equipment includes a wire feeding mechanism and a motor drive mechanism. The central processing module 4 automatically sends precise control commands to the motor drive system and wire feeding mechanism of the wire winding equipment. For example, by adjusting the motor speed, the fiber supply speed can be precisely varied, and the wire feeding resistance can be finely adjusted in real time using the tension adjustment device of the wire feeding mechanism. This ensures that the winding tension of the basalt fiber is always stable within the target range, and the prestress loss can be precisely controlled at an extremely low level, effectively guaranteeing the stability and consistency of the pipe winding quality.

[0060] In this embodiment, the tension acquisition module 2 includes a tension sensor, which can capture the tension changes of the fiber filament in real time during the winding process and transmit the data to the central processing module 4, which then controls the winding equipment.

[0061] In this embodiment, the real-time monitoring module also includes a fluorescence detection module 3, which is located after the tension acquisition module 2 and is used in the winding process to detect the number and density of fiber winding layers.

[0062] In this embodiment, the winding equipment includes fibers impregnated with fluorescent agents and a fiber feeding mechanism. The fluorescence detection module 3 includes an ultraviolet fluorescence detection device, which can detect the uniformity of the distribution of special fluorescent marks on the fibers and determine whether the number and density of the fiber winding layers meet the standards through the central processing module 4. The winding equipment is then adjusted to rewind areas that do not meet the standards. By additionally configuring the fluorescence detection module 3 and using ultraviolet light to irradiate the surface of the wound fibers, the uniformity of the distribution of special fluorescent marks on the fibers is detected to determine whether the number and density of the fiber winding layers meet the process requirements. The detection image data is then transmitted to the central processing module 4 for analysis and processing, thereby ensuring that the winding process meets the standards.

[0063] In this embodiment, the real-time monitoring module further includes a visual recognition module 5 and a mortar thickness detection module 6. The visual recognition module 5 is applied in the welding process, which identifies the appearance quality by capturing images of the welding points in real time. The mortar thickness detection module 6 is applied in the spraying process to monitor the mortar spraying thickness and crack defects in real time.

[0064] In the fiber-reinforced mortar spraying process, the mortar thickness detection module 6 is specifically an electromagnetic induction sensor, which is an embedded electromagnetic induction sensor array placed around the nozzle of the spraying equipment. These sensors can detect the mortar spraying thickness distribution on the inner wall of the corrugated steel cylinder in real time and whether there are defects such as microcracks. By converting the induction signals into mortar layer thickness data and crack characteristic information, the data is synchronously sent to the central processing module 4, thereby allowing the central processing module 4 to control the blasting thickness.

[0065] In the welding process of longitudinal and transverse reinforcing bars, the visual recognition module 5 captures images of the welding points in real time from multiple angles. The image recognition algorithm accurately identifies the appearance quality of the welding points, including welding saturation, presence of slag inclusions, and accuracy of the welding position. The image feature data is then transmitted to the central processing module 4, which adjusts the welding equipment accordingly.

[0066] Taking the production of corrugated steel cylinder fiber reinforced pipe with a diameter of 1.5 meters and a length of 6 meters as an example, during the corrugated steel cylinder forming stage, the laser scanning module 1 performs an all-round scan of the formed steel cylinder at a frequency of 5 times per second. The collected data such as the peak height, valley depth, and pitch are accurate to the level of 0.1 mm and are transmitted to the central processing module 4 in real time. The central processing module 4 uses data fitting algorithms such as the least squares method to compare and analyze the pre-stored qualified corrugated steel cylinder shape parameter template. Once it finds that the actual parameter deviation exceeds the allowable tolerance (such as the peak height deviation exceeding 2 mm), it immediately sends an adjustment command to the hydraulic control system of the forming equipment to precisely control the opening and closing degree of the mold and the rolling pressure to ensure that the shape accuracy of the subsequently formed corrugated steel cylinder meets the requirements.

[0067] During the basalt fiber winding process, the tension acquisition module 2 monitors the tension changes in real time, and the central processing module 4 makes a tension adjustment decision every 0.1 seconds based on the deep learning algorithm model. For example, when the winding reaches the middle position of the corrugated steel cylinder, if the tension increases by 10% instantaneously due to the fluctuation of the fiber release speed, the system instantly instructs the motor to reduce the speed and adjusts the tension adjustment device of the release mechanism to make the tension quickly fall back to the target range, ensuring that the prestress loss of fiber winding is always controlled within 2%, and ensuring the reliability of the pipe winding quality.

[0068] During the welding of longitudinal and circumferential reinforcing bars, the vision recognition module 5 captures real-time images of the welding point from four angles: top, bottom, left, and right. It can collect 20 high-definition images per second. Through image recognition algorithms, it can accurately identify appearance defects of the welding point, such as incomplete welding and slag inclusions. Once a substandard welding point is found, the central processing module 4 immediately controls the welding robot to return to the welding point for repair welding or adjust the welding parameters and re-weld, ensuring the firmness and stability of the reinforcing bar connection and improving the overall structural strength of the pipe.

[0069] In the fiber-reinforced mortar spraying process, an embedded electromagnetic induction sensor array monitors the mortar spraying thickness in real time at a frequency of once every 0.5 seconds, with a monitoring accuracy of 0.5 mm. When the mortar thickness in a certain area is lower than the design minimum limit, the central processing module 4 quickly instructs the nozzle of the spraying equipment to increase the mortar flow rate in that area, while adjusting the robot's moving speed to ensure that the mortar layer is sprayed evenly to the specified thickness, effectively preventing insufficient pipe strength caused by an excessively thin mortar layer.

[0070] In summary, based on the data collected by the real-time monitoring module and the output of the central processing module 4, once the quality data exceeds the preset threshold, an early warning message is immediately generated and a real-time feedback instruction is sent to the corresponding process equipment. This achieves closed-loop control of the entire process from data collection and analysis to equipment adjustment, ensuring that the quality parameters of each process remain stable within the qualified range. This enables the pipe manufacturing process to be precise, efficient, and intelligent, effectively avoiding the problems of manual control dominating the production process, each manufacturing process being relatively independent, lacking effective integration and coordination, and the quality monitoring of the completed corrugated steel cylinder fiber reinforced pipe relying mainly on manual sampling or local inspection.

[0071] Second Embodiment

[0072] However, in actual use, operators found that because the initial quality of each batch of steel cylinders was not completely consistent, two unexpected situations would occur when the steel cylinder hydraulic forming equipment was used for forming operations. One was that the quality of a single corrugated groove of the steel cylinder was substandard; the other was that the quality of multiple consecutive corrugated grooves of the steel cylinder was substandard. If the central processing module 4 used the parameters of the single substandard corrugated groove as the standard to adjust the steel cylinder hydraulic forming equipment, it would cause all subsequent steel cylinders to be substandard.

[0073] Therefore, to solve the above problems, the system also includes the following settings: the central processing module 4 can compare and analyze real-time data with preset data to determine whether the corrugated steel cylinder meets the standards, and adjust the processing parameters of the steel cylinder hydraulic forming equipment according to the frequency of substandard corrugated grooves.

[0074] When the central processing module 4 analyzes the data collected by the laser scanning module 1, if the analysis shows that the non-compliance rate of the corrugated groove on the steel cylinder is lower than the preset value, the central processing module 4 marks the non-compliant area. At the same time, it checks the next steel cylinder. If the area is still found to be non-compliant, the central processing module 4 determines that the processing parameters of this area are abnormal and adjusts the parameters of the steel cylinder hydraulic forming equipment. If the data from the next steel cylinder inspection shows that the area meets the standard, it means that the reason for non-compliance is not abnormal processing parameters, but a quality problem of the steel cylinder itself, and the processing parameters are not changed.

[0075] If the analysis shows that the non-compliance rate of the corrugated groove on the steel cylinder is higher than the preset value, the processing parameters are determined to be abnormal, the central processing module 4 issues a warning message, and adjusts the parameters.

[0076] Third Embodiment

[0077] However, in actual use, operators found that relying solely on tension sensors to detect tension changes and adjusting the forward and rotation speeds accordingly can lead to excessive tension fluctuations if the difference between the previous corrugated groove and the one to be wound is too large. This can result in breakage or insufficient winding strength. Furthermore, data transmission has a certain delay, requiring high-precision and highly sensitive equipment, which is costly.

[0078] Therefore, to solve the above problems, the system also includes the following configuration: the central processing module 4 can predict the winding tension of the fiber filament based on the depth of each corrugated groove collected by the laser scanning module 1, and adjust the winding device in advance according to its prediction results.

[0079] When the wire winding operation is carried out in the corrugated groove by the wire winding equipment, the depth and width data of each corrugated groove detected by the laser scanning module 1 are transmitted to the central processing module 4. The central processing module 4 constructs a corrugated groove depth model based on the above data. If the depth difference between the corrugated groove in the current wire winding operation and the next corrugated groove is within the preset range, the central processing module 4 controls the wire winding equipment and tension acquisition module to operate normally and makes real-time adjustments based on the tension changes.

[0080] If the depth difference between the corrugated groove currently undergoing wire winding and the next corrugated groove exceeds the preset range, it indicates that the depth difference between the two adjacent corrugated grooves is large. At this time, the central processing module 4 issues a control command to the wire winding equipment in advance. The command is divided into two parts. The first part is to slow down the wire winding rate, that is, to reduce the steel cylinder travel rate and the wire feeding rate of the wire feeding mechanism, so as to avoid the problem of excessive tension change and breakage caused by instantaneous control of the forward speed and rotation speed. The second part is to calculate the matching wire winding rate based on the collected data. After the first part is completed, the second part of the control is performed to avoid the problem of a certain delay in data transmission.

[0081] Fourth embodiment

[0082] However, in actual use, operators found that when the number of fiber layers wound in the corrugated groove of the steel cylinder reached the preset number, the degree of resin solidification was judged solely by time when resin was sprayed. Since the degree of resin solidification is affected by environmental factors, the accuracy was insufficient, which affected subsequent processing.

[0083] Therefore, to solve the above problems, the system also includes the following settings: the wire winding equipment also includes a resin coating containing fluorescent agent and a resin spraying mechanism, the fluorescence detection module 3 also includes a timing module, which can time the solidification of the resin after the resin spraying mechanism completes the spraying operation, and the central processing module 4 can perform secondary detection of the solidification degree of the resin in coordination with the tension acquisition module 2 and the fluorescence detection module 3 based on the timing of the timing module.

[0084] After the resin spraying operation is completed, the resin curing time is timed by the timing module. When the preset time is reached, because the sprayed resin contains fluorescent substances, and the molecular structure changes during the resin curing process, which affect the fluorescence properties, the central processing module 4 controls the fluorescence detection module 3 to perform fluorescence detection on the resin layer to determine whether it has completed curing. At the same time, the central processing module 4 controls the winding equipment to wind the limiting wire on the surface of the resin. Since the hardness of the resin layer is different in the cured and uncured states, the tension is also different when the winding equipment parameters remain unchanged. The tension combined with the fluorescence intensity is used to make a second judgment on whether the resin layer has completed curing, thereby avoiding the problem of the resin layer not being fully cured and affecting the next process.

[0085] Fifth embodiment

[0086] This invention also provides an intelligent manufacturing method for corrugated steel cylinder fiber-reinforced tube structures. This method utilizes the intelligent system described in the above embodiments to manufacture the corrugated steel cylinder fiber-reinforced tube structures, and includes the following steps:

[0087] S100, Hydraulic Forming and Inspection: The corrugated grooves on the steel cylinder are formed by the hydraulic forming equipment. The forming parameters of each corrugated groove are detected and recorded by the laser scanning module 1. The processing parameters of the hydraulic forming equipment are adjusted by the central processing module 4.

[0088] S200, steel cylinder winding and tension detection: The steel cylinder is wound with wire by the winding equipment, and the tension acquisition module monitors the change of fiber tension in real time. Combined with the data obtained by the laser scanning module 1, the processing parameters of the winding equipment are pre-adjusted by the central processing module 4 to reduce the response time.

[0089] S300, resin spraying and fluorescence detection: The resin spraying mechanism sprays a resin coating containing a fluorescent agent into the corrugated part of the steel cylinder after the wire winding operation, and the central processing module 4 performs secondary detection on the solidification degree of the resin in coordination with the timing module, the tension acquisition module 2 and the fluorescence detection module 3.

[0090] S400, steel bar welding and visual recognition, through the welding equipment to weld longitudinal steel bars and circumferential steel bars, and through the visual recognition module 5 to capture images of the welding points in real time and through the central processing module 4 to identify the appearance quality.

[0091] S500, Sandblasting and Inspection of Steel Cylinder: The inside of the steel cylinder is sandblasted using a mortar spraying equipment, and the sandblasting thickness is detected by a mortar thickness detection module. At the same time, the central processing module 4 judges whether the sandblasting thickness meets the standard.

[0092] In this implementation, S200 includes the following steps:

[0093] S210. The tension data of the fiber filament is collected in real time through the tension acquisition module 2, and the data is processed and transmitted to the central processing module 4.

[0094] S220: The central processing module 4 analyzes and judges the tension based on the data from the tension acquisition module 2 and the laser scanning module 1. It determines whether the tension meets the standard. If it does, it maintains the current parameters and continues to operate. If not, it proceeds to S230.

[0095] S230. By calculating and analyzing the difference between the current tension and the preset tension, a control command is generated to control the winding equipment for adjustment, and then proceed to step S210.

[0096] In this embodiment, step S300 includes the following steps:

[0097] S310. The fluorescence data on the fiber is collected through the fluorescence detection module 3.

[0098] S320, and the central processing module 4 judges whether the number of winding layers and density of the fiber filaments meet the standards. If not, the winding equipment is controlled to rewind and proceed to S310; if so, proceed to S330.

[0099] S330: Maintain current parameters and continue operation. When the number of winding layers reaches the preset number, control the resin spraying mechanism to spray resin and use the timing module to keep track of the time.

[0100] S340: The central processing module 4 determines whether the solidification time is met based on the data from the timing module. If not, solidification continues; if so, it proceeds to S350.

[0101] S350, the central processing module 4 detects the solidification degree of the resin layer through the tension acquisition module 2 and the fluorescence detection module 3 to determine whether the solidification degree of the resin meets the standard. If yes, it proceeds to S400; otherwise, it waits for solidification.

[0102] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A smart manufacturing system for corrugated steel cylinder fiber-reinforced pipe structures, comprising a real-time quality monitoring system, characterized in that, The system includes: a real-time monitoring module for monitoring the processing quality of multiple processes; the real-time monitoring module also includes a laser scanning module applied in the steel cylinder forming process, which acquires the corrugation shape and size parameters by scanning in all directions multiple times per second. The laser scanning module includes multiple laser scanners arranged around the steel cylinder. These scanners can perform omnidirectional three-dimensional laser scanning on the formed corrugated steel cylinder according to a preset scanning path and frequency, and transmit the data to the central processing module. The central processing module can compare and analyze the real-time data with the preset data to determine whether the corrugated steel cylinder meets the standards, and adjust the processing parameters of the steel cylinder hydraulic forming equipment according to the frequency of substandard corrugated grooves. The tension acquisition module is used in the winding process to capture fiber winding tension data in real time at millisecond frequency. The tension acquisition module includes a tension sensor, which can capture the tension change of the fiber during the winding process in real time and transmit the data to the central processing module. The central processing module can predict the winding tension of the fiber based on the depth of each corrugated groove acquired by the laser scanning module, and adjust the winding equipment in advance according to the prediction results. The winding equipment includes fiber filaments impregnated with fluorescent agent and a fiber feeding mechanism. The fluorescence detection module includes an ultraviolet fluorescence detection device, which can detect the uniformity of the distribution of special fluorescent marks on the fiber filaments, and judge whether the number and density of the fiber filament winding layers meet the standards through the central processing module, and control the winding equipment to rewind the non-compliant areas. The fluorescence detection module is located after the tension acquisition module and is used in the winding process to detect the number and density of fiber winding layers. The central processing module is used to perform instantaneous analysis of the data from the real-time monitoring module and generate control commands to regulate the processing parameters of the production equipment, thereby achieving closed-loop control of the entire process from data acquisition and analysis to equipment adjustment, and ensuring that the quality parameters of each process remain stable within the qualified range.

2. The intelligent manufacturing system according to claim 1, characterized in that, The real-time monitoring module also includes a visual recognition module and a mortar thickness detection module. The visual recognition module is used in the welding process to identify the appearance quality by capturing images of the welding points in real time. The mortar thickness detection module is used in the spraying process to monitor the mortar spraying thickness and crack defects in real time.

3. The intelligent manufacturing system according to claim 2, characterized in that, The system also includes a steel cylinder hydraulic forming equipment, a wire winding equipment, a resin spraying equipment, a welding equipment, and a mortar spraying equipment. These devices correspond to the steel cylinder forming process, the wire winding process, the welding process, and the spraying process, respectively. The tension acquisition module and the fluorescence detection module are both used in the wire winding process.

4. The intelligent manufacturing system according to claim 3, characterized in that, The winding equipment also includes a resin coating containing fluorescent agent and a resin spraying mechanism. The fluorescence detection module also includes a timing module, which can time the solidification of the resin after the resin spraying mechanism completes the spraying operation. The central processing module can perform secondary detection of the solidification degree of the resin based on the timing of the timing module in conjunction with the tension acquisition module and the fluorescence detection module.

5. The intelligent manufacturing system according to claim 4, characterized in that, The system also includes a pushing mechanism and a rotating mechanism. The pushing mechanism can move the steel cylinder through multiple processes, and the rotating mechanism can drive the steel cylinder to rotate to assist the real-time monitoring module in monitoring and processing the steel cylinder.

6. A method for intelligent manufacturing of corrugated steel cylinder fiber-reinforced tube structures, wherein the method utilizes the intelligent system of any one of claims 1-5 to manufacture the corrugated steel cylinder fiber-reinforced tube structures, characterized in that, Includes the following steps: S100, Hydraulic forming and inspection: The forming process of corrugated grooves on the steel cylinder is completed by the steel cylinder hydraulic forming equipment, and the forming parameters of each corrugated groove are detected and recorded by the laser scanning module, and the processing parameters of the steel cylinder hydraulic forming equipment are adjusted by the central processing module. S200, Steel cylinder winding and tension detection: The winding equipment winds the steel cylinder with wire, and the tension acquisition module monitors the change of fiber tension in real time. Combined with the data obtained by the laser scanning module, the processing parameters of the winding equipment are pre-adjusted by the central processing module to reduce the response time. S300, Resin Spraying and Fluorescence Detection: The resin spraying mechanism sprays a resin coating containing a fluorescent agent onto the corrugated part of the steel cylinder after the wire winding operation, and the central processing module performs secondary detection on the degree of resin solidification based on the timing of the timing module, the tension acquisition module and the fluorescence detection module. S400, Rebar Welding and Visual Recognition: The welding process of longitudinal and circumferential reinforcing bars is carried out through the welding equipment, and the welding point image is captured in real time by the visual recognition module and the appearance quality is identified by the central processing module. S500, Sandblasting and Inspection Inside the Steel Cylinder: The inside of the steel cylinder is sandblasted using a mortar spraying device, and the sandblasting thickness is detected by a mortar thickness detection module. At the same time, the central processing module determines whether the sandblasting thickness meets the standard.

7. The intelligent manufacturing method according to claim 6, characterized in that, S200 includes the following steps: S210. The tension data of the fiber filament is collected in real time through the tension acquisition module, and the data is processed and transmitted to the central processing module. S220. The central processing module analyzes and judges the tension using data from the tension acquisition module and the laser scanning module to determine whether the tension meets the standard. If it does, the current parameters are maintained and the operation continues. If not, the process proceeds to S230. S230. By calculating and analyzing the difference between the current tension and the preset tension, a control command is generated to control the winding equipment for adjustment, and then proceed to step S210.

8. The intelligent manufacturing method according to claim 7, characterized in that, Step S300 includes the following steps: S310. The fluorescence data on the fiber filament is collected through the fluorescence detection module; S320, and the central processing module judges whether the number of winding layers and density of the fiber filaments meet the standards. If not, the winding equipment is controlled to rewind and proceed to S310; if yes, proceed to S330. S330: Maintain the current parameters and continue operation. When the number of winding layers reaches the preset number, control the resin spraying mechanism to spray resin and use the timing module to keep track of the time. S340. The central processing module determines whether the solidification time is met based on the data from the timing module. If not, solidification continues; if so, proceed to S350. S350. The central processing module detects the solidification degree of the resin layer through the tension acquisition module and the fluorescence detection module to determine whether the solidification degree of the resin meets the standard. If yes, proceed to S400; otherwise, wait for solidification.

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