Digital twin modeling and simulation system for customized production of marine steel ladders

Abstract

The present application relates to the technical field of digital twinning and intelligent manufacturing, in particular to a digital twinning modeling and simulation system for customized production of marine steel ladders, comprising: a parameter acquisition unit for acquiring the acoustic vibration spectrum, galvanic potential difference and weld residual stress of the steel ladder mounting interface; a coupling factor quantization unit for determining the acoustic vibration acceleration factor and the interface electrochemical corrosion degradation factor; a locked strain energy solving unit for solving the locked strain energy; a risk assessment and early warning unit for calculating the catastrophic displacement vector and generating the failure risk index based on the catastrophic displacement vector and the preset design installation tolerance, and then determining the risk level; and a process correction decision unit for generating the process correction instruction in response to the risk level determined by the risk assessment and early warning unit. The present application can accurately predict the installation interface failure risk caused by the coupling effect of multiple physical fields and provide a forward-looking process correction decision.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of digital twinning and intelligent manufacturing, in particular to a digital twinning modeling and simulation system for customized production of marine steel ladders. BACKGROUND

[0002] In the customized construction process of large and complex ships, the installation precision of structural components has strict requirements. The precise installation interface of key components such as marine steel ladders is exposed to the coupling effects of sound, vibration, electrochemical corrosion and other multi-physical fields for a long time during manufacturing and service;

[0003] Traditional design analysis methods usually simplify or ignore these implicit and interdisciplinary coupling effects, making it difficult to quantitatively predict the potential failure risk of the installation interface, resulting in delayed problem discovery and often passive response after quality defects caused by sudden displacement;

[0004] Therefore, how to accurately assess and predict the installation interface failure risk caused by multi-physical field coupling, so as to actively avoid in the feedforward process decision, has become a key technical problem that needs to be solved in the field. SUMMARY

[0005] To solve the above technical problems, the present application provides a digital twinning modeling and simulation system for customized production of marine steel ladders, specifically, the technical solution of the present application is:

[0006] A digital twinning modeling and simulation system for customized production of marine steel ladders, comprising:

[0007] A parameter acquisition unit for acquiring the sound-vibration spectrum, galvanic potential difference and weld residual stress of the steel ladder installation interface;

[0008] A coupling factor quantization unit for determining the sound-vibration acceleration factor based on the sound-vibration spectrum acquired by the parameter acquisition unit; and for determining the interface electrochemical corrosion degradation factor based on the galvanic potential difference;

[0009] A locked strain energy solving unit for solving the locked strain energy in combination with the sound-vibration acceleration factor, the interface electrochemical corrosion degradation factor and the weld residual stress acquired by the parameter acquisition unit;

[0010] A risk assessment and early warning unit for comparing the locked strain energy with a preset critical energy threshold; when the locked strain energy is greater than the critical energy threshold, for calculating a sudden displacement vector and generating a failure risk index based on the sudden displacement vector and a preset design installation tolerance, and then determining a risk level;

[0011] A process correction decision unit for generating a process correction instruction in response to the risk level determined by the risk assessment and early warning unit.

[0012] Preferably, the determination process of the acoustic vibration acceleration factor is as follows:

[0013] Based on the real-time acoustic vibration power spectrum density collected by the parameter acquisition unit, the risk-weighted vibration energy is calculated;

[0014] Based on the preset reference power spectrum density, the reference energy is calculated;

[0015] The risk-weighted vibration energy and the reference energy are normalized and compared to generate the acoustic vibration acceleration factor.

[0016] Preferably, the determination process of the interface electrochemical corrosion degradation factor is as follows:

[0017] Based on the galvanic potential difference collected by the parameter acquisition unit, combined with the preset corrosion rate constant and exposure time, the interface electrochemical corrosion degradation factor is calculated through the exponential decay model.

[0018] Preferably, the calculation process of the locked strain energy is as follows:

[0019] Determine the effective action volume overlapped by the stress concentration area and the weld heat affected zone;

[0020] Get the preset reference locked strain;

[0021] Combined with the effective action volume, the reference locked strain, and the weld residual stress collected by the parameter acquisition unit, the basic strain energy is calculated;

[0022] The basic strain energy is amplified by the acoustic vibration acceleration factor and the interface electrochemical corrosion degradation factor to obtain the locked strain energy.

[0023] Preferably, the calculation process of the sudden displacement vector is as follows:

[0024] Get the difference between the locked strain energy and the critical energy threshold, and determine the difference as the release energy;

[0025] Through the buckling analysis of the interface finite element model, the instability direction vector is obtained;

[0026] Based on the release energy and the instability direction vector, the sudden displacement vector is calculated.

[0027] Preferably, the calculation process of the critical energy threshold is as follows:

[0028] Get the yield strength and yield strain of the preset interface material;

[0029] Combined with the yield strength, the yield strain, and the effective action volume determined by the locked strain energy calculation unit, the product is processed to obtain the critical energy threshold.

[0030] Preferably, the risk level determination process is as follows:

[0031] When the failure risk index is not greater than the first preset threshold, the risk level is determined as safe;

[0032] When the failure risk index is greater than the first preset threshold and not greater than the second preset threshold, the risk level is determined as a first-level warning;

[0033] When the failure risk index is greater than the second preset threshold, the risk level is determined as a second-level warning.

[0034] Preferably, the process correction decision unit generates a process correction instruction for implementing a stress relief and energy dissipation strategy in response to the risk level of the first-level warning, including adjusting the welding process to reduce the acoustic vibration acceleration factor, or applying a high-damping coating to improve the system energy dissipation capability.

[0035] Preferably, the process correction decision unit generates a process correction instruction for implementing an active unlocking and root isolation strategy in response to the risk level of the second-level warning, including introducing a flexible connection unit to actively release the locking strain energy, or replacing the coating material system to suppress the growth of the interface electrochemical corrosion degradation factor.

[0036] Compared with the prior art, the present application has the following beneficial effects:

[0037] 1. The system is a digital twin modeling and simulation system applied to customized production of marine steel ladders, which accurately predicts the installation interface failure risk caused by the coupling effect of multiple physical fields, and provides prospective process correction decisions, aiming to ensure the installation accuracy and structural reliability of large ship steel ladders;

[0038] 2. A major technical breakthrough of the system is that it first includes hidden physical field effects such as acoustic vibration and electrochemical corrosion into the prediction model. It standardizes the acoustic vibration spectrum and galvanic potential difference through a unique coupling factor quantization unit, realizes targeted identification of risks, eliminates the influence of working condition differences, and greatly improves the accuracy and robustness of risk assessment;

[0039] 3. The system uses an innovative nonlinear amplification model to evaluate potential risks; through a locking strain energy solving unit, the system combines basic strain energy with residual stress, acoustic vibration, corrosion and other factors, which can reveal high-energy accumulation risks that cannot be found by traditional linear models. Its risk assessment is based on objective threshold values set by material physical properties, making the judgment criteria more scientific and stable;

[0040] 4. The system realizes closed-loop management from risk assessment to active decision, which can convert abstract energy risk into specific displacement prediction in millimeters, and generate clear risk levels accordingly. The system can automatically push targeted process correction instructions, such as adjusting welding process or introducing flexible connection, to realize intelligent production mode from passive response to active avoidance. BRIEF DESCRIPTION OF DRAWINGS

[0041] The application will be further explained in connection with the accompanying drawings and embodiments:

[0042] Figure 1 is a structural block diagram of the system of the application. DETAILED DESCRIPTION

[0043] In order to make the purpose, technical scheme and advantages of the application more clear and explicit, the application will be further described in detail below in connection with specific embodiments. EMBODIMENT

[0044] Please refer to Figure 1 A digital twin modeling and simulation system for customized production of marine steel ladders, comprising:

[0045] A parameter acquisition unit for acquiring the acoustic vibration spectrum, galvanic potential difference and weld residual stress of the steel ladder mounting interface;

[0046] A coupling factor quantization unit for determining the acoustic vibration acceleration factor based on the acoustic vibration spectrum acquired by the parameter acquisition unit, and for determining the interface electrochemical corrosion degradation factor based on the galvanic potential difference;

[0047] A locked strain energy solving unit for solving the locked strain energy in combination with the acoustic vibration acceleration factor, the interface electrochemical corrosion degradation factor and the weld residual stress acquired by the parameter acquisition unit;

[0048] A risk assessment and early warning unit for comparing the locked strain energy with a preset critical energy threshold; when the locked strain energy is greater than the critical energy threshold, for calculating a sudden displacement vector, and generating a failure risk index based on the sudden displacement vector and a preset design installation tolerance, and further determining a risk level;

[0049] A process correction decision unit for generating a process correction instruction in response to the risk level determined by the risk assessment and early warning unit;

[0050] The system further comprises an offline model calibration unit, which is responsible for determining the effective action volume , frequency weight function , corrosion rate constant Key model parameters are determined and input as preset values into the corresponding calculation units, ensuring the initial accuracy and applicability of the model.

[0051] The embodiment provides a digital twin modeling and simulation system for customized production of marine steel ladder, which aims to solve the problem of steel ladder precision installation interface failure caused by multi-physical field coupling such as sound, vibration, and electrochemistry in the process of manufacturing large and complex ships; the system quantitatively predicts the hidden risks in the installation process by building a digital twin model, and provides process correction decisions in a feedforward manner, thereby ensuring installation accuracy and structural reliability; the system comprises a parameter acquisition unit, a coupling factor quantization unit, a locked strain energy solving unit, a risk assessment and early warning unit, and a process correction decision unit.

[0052] The parameter acquisition unit aims to provide comprehensive and real-time physical world input data for the digital twin model; in the embodiment, the parameter acquisition unit refers to an integrated multi-source sensor and information system, which comprehensively digitizes the complex physical environment around the steel ladder installation interface; the unit realizes the following:

[0053] Collection of weld residual stress: strain gauge array and non-destructive X-ray diffraction method are combined to accurately obtain the microscale residual stress tensor in the installation interface weld and its heat-affected zone;

[0054] Collection of acoustic vibration spectrum: high-frequency acoustic sensors are deployed on the upper part of the ship section adjacent to the steel ladder installation interface to monitor the acoustic vibration environment generated by high-frequency impact welding and other construction activities in real time, and convert them into acoustic vibration power spectrum density data ;

[0055] Collection of galvanic potential difference: micro electrochemical probes are deployed between the flange of the installation interface and the coating of the ship base to measure the galvanic potential difference formed by the contact of different metals or coating materials ;

[0056] All the above-mentioned collected parameters are input into the subsequent calculation unit as known quantities in real time;

[0057] The coupling factor quantization unit aims to quantitatively express the influence of sound field and electrochemical effect on structural stability, which is usually ignored or simplified in traditional models; in the embodiment, based on the data collected by the parameter acquisition unit, the unit constructs two core dimensionless coupling factors:

[0058] The unit determines the acoustic vibration acceleration factor according to the collected acoustic vibration spectrum; the function of the factor is to quantify the acceleration effect of the acoustic vibration environment on the accumulation of locked strain energy;

[0059] The unit also determines an interface electrochemical corrosion degradation factor according to the collected galvanic potential difference; the role of the factor is to quantify the degradation degree of the mechanical properties of the interface material caused by the electrochemical corrosion process;

[0060] A locked strain energy solving unit aims to calculate a total potential energy stored in the microstructure of the installation interface under the combined action of residual stress, acoustic vibration excitation and electrochemical corrosion; in the embodiment, the unit combines the acoustic vibration acceleration factor determined by the coupling factor quantizing unit, the interface electrochemical corrosion degradation factor, and the weld residual stress collected by the parameter collecting unit, and solves the locked strain energy through a modified strain energy model; the locked strain energy refers to the elastic energy that is “locked” by the micro-lattice defects and may be suddenly released under disturbance in the multi-physical field environment, and has the dimension of joule;

[0061] A risk assessment and early warning unit aims to convert the calculated abstract potential energy value into physical quantities and risk levels that have direct guiding significance for engineering practice; in the embodiment, the unit compares the locked strain energy solved by the locked strain energy solving unit with a preset critical energy threshold; the critical energy threshold refers to the maximum energy limit that can be absorbed by the interface material when it changes from elastic deformation to plastic instability; when the locked strain energy is greater than the critical energy threshold, it indicates that the system is in an unstable state, and the unit further calculates a sudden displacement vector and generates a standardized failure risk index based on the vector and a preset design installation tolerance, to determine the specific risk level according to the index;

[0062] A process correction decision unit aims to automatically generate and push forward-looking and executable process adjustment instructions according to the assessed risk level, to realize the production mode change from passive response to active avoidance; in the embodiment, the unit matches different correction strategy libraries for different risk levels and generates specific process correction instructions in response to the risk level determined by the risk assessment and early warning unit;

[0063] The above-mentioned units work together to build a closed-loop perception-analysis-decision-execution digital twin system; it first introduces the effects of implicit physical fields such as acoustic vibration and electrochemical corrosion into the prediction model of the installation failure of marine steel ladders, and realizes the precise assessment and early warning of the installation risk by quantifying the locked strain energy and predicting the sudden displacement; the system can convert complex, multi-physical field coupled failure problems into clear risk levels and explicit process correction instructions, thereby effectively avoiding rework or quality defects caused by sudden displacement of the installation interface in the early stage of production, and significantly improving the precision, efficiency and safety of customized construction of large ships.

[0064] Embodiment 2:

[0065] The determination process of the acoustic vibration acceleration factor is as follows:

[0066] Based on the real-time acoustic vibration power spectral density collected by the parameter acquisition unit, the risk-weighted vibration energy is calculated;

[0067] Based on the preset reference power spectral density, the reference energy is calculated;

[0068] The risk-weighted vibration energy and the reference energy are normalized and compared to generate the acoustic vibration acceleration factor.

[0069] This embodiment further defines the determination process of the acoustic vibration acceleration factor in the coupling factor quantization unit based on Embodiment 1; this specific scheme aims to more accurately capture the vibration energy that has the greatest impact on structural stability;

[0070] The determination process of the acoustic vibration acceleration factor includes the following steps:

[0071] The real-time acoustic vibration power spectral density collected by the parameter acquisition unit ; the purpose of this step is not to calculate the total vibration energy, but to identify and weight the specific frequency band energy that is most likely to excite structural instability; in this embodiment, the calculation method of the risk-weighted vibration energy is as follows:

[0072] Risk-weighted vibration energy

[0073] Based on the preset reference power spectral density , the reference energy is calculated; the reference energy refers to the vibration energy integral value in the same frequency band under a typical safe working condition that has not led to installation failure in history, and its role is to provide a standardized reference system for risk assessment; this energy is calculated by the following formula:

[0074] The risk-weighted vibration energy and the reference energy are normalized and compared to generate the acoustic vibration acceleration factor , and the calculation formula is as follows:

[0075] Wherein, The real-time acoustic vibration power spectral density has a dimension of , and its source is obtained by real-time monitoring of the acoustic sensor of the parameter acquisition unit;

[0076] Frequency weight function, dimensionless, which is determined according to statistical analysis of historical failure data; the frequency weight function is a function with special meaning in the specific technical environment of the application, which is not a uniform weight, but takes a peak value in the sensitive frequency band where the structure stability is most threatened, and the weight is lower in other frequency bands; this reflects the technical consideration of the application for accurate identification of risk sources, which is different from the practice of regarding all frequencies as the same in traditional vibration analysis;

[0077] For example, It can be modeled in the form of a Gaussian function: wherein is the center of the most dangerous resonance frequency determined by spectral analysis of historical failure data, and and are the weight amplitude and bandwidth parameters determined according to the risk level and the influence range.

[0078] Integral frequency boundary, dimension of Hz, which is determined by pre-setting according to the inherent frequency characteristics of the ship structure and the spectral characteristics of the welding sound source;

[0079] Reference power spectral density, dimension of , which is the average value of one or more groups of power spectrum data of typical safe working conditions selected from the historical database;

[0080] The resulting acoustic vibration acceleration factor is a dimensionless parameter that intuitively represents the multiple relationship of the current acoustic vibration environment relative to the safe benchmark;

[0081] Through the above specific calculation method, the embodiment not only quantifies the influence of the acoustic vibration environment, but also realizes the targeted identification of the risk by introducing the frequency weight function , so that the model can more sensitively capture the most destructive vibration frequency components; this quantitative method based on normalization eliminates the dimensional influence of absolute energy value and the difference between working conditions, so that the acoustic vibration risks at different times and locations have comparability, greatly improving the accuracy and robustness of risk assessment.

[0082] Embodiment 3:

[0083] The determination process of the interface electrochemical corrosion degradation factor is as follows:

[0084] Based on the galvanic potential difference collected by the parameter acquisition unit, combined with the pre-set corrosion rate constant and exposure time, the interface electrochemical corrosion degradation factor is generated by calculating through the exponential decay model.

[0085] The embodiment is based on embodiment 1, and the determination process of the interface electrochemical corrosion degradation factor in the coupling factor quantization unit is specifically limited; the scheme aims to quantify the time decay process of the interface mechanical performance caused by the electrochemical effect through a recognized kinetic model;

[0086] The determination process of the interface electrochemical corrosion degradation factor is as follows:

[0087] Based on the galvanic potential difference collected by the parameter acquisition unit , in combination with the preset corrosion rate constant and the exposure time , the interface electrochemical corrosion degradation factor is calculated through an exponential decay model; the physical meaning of the model is that the structural health of the installation interface will decrease exponentially with the increase of the corrosion driving force and the action time, and the calculation formula is as follows:

[0088] Wherein, The interface electrochemical corrosion degradation factor is dimensionless, and is obtained by calculation in this step; the value changes between 0 and 1, indicates that the interface is intact, tends to 1, indicating that the interface is seriously degraded due to corrosion, that is, the mechanical bearing capacity will be lost;

[0089] The corrosion rate constant has a dimension of , which is obtained by calibrating through a salt spray accelerated aging experiment for a specific coating and metal material combination; the parameter is an empirical calibration parameter in the application, which associates the macroscopic experimental results with the microscopic corrosion kinetic model;

[0090] The galvanic potential difference has a dimension of , which is obtained by real-time measurement of the electrochemical probe of the parameter acquisition unit;

[0091] The exposure time has a dimension of , which is obtained by cumulative recording of the system timer since the installation interface is formed;

[0092] The method converts the gradual electrochemical corrosion damage which is difficult to directly measure into a time-evolving and quantifiable dimensionless factor ; by applying a mature exponential decay model and combining with the material constant calibrated by experiment, the corrosion risk assessment has a solid theoretical basis and engineering practicability for specific material systems, thereby significantly improving the long-term prediction accuracy of the multi-physical field coupling model.

[0093] Embodiment 4:

[0094] The calculation process of the locked strain energy is as follows:

[0095] determining the effective action volume overlapped by the stress concentration area and the weld heat affected zone;

[0096] acquiring the preset reference locked strain;

[0097] combining the effective action volume, the reference locked strain, and the weld residual stress collected by the parameter collection unit, calculating the basic strain energy;

[0098] amplifying the basic strain energy by using the acoustic vibration acceleration factor and the interface electrochemical corrosion degradation factor to obtain the locked strain energy.

[0099] This embodiment specifically defines the calculation process of the locked strain energy in the locked strain energy calculation unit based on embodiment 1; the core innovation of this scheme is that it does not follow the traditional linear superposition strain energy idea, but constructs a model for nonlinear amplification of the basic strain energy and the multi-physical field coupling factor to reveal potential mutation risks.

[0100] The calculation process of the locked strain energy is as follows:

[0101] The first step of the calculation process is to determine the effective action volume overlapped by the stress concentration area and the weld heat affected zone ; the effective action volume has a specific technical meaning in the present application, and is not the macroscopic geometric volume of the interface, but refers to the core area of energy accumulation and release; its role is to define a spatial boundary with clear physical meaning for potential energy calculation; its determination method is: finding out the stress concentration area of the installation interface through initial finite element analysis , determining the actual range of the weld heat affected zone by metallographic analysis experiment, that is, the overlapped part volume of the two areas in space;

[0102] The second step of the calculation process is to acquire the basic mechanical property parameters such as the elastic modulus and Poisson's ratio of the material, which are obtained through standard material tests;

[0103] Based on the above parameters, the effective action volume and the weld residual stress tensor collected by the parameter collection unit, the basic strain energy In this embodiment, in order to more accurately reflect the stress state closely related to the plastic deformation and failure risk of the material, we first calculate the von Mises equivalent stress , and the basic strain energy is calculated according to the elastic strain energy theory, and the formula is:

[0104] The formula determines the strain energy density decided by the von Mises equivalent stress The integral is carried out in the effective action volume , so as to more truly reflect the basic energy stored due to residual stress which may lead to failure.

[0105] The basic strain energy is amplified by using the acoustic vibration acceleration factor and the interface electrochemical corrosion degradation factor to obtain the locked strain energy ; this step is one of the core innovations of the present application, which embodies the nonlinear coupling effect of multiple physical fields;

[0106] The formula shows that the excitation of the acoustic vibration environment and the electrochemical corrosion degradation are not simply energy superposition, but as an amplification factor, the basic strain energy is multiplied, so as to explain why in some working conditions, seemingly not high residual stress can trigger catastrophic structural instability;

[0107] It should be noted that the product amplification model used in this embodiment is a simplified model designed for engineering application, which captures the main contribution of each factor to the risk. In a more precise model, coupling terms can be introduced to describe the interaction between acoustic vibration and corrosion to further improve the prediction accuracy;

[0108] This embodiment constructs a potential energy model that can better reflect the physical reality; it accurately defines the effective action volume and calibrates the reference locked strain, ensuring the physical accuracy of the model basis; more importantly, by introducing acoustic vibration and corrosion effects as amplification factors, the sensitivity of the model to potential risks is greatly improved; this nonlinear amplification process can reveal unexpected high-energy accumulation risks caused by the synergistic effect of multiple factors, which cannot be discovered by traditional linear superposition models.

[0109] Embodiment 5:

[0110] The calculation process of the mutation displacement vector is as follows:

[0111] The difference between the locked strain energy and the critical energy threshold is obtained, and the difference is determined as the release energy;

[0112] The buckling analysis is carried out on the interface finite element model to obtain the instability direction vector;

[0113] Based on the released energy and the instability direction vector, the abrupt displacement vector is calculated.

[0114] Based on Example 1, this embodiment specifies the calculation process of the sudden displacement vector in the risk assessment and early warning unit; the purpose of this calculation is to transform an abstract energy value into a geometric quantity with clear physical meaning and engineering guidance value.

[0115] Sudden displacement vector The calculation process unfolds as follows:

[0116] Acquiring Locking Strain Energy With critical energy threshold The difference is used to determine the released energy. The physical logic of this step is: only when the system has accumulated energy... Exceeding its stable load-bearing limit Only when this excess energy is released in an unstable form will it be converted into kinetic and potential energy that causes the interface to deform; this logic ensures that only when... Only when the energy released is positive;

[0117] Buckling analysis was performed on the interface finite element model to obtain the buckling direction vector. Instability direction vector It is a unit vector that indicates the spatial direction in which the interface is most likely to undergo displacement when instability occurs; in this embodiment, it is obtained by using a pre-established high-precision finite element model of the installation interface. By applying a virtual load and performing eigenvalue buckling analysis, the mode shape direction of the first buckling mode is obtained, which is the buckling direction vector. ;

[0118] Based on energy release with the instability direction vector Solve for the abrupt shift vector This step is based on the law of conservation of energy: the energy released... This is entirely converted into the work done by the interface deforming along the instability direction; the deformation work can be expressed as... ,in It is the equivalent stiffness of the interface in the instability direction. It is the magnitude of the displacement; therefore, the magnitude of the displacement is:

[0119] in, For equivalent stiffness, the dimension is Its origin is the stiffness matrix of the interface. and the instability direction vector The calculation shows that, ;

[0120] Sudden displacement vector That is, the module length With direction vector The product of:

[0121] This calculation process successfully establishes a quantitative correlation between the energy domain and the geometric domain; it no longer merely provides a general "high-risk" conclusion, but can accurately predict the magnitude and direction of the interface displacement that may occur in the worst case, in meters (m) or millimeters (mm). This specific displacement prediction value can be directly compared with the design and installation tolerances in the engineering design, making the risk assessment results more intuitive and quantitative, and providing the most direct physical basis for subsequent risk classification and process modification.

[0122] Example 6:

[0123] The calculation process for the critical energy threshold is as follows:

[0124] Obtain the preset yield strength and yield strain of the interface material;

[0125] By combining the yield strength, yield strain, and effective working volume determined by the locked strain energy calculation unit, the critical energy threshold is obtained through multiplication.

[0126] This embodiment focuses on the key input parameter—the critical energy threshold. The calculation process was specifically defined; the scheme aims to ensure that the scale used for risk assessment is based on the inherent properties of the material, thus giving the entire assessment system a solid physical basis.

[0127] Critical energy threshold The calculation process is as follows:

[0128] Before calculation, obtain the preset yield strength of the interface material. With yield strain Yield strength and yield strain are core mechanical performance parameters that characterize the critical point at which a material transitions from the elastic deformation stage to the plastic deformation stage. In this embodiment, these two parameters are obtained by conducting standard uniaxial tensile tests on the key materials constituting the installation interface, in accordance with national or industry standards.

[0129] Combined yield strength Yield strain and the effective working volume determined by the locked strain energy calculation unit Perform multiplication to obtain the critical energy threshold. The physical meaning of this calculation is that, within the effective working volume... The total elastic strain energy stored by the material when it reaches its plastic instability limit, calculated by the formula: Wherein, Effective volume, dimensionless ;

[0130] Yield strength, dimensionless Or The source is the standard material performance test;

[0131] Yield strain, dimensionless, the source is the standard material performance test;

[0132] The dimension of the formula is , i.e. energy unit joule The dimension of the locking strain energy is exactly the same, which ensures the physical consistency of the comparison;

[0133] By linking the calculation of the critical energy threshold with the most basic mechanical properties of the material and the core area where failure occurs, this embodiment provides an objective, stable and clearly physically meaningful judgment benchmark for risk assessment; This avoids the uncertainty and arbitrariness brought by subjective setting or purely empirical threshold, making the conclusion of the entire risk assessment and early warning system more reliable and persuasive.

[0134] Embodiment 7:

[0135] The determination process of the risk level is as follows:

[0136] When the failure risk index is not greater than the first preset threshold, the risk level is determined to be safe;

[0137] When the failure risk index is greater than the first preset threshold and not greater than the second preset threshold, the risk level is determined to be a first warning;

[0138] When the failure risk index is greater than the second preset threshold, the risk level is determined to be a second warning.

[0139] This embodiment further limits the determination process of the risk level in the risk assessment and early warning unit based on embodiment 1; The purpose of this scheme is to convert the continuous displacement prediction value with physical dimension into discrete, standardized, and convenient risk level for management and decision-making;

[0140] The determination process of the risk level is based on the calculation of a standardized failure risk index As a prerequisite, the definition of the index is:

[0141] Wherein, Failure risk index, dimensionless, which is calculated in this step; its function is to intuitively reflect the multiple relationship between the predicted mutation displacement and the engineering allowable limit;

[0142] Mutation displacement module, dimensionless ;

[0143] Design installation tolerance, dimensionless , which is set in advance according to the ship design drawings and installation process specifications, allowing the maximum geometric deviation of the installation interface to exist;

[0144] After calculating the failure risk index , the risk level is determined by comparing it with two preset thresholds; the setting logic of the threshold is to correspond the risk degree with the engineering disposal measures:

[0145] When the failure risk index is not greater than the first preset threshold, the risk level is determined to be safe; in this embodiment, the first preset threshold is set to 1 according to the physical boundary of the engineering tolerance; , which means that the predicted mutation displacement module is within the design installation tolerance range, belonging to an acceptable safe state;

[0146] When the failure risk index is greater than the first preset threshold (1) and not greater than the second preset threshold, the risk level is determined to be a first-level warning; in this embodiment, the second preset threshold is set to 1.5 according to a large amount of historical data statistics and engineering practice experience, which is an effective dividing point to distinguish between general risk and high-risk; , which means that the predicted displacement has slightly exceeded the tolerance, there is a significant failure risk, and intervention measures need to be started, but there is still a window period to solve it through process optimization;

[0147] When the failure risk index is greater than the second preset threshold (1.5), the risk level is determined to be a second-level warning; , which means that the predicted displacement has seriously exceeded the tolerance, and it is difficult to avoid failure through conventional process adjustment, so more fundamental design or process changes must be taken;

[0148] This risk grading method converts complex simulation results into three clear and explicit operation instructions: safe, first-level warning, and second-level warning; it is directly related to engineering design standards, making the risk assessment results have strong practical guiding significance; this grading strategy provides clear trigger conditions for the subsequent process correction decision unit, realizing seamless connection from quantitative evaluation to grading decision, making the response logic of the entire system clear and highly automated;

[0149] The system takes into account boundary conditions in the design to ensure robustness, for example, when the calculated equivalent stiffness is lower than the preset minimum threshold value, the system will directly determine that the structure is unstable and trigger the highest level of warning, rather than calculating a meaningless maximum displacement. When the input residual stress is zero, although the basic strain energy is zero, the process modification decision unit will still independently evaluate the values of the acoustic vibration acceleration factor and the corrosion degradation factor to prevent risks directly caused by extreme external environments. When the corrosion degradation factor tends to 1, the system will mark the interface as severely corroded and recommend forced inspection or replacement, rather than relying solely on the calculation results of the energy model.

[0150] Embodiment 8:

[0151] The process modification decision unit generates process modification instructions in response to the risk level of the first warning, which implements stress relief and energy dissipation strategies, including adjusting the welding process to reduce the acoustic vibration acceleration factor, or applying a high-damping coating to improve the system's energy dissipation capacity.

[0152] This embodiment is based on Embodiment 1 and defines the specific process modification instructions generated by the process modification decision unit in response to the risk level of the first warning; this scheme aims to provide a set of cost-effective and easy-to-implement risk reduction strategy combinations for medium-risk scenarios;

[0153] The process modification decision unit will start implementing stress relief and energy dissipation strategies after receiving the first warning risk level determined by the risk assessment warning unit; the core idea of this strategy is not to make revolutionary design changes, but to actively reduce risk factors or enhance the energy dissipation capacity of the system within the existing process framework; the generated process modification instructions specifically include:

[0154] Adjusting the welding process to reduce the acoustic vibration acceleration factor; when the system's backtracking analysis finds that the risk is mainly contributed by the excessively high acoustic vibration acceleration factor , the instruction will explicitly recommend adjusting the high-frequency impact welding sequence in the adjacent area to avoid the time window coinciding with the interface structure sensitive frequency; or optimizing the welding process parameters such as current and voltage to actively change the acoustic vibration spectrum so that the energy peak deviates from the sensitive frequency band, thereby directly reducing ;

[0155] or applying a high-damping coating to improve the system's energy dissipation capacity; when the risk mainly comes from the energy accumulation of the interface itself, the instructions will recommend using a specific high-damping viscoelastic coating between the mounting flange and the ship body base; this coating can convert part of the mechanical energy into heat energy and dissipate it when the structure is slightly vibrating, and its effect is equivalent to increasing the critical energy threshold of the system , thereby improving the stability margin of the system without changing the locking strain energy ;

[0156] This embodiment provides a targeted and operable correction scheme for the first level of early warning; it can intelligently identify the main source of risk and give targeted solutions; this symptomatic correction strategy avoids the one-size-fits-all overcorrection and can effectively resolve potential installation failure risks with the smallest process adjustment cost and time cost under the premise of ensuring installation quality.

[0157] Embodiment 9:

[0158] The process correction decision unit generates process correction instructions for implementing the active unlocking and root isolation strategy in response to the risk level of the second level of early warning, including introducing a flexible connection unit to actively release the locking strain energy or replacing the coating material system to suppress the growth of the interface electrochemical corrosion degradation factor.

[0159] This embodiment limits the specific process correction instructions generated by the process correction decision unit in response to the risk level of the second level of early warning based on Embodiment 1; this solution provides a more decisive and fundamental solution for high-risk scenarios, aiming to eliminate failure risks from the source;

[0160] After receiving the risk level of the second level of early warning, the process correction decision unit will determine that the risk cannot be solved by simple process optimization and must start the active unlocking and root isolation strategy; the core idea of this strategy is to actively release or suppress the excessive accumulation of energy by introducing new design elements or changing the material system; the generated process correction instructions specifically include:

[0161] Introducing a flexible connection unit to actively release the locking strain energy; this is an active unlocking measure; the system will forcibly require design changes, for example, in the original rigid connection flange design, a flexible connection unit with a preset yield point or specific elastic elements is introduced; this unit is designed to undergo a controllable, slight plastic deformation or elastic displacement when the locking strain energy accumulates to a certain safety value far below the critical energy threshold ; this controllable micro-deformation can actively and safely release the accumulated energy, avoiding its continuous accumulation until a catastrophic displacement occurs

[0162] or replacing the coating material system to inhibit the growth of the interface electrochemical corrosion degradation factor; this is a root isolation measure; when the system backtracking analysis finds that the risk mainly comes from the continuously growing interface electrochemical corrosion degradation factor the instruction will force the replacement of the coating material system at the installation interface; for example, the selection of the galvanic potential difference a smaller, even close to zero, material combination, or the use of an advanced coating with stronger electrochemical inertness; this will fundamentally control the interface electrochemical corrosion degradation factor below the safety threshold, greatly slowing down or even stopping the growth of the factor, thereby eradicating the long-term risk brought by electrochemical corrosion;

[0163] This embodiment provides a root-and-branch solution for this high-risk situation of secondary warning; it is no longer limited to repairing the existing process, but rises to the level of design and material to make fundamental intervention; whether it is through a flexible connection unit to provide a safe pressure relief valve for energy, or through the replacement of the coating system to close the corrosion faucet, these measures can essentially change the dynamics of risk accumulation, thereby avoiding major installation failure accidents with the highest reliability, and embodying the decision-making and foresight of the application when dealing with high-level risks.

[0164] The above is only a preferred embodiment of the present application, and is not intended to limit the protection scope of the present application; any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

[0165] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present application and are not limiting; although the present application has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present application can be modified or replaced equivalently without departing from the spirit and scope of the technical solutions of the present application.

Claims

1. A digital twin modeling and simulation system for the customized production of marine steel ladders, characterized in that, include: The parameter acquisition unit is used to acquire the acoustic and vibration spectrum, galvanic potential difference, and residual stress of the weld at the steel ladder installation interface. The coupling factor quantization unit is used to determine the acoustic vibration acceleration factor based on the acoustic vibration spectrum acquired by the parameter acquisition unit. It is also used to determine the interfacial electrochemical corrosion degradation factor based on the galvanic potential difference; The locked strain energy calculation unit is used to calculate the locked strain energy by combining the acoustic vibration acceleration factor, the interface electrochemical corrosion degradation factor, and the weld residual stress collected by the parameter acquisition unit. The risk assessment and early warning unit is used to compare the locking strain energy with the preset critical energy threshold. When the locking strain energy is greater than the critical energy threshold, it is used to calculate the sudden displacement vector and generate a failure risk index based on the sudden displacement vector and the preset design and installation tolerance, thereby determining the risk level. The process correction decision unit is used to generate process correction instructions in response to the risk level determined by the risk assessment and early warning unit. The process for determining the interfacial electrochemical corrosion degradation factor is as follows: Based on the galvanic potential difference acquired by the parameter acquisition unit, combined with the preset corrosion rate constant and exposure time, the interface electrochemical corrosion degradation factor is generated by calculation through the exponential decay model. The calculation process for locked strain energy is as follows: Determine the effective volume of the overlap between the stress concentration region and the weld heat-affected zone; Obtain the preset reference locking strain; The basic strain energy is calculated by combining the effective working volume, the reference locking strain, and the weld residual stress acquired by the parameter acquisition unit. The basic strain energy was amplified by using the acoustic vibration acceleration factor and the interfacial electrochemical corrosion degradation factor to obtain the locked strain energy. The calculation process for the abrupt shift vector is as follows: Obtain the difference between the locked strain energy and the critical energy threshold, and determine the difference as the released energy; Buckling analysis was performed on the interface finite element model to obtain the instability direction vector; Based on the released energy and the instability direction vector, the abrupt displacement vector is calculated.

2. The digital twin modeling and simulation system for customized production of marine steel ladders according to claim 1, characterized in that, The process for determining the acoustic vibration acceleration factor is as follows: Risk-weighted vibration energy is calculated based on the real-time acoustic and vibration power spectral density acquired by the parameter acquisition unit. The reference energy is calculated based on the preset reference power spectral density; The risk-weighted vibration energy is normalized and compared with the baseline energy to generate an acoustic vibration acceleration factor.

3. The digital twin modeling and simulation system for customized production of marine steel ladders according to claim 1, characterized in that, The calculation process for the critical energy threshold is as follows: Obtain the preset yield strength and yield strain of the interface material; By combining the yield strength, yield strain, and effective working volume determined by the locked strain energy calculation unit, the critical energy threshold is obtained through multiplication.

4. The digital twin modeling and simulation system for customized production of marine steel ladders according to claim 1, characterized in that, The process for determining the risk level is as follows: When the failure risk index is not greater than the first preset threshold, the risk level is determined to be safe. When the failure risk index is greater than the first preset threshold but not greater than the second preset threshold, the risk level is determined to be a Level 1 warning. When the failure risk index is greater than the second preset threshold, the risk level will be determined as a level two warning.

5. The digital twin modeling and simulation system for customized production of marine steel ladders according to claim 4, characterized in that, The process correction decision unit responds to the risk level of the first-level warning and generates process correction instructions to implement stress relief and energy dissipation strategies, including adjusting the welding process to reduce the acoustic vibration acceleration factor, or applying a high-damping coating to improve the system's energy dissipation capability.

6. The digital twin modeling and simulation system for customized production of marine steel ladders according to claim 4, characterized in that, The process correction decision unit responds to the risk level of the Level 2 warning and generates process correction instructions to implement proactive unlocking and root cause isolation strategies, including introducing flexible connection units to proactively release locked strain energy, or replacing the coating material system to suppress the growth of interfacial electrochemical corrosion degradation factors.

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