Intelligent movable external force auxiliary electromagnetic leveling equipment and leveling method thereof

Abstract

The invention belongs to the technical field of marine thin plate leveling equipment, and discloses intelligent movable external force auxiliary electromagnetic leveling equipment and a leveling method thereof.The intelligent movable external force auxiliary electromagnetic leveling equipment comprises a supporting frame, a chassis frame, crawler wheels, a control module and a driving motor, the driving motor is connected with the crawler wheels, and the crawler wheels are sleeved with crawler belts; the center of the top of the supporting frame is fixedly connected with a base. The base is sequentially connected with a rotating disc, a supporting shoulder, a shoulder motor, a supporting elbow, an elbow motor, a connecting wrist, a wrist motor and a flattening mechanism. The leveling mechanism is connected with the wrist motor through a telescopic rod, and the leveling mechanism comprises a heating leveling module and an external force auxiliary leveling module; a visual module is arranged on the supporting frame in the advancing direction of the leveling equipment, and a thin plate detection module is arranged on the external force auxiliary leveling module. By adopting the mode of combining electromagnetic heating flattening and electromagnetic force auxiliary flattening, the problem of tiny deformation residues after single electromagnetic flattening is effectively solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ship plate flattening equipment, and particularly relates to an intelligent mobile external force assisted electromagnetic flattening equipment and a flattening method thereof. BACKGROUND

[0002] At present, welding processes are widely used in shipbuilding industry to process various sections and plates. In the welding process of ship plate materials, residual stress may be generated in the internal structure of the plate due to uneven heating of the welding area and the non-welding area, thermal expansion and contraction, and unskilled manual techniques, which may further cause plate deformation and other consequences.

[0003] Electromagnetic flattening technology has developed rapidly in the shipbuilding industry in recent years. Compared with traditional water fire flattening, it has a fast heating speed and can reach the required temperature in a very short time. After induction heating, the workpiece has good fatigue resistance. Its principle is to use high-frequency electricity to form a magnetic field, and the metal molecules move quickly in the magnetic field to generate heat, which releases the residual stress generated by welding in the metal, thereby achieving the purpose of flattening.

[0004] Chinese invention patent: publication number "CN107716738A", named "a mobile heater for induction heating leveling machine", discloses an induction heating flattening equipment, which realizes flattening through manual operation. However, in the actual plate flattening operation process, it is often difficult to meet the strict requirements of shipbuilding for high-precision flatness of the plate only by relying on electromagnetic flattening. The plate after electromagnetic flattening may still have slight deformation. On the one hand, the ship plate may have undergone complex forming processes such as rolling and bending before processing, which may cause complex residual stress distribution in the plate, making it difficult for electromagnetic flattening to fully eliminate these stresses and achieve ideal flatness. On the other hand, factors such as the uniformity of the magnetic field distribution of the electromagnetic flattening equipment and the energy transfer efficiency may also limit the flattening effect. For example, in the edge area of the plate or the irregular shaped parts, the effect of electromagnetic heating may be weakened, resulting in poor flattening effect in these areas.

[0005] In addition, with the continuous development of shipbuilding industry, the requirements for the material and specifications of ship plate are also increasingly diversified. Plates of different materials, such as high-strength alloy steel and aluminum alloy, have large differences in physical and mechanical properties, and different adaptability to flattening processes. Some new type of plate material may have low sensitivity to electromagnetic flattening, which requires more precise and individualized flattening method. At the same time, for plates of different thickness and size, the existing electromagnetic flattening equipment also has certain limitations in parameter adjustment and process control. SUMMARY

[0006] In order to solve the problem that the thin plate is difficult to achieve ideal flatness by relying on electromagnetic flattening in the prior art, the application provides an intelligent mobile external force assisted electromagnetic flattening device and a flattening method thereof, through the cooperative design of a crawler, a multi-degree-of-freedom mechanical arm and a self-adaptive electromagnetic force supporting module, the automatic flattening of a thin plate deformation area is realized, and the stability in the operation process is ensured.

[0007] The application is achieved by the following technical scheme: a support frame is horizontally arranged, a chassis frame and a crawler wheel are arranged at the bottom of the support frame, a control module and a driving motor are arranged in the chassis frame, the driving motor is connected with the crawler wheel, and a crawler belt is arranged outside the crawler wheel; a base is fixedly connected to the top center of the support frame, a rotating disc, a support shoulder, a shoulder motor, a support elbow, an elbow motor, a connecting wrist, a wrist motor and a flattening mechanism are sequentially connected to the base; the flattening mechanism is connected with the wrist motor through an extension rod, the flattening mechanism comprises a heating flattening module and an external force assisted flattening module, the external force assisted flattening module is arranged at one end of the extension rod close to the wrist motor, and the heating flattening module is arranged at the other end of the extension rod away from the wrist motor; a visual module is arranged on the support frame along the running direction of the flattening device, and a thin plate detection module is arranged on the external force assisted flattening module; and the control module is electrically connected with the visual module, the thin plate detection module, the driving motor, the heating flattening module, the external force assisted flattening module, the wrist motor, the elbow motor, the shoulder motor and the rotating disc.

[0008] As a further optimization, the heating flattening module comprises a sliding strip and a magnetic gathering heating block arranged at the center of the sliding strip, two sliding grooves are symmetrically arranged on the sliding strip relative to the magnetic gathering heating block, one ceramic gasket is arranged in each sliding groove, and the ceramic gasket is outward convex relative to the heating surface of the magnetic gathering heating block.

[0009] As a further optimization, the external force assisted flattening module comprises a U-shaped frame arranged parallel to the extension rod and having an opening facing away from the wrist motor, an extension frame, a moving sliding rail and a flattening suction disc, the extension frame, the moving sliding rail and the flattening suction disc are arranged in two groups and symmetrically relative to the heating flattening module, one end of the extension frame is fixedly connected with the U-shaped frame, the other end is connected with the moving sliding rail, and the flattening suction disc is connected with the moving sliding rail; a telescopic cylinder is arranged in the extension frame, the telescopic cylinder comprises a stepping motor, a cylinder body, a sliding rod, a connecting frame and a telescopic baffle, the cylinder body is fixedly connected with the extension frame, the sliding rod is arranged in the cylinder body and connected with the stepping motor and the connecting frame at both ends, and the other end of the connecting frame is fixedly connected with the moving sliding rail.

[0010] As a further optimization, leg sleeves are arranged at four corners below the support frame, one end of the leg sleeve is connected with the output end of a servo motor arranged above the support frame, and the other end of the leg sleeve is fixedly connected with an electromagnetic suction disc.

[0011] The application also provides a flattening method suitable for the intelligent mobile external force assisted electromagnetic flattening device.

[0012] S1, start the driving motor to drive the track wheel to move to the target area to be flattened;

[0013] S2, the supporting leg sleeve is extended, and the electromagnetic chuck adsorbs the sheet;

[0014] S3, start the control module and the vision module, adjust the direction and the distance from the sheet surface, so that the heating flattening module is perpendicular to the sheet surface and is aligned with the target area to be flattened;

[0015] S4, the telescopic rod is extended, so that the ceramic gasket of the heating flattening module is in close contact with the sheet surface, and the sheet is heated and flattened;

[0016] S5, after the heating is completed, the telescopic rod is retracted, the sheet surface is separated, and the deformed state of the heated sheet is detected, and it is judged whether the sheet deformation amount is less than the set threshold value with respect to the horizontal reference line, if not, step S6 is executed; otherwise, step S10 is executed;

[0017] S6, start the external force assisted flattening module and the sheet detection module, the control module calculates the force direction angle θ adjust according to the sheet deformation gradient field data fed back by the sheet detection module, adjusts the force direction, and judges the sheet deformation state;

[0018] S61, the control module calculates the force direction angle θ adjust according to the sheet deformation gradient field data fed back by the sheet detection module, and the formula is as follows:

[0019]

[0020] wherein are the gradient components of the sheet height field in x and y directions respectively; x is the direction perpendicular to the weld, and y is the direction along the weld;

[0021] S62, the control module calculates the height field gradient according to the height data of the rectangular area centered on the weld fed back by the sheet detection module, and extracts the characteristic parameters, and the formula is as follows:

[0022]

[0023] wherein is the height field gradient; Δh L is the average height on the left side of the weld; Δh R is the average height on the right side of the weld; σ h is the standard deviation of the height of the single side area; N represents the sample number; h irepresents the height of the i-th sample; x i , y i represents the coordinates of the i-th sample.

[0024] S63, according to the feature parameters extracted in step S62, the thin plate deformation state is judged;

[0025] S7, according to the thin plate deformation state obtained in step S6, the adaptive PID algorithm is used to dynamically adjust the collaborative pressing or pulling action of the telescopic cylinders on both sides of the U-shaped frame, and the size of the telescopic cylinder output force is optimized;

[0026] S8, the overturning moment M ext is monitored in real time, and the adsorption force is dynamically distributed by the electromagnetic chuck;

[0027] S9, the thin plate detection module monitors the thin plate deformation in real time until the given threshold is reached;

[0028] S10, the target area flattening operation is completed, each module is reset, and the equipment moves to the next operation area.

[0029] As a further optimization, the specific steps of step S7 are as follows:

[0030] S71, when the weld on both sides is convex deformation, the telescopic cylinder output force formula is as follows:

[0031]

[0032] F base =k·σ s ·A

[0033] In the formula, F i is the telescopic cylinder output force; F base is the basic output force; k is the safety factor; σ s is the yield strength of the thin plate material; A is the contact area of the flattening chuck and the thin plate; β is the priority side force amplification coefficient; ε is the height deviation threshold; Δh i and Δh j are the measured deformation of the left and right sides of the weld respectively;

[0034] S72, when the weld on both sides is concave deformation, the telescopic cylinder output force formula is as follows:

[0035]

[0036] F base =k·σ s ·A

[0037] In the formula, γ is the concave depth difference coefficient;

[0038] S73, When the weld single side protruding deformation the other side recessed deformation, the telescopic cylinder output force formula as follows:

[0039]

[0040] |F push +F pull |≤F max

[0041] In the formula, δ is the composite deformation coordination coefficient; F max is the system maximum output threshold;

[0042] S74, using adaptive PID algorithm dynamic adjustment telescopic cylinder output force, formula as follows:

[0043]

[0044] In the formula, F t is the real-time telescopic cylinder output force; Δh is the target deformation; K p ,K i ,K d respectively, the proportion of PID algorithm, integral and differential;

[0045] S741, according to the interpolation function of ship plate commonly used material database, material thickness and yield strength, mapping to get the initial parameters Formula as follows:

[0046]

[0047] In the formula, u is the material thickness; σ s is the material yield strength; f is the interpolation function based on the ship plate commonly used material database;

[0048] S742, according to the real-time deformation Δh change rate v Δh , get dynamic proportional coefficient K p , formula as follows:

[0049]

[0050] In the formula, μ is the correction coefficient, through the material simulation experiment calibration; Δh max is the preset maximum deformation threshold;

[0051] S743, according to the cumulative error of deformation ∫Δh dt and the maximum residual stress σ x allowed by the sheet material, get dynamic integral coefficient K i , formula as follows:

[0052]

[0053] In the formula, ω is an attenuation coefficient, calibrated through a material simulation experiment, and E is an elastic modulus of the thin plate material;

[0054] S744、According to the thin plate curvature change rate, a dynamic differential coefficient K is obtained d , and the formula is as follows:

[0055]

[0056] In the formula, ψ is a sensitive coefficient, calibrated through a material simulation experiment, C max is a preset maximum curvature threshold.

[0057] Compared with the prior art, the present application has the beneficial effects that:

[0058] 1. The present application adopts a combination of electromagnetic heating flattening and electromagnetic force auxiliary flattening, effectively solving the problem of residual micro-deformation after single electromagnetic flattening.

[0059] 2. The flattening mechanism designed in the present application integrates a vision module and a thin plate deformation detection module, and based on gradient field and adaptive PID algorithm optimization parameters, the force direction and size are calculated in real time, the flattening period is shortened, and the flattening efficiency is improved.

[0060] 3. The ceramic gasket designed in the present application is designed to form a controllable gap, avoiding high-temperature damage to the magnetic block, prolonging the service life of the equipment.

[0061] 4. The working method of the present application dynamically allocates the adsorption force of the support leg through the moment balance equation, offsets the overturning moment, and ensures the stability of the equipment when working on complex curved surfaces.

[0062] 5. The tracked mobile chassis designed in the present application makes the equipment have good mobility and adaptability, and can flexibly work on the surface of the ship body, suitable for flattening of thin plates of different sizes and shapes for ships. BRIEF DESCRIPTION OF DRAWINGS

[0063] Figure 1 is a schematic diagram of the overall structure of the present application.

[0064] Figure 2 is a partial enlarged schematic diagram of the structure of the heating flattening module of the present application.

[0065] Figure 3 is a partial enlarged schematic diagram of the structure of the external force auxiliary flattening module of the present application.

[0066] Figure 4 is a partial enlarged schematic diagram of the structure of the electric telescopic cylinder of the present application.

[0067] Figure 5 is a schematic diagram of the thin plate deformation state in the present application.

[0068] Figure 6 Fig. 3 is a schematic diagram of a third deformed state of the sheet in the present application.

[0069] Figure 7 Fig. 4 is a schematic diagram of a fourth deformed state of the sheet in the present application.

[0070] Figure 8 Fig. 5 is a flow chart of the flattening method in the present application.

[0071] Indicated in the figure:

[0072] 1, heating flattening module; 2, external force assisted flattening module; 3, sheet detection module; 4, wrist motor; 5, connecting wrist; 6, elbow motor; 7, supporting elbow; 8, shoulder motor; 9, supporting shoulder; 10, rotating disc; 11, base; 12, servo motor; 13, support leg sleeve; 14, electromagnetic chuck; 15, crawler wheel; 16, chassis frame; 17, driving motor; 18, control module; 19, support frame; 20, vision module; 21, telescopic rod; 22, ceramic gasket; 23, sliding bar; 24, magnetic heating block; 25, positioning block; 26, U-shaped frame; 27, telescopic frame; 28, moving slide rail; 29, flattening chuck; 30, strip-shaped groove; 31, stepping motor; 32, cylinder body; 33, sliding rod; 34, connecting frame; 35, telescopic baffle. DETAILED DESCRIPTION

[0073] The advantages and features of the present application will be illustrated and explained by the following non-limiting description of preferred embodiments, which are given by way of example only, with reference to the accompanying drawings.

[0074] As Figures 1 to 4As shown, the present application provides a kind of intelligent mobile external force assisted electromagnetic flattening equipment, including support frame 19, the support frame 19 is preferably cross-shaped frame, the support frame 19 is horizontally arranged, the bottom of the support frame 19 is provided with chassis frame 16 and track wheel 15, track is set on the track wheel 15, control module 18 and drive motor 17 are arranged in the chassis frame 16, the drive motor 17 is connected with track wheel 15, for driving track wheel 15 rotation.The control module 18 is connected with drive motor 17, and the rotational speed of drive motor 17 is controlled by differential signal control module 18, realizes forward, backward and in-place steering function.The drive motor 17, track wheel 15 and track constitute the walking mechanism of flattening device.The track wheel 15 and track have two groups, symmetrically arranged relative to chassis frame 16, and the corresponding number of drive motor 17 is two, respectively drive two groups of track wheel 15 and track, and the drive motor 17 can drive the rotation and movement direction of track wheel 15, and two drive motors 17 are responsible for the drive and control of track wheel 15 on left and right sides respectively.In actual operation, when in-place steering needs to be realized, two drive motors can be controlled to make the track wheel 15 on both sides rotate reversely, and in forward working condition, only the track wheel 15 on both sides needs to be controlled to rotate in the same direction, so that the device can move forward stably.In order to facilitate fixation at flattening position, and to prevent the equipment from deviating and shaking during flattening process, four corners below the support frame 19 are provided with leg sleeve 13, one end of the leg sleeve 13 is connected with the output end of servo motor 12 arranged above the support frame 19, the other end of the leg sleeve 13 is fixedly connected with electromagnetic chuck 14, and the adsorption force of the electromagnetic chuck 14 is dynamically adjustable in the range of 0 to 2000 N.The servo motor 12 is fixed on the four corners above the support frame 19 by bolts.As preferred, the output end of the servo motor 12 is fixedly connected with shaft coupling through key groove, the other end of the shaft coupling is fixedly connected with ball screw of ball screw pair, and screw nut of the ball screw pair is fixed on the inner wall of the leg sleeve 13 by bolts, and the maximum stroke of the leg sleeve 13 is 500 mm.In order to ensure that the leg sleeve 13 moves stably without shaking during extension and retraction, a linear guide rail can be embedded in the leg sleeve 13.The leg sleeve 13 and the electromagnetic chuck 14 can be connected by ball hinge, so as to adapt to the slight curvature change of sheet surface.The leg sleeve 13 adopts hollow structure, so that the power line and signal line of the electromagnetic chuck 14 on the leg sleeve 13 pass through the hollow structure of the leg sleeve 13, are connected to the control module 18 through slip ring, and ensure that the line is not wound during extension and retraction.

[0075] The top center of the support frame 19 is fixedly connected with a base 11, the base 11 is sequentially connected with a rotating disc 10, a support shoulder 9, a shoulder motor 8, a support elbow 7, an elbow motor 6, a connecting wrist 5, a wrist motor 4 and a flattening mechanism. The base 11 is fixedly connected with the support frame 19 through bolts, the rotating disc 10 is installed inside the base 11, the support shoulder 9 can rotate 360° along the horizontal direction, the support shoulder 9 is fixed in the center of the rotating disc 10, the other end of the support shoulder 9 is connected with the support elbow 7 and the shoulder motor 8, the other end of the support elbow 7 is connected with the connecting wrist 5 and the elbow motor 6, the other end of the connecting wrist 5 is installed with the wrist motor 4, the connecting wrist 5 is driven to rotate along the vertical direction by the elbow motor 6. The flattening mechanism is connected with the wrist motor 4 through the telescopic rod 21, the flattening mechanism comprises a heating flattening module 1 and an external force auxiliary flattening module 2, the external force auxiliary flattening module 2 is arranged at one end of the telescopic rod 21 close to the wrist motor 4, and the heating flattening module 1 is arranged at the other end of the telescopic rod 21 away from the wrist motor 4. The wrist motor 4 is used for driving the telescopic rod 21 to stretch and retract and driving the flattening mechanism to rotate along the central axis of the connecting wrist 5, and the repeated positioning accuracy of the wrist motor 4 is ±0.1mm. The wrist motor 4, the elbow motor 6, the shoulder motor 8 and the rotating disc 10 constitute a transmission assembly of the flattening equipment of the present application, and the flattening mechanism can be adjusted to be opposite to the surface of the sheet for the heating flattening operation and the electromagnetic auxiliary flattening operation.

[0076] As shown in Figure 2 Fig. 3 is a structural schematic view of the heating flattening module 1, the heating flattening module 1 is composed of a ceramic gasket 22, a magnetic heating block 24 and a sliding bar 23. The bottom of the ceramic gasket 22 adopts an outward protruding design, that is, the distance between the magnetic heating block 24 and the sheet is greater than the distance between the ceramic gasket 22 and the sheet, so that a controllable gap is formed between the heating block and the surface of the sheet, and the reasonable distance between the two is ensured during the operation of the equipment, thereby avoiding the influence of the high temperature of the surface of the sheet on the work of the magnetic heating block 24 itself during heating. The magnetic heating block 24 is made of nanocrystalline alloy material and is embedded in the center of the sliding bar 23, two sliding grooves are symmetrically arranged on the sliding bar 23 relative to the magnetic heating block 24, one ceramic gasket 22 is arranged in each sliding groove, the ceramic gasket 22 protrudes outward by 3mm relative to the heating surface of the magnetic heating block 24, and a controllable gap is formed between the ceramic gasket 22 and the surface of the sheet, thereby avoiding the damage of the magnetic heating block 24 caused by overheating and affecting the flattening work. The sliding bar 23 is provided with a protrusion on the outer side, and the protrusion on the outer side of the sliding bar 23 is arranged in a direction parallel to the telescopic rod 21.

[0077] As shown in Figure 3 and Figure 4As shown, it is a structural schematic diagram of the external force assisted flattening module 2, which includes a positioning block 25, a U-shaped frame 26, a telescopic frame 27, a moving slide rail 28, a flattening suction cup 29 and a strip-shaped groove 30. The positioning block 25 is arranged on the U-shaped frame 26 for installing the thin plate detection module 3. The U-shaped frame 26 is arranged parallel to the telescopic rod 21, and the opening of the U-shaped frame 26 faces away from the wrist motor 4, and the telescopic rod 21 is connected with the heating flattening module 1 after penetrating through the U-shaped frame 26. The telescopic frame 27, the moving slide rail 28 and the flattening suction cup 29 have two groups, which are symmetrically arranged relative to the heating flattening module 1. One end of the telescopic frame 27 is fixedly connected with the U-shaped frame 26, the other end is connected with the moving slide rail 28, and the flattening suction cup 29 is connected with the moving slide rail 28. The U-shaped frame 26 is also provided with a strip-shaped groove 30, which is arranged along the direction parallel to the telescopic rod 21, and the strip-shaped groove 30 is matched with the protrusion on the slide bar 23, so as to avoid the movement interference between the heating flattening module 1 and the external force assisted flattening module 2. The telescopic frame 27 is internally provided with a telescopic cylinder, which includes a stepping motor 31, a cylinder body 32, a slide rod 33, a connecting frame 34 and a telescopic baffle 35. The cylinder body 32 is fixedly connected with the telescopic frame 27, the slide rod 33 is arranged in the cylinder body 32 and connected with the stepping motor 31 and the connecting frame 34 at both ends, and the other end of the connecting frame 34 is fixedly connected with the moving slide rail 28. As preferred, the flattening suction cup 29 is installed on the moving slide rail 28 through a ball hinge, which is convenient for adapting to the plane of the thin plate. The moving slide rail 28 is driven by a motor and a screw rod, so as to realize the movement of the flattening suction cup 29 in the direction of the moving slide rail 28, and meet the self-adaptation of the thin plate suction.

[0078] The intelligent mobile external force auxiliary electromagnetic flattening device provided by the application further comprises a vision module 20 and a sheet detection module 3, the sheet detection module 3 is arranged on the U-shaped frame 26 of the external force auxiliary flattening module 2, the vision module 20 is arranged on the top of the support frame 19, and the vision module 20 is arranged at the front end in the running direction of the flattening device. The control module 18 is electrically connected with the vision module 20, the sheet detection module 3, the driving motor 17, the heating flattening module 1, the external force auxiliary flattening module 2, the wrist motor 4, the elbow motor 6, the shoulder motor 8, the servo motor 12 and the rotating disc 10 respectively. The vision module 20 adopts an intelligent camera, provides visual protection for the movement of the device, and the internal vision system adopts an obstacle avoidance mechanism and path planning, so that the mutual interference between the flattening mechanism and the support frame 19 is avoided. The sheet detection module 3 adopts four laser displacement sensors, which are symmetrically distributed on both sides of the U-shaped frame 26, the sampling frequency is 1 kHz, specific areas on both sides of the weld are covered, the principle that a laser beam is reflected by the surface of a sheet is used, the deformation of the surface of the sheet is measured, and the slight change of the height of the surface of the sheet is monitored in real time. The control module 18 adopts a single-chip microcomputer, combines the sheet deformation data detected by the sheet detection module 3 in real time, calculates the best force application direction and the force application size in real time, adjusts the adsorption force size of the electromagnetic chuck 14 according to the moment balance equation, and ensures the stability of the device during work.

[0079] As shown in Figure 5 , Figure 6 and Figure 7 , three kinds of deformation states in the deformation of the sheet welding are shown, and the weld on both sides is convex, the weld on both sides is concave, and the weld on one side is concave and the weld on the other side is convex.

[0080] As shown in Figure 8 , the application further provides a flattening method suitable for the intelligent mobile external force auxiliary electromagnetic flattening device.

[0081] Step 1, the driving motor 17 is started to drive the track wheel 15 to move to a target area to be flattened;

[0082] Step 2, the supporting leg sleeve 13 is synchronously extended, the electromagnetic chuck 14 at the end of the supporting leg sleeve 13 is adaptively adsorbed to the sheet, and the adsorption force has an initial value of 600N;

[0083] Step 3, the control module 18 and the vision module 20 are started, the direction and the distance from the surface of the sheet are adjusted, the heating flattening module 1 is perpendicular to the surface of the sheet and is aligned with the area to be flattened;

[0084] Step 4, the telescopic rod 21 is extended, the ceramic gasket 22 of the heating flattening module 1 is closely contacted with the surface of the sheet, at the same time, the set current is turned on, the flattening area is heated to a target temperature, the temperature is kept for 10s, and the residual stress is released;

[0085] Step 5, after heating is completed, the telescopic rod 21 is retracted, the surface of the sheet is separated, and the deformed state of the sheet after heating is detected to determine whether the deformation of the sheet is less than the set threshold value relative to the horizontal reference line. If not, the external force assisted flattening mode is started, that is, step 6 is executed; otherwise, the next flattening area is entered for flattening work, that is, step 10 is executed.

[0086] In the heating and flattening stage of the sheet, the magnetic gathering heating block 24 of the heating and flattening module 1 is aligned along the weld by the transmission assembly controlled by the control module 18, and the ceramic gasket 22 of the heating and flattening module 1 is in contact with the surface of the sheet. The heating mode is turned on, and when the heating temperature reaches the target temperature, the heating mode is turned off. The sheet detection module 3 detects the area of the sheet after heating and flattening to determine whether the deformation meets the standard (such as whether the height difference relative to the horizontal reference line is within ±3mm). If not, the wave deformation, local concave-convex or residual deformation position caused by weld shrinkage of the non-compliant area is determined, and the external force assisted flattening mode is started after waiting for a few seconds.

[0087] Step 6, start the external force assisted flattening module 2 and the sheet detection module 3. The control module 18 calculates the force direction angle θ adjust according to the sheet deformation gradient field data fed back by the sheet detection module 3, adjusts and sets the force direction, and at the same time makes the flattening suction cup 29 be stably adsorbed on the surface of the sheet according to the force direction, and judges the deformation state of the sheet.

[0088] Step 61, the control module 18 calculates the force direction angle θ adjust according to the sheet deformation gradient field data fed back by the sheet detection module 3, and the formula is as follows:

[0089]

[0090] wherein are the gradient components of the sheet height field in the x and y directions, respectively, and are obtained by least square surface fitting of partial derivatives; x is the direction perpendicular to the weld, and y is the direction along the weld.

[0091] In the external force assisted flattening stage, the force direction should be dynamically adjusted according to the deformation state of the sheet in specific flattening work. Therefore, based on the surface deformation gradient field of the ship sheet (measured in real time by the sheet detection module), the optimal force angle is calculated by the sheet surface height change rate, and the formula for calculating the force direction angle is as follows:

[0092]

[0093] wherein The gradient components of the sheet height field in x and y directions, respectively, are obtained by least square surface fitting of the partial derivatives of the central position of the flattening mechanism as the origin; x is the direction perpendicular to the weld, and y is the direction along the weld.

[0094] Step 62, the control module 18 calculates the height field gradient and extracts the characteristic parameters according to the height data of the rectangular region centered on the weld feedback by the sheet detection module 3, and the formula is as follows:

[0095]

[0096] In the formula, is the height field gradient; Δh L is the average height of the left side of the weld; Δh R is the average height of the right side of the weld; σ h is the standard deviation of the height of the single side region; N represents the sample number; h i represents the height of the i-th sample; x i , y i represents the coordinates of the i-th sample.

[0097] Step 63, according to the characteristic parameters extracted in step 62, the deformation state of the sheet is determined:

[0098] When the average height of the left side of the weld Δh L and the average height of the right side of the weld Δh R satisfy Δh L > h0+ò and Δh R > h0+ò at the same time, it is determined that the deformation state is double-sided convex. Wherein, h0 is the reference height, and ò is the height deviation threshold value, which is set according to the flattening standard;

[0099] When the average height of the left side of the weld Δh L < h0-ò and Δh R < h0-ò at the same time, it is determined that the deformation state of the sheet is double-sided concave;

[0100] When the average height of the left side of the weld Δh L > h0+ò and Δh R < h0-ò at the same time, it is determined that the deformation state of the sheet is left convex and right concave;

[0101] When the average height of the left side of the weld Δh L < h0-ò and Δh R < h0+ò at the same time, it is determined that the deformation state of the sheet is right convex and left concave;

[0102] When the height h i of all detection points satisfies max|h iWhen -h0|≤ò(i=1,2,…,N), the thin plate is determined to be in a flat state and no external force is needed to level it.

[0103] The reference height h0 is obtained by controlling the rotating disk of the transmission component to rotate the leveling mechanism horizontally to a flat area near the equipment support point, keeping the height of the telescopic cylinder fixed. The laser displacement sensor of the thin plate detection module collects surface height data of the flat area at a certain sampling frequency and processes abnormal data according to the 3σ criterion. in Let σ be the mean of the original data and σ be the sample standard deviation. Then, the reference height... Where M is the number of valid data points h n Let be the height of the nth valid data point.

[0104] Step 7: Based on the deformation state of the thin plate obtained in Step 6, the adaptive PID algorithm is used to dynamically adjust the coordinated pressing or pulling action of the telescopic cylinders on both sides of the U-shaped frame 26, and optimize the output force of the telescopic cylinders. The double-sided coordinated mode is started after correcting the side with high deformation. Combined with the torque balance equation of the electromagnetic chuck of the support leg (real-time compensation of adsorption force every 50ms), the leveling process is ensured to be stable and efficient.

[0105] Step 71: When both sides of the weld are deformed by bulges, the formula for the output force of the telescopic cylinder is as follows:

[0106]

[0107] F base =k·σ s ·A

[0108] In the formula, F i For the output force of the telescopic cylinder; F base The basic output force; k is the safety factor (0 < k < 1); σ s Δh represents the yield strength of the thin sheet material; A represents the contact area between the leveling suction cup 29 and the thin sheet; β represents the preferred lateral force amplification factor; ε represents the height deviation threshold; and Δh represents the height deviation threshold. i and Δh j These are the measured deformations on the left and right sides of the weld, respectively.

[0109] Step 72: When both sides of the weld are concave and deformed, the formula for the output force of the telescopic cylinder is as follows:

[0110]

[0111] F base =k·σ s ·A

[0112] In the formula, γ is the difference coefficient of indentation depth.

[0113] Step 73, when the single-sided convex deformation of the weld is deformed on the other side, the telescopic cylinder output force formula is as follows:

[0114]

[0115] |F push +F pull |≤F max

[0116] In the formula, δ is the composite deformation coordination coefficient; F max is the maximum output threshold of the system.

[0117] The output force of the telescopic cylinder calculated in steps 71, 72 and 73 is the initial output force, and the size of the telescopic cylinder output force is dynamically adjusted by the PID algorithm subsequently.

[0118] Step 74, the self-adaptive PID algorithm is used to dynamically adjust the output force of the telescopic cylinder, and the formula is as follows:

[0119]

[0120] In the formula, F t is the real-time telescopic cylinder output force; Δh is the target deformation; K p ,K i ,K d are the proportion, integral and differential of the PID algorithm, which can be adaptively optimized according to the material thickness and yield strength.

[0121] The optimization process of the PID algorithm is as follows:

[0122] Step 741, according to the interpolation function of the ship plate commonly used material database, the material thickness and the yield strength, the initial parameters are mapped as follows:

[0123]

[0124] In the formula, u is the material thickness; σ s is the material yield strength; f is the interpolation function based on the ship plate commonly used material database.

[0125] Initialization parameter mapping: for the determination of K p ,K i ,K d control parameters, the mapping relationship between the material thickness u of the ship plate and the yield strength σ s and the initial parameters of the PID is established, and the initial parameter matching is realized through the mapping function: Wherein, f is the interpolation function based on the ship plate commonly used material database, which is fitted through material simulation experiment. When the equipment is working, the thickness u and yield strength σ of the material are obtained by inputting the corresponding material code.s Then, the mapping function is called to calculate the initial parameters.

[0126] Step 742: Based on the rate of change v of the real-time deformation Δh Δh The dynamic proportional coefficient K is obtained. p The formula is as follows:

[0127]

[0128] In the formula, μ and Δh are correction coefficients, calibrated through material simulation experiments; max This is the preset maximum deformation threshold.

[0129] Step 743: Based on the cumulative error of deformation ∫Δh dt and the maximum allowable residual stress σ of the thin plate material... x The dynamic integral coefficient K is obtained. i The formula is as follows:

[0130]

[0131] In the formula, ω is the attenuation coefficient, which is calibrated through material simulation experiments, and E is the elastic modulus of the thin plate material.

[0132] Step 744: Obtain the dynamic differential coefficient K based on the rate of change of the thin plate's curvature. d The formula is as follows:

[0133]

[0134] Where ψ is the sensitivity coefficient, calibrated through material simulation experiments; C max This is the preset maximum curvature threshold.

[0135] Real-time parameter adjustment: During the external force-assisted leveling stage, the thin plate detection module of the equipment collects deformation data every 50ms to determine the rate of change v of the real-time deformation Δh. Δh Then the proportionality coefficient K p The dynamic iteration formula is: Where μ is the correction coefficient, calibrated through material simulation experiments, and Δh max To preset the maximum deformation threshold, K is increased when the deformation converges slowly. p Conversely, it decreases. This applies to the integral coefficient K. i The cumulative error of deformation ∫Δh dt is compared with the maximum allowable residual stress σ of the thin plate material. x If we perform correlation, then the integral coefficient K i The dynamic iteration formula is: Where ω is the attenuation coefficient, calibrated through material simulation experiments, E is the elastic modulus of the thin plate material, and K is decreased when the cumulative error approaches the material's yield limit.i , avoid overcorrection. For the differential coefficient K d , the second derivative of the deformation gradient (i.e. the rate of change of curvature) is related to it, and the change in the slope of the sheet surface is monitored in real time by a laser displacement sensor, then the dynamic iterative formula of the differential coefficient K d is: Where ψ is the sensitivity coefficient, calibrated by material simulation experiment, C max is the preset maximum curvature threshold value, which increases K d when the local deformation suddenly changes, inhibits vibration, and increases the stability of the external force during the flattening process.

[0136] When the sheet detection module 3 detects that the sheet deformation state is convex along both sides of the weld, due to the diversity of sheet deformation, the deformation amounts of the two sides of the sheet are inconsistent (one side has a large deformation amount and the other side has a small deformation amount), the sheet detection module 3 monitors the deformation amounts of the two sides of the sheet in real time, the control module 18 controls the moving slide rail 28 to automatically plan the adsorption position of the flattening suction cup 29 according to the deformation condition, the flattening suction cup 29 is electrified and stably adsorbed on the surface of the sheet, the electric telescopic cylinders installed on both sides of the U-shaped frame 26 drive the telescopic frame 27 to extend, the double flattening suction cups 29 implement pressure on the surface of the sheet, compress the convex height, and preferentially correct the side with a large deformation amount, after the deformation amount of the side is reduced to be similar to that of the other side, the double-sided cooperative downward pressing mode is started, and until the sheet detection module 3 detects that the deformation amounts of the two sides meet the standard.

[0137] When the sheet detection module 3 detects that the sheet deformation state is concave along both sides of the weld, the sheet detection module 3 monitors the deformation amounts of the two sides of the sheet in real time, the flattening suction cup 29 is electrified and stably adsorbed on the surface of the sheet, the electric telescopic cylinders installed on both sides of the U-shaped frame 26 drive the telescopic frame 27 to retract, the double flattening suction cups 29 implement pulling force on the surface of the sheet to flatten the concave area, preferentially correct the side with a large concave deformation amount, after the deformation amount of the side is reduced to be similar to that of the other side, the double-sided cooperative pulling mode is started, and until the sheet detection module 3 detects that the deformation amounts of the two sides meet the standard.

[0138] When the sheet detection module 3 detects that the sheet deformation state is convex on one side along the weld and concave on the other side, the sheet detection module 3 monitors the deformation amounts of the two sides of the sheet in real time, the flattening suction cup 29 is electrified and stably adsorbed on the surface of the sheet, the convex side starts the electric cylinder to drive the telescopic frame 27 to extend and apply pressure on the surface of the sheet, the concave side starts the electric cylinder to drive the telescopic frame 27 to retract and apply pulling force on the surface of the sheet, and until the sheet detection module 3 detects that the deformation amounts of the two sides meet the standard.

[0139] Step 8, monitor the overturning moment M ext in real time, dynamically distribute the adsorption force through the electromagnetic suction cup 14 at the end of the support leg sleeve 13, and ensure that the equipment has no risk of overturning.

[0140] The whole device meets the mechanical balance mechanism, so that the device remains stable during the flattening operation, that is, the electromagnetic chuck suction force of the four supporting legs meets the torque balance equation: Wherein L i is the horizontal distance from the i-th supporting leg sleeve 13 to the center of gravity of the device, which is a fixed value; M ext is the overturning moment generated by the force applied during external force assisted flattening, and at the same time, the control moment is real-time compensated during the operation. According to the torque balance equation, the electromagnetic chuck suction force of the supporting leg sleeve 13 is updated every 50 ms, and the dynamic adjustment of the suction force F ads,i of the electromagnetic chuck 14 is realized by adjusting the input current of the control module 18.

[0141] Step 9, the sheet detection module 3 monitors the sheet deformation in real time until the given threshold is reached.

[0142] Step 10, the target area flattening operation is completed, each module is reset, and the device moves to the next operation area.

[0143] In addition to the above embodiments, the present application can also have other implementation manners, and any technical solutions formed by equivalent replacement or equivalent transformation shall fall within the protection scope required by the present application.

Claims

1. An intelligent mobile external force-assisted electromagnetic leveling device, comprising a horizontally arranged support frame (19) and a chassis frame (16) and track wheels (15) disposed at the bottom of the support frame (19), characterized in that: It also includes a control module (18) and a drive motor (17) set inside the chassis frame (16). The drive motor (17) is connected to the track wheel (15), and the track wheel (15) is fitted with a track. A base (11) is fixedly connected to the top center of the support frame (19). A rotating disk (10), a support shoulder (9), a shoulder motor (8), a support elbow (7), an elbow motor (6), a connecting wrist (5), a wrist motor (4), and a leveling mechanism are connected in sequence on the base (11). The leveling mechanism is connected to the wrist motor (4) through a telescopic rod (21). The leveling mechanism includes a heating leveling module (1) and an external force-assisted leveling module (2). The external force-assisted leveling module (2) is located at one end of the telescopic rod (21) near the wrist motor (4), and the heating leveling module (1) is located at one end of the telescopic rod (21) away from the wrist motor (4); a vision module (20) is provided on the support frame (19) along the traveling direction of the leveling device, and a thin plate detection module (3) is provided on the external force-assisted leveling module (2); the control module (18) is electrically connected to the vision module (20), the thin plate detection module (3), the drive motor (17), the heating leveling module (1), the external force-assisted leveling module (2), the wrist motor (4), the elbow motor (6), the shoulder motor (8), and the rotating disk (10).

2. The intelligent mobile external force-assisted electromagnetic leveling device according to claim 1, characterized in that: The heating and leveling module (1) includes a slide bar (23) and a magnetic heating block (24) disposed in the center of the slide bar (23). Two slide grooves are symmetrically arranged on the slide bar (23) relative to the magnetic heating block (24). A ceramic pad (22) is disposed in each slide groove. The ceramic pad (22) protrudes outward relative to the heating surface of the magnetic heating block (24).

3. The intelligent mobile external force-assisted electromagnetic leveling device according to claim 2, characterized in that: The external force-assisted leveling module (2) includes a U-shaped frame (26) parallel to the telescopic rod (21) and with its opening facing away from the wrist motor (4), a telescopic frame (27), a sliding rail (28), and a leveling suction cup (29). There are two sets of the telescopic frame (27), sliding rail (28), and leveling suction cup (29), symmetrically arranged relative to the heating leveling module (1). One end of the telescopic frame (27) is fixedly connected to the U-shaped frame (26), and the other end is connected to the sliding rail (28). The flat suction cup (29) is connected to the movable slide rail (28); the telescopic frame (27) is equipped with a telescopic cylinder, which includes a stepper motor (31), a cylinder body (32), a slide rod (33), a connecting frame (34), and a telescopic baffle (35); the cylinder body (32) is fixedly connected to the telescopic frame (27), and the slide rod (33) is set inside the cylinder body (32) and its two ends are respectively connected to the stepper motor (31) and the connecting frame (34), and the other end of the connecting frame (34) is fixedly connected to the movable slide rail (28).

4. The intelligent mobile external force-assisted electromagnetic leveling device according to claim 3, characterized in that: The support frame (19) has four corners with support leg sleeves (13). One end of the support leg sleeve (13) is connected to the output end of the servo motor (12) located above the support frame (19), and the other end of the support leg sleeve (13) is fixedly connected to an electromagnetic chuck (14).

5. The intelligent mobile external force-assisted electromagnetic leveling device according to claim 4, characterized in that: The output end of the servo motor (12) is fixedly connected to the coupling via a keyway, and the other end of the coupling is fixedly connected to the ball screw of the ball screw pair. The screw nut of the ball screw pair is fixed to the inner wall of the support sleeve (13) by bolts.

6. The intelligent mobile external force-assisted electromagnetic leveling device according to claim 4, characterized in that: The slide bar (23) has a protrusion on its outer side, and the protrusion on the outer side of the slide bar (23) is arranged in a direction parallel to the telescopic rod (21); the U-shaped frame (26) is also provided with a strip groove (30), and the strip groove (30) is opened in a direction parallel to the telescopic rod (21); the protrusion on the slide bar (23) cooperates with the strip groove (30).

7. The intelligent mobile external force-assisted electromagnetic leveling device according to claim 4, characterized in that: The outrigger sleeve (13) is connected to the electromagnetic chuck (14) by a ball joint; the leveling chuck (29) is mounted on the movable slide rail (28) by a ball joint.

8. The intelligent mobile external force-assisted electromagnetic leveling device according to claim 4, characterized in that: The support frame (19) is a cross-shaped frame.

9. A leveling method applicable to the intelligent mobile external force-assisted electromagnetic leveling device according to any one of claims 4 to 8, characterized in that: Includes the following steps: S1. Start the drive motor (17) to drive the track wheel (15) to move to the target area to be leveled; S2, the outrigger sleeve (13) extends out, and the electromagnetic chuck (14) adsorbs the thin plate; S3. Start the control module (18) and vision module (20), adjust the direction and distance from the thin plate surface, so that the heating and leveling module (1) is perpendicular to the thin plate surface and aligned with the area to be leveled; S4. The telescopic rod (21) extends, so that the ceramic pad (22) of the heating and leveling module (1) is in close contact with the surface of the thin plate for heating and leveling. S5. After heating is completed, the telescopic rod (21) retracts, detaches from the surface of the thin plate, and detects the deformation state of the thin plate after heating. It is determined whether the deformation of the thin plate relative to the horizontal baseline is less than the set threshold. If it does not meet the standard, step S6 is executed; otherwise, step S10 is executed. S6. Start the external force-assisted leveling module (2) and the thin plate detection module (3). The control module (18) calculates the force application direction angle θ based on the thin plate deformation gradient field data fed back by the thin plate detection module (3). adjust Adjust the direction of force application and determine the deformation state of the thin plate; S61, The control module (18) calculates the force application direction angle θ based on the thin plate deformation gradient field data fed back by the thin plate detection module (3). adjust The formula is as follows: in These are the gradient components of the plate height field in the x and y directions, respectively; x is perpendicular to the weld direction, and y is along the weld direction. S62. The control module (18) calculates the height field gradient based on the height data of the rectangular area centered on the weld seam fed back by the thin plate detection module (3), and extracts the feature parameters as follows: In the formula, The gradient of the height field; Δh L Δh represents the average height on the left side of the weld. R σ represents the average height on the right side of the weld. h The standard deviation of the height of a one-sided region; N represents the sample size; h i x represents the height of the i-th sample; i y i Represents the coordinates of the i-th sample; S63. Based on the feature parameters extracted in step S62, determine the deformation state of the thin plate; S7. Based on the deformation state of the thin plate obtained in step S6, the adaptive PID algorithm is used to dynamically adjust the coordinated pressing or pulling action of the telescopic cylinders on both sides of the U-shaped frame (26) and optimize the magnitude of the output force of the telescopic cylinders. S8, Real-time monitoring of overturning moment M ext The adsorption force is dynamically distributed through the electromagnetic chuck (14); S9. Thin plate detection module (3) monitors the deformation of the thin plate in real time until it reaches the given threshold. S10. The target area leveling operation is completed, all modules are reset, and the equipment is moved to the next work area.

10. The leveling method of the intelligent mobile external force-assisted electromagnetic leveling device according to claim 9, characterized in that: The specific steps of step S7 are as follows: S71. When both sides of the weld seam are convex deformations, the formula for the output force of the telescopic cylinder is as follows: F base =k·s s ·A In the formula, F i For the output force of the telescopic cylinder; F base The basic output force; k is the safety factor; σ s Δh is the yield strength of the thin plate material; A is the contact area between the leveling suction cup (29) and the thin plate; β is the preferred lateral force amplification factor; ε is the height deviation threshold; Δh i and Δh j The measured deformation amounts are for the left and right sides of the weld, respectively. S72. When both sides of the weld are concave deformation, the formula for the output force of the telescopic cylinder is as follows: F base =k·s s ·A In the formula, γ is the difference coefficient of indentation depth; S73. When the weld seam deforms with a convex shape on one side and a concave shape on the other side, the formula for the output force of the telescopic cylinder is as follows: |F push +F pull |≤F max In the formula, δ is the composite deformation compatibility coefficient; F max This is the maximum output threshold of the system; S74. The output force of the telescopic cylinder is dynamically adjusted using an adaptive PID algorithm, as shown in the following formula: In the formula, F t The real-time output force of the telescopic cylinder; Δh is the target deformation; K p ,K i ,K d These are the proportional, integral, and derivative functions of the PID algorithm, respectively. S741. Based on the interpolation function of the database of commonly used marine thin plates, the material thickness, and the yield strength, the initial parameters are mapped to obtain... The formula is as follows: In the formula, u represents the material thickness; σ s is the yield strength of the material; f is the interpolation function based on a database of commonly used materials for marine thin plates; S742, Based on the rate of change of the real-time deformation Δh, v Δh The dynamic proportional coefficient K is obtained. p The formula is as follows: In the formula, μ and Δh are correction coefficients, calibrated through material simulation experiments; max The preset maximum deformation threshold; S743. Based on the cumulative error of deformation ∫Δh dt and the maximum allowable residual stress σ of the thin plate material... x The dynamic integral coefficient K is obtained. i The formula is as follows: In the formula, ω is the attenuation coefficient, which is calibrated through material simulation experiments, and E is the elastic modulus of the thin plate material; S744. Based on the rate of change of the curvature of the thin plate, obtain the dynamic differential coefficient K. d The formula is as follows: Where ψ is the sensitivity coefficient, calibrated through material simulation experiments; C max This is the preset maximum curvature threshold.

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