A weld seam detection remanufacturing system and device for hydraulic supports

Abstract

The application discloses a weld seam detection remanufacturing system and device for hydraulic support, and particularly relates to the field of remanufacturing technology of mining equipment, and is used for solving the secondary stress migration and base metal cracking problems caused by local heat input during in-situ repair of box-shaped structural parts; the data acquisition module is used for collecting the repair area contour coordinates and the base metal thickness distribution; the unit division module is used for dividing the stress buffer unit containing the heat input control sub-area based on the thickness gradient and the rib plate layout; the boundary redivision module is used for dynamically optimizing the sub-area boundary through the geomagnetic field gradient scanning; the thermal excitation control module is used for performing layered repair welding and sequentially activating the sub-area heat input; the energy ratio monitoring module is used for switching and activating the sub-area in real time according to the acoustic emission energy ratio to block the microscopic plastic deformation; the stress processing module is used for eliminating the migration stress peak value through the residual stress scanning of the expanded area and the local thermal relaxation; the whole process regulation of the stress evolution during the repair process is realized, and the repair safety and service life of the box-shaped structural parts are ensured under the unmovable working condition.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of remanufacturing of mining equipment, and more particularly, to a weld detection remanufacturing system and device for a hydraulic support. BACKGROUND

[0002] In the remanufacturing process of a mining hydraulic support, the weld repair of a box-shaped structural member (such as a base or a top beam) needs to be implemented in situ. Due to the immobility of the support as a whole and the large structure, the repair operation can only be carried out on the local welding of the damaged area. The high-temperature heat input generated in such a welding process will significantly change the residual stress distribution state inside the original structure, and the local heat source regulation means relied on by the prior art is difficult to coordinate the stress balance of the whole structure.

[0003] The existing welding remanufacturing method, when implementing local repair, due to the high restraint characteristics of the box-shaped structure and the local concentration effect of heat input, causes unintended redistribution of residual stress around the repair area, causing the secondary stress peak to migrate to the adjacent base material area, resulting in the risk of structural cracking of the base material outside the repair area boundary. SUMMARY

[0004] In order to overcome the above-mentioned defects of the prior art, the present application provides a weld detection remanufacturing system and device for a hydraulic support to solve the problems raised in the background art.

[0005] To achieve the above-mentioned purpose, the present application provides the following technical solutions:

[0006] A weld detection remanufacturing system for a hydraulic support, comprising:

[0007] A data acquisition module: acquiring the contour coordinates of the weld repair area and the base material thickness distribution;

[0008] A unit division module: dividing a stress buffer unit around the repair area according to the base material thickness distribution and the layout of the rib plate, the stress buffer unit containing at least two heat input regulation sub-areas;

[0009] A boundary redrawing module: scanning the geomagnetic field intensity component of the stress buffer unit boundary and calculating the gradient vector, and if the modulus value of the gradient vector exceeds the critical angle, the heat input regulation sub-area boundary is redrawn;

[0010] A heat excitation control module: performing layered repair welding on the repair area, and simultaneously activating heat input in the heat input regulation sub-area in a predetermined order;

[0011] An energy ratio monitoring module: collecting the acoustic emission signals of the heat input regulation sub-area, extracting the high-frequency and low-frequency energy to calculate the energy ratio; when the energy ratio difference of adjacent heat input regulation sub-areas exceeds the threshold value, switch to the heat input regulation sub-area with high energy ratio;

[0012] Stress treatment module: determine the residual stress scanning area outside the repair area boundary based on the contour coordinates, and if the stress peak migration amount exceeds the safety threshold, implement local thermal relaxation treatment on the migrated peak area.

[0013] Further, the contour coordinates and the base material thickness distribution of the weld repair area are obtained, including:

[0014] The three-dimensional point cloud data of the weld repair area is obtained by a laser scanning device, the heat affected zone boundary is identified based on the curvature distribution of the three-dimensional point cloud data, and the spatial position coordinates of the curvature mutation points are taken as the contour coordinates of the weld repair area.

[0015] The grid thickness measurement is performed in the extended area outside the boundary defined by the contour coordinates of the weld repair area by an ultrasonic thickness gauge, the base material thickness measurement values of each node are obtained, and the base material thickness distribution is generated.

[0016] Further, the node spacing of the grid thickness measurement is set according to the spacing of the rib plates in the box-shaped structural member rib plate layout.

[0017] Further, the stress buffer unit around the repair area is divided according to the base material thickness distribution and the rib plate layout, and the stress buffer unit includes at least two heat input regulation sub-areas, including:

[0018] The minimum distance from the outer edge of the repair area contour coordinates to the stress buffer unit boundary is determined based on the base material thickness distribution, and the minimum distance is equal to the product of the maximum thickness value in the base material thickness distribution and a constant coefficient.

[0019] Taking the rib plate welding end part in the rib plate layout of the box-shaped structural member as the reference point, the extension division line is extended in the direction of the maximum thickness gradient change in the base material thickness distribution.

[0020] The closed area formed by the extension division line and the minimum distance of the repair area contour coordinates is taken as the stress buffer unit.

[0021] In the stress buffer unit, the stress buffer unit is divided into at least two heat input regulation sub-areas with the rib plate welding end part as the starting point of the sub-area boundary.

[0022] Further, the geomagnetic field intensity component of the stress buffer unit boundary is scanned and the gradient vector is calculated, and if the modulus of the gradient vector exceeds the critical angle, the heat input regulation sub-area boundary is re-divided, including:

[0023] The magnetic memory sensor array is arranged along the stress buffer unit boundary, and the normal component of the geomagnetic field intensity is continuously collected;

[0024] The gradient vector is calculated based on the difference of the normal component of the geomagnetic field intensity of adjacent sensor nodes, and the modulus of the gradient vector is the absolute value of the change rate of the normal component of the geomagnetic field intensity.

[0025] When the magnitude of the gradient vector exceeds the critical angle, the boundary of the corresponding heat input control sub-region is moved along the gradient vector direction to the position with the lowest magnetic memory equipotential line density within the stress buffer unit.

[0026] The heat input control sub-region division is updated using the moved sub-region boundary.

[0027] Furthermore, the critical angle is set as the arcsine function value corresponding to the ratio of the material's yield strength to its tensile strength.

[0028] Furthermore, layered welding is performed on the repair area, and heat input is activated in a preset sequence within the heat input control sub-region, including:

[0029] Based on the updated heat input control sub-region division, the repair area is divided into multiple weld beads along the depth direction, and the thickness of each weld bead is determined by the upper limit value based on the minimum base material thickness of the repair area.

[0030] The preset sequence is set as a radial activation path from the contour coordinate position of the repair area to the outer edge of the stress buffer unit;

[0031] Within a single heat input control sub-zone, heat input activation is achieved by controlling the on / off power supply of the welding torch heat source within the sub-zone through an independent temperature control device.

[0032] During the activation process, the distance between the activation start points of adjacent heat input control sub-regions should be greater than the effective range of the welding torch heat source.

[0033] Once all heat input control sub-regions of the current layer are activated, the layered repair welding of the next layer of weld beads is performed.

[0034] Further, acoustic emission signals from the heat input control sub-region are collected, and the energy ratio of the high-frequency and low-frequency bands is calculated. When the energy ratio difference between adjacent heat input control sub-regions exceeds a threshold, the system switches to the heat input control sub-region with the higher energy ratio, including:

[0035] Acoustic emission sensors are placed at the activation start point of each heat input control sub-region to collect the raw acoustic emission signals during the welding process;

[0036] The original acoustic emission signal is separated into the dislocation slip characteristic frequency band signal and the grain boundary friction characteristic frequency band signal by using a physical bandpass filter;

[0037] The high-frequency energy is obtained by full-wave rectification and integration of the dislocation slip characteristic frequency band signal, and the low-frequency energy is obtained by full-wave rectification and integration of the grain boundary friction characteristic frequency band signal.

[0038] The ratio of high-frequency energy to low-frequency energy is used as the energy ratio;

[0039] Real-time calculation of the energy ratio difference of adjacent heat input regulation sub-regions, and when the energy ratio difference exceeds the proportional threshold of the maximum energy ratio of the current welding stage, a switching instruction is sent to the heat input activation device to the heat input regulation sub-region with high energy ratio.

[0040] Further, based on the contour coordinates, an outer expansion area of the repair region boundary is determined for residual stress scanning, and if the stress peak migration amount exceeds a safety threshold, local thermal relaxation treatment is implemented on the migrated peak value area, including:

[0041] The residual stress scanning area is extended outward from the stress buffer unit minimum distance by an integer multiple range based on the contour coordinates;

[0042] An X-ray diffractometer is used to scan the residual stress field along the grid thickness measurement nodes in the residual stress scanning area;

[0043] The stress peak migration amount is calculated by comparing the residual stress field data before and after the repair welding, and the safety threshold is set as a proportional value of the material fatigue limit;

[0044] When the stress peak migration amount exceeds the safety threshold, the current stress peak maximum position is marked as the migrated peak value area;

[0045] A high-frequency alternating magnetic field is applied to the surface of the migrated peak value area, and through eddy current effect, the surface layer metal of the migrated peak value area reaches the recrystallization temperature and is kept warm;

[0046] After the heat preservation is completed, the high-frequency alternating magnetic field is stopped, and the migrated peak value area is forced to air cooling to room temperature to complete the local thermal relaxation treatment.

[0047] On the other hand, the present application provides a kind of for hydraulic support's weld detection remanufacturing device, carries a kind of for hydraulic support's weld detection remanufacturing system.

[0048] Compared with the prior art, the present application has the following beneficial effects:

[0049] 1、The present application solves the problem of secondary stress migration during in-situ repair of box-type structural parts by constructing a multi-level collaborative stress regulation system; through the stress buffer unit division mechanism combined with the thickness gradient of the base material and the layout characteristics of the rib plate, a dynamic stress buffer zone is established around the repair area, and through the partition activation strategy of the heat input regulation sub-region, the concentrated heat input is dispersed into a multi-source coordinated heat action sequence, which significantly weakens the stress concentration effect of the welding heat affected zone; the implicit stress migration path prediction is integrated into the welding planning stage through the geomagnetic field gradient boundary redivision, and the stress sensitive channel is avoided in advance through the critical angle determination, thereby inhibiting the escape tendency of the residual stress peak value to the base material region from the source.

[0050] 2. The real-time acoustic emission energy ratio control mechanism breaks through the lag limitation of traditional temperature monitoring. It utilizes the abrupt change in the ratio of high-frequency dislocation slip energy to low-frequency grain boundary friction energy to immediately switch the heat input target sub-region at the beginning stage of microscopic plastic deformation, thus achieving active intervention. The closed-loop residual stress reduction design locates the migration peak region through the outward scanning area and uses high-frequency magnetic field-induced local recrystallization treatment to release the migration stress in a directional manner during thermal relaxation, eliminating the risk of secondary cracking outside the repair zone boundary. Under the premise of maintaining the overall structural restraint state, it achieves adaptive synergy between local repair and global stress balance. Attached Figure Description

[0051] Figure 1 This is a schematic diagram of the structure of a weld inspection and remanufacturing system for hydraulic supports according to the present invention. Detailed Implementation

[0052] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0053] Example 1: Figure 1 A schematic diagram of a weld inspection and remanufacturing system for hydraulic supports according to the present invention is provided, comprising the following modules:

[0054] Data acquisition module: Acquires the contour coordinates of the weld repair area and the thickness distribution of the base material;

[0055] Unit division module: Based on the thickness distribution of the base material and the layout of the stiffeners, stress buffer units are divided around the repair area. Each stress buffer unit contains at least two heat input control sub-regions.

[0056] Boundary redrawing module: Scans the geomagnetic field intensity components of the stress buffer unit boundary and calculates the gradient vector. If the magnitude of the gradient vector exceeds the critical angle, the boundary of the heat input control sub-region is redrawn.

[0057] Thermal shock control module: Performs layered welding on the repair area, and activates thermal input in a preset order within the thermal input control sub-area;

[0058] Energy ratio monitoring module: collects acoustic emission signals from the heat input control sub-region, extracts high-frequency and low-frequency energy to calculate the energy ratio; when the energy ratio difference between adjacent heat input control sub-regions exceeds the threshold, it switches to the heat input control sub-region with the higher energy ratio.

[0059] The stress treatment module: based on the profile coordinates to determine the repair area boundary expansion area to scan the residual stress, if the stress peak migration amount exceeds the safety threshold, then the peak migration area is implemented local thermal relaxation treatment.

[0060] The data acquisition module outputs the profile coordinates and the base material thickness distribution to the unit division module, which divides the stress buffer unit and the heat input control sub-area based on the data and the rib layout; the output of the unit division module is connected to the boundary redrawing module, which redraws the sub-area boundary when the gradient vector module value is supercritical by scanning the magnetic field intensity component of the unit boundary and calculating the gradient vector module value, thereby predicting and avoiding the implicit stress migration path before welding; the output of the boundary redrawing module is fed into the heat excitation control module, which activates the sub-area heat input in sequence while performing layered repair welding in the repair area and receives real-time feedback from the energy ratio monitoring module; the energy ratio monitoring module collects acoustic emission signals in the sub-area, extracts high-frequency and low-frequency energy to calculate the energy ratio, and when the energy ratio difference between adjacent sub-areas exceeds the threshold, immediately switches the activation target of the heat excitation control module to the sub-area with high energy ratio, captures the dislocation slip initiation (high-frequency energy drop) to replace traditional temperature monitoring, and blocks microplastic deformation in advance; the stress treatment module is based on the profile coordinates of the data acquisition module to locate the repair area boundary expansion area, perform residual stress scanning, and implement local thermal relaxation treatment on the peak migration area when the stress peak migration amount exceeds the safety threshold.

[0061] The specific implementation process of obtaining the profile coordinates of the weld repair area and the thickness distribution of the base material is as follows: obtaining three-dimensional point cloud data of the weld repair area by a laser scanning device, the laser scanning device scans the surface of the repair area with a line laser beam, for example, the wavelength of the laser beam is 650 nanometers, the angle between the scanning head axis and the normal line of the repair area surface is maintained to be not more than 30 degrees during the scanning process, and the scanning distance is controlled to be in the range of, for example, 300 millimeters to 500 millimeters; the obtained three-dimensional point cloud data contains the spatial position coordinate information of each measurement point on the surface of the repair area; the specific process of identifying the boundary of the heat-affected zone based on the curvature distribution of the three-dimensional point cloud data is as follows: first, the three-dimensional point cloud data is constructed into a triangular mesh surface model, then the principal curvature value at each mesh vertex is calculated, the principal curvature value is calculated by using the differential geometry method, that is, for each triangular mesh vertex, the normal vector of its adjacent triangular facets is extracted, a local quadratic surface equation is fitted by using the least square method, and then the eigenvalue of the Hessian matrix of the surface equation is solved, the maximum eigenvalue is the principal curvature value of the vertex; a curvature change threshold is set, for example, 0.25 millimeters negative power, when the principal curvature difference of adjacent mesh vertices exceeds the threshold, it is determined as a curvature abrupt point; the spatial position coordinates of all curvature abrupt points are extracted, when the boundary formed by the curvature abrupt points has a non-continuous gap, sampling points are supplemented at the gap position and the curvature is recalculated until a complete closed boundary is formed; finally, all the curvature abrupt points are connected to form a closed polygon boundary, the vertex coordinate set of the closed polygon boundary is the profile coordinates of the weld repair area; the spatial positioning accuracy of the profile coordinates reaches, for example, 0.05 millimeters, and the coordinate system of the profile coordinates is consistent with the global coordinate system of the laser scanning device.

[0062] The ultrasonic thickness gauge is used to measure the thickness of the grid nodes in the boundary extension area. The boundary extension area is formed by offsetting outward by a distance of, for example, 5 mm based on the contour coordinates. The boundary extension area serves as the measurement range. The node spacing of the grid measurement is set according to the spacing of the gusset layout in the box structure. Specifically, the gusset center line spacing is measured from the gusset layout design drawing. If there is a difference in the spacing between adjacent gussets, the minimum value is taken as the set reference. When the gusset spacing is in the range of, for example, 80 mm to 120 mm, the node spacing is one sixth of the gusset spacing. When the gusset spacing is greater than, for example, 120 mm, the node spacing is fixed at, for example, 20 mm. The measurement grid is arranged in the boundary extension area according to the set node spacing, and the intersection of the grid is the measurement node. The probe of the ultrasonic thickness gauge is controlled to vertically touch each node position. The probe diameter is, for example, 6 mm, and the contact pressure is, for example, 0.5 MPa. Surface pretreatment is performed before ultrasonic thickness measurement, including using an angle grinder to remove the oxide layer and dirt on the surface of the repair area, and the surface roughness is controlled within, for example, Ra3.2 microns. Then, a layer of ultrasonic coupling agent glycerol with a thickness of, for example, 0.2 mm is uniformly applied. The ultrasonic echo time interval is obtained, and the thickness measurement value of each node is calculated based on the sound speed of, for example, 5900 m / s. When the ambient temperature deviates from the standard temperature of 20°C, the thickness value is corrected according to the thermal expansion coefficient of steel, which is 11.7 x 10-6 per degree Celsius. Three repeated measurements are performed for each node, and the median value is taken as the final thickness measurement value. The thickness measurement values of all nodes are spatially arranged according to the grid topology to form a parent material thickness distribution data set. The data set includes the three-dimensional coordinates and corresponding thickness values of each node. When the thickness value of a node deviates from the average value of the adjacent eight nodes by more than 15%, the measurement is repositioned and the average value of the two measurements is taken as the final value. The thickness measurement value resolution is, for example, 0.01 mm.

[0063] The verification method of the profile coordinates is to drill holes at the boundary positions identified by the profile coordinates, observe the microstructure under a metallographic microscope, and confirm that the spatial deviation between the heat-affected zone boundary and the profile coordinates is not more than, for example, 0.1 millimeter; the determination standard of the heat-affected zone boundary is the boundary of the region where the bainite transformation appears in the metallographic structure, and the boundary forms a clear boundary with the ferrite pearlite structure of the base material; the noise filtering processing of the three-dimensional point cloud data adopts a median filter, takes a 5x5 neighborhood point set as the center of each point, sorts the Z coordinate values, and replaces the original values with the median values; the screening rule of the curvature mutation points is that, on the basis of the curvature difference value exceeding the threshold value, the number of continuous occurrence of the mutation points is required to be not less than 3 times; the sound velocity calibration method during ultrasonic thickness measurement is to measure the sample with a known thickness on the same material standard block, and adjust the sound velocity value so that the measurement error is less than 1%; the interpolation processing of the base material thickness distribution data adopts a linear interpolation method, and the distance weighted average value of the thickness of the nearest four valid nodes is taken at the invalid value position; the data structure definition of the profile coordinates is an ordered point list, the point list order is arranged in the clockwise direction of the boundary, and the distance between adjacent points is not greater than twice the laser scanning point distance.

[0064] The grid direction setting of the grid thickness measurement is based on the following principles: when the rib plate layout is orthogonally distributed, a rectangular grid is used; when the rib plate is radially distributed, a polar coordinate grid is used, and the radial node line extends along the rib plate direction; the shape control principle of the boundary expansion area is that when the profile coordinates are convex polygons, the expansion area remains similar, and when there are concave angles, a circular arc transition is used at the concave angle, and the circular arc radius is equal to the expansion distance; the adaptive adjustment of the node spacing is to automatically reduce the node spacing to half of the original value in the area where the thickness gradient is greater than 1 millimeter per millimeter; the storage format of the base material thickness distribution data set is a two-dimensional matrix, the matrix row number corresponds to the node Y coordinate, the column number corresponds to the node X coordinate, and the matrix element value is the thickness value; the integrity verification method of the base material thickness distribution data is to calculate the proportion of valid measurement nodes, and when it is less than 95%, additional measurement is performed in the missing area; the reliability evaluation index of the base material thickness measurement value is that the ultrasonic echo signal-to-noise ratio is greater than 20 decibels, and the waveform rising edge steepness is greater than 5 volts per microsecond.

[0065] The coordinate system alignment of three-dimensional point cloud data is achieved by calibration, three reference target balls are fixedly installed beside the repair area, the center coordinates of the target balls are accurately known in the global coordinate system, and the scanning data is spatially registered through the center coordinates of the target balls; the node positioning of the meshing thickness measurement adopts a mechanical positioning device, an ultrasonic probe installed on a three-axis moving platform automatically moves and positions according to the preset node coordinates, and the positioning accuracy reaches, for example, 0.02 mm; the visualization of the base material thickness distribution data is achieved by color mapping, the thickness distribution is rendered on the surface of the three-dimensional model in different colors, for example, the red area represents a thickness less than 10 mm, the yellow area represents 10 mm to 15 mm, and the green area represents greater than 15 mm; the application constraint condition of the contour coordinates is that the continuous weld with a length greater than 50 mm and a width greater than 10 mm is applicable, and a circular boundary treatment is required for point defects; the boundary point coordinates of the boundary expansion area are obtained by calculating the normal offset of the contour coordinate points, and the normal direction is determined by the normal vector of the plane determined by the adjacent three points.

[0066] The specific implementation process of dividing the stress buffer unit around the repair area and containing at least two heat input regulation sub-areas is as follows: based on the base material thickness distribution data set, the minimum distance from the outer edge of the repair area contour coordinates to the stress buffer unit boundary is determined, the calculation method of the minimum distance is to extract the maximum value of all node thickness measurement values in the base material thickness distribution data set, multiply the maximum value by a constant coefficient, and the value range of the constant coefficient is determined according to the material thermal conductivity characteristics, for example, the constant coefficient of Q345 steel is taken as 1.2 to 1.5; the constant coefficient is determined by material thermal physical property test during specific implementation, and the test method is to measure the weld heat affected zone width of test pieces with different thicknesses, establish a linear regression equation of thickness and heat affected zone width, and take the regression coefficient as the reference value of the constant coefficient; the finally determined minimum distance value is taken as the reference size of the stress buffer unit boundary positioning.

[0067] The positioning method taking the weld end of the gusset in the gusset layout of the box structure as the reference point is as follows: obtaining the design drawing of the box structure, identifying the connection weld end position of the gusset and the base material, and the spatial coordinates of the end position are the reference point of the gusset weld end; when there are multiple weld ends in the gusset layout, the three closest to the repair area contour coordinates are selected as the main reference points; the extension division line is determined along the direction with the maximum thickness gradient change in the base material thickness distribution, and the calculation method of the direction with the maximum thickness gradient change is as follows: in the base material thickness distribution data set, the thickness difference vector of the eight neighborhood nodes is calculated for each node, the thickness difference vectors of all nodes are summarized and the vector sum is calculated, and the direction of the vector sum is the direction with the maximum thickness gradient change; the extension division line extends from the gusset weld end reference point along the direction with the maximum thickness gradient change, and the extension length is equal to twice the minimum distance value.

[0068] The specific operation of the closed region formed by extending the division line and the minimum distance of the repair area contour coordinates includes: first, performing an extension treatment on the repair area contour coordinates, the extension method is to translate each side of the contour coordinate polygon in the normal direction by a minimum distance value, and a new polygon boundary is formed after the extension; then connecting the terminal points of the extended division line and the vertices of the extended polygon boundary to form a closed region surrounded by the extended division line, the extended boundary line segment and the connecting line segment; when there are multiple extended division lines, the region between adjacent extended division lines is connected by a spline curve, and the control points of the spline curve are located on the extended polygon boundary; the finally formed closed region is the stress buffer unit, and the spatial range of the unit is represented by a set of three-dimensional coordinate points.

[0069] The process of dividing the heat input regulation sub-area in the stress buffer unit is: taking the web plate welding end as the starting point of the sub-area boundary, and dividing the stress buffer unit along the thickness gradient change direction; the division method uses the equidistant vertical division method, which specifically is to make a vertical division line in the thickness gradient change direction at a set interval, and the set interval is determined according to the length of the stress buffer unit, for example, the interval is 50 mm when the unit length is 100 mm to 200 mm; the starting point of the division line is the reference point of the web plate welding end, and the terminal point is the opposite boundary of the stress buffer unit; each division line is perpendicular to the thickness gradient change direction; the region between adjacent division lines forms a heat input regulation sub-area; the number of sub-areas is at least two, and when the size of the stress buffer unit is small, the minimum area constraint control is used, for example, the area of each sub-area is not less than 400 square millimeters; the boundary line coordinate set of all sub-areas constitutes a complete sub-area division scheme.

[0070] In the calculation process of the thickness gradient change direction, the calculation method of the eight-neighborhood thickness difference vector is supplemented: assuming that the center node coordinates are (x0, y0), the thickness is h0, the coordinates of the adjacent eight nodes are (xi, yi), and the thickness is hi, i is the node coordinate number, then the difference vector Vi=(xi-x0, yi-y0, hi-h0), the vector sum S=∑Vi(i=1 to 8), and the final direction is the inverse tangent value of the vector (Sx, Sy); the conflict processing rule of the extended division line under complex layout is: when the extended lines from different web plate welding ends intersect, the intersection point is truncated and the path is re-planned, so that each extended line does not overlap. The geometric verification requirement of the stress buffer unit is that the shortest distance from any point in the closed region to the boundary of the repair area contour coordinates is not less than the minimum distance value.

[0071] The boundary marking method of the heat input regulation sub-area is: each sub-area is assigned a unique number, and the number sequence is arranged from the high thickness area to the low thickness area according to the thickness gradient change direction; the data structure of the sub-area boundary line is defined as an ordered point list, and the point list includes the start point coordinates, the end point coordinates and the intermediate interpolation point coordinates of the boundary line; the storage format of the sub-area division result is a topological relationship table, and the table records the common boundary information of adjacent sub-areas; when the end of the rib plate welding is not at the boundary of the stress buffer unit, the start point adjustment mechanism of the sub-area boundary is: a perpendicular line is drawn from the end of the rib plate welding to the boundary of the stress buffer unit, and the foot of the perpendicular line is taken as the actual division start point.

[0072] The minimum distance value dynamic adjustment mechanism of the stress buffer unit is: when the distance between the repaired area contour coordinates after the minimum distance expansion and the structure boundary is insufficient, the minimum distance value is reduced according to the actual available space, but the reduction ratio is not more than 30%; the direction correction method of the extended division line is: when the maximum direction of the thickness gradient change deviates from the rib plate extension direction by more than 20 degrees, the rib plate extension direction is taken as the final direction; the area balance control method of the heat input regulation sub-area is: when the area difference of the sub-area exceeds 1.5 times, a division line is added in the larger sub-area; the generation precision requirement of the division line is: the straightness error is less than 0.1 mm / 100 mm, and the position repeated positioning precision reaches 0.05 mm.

[0073] The boundary coordinate output format of the stress buffer unit is a DXF graphics file, which contains the spatial coordinate data of all boundary line segments; the visual expression of the heat input regulation sub-area adopts the color filling method, different sub-areas are filled with different colors, and the color coding is associated with the thickness gradient range, for example, blue represents a thickness gradient less than 0.5 mm per mm, and red represents more than 1 mm per mm; the verification method of the division result is to calculate the coverage completeness of the sub-area, which requires that there is no unallocated area in the stress buffer unit, and there is no overlapping area between the sub-areas; the abnormal processing mechanism includes: when the maximum direction of the thickness gradient change cannot be determined, the normal direction of the longest side of the repaired area contour coordinates is taken as the default.

[0074] The identification fault tolerance rule of the rib plate welding end is: when the design drawing is missing, the color difference area of the weld is identified by actual structure scanning, and the color division point of the weld color and the base material color is taken as the welding end; the preprocessing of the thickness distribution data set includes: data smoothing is performed on the area with a thickness gradient greater than 2 mm per mm, and 3*3 mean filtering is used to eliminate abnormal fluctuations; the projection correction requirement of the extended division line in the three-dimensional space is: when the base material surface is not planar, the extension line extends along the shortest path of the curved surface, and the path calculation adopts the Dijkstra algorithm principle to calculate the shortest path by taking the distance between adjacent nodes as the weight; the topological closure verification of the closed area adopts the ray method: a ray is emitted from a point inside the area, and the number of times of crossing the boundary is counted, and an odd number of times means a closed area.

[0075] The number control algorithm of the heat input regulation sub-area is: set the stress buffer unit area as S, and the minimum sub-area Amin, then the maximum sub-area number Nmax=S / Amin, the actual division number is min(6, Nmax) and not less than 2; the standby scheme of the sub-area boundary starting point under the special structure is: when the end of the rib plate welding is not available, the maximum curvature point of the contour coordinates of the repair area is taken as the alternative starting point; the digital output of the division result includes: the center point coordinates of each sub-area, the boundary point coordinate set, the average thickness gradient value and the stress buffer unit number; the implementation process record includes: the division operation time, the operator identification, the equipment model used and the parameter version number.

[0076] The magnetic field strength component of the stress buffer unit boundary is scanned and the gradient vector is calculated, if the modulus value of the gradient vector exceeds the critical angle, the specific implementation process of the heat input regulation sub-area boundary is as follows: the magnetic memory sensor array is arranged along the stress buffer unit boundary, the arrangement rule of the sensor array is to set the sensor nodes on the stress buffer unit boundary line at equal intervals, the node spacing is determined according to the total length of the stress buffer unit boundary, for example, the node spacing is taken as 20 mm when the boundary length is 500 mm to 1000 mm; the magnetic memory sensor adopts TSC-1M-4 type magnetoelastic sensor, the sensor probe axis is perpendicular to the surface of the base material, and is fixed by a vacuum adsorption device during installation, the adsorption force is for example 0.3 megapascal; the sampling frequency of the normal component of the geomagnetic field strength is set to for example 100 Hz, and the duration of each collection is 5 seconds; the distance between the sensor probe and the base material surface is kept constant at 1 mm during the collection process, and the environmental electromagnetic interference strength is controlled to be less than 1 gauss.

[0077] The specific method for calculating the gradient vector based on the difference of the normal component of the geomagnetic field strength of adjacent sensor nodes is: set the spatial distance of the adjacent two nodes as D, the normal component value of the geomagnetic field strength of node A as HA, and the value of node B as HB, then the modulus value G of the gradient vector is calculated according to the formula |HB - HA| / D; the calculation is completed in real time in the signal processor, which is integrated in the sensor array control box; the direction of the gradient vector is defined as pointing from the low magnetic field strength node to the high magnetic field strength node; the modulus value of the gradient vector is the absolute value of the change rate of the normal component of the geomagnetic field strength, and its dimension is ampere per meter square millimeter; when the boundary line is a curve, the spatial distance D takes the geodesic distance between the two nodes, which is obtained by calculating the difference of three-dimensional coordinates.

[0078] The method for setting the critical angle is: obtaining measured values of the yield strength σs and the tensile strength σb of the material, calculating the ratio R = σs / σb, and calculating the critical angle θcrit according to the formula θcrit = arcsin(R); the material strength data is derived from the standard values in the material warranty book or the tensile test results of on-site sampling; for Q345 steel, the yield strength is, for example, 345 MPa, and the tensile strength is, for example, 470 MPa, so R ≈ 0.73 and θcrit ≈ 47 degrees; the critical angle parameter is stored in the parameter database of the control system and can be automatically called according to the material grade.

[0079] When the modulus of the gradient vector exceeds the critical angle, the sub-region boundary moving operation is performed: first, locate the boundary line segment corresponding to the gradient vector modulus exceeding the critical angle, and the stress buffer unit boundary position where the line segment is located is the region to be adjusted; scan the magnetic memory isochromatic line density in the stress buffer unit, and the isochromatic line density is defined as the number of magnetic field strength contour lines per millimeter; construct the magnetic field strength contour line distribution map of the entire stress buffer unit by interpolation method, and the contour line interval is set to, for example, 1 ampere per meter; identify the position with the lowest isochromatic line density, which satisfies the condition that the isochromatic line spacing is greater than, for example, 5 mm; move the corresponding heat input control sub-region boundary to the position with the lowest isochromatic line density in the direction of the gradient vector, and the moving distance is controlled within, for example, ±15 mm of the original boundary; the moving method is the overall translation of the boundary line, and the boundary line maintains the original curvature characteristics after translation.

[0080] The specific operation of updating the heat input control sub-region division after moving the sub-region boundary is: replacing the coordinate data of the moved boundary line with the corresponding boundary in the original sub-region division scheme; recalculating the common boundaries of adjacent sub-regions to ensure correct topological relationship; storing the updated sub-region division scheme as a topological relationship table, which records the new boundary coordinates and adjacent relationships of each sub-region; after the boundary is moved, the area of the new sub-region needs to be verified, and when the area change exceeds 20%, the adjacent sub-region boundaries are automatically adjusted for compensation.

[0081] The data preprocessing of the magnetic memory sensor array includes: performing sliding average filtering on the original signal, and the filtering window width is, for example, 5 sampling points; the abnormal value elimination rule when calculating the gradient vector is: when the value of |HB - HA| is greater than 3 times the standard deviation of the average value, the data of the previous and next nodes is used for interpolation to replace it; the search algorithm for the position with the lowest isochromatic line density uses the region segmentation method: dividing the stress buffer unit into, for example, 1 mm x 1 mm grids, calculating the isochromatic line density value of each grid unit, and taking the center point of the grid with the smallest density value as the target position.

[0082] The constraint conditions of the boundary movement include: the sub-region boundary after movement cannot cross the reference point of the end of the rib plate welding; the maximum movement distance is not more than one fourth of the minimum distance value of the stress buffer unit; the curvature radius of the boundary line after movement is not less than, for example, 50 mm; and the updated sub-region division scheme needs to meet all the connectivity requirements of the sub-regions.

[0083] The implementation effect verification method is: performing magnetic powder detection before and after the boundary movement, comparing the number of stress concentration indication strips; recording the coordinates of the heat input regulation sub-region boundary after re-division, and performing difference analysis with the original scheme; the system automatically generates a boundary adjustment report, including adjustment position coordinates, movement distance, critical angle exceeding value and new sub-region area data.

[0084] The calibration process of the magnetic memory sensor array is: collecting reference magnetic field values on a standard stress-free test block, and performing zero-point calibration before daily operation; the display mode of the gradient vector module value is rendered as a color band on a three-dimensional model, with red representing high gradient area and blue representing low gradient area; the alarm threshold of the critical angle exceeding is that the gradient vector module value is greater than, for example, 5 ampere per meter square millimeter; and the positioning accuracy of the minimum position of the equipotential line density reaches 0.5 mm.

[0085] The mechanical execution mechanism of the boundary movement operation is a micro-displacement platform driven by a servo motor, with a platform positioning accuracy of 0.01 mm; the output format of the updated sub-region division data is a DXF graphic file, which is also written into the historical record of the process database; when there is no available low-density position in the stress buffer unit, a secondary optimization scheme is adopted: moving the boundary to the second-lowest position of the equipotential line density in the opposite direction of the gradient vector; and the boundary after movement is smoothed by using a cubic spline interpolation method to eliminate the corner.

[0086] The abnormal handling of the sub-region boundary update includes: when the distance between the new boundary and the repair area contour coordinates is less than a safety value, the movement is terminated and manual intervention is triggered; the maximum allowed number of update operations is set to 3 times; the implementation process record includes sensor data, calculation parameters, movement trajectory and operation timestamp; and the final output of the updated heat input regulation sub-region division scheme includes the spatial coordinate range of each sub-region, the boundary equation coefficient and the topological relationship matrix.

[0087] The specific implementation process of performing layered repair welding on the repair area and activating the heat input in the preset order in the heat input regulation sub-area is as follows: based on the updated heat input regulation sub-area division scheme, the repair area is divided into multiple layers of weld beads along the depth direction; the upper limit value of the thickness of each layer of weld bead is determined as follows: a set of base material thickness distribution data within the contour coordinate range of the repair area is extracted, and the minimum value of all node thickness measurement values is found, which is denoted as δmin; the upper limit value of the weld bead thickness is set to δmin multiplied by a penetration control coefficient, and the penetration control coefficient is determined according to the deposition characteristics of the welding material, for example, 0.6 to 0.8 for ER50-6 welding wire; the coefficient is determined by a penetration test during specific implementation, and the test method is to perform single-pass welding on a test plate of the same thickness, measure the ratio of the cross-sectional penetration depth to the weld bead thickness, and take the average value of five tests as the coefficient reference value; the final number of weld bead layers is calculated by dividing the maximum depth of the repair area by the upper limit value of the weld bead thickness and rounding up.

[0088] The generation method of the radial activation path of the preset order is as follows: an polar coordinate system is established with the geometric center of the contour coordinates of the repair area as the origin; radial lines are drawn from the origin to the outer edge of the stress buffer unit, and the number of radial lines is equal to the number of heat input regulation sub-areas; the starting point of each radial line path is located on the boundary of the contour coordinates of the repair area closest to the origin, and the ending point is located at the position where the radial line passes through the outer boundary of the stress buffer unit; the radial line paths are distributed according to the angle equidistribution principle, for example, when the number of sub-areas is 4, the radial lines are spaced 90 degrees apart; the path coordinate sequence is interpolated to generate discrete path points at an interval of 1 millimeter in the direction from the starting point to the ending point; the sorting rule of the activation path is to execute in turn in the clockwise direction according to the angle.

[0089] The operation of controlling the heat input activation in a single heat input regulation sub-area by an independent temperature control device includes: the independent temperature control device uses a temperature control instrument with a relay output, for example, XMTG-808, and each heat input regulation sub-area corresponds to an independent instrument channel; the temperature control device is connected to the power circuit of the welding gun heat source to realize heat input activation by controlling the on-off power; the specific control logic is as follows: when the welding gun moves to the starting point of the sub-area along the activation path, the temperature control device outputs a power-on signal to start the welding gun heat source; when the welding gun moves to the end point of the path, the temperature control device outputs a power-off signal to stop the heat source; the temperature feedback signal of the welding gun heat source is monitored in real time during the activation of the heat source, and when the temperature exceeds a set upper limit value, for example, 300 degrees Celsius, the power-on is automatically interrupted and an alarm is given; the on-off power response time of the temperature control device is less than 50 milliseconds.

[0090] The implementation method for maintaining the spacing between activation start points of adjacent heat input control sub-regions during activation is as follows: obtain the spatial coordinates of the activation start points of all heat input control sub-regions; calculate the Euclidean distance between the start points of adjacent sub-regions; the method for determining the effective range of the welding torch heat source is as follows: conduct a single-point welding test on a standard test plate, measure the diameter of the molten pool and add a 20% safety margin as the effective range radius R; when the spacing between adjacent start points is less than 2R, adjust the activation sequence so that the activation time interval between adjacent sub-regions is greater than the heat diffusion time constant; the time constant is calculated through the heat conduction equation, and for Q345 steel, a value of, for example, 15 seconds is taken; in real-time monitoring, an infrared thermal imager is used to scan the activation area, and when overlapping heat-affected zones are detected, subsequent activation is automatically paused.

[0091] The interlayer connection operation for layered repair welding is as follows: After activating all heat input control sub-regions of the current layer, weld bead cleaning is performed; the cleaning method uses a stainless steel wire brush to mechanically grind away the oxide layer, with a grinding depth not exceeding 0.2 mm; after cleaning, the surface is cleaned with industrial alcohol and dried; the welding path of the next layer is offset in the Z-axis direction based on the current layer path, and the offset amount is equal to the measured value of the current layer weld bead thickness; the actual weld bead thickness is measured online by a laser displacement sensor, which is installed 20 mm behind the welding torch; when the remaining thickness to be welded in the depth direction of the repair area is less than the upper limit of the layer thickness, the welding parameters are adjusted according to the actual remaining thickness, and the current is reduced by 10% to 20%; after completing the final layer welding, overall slow cooling treatment is performed, and the slow cooling rate is controlled within 50 degrees Celsius per hour.

[0092] The data management of weld bead layering adopts three-dimensional model marking: each weld layer is marked with different colors in the digital model of the repair area and associated with welding parameter records; the correction mechanism of radial path includes: when the path encounters structural obstacles, an obstacle avoidance path is automatically generated, and the obstacle avoidance principle is the shortest detour path along the obstacle boundary; the temperature feedback calibration method of the temperature control device is: monthly calibration using thermocouples in a standard temperature field, and the calibration procedure is triggered when the error exceeds 5 degrees Celsius; the dynamic adjustment rule for the starting point spacing is: when abnormal local heat dissipation of the material is detected, the spacing requirement is expanded according to the actual temperature distribution measured by the thermal imager.

[0093] The quality verification method for interlayer cleaning is as follows: a surface roughness meter is used for testing, and the Ra value is required to be no greater than 6.3 micrometers; the sampling frequency for online measurement of weld thickness is 10 Hz, and the measured value is entered into the process database in real time; the interlayer temperature control requirements for multi-layer welds are: the temperature of the previous layer must be cooled to below 100 degrees Celsius when the next layer of welding begins; the slow cooling treatment is implemented by covering with a ceramic fiber insulation blanket, with a thickness of, for example, 25 mm; the environmental control requirements for the entire welding process are: ambient temperature above 5 degrees Celsius, relative humidity below 70%, and wind speed less than 2 meters per second.

[0094] The abnormality processing mechanism includes: starting the timeout protection when the single-layer welding time exceeds the preset value, suspending the work and checking the path planning; forcibly cooling down when the welding torch heat source is continuously activated for more than 5 minutes; the real-time monitoring data in the welding process includes: the activation time of each sub-area, the cumulative value of heat input, the interlayer temperature curve and the weld geometry size; the final output welding record includes: the schematic diagram of the layered structure, the welding parameter statistical table, the heat input distribution cloud diagram and the quality inspection report.

[0095] The coordinate conversion implementation of the radial path is: mapping the polar coordinate path point to the workpiece coordinate system through a conversion matrix; the movement control of the welding torch heat source adopts a six-axis welding robot, and the repeated positioning accuracy is 0.05 mm; the relay contact capacity of the independent temperature control device is 40 amperes / 220 volts AC, and the electrical isolation withstand voltage is 2000 volts; the verification frequency of the welding torch heat source action range is to perform a calibration test on a test plate before each shift operation; the requirements for the multi-layer bead arc collection processing are: the end-of-layer weld overlap length is not less than 10 mm; the final welding layer surface needs to be ground, and the surface undulation height difference is not more than 0.5 mm.

[0096] The timing control logic of heat input activation is: allowing parallel activation of two non-adjacent sub-areas when the activation starting point distance meets the requirements; the activation progress visual display is a progress bar and real-time rendering of a three-dimensional model; the interlayer non-destructive testing requirements of layered repair welding are: ultrasonic flaw detection is performed every three layers; the welding parameter self-adaptive adjustment rule is: when the penetration is insufficient, the current of the next layer is increased by 5%, and when the undercut occurs, the voltage is reduced by 0.5 volts; the implementation process record includes: welding operator information, equipment running state log, environmental parameters and quality sampling data.

[0097] The specific implementation process of collecting acoustic emission signals of the heat input regulated sub-area and switching the activation of the sub-area based on the energy ratio is as follows: acoustic emission sensors are arranged at the activation starting point position of each heat input regulated sub-area, the sensor arrangement mode is to use a magnetic base to fix on the surface of the base material, and the installation position is, for example, 10 mm away from the starting point of the welding torch heat source movement path; the acoustic emission sensor model is, for example, a WD type wideband sensor, and the frequency response range is 50 kHz to 1 MHz; when collecting the acoustic emission original signal in the welding process, the sampling frequency is set to, for example, 2 MHz, and the sampling accuracy is 16 bits; the signal transmission adopts shielded twisted pair line connection to the signal acquisition box, and the cable length is not more than 5 meters to reduce signal attenuation; the signal-to-noise ratio is monitored in real time during the collection process, and when the environmental noise exceeds the set threshold value, for example, 40 decibels, the digital filtering is automatically started.

[0098] The specific implementation of separating the signals by a physical band-pass filter is that the physical band-pass filter is an active filter circuit constructed by two-stage operational amplifiers, the first stage is a high-pass filter with a cut-off frequency of, for example, 300 kHz, used for extracting the dislocation slip characteristic frequency band signal, and the second stage is a low-pass filter with a cut-off frequency of, for example, 150 kHz, used for extracting the grain boundary friction characteristic frequency band signal; the filter circuit board is installed in the sensor junction box, and the temperature drift coefficient is less than 0.1% per degree Celsius; the frequency band range of the dislocation slip characteristic frequency band signal is defined as 300 kHz to 1 MHz, and the frequency band range of the grain boundary friction characteristic frequency band signal is defined as 20 kHz to 150 kHz; the frequency band range is determined according to the test data of the acoustic emission spectrum characteristics of metal material deformation.

[0099] The process of integrating the dislocation slip characteristic frequency band signal after full-wave rectification includes: the full-wave rectification circuit adopts a bridge rectification circuit composed of four diodes, and the input signal first passes through a preamplifier with a gain of, for example, 60 decibels; the rectified signal is input into an RC integration circuit, and the integration time constant is set to, for example, 0.1 second; the output voltage value of the integration circuit is the high-frequency band energy value, and the dimension is volt-second; the grain boundary friction characteristic frequency band signal adopts the same processing procedure, but the integration time constant is set to, for example, 0.5 second, and the output is the low-frequency band energy value; the calibration method of the energy value is to apply a known energy impact on a standard test piece to establish a corresponding relationship curve between the output voltage and the energy.

[0100] The ratio of the high-frequency band energy to the low-frequency band energy is calculated in the microprocessor: the high-frequency band energy value Eh and the low-frequency band energy value El are read every interval of, for example, 200 milliseconds; the energy ratio R is calculated according to the formula R = Eh / El; the calculation result is stored as time series data; a real-time energy ratio curve is displayed, with the horizontal coordinate being the welding time and the vertical coordinate being the R value; when the El value is zero, the value of negative five to the power of 10 is automatically assigned to avoid division by zero error; the validity verification rule of the energy ratio data is to discard the sampling when Eh or El exceeds the range.

[0101] The operation of real-time calculation of the energy ratio difference value of adjacent heat input regulation sub-regions is: identifying the current activated heat input regulation sub-region number N; obtaining the latest energy ratio RN and RN1 of the adjacent sub-region number N+1; calculating the energy ratio difference value AR = |RN - RN1|; the maximum energy ratio Rmax of the current welding stage is obtained in the following way: the maximum value of all sub-region energy ratios since the start of the current layer welding; the proportional threshold is set to Rmax multiplied by a dynamic coefficient K, and the value of K is determined according to the number of welding layers, for example, K is taken as 0.3 for the first layer, and K is taken as 0.2 for subsequent layers; a switching instruction is generated when AR exceeds K·Rmax.

[0102] The specific execution process of sending the switching instruction to the heat input activation device is as follows: the switching instruction is a digital switching signal, which is output to the control terminal of the independent temperature control device through an optical coupling isolation circuit; the instruction contains a target sub-area number and a switching time mark; the switching action is performed after the welding gun completes the current path segment, and the maximum delay is not more than 500 milliseconds; the energy ratio data buffer is automatically reset after switching; the feedback mechanism of instruction transmission is that the temperature control device of the target sub-area returns a state confirmation signal, and if there is no response after a timeout, the instruction is retransmitted.

[0103] The temperature compensation measure of the acoustic emission sensor is that a temperature sensor is embedded in the sensor, and the compensation algorithm is automatically started when the temperature exceeds 80 degrees Celsius; the frequency band calibration method of the physical band-pass filter is that a standard signal generator is used to input a sinusoidal sweep signal every month, and the capacitance value is adjusted so that the cutoff frequency deviation is less than 1%; the zero drift correction rule of the energy integration circuit is that 10 seconds of background noise is collected before each welding starts, and the integral value is used as the reference zero point.

[0104] The calculation timing control of the energy ratio difference value is that the calculation is started only after the adjacent sub-areas have completed at least 5 sampling periods; the adjustment rule of the proportional threshold dynamic coefficient includes that when the detected material thickness is greater than 30 millimeters, the K value is reduced by 0.05; the priority of the switching instruction is set as follows: when the same sub-area receives switching requests twice in a row, the priority is raised to the highest; the implementation process monitoring data includes the real-time energy ratio curve of each sub-area, the difference value trend graph, and the switching event log.

[0105] The abnormality processing mechanism includes the following: when the energy ratio data continuously fluctuates abnormally for 10 times, the sensor self-check is triggered; the filter circuit fault diagnosis is verified by injecting a signal through the test port; the switching instruction conflict resolution strategy is that when multiple sub-areas simultaneously meet the switching conditions, the sub-area with the largest difference value is preferentially switched; the time synchronization accuracy of all signal processing processes reaches 1 millisecond, which is uniformly time-stamped by a central clock module; the final output data record includes the original acoustic emission waveform, the band-separated signal, the energy integral value, the energy ratio curve, and the switching instruction sequence.

[0106] The verification method of the dislocation slip characteristic frequency band is as follows: acoustic emission signals are collected on a pre-crack test piece, and the characteristic frequency spectrum during crack propagation is compared; the calibration test of the grain boundary friction characteristic frequency band is as follows: grain boundary slip acoustic emission data are obtained on a high-temperature friction testing machine; the capacitor in the integration circuit is a polypropylene film capacitor with a temperature coefficient of 50 ppm / °C; the calculation period of the microprocessor is matched with the welding speed as follows: the energy ratio is updated once for every 1 millimeter movement of the welding gun; the execution response time test method of the switching instruction is as follows: the time interval from the difference exceeding the standard to the activation of the target sub-area is not more than 800 milliseconds.

[0107] The determination logic of adjacent sub-regions is: querying the number of spatially adjacent sub-regions in the topological relationship table; the basis for the adaptive adjustment of the dynamic coefficient is: when the material heat dissipation condition changes is detected, the K value is corrected according to the thermal imager data; the storage format of the energy ratio data is a three-tuple of timestamp-sub-region number-energy ratio value; the mechanical execution mechanism of the switching operation is the coordinate repositioning instruction of the welding gun positioning system; the quality tracking of the implementation process is realized by synchronizing the acoustic emission data with the welding video frames.

[0108] The specific implementation process of expanding the residual stress scanning and thermal relaxation treatment area outside the repair area boundary based on the contour coordinates is as follows: taking the contour coordinates as the reference, the residual stress scanning area is expanded outward by an integer multiple of the minimum distance of the stress buffer unit, the determination method of the expansion multiple is to obtain the minimum distance value of the stress buffer unit, which has been defined in the unit division step, and the expansion multiple is selected according to the material stress concentration coefficient, for example, 2 times or 3 times for Q345 steel; the boundary coordinates of the residual stress scanning area are generated by translating the contour coordinate polygon along the normal direction by the expansion multiple multiplied by the minimum distance value, and the translation direction points to the outer edge of the stress buffer unit; when there is a concave corner in the contour coordinates, a circular arc transition is used at the concave corner, and the circular arc radius is equal to the expansion multiple multiplied by the minimum distance value; the finally formed scanning area is a closed area expanded outside the contour coordinates, and its area is not less than 4 times the area of the original repair area.

[0109] The operation of residual stress field scanning by X-ray diffractometer includes: multiplexing the positions of the grid thickness measurement nodes in the scanning area, which have been established in the data acquisition step, and keeping the node spacing consistent with the original thickness measurement grid; the measurement point positioning uses a laser tracker to guide; at each measurement point, a multi-angle swing method is performed, and the angle range is set to, for example, -45 degrees to +45 degrees, with a step angle of 5 degrees; the diffraction peak shift is obtained and the residual stress value is calculated according to the material crystal structure characteristics, and the material elastic constants take the Young's modulus and Poisson's ratio values in the standard manual; the stress values of all measurement points constitute a residual stress field data matrix, and the matrix dimension is the same as the topological structure of the grid thickness measurement nodes.

[0110] The process of calculating the stress peak migration amount from the residual stress field data before and after repair welding is as follows: extracting the reference stress field data before repair welding and the current scanning data, the data before repair welding is obtained by scanning before repair; calculating the stress change amount at the same grid node position, the change amount is the difference between the current stress value and the stress value before repair; finding the maximum value of the absolute value of the stress change amount by traversing all nodes, which is the stress peak migration amount; the setting method of the safety threshold is to obtain the material fatigue limit, which is obtained by standard rotary bending test, the safety threshold is the product of the material fatigue limit and the proportion coefficient, the proportion coefficient is determined according to the safety grade of the structure, for example, 0.6 for important load-bearing structures and 0.8 for general structures; the adjustment basis of the proportion coefficient is the structure design life requirement, the proportion coefficient decreases by 0.05 for every 50,000 hours of life requirement.

[0111] When the stress peak migration amount exceeds the safety threshold, locate the migration peak area: locate the node coordinates in the residual stress field data matrix where the absolute value of the stress change amount is equal to the stress peak migration amount; take the adjacent 25 nodes area centered on the node, calculate the average stress change amount of the area; when the neighborhood average value exceeds 90% of the stress peak migration amount, mark the neighborhood range as the migration peak area; the spatial range of the migration peak area is represented by the minimum circumscribed rectangle; the marking result is highlighted in the three-dimensional model, and the center coordinates and size data of the area are output.

[0112] Implementing thermal relaxation treatment by applying high-frequency alternating magnetic field on the surface of the migration peak area: using medium-frequency induction heating equipment, the frequency range is for example 200 kHz to 300 kHz; the shape of the induction coil is customized according to the circumscribed rectangle of the migration peak area; the applied magnetic field strength is controlled to make the surface eddy current density reach a certain value; the surface temperature is monitored in real time by an infrared thermal imager, when the temperature reaches the material recrystallization temperature, the temperature is entered into the holding stage, the recrystallization temperature is set according to the material grade; the holding time is obtained by calculation, the calculation formula is the square of the average depth of the migration peak area divided by four times the material thermal diffusion coefficient, the average depth is obtained by ultrasonic depth measurement, and the thermal diffusion coefficient takes the standard value of the material; the temperature fluctuation in the holding stage is controlled within ± 15 degrees Celsius.

[0113] After the holding is completed, stop the high-frequency alternating magnetic field and start forced air cooling: immediately turn on the high-pressure air cooling system after turning off the induction power supply; the temperature gradient is monitored in real time during the cooling process to control the cooling rate within a certain range; when the temperature drops to 100 degrees Celsius, the air speed is reduced; the cooling is completed when the temperature drops to room temperature; the surface of the treated area is detected by magnetic powder to verify that no cracks are generated.

[0114] Residual stress scanning area expansion multiple verification method: confirm the coverage of the outer expansion range by computer simulation stress distribution; the reuse rule of grid thickness measurement nodes is to replace the nearest neighbor node when the original node is unreachable; X-ray measurement protection measures include setting a shielding room and personnel dose monitoring; fault tolerance mechanism for stress peak migration amount calculation: when the pre-welding data is missing, replace it with reference data at the symmetric position.

[0115] Dynamic adjustment of safety threshold: when the ambient temperature is lower than 5 degrees Celsius, the proportion coefficient is increased by 0.1; the depth measurement of the migration peak area uses an ultrasonic thickness gauge; temperature calibration of induction heating is performed periodically; the temperature monitoring points of forced air cooling are arranged at key positions in the area.

[0116] Effect verification of thermal relaxation treatment: after treatment, the residual stress in the migration peak area is re-measured, and the stress value drop rate is required to be greater than 40%; the treatment record includes complete parameter curves and result data; abnormal treatment includes automatic power cut-off when the temperature exceeds the standard; safety interlock prevents cross operation.

[0117] The parameters of induction heating are determined through optimization tests; the nozzle layout of forced air cooling uses an array to cover; the microstructure inspection after treatment requires that the grain refinement meets the standard; the final output includes a complete report containing position coordinates, treatment parameters and verification data.

[0118] All implementation steps are automatically executed through an industrial control system: the scanning area generation algorithm is integrated into a CAD software plug-in; the X-ray diffractometer is cooperated with the robot for positioning; the stress calculation module is embedded with a material database; the thermal relaxation treatment parameters are set and stored through the HMI interface; the treatment report is automatically generated as a PDF document. The units of physical quantities are uniformly specified: stress unit is megapascal, temperature unit is Celsius, distance unit is millimeter, and time unit is second. The data correlation mechanism ensures that the contour coordinates, grid nodes, stress measurement points and treatment area spatial positions strictly match.

[0119] Example 2: A kind of welding seam detection remanufacturing device for hydraulic support, which is equipped with a kind of welding seam detection remanufacturing system for hydraulic support.

[0120] The calculations involved in the examples are all de-dimensioned to calculate their numerical values, and the preset parameters and threshold values in the calculations are set by those skilled in the art according to the actual situation.

[0121] The above examples can be realized all or partially by software, hardware, firmware or any other combination. When realized by software, the above examples can be realized all or partially in the form of a computer program product.

[0122] Those skilled in the art can understand that the modules and algorithm steps of each example described in combination with the embodiments disclosed herein can be realized in electronic hardware or a combination of computer software and electronic hardware. Whether the functions are realized in hardware or software depends on the specific application and the constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the present application.

[0123] In addition, each functional module in each embodiment of the present application can be integrated into one processing module, or each module can exist physically independently, or two or more modules can be integrated into one module.

[0124] In several embodiments provided in the present application, it should be understood that the disclosed system, device and method can be implemented in other ways. For example, the device embodiments described above are merely illustrative. For example, the division of the modules is only a logical function division. In actual implementation, another division manner can be used, for example, a plurality of modules or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the coupling or direct coupling or communication connection between the displayed or discussed modules can be indirect coupling or communication connection through some interfaces, devices or modules, and can be electrical, mechanical or other forms.

[0125] The above is merely specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art can easily think of changes or replacements within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

[0126] Finally: the above is merely preferred embodiments of the present application, and is not used to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the protection scope of the present application.

Claims

1. A weld inspection and remanufacturing system for hydraulic supports, characterized in that, include: Data acquisition module: Acquires the contour coordinates of the weld repair area and the thickness distribution of the base material; Unit division module: Based on the thickness distribution of the base material and the layout of the stiffeners, stress buffer units are divided around the repair area. Each stress buffer unit contains at least two heat input control sub-regions, including: The minimum distance from the outer edge of the repair zone contour coordinates to the boundary of the stress buffer unit is determined based on the thickness distribution of the parent material. The minimum distance is equal to the product of the maximum thickness value in the parent material thickness distribution and the constant coefficient. Taking the welded end of the stiffener plate in the stiffener plate layout of the box-type structural member as the reference point, the dividing line is extended along the direction of the greatest change in thickness gradient in the thickness distribution of the base material. The closed region formed by the minimum outward expansion distance between the extended dividing line and the contour coordinates of the repair area is used as a stress buffer unit. Within the stress buffer unit, the stress buffer unit is divided into at least two heat input control sub-regions, with the welded end of the stiffener plate as the starting point of the sub-region boundary, along the direction of thickness gradient change. Boundary redrawing module: Scans the geomagnetic field intensity components of the stress buffer unit boundary and calculates the gradient vector. If the magnitude of the gradient vector exceeds the critical angle, the boundary of the heat input control sub-region is redrawn, including: A magnetic memory sensor array is arranged along the boundary of the stress buffer unit to continuously collect the normal component of the geomagnetic field intensity. The gradient vector is calculated based on the difference between the normal components of the geomagnetic field intensity of adjacent sensor nodes. The magnitude of the gradient vector is the absolute value of the rate of change of the normal components of the geomagnetic field intensity. When the magnitude of the gradient vector exceeds the critical angle, the boundary of the corresponding heat input control sub-region is moved along the gradient vector direction to the position with the lowest magnetic memory equipotential line density within the stress buffer unit. The heat input control sub-region division is updated using the moved sub-region boundaries; Thermal shock control module: Performs layered repair welding on the repair area, and simultaneously activates thermal input in a preset sequence within the thermal input control sub-region, including: Based on the updated heat input control sub-region division, the repair area is divided into multiple weld beads along the depth direction, and the thickness of each weld bead is determined by the upper limit value based on the minimum base material thickness of the repair area. The preset sequence is set as a radial activation path from the contour coordinate position of the repair area to the outer edge of the stress buffer unit; Within a single heat input control sub-zone, heat input activation is achieved by controlling the on / off power supply of the welding torch heat source within the sub-zone through an independent temperature control device. During the activation process, the distance between the activation start points of adjacent heat input control sub-regions should be greater than the effective range of the welding torch heat source. After activating all heat input control sub-regions in the current layer, perform layered repair welding of the next layer of weld beads; Energy ratio monitoring module: Collects acoustic emission signals from the heat input control sub-region, extracts high-frequency and low-frequency energy to calculate the energy ratio; when the energy ratio difference between adjacent heat input control sub-regions exceeds a threshold, it switches to the heat input control sub-region with the higher energy ratio, including: Acoustic emission sensors are placed at the activation start point of each heat input control sub-region to collect the raw acoustic emission signals during the welding process; The original acoustic emission signal is separated into the dislocation slip characteristic frequency band signal and the grain boundary friction characteristic frequency band signal by using a physical bandpass filter; The high-frequency energy is obtained by full-wave rectification and integration of the dislocation slip characteristic frequency band signal, and the low-frequency energy is obtained by full-wave rectification and integration of the grain boundary friction characteristic frequency band signal. The ratio of high-frequency energy to low-frequency energy is used as the energy ratio; The energy ratio difference between adjacent heat input control sub-regions is calculated in real time. When the energy ratio difference exceeds the proportional threshold of the maximum energy ratio in the current welding stage, a switching command is sent to the heat input activation device to the heat input control sub-region with a higher energy ratio. Stress processing module: Based on the contour coordinates, residual stress is scanned in the area extending beyond the repair zone boundary. If the stress peak migration exceeds the safety threshold, local thermal relaxation processing is performed on the migration peak area, including: The residual stress scanning area is defined as an integer multiple of the minimum distance of the stress buffer unit, which is extended outward from the contour coordinates. The residual stress field was scanned along the gridded thickness measurement nodes within the residual stress scanning region using an X-ray diffractometer. The stress peak migration was calculated by comparing the residual stress field data before and after the repair welding, and the safety threshold was set as a proportion of the material fatigue limit. When the stress peak migration exceeds the safety threshold, the current location of the maximum stress peak is marked as the migration peak region; A high-frequency alternating magnetic field is applied to the surface of the migration peak region, and the surface metal of the migration peak region is brought to the recrystallization temperature and kept at that temperature through the eddy current effect. After the heat preservation is completed, the high-frequency alternating magnetic field is stopped, and the migration peak area is forced to be cooled to room temperature to complete the local thermal relaxation treatment.

2. The weld inspection and remanufacturing system for hydraulic supports according to claim 1, characterized in that, Obtain the contour coordinates and base metal thickness distribution of the weld repair zone, including: Three-dimensional point cloud data of the weld repair area is obtained by a laser scanning device. The boundary of the heat-affected zone is identified based on the curvature distribution of the three-dimensional point cloud data. The spatial coordinates of the curvature change point are used as the contour coordinates of the weld repair area. The thickness of the base material is measured in a gridded manner within the boundary area defined by the contour coordinates of the weld repair zone using an ultrasonic thickness gauge, and the base material thickness distribution is generated.

3. The weld inspection and remanufacturing system for hydraulic supports according to claim 2, characterized in that, The node spacing for mesh-based thickness measurement is set based on the stiffener spacing in the stiffener layout of the box-type structural member.

4. The weld inspection and remanufacturing system for hydraulic supports according to claim 1, characterized in that, The critical angle is set as the arcsine function value corresponding to the ratio of the material's yield strength to its tensile strength.

5. A weld inspection and remanufacturing device for hydraulic supports, characterized in that, The system is equipped with a weld inspection and remanufacturing system for hydraulic supports according to any one of claims 1 to 4.

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