Self-adaptive adjusting method for integrated connection intelligent manufacturing process

Abstract

The invention discloses a self-adaptive adjustment method for an integrated connection intelligent manufacturing process, which mainly solves the problem of automatic adjustment of position parameters and process parameters of each device in the working process of welding-casting-stirring integrated connection manufacturing equipment. According to the technical scheme, the method is characterized in that before working, a visual sensor is used for obtaining position and shape information of a workpiece and welding seam shape information, an information analysis system is used for analysis and operation, and the positions of all devices are pre-calibrated through a position adjusting system; during working, equipment manufacturing speed information is transmitted to the information analysis system to be analyzed and calculated and is output to the process adjusting system, and the filling liquid flow rate, the plasma arc power, the stirrer rotating speed and the TIG arc power are adjusted in real time, so that in the connection manufacturing process, the equipment manufacturing speed can be adjusted in real time. And position parameters and process parameters of all devices in the welding-casting-stirring connection manufacturing integrated equipment are subjected to self-adaptive control.

Description

Technical Field

[0001] This invention specifically relates to an integrated intelligent manufacturing process adaptive adjustment method, which belongs to the field of intelligent manufacturing. Background Technology

[0002] With the continuous development of modern manufacturing and the improvement of automation levels, welding technology, as one of the important processes in manufacturing, has been widely used. Traditional welding processes mainly rely on manual operation, and the stability of the process and the welding quality are greatly affected by the skill level of the operators, making it difficult to meet the requirements of high precision and high consistency. To solve this problem, automated welding technology has emerged and has been widely used in aerospace, automobile manufacturing, shipbuilding and other fields. However, most existing automated welding systems have certain limitations, such as a lack of adaptability to complex weld morphologies and the inability to adjust in real time according to the shape of the workpiece and the weld morphology, resulting in unstable welding quality.

[0003] To address the aforementioned problems, this invention proposes an adaptive control method implemented through an integrated intelligent manufacturing process adaptive adjustment system. This method utilizes advanced vision sensors and information processing technology, combined with multiple processes such as plasma welding, TIG welding, filler fluid supply, and stirring, to identify the shape, position, and weld morphology of the workpiece in real time, dynamically adjusting the operating parameters of each welding device to achieve intelligent control and adaptive adjustment of the welding process. The integrated intelligent manufacturing process adaptive adjustment system described in this invention overcomes the shortcomings of existing technologies, improving the automation level and welding quality of the welding process, adapting to workpieces of different shapes and weld morphologies, increasing production efficiency, and reducing manufacturing costs. Through the coordinated operation of an information management and adjustment center, vision sensors, plasma welding torches, filler fluid conduits, stirrers, and TIG welding torches, the system achieves comprehensive control and real-time adjustment of the welding process, ensuring its stability and consistency. Summary of the Invention

[0004] The purpose of this invention is to provide an integrated intelligent manufacturing process adaptive adjustment system, which designs an adaptive adjustment system based on an integrated welding-casting-stirring thick plate connection manufacturing device, and combines visual sensing and the principle of adaptive adjustment system to realize this method.

[0005] The objective of this invention is achieved through the following technical solution: the method is implemented through an integrated intelligent manufacturing process adaptive adjustment system, such as... Figure 1The adaptive control system includes an information management and adjustment center, vision sensors, a plasma welding torch, a filler fluid conduit, a stirrer, and a TIG welding torch. The information management and adjustment center comprises an information analysis system, a position adjustment system, and a process adjustment system. Its key features are: before operation, a vision sensor identifies the shape, position, and weld morphology of the workpiece. The visual information obtained by the vision sensor is fed back to the information analysis system, and the processed information is transmitted to the position adjustment system. Based on the weld morphology, a stirrer head with a different diameter *d* is replaced. Then, based on the functional relationships H = f(w, h) and X = g(w, h), the distances (H1, H2, H3, H4) between the plasma welding torch, filler fluid conduit, stirrer, TIG welding torch, and workpiece surface, as well as the lateral spacing (X1, X2, X3) between each device, are calculated. This allows for the pre-calibration of the spatial positions of the plasma welding torch, filler fluid conduit, TIG welding torch, and stirrer. During operation, the equipment manufacturing speed *v* is input and transmitted to the information analysis system. The system analyzes the data and, based on the relationship between the process parameters of each unit and the equipment manufacturing speed, calculates the filling fluid flow rate A(v, V), plasma arc power B(v, P1), stirrer speed C(v, n), and TIG arc power E(v, P2), obtaining suitable process parameters. This information is then transmitted to the process control system. This achieves integrated manufacturing by adjusting the spatial position of each unit and automatically adjusting process parameters.

[0006] The information management and control center can receive position information fed back from the visual sensor and has data analysis capabilities. It can output deviation data to the control mechanism. At the same time, the information management and control center stores the function calculation formulas of the process parameters of each device and can make autonomous judgments quickly and accurately.

[0007] The aforementioned vision sensor can identify and monitor the position of the workpiece and the position of the plasma welding torch in real time. Utilizing advanced vision technology, the vision sensor provides real-time position and shape information to the information management and control center, assisting the control system in controlling the parameters of the device and ensuring the accuracy and stability of the welding process.

[0008] Before and during operation, the parameters of each device are determined. Before operation, the vision sensor is activated to identify the shape, position, and weld morphology of the workpiece. The positions of the plasma welding torch, filler fluid conduit, stirrer, and TIG welding torch are then accurately adjusted. The information management and control center possesses a large amount of positional reference information, which can adapt to different workpiece shapes and weld morphologies. During operation, the equipment begins to move, and real-time speed information is fed back to the information management and control center. This information is then processed and analyzed to determine the filler fluid flow rate, plasma arc power, stirrer speed, and TIG arc power. Finally, the actuator precisely controls the output of each parameter according to the instructions from the information management and control center, ensuring the stability and high quality of the welding process.

[0009] The principle of the integrated intelligent manufacturing process adaptive adjustment system described above is as follows: Figure 1 , Figure 2 As shown, before the equipment starts operating, visual positioning is used for pre-calibration of the working stage, obtaining real-time position information of the workpiece to be processed, plasma welding torch, filler fluid conduit, agitator, and TIG welding torch; during operation, the process parameters of each device are determined according to the equipment's manufacturing speed. For example... Figure 1 The following is an analysis of the pre-calibration of the equipment position before operation: Before operation, the adjustment mechanism is activated to reset each device, that is, to adjust it to the initial position. Then, the vision sensor is turned on to identify the shape, position and weld morphology of the workpiece. Based on relevant references, a reference value is given to the information management and adjustment center. The appropriate stirring head is replaced. According to the position function relationship H=f(w,h) and X=g(w,h), the position adjustment system is used to adjust the distances (H1,H2,H3,H4) between the plasma welding torch, the filler pipe, the stirrer, the TIG welding torch and the workpiece surface, as well as the lateral spacing (X1,X2,X3) between each device to the optimal value. The data adjusted at this time is calibrated and recorded as the position pre-calibration. The adjustment command is then executed by the actuator. During operation, the equipment begins to move at a stable and uniform speed. At this time, the detected equipment manufacturing speed v is fed back to the information management and control center. The information management and control center analyzes and calculates the relationship between the filling liquid flow rate V and the equipment manufacturing speed v, denoted as A(V, v), the relationship between the plasma arc power P1 and the equipment manufacturing speed as B(v, P1), the relationship between the stirrer speed n and the equipment manufacturing speed as C(v, n), and the relationship between the TIG arc power P2 and the equipment manufacturing speed as E(v, P2). The information management and control center transmits the calculated information to the actuators to control the process parameters of each device.

[0010] The main features of this invention are: before the equipment operates, visual sensors are used to accurately identify and pre-calibrate the positions of the workpiece, plasma welding torch, filler fluid conduit, stirrer, and TIG welding torch, ensuring the initial positions of each device are accurate. This process includes identifying the shape, position, and weld morphology of the workpiece, and selecting a suitable stirring head based on the weld morphology. During operation, the system adjusts the process parameters of each device in real time according to the equipment manufacturing speed v. The information analysis system analyzes the detected manufacturing speed, automatically calculates the optimal values ​​for filler fluid flow rate, plasma arc power, stirrer speed, and TIG arc power, and transmits this information to the process adjustment system for dynamic optimization control. Through pre-calibration and real-time feedback mechanisms, the system can precisely adjust the distances between the plasma welding torch, filler fluid conduit, stirrer, and TIG welding torch and the workpiece surface, ensuring high quality and high efficiency during the welding process. Integrating advanced visual sensing technology and intelligent control algorithms, it can automatically identify weld morphology, reduce manual intervention, and improve the efficiency and accuracy of welding work.

[0011] The beneficial effects of this invention are that it provides an integrated intelligent manufacturing process adaptive adjustment system. Through visual positioning and pre-calibration technology, this invention ensures the accurate initial position of each device. During operation, the system automatically calculates and adjusts process parameters such as filler flow rate, plasma arc power, stirrer speed, and TIG arc power based on the real-time detected manufacturing speed. This precise control mechanism ensures high quality and consistency in the welding process, reduces human error, and improves welding reliability and stability. This invention, by introducing an adaptive adjustment system, achieves automation and intelligence in the welding process. Such automation significantly improves production efficiency, shortens production cycles, and reduces operating costs. It can automatically select the appropriate stirring head according to different weld morphologies and adjust the distance between each device and the workpiece surface and the spacing between them according to actual conditions, exhibiting strong adaptability. This adaptability makes this invention widely applicable in various industrial applications, meeting the high requirements of different industries for welding quality and efficiency. It achieves automation and intelligence in the welding process. Traditional welding requires constant adjustment and monitoring by operators, while this invention achieves fully automated operation through visual sensors and an information management and adjustment center, requiring only simple monitoring and maintenance by operators. This not only reduces labor intensity but also lowers the technical requirements for operators and reduces training costs. By precisely controlling the filler fluid flow rate and welding parameters, the system can maximize material utilization, reduce welding defects and rework, thereby saving costs. At the same time, the efficient welding process reduces energy consumption, helping to lower production costs and reduce environmental impact. Attached Figure Description

[0012] Figure 1 Schematic diagram of adaptive adjustment system and device

[0013] Figure 2 Adaptive adjustment flowchart Detailed Implementation

[0014] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0015] Case Study 1: Welding of Thick Plate Protective Doors: Thick plate protective doors are widely used in nuclear power plants, military protective facilities, and high-security buildings. These protective doors are typically composed of multiple layers of thick steel plates, possessing extremely high strength and impact resistance. Traditional welding methods are inefficient, prone to weld defects, and unable to meet the requirements of high-strength, high-quality welding. This invention introduces an adaptive control system, using visual sensors and automated adjustments to achieve efficient and high-quality welding of thick plate protective doors. The specific implementation is as follows: First, the plasma welding torch, filler fluid conduit, stirrer, and TIG welding torch are reset. The visual sensor identifies the shape, position, and weld morphology of the door panel, feeding this information back to the information analysis system. After processing, the information is transmitted to the position adjustment system, which selects a stirrer head of appropriate diameter. The position adjustment system pre-calibrates the spatial position of each device and sends instructions to the actuators to control each device to move to the pre-calibrated position. During operation, the equipment moves stably, and the manufacturing speed v is detected in real time and transmitted to the information analysis system. The system calculates the optimal values ​​for the filler fluid flow rate V, plasma arc power P1, stirrer speed n, and TIG arc power P2, and finally transmits these values ​​to the process adjustment system to adjust the parameters. This method ensures a highly efficient and stable welding process with high-quality welds, making it suitable for the high-strength welding requirements of protective doors and guaranteeing that the welded doors have good durability and stability.

[0016] Case Study 2: Oil and Gas Pipeline Welding: Oil and gas pipelines are critical infrastructure for energy transmission, and their welding quality directly affects the safe operation of the pipelines. Oil and gas pipelines are typically laid in complex terrain environments, presenting welding challenges involving long distances and high intensity. Traditional welding methods are not only inefficient but also prone to welding defects, increasing the risk of pipeline leaks and accidents. The adaptive adjustment system provided by this invention ensures weld consistency and quality by adjusting welding parameters in real time, adapting to different environments and workpiece shapes. The specific implementation is as follows: First, the equipment resets all devices, activates the vision sensor to identify the pipeline shape, position, and weld morphology, and feeds the information back to the information analysis system. The processed data is then transmitted to the position adjustment system, which selects a suitable stirring head. The position adjustment system pre-calibrates the spatial positions of the plasma welding torch, filler fluid conduit, stirrer, and TIG welding torch, and finally, the actuator performs the adjustment. During operation, the equipment moves stably, and the manufacturing speed v is detected in real time and fed back to the information analysis system. The system calculates the optimal filler fluid flow rate V, plasma arc power P1, stirrer speed n, and TIG arc power P2 based on the speed v, and adjusts them through the process adjustment system. This adaptive adjustment system enables efficient pipe welding and produces high-quality welds, making it particularly suitable for continuous welding of long-distance pipelines, ensuring the safety and durability of the pipelines.

Claims

1. Integrated connection intelligent manufacturing process adaptive adjustment method, the position parameter adjustment feature is: make the position parameter and process parameter adaptive adjustment system of each device in the integrated equipment, before the equipment works, use visual sensor to identify the shape, position and weld form of the workpiece, feed the visual identification information obtained by the visual sensor to the information management adjustment center, according to the weld form, replace the mixing head (5) with different diameter d, then calculate the distance (H1, H2, H3, H4) between the plasma arc welding gun, the filler liquid guide pipe, the stirrer, the TIG welding gun and the workpiece surface, and the lateral interval (X1, X2, X3) between each device, pre-mark the space position of the plasma arc welding gun, the filler liquid guide pipe, the TIG welding gun and the stirrer respectively, send the distance parameter and the interval parameter to the position adjustment system, the position adjustment system sends instructions to the actuator to control each device to move to the pre-marked position, and prepares to start work.

2. The integrated connected smart manufacturing process self-adaptive adjustment method according to claim 1, characterized in that: The main components of the adaptive adjustment system include visual sensor (1), plasma arc welding gun (2), filler liquid guide pipe (3), stirrer (6), TIG welding gun (7), information management adjustment center (8) and actuator. Among them, the information management adjustment center includes information analysis system, position adjustment system and process adjustment system. The information analysis system is used to analyze the process parameter information and visual identification information in the integrated equipment, the position adjustment system can adjust the space position of each device, and the process adjustment system can adjust the process parameters of each device and control the opening time of each device.

3. The plasma torch, filler fluid conduit, stirrer, TIG torch and workpiece surface distance H and lateral spacing X between devices of claim 1 wherein The distance parameter H and the lateral interval X satisfy the relationship H = f (w, h) and X = g (w, h) according to the weld form characteristics (weld width w, weld depth h). The calculated distance parameter H and interval parameter X are sent to the position adjustment system for subsequent work.

4. The integrated connection intelligent manufacturing process adaptive adjustment method according to claim 1 and claim 2, the process parameter feature is: during work, set the integrated equipment manufacturing speed v, the information analysis system quickly analyzes according to the manufacturing speed and the visual identification information to obtain suitable process parameters, and the process adjustment system adjusts the filler liquid flow rate A (v, V), the plasma arc power B (v, P1), the stirrer speed C (v, n) and the TIG arc power E (v, P2) according to the functional relationship between the process parameters and the equipment manufacturing speed v. In this way, the spatial position adjustment of each device in the integrated connection intelligent manufacturing and the automatic adjustment of the process parameters are realized.

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