Portal type online quality detection device and method for complex weld joints of hull structure

Abstract

The invention discloses a gantry type online quality detection device and method for complex weld joints of a hull structure, and relates to the technical field of ship manufacturing. The system comprises an X-axis movement module, a Y-axis movement module arranged on the X-axis movement module, a Z-axis movement module arranged on the Y-axis movement module, a six-axis robot arranged at the tail end of the Z-axis movement module and a welding seam quality detection module arranged at the tail end of the six-axis robot. Through cooperative movement of the X-axis movement module, the Y-axis movement module, the Z-axis movement module and the six-axis robot, the weld joint quality detection module moves in the X-axis direction, the Y-axis direction and the Z-axis direction and then reaches the weld joint position needing to be detected for weld joint quality detection. According to the invention, the complex welding seam of the hull structure can be automatically detected, the manual labor intensity is effectively reduced, and the detection efficiency and accuracy are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of shipbuilding, in particular to a gantry type online quality detection device and method for complex welds of ship structure. BACKGROUND

[0002] There are a large number of welds in the process of manufacturing and assembling of ship structure, and the welds in the stages of mid-assembly, lattice, etc. have the characteristics of staggered distribution of longitudinal and transverse welds, coexistence of butt joint and longitudinal bone angle joint welds, small working space around the weld, and more complex welds such as cross-welds and special-shaped welds. These characteristics increase the welding difficulty on the one hand, making it more likely to have defects such as cracks, pores and undercut in the welds that affect the quality of the welds, and on the other hand, increase the workload of weld quality detection, which is not conducive to the judgment of weld quality by the detection personnel.

[0003] The common detection methods for complex welds of ship structure include non-destructive testing methods such as ultrasonic testing, magnetic particle testing and penetration testing. These detection methods usually rely on detection personnel to detect and data discriminate the welds one by one and section by section. When detecting the weld quality in the complex space of ship structure, the detection personnel need to frequently adjust the equipment according to the type of weld in the operation process due to the scattered distribution and short length of the welds, resulting in low detection efficiency. Moreover, the type of weld is complex, which may include multiple processes, multiple structures and special-shaped welds, increasing the complexity of data discrimination and putting a great test on the professional level and detection ability of the detection personnel. Furthermore, the welds in the complex space of ship structure are often distributed in a small and semi-enclosed space, making it difficult for personnel and equipment to enter and exit, and prone to safety accidents, so the efficiency of the manual detection method with low automation level is low. SUMMARY

[0004] In view of the above-mentioned defects of the prior art, the technical problem to be solved by the present application is how to realize the automatic detection of complex welds of ship structure, reduce the labor intensity, and improve the detection efficiency and accuracy.

[0005] To achieve the above-mentioned purpose, the present application provides a gantry type online quality detection device for complex welds of ship structure, which comprises an X-axis movement module, a Y-axis movement module arranged on the X-axis movement module, a Z-axis movement module arranged on the Y-axis movement module, a six-axis robot arranged at the end of the Z-axis movement module, and a weld quality detection module arranged at the end of the six-axis robot. Through the cooperative movement of the X-axis movement module, Y-axis movement module, Z-axis movement module and six-axis robot, the weld quality detection module moves in the X, Y and Z axis directions to reach the position of the weld to be detected for weld quality detection.

[0006] Further, the X-axis movement module comprises an X-axis sliding table, which is movably arranged on the track, and the bottom of the X-axis sliding table is provided with an H-shaped sliding table load wheel and a sliding table gear, the H-shaped sliding table load wheel is arranged in cooperation with the I-beam on the track, the inside of the X-axis sliding table is provided with a sliding table motor, the sliding table motor is provided with an encoder, the sliding table motor is connected with the sliding table gear through a gear box, the sliding table gear is arranged in meshing with a track rack on the track, and a sensor is arranged on the track rack.

[0007] Further, the X-axis sliding table is provided with a work platform, an electric control cabinet, an X-axis stand and an industrial computer, the electric control cabinet is provided with a PLC and a power supply, and the PLC communicates with the upper computer through wireless WIFI.

[0008] Further, the Y-axis movement module is arranged on the X-axis stand, and the Y-axis movement module comprises a Y-axis cross beam and a Y-axis sliding plate which cooperate with each other, the Y-axis cross beam is arranged on the X-axis stand, the Y-axis cross beam is provided with a Y-axis cross beam rack and a Y-axis cross beam sliding rail, the Y-axis cross beam sliding rail cooperates with a sliding block on the Y-axis sliding plate, the Y-axis cross beam rack is in meshing with a Y-axis motor output shaft gear arranged on the Y-axis sliding plate, and the Y-axis sliding plate is provided with a Y-axis linear laser sensor and a Y-axis switch.

[0009] Further, the Z-axis movement module comprises a Z-axis stand, the Z-axis stand cooperates with the Y-axis sliding plate, the back of the Z-axis stand is provided with a sliding rail, the sliding rail cooperates with a Z-axis sliding block arranged on the Y-axis sliding plate, one side of the Z-axis stand is provided with a Z-axis stand rack, the Z-axis stand rack is in meshing with a gear arranged on a Z-axis motor output shaft arranged on the Y-axis sliding plate, and the Z-axis stand is further provided with a Z-axis linear laser sensor and a coupling agent storage box.

[0010] Further, the six-axis robot is arranged at the end of the Z-axis stand.

[0011] Further, the weld quality detection module comprises a linear laser sensor, a phased array ultrasonic probe and an encoder, and can realize online detection of weld surface defects and internal defects.

[0012] Further, the ship body structure complex weld gantry type online quality detection device further comprises a weld recognition algorithm, a detection path planning algorithm and a detection result online transmission scheme.

[0013] Further, the ship body structure complex weld gantry type online quality detection device is suitable for the working scene of the ship body structure which contains multiple types of welds, a narrow working space and discrete distribution of short welds, and is suitable for multiple types, multiple structures and discrete arrangement of welds in the ship body structure.

[0014] The application also provides a method for detecting the complex weld of the ship structure using the above-mentioned gantry type online quality detection device for the complex weld of the ship structure, comprising the following steps: Step 1, scanning the point cloud data of the ship structure; Step 2, identifying the weld features; Step 3, calculating the weld coordinates; Step 4, planning the inspection path; Step 5, solving the nine-axis motion path of the robot; Step 6, controlling the robot motion by the upper computer; Step 7, collecting data by the quality detection module; Step 8, returning the detection data to the upper computer; Step 9, ending the detection by the upper computer control device.

[0015] Compared with the prior art, the application has the following advantages: The application can not only collect the surface quality and internal quality data of the complex weld, but also transmit the data in real time, which is beneficial to the subsequent process of interpreting the quality data, effectively reduces the labor intensity, and improves the detection efficiency and accuracy.

[0016] The concept, specific structure and technical effects of the application will be further described below with reference to the drawings, so as to fully understand the purpose, features and effects of the application. DETAILED DESCRIPTION

[0017] Figure 1 It is a schematic structural diagram of the gantry type detection device of the embodiment of the application; Figure 2 It is a schematic structural diagram of the X-axis sliding table of the gantry type detection device of the embodiment of the application; Figure 3 It is a schematic structural diagram of the Y-axis sliding plate of the gantry type detection device of the embodiment of the application; Figure 4 It is a schematic structural diagram of the Z-axis stand column of the gantry type detection device of the embodiment of the application; Figure 5 It is a schematic diagram of the working scene of the gantry type quality detection device of the embodiment of the application; Figure 6 It is a schematic diagram of the detection method of the gantry type quality detection device of the embodiment of the application.

[0018] 1-ship structure complex weld gantry type on-line quality detection device, 2-track, 3-ship structure, 4-X axis sliding table, 41-track rack, 42-sliding table motor, 43-sliding table gear, 44-sliding table bearing wheel, 5-X axis stand, 51-Y axis switch, 52-Y axis motor, 53-Y axis beam rack, 54-Y axis beam sliding rail, 55-Z axis motor, 56-Z axis sliding block, 6-electric control cabinet, 61-Z axis stand rack, 62-edge controller, 63-Z axis switch, 64-coupling agent storage box, 7-Y axis beam, 8-Y axis line laser sensor, 9-Y axis sliding plate, 10-Z axis stand, 11-Z axis line laser sensor, 12-six-axis robot, 13-weld quality detection module, 14-work platform, 15-industrial computer. DETAILED DESCRIPTION

[0019] The preferred embodiments of the present application are described below with reference to the accompanying drawings, so that the technical contents can be more clearly understood and be convenient for understanding. The present application can be embodied in many different forms and the protection scope of the present application is not limited to the embodiments mentioned herein.

[0020] In the drawings, the same components have the same reference numerals, and components having similar structures or functions have similar reference numerals. The size and thickness of each component shown in the drawings are arbitrarily shown, and the present application is not limited to the size and thickness of each component. In order to make the drawing clearer, the thickness of some components is appropriately exaggerated in some places in the drawing.

[0021] As shown in Figure 1 , 2 , 3, 4, and 5, the ship structure complex weld gantry type on-line quality detection device 1 (referred to as gantry type detection device) is shown in the structural composition schematic diagram, and the gantry type detection device includes an X-axis movement module, a Y-axis movement module installed on the X-axis movement module, a Z-axis movement module installed on the Y-axis movement module, a six-axis robot 12 installed at the end of the Z-axis movement module, and a weld quality detection module 13 installed at the end of the six-axis robot 12. The gantry type detection device is installed on the track 2 through the X-axis movement module, the track 2 is used to bear the gantry type detection device, and the movement of the X-axis movement module relative to the track 2 is driven by the X-axis movement module to move the gantry type detection device along the X-axis direction, the movement of the Z-axis movement module along the Y-axis direction is realized through the Y-axis movement module, the movement of the six-axis robot 12 along the Z-axis direction is realized through the Z-axis movement module, and the movement of the weld quality detection module 13 in the X, Y, and Z-axis directions is realized through the six-axis robot 12 to reach the weld position to be detected.

[0022] As shown in Figure 1 , 2As shown in Figure 5, the X-axis motion module includes two X-axis slides 4, and the bottom of the gantry-type detection device is movably connected to the track 2 via the X-axis slides 4. Figure 2 As shown, the bottom of the X-axis slide table 4 has two H-shaped slide table support rollers 44, which cooperate with the I-beams on the track 2 to support the equipment and restrict the freedom of the X-axis slide table 4 to translate along the Y and Z axes and rotate along the X, Y, and Z axes, so that the X-axis slide table 4 can only move horizontally along the X-axis relative to the track 2. The X-axis slide table 4 has a slide table motor 42 installed inside, which is connected to the slide table gear 43 through a gearbox. The slide table gear 43 meshes with the track rack 41 on the track 2.

[0023] A work platform 14, an electrical control cabinet 6, and an X-axis column 5 are mounted above the X-axis slide table 4. The work platform 14 provides a safe operating space for operators, facilitating the operation of the electrical control cabinet 6 and the industrial computer 15. The electrical control cabinet 6 houses a PLC and a power supply, providing control signals and power input to the drive motors, detection sensors, robots, and other components in the gantry-type inspection device. The PLC communicates with the host computer via wireless WIFI, receiving instructions from the host computer and controlling the various components in the gantry-type inspection device to achieve the inspection function. The PLC in the electrical control cabinet 6 can drive the gantry-type inspection device to move along the X-axis track 2 by controlling the rotation of the slide table motor 42, and accurately calculates the speed and distance of the gantry-type inspection device moving along the X-axis track 2 through the encoder in the slide table motor 42 and the sensor on the track rack 41.

[0024] like Figure 1 and 3As shown, the Y-axis movement module is mounted on the X-axis column 5, and the Y-axis movement module includes a Y-axis crossbeam 7 and a Y-axis sliding plate 9 that cooperate with each other. The gantry detection device realizes the horizontal movement of the end robot in the Y-axis through the cooperation of the Y-axis crossbeam 7 and the Y-axis sliding plate 9. The X-axis column 5 provides support for the Y-axis crossbeam 7, and the height of the X-axis column 5 is adjusted to ensure the horizontal movement of the Y-axis crossbeam 7, thereby ensuring that the Y-axis sliding plate 9 in the gantry detection device can move horizontally along the Y-axis. The Y-axis crossbeam 7 is provided with a Y-axis crossbeam rack 53 and two Y-axis crossbeam sliding rails 54. The Y-axis crossbeam sliding rails 54 cooperate with the sliding blocks on the Y-axis sliding plate 9 to provide support for the Y-axis sliding plate 9, limit the freedom of the Y-axis sliding plate 9 to translate along the X and Z axes and rotate along the X, Y and Z axes, so that the Y-axis sliding plate 9 can only move along the Y-axis relative to the Y-axis crossbeam 7; the Y-axis motor 52 output shaft gear installed on the Y-axis sliding plate 9 meshes with the Y-axis crossbeam rack 53, converting the rotary motion of the Y-axis motor 52 into the linear motion of the Y-axis sliding plate 9. By adjusting the horizontal degree of the Y-axis crossbeam sliding rail 54, the horizontal movement of the Y-axis sliding plate 9 along the Y-axis can be ensured. At the same time, the Y-axis linear laser sensor 8 is installed on the Y-axis sliding plate 9. The sensor is a large field of view line laser scanner, which can scan and obtain the three-dimensional point cloud data of the ship structure 3 below the gantry detection device, and transmit the collected data to the upper computer through the Y-axis switch 51 for data processing. After the point cloud obtained by scanning is registered with the three-dimensional model of the ship structure 3, the position information of the weld in the world coordinate system can be obtained.

[0025] As shown in Figure 1 and 4 The Z-axis movement module includes a Z-axis column 10, and the Y-axis sliding plate 9 and the Y-axis crossbeam 7 provide support for the Z-axis column 10. The gantry detection device realizes the vertical movement of the end robot in the Z-axis through the cooperation of the Z-axis column 10 and the Y-axis sliding plate 9. At the same time, the Y-axis linear laser sensor 8 is installed on the Y-axis sliding plate 9, which has a larger field of view due to its installation height advantage, and can quickly and efficiently obtain complete point cloud data of the ship structure 3.

[0026] The back of the Z-axis column 10 has a slide rail that engages with the Z-axis slider 56 on the Y-axis slide plate 9, restricting the Z-axis column 10's freedom of translation along the Y and X axes, as well as its rotation along the X, Y, and Z axes. This ensures that the Z-axis column 10 can only move along the Z-axis relative to the Y-axis slide plate 9. A Z-axis column rack 61 on one side of the Z-axis column 10 meshes with a gear on the output shaft of the Z-axis motor 55 on the Y-axis slide plate 9, converting the rotational motion of the Z-axis motor 55 into vertical motion of the Z-axis column 10 in the Z direction. Through this mechanism, the host computer can control the rotation of the Z-axis motor 55 to control the movement of the six-axis robot 12 at the end of the gantry-type inspection device along the Z-axis. A Z-axis laser sensor 11 is also installed on the Z-axis column 10. Due to its lower installation height, this sensor has a smaller field of view and higher measurement accuracy compared to the Y-axis laser sensor 8, providing a more precise point cloud of the hull structure 3. This point cloud is used to rescan the hull structure 3 before controlling the six-axis robot 12 to perform inspection work, correcting the accuracy of the weld coordinates. A coupling agent storage box 64 is also installed on the Z-axis column 10 by bolts. The coupling agent storage box 64 is used by the weld quality inspection module 13 to deliver coupling agent.

[0027] like Figure 1 and 4 As shown, the six-axis robot 12 is installed at the end of the Z-axis column 10. After the end of the Z-axis column 10 moves along the X, Y and Z axes to the designated detection area through the above mechanism, the six-axis robot 12 carries the weld quality detection module 13 to the weld area and controls the weld quality detection module 13 to fit onto the surface of the weld to be inspected for quality detection.

[0028] like Figure 1 and 4 As shown, the weld quality inspection module 13 includes a line laser sensor, a phased array ultrasonic probe, and an encoder. The line laser sensor is used to scan the point cloud on the weld surface. On the one hand, it can identify weld features, further accurately locate the weld position, and correct the inspection path calculated by the previous process; on the other hand, it is used to identify defects such as undercut, insufficient weld height, and porosity on the weld surface. The phased array ultrasonic probe is used to collect the internal sound field data of the weld and identify defects such as internal cracks, lack of fusion, and incomplete penetration. During the internal defect detection process, the coupling agent is delivered to the phased array ultrasonic probe through the coupling agent storage box 64, and the encoder records the scanned weld length and the position information of the quality data along the weld length direction. The weld quality data collected by the weld quality inspection module 13 is first transmitted back to the phased array ultrasonic acquisition card and the line laser acquisition card in the edge controller 62, and then transmitted to the host computer through the Z-axis switch 63. The host computer performs weld quality data processing and defect identification calculations.

[0029] The gantry type detection device can receive control signals from the upper computer, control the movement mechanisms of the X-axis, Y-axis and Z-axis respectively, so that the base of the six-axis robot 12 can translate along the X-axis, Y-axis and Z-axis in the world coordinate system respectively, reach the planned detection area, and then the welding seam quality detection module 13 is controlled by the six-axis robot 12 to reach the surface of the welding seam of the ship structure 3 to be detected for welding seam quality detection, and the collected welding seam surface and internal quality data are transmitted back to the upper computer for data processing to identify welding seam defects. The gantry type detection device is connected with the upper computer through a network cable, and the upper computer receives the data collected by the gantry type detection device and controls the movement of the gantry type detection device.

[0030] As shown in Figure 5 The working scene diagram of the gantry type online quality detection device for complex welding seams of a ship structure 1 is shown in Figure 6 The detection method of the gantry type online quality detection device for complex welding seams of a ship structure 1 is shown in

[0031] Before starting the detection, the upper computer first controls the gantry type detection device to scan the point cloud model of the ship structure 3 using the line laser sensor, registers the point cloud model with the designed three-dimensional model of the ship structure 3, identifies the welding seam feature information and calculates the position coordinates of the welding seam in the world coordinate system. Then, the detection path is planned according to the position coordinates of the welding seam to be detected, the detection path is optimized according to the principle of minimizing the detection time and avoiding interference with the ship structure 3, and the movement trajectories of each movement axis of the nine-axis robot are reversely solved according to the world coordinates of the detection path, including the six axes of the six-axis robot 12 and three external axes. Finally, according to the calculated nine-axis movement trajectories, the upper computer controls the gantry type detection device to reach the detection starting point, and after the quality detection module confirms the arrival of the welding seam data collection point, the detection function is started to collect the welding seam surface quality data and internal quality data. The upper computer controls the nine-axis movement while collecting the data returned by the welding seam quality detection module 13, so as to realize the quality data collection of the complex welding seam of the ship structure 3. After the collection of the planned detection path is completed, the upper computer controls the gantry type detection device to end the work, and the gantry type detection device moves to the standby position to arrange and summarize the collected welding seam quality data.

[0032] The present application can automatically identify the weld, intelligently plan the path, integrally collect the surface quality data and internal quality data of the weld, and transmit the detection data online, thereby realizing continuous and efficient online quality detection of various types and structures of welds scattered in the ship structure. Not only can the surface quality and internal quality data of complex welds be collected, but also the collected data can be transmitted online in real time, which is beneficial to subsequent process interpretation of quality data, effectively reduces the labor intensity, improves the detection efficiency and accuracy, and is suitable for the working scene of the ship structure containing various types of welds, small working space, and scattered distribution of short welds.

[0033] The preferred embodiments of the present application are described in detail above. It should be understood that those of ordinary skill in the art can make many modifications and changes to the present application without creative labor based on the concept of the present application. Therefore, any technical solutions obtained by logical analysis, reasoning or limited experiments based on the prior art within the concept of the present application shall be within the protection scope determined by the claims.

Claims

1. A gantry-type online quality inspection device for complex weld seams in ship hull structures, characterized in that, The system includes an X-axis motion module, a Y-axis motion module mounted on the X-axis motion module, a Z-axis motion module mounted on the Y-axis motion module, a six-axis robot mounted at the end of the Z-axis motion module, and a weld quality inspection module mounted at the end of the six-axis robot. Through the coordinated motion of the X-axis motion module, the Y-axis motion module, the Z-axis motion module, and the six-axis robot, the weld quality inspection module moves in the X, Y, and Z-axis directions to reach the weld position to be inspected and perform weld quality inspection.

2. The gantry-type online quality inspection device for complex weld seams in ship hull structures as described in claim 1, characterized in that, The X-axis motion module includes an X-axis slide, which is movably connected to a track. The bottom of the X-axis slide has an H-shaped support roller and a slide gear. The H-shaped support roller engages with an I-beam on the track. A slide motor is installed inside the X-axis slide, and the slide motor is equipped with an encoder. The slide motor is connected to the slide gear via a gearbox. The slide gear meshes with a track rack on the track, and a sensor is installed on the track rack.

3. The gantry-type online quality inspection device for complex weld seams in ship hull structures as described in claim 2, characterized in that, The X-axis slide is equipped with a work platform, an electrical control cabinet, an X-axis column, and an industrial computer. The electrical control cabinet contains a PLC and a power supply. The PLC communicates with the host computer via wireless WIFI.

4. The gantry-type online quality inspection device for complex weld seams in ship hull structures as described in claim 3, characterized in that, The Y-axis motion module is mounted on the X-axis column. The Y-axis motion module includes a Y-axis crossbeam and a Y-axis slide plate that cooperate with each other. The Y-axis crossbeam is mounted on the X-axis column. The Y-axis crossbeam is equipped with a Y-axis crossbeam rack and a Y-axis crossbeam slide rail. The Y-axis crossbeam slide rail cooperates with a slider on the Y-axis slide plate. The Y-axis crossbeam rack meshes with a gear on the output shaft of the Y-axis motor mounted on the Y-axis slide plate. The Y-axis slide plate is equipped with a Y-axis laser sensor and a Y-axis switch.

5. The gantry-type online quality inspection device for complex weld seams in ship hull structures as described in claim 4, characterized in that, The Z-axis motion module includes a Z-axis column that engages with the Y-axis slide plate. A slide rail is provided on the back of the Z-axis column, which engages with a Z-axis slider mounted on the Y-axis slide plate. A Z-axis column rack is provided on one side of the Z-axis column, and the Z-axis column rack meshes with a gear on the output shaft of the Z-axis motor mounted on the Y-axis slide plate. The Z-axis column also includes a Z-axis laser sensor and a coupling agent storage box.

6. The gantry-type online quality inspection device for complex weld seams in ship hull structures as described in claim 5, characterized in that, The six-axis robot is positioned at the end of the Z-axis column.

7. The gantry-type online quality inspection device for complex weld seams in ship hull structures as described in claim 1, characterized in that, The weld quality inspection module includes a line laser sensor, a phased array ultrasonic probe, and an encoder, which can realize online detection of surface and internal defects in welds.

8. The gantry-type online quality inspection device for complex weld seams in ship hull structures as described in claim 1, characterized in that, It also includes weld seam recognition algorithms, detection path planning algorithms, and online transmission schemes for detection results.

9. The gantry-type online quality inspection device for complex weld seams in ship hull structures as described in claim 1, characterized in that, It is suitable for working scenarios where the hull structure contains multiple types of welds, the working space is small, and the short welds are discretely distributed. It is applicable to welds of various types, structures, and dispersed arrangements in the hull structure.

10. A method for inspecting complex welds in ship hull structures using a gantry-type online quality inspection device for complex welds as described in any one of claims 1-9, characterized in that, Includes the following steps: Step 1: Scan the point cloud data of the ship's hull structure; Step 2: Identify weld features; Step 3: Calculate the weld coordinates; Step 4: Plan the inspection route; Step 5: Solve for the robot's nine-axis motion path; Step 6: The host computer controls the robot's movement; Step 7: The quality inspection module collects data; Step 8: Send the detection data back to the host computer; Step 9: The host computer control device completes the test.

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