A method for online correction of welding deformation of a spherical tank

Abstract

This invention discloses an online correction method for welding deformation of spherical tanks, specifically relating to the field of spherical tank welding deformation correction technology. It addresses the problems of inaccurate correction timing, susceptibility to deviation in correction direction, and potential instability in continuity of adjacent areas after correction in existing spherical tank welding deformation correction methods. By dividing the spherical tank welding area into spherical correction zones, establishing adjacency mapping and symmetry mapping relationships, and combining the zone deformation accumulation state, spherical correction reference, correction permission state, main release direction, restricted correction parameters, and spherical continuity state to update the correction permission state of subsequent welding zones, this method integrates the effects of local thermally induced deformation, adjacent area constraint transmission, and symmetry imbalance during the welding process into a single closed-loop correction link for constraint determination and graded correction. This avoids the problems of delayed spherical correction, inaccurate correction direction, and subsequent loss of continuity control in the welding area caused by relying solely on single-point measurements or single-time experience corrections in existing technologies.

Description

Technical Field

[0001] This invention relates to the field of welding deformation correction technology for spherical tanks, specifically to an online correction method for welding deformation of spherical tanks. Background Technology

[0002] Spherical tanks are typical large, thin-walled welded structures. During manufacturing and on-site installation, after the shell plates are assembled, tack welded, and then formally welded, phenomena such as bulging, localized inward contraction, uneven boundary transitions, and changes in continuity between sections are prone to occur near the weld seams. Because the spherical tank has continuous curved surfaces, numerous sections, and complex weld seam intersections, the welding heat input not only affects the current welding area but also propagates along adjacent plates, weld seam intersections, and local constraint paths to the surrounding areas. Therefore, deformation caused by the same weld bead typically exhibits zoned linkage and temporal evolution characteristics. Current on-site handling methods usually involve first manually verifying the out-of-tolerance areas based on manufacturing drawings and post-weld measurements, and then, based on experience, applying mechanical pressure, tension / compression correction, or localized heating to bring the deformation back within acceptable limits.

[0003] Current technologies for controlling welding deformation in spherical tanks primarily focus on optimizing the welding sequence, adjusting welding process parameters, post-weld overall inspection, and corrective measures for localized deviations. In the specific correction phase, on-site judgment is often based on geometric deviations near a single measuring point or weld seam, or a single inspection result, combined with operator experience to determine whether correction is necessary, in which direction, and to what extent. While this approach can handle basic issues in typical localized correction scenarios, for spherical tank structures undergoing continuous welding, the thermal changes, constraint transmission, and deformation coupling between the current welding area and adjacent or symmetrical areas make correction decisions based solely on isolated areas or single measurement results. This can easily lead to situations where the state of adjacent areas changes after the current area is corrected, or the continuity of subsequent welding areas is disrupted despite the correction of the local shape.

[0004] Therefore, in the continuous welding process of spherical tanks, the existing technology lacks an online correction mechanism that can simultaneously judge the state of the target area and its adjacent and symmetrically related areas in combination with the current welding process, and determine the correction timing, correction direction and the impact on continuity after correction. This results in inaccurate correction timing, easy deviation of correction direction, and easy instability of continuity in adjacent areas after correction, which in turn affects the subsequent welding and overall forming quality. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an online correction method for welding deformation of spherical tanks, thereby solving the problems mentioned in the background section.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an online correction method for welding deformation of spherical tanks, comprising: S1. Divide the spherical correction zones according to the welding area of ​​the spherical tank, establish the adjacency mapping relationship and symmetry mapping relationship of each spherical correction zone, and generate the spherical correction reference corresponding to each spherical correction zone. S2. Collect the thermal response information and morphological response information of the target spherical correction zone and associated spherical correction zones according to the current welding process, and generate the cumulative deformation state of the target spherical correction zone. S3. Based on the cumulative deformation state of the partition, the adjacency mapping relationship, the symmetric mapping relationship, and the spherical correction reference, determine the correction permission state and main release direction of the target spherical correction partition; S4. When the calibration permission state is established, generate the restricted calibration parameters of the target spherical calibration zone based on the main release direction, the spherical calibration reference and the constraint state of the associated spherical calibration zone. S5. Based on the limited correction parameters, perform graded correction on the target spherical correction zone, and collect thermal response information and morphological response information again after each correction. S6. Based on the results of the re-collection, determine the spherical continuity status of the target spherical correction zone and update the correction permission status of the subsequent spherical correction zones to be welded.

[0007] Furthermore, S1 includes: The primary partition is defined by the nominal boundary of a single spherical shell plate; Within the primary zone, divide the longitudinal seam influence sub-zones along both sides of the longitudinal seam centerline, and divide the circumferential seam influence sub-zones along both sides of the circumferential seam centerline. The overlapping portion of the longitudinal joint influence sub-zone and the circumferential joint influence sub-zone is divided into an intersection sub-zone; Based on the preset distance of the parameter version bound to the current work order, divide the opening constraint sub-partition outside the outer edge of the opening.

[0008] Furthermore, including: Generate the nominal spherical surface of the entire tank according to the design radius and the geometric center of the spherical tank, and cut the nominal base surface of the partition according to the current spherical surface correction partition boundary; Compare the initial measured points before welding with the nominal datum plane of the partition; The overall translation correction is determined based on the weighted offset of the effective measured points relative to the nominal datum of the partition, and the attitude correction is determined based on the offset difference between the boundary points and the partition center point, and a spherical correction reference is formed accordingly.

[0009] Furthermore, S2 includes: Based on the weld sequence, weld position and partition version number in the current work order, lock the spherical correction partition that is being welded as the target spherical correction partition; Identify spherical correction partitions that have an adjacency mapping relationship or a symmetric mapping relationship with the target spherical correction partition and are in an allowed call state as associated spherical correction partitions; Thermal response information and morphological response information were collected within the target spherical correction zone and associated spherical correction zones. Within the observation window, a sub-window is captured, and the thermal cumulative level and morphological cumulative level are determined separately and written into the partition deformation cumulative state. The results of constraint coupling and symmetric equilibrium are written into the partitioned deformation cumulative state.

[0010] Furthermore, S3 includes: The correction permission status is determined in the following order: partition status mark, spherical correction reference deviation status, thermal cumulative level, morphological cumulative level, symmetry balance result, and constraint coupling result. The main release direction is determined by following the order of displacement direction, partition center point offset direction, boundary arc length change direction, and weld adjacent point spacing change direction, combined with the synchronous change direction of the partitions corresponding to the adjacency mapping relationship and the partitions corresponding to the symmetric mapping relationship.

[0011] Furthermore, S4 includes: The latest effective partition deformation cumulative state records, constraint coupling results, symmetry balance results and partition state markers of all effective adjacent partitions and effective symmetric partitions are summarized in a fixed order to determine the constraint state of the associated spherical correction partition. The constraint states are fixed as low constraint, medium constraint, and high constraint.

[0012] Furthermore, S4 also includes: After the constraint state of the associated spherical correction zone has been determined, the correction action area, correction action direction and correction level are determined according to the main release direction and spherical correction reference. The single hold duration is determined based on the current equipment type and calibration level; and the level switching conditions and stop boundaries are generated.

[0013] Furthermore, S5 includes: Locate the application point and application edge according to the correction application area mark, drive the corresponding equipment into the preparatory action according to the correction application direction, and apply the single holding duration according to the gear table corresponding to the current correction level. After the duration of a single hold expires, the current level is stopped, and thermal response information and morphological response information are collected again under the same session identifier; Based on the results of the re-collection, the stop boundary determination and the level switching condition determination are performed.

[0014] Furthermore, S6 includes: The determination is made in the order of baseline regression state, boundary transition state, and symmetric coordination state. The continuous state of the sphere is determined based on the results of the baseline regression state, boundary transition state, and symmetric coordination state. Based on the continuous state of the spherical surface, the correction permission status of the subsequent spherical correction zones to be welded is updated in the order of direct adjacency, symmetric mapping, and the influence of welding sequence.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. By dividing the spherical correction zone according to the welding area of ​​the spherical tank, an adjacency mapping relationship and a symmetry mapping relationship are established. The correction permission state of the subsequent welding zone is updated by combining the cumulative deformation state of the zone, the spherical correction reference, the correction permission state, the main release direction, the restricted correction parameters, and the spherical continuity state. This achieves the goal of incorporating the local thermal deformation, adjacent area constraint transmission, and symmetry imbalance effects during the welding process into the same closed-loop correction link for constraint judgment and graded correction. This avoids the problems of spherical correction lag, inaccurate correction direction, and loss of control of subsequent welding zone continuity caused by relying only on single-point measurement or single experience correction in the existing technology.

[0016] 2. By collecting thermal response and morphological response information again after each level of correction, and making dynamic decisions on the correction process based on the rapid retest results, stop boundaries, level switching conditions, and the constraint status of the associated spherical correction zones, the correction action is restricted to a limited range that matches the current welding process. This reduces the risk of overcorrection, reverse offset, and imbalance in adjacent zones, and improves the stability, continuity, and field feasibility of online correction of spherical tank welding deformation. Attached Figure Description

[0017] Figure 1 This is a schematic flowchart of an online correction method for welding deformation of a spherical tank according to the present invention. Detailed Implementation

[0018] 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 skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Example: Figure 1 A flowchart illustrating an online correction method for welding deformation of a spherical tank according to the present invention is provided. The online correction method for welding deformation of a spherical tank includes: S1. Divide the spherical correction zones according to the welding area of ​​the spherical tank, establish the adjacency mapping relationship and symmetry mapping relationship of each spherical correction zone, and generate the spherical correction reference corresponding to each spherical correction zone. The specific implementation is as follows: First, the spherical calibration zones are divided according to the welding area of ​​the spherical tank. Specifically, before the spherical tank is assembled on site and enters the formal welding stage, the process control terminal at the welding station retrieves the manufacturing drawings, installation drawings, layout drawings, assembly records, and the current welding plan, and positions all zones according to a unified coordinate system. The unified coordinate system is fixed as a spherical coordinate system with the geometric center of the spherical tank as the origin, the equatorial plane as the reference plane, and the radial plane passing through the center line of the reference longitudinal seam as the zero-degree plane. All points measured on site are converted to this coordinate system, and the use of local coordinates is not allowed.

[0020] The welding zone refers to a spatial unit determined by the location of the spherical shell plate zone, the location of the weld type, the location of the opening, and the location of the reinforcement. It is determined on site by corresponding to the drawing number, the coordinates of the measuring point, and the weld number in the welding plan.

[0021] During the partitioning process, a primary partition is first formed using the nominal boundary of a single spherical shell plate. Then, within the primary partition, the longitudinal seam centerline on both sides is divided according to the preset width of the parameter version bound to the current work order to form longitudinal seam influence sub-partitions. Similarly, the circumferential seam centerline on both sides is divided according to the preset width of the parameter version bound to the current work order to form circumferential seam influence sub-partitions. The overlapping portion of the longitudinal seam influence sub-partitions and the circumferential seam influence sub-partitions independently forms an intersection sub-partition. The outer edge of the opening is extended outward by the preset distance of the parameter version bound to the current work order to form an opening constraint sub-partition, which preferentially covers the original partition. The minimum arc length, minimum area, partition width, and extension distance of the partition all adopt the preset values ​​of the parameter version bound to the current work order. The parameter version is generated by the corresponding process document and is issued synchronously with the current work order.

[0022] The spherical correction zone mentioned here refers to a local spherical area that is affected by the same welding heat input and adjacent constraints during the actual welding process and needs to be corrected and the action issued as a whole. This area is located and determined by using a total station, laser tracker, or fixed target measuring points to locate the zone boundary points, zone center points, and weld adjacent points. The zone boundary points are measuring points located on the closed boundary of the zone, the zone center points are measuring points located near the geometric center of the zone to reflect the overall offset state, and the weld adjacent points are measuring points located within a fixed distance on both sides of the weld centerline to reflect the welding heat-induced deformation. The names, location calibers, and numbering rules of the three types of points are kept consistent throughout the entire process of the same spherical tank.

[0023] The nominal radius of curvature from the design system, the out-of-plane deviation from the assembly measurement system, the weld sequence from the welding plan system, and the measurement point number from the field sensor link are first aligned by time, coordinate, and number upon entering the process control terminal. Time alignment uses the time of the previous work order as the unified zero point, and then associates and maps it with the arc ignition time of the welding machine after entering the formal welding. Number alignment uses the combination of the spherical tank number, work order number, partition number, and measurement point number as the unique key. For missing measurement points, only when the spherical arc length between two adjacent valid points in the same partition is not greater than the preset upper limit of the parameter version bound to the current work order and the deviation direction of the two points relative to the nominal sphere is consistent, it is allowed to fill in the missing points by combining the corresponding position value of the nominal sphere with the average deviation of the valid points on both sides. If the deviation directions of the two points are opposite or the spacing exceeds the limit, the gap is maintained and the current partition is marked as pending retesting, and subsequent correction judgment is not allowed.

[0024] After completing the spherical correction partitioning, the adjacency mapping relationship and symmetric mapping relationship of each spherical correction partition are established.

[0025] The adjacency mapping relationship mentioned here refers to the correspondence between the current spherical correction zone and the surrounding spherical correction zones that directly affect its deformation evolution in the actual heat conduction, welding restraint transmission, and structural tension path. The determination order is fixed as follows: first determine the common edge, then determine the shortest arc length of the sphere, and then determine the shared restraints that are in a locked state. When the length of the common edge of two zones reaches the preset proportion of the total length of the boundary of any zone to the parameter version bound to the current work order, they are directly determined as first-level adjacency. If the proportion is not reached, if the shortest arc length of the sphere between the boundaries of the two zones is not greater than the preset distance of the parameter version bound to the current work order, they are determined as second-level adjacency. If the condition is still not met, if the two zones share tooling or temporary restraints that are in a locked state, they are determined as third-level adjacency. When multiple conditions are met, only the highest level is retained and not recorded repeatedly.

[0026] The symmetry mapping relationship mentioned here refers to the correspondence between the paired spherical correction partitions that play a balancing role in structural constraints, corresponding to the main symmetry plane formed relative to the geometric center of the spherical tank. The main symmetry plane is fixed as a vertical radial plane that passes through the geometric center of the spherical tank and through the center point of the current partition. Only when this plane cannot form a unique corresponding partition is it allowed to call the equatorial plane as an auxiliary symmetry plane. If it still cannot form a unique corresponding partition, the partition is recorded as a partition without symmetry mapping and a trace is left. The partition is only allowed to enter the next stage according to the adjacency mapping relationship. Symmetry constraint judgment is not called and manual arbitrary specification is not allowed.

[0027] By setting up the above settings, the subsequent judgment is based on the surrounding constraint relationship and symmetrical balance relationship. It is applicable to the manufacturing and on-site installation of spherical tanks where the spherical shell plate is clearly divided into blocks, the weld path can be traced, and the measuring points can be reliably measured. It is not applicable to temporary repair scenarios where the drawings are missing, the measuring points cannot be maintained, or the weld boundary cannot be confirmed.

[0028] After completing the adjacency mapping and symmetric mapping relationships, the spherical correction references corresponding to each spherical correction partition are generated. The spherical calibration datum here refers to the sole reference datum used for comparing the out-of-plane deviation, curvature continuity, and symmetry coordination of each subsequent spherical calibration zone. Its formation order is fixed as follows: first, generate the nominal spherical surface of the entire tank according to the design radius and the geometric center of the spherical tank; then, cut the nominal datum surface of the zone from the nominal spherical surface according to the current zone boundary; and then collect the initial measured points before welding and compare them point by point with the nominal datum surface of the zone. If the difference between two consecutive remeasurements of the same point exceeds the instrument's repeatability tolerance and the deviation direction is inconsistent with at least two of the three nearest adjacent valid points, the instrument's repeatability tolerance is based on the calibration value in the most recent valid metrological calibration record of the corresponding measuring equipment. Only after excluding probe loosening, target offset, and tooling obstruction are they judged as outliers and removed. The three nearest adjacent valid points are fixed as the three valid points with the closest spherical arc length on both sides of the closed sequence of the zone boundary where the current point is located. When there are not enough boundary points to take three, they are supplemented according to the principle of the closest spherical arc length to the current point within the same zone.

[0029] When the number of valid points reaches the preset lower limit of the parameter version bound to the current work order, statistics are performed with boundary points having a weight of 0.5, weld adjacent points having a weight of 0.3, and partition center points having a weight of 0.2. When the number of points of a certain type is insufficient, its weight is not distributed to other types of points, but is normalized according to the original weight ratio of the remaining valid points. On this basis, the offset of all valid points relative to the partition nominal datum is statistically analyzed in the order of boundary points first, weld adjacent points second, and partition center points third. First, the overall translation correction of the partition nominal datum is determined, and then the attitude correction of the partition nominal datum is determined by the offset difference between the boundary points and the partition center points. A spherical calibration reference is established. The overall translation correction is determined by the weighted average offset of all valid points relative to the nominal datum of the partition, and the attitude correction is determined by the radial offset difference between the partition center point and the boundary point relative to the geometric center of the spherical tank. If the correction direction of the boundary point is opposite to that of the partition center point, the correction direction of the boundary point is taken as the reference and the current partition is marked as a high-constraint partition. A high-constraint partition is a spherical calibration partition whose boundary point correction direction is opposite to that of the partition center point correction direction, which cannot be directly entered into the automatic calibration amplification process in subsequent steps, and which is only allowed to use a conservative calibration parameter set. When the number of valid points is insufficient, only a mark to be measured is generated, and no spherical calibration reference is generated.

[0030] The aforementioned ratios, distances, upper and lower limits, waiting times, number of retries, and sampling ratios are all synchronously fixed in the parameter version when the current work order is issued. The parameter version number is written into the record and participates in subsequent calls, and will not change due to changes in work groups, equipment, or operators.

[0031] To ensure traceability and reproducibility, once the spherical calibration partitions, adjacency mapping relationships, symmetry mapping relationships, and spherical calibration datums are formed, they are uniformly written into the manufacturing execution server connected to the process control terminal. The storage format is fixed and includes the spherical tank number, work order number, partition number, partition version number, parameter version number, measurement point list, mapping list, datum status, generator identifier, and timestamp. The datum status is fixed and includes generated, pending supplementary measurement, and prohibited from being called. An idempotent key composed of the spherical tank number, work order number, partition number, version number, parameter version number, and generation time is generated. Only one valid record is allowed to be retained for the same idempotent key. When resubmitting, the earliest completed and verified record is used, and the remaining records are transferred to the duplicate record retention area without overwriting the valid records. The duplicate record retention area is used to store historical records that were not recognized as valid records due to duplicate idempotent keys. The record activation order is fixed as follows: first solidify the spherical calibration partitions, then solidify the adjacency mapping relationships and symmetry mapping relationships, and finally solidify the spherical calibration datum. The absence of any preceding record will not trigger the activation of subsequent records.

[0032] The communication method can be industrial Ethernet or fieldbus forwarded through a gateway. The minimum calling fields provided by the current step to the next step include the spherical tank number, partition number, list of adjacent partition numbers, symmetrical partition number, baseline version number, parameter version number, and effective time. The return status includes at least five categories: success, duplicate, missing test, unauthorized change, and version inconsistency, corresponding to codes 0, 1, 2, 3, and 4, respectively. When the communication delay exceeds the allowable waiting time for the current weld bead, the system does not block the welding machine's pressure holding action, but marks the current partition as a prohibited calling state. The prohibited calling state also prevents the old version from being overwritten and prevents manual skipping of verification and direct release. When subsequent steps read this status, they must not generate subsequent correction records for this partition. After manual review and cancellation, a new version record must be generated and an idempotent key must be regenerated. The old version must not be overwritten.

[0033] To control resource consumption, a single process control terminal can be set to manage multiple spherical calibration partitions concurrently, but only one partition is allowed to perform baseline writing at any given time. If the writing fails, it can be retried a preset number of times according to the parameter version bound to the current work order. If the limit is exceeded, the current work order will be frozen and a retest prompt will be issued. The reason for the retest, the personnel who performed it, and the handling result will be written into the evidence chain record.

[0034] During on-site inspection, the parameters bound to the current work order in the partitioned area of ​​the current shift are sampled at a preset ratio. The inspection items are fixed and include the consistency of partition boundary closure, the accuracy of adjacency mapping, the accuracy of symmetry mapping, and the deviation of benchmark retest. If any item fails to meet the requirements, the entire tank must be re-executed.

[0035] Preferably, in the installation condition of a spherical tank with a diameter of 18m and a plate thickness of 28mm, the entire tank can be divided into 48 spherical correction zones. Each zone has 12 initial measured points, with a point re-measurement tolerance of 0.5mm. The dividing width of the longitudinal joint influence sub-zone and the circumferential joint influence sub-zone is set to 150mm, the outward expansion distance of the opening constraint sub-zone is set to 200mm, the minimum arc length of the zone is set to 300mm, and the minimum area of ​​the zone is set to 0.15m². 2 The first-level adjacency determination ratio is set to 20%, the second-level adjacency determination distance is set to 250mm, the minimum number of valid points is set to 7, the maximum round-trip delay of industrial Ethernet packets is set to 200ms, the number of retry attempts for repeated writing is set to 3, the sampling inspection ratio is set to 20%, and the next step is allowed after two consecutive sampling inspections are passed; for example, in the absence of a laser tracker, a total station can be used in conjunction with a fixed measuring point target to complete the same diameter measurement. As long as the spherical calibration benchmark is formed according to the same partitioning order, mapping rules, benchmark generation order, parameter version locking rules and traceability requirements, it is an equivalent implementation of this step.

[0036] S2. Collect the thermal response information and morphological response information of the target spherical correction zone and associated spherical correction zones according to the current welding process, and generate the cumulative deformation state of the target spherical correction zone. The specific implementation is as follows: After the spherical correction partition, adjacent mapping relationship, symmetric mapping relationship and spherical correction benchmark are solidified, the process control terminal on the welding station locks the spherical correction partition being welded as the target spherical correction partition according to the weld sequence, weld position and partition version number in the current work order, and determines the spherical correction partition that has an adjacent mapping relationship or symmetric mapping relationship with the target spherical correction partition and is in the callable state as the associated spherical correction partition; the current welding process refers to the continuous construction progress from the start of the welding machine igniting the arc in the current weld to the end of the arc in the current weld and before entering the interlayer interval or moving to the next weld. It is determined on site by the arc ignition time, arc termination time, welding length increment and weld layer number uploaded by the welding machine controller.

[0037] Thermal response information is the temperature status information continuously acquired within the observation window during the welding process and after the arc is extinguished, within the target spherical correction zone and associated spherical correction zones. It is acquired on-site through contact temperature measuring points on both sides of the weld centerline, infrared thermography, or thermal imaging acquisition devices. The acquired content is fixed and includes the surface temperature of the weld area, the zone boundary temperature, the interpass temperature, and the temperature change rhythm. The temperature change rhythm is fixed as the continuous direction and average change amplitude of the temperature difference between adjacent sampling times at the same measuring point within the current sub-window. The surface temperature of the weld area is first obtained point by point, and then summarized with equal weight according to the number of measuring points. When more than half of the measuring points in the same sub-window have the same change direction, the temperature change rhythm direction of the current sub-window is considered to be valid.

[0038] Morphological response information is the geometric morphological change information continuously acquired within the same time period. It is obtained on-site using a total station, laser tracker, fixed target measuring point, or displacement probe. The acquired content is fixed and includes out-of-plane displacement, boundary arc length change, weld adjacent point spacing change, and partition center point offset. Among them, the boundary arc length change is fixed as the difference between the total arc length of the partition boundary closed curve at the end of the current sub-window and the total arc length of the initial measured closed curve before welding. The weld adjacent point spacing change is fixed as the difference between the spherical arc length distance between a pair of weld adjacent points with corresponding numbers on both sides of the weld center line and the baseline before arc termination. If multiple pairs of points are set up for the same weld, they are calculated one pair at a time in numerical order and the median value is taken.

[0039] To ensure that the collected results can be directly accessed between upstream and downstream processes, the process control terminal generates a session identifier for this round of data collection after each successful arc ignition by the welding machine, based on the work order number, partition number, weld number, and parameter version number. It then only calls the target spherical correction partition and associated spherical correction partition measurement points that match the session identifier. If the associated spherical correction partition is marked as a partition without symmetric mapping, this step only collects the measurement points corresponding to its adjacent mapping.

[0040] All records from the welding machine controller, temperature acquisition device, and geometric measurement device undergo time alignment, coordinate alignment, and number alignment upon entering the process control terminal. Time alignment uses the arc ignition time corresponding to the current acquisition session identifier as the unified zero point. Coordinate alignment uses the spherical coordinate system locked in the previous step. Number alignment uses the unique keys of the spherical tank number, work order number, zone number, measurement point number, and weld number. For isolated jump values ​​in the temperature signal, only when both the previous and subsequent samples are valid, the temperature change direction of two adjacent sampling times is consistent, and the current value deviates from the average of the previous and subsequent samples by more than the work order locking range, is it judged as a single interference value and replaced by the average of two adjacent valid values. For missing measurement points in the morphological signal, only when the duration of the missing measurement does not exceed the work order locking duration and the displacement change direction of the adjacent valid measurement points on both sides of the point is consistent, is it filled by the average current offset of the valid measurement points on both sides. If the duration exceeds this or the direction is opposite, the gap is maintained and the zone to which the measurement point belongs is marked as a degraded acquisition state.

[0041] The partitioned deformation cumulative state is a partitioned state record formed by accumulating the thermal response information and morphological response information of the target spherical correction partition and the associated spherical correction partition in a continuous observation window in a fixed order under the current welding process. The starting point of the observation window is fixed at the arc initiation time of this round, and the ending point is fixed at the time when the work order lock time expires after the current weld arc is extinguished. Within the observation window, sub-windows are rolled and intercepted according to the work order lock rhythm, and the three most recent sub-windows are retrieved and re-judged once for each new sub-window added in the sliding window manner.

[0042] The thermal accumulation level is fixedly divided into level 0, level 1, level 2, and level 3. The range of temperature difference between the weld zone surface temperature and the zone boundary temperature, the range of interpass temperature change, and the threshold for judging the continuity of temperature change rhythm corresponding to each level are all given in advance by the parameter version bound to the current work order and issued synchronously with the work order. This step only compares each item according to the parameter version and does not allow on-site re-file. In the first observation window, the interpass temperature change is taken as the baseline of the most recent effective interpass temperature record before the arc is struck in the previous weld layer. If there is no such record, the initial value of the interpass temperature obtained before the arc is struck in the current weld bead is taken as the baseline.

[0043] The current sub-window thermal accumulation level is formed in the following order: first, compare the range of differences between the weld zone surface temperature and the zone boundary temperature; then, compare the range of changes in interlayer temperature relative to the last value of the previous observation window or the baseline of the first window; finally, compare whether the temperature change rhythm is consistent in direction within two consecutive sub-windows. If the three results are consistent, the corresponding level is directly taken; if the three results are inconsistent, the highest level is taken and then downgraded by 1 level as the current sub-window thermal accumulation level.

[0044] The cumulative morphology levels are fixed at 0, 1, 2, and 3. The corresponding ranges for off-plane displacement, boundary arc length variation, weld adjacent point spacing variation, and partition center point offset are all pre-defined by the parameter version bound to the current work order and issued synchronously with the work order. This step only compares each item according to the parameter version and does not allow on-site re-fileing. The formation order of the current sub-window morphology cumulative level is fixed as follows: first, compare the range of the off-plane displacement relative to the spherical correction reference; then, compare the ranges of the boundary arc length variation and weld adjacent point spacing variation; and finally, compare the range of the partition center point offset. If two or more of the four items fall into the same level range, then that level is taken as the current sub-window morphology cumulative level. If no two or more items fall into the same level range, then the highest level is taken and then downgraded by one level as the current sub-window morphology cumulative level. When the associated spherical correction partitions participate in the cumulative determination, the partitions corresponding to the adjacent mapping relationship are given priority. The direction of the change in the off-plane displacement and the distance between adjacent weld points of the target spherical correction partition and each adjacent partition is compared. When more than half of the adjacent partitions are consistent with the target spherical correction partition in most of the two aspects, it is recorded that the constraint coupling is established. For a single adjacent partition, if the direction of the off-plane displacement is consistent with the target spherical correction partition and the direction of the change in the distance between adjacent weld points is not reversed, or the direction of the change in the distance between adjacent weld points is consistent and the direction of the off-plane displacement is not reversed, it is recorded that the adjacent partition is consistent in direction. Then, the difference in the magnitude of the offset of the partition center point and the change in the boundary arc length between the target spherical correction partition and the symmetric mapping partition is compared to see if it exceeds the work order locking difference value. If it does not exceed, it is recorded as symmetric balance. If it exceeds, it is recorded as symmetric imbalance. Except for the aforementioned fixed specified quantities, no other quantities are called to participate in the associated partition determination. The constraint coupling result and the symmetric balance result are written into the partition deformation cumulative state.

[0045] When writing the current sub-window result, the thermal cumulative level and the morphological cumulative level are determined independently. The writing of the thermal cumulative level and the morphological cumulative level are independent of each other. If one condition is met, it does not depend on whether the other condition is met. When two consecutive sub-windows change in the same direction, only the corresponding item is written to the partition deformation cumulative state. When two consecutive sub-windows change in opposite directions, only the result of the latter sub-window is retained. The former sub-window is recorded as a fluctuation trace and does not participate in the automatic permission determination. After the observation window ends, the result of the last valid sub-window is used as the end state of the observation window. At the same time, all sub-window trajectories are retained for subsequent permission determination and review. Within the same weld bead, the end state of the previous observation window is inherited across observation windows. When a new weld bead starts, it is cleared and rebuilt.

[0046] The partition status markings are fixed and include four categories: normal acquisition, acquisition degradation, pending review, and prohibited access. These four statuses are mutually exclusive, with the priority order being prohibited access, pending review, acquisition degradation, and normal acquisition. When two or more of the three consecutive sub-windows are marked as acquisition degradation, only restricted records are generated for this round of partition deformation accumulation. Restricted records refer to partition deformation accumulation records that are only for manual review and subsequent trend viewing and cannot be directly used for automatic correction permission status determination.

[0047] After the zonal deformation cumulative state is generated, the process control terminal writes it to the manufacturing execution server. The stored content is fixed and includes the spherical tank number, work order number, zonal number, list of associated zonal numbers, weld number, session sequence number, thermal cumulative level, morphological cumulative level, constraint coupling result, symmetry balance result, zonal status marker, parameter version number, generator identifier, and timestamp. An idempotent key composed of the spherical tank number, work order number, zonal number, weld number, session sequence number, and parameter version number is generated. Only one valid record is allowed to be retained for the same idempotent key. When resubmitting, the earliest completed record with complete fields is used, and the remaining records are transferred to the repetition record area without overwriting the valid record. The record activation order is fixed as follows: first, solidify the thermal response information record, then solidify the morphological response information record, and finally solidify the zonal deformation cumulative state record. The absence of any preceding record will not trigger the activation of the subsequent record.

[0048] The communication method can be industrial Ethernet or fieldbus forwarded through a gateway. The minimum calling fields provided by the current step to the next step include the spherical tank number, partition number, weld number, session sequence number, thermal cumulative level, morphological cumulative level, constraint coupling result, symmetry balance result, partition status flag, parameter version number, and effective time. The returned status includes at least five categories: success, duplicate, missing test, unauthorized change, and version inconsistency, corresponding to codes 0, 1, 2, 3, and 4, respectively. When the communication delay exceeds the allowable waiting time for the current weld, the system does not block the welding machine from continuing to weld, but marks the current record as a delayed arrival status. When subsequent steps read this status, they are only allowed to cache and wait, and are not allowed to generate the correction permission status for this partition before this record.

[0049] During on-site inspection, sampling is conducted based on the work order locking ratio of the current shift's generated zonal deformation cumulative state records. The inspection items are fixed and include temperature record completeness rate, geometric record completeness rate, time alignment consistency rate, zonal status mark accuracy rate, and cumulative state recalculation consistency rate. The pass threshold for each inspection item is pre-given by the parameter version bound to the current work order and is issued synchronously with the work order. Among them, the temperature record completeness rate is the ratio of the number of temperature fields to be collected to the number of effective temperature fields actually collected; the geometric record completeness rate is the ratio of the number of geometric fields to be collected to the number of effective geometric fields actually collected; the time alignment consistency rate is the proportion of timestamps recorded by each device under the same session identifier that fall within the work order locking tolerance; and the cumulative state recalculation consistency rate is the proportion of records that are consistent with the original records after the thermal cumulative level, morphological cumulative level, and zonal status mark are regenerated according to the same parameter version. If any item is lower than the corresponding threshold, this step is re-executed for the zonal area involved in the current shift.

[0050] Preferably, in the installation condition of a spherical tank with a diameter of 18m and a plate thickness of 28mm, the observation window duration can be set to 240s, the sub-window rhythm to 20s, the acquisition rhythms of weld zone surface temperature, partition boundary temperature, and interlayer temperature to 1s, the acquisition rhythms of surface displacement and partition center point offset to 5s, the single interference value judgment amplitude to 15℃, the allowable time for missing measurements to 10s, and the number of acquisition degradation triggers to 3; during the continuous welding process of a certain longitudinal seam affecting a sub-partition, the target spherical correction partition and two first-level adjacent partitions jointly Sampling, at the end of one observation window, generates a partitioned deformation accumulation state record with thermal accumulation level 2, morphological accumulation level 1, constraint coupling established, and symmetry equilibrium established, which can be directly used for the next step; for example, in the field without infrared thermal imaging acquisition device, contact temperature measurement points can be used in conjunction with partition boundary temperature measurement points to complete thermal acquisition of the same diameter. As long as the partitioned deformation accumulation state is generated according to the same observation window, the same sub-window rhythm, the same accumulation rule, the same version locking rule, and the same traceability requirements, it belongs to the equivalent implementation form of this step.

[0051] S3. Based on the cumulative deformation state of the partition, the adjacency mapping relationship, the symmetry mapping relationship, and the spherical correction reference, determine the correction permission state and main release direction of the target spherical correction partition. The specific implementation is as follows: After the cumulative deformation state of the target spherical correction partition is solidified, the process control terminal on the welding station immediately starts the current round of judgment after the current weld observation window ends and the corresponding partition deformation cumulative state record takes effect. Under the same session identifier, it retrieves the thermal cumulative level, morphological cumulative level, constraint coupling result, symmetry balance result, partition status mark of the target spherical correction partition from the manufacturing execution server, as well as the adjacency mapping relationship, symmetry mapping relationship and spherical correction reference bound to the target spherical correction partition.

[0052] The correction permission status is the only state conclusion under the current welding process regarding whether the target spherical correction zone is allowed to enter the subsequent restricted correction parameter generation stage. It is obtained on-site at the end of the observation window corresponding to the current session identifier by comparing the zone deformation accumulation state, adjacency mapping relationship, symmetry mapping relationship and spherical correction benchmark item by item in a fixed order. The fixed values ​​include three categories: permission, non-permission and restricted permission. The three categories are mutually exclusive, and their priority is non-permission, restricted permission and permission in that order.

[0053] The main release direction is the sole directional conclusion used to constrain the subsequent correction action area and direction when the correction permission state is not "disallowed". It is determined on-site by comparing the out-of-plane displacement direction of the target spherical correction zone relative to the spherical correction reference, the direction of boundary arc length change, the direction of weld adjacent point spacing change, and the direction of zone center point offset, combined with the synchronous change direction of the corresponding zones according to the adjacency mapping relationship and symmetry mapping relationship. Fixed values ​​include five categories: outward convex release, inward retraction release, longitudinal seam extension release, circumferential seam extension release, and local retention. Adding other direction names on-site is not permitted. The radial direction pointing from the geometric center of the spherical tank to the zone surface is defined as the outer side, and is related to this... Radial opposite direction is defined as inside; the corresponding quantities are fixed as out-of-plane displacement, change in distance between adjacent weld points, offset of partition center point, and change in boundary arc length, and other quantities are not called to participate in the direction determination in this step; same-direction change is fixed as the corresponding quantity increases or decreases relative to its respective baseline value. If the absolute change value is less than the parameter version locking noise threshold, the quantity does not participate in the direction determination; opposite direction is fixed as the displacement direction corresponding to the main release direction is opposite to the change direction of the corresponding quantity of more than half of the effective adjacent partitions; direction non-dominant is fixed as less than 3 same-direction support items among the 4 items of out-of-plane displacement direction, partition center point offset direction, boundary arc length change direction, and weld adjacent point distance change direction.

[0054] The purpose of this setting is to base the judgment of whether correction is allowed and which direction to release in the priority on the same round of observation records and the same version of parameters, so as to avoid misjudging transient thermal expansion, local fluctuations or unstable states on the symmetrical side as correctable states. It is suitable for spherical tank manufacturing and on-site installation scenarios where the weld process is traceable, the partition boundaries are clear, and the cumulative state of the previous partition deformation has been effectively solidified. It is not suitable for scenarios where the cumulative state of partition deformation is still in a delayed arrival state, the partition state is marked as a prohibited call state, or the spherical correction reference has not taken effect.

[0055] To ensure consistency in judgment criteria, the process control terminal performs field integrity verification and version consistency verification after the session identifier takes effect. Field integrity verification specifically checks the partition number, session sequence number, thermal cumulative level, morphological cumulative level, constraint coupling result, symmetry balance result, partition status flag, adjacency mapping relationship version number, symmetry mapping relationship version number, and spherical correction reference version number. Version consistency verification specifically requires that the partition version number and parameter version number in the partition deformation cumulative state record, mapping relationship record, and spherical correction reference record are all consistent. If any field is missing or the version is inconsistent, the correction permission status is directly recorded as permissionless, and the partition status flag is updated to pending verification and written into the current round of records.

[0056] The order of determining the calibration permission status is fixed as follows: first, determine the partition status flag; then, determine the spherical calibration reference deviation status; then, determine the thermal cumulative level and morphological cumulative level; then, determine the symmetry balance result; and finally, determine the constraint coupling result. Among them, when the partition status flag is prohibited from being called, it is directly determined as not permitted; when the partition status flag is pending review, it is directly determined as not permitted; when the partition status flag is downgraded and the current record is a restricted record, it is determined as restricted permission; when the partition status flag is normal acquisition, subsequent determinations continue.

[0057] The spherical correction reference deviation status here refers to the deviation conclusion formed after comparing the out-of-plane displacement, boundary arc length change, weld adjacent point spacing change, and partition center point offset of the target spherical correction partition with the allowable deviation zone corresponding to the spherical correction reference item by item at the end of the observation window corresponding to the current session identifier. Specifically, after the result of the last valid sub-window takes effect, the measured deviation of each measuring point in that sub-window relative to the spherical correction reference is read, and each item is judged according to the preset allowable deviation zone in the parameter version. When all four items fall within the allowable deviation zone, it is recorded as within the reference; when one item falls within the allowable deviation zone, it is recorded as within the reference. If two items exceed the allowable deviation zone, it is recorded as outside the reference zone; if three or four items exceed the allowable deviation zone, it is recorded as significantly outside the reference zone. In the determination of the correction permission status, if the spherical correction reference deviation status is within the reference zone, it is directly judged as not permitted. If the spherical correction reference deviation status is outside the reference zone, it enters the determination of the thermal cumulative level and the morphological cumulative level. If the spherical correction reference deviation status is significantly outside the reference zone, and the partition status is marked as normal acquisition and the symmetric balance result is symmetric balance, it shall not be directly judged as not permitted simply because it is significantly outside the reference zone. It shall continue to determine permission or limited permission based on the constraint coupling result.

[0058] The ranges for both thermal cumulative level and morphological cumulative level use the fixed classifications pre-defined and synchronously issued by the current work order's bound parameter version in the previous step, and on-site reclassification is not allowed. The intermediate stable level and levels above the intermediate level are pre-specified by the current work order's bound parameter version. This step only calls upon these parameter versions and on-site modification is not allowed. The parameter version must include at least a thermal cumulative level classification table, a morphological cumulative level classification table, an intermediate stable level identifier, an intermediate level and above identifier, and a minimum permitted level and above identifier. If the thermal cumulative level reaches the highest level specified by the parameter version but the morphological cumulative level does not reach the minimum permitted level specified by the parameter version, it is directly judged as disallowed. If the thermal cumulative level is at the intermediate stable level specified by the parameter version and the morphological cumulative level reaches the intermediate level and above specified by the parameter version, it proceeds to the next judgment. If the thermal cumulative level is lower than the intermediate stable level but the morphological cumulative level reaches the intermediate level and above specified by the parameter version, it is judged as restricted permission.

[0059] When the symmetric balance result is symmetric imbalance, if the offset of the center point of the target spherical correction zone relative to the spherical correction reference and the change of the boundary arc length both exceed the work order locking difference, it will be directly judged as unpermitted. If only one item exceeds, it will be judged as restricted permission. When there is no symmetric mapping zone, it will not participate in the symmetric balance decision. The correction permission status will be determined only according to the zone status mark, the deviation status of the spherical correction reference, the thermal cumulative level, the morphological cumulative level, and the constraint coupling result.

[0060] If the constraint coupling result is valid, the ratio of the number of valid adjacent partitions changing in the same direction to the total number of valid adjacent partitions in the partition corresponding to the adjacency mapping relationship is compared. If the number of valid adjacent partitions is less than 2, the adjacency same-direction ratio is not used for adjacency determination, and the maximum judgment in this round is restricted permission. If the number of valid adjacent partitions is not less than 2, a ratio greater than 50% is counted as more than half, and a ratio less than or equal to 50% is not counted as more than half. Permission is only determined when the main release direction is opposite to the change direction of more than half of the valid adjacent partitions. If they are in the same direction, it is determined as restricted permission. If the number of valid adjacent partitions is not less than 2 and the same-direction ratio is less than or equal to 50%, it is considered that no majority constraint direction has been formed, and the judgment in this round is based on permission. If the constraint coupling result is invalid and no non-permission or restricted permission has been triggered in the previous sequence, it is directly judged as permission.

[0061] The determination order of the main release direction is fixed as follows: first, compare the offset direction of the target spherical correction zone's out-of-plane displacement relative to the spherical correction reference; then compare the offset direction of the zone's center point; subsequently, compare the change direction of the boundary arc length and the change direction of the weld's adjacent point spacing; finally, combine the synchronous change direction of the zones corresponding to the adjacency mapping relationship and the symmetry mapping relationship to make a consistency decision. When both the out-of-plane displacement and the zone's center point offset point outward from the spherical correction reference, and the boundary arc length change shows expansion and the weld's adjacent point spacing change shows an increase, it is recorded as an outward convex release. When both the out-of-plane displacement and the zone's center point offset point inward from the spherical correction reference, and the boundary arc length change shows contraction and the weld's adjacent point spacing change shows a decrease, it is recorded as an inward retraction release. When the out-of-plane displacement direction is not dominant, but the weld's adjacent point spacing change and the boundary arc length change are both along the longitudinal seam extension direction... When two consecutive sub-windows show expansion or contraction, it is recorded as longitudinal seam extension release; when the out-of-plane displacement direction is not dominant and the changes in the distance between adjacent weld points and the changes in the boundary arc length are both along the circumferential seam extension direction, two consecutive sub-windows show expansion or contraction, it is recorded as circumferential seam extension release; when none of the above four types of directions meet the majority consistency condition, or when the partition corresponding to the adjacency mapping relationship and the partition corresponding to the symmetric mapping relationship form opposite directional constraints on the target spherical correction partition, it is recorded as local retention; the majority consistency condition is fixed as at least three of the four items—out-of-plane displacement direction, partition center point offset direction, boundary arc length change direction, and weld adjacent point distance change direction—are consistent; the priority of the main release direction is fixed as convex release, inward release, longitudinal seam extension release, circumferential seam extension release, and local retention. When multiple directions are satisfied simultaneously, only the one with the highest priority is retained.

[0062] To prevent the main release direction from being affected by fluctuations at isolated measurement points, this step first performs noise reduction and verification on the direction-related signals, prioritizing the consistent state at the end of two consecutive observation windows as the condition for the final main release direction to be established; only when the current weld has not yet formed two end states at the end of observation windows is it allowed to use the consistency of two consecutive effective sub-windows within the same observation window as a substitute condition; if the directions are opposite, the end state of the latter observation window is taken as the standard and the former state is recorded as a fluctuation trace; if the direction conclusion is locally maintained, subsequent steps must not generate automatic amplification parameters, only conservative correction parameter sets are allowed to be generated, where automatic amplification parameters refer to the parameter files in the subsequent restricted correction parameters that are allowed to be output at a larger level, and conservative correction parameter sets refer to the parameter files in the subsequent restricted correction parameters that are only allowed to be output at the lowest level and the smallest effective range.

[0063] After completing this round of judgment, the process control terminal writes the correction permission status and main release direction to the manufacturing execution server. The stored content is fixed and includes the spherical tank number, work order number, partition number, weld number, session sequence number, correction permission status, main release direction, spherical correction reference deviation status, constraint coupling result, symmetry balance result, partition status mark, parameter version number, generator identifier, and timestamp. It also generates an idempotent key composed of the spherical tank number, work order number, partition number, weld number, session sequence number, and parameter version number. Only one valid record is allowed to be retained for the same idempotent key. When resubmitting, the earliest completed record with complete fields shall prevail, and the remaining records shall be transferred to the repetition record area without overwriting the valid record. The record activation order is fixed as follows: first, solidify the partition deformation cumulative state record, then solidify the correction permission status record, and finally solidify the main release direction record. If any preceding record is missing, the subsequent record shall not be activated.

[0064] The communication method can be industrial Ethernet or fieldbus forwarded through a gateway. The minimum calling fields provided by the current step to the next step include the spherical tank number, partition number, weld number, session sequence number, calibration permission status, main release direction, spherical calibration reference deviation status, parameter version number, and effective time. The return status includes at least five categories: success, duplicate, missing test, unauthorized change, and version inconsistency, corresponding to codes 0, 1, 2, 3, and 4, respectively. When the communication delay exceeds the allowable waiting time for the current weld, the system does not block the welding machine from entering the interlayer interval, but marks the current round of judgment record as delayed arrival. When subsequent steps read this status, they are only allowed to wait in the cache and are not allowed to generate restricted calibration parameters before this record. If the write fails, it can be retried according to the number of times locked in the current work order. If the limit is exceeded, the current round of session is frozen and a manual review prompt is issued. The review reason, the executor, and the handling result are written into the evidence chain record.

[0065] During on-site inspection, the work orders with generated correction permission status records for the current shift are sampled for inspection. The inspection items are fixed and include the permission status re-judgment consistency rate, the main release direction re-judgment consistency rate, the version consistency rate, the field completeness rate, and the delayed arrival handling consistency rate. The pass threshold for each inspection item is pre-given by the parameter version bound to the current work order and is issued synchronously with the work order. If any item is lower than the corresponding threshold, the partition involved in the current shift will re-execute this step.

[0066] Preferably, in the installation condition of a spherical tank with a diameter of 18m and a plate thickness of 28mm, the permissible threshold for the proportion of change in the same direction of adjacent partitions can be set to 60%, the threshold for the difference in the offset of the center point of the symmetrical side partition can be set to 3mm, the threshold for the difference in the boundary arc length can be set to 2mm, and the upper limit of the allowable deviation zone for the out-of-plane displacement can be set to 4mm; during the continuous welding process of a certain longitudinal seam affecting the sub-partition, the thermal cumulative level of the target spherical correction partition is level 2, the morphological cumulative level is level 2, the constraint coupling is established, the symmetry balance is established, the spherical correction reference deviation state is outside the reference, and the out-of-plane displacement and the partition center point If the offsets all point to the outside of the spherical correction reference, and the changes in boundary arc length and the distance between adjacent points of the weld increase for two consecutive observation windows, then the judgment result of this round is to take the correction permission state as permission, take the outward release direction as the main release direction, and directly use it for the next step; for example, in the field where there is no laser tracker, a fixed target measuring point can be used in conjunction with a displacement probe to complete the shape direction judgment. As long as the correction permission state and the main release direction are generated according to the same permission order, the same direction adjudication rules, the same parameter version locking rules, and the same trace requirements, they are all equivalent implementation forms of this step.

[0067] S4. When the calibration permission state is established, based on the main release direction, the spherical calibration reference, and the constraint state of the associated spherical calibration zone, the restricted calibration parameters of the target spherical calibration zone are generated, specifically as follows: After the calibration permission status and main release direction are solidified, the process control terminal at the welding station retrieves the calibration permission status, main release direction, spherical calibration reference deviation status, constraint coupling result, symmetry balance result, partition status mark, spherical calibration reference record, and the adjacency mapping relationship, symmetry mapping relationship, and latest effective partition deformation accumulation state record of the target spherical calibration partition from the manufacturing execution server under the same session identifier. The parameter generation for this round is completed within the allowable waiting period after the current weld arc ends. The restricted calibration parameters are a unique set of parameters that allow subsequent calibration actions on the target spherical calibration partition to be used, including the action area, action direction, action level, holding duration, and stop boundary, provided that the calibration permission status for this round has been established and the main release direction has been determined. The parameters are fixed and include 6 items: calibration action area, calibration action direction, calibration level, single holding duration, level switching condition, and stop boundary. Fields cannot be added or deleted on-site.

[0068] The constraint state of the associated spherical correction partition refers to the constraint conclusion formed by summarizing the latest cumulative state records of partition deformation, constraint coupling results, symmetry balance results, and partition state markings of all effective adjacent partitions and effective symmetric partitions in a fixed order during the parameter generation of this round. The fixed values ​​include three categories: low constraint, medium constraint, and high constraint. The three categories of states are mutually exclusive, and the decision priority is fixed as high constraint, medium constraint, and low constraint. When more than half of the effective adjacent partitions are in the same direction as the main release direction of the target spherical correction partition and more than two symmetry imbalances occur in the effective symmetric partitions, or any associated spherical correction partition is marked as a high constraint partition, it is recorded as a high constraint partition. When more than half of the effective adjacent partitions are in the same direction as the main release direction of the target spherical correction partition, or one symmetry imbalance occurs in the effective symmetric partition, it is recorded as a medium constraint partition. All other cases are recorded as low constraints partitions. When there are no symmetric mapping partitions, only the decision is made based on the effective adjacent partitions. If no majority direction is formed, it is directly recorded as a low constraint partition.

[0069] The purpose of this setting is not to directly equate the main release direction with the executable correction action, but to first combine the spherical correction reference deviation state and the constraint state of the associated spherical correction partition to compress the subsequent correction action to a limited range, so as to avoid applying excessive correction directly when the adjacent partition is still in the same direction expansion and contraction stage or the symmetrical side is still in the unbalanced stage.

[0070] To ensure consistency in parameter generation, the process control terminal performs field integrity and version consistency checks before generation. If any field is missing or the version is inconsistent, the restricted correction parameter is not generated, and the parameter generation status of this round is directly recorded as failed and written to the pending review log.

[0071] The generation order of the restricted correction parameters is fixed as follows: first, determine the correction action area; then, determine the correction action direction; then, determine the correction level; then, determine the single hold duration; and finally, determine the level switching conditions and stop boundary. The correction action area, after the main release direction has been determined, is the local area of ​​action formed by projecting the out-of-plane displacement measurement points, boundary arc length variation deviations, weld adjacent point spacing variation deviations, and partition center point offset deviations of the target spherical correction partition relative to the spherical correction reference onto the same partition boundary using spherical coordinates. This is defined at the end of the last effective observation window. After the state takes effect, all measurement points and segments exceeding the allowable deviation zone of the spherical correction reference are read and determined according to the closed range of continuous out-of-tolerance positions. Continuous out-of-tolerance positions are connected in the order of the numbers of adjacent measurement points or segments in the same partition. Only when the spherical arc length between adjacent out-of-tolerance points does not exceed the parameter version locking connection threshold is it considered continuous. If it exceeds the threshold, it is disconnected to form multiple action area candidates. When there are multiple action area candidates in the same partition, only the region with the largest cumulative out-of-tolerance amplitude is retained as the action area of ​​this round of correction. The remaining regions are written into the trace and do not participate in the generation of parameters in this round.

[0072] When the main release direction is outward convex release or inward retraction release, the correction action area is fixedly covered by the continuous closed area where the out-of-plane displacement deviation measurement point is located, and extends to both sides of the weld centerline according to the locked width of the parameter version; when the main release direction is longitudinal seam extension release, the correction action area is fixedly formed by the continuous deviation segment on both sides of the longitudinal seam centerline to form a strip area; when the main release direction is circumferential seam extension release, the correction action area is fixedly formed by the continuous deviation segment on both sides of the circumferential seam centerline to form a strip area; when the main release direction is local maintenance, only the minimum action area is generated. The minimum action area is fixed as a local area containing one set of continuous deviation measurement points and with a coverage length not less than the minimum action length of the parameter version, and the coverage range is not allowed to be expanded.

[0073] The direction of correction is fixed and directly mapped from the main release direction. When the main release direction is outward convex release, the direction of correction converges towards the inner side of the spherical correction reference; when the main release direction is inward retraction release, the direction of correction opens towards the outer side of the spherical correction reference; when the main release direction is longitudinal seam extension release, the direction of correction is taken along the longitudinal seam extension direction; when the main release direction is circumferential seam extension release, the direction of correction is taken along the circumferential seam extension direction; when the main release direction is locally maintained, the direction of correction is fixed as maintained, and automatic amplification parameters are not allowed to be issued.

[0074] The correction levels are fixed at 1, 2, and 3, with higher levels indicating a larger allowable correction range. Mechanical pressing only uses the displacement and pressure holding ranges, limit tension only uses the stroke and pressure holding ranges, and local thermal modulation only uses the heating and pressure holding ranges. The current equipment type is obtained by matching the equipment number sent by the equipment controller with the equipment list bound to the work order. If the matching fails, the restricted correction parameters cannot be generated.

[0075] The level tables corresponding to Levels 1, 2, and 3 are all pre-defined and synchronously issued by the parameter version bound to the current work order. This step only calls the level table corresponding to the current equipment type in the parameter version; on-site resetting is not allowed. When the spherical correction reference deviation status is outside the reference, the constraint status of the associated spherical correction partition is low constraint, and the correction permission status is permission, if there is 1 out-of-tolerance item, Level 2 is used; if there are 2 out-of-tolerance items, Level 3 is used. When the spherical correction reference deviation status is clearly outside the reference, it is only applied when the constraint status of the associated spherical correction partition is... Level 3 is allowed when there is low constraint and no symmetry restriction or symmetry imbalance; in other cases, the maximum level is 2. When the spherical correction reference deviation state is outside the reference and the constraint state of the associated spherical correction zone is medium constraint or the correction permission state is restricted permission, level 2 is allowed if symmetry balance is established, and level 1 is allowed if symmetry imbalance or local maintenance is achieved. When the spherical correction reference deviation state is obviously outside the reference and the constraint state of the associated spherical correction zone is high constraint, the maximum level allowed in this round is only 1. When the main release direction is local maintenance, the maximum level allowed in this round is only 1.

[0076] The single hold duration is fixed and is only constrained by the current device type and calibration level. It is no longer affected by the main release direction and constraint status. The value is directly called from the gear table corresponding to the current work order's bound parameter version.

[0077] The rapid retest result refers to the retest record of the displacement from the surface, the change of the boundary arc length, the change of the distance between adjacent points of the weld, and the offset of the partition center point after each single hold time expires, under the premise that the current session identifier remains unchanged. The rapid retest result is extracted from the morphological response quantity in the re-acquisition record. No other set of measurement actions is started separately. Its acquisition device, acquisition rhythm, allowable delay and valid fields are consistent with the previous step. In case of manual interruption, early equipment stoppage or communication delay, one rapid retest should still be completed under the current session identifier before proceeding to the subsequent decision.

[0078] The level switching condition is determined after each single hold duration expires by rereading the rapid retest results. The corresponding conditions for maintaining the current level and downgrading by 1 level are further determined by the subsequent hierarchical correction steps based on the rapid retest results. This step only generates the level switching condition field and the stop boundary field. Subsequent execution steps will make decisions based on the rapid retest results and the re-collection results.

[0079] A decrease in deviation means that the absolute deviation value of the same corresponding quantity exceeding the allowable deviation zone decreases relative to the previous rapid retest result; a reverse increase means that the direction of change of the corresponding quantity relative to the previous round of rapid retest is opposite to the direction of the current round of correction, and its absolute deviation value exceeding the allowable deviation zone increases.

[0080] The priority of the stop boundary is fixed as immediate stop, stop reached, and degraded continue; when the number of out-of-tolerance items increases, the symmetric mapping partition changes from balanced to unbalanced, the constraint status of the associated spherical correction partition changes from low or medium constraint to high constraint, and the partition status mark of the target spherical correction partition is updated to pending review or prohibited from being called, it is recorded as immediate stop; when all four corresponding quantities return to the allowable deviation zone, it is recorded as stop reached; when one or two items still have not returned to the allowable deviation zone, but the out-of-tolerance amount is smaller than the previous rapid retest, it is recorded as degraded continue; the counting starting point for two consecutive rapid retests is fixed as the first rapid retest after the expiration of the first single holding time of this round.

[0081] To prevent parameter generation from being affected by a single fluctuation, this step only allows the generation of a correction level of 2 or higher if the correction permission state remains valid in the end state of two consecutive observation windows, or if it remains valid in two consecutive rapid retests within the same observation window before the current weld bead has formed two end states. Otherwise, the highest level allowed in this round is only 1.

[0082] After completing the parameter generation for this round, the process control terminal writes the restricted correction parameters to the manufacturing execution server. The stored content is fixed and includes the spherical tank number, work order number, partition number, weld number, session sequence number, correction action area identifier, correction action direction, correction level, single hold duration, level switching conditions, stop boundary, constraint status of associated spherical correction partition, parameter version number, generator identifier, and timestamp. The stored content also includes parameter file type, which is fixed and includes conservative file, normal file, and amplified file. An idempotent key composed of spherical tank number, work order number, partition number, weld number, session sequence number, and parameter version number is generated. Only one valid record is allowed to be retained for the same idempotent key. When resubmitting, the earliest completed record with complete fields is used, and the remaining records are transferred to the repetition record area without overwriting the valid record. The record activation order is fixed as follows: first, the correction permission status record is fixed, then the main release direction record is fixed, and finally the restricted correction parameter record is fixed. The absence of any preceding record will not trigger the activation of the subsequent record.

[0083] The communication method can be industrial Ethernet or fieldbus forwarded through a gateway. The minimum calling fields provided by the current step to the next step include spherical tank number, partition number, weld number, session sequence number, correction action area identifier, correction action direction, correction level, single hold duration, stop boundary, constraint status of associated spherical correction partition, parameter version number, and effective time. The return status includes at least five categories: success, duplicate, missing test, unauthorized change, and version inconsistency, corresponding to codes 0, 1, 2, 3, and 4, respectively. When the communication delay exceeds the allowable waiting time for the current weld, the system does not block the field equipment from entering the safety lock waiting state for manual takeover, but marks the parameter record of this round as delayed arrival. When the subsequent steps read this status, they must not directly execute automatic correction, but only allow caching or manual review.

[0084] During on-site inspection, the work orders with restricted correction parameter records generated in the current shift are sampled for inspection according to the locked ratio. The inspection items are fixed and include parameter generation consistency rate, action area re-judgment consistency rate, level call consistency rate, stop boundary re-judgment consistency rate, version consistency rate, and field completeness rate. The pass threshold for each inspection item is pre-given by the parameter version bound to the current work order and is issued synchronously with the work order. If any item is lower than the corresponding threshold, the partition involved in the current shift will re-execute this step.

[0085] Preferably, in the installation condition of a spherical tank with a diameter of 18m and a plate thickness of 28mm, when the target spherical correction zone correction permission status is permitted, the main release direction is outward convex release, the spherical correction reference deviation status is outside the reference, and the constraint status of the associated spherical correction zone is in the middle constraint, the correction action area can be set as a continuous out-of-tolerance area of ​​150mm on both sides of the weld centerline, the correction action direction is set to converge toward the inside of the spherical correction reference, the correction level is set to level 2, the single holding time is set to 12s, and the stop boundary is set to the point where all four corresponding quantities return to the allowable deviation zone or the out-of-tolerance items increase in the opposite direction after two consecutive rapid retests; for example, in the field where there is no local heat modulation equipment, a mechanical pressing device or a limiting tension and compression device can also be used to generate restricted correction parameters of the same diameter. As long as the restricted correction parameters are formed according to the same parameter fields, the same level of adjudication rules, the same stop boundary, and the same version of locking rules, they are all equivalent implementation forms of this step.

[0086] S5. Based on the limited correction parameters, perform graded correction on the target spherical correction zone, and collect thermal response information and morphological response information again after each correction. The specific implementation is as follows: After the constrained correction parameters have been solidified in the previous step, the process control terminal at the welding station retrieves the correction action zone identifier, correction direction, correction level, single hold duration, level switching conditions, stop boundary, constraint status of associated spherical correction zones, parameter version number, and corresponding equipment type identifier from the manufacturing execution server under the same session identifier. Within the allowable waiting period after the current weld arc ends, it issues the correction execution command for this round to the field equipment. Graded correction refers to applying constrained amplitude, constrained duration, and constrained direction in stages to the correction action zone within the same target spherical correction zone, according to the determined correction level order in the constrained correction parameters. The first execution of this round is fixed from... Starting from the current correction level in the restricted correction parameter record, during this round of execution, only maintaining the current level or gradually lowering it is allowed; raising or lowering is not permitted, and after any level is terminated, it cannot be restored to a higher level. Mechanical pressing equipment is executed according to the action displacement level and action holding pressure level; limit tension and compression equipment is executed according to the action stroke level and action holding pressure level; local heat modulation equipment is executed according to the action heating level and action holding pressure level. The preparatory action for mechanical pressing is fixed as no-load alignment and pre-tightening to the zero-load baseline; for limit tension and compression, it is fixed as clamping closure and stroke returning to zero; for local heat modulation, it is fixed as heat source positioning and entering power standby. All equipment types are determined by corresponding to the equipment list bound to the work order through the equipment number. This step cannot be executed if the equipment identity does not match.

[0087] The purpose of this setup is to transform the limited correction parameters generated in the previous step into actionable actions on the ground. At the same time, by collecting thermal and morphological response information again after each correction, it is possible to determine whether the current level is still applicable, thus avoiding the occurrence of reverse shift of the target spherical correction zone, synchronous imbalance of the associated spherical correction zone, or out-of-tolerance on the symmetrical side due to continuous excessive correction.

[0088] To ensure consistency in execution, the process control terminal performs field integrity verification and version consistency verification before issuing each correction execution command. If any field is missing or the version is inconsistent, the graded correction will not be performed in this round, and a failure record will be generated directly with a manual review prompt.

[0089] When implementing graded correction, first locate the action point and action edge according to the correction action area identifier, then drive the equipment into the preparatory action according to the correction action direction, and then apply the single hold duration according to the gear table corresponding to the current correction level. When the single hold duration expires, the current level will automatically stop and enter the re-acquisition. The re-acquisition refers to the re-acquisition of the weld zone surface temperature, zone boundary temperature, interlayer temperature, temperature change rhythm, off-surface displacement, boundary arc length change, weld adjacent point spacing change and zone center point offset of the target spherical correction zone and associated spherical correction zone under the same session identifier after each single hold duration expires and the current level action stops. The acquisition name, unit, rhythm, tolerance, time alignment, coordinate alignment, number alignment, noise reduction rules and missing measurement completion rules all follow the aforementioned steps. The parameter version lock delay time is preset by the parameter version bound to the current work order according to the equipment type, and is used to wait for mechanical rebound decay or thermal inertia relief before allowing re-acquisition to start.

[0090] The validity of the re-acquisition results is determined by at least the formation of valid records for all four morphological response quantities and three thermal response quantities of the target spherical correction zone. If the associated spherical correction zone is missing a measurement, it is fixed as a conservative judgment. A conservative judgment means that automatic graded correction should not continue, the current round of graded correction should be terminated and the data should be transferred to manual review. At the same time, a conservative termination record should be written. The re-acquisition completeness rate is fixed as the ratio of the number of fields to be collected to the number of valid fields actually collected.

[0091] To avoid misjudgments caused by single equipment rebound or thermal inertia, the records generated after re-collection are first subjected to a stability retest after entering the process control terminal. The stability retest requires that at least three of the following parameters—displacement, change in distance between adjacent points of the weld, offset of the partition center point, and change in boundary arc length—show a decrease in the same direction compared to the same quantity before the current level execution, and that the sudden increase in interpass temperature and the reverse increase in surface temperature of the weld area do not exceed the parameter version lock threshold. If this condition is not met, this re-collection is only recorded as a fluctuation record. Fluctuation records, failure records, and conservative termination records are all recorded as different state values ​​in the evidence chain. This record is neither used as the basis for level switching nor as the basis for stop boundary. The automatic classification correction of this round is directly terminated and transferred to manual review. If this condition is met, the stop boundary judgment and level switching condition judgment are performed.

[0092] The execution order of stopping boundaries and level switching is fixed as follows: first determine the stopping boundary, then determine whether to continue downgraded. The priority of the stopping boundary is fixed as immediate stop, reaching stop, and continuing downgraded. When the number of out-of-tolerance items increases, the symmetric mapping partition changes from balanced to unbalanced, the constraint status of the associated spherical correction partition changes from low or medium constraint to high constraint, and the partition status mark of the target spherical correction partition is updated to pending review or prohibited from being called, it is recorded as immediate stop. When all four corresponding quantities return to the allowable deviation zone, it is recorded as reaching stop. When one or two items still have not returned to the allowable deviation zone, but their out-of-tolerance amount is reduced relative to the previous rapid retest result, it is recorded as continuing downgraded.

[0093] The rapid retest result refers to the retest record of the displacement from the surface, the change of the boundary arc length, the change of the distance between adjacent points of the weld, and the offset of the partition center point after each single hold period expires, under the premise that the current session identifier remains unchanged. The acquisition device, acquisition rhythm, allowable delay and valid fields are consistent with the previous step. In case of manual interruption, early equipment stoppage or communication delay, one rapid retest should still be completed under the current session identifier before proceeding to the subsequent decision. During the first rapid retest of this round, the result of the previous rapid retest is fixed to the baseline value of the same quantity before the execution of the current level. From the second rapid retest onwards, the result of the previous rapid retest is fixed to the record of the rapid retest immediately preceding the current round.

[0094] The level switching conditions are fixed as follows: if more than 2 of the 4 corresponding quantities have decreased in terms of out-of-tolerance amount compared to the previous rapid retest, and there are still more than 2 quantities that have not returned to the allowable deviation zone, then the level is downgraded by 1 level; if more than 2 of the 4 corresponding quantities have decreased in terms of out-of-tolerance amount, and there is only 1 quantity that has not returned to the allowable deviation zone, then the current level is maintained and the test is performed again; if more than 2 of the 4 quantities have not decreased or have increased in the opposite direction, then the current round of graded correction is terminated, the stop boundary judgment result is recorded as immediate stop, and the test is transferred to manual review.

[0095] If the current level is already level 1 and the downgrade continuation condition is met, only same-level maintenance is allowed. The counting starting point for two consecutive same-level maintenances is fixed at the completion of the first same-level maintenance after the first downgrade to level 1. If the stop is not reached after two consecutive same-level maintenances, the current round of graded correction is terminated and a conservative termination record is written.

[0096] To meet safety and compliance boundaries, during the graded calibration execution, the field equipment controller continuously monitors the upper limit of equipment displacement, the upper limit of pressure holding time, the upper limit of local temperature rise, and the personnel entry protection zone signal. The personnel entry protection zone signal is transmitted by the field safety light curtain, access control interlock, or area presence sensor. When any safety boundary is triggered, the current level action is immediately stopped and a re-acquisition is performed. This re-acquisition is written into the level execution record, but it will not enter the level switching chain again. The stop boundary judgment result of this round is fixed as immediate stop. The current equipment safety lock state is fixed as stop drive, maintain clamping constraint, or disconnect thermal power and retain equipment positioning.

[0097] After completing this round of execution, the process control terminal generates a level execution record for each level of calibration process. The minimum field set of the gear table is fixed, including gear number, gear value, value unit, applicable equipment type and parameter version number. The fields are written into the execution record in a fixed order. The level execution record, the re-acquisition record, and the level switching conclusion record are fixed in the order of execution, acquisition, and conclusion. If any preceding record is missing, the subsequent record shall not be triggered.

[0098] When communication is delayed, subsequent steps must not be upgraded to a higher level. If the current level is higher than level 1, it is only allowed to maintain the current level once before being transferred to manual review. If the current level is level 1, it is directly transferred to manual review and automatic level correction is not allowed.

[0099] During on-site inspection, the work orders that have undergone graded correction in the current shift are sampled for inspection. The inspection items are fixed and include graded execution consistency rate, re-collection completeness rate, stop boundary re-judgment consistency rate, retest stability judgment consistency rate, version consistency rate, and field completeness rate. The pass threshold for each inspection item is pre-given by the version of the parameter bound to the current work order and is issued synchronously with the work order. If any item is lower than the corresponding threshold, the relevant partitions in the current shift will re-execute this step.

[0100] Preferably, in the installation condition of a spherical tank with a diameter of 18m and a plate thickness of 28mm, when the target spherical surface correction zone is performed by mechanical jacking equipment for graded correction, the current correction level is level 2, and the single holding time is 12s, a 3s delay can be allowed after each level to start the re-acquisition, and the thermal response information and morphological response information can be re-measured within a 20s acquisition window; if the deviation of the out-of-surface displacement and the deviation of the zone center point offset decrease after the first level, but one of the boundary arc length change and the weld adjacent point spacing change still has not returned to the allowable deviation zone, then the current level is maintained and the operation is performed again. If subsequent... If the stop is not reached, the level is downgraded to level 1. If all four morphological response quantities return to the allowable deviation range after the second acquisition, the current round of graded correction is terminated and the stop boundary judgment result is recorded as having reached the stop. For example, in the absence of mechanical pressing equipment, limit tensioning equipment or local thermal modulation equipment can be used to implement graded correction according to the same session identifier, the same level execution order, the same re-acquisition rules, the same stop boundary priority, and the same version locking rules. After each level of correction, thermal response information and morphological response information are acquired again, which are all equivalent implementation forms of this step.

[0101] S6. Based on the re-acquisition results, determine the spherical continuity status of the target spherical correction zone, and update the correction permission status of subsequent spherical correction zones to be welded. The specific implementation is as follows: After the previous step has completed the recording and solidification of graded correction execution records, re-acquisition records, stop boundary judgment results, and grade switching conclusions, the process control terminal at the welding station retrieves the last valid re-acquisition record of the target spherical correction partition, the spherical correction reference record, the adjacency mapping relationship, the symmetry mapping relationship, the latest valid partition deformation cumulative state record of the associated spherical correction partition, and the list of subsequent spherical correction partitions to be welded from the manufacturing execution server under the same session identifier. Within the allowed waiting period after the current weld bead ends, the spherical continuity status judgment and correction permission status update for this round are completed. The spherical continuity status refers to the continuity conclusion formed by the target spherical correction partition's displacement from the surface, boundary arc length change, weld adjacent point spacing change, and partition center point offset relative to the spherical correction reference and adjacent partition boundary transition relationship after completing this round of graded correction and re-acquisition. Fixed values ​​include three categories: continuous, restricted continuous, and discontinuous. The three categories are mutually exclusive, with the priority order being discontinuous, restricted continuous, and continuous.

[0102] To ensure consistency in judgment criteria, the process control terminal performs field integrity verification and version consistency verification before this round of judgment. If any field is missing or the version is inconsistent, the continuous spherical state is not generated. Instead, the target spherical correction partition is directly recorded as discontinuous, and the correction permission status of the subsequent spherical correction partitions to be welded is uniformly updated to disallowed. At the same time, it is written into the pending verification record.

[0103] The determination order of the continuous state of the spherical surface is fixed as follows: first, determine the reference regression state; then, determine the boundary transition state; and finally, determine the symmetry coordination state. The reference regression state is the regression conclusion formed after the last valid re-acquisition record takes effect. The displacement from the surface, the change of the boundary arc length, the change of the distance between adjacent points of the weld, and the offset of the center point of the partition are compared with the allowable deviation zone of the spherical surface correction reference item by item. When all four items fall within the allowable deviation zone, it is recorded as complete regression. When one item does not regress or one item is missing, it is recorded as partial non-regression. When two or more items do not regress, it is recorded as obvious non-regression.

[0104] The boundary transition state is determined by pairing boundary measurement points on the closed curve of the target spherical correction partition boundary with boundary measurement points of all effective adjacent partitions at the same boundary position within the same time period, and comparing the difference in surface deviation and the difference in boundary arc length between corresponding boundary points. Boundary measurement points are paired one-to-one according to their boundary point numbers. If a number is missing, it is supplemented according to the principle of closest spherical arc length. The same boundary point is only allowed to participate in pairing once. Measurement points that cross the boundary of the opening constraint sub-partition do not participate in pairing. The number of effective pairing points is lower than the parameter version locking lower limit, which means that the number of effective pairing points formed by a single shared boundary between the target spherical correction partition and a single effective adjacent partition is lower than the minimum pairing number threshold corresponding to the shared boundary, rather than the sum of all adjacent boundary pairings. When the difference of all paired boundary points falls within the parameter version locking transition threshold, it is called a smooth transition. When only some boundary points exceed the transition threshold and the number of exceedances does not exceed the parameter version locking ratio, it is called a restricted transition. When the number of exceedances exceeds the ratio or the number of effective pairing points is lower than the parameter version locking lower limit, it is called a broken transition.

[0105] The symmetric coordination state is a coordination conclusion formed after the last valid re-acquisition record takes effect, by comparing the offset of the center point of the target spherical correction partition and the change of the boundary arc length with the same quantity of the partition corresponding to the symmetric mapping relationship. When the difference falls within the parameter version locking coordination threshold, it is recorded as symmetric coordination. When only one item exceeds the coordination threshold or the symmetric mapping partition exists but its latest valid re-acquisition record is missing, it is recorded as symmetric restriction. When both items exceed the coordination threshold, it is recorded as symmetric imbalance. When there is no symmetric mapping partition, it does not participate in the symmetric coordination state adjudication, and only the spherical continuity state is determined according to the baseline regression state and the boundary transition state.

[0106] The decision order for the continuous state of a sphere is fixed as follows: first, determine discontinuity; then, determine restricted continuity; and finally, determine continuity. When the baseline regression state is clearly non-regressive, or the boundary transition state is a transitional break, or the symmetric coordination state is symmetrically unbalanced, it is directly determined as discontinuous. When the baseline regression state is locally non-regressive, or the boundary transition state is a transitional restriction, or the symmetric coordination state is symmetrically restricted, and no discontinuity condition is triggered, it is determined as restricted continuity. It is determined as continuous only when the baseline regression state is fully regressive, the boundary transition state is a smooth transition, and the symmetric coordination state is symmetrically coordinated, or there is no symmetric mapping partition and the first two terms reach the optimal conclusion. The optimal conclusion for the baseline regression state is fixed as fully regressive, the optimal conclusion for the boundary transition state is fixed as a smooth transition, and the optimal conclusion for the symmetric coordination state is fixed as symmetrically coordinated.

[0107] Subsequent spherical correction zones to be welded refer to spherical correction zones that have not yet been ignited and welded after the current weld pass, and that have a direct adjacency, symmetrical mapping, or welding sequence influence relationship with the target spherical correction zone in the welding plan, and that require readjustment of the correction permission status based on the current spherical continuity status. The generation order of the list of subsequent spherical correction zones to be welded is fixed as follows: first, all spherical correction zones to be welded are screened out from the list of incomplete weld passes in the current work order; then, they are tagged item by item according to direct adjacency, symmetrical mapping, and welding sequence influence relationship; finally, duplicates are removed and a unique list is formed in the order that direct adjacency takes precedence over symmetrical mapping, and the latter takes precedence over welding sequence influence relationship. The welding sequence influence relationship is fixed as the spherical correction zone to be welded that is listed after the corresponding weld pass of the target spherical correction zone in the welding sequence table of the current work order, and that is in the same zone as the target spherical correction zone or shares the same weld intersection zone.

[0108] The update order for correction permission status is fixed as follows: direct adjacency relationships take precedence over symmetric mapping relationships, which in turn take precedence over welding sequence influence relationships. When the same subsequent spherical correction partition to be welded hits multiple types of relationships, only the highest priority type is updated. When the spherical continuity state of the target spherical correction partition is continuous, the subsequent spherical correction partitions directly adjacent to it retain their original correction permission status. The subsequent spherical correction partitions corresponding to its symmetric mapping, if originally in a restricted permission state, are restored to permission. Only subsequent spherical correction partitions with welding sequence influence relationships retain their original state. When the spherical continuity state of the target spherical correction partition is restricted continuity, the subsequent spherical correction partitions directly adjacent to it, if originally in a permission state, are uniformly downgraded to restricted permission. Those originally in a restricted permission or non-permission state remain unchanged. The subsequent spherical correction partitions corresponding to its symmetric mapping, if originally in a permission state, retain permission but are written to a restricted view. The restricted observation mark means that when a partition enters the pre-arc correction permission state call chain, it must undergo one continuous state verification and cannot be skipped directly. The restricted observation mark is removed when the corresponding subsequent spherical correction partition to be welded completes the pre-arc correction continuous state verification and the verification result reaches continuity. Only subsequent spherical correction partitions to be welded that have a welding sequence before and after influence relationship retain their original state. When the spherical continuity state of the target spherical correction partition is discontinuous, the subsequent spherical correction partitions to be welded that are directly adjacent to it are uniformly updated to disallowed. The subsequent spherical correction partitions to be welded that are originally permitted or restricted permitted according to its symmetric mapping are uniformly updated to restricted permitted. Only subsequent spherical correction partitions to be welded that are originally permitted according to the welding sequence before and after influence relationship are updated to restricted permitted. The rest remain unchanged. Among them, only when the welding sequence before and after influence relationship does not form a direct geometric constraint, it is not directly prohibited due to the discontinuity of the target partition, but only a level 1 reduction processing is performed.

[0109] To prevent fluctuations from a single re-acquisition from overly restricting subsequent spherical correction zones to be welded, this step first performs a continuity stability check on the continuous state of the spherical surface. Only when the continuous state of the same spherical surface remains consistent in two consecutive valid re-acquisition records, or when the current weld bead only forms one valid re-acquisition record but the baseline regression state, boundary transition state, and symmetry coordination state when there is a valid symmetry mapping zone all reach the optimal conclusion, is it permissible to update the correction permission state of the subsequent spherical correction zones to be welded according to the above rules. As long as a symmetry mapping zone exists but its latest valid re-acquisition record is missing, the shortcut of updating with only one valid re-acquisition record shall not be applied. If the above conditions are not met, this round only generates continuous state observation traces and does not update the correction permission state of the subsequent spherical correction zones to be welded.

[0110] After completing this round of judgment and update, the process control terminal writes the spherical continuous state record and the correction permission status update record to the manufacturing execution server. The minimum set of fields for the spherical continuous state record is fixed, including spherical tank number, work order number, target partition number, weld number, session sequence number, baseline regression status, boundary transition status, symmetry coordination status, spherical continuous state, parameter version number, generator identifier, and timestamp. The minimum set of fields for the correction permission status update record is fixed, including spherical tank number, work order number, target partition number, subsequent spherical correction partition number to be welded, relationship type, correction permission status before update, correction permission status after update, update reason, parameter version number, generator identifier, and timestamp. Among these, the relationship type is fixed, including direct adjacency relationship, symmetric mapping relationship, and welding sequence before and after influence relationship. The update reason is fixed, including continuous maintenance, continuous recovery, and restricted degradation. Discontinuous prohibition and manual review freezing; when maintaining the original status, restoring to permitted, downgrading to restricted permitted, or updating to unpermitted, a new version of the correction permitted status update record is generated without overwriting the original record. Maintaining the original status means that the correction permitted status before and after the update has the same value, but a new status update record is still generated. Restoring to permitted means that a new permitted status record is generated while retaining the historical record. Automatic release means that the corresponding subsequent spherical correction partition to be welded is allowed to directly enter the pre-arc correction permitted status call chain according to the current work order. When the same subsequent spherical correction partition to be welded receives multiple update results in the same work order and the same weld stage, the decision is made according to the relationship priority and update time order, with the higher priority overriding the lower priority. When the priorities are the same, the later result with the same version shall prevail. When the priorities are the same, if the later result is more lenient than the earlier result, the stricter result shall be retained.

[0111] When communication is delayed, subsequent processes should not automatically allow the corresponding subsequent spherical correction partition to be welded. If the delay status continues to exceed the current work order's lockout waiting limit, it will be switched to manual review and will no longer be cached.

[0112] During on-site inspection, random checks are conducted based on the locked proportion of work orders that have generated continuous spherical state records for the current shift. The inspection items are fixed and include the consistency rate of continuous state re-judgment, the consistency rate of boundary transition state re-judgment, the consistency rate of symmetric coordination state re-judgment, the consistency rate of permitted state update, the version consistency rate, and the field completeness rate. The pass threshold for each inspection item is pre-given by the version of the parameter bound to the current work order and is issued synchronously with the work order. If any item is lower than the corresponding threshold, the partition involved in the current shift will re-execute this step.

[0113] Preferably, in the installation condition of a spherical tank with a diameter of 18m and a plate thickness of 28mm, when the last effective re-acquisition record after the target spherical correction zone completes the graded correction shows that all four morphological response quantities have returned to the allowable deviation zone, more than 95% of the differences among the paired points of adjacent zone boundaries fall into the transition threshold, and 95% is the boundary transition qualification ratio set in the parameter version under the corresponding working condition, and the difference between the offset of the center point of the symmetrical mapping zone and the change in the boundary arc length does not exceed the coordination threshold, the spherical continuity state of this round is determined to be continuous, the two subsequent spherical correction zones directly adjacent to it maintain the original correction permission state unchanged, and the one subsequent spherical correction zone corresponding to its symmetrical mapping is restored from restricted permission to permission; for example, in the field without a laser tracker, fixed target measuring points can also be used in conjunction with a total station to complete the boundary transition state and symmetrical coordination state determination, as long as the same session identifier, the same continuous state adjudication order, the same permission state update rule and the same version locking rule are still used to generate the spherical continuity state and update the correction permission state of the subsequent spherical correction zones to be welded, it is all an equivalent implementation form of this step.

[0114] All calculations involved in the embodiments are dimensionless numerical calculations, and the preset parameters and thresholds in the calculations are set by those skilled in the art according to the actual situation.

[0115] It should be noted that this invention can be deployed on the device itself to realize embedded applications, or it can run on a PC or other terminal with a user interface, thereby meeting various hardware environments and usage requirements.

[0116] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, as a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, all or part of the processes or functions described in the embodiments of this application are generated. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via wireless or wired transmission; wired transmission methods include optical fiber, twisted pair, coaxial cable, etc.; wireless transmission includes infrared, microwave, etc. The computer-readable storage medium can be any available medium that a computer can access or a data storage device such as a server or data center containing one or more sets of available media. The available medium can be a magnetic medium (e.g., floppy disk, hard disk, magnetic tape), an optical medium (e.g., DVD), or a semiconductor medium. A semiconductor medium can be a solid-state drive.

[0117] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and modules described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0118] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of modules is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple modules or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or modules may be electrical, mechanical, or other forms.

[0119] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical modules; they may be located in one place or distributed across multiple network modules. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0120] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0121] If the aforementioned functions are implemented as software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0122] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0123] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for online correction of welding deformation in spherical tanks, characterized in that, include: S1. Divide the spherical correction zones according to the welding area of ​​the spherical tank, establish the adjacency mapping relationship and symmetry mapping relationship of each spherical correction zone, and generate the spherical correction reference corresponding to each spherical correction zone. S2. Collect the thermal response information and morphological response information of the target spherical correction zone and associated spherical correction zones according to the current welding process, and generate the cumulative deformation state of the target spherical correction zone. S3. Based on the cumulative deformation state of the partition, the adjacency mapping relationship, the symmetric mapping relationship, and the spherical correction reference, determine the correction permission state and main release direction of the target spherical correction partition; S4. When the calibration permission state is established, generate the restricted calibration parameters of the target spherical calibration zone based on the main release direction, the spherical calibration reference and the constraint state of the associated spherical calibration zone. S5. Based on the limited correction parameters, perform graded correction on the target spherical correction zone, and collect thermal response information and morphological response information again after each correction. S6. Based on the results of the re-collection, determine the spherical continuity status of the target spherical correction zone and update the correction permission status of the subsequent spherical correction zones to be welded.

2. The method for online correction of welding deformation of a spherical tank according to claim 1, characterized in that, S1 includes: The primary partition is defined by the nominal boundary of a single spherical shell plate; Within the primary zone, divide the longitudinal seam influence sub-zones along both sides of the longitudinal seam centerline, and divide the circumferential seam influence sub-zones along both sides of the circumferential seam centerline. The overlapping portion of the longitudinal joint influence sub-zone and the circumferential joint influence sub-zone is divided into an intersection sub-zone; Based on the preset distance of the parameter version bound to the current work order, divide the opening constraint sub-partition outside the outer edge of the opening.

3. The method for online correction of welding deformation of a spherical tank according to claim 1, characterized in that, Generate spherical calibration references for each spherical calibration zone, including: Generate the nominal spherical surface of the entire tank according to the design radius and the geometric center of the spherical tank, and cut the nominal base surface of the partition according to the current spherical surface correction partition boundary; Compare the initial measured points before welding with the nominal datum plane of the partition; The overall translation correction is determined based on the weighted offset of the effective measured points relative to the nominal datum of the partition, and the attitude correction is determined based on the offset difference between the boundary points and the partition center point, and a spherical correction reference is formed accordingly.

4. The online correction method for welding deformation of a spherical tank according to claim 1, characterized in that, S2 include: Based on the weld sequence, weld position and partition version number in the current work order, lock the spherical correction partition that is being welded as the target spherical correction partition; Identify spherical correction partitions that have an adjacency mapping relationship or a symmetric mapping relationship with the target spherical correction partition and are in an allowed call state as associated spherical correction partitions; Thermal response information and morphological response information were collected within the target spherical correction zone and associated spherical correction zones. Within the observation window, a sub-window is captured, and the thermal cumulative level and morphological cumulative level are determined separately and written into the partition deformation cumulative state. The results of constraint coupling and symmetric equilibrium are written into the partitioned deformation cumulative state.

5. The method for online correction of welding deformation of a spherical tank according to claim 1, characterized in that, S3 includes: The correction permission status is determined in the following order: partition status mark, spherical correction reference deviation status, thermal cumulative level, morphological cumulative level, symmetry balance result, and constraint coupling result. The main release direction is determined by following the order of displacement direction, partition center point offset direction, boundary arc length change direction, and weld adjacent point spacing change direction, combined with the synchronous change direction of the partitions corresponding to the adjacency mapping relationship and the partitions corresponding to the symmetric mapping relationship.

6. The method for online correction of welding deformation of a spherical tank according to claim 1, characterized in that, S4 includes: The latest effective partition deformation cumulative state records, constraint coupling results, symmetry balance results and partition state markers of all effective adjacent partitions and effective symmetric partitions are summarized in a fixed order to determine the constraint state of the associated spherical correction partition. The constraint states are fixed as low constraint, medium constraint, and high constraint.

7. The method for online correction of welding deformation of a spherical tank according to claim 6, characterized in that, S4 also includes: After the constraint state of the associated spherical correction zone has been determined, the correction action area, correction action direction and correction level are determined according to the main release direction and spherical correction reference. The single hold duration is determined based on the current equipment type and calibration level; and the level switching conditions and stop boundaries are generated.

8. The online correction method for welding deformation of a spherical tank according to claim 1, characterized in that, S5 include: Locate the application point and application edge according to the correction application area mark, drive the corresponding equipment into the preparatory action according to the correction application direction, and apply the single holding duration according to the gear table corresponding to the current correction level. After the duration of a single hold expires, the current level is stopped, and thermal response information and morphological response information are collected again under the same session identifier; Based on the results of the re-collection, the stop boundary determination and the level switching condition determination are performed.

9. The online correction method for welding deformation of a spherical tank according to claim 1, characterized in that, S6 include: The determination is made in the order of baseline regression state, boundary transition state, and symmetric coordination state. The continuous state of the sphere is determined based on the results of the baseline regression state, boundary transition state, and symmetric coordination state. Based on the continuous state of the spherical surface, the correction permission status of the subsequent spherical correction zones to be welded is updated in the order of direct adjacency, symmetric mapping, and the influence of welding sequence.

Images