A flexible steel pipe production system and its working method

Abstract

This invention discloses a flexible steel pipe production system and its operating method, belonging to the field of steel pipe deep processing technology. It includes a first automated storage and retrieval system (AS / RS) extending along its length. At least one upstream production line is arranged along its length on one side of the first AS / RS, and at least one downstream production line is arranged along its length on the other side. A second AS / RS is located beside the end of the first AS / RS. The first AS / RS has multiple portal openings along its length, each with a transport mechanism connected to a corresponding upstream or downstream production line. A first stacker crane is installed inside the first AS / RS, and this stacker crane connects to each transport mechanism. This invention improves the level of automation throughout the entire production process, reduces manual intervention and overhead crane handling, and solves the problems of large footprint, low efficiency, complex scheduling, and unstable production quality in existing steel pipe deep processing production systems.

Description

Technical Field

[0001] This invention relates to the field of deep processing technology for steel pipes, specifically to a flexible steel pipe production system and its working method. Background Technology

[0002] In existing technologies, steel pipe deep processing workshops generally adopt a traditional model of decentralized layout with manual assisted transfer. Specifically, each main equipment, such as cold drawing machines, heat treatment furnaces, straightening machines, and flaw detectors, is arranged independently. Each piece of equipment is equipped with a dedicated loading and unloading platform or material basket. The transfer of semi-finished steel pipes between the various pieces of equipment mainly relies on overhead cranes or cross-haul trucks within the workshop for transshipment. To alleviate the problem of mismatched production capacity between different processes, a large number of intermediate temporary storage racks for semi-finished products are also set up in the workshop. This traditional layout has many drawbacks: First, the equipment is scattered and the processes are loosely connected, making production organization and scheduling complex. Especially in the scenario of multiple specifications and small batch orders, it is difficult to flexibly adjust the production process, which can easily lead to the accumulation of semi-finished products or order delays. Moreover, since semi-finished products need to be stored on a flat surface or in simple elevated storage, they occupy a huge amount of workshop space and affect the space utilization rate.

[0003] Meanwhile, during the transfer of semi-finished products, overhead cranes and cross-pass cranes are used very frequently, which not only results in high energy consumption and maintenance costs, but also easily leads to transportation congestion and scheduling conflicts, causing production rhythm disorder. Furthermore, frequent hoisting and transfer can easily scratch the surface of steel pipes or cause collisions and deformation, affecting the processing accuracy of products. Summary of the Invention

[0004] To address the problems existing in the prior art, this invention provides a flexible steel pipe production system and its working method, which features a flexible line process layout, can improve the degree of automation of the entire production process, reduce manual intervention and overhead crane handling, and solve the problems of large footprint, low efficiency, complex scheduling and unstable production quality in the existing steel pipe deep processing production system.

[0005] The technical solution of the present invention is as follows: In a first aspect of the present invention, a flexible steel pipe production system is provided, including a first automated warehouse, the first automated warehouse extending along its own length direction, at least one upstream production line arranged along its length direction on one side of the first automated warehouse, at least one downstream production line arranged along its length direction on the other side of the first automated warehouse, and a second automated warehouse arranged beside the end of the first automated warehouse. The first automated warehouse has multiple door-shaped openings along its length, and each door-shaped opening is equipped with a transport mechanism. Each transport mechanism is connected to the corresponding upstream or downstream production line. The first automated warehouse is equipped with a first stacker crane, which is connected to various transportation mechanisms.

[0006] In some embodiments of the present invention, the upstream production line includes a seamless pipe production line, a welded pipe production line, a first heat treatment line and a second heat treatment line. The seamless pipe production line, the welded pipe production line, the first heat treatment line and the second heat treatment line are all extended along the length direction of the first automated warehouse, and the seamless pipe production line, the welded pipe production line, the first heat treatment line and the second heat treatment line are arranged sequentially along the width direction of the first automated warehouse. The second heat treatment line is located close to the first automated storage and retrieval system, the first heat treatment line is located on the side of the first heat treatment line away from the first automated storage and retrieval system, the welded pipe production line is located on the side of the first heat treatment line away from the second heat treatment line, and the seamless pipe production line is located on the side of the welded pipe production line away from the first heat treatment line.

[0007] In some embodiments of the present invention, the downstream production line includes a first finishing line, a second finishing line, a first oil-immersion cold drawing production line, and a second oil-immersion cold drawing production line. The first finishing line, the second finishing line, the first oil-immersion cold drawing production line, and the second oil-immersion cold drawing production line extend along the length direction of the first automated warehouse and are arranged sequentially.

[0008] In some embodiments of the present invention, the second automated storage and retrieval system is located at the end of the first automated storage and retrieval system, and the second automated storage and retrieval system is connected to the first automated storage and retrieval system via an inter-storage lateral transport chain, and a second stacker crane is installed inside the second automated storage and retrieval system.

[0009] In some embodiments of the present invention, the first automated storage and retrieval system is a single-lane automated storage and retrieval system, which is equipped with multiple cantilever racks, and the cantilever racks have multiple virtual material positions.

[0010] In some embodiments of the present invention, the transport mechanism includes an outlet transverse transport chain of a first heat treatment line, an inlet transverse transport chain of a second heat treatment line, and an outlet transverse transport chain. The lateral transport chain of the first finishing line, and the lateral transport chain of the second finishing line; The inlet and outlet transverse transport chains of the first oil-immersion cold drawing production line, and the inlet and outlet transverse transport chains of the second oil-immersion cold drawing production line.

[0011] In a second aspect of the invention, a method for operating a flexible steel pipe production system is provided, wherein after the upstream production line completes processing, rows of steel pipes are transferred to the corresponding transport mechanism. The first stacker crane in the first automated warehouse retrieves rows of steel pipes from the transport mechanism and stores them in the vacant material locations within the first automated warehouse; When a downstream process needs to be executed, the first stacker crane takes out a row of steel pipes from the corresponding material position and places them on the transport mechanism corresponding to the downstream process. The downstream production line receives the row of steel pipes for processing. After processing, the rows of steel pipes are returned by the transportation mechanism and stored again in the first automated warehouse by the first stacker crane. The first stacker crane performs debris sorting during the intervals when there are no transport tasks, moving semi-finished products from scattered idle material areas to continuous idle areas.

[0012] In some embodiments of the present invention, when a heat treatment process is required, the first stacker takes out the row of steel pipes from the first automated warehouse and places them on the furnace-entry transverse conveyor chain of the second heat treatment line. The steel pipes after being treated by the second heat treatment line are returned by the furnace-exit transverse conveyor chain of the second heat treatment line, and the first stacker stores them in the first automated warehouse. Alternatively, the first stacker crane will transfer rows of steel pipes to the second automated warehouse via a transverse transport chain between the automated warehouses, and the second stacker crane in the second automated warehouse will then transport them to the first heat treatment line.

[0013] In some embodiments of the present invention, when the oil immersion and cold drawing process needs to be performed, the first stacker takes out the row of steel pipes from the first automated warehouse and places them on the inlet transverse conveyor chain of the first oil immersion and cold drawing production line or the second oil immersion and cold drawing production line. The steel pipes after oil immersion and cold drawing are returned by the outlet transverse conveyor chain corresponding to the first oil immersion and cold drawing production line or the second oil immersion and cold drawing production line, and the first stacker puts them back into the first automated warehouse.

[0014] In some embodiments of the present invention, when steel pipes need to be taken out of the warehouse, the first stacker crane takes out rows of steel pipes from the first automated warehouse, places them in the inbound / outbound area equipment, and transfers them to the collection basket. When external steel pipes enter the warehouse, the rows of steel pipes, after being loosely bundled, divided, and aligned, are placed in the equipment in the warehouse entry and exit area, and the first stacker crane takes them away and stores them in the first automated warehouse.

[0015] One or more technical solutions of the present invention have the following beneficial effects: By placing the first automated warehouse in the center of the workshop, with all upstream and downstream production lines surrounding it on both sides and directly connected by portal frames and transverse transport chains, a fully enclosed material flow is achieved, where steel pipes are directly stored in the warehouse after coming off the upstream line and then automatically delivered to any downstream process by a stacker crane.

[0016] The automated storage and retrieval system transforms semi-finished products from flat stacking to three-dimensional storage, completely eliminating large-area ground storage areas. The first stacker crane, the second stacker crane, and the transportation mechanism completely replace overhead cranes for hoisting, avoiding the collisions and scratches of steel pipes during frequent handling.

[0017] After each process is completed, the semi-finished products are returned to the first automated warehouse for temporary storage, which completely decouples the production lines. The production management system can dynamically adjust the processing path according to order requirements. Any equipment shutdown or production change will not affect the continuous operation of other lines, which significantly improves the scheduling efficiency and space utilization in multi-variety, small-batch scenarios and realizes fully automated flexible production line production for deep processing of steel pipes. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the layout of a flexible steel pipe production system provided in Embodiment 1 of the present invention; Figure 2 This is a schematic diagram of the layout of the three-dimensional inter-warehouse transverse transport chain provided in Embodiment 1 of the present invention.

[0019] In the diagram: 1. Seamless pipe production line, 2. Welded pipe production line, 3. First heat treatment line, 4. Second heat treatment line, 5. First finishing line, 6. Second finishing line, 7. First oil-immersion cold drawing production line, 8. Second oil-immersion cold drawing production line, 9. First automated warehouse, 10. Second automated warehouse, 11. Horizontal transport chain between automated warehouses. Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] Example 1 In a typical embodiment of the present invention, such as Figure 1 As shown, a flexible steel pipe production system includes a first automated storage and retrieval system (AS / RS) 9. The AS / RS 9 extends along its length and is arranged in a long strip shape in the central area of ​​the workshop. Multiple upstream production lines are arranged along one side of the AS / RS 9 along its length, and multiple downstream production lines are arranged along the other side of the AS / RS 9 along its length. A second automated storage and retrieval system (AS / RS 10) is located beside the end of the AS / RS 9.

[0022] This structure, centered on an automated storage and retrieval system (AS / RS) with production lines arranged around it, completely transforms the traditional chaotic situation of scattered equipment and piles of semi-finished products. AS / RS 9 serves as a unified storage and transfer hub for semi-finished steel pipes, eliminating the need for ground-level stacking and long-distance overhead crane transport of materials. Upstream and downstream production lines are located on opposite sides, creating a clear flow of materials: steel pipes enter the AS / RS from upstream and are then distributed downstream for finishing. This layout significantly shortens material handling paths, laying the foundation for fully automated flexible production.

[0023] The first automated storage and retrieval system (AS / RS) 9 has multiple portal-shaped openings along its length. Each portal-shaped opening is equipped with a transport mechanism, which connects to the corresponding upstream or downstream production line. The length of the portal-shaped opening is greater than the maximum length of the steel pipe, and the height meets the requirements for the lateral movement of the steel pipe, ensuring smooth passage. The transport mechanism is specifically a lateral transport chain, used to move rows of steel pipes from external equipment into the first AS / RS 9, or to receive steel pipes transported by a stacker crane and move them laterally to the docking station outside the warehouse.

[0024] Through the design of the portal and transport mechanism, the first automated warehouse 9 is physically connected directly with the surrounding production lines. There is no longer a need for overhead cranes or cross-trains to transfer steel pipes between equipment. The incoming and outgoing materials of each process are automatically completed through a fixed-path transport chain, which greatly reduces the risk of manual intervention and hoisting damage.

[0025] The first automated warehouse 9 is equipped with a first stacker crane, which is connected to various transportation mechanisms. The first stacker crane consists of a vehicle body, a traveling mechanism, a lifting mechanism, a lifting frame, and forks, and can travel along tracks in the aisles of the first automated warehouse 9 and move up and down in the vertical direction.

[0026] The first stacker crane can retrieve rows of steel pipes from any transport mechanism and store them in any available location within the first automated storage and retrieval system 9; it can also retrieve steel pipes from any location and place them on any transport mechanism. This flexible retrieval capability makes the first automated storage and retrieval system 9 a highly intelligent transfer station.

[0027] The first stacker crane can also perform a repositioning operation, which involves organizing fragmented materials in the storage area during periods of no work, merging scattered idle locations, and continuously maximizing storage capacity. The automatic operation of the first stacker crane completely replaces the frequent lifting of semi-finished products by overhead cranes in traditional workshops, improving efficiency and avoiding scratches on the surface of steel pipes.

[0028] like Figure 1 As shown, the upstream production lines include a seamless pipe production line 1, a welded pipe production line 2, a first heat treatment line 3, and a second heat treatment line 4. These production lines all extend along the length of the first automated storage and retrieval system 9 and are arranged sequentially along its width. Specifically, the second heat treatment line 4 is located close to the first automated storage and retrieval system 9, the first heat treatment line 3 is located on the side of the first heat treatment line 3 away from the first automated storage and retrieval system 9, the welded pipe production line 2 is located on the side of the first heat treatment line 3 away from the second heat treatment line 4, and the seamless pipe production line 1 is located on the side of the welded pipe production line 2 away from the first heat treatment line 3.

[0029] This layout fully considers the raw material sources and process integration requirements of each production line. Seamless pipe production line 1 and welded pipe production line 2, as the initial production stages of steel pipes, are located on the outermost side for easy raw material input. The first heat treatment line 3 and the second heat treatment line 4 need to frequently exchange materials with the first automated storage and retrieval system 9, so they are located close to the automated storage and retrieval system, and rapid connection is achieved through their respective transportation mechanisms.

[0030] Seamless tube production line 1 is equipped with hot rolling equipment such as heating furnace, piercing mill, sizing mill, cooling bed and sawing machine to complete the rolling, cooling and length sawing of seamless tubes from round billets. At the end of the production line, there is a row of steel pipe collection platform.

[0031] The welded pipe production line 2 is equipped with an uncoiler, looper, forming machine, high-frequency welding system, sizing machine and sawing machine, which produces welded pipes from strip steel and cuts them into fixed lengths.

[0032] The two heat treatment lines are respectively equipped with a wide roller conveyor for furnace entry, a heating furnace, a lifting chain conveyor for furnace exit, and a wide roller conveyor for furnace exit.

[0033] The steel pipes produced by seamless pipe production line 1 and welded pipe production line 2 are first temporarily stored in the second automated storage and retrieval system 10, or directly transported to the first heat treatment line 3 via a transport mechanism. The first heat treatment line 3 and the second heat treatment line 4 are connected to the first automated storage and retrieval system 9 through their respective transverse transport chains, enabling automatic material handling. This layout allows the entire process of steel pipe production from blank production to heat treatment to be completed entirely by automated transport lines and stacker cranes without the need for overhead cranes.

[0034] The downstream production lines include a first finishing line 5, a second finishing line 6, a first oil-immersion cold drawing production line 7, and a second oil-immersion cold drawing production line 8. These production lines all extend along the length of the first automated storage and retrieval system 9 and are arranged sequentially along its length. Specifically, as follows... Figure 1 As shown, from left to right, they are the first finishing line 5, the second finishing line 6, the first oil-immersion cold drawing production line 7, and the second oil-immersion cold drawing production line 8.

[0035] The first finishing line 5 and the second finishing line 6 are used for the final processing of steel pipes, such as straightening, flaw detection, sawing, collection and packaging. The first oil-immersion cold drawing production line 7 and the second oil-immersion cold drawing production line 8 are used for the processes of bundling, oil immersion, draining, cold drawing, cutting and arranging steel pipes.

[0036] The downstream production line is located on the other side of the first automated warehouse 9, opposite the upstream production line, making the path of steel pipes from upstream to downstream clear and avoiding logistics intersections and congestion. Each downstream production line connects to the door openings of the first automated warehouse 9 through its own transverse transport chain to achieve automatic loading and unloading.

[0037] The first automated storage and retrieval system (AS / RS) 9 is a single-aisle AS / RS with multiple cantilever racks inside, each with multiple virtual storage locations. Multiple cantilever racks are arranged along the length of the aisle, with each layer spaced at a certain distance in the height direction to accommodate steel pipe storage and the working distance of the stacker crane forks.

[0038] Virtual storage locations are logical storage positions defined based on the length and number of layers of the stored steel pipes. This adapts to the production needs of steel pipes of varying lengths, maximizing storage capacity through layout adjustments. Since virtual storage locations may create gaps during production, the stacker crane will automatically organize the fragments according to rules during off-peak hours, continuously maintaining maximum storage capacity. This automated storage method transforms the large amount of workshop floor space occupied by traditional planar stacking into upward-expanding space, significantly improving workshop area utilization.

[0039] The second automated storage unit 10 is located at the end of the first automated storage unit 9. Specifically, as follows... Figure 1 As shown, the second automated warehouse 10 is located to the left of the first automated warehouse 9, and is adjacent to the left end of the seamless pipe production line 1, the welded pipe production line 2, the first heat treatment line 3 and the second heat treatment line 4. The second automated warehouse 10 and the first automated warehouse 9 are connected by an inter-warehouse transverse transport chain 11. A second stacker crane is installed inside the second automated warehouse 10.

[0040] The second automated storage and retrieval system (AS / RS) 10 is a multi-aisle AS / RS, and the second stacker crane is a long material stacker crane that can span across aisles. The main function of the second AS / RS 10 is to expand intermediate storage capacity and serve as the first-level buffer for incoming materials from seamless pipe production line 1 and welded pipe production line 2.

[0041] The rows of steel pipes on the end collection platform of seamless pipe production line 1 are picked up by the second stacker crane and stored in the second automated warehouse 10. The rows of steel pipes produced by welded pipe production line 2 are transported to the second automated warehouse 10 through the welded pipe finished product wide roller conveyor.

[0042] The second stacker crane can also retrieve rows of steel pipes from any material location within the second automated storage and retrieval system 10 and transport them to the furnace feed roller conveyor of the first heat treatment line 3, or send the steel pipes to the inter-automatic storage and retrieval system transverse transport chain 11 to interact with the first automated storage and retrieval system 9.

[0043] The transport mechanism specifically includes multiple transverse transport chains. Specifically, these include: the furnace exit transverse transport chain of the first heat treatment line 3; the furnace inlet transverse transport chain and the furnace exit transverse transport chain of the second heat treatment line 4; the transverse transport chain of the first finishing line 5; the transverse transport chain of the second finishing line 6; the inlet transverse transport chain and the outlet transverse transport chain of the first oil-immersion cold drawing production line 7; and the inlet transverse transport chain and the outlet transverse transport chain of the second oil-immersion cold drawing production line 8.

[0044] Each traverse conveyor chain is positioned at the corresponding gate opening of the first automated storage and retrieval system (AS / RS) 9. One end extends into AS / RS 9 and connects to the first stacker crane, while the other end connects to the loading or unloading equipment of the corresponding production line. This configuration allows any production line to independently exchange materials with AS / RS 9 without interference. The production management system can dynamically determine which production line a batch of steel pipes should next enter based on order requirements, and the stacker crane and traverse conveyor chains automatically execute the instructions.

[0045] The following is combined with Figure 1 and Figure 2 Provide a detailed explanation of how this system works.

[0046] First, after the upstream production line completes processing, rows of steel pipes are transferred to the corresponding transportation mechanism.

[0047] For example, after the seamless pipe production line 1 completes rolling and sawing, rows of steel pipes are sent to the collection platform at their end, and the second stacker in the second automated warehouse 10 takes the steel pipes away and stores them in the material position of the second automated warehouse 10. The rows of steel pipes produced by welded pipe production line 2 are directly fed into the second automated warehouse 10 via a wide roller conveyor. The steel pipes treated in the first heat treatment line 3 are moved laterally to their respective exit conveyor chains via an exit lifting chain conveyor; the steel pipes treated in the second heat treatment line 4 are moved laterally to their respective exit conveyor chains via an exit lifting chain conveyor. All conveying mechanisms are driven by an automated control system, requiring no manual intervention.

[0048] The first stacker crane in the first automated storage and retrieval system (AS / RS) 9 retrieves rows of steel pipes from the transport mechanism and stores them in available locations within AS / RS 9. Specifically, when steel pipes are on the transverse conveyor chain of the first heat treatment line 3, the first stacker crane moves to the corresponding portal, extends its forks to pick up the rows of steel pipes, then moves along the aisle and rises and falls to the selected available location, placing the steel pipes on the cantilever rack. The system simultaneously records information such as the storage location, specifications, and completed processes for this batch of steel pipes. Because AS / RS 9 has a large number of virtual locations, it can simultaneously store semi-finished steel pipes from different upstream production lines and different batches. In this way, the capacity difference between processes is no longer a bottleneck; if the upstream process is producing quickly, the pipes can be temporarily stored in the AS / RS, and if the downstream process is producing slowly, it will not cause the upstream process to stop.

[0049] When downstream processes are required, the first stacker crane retrieves rows of steel pipes from the corresponding storage location and places them on the transport mechanism corresponding to the downstream process. The downstream production line receives the rows of steel pipes for processing. For example, when a batch of steel pipes needs to be sent to the first finishing line 5 for straightening and flaw detection, the production management system issues an instruction. The first stacker crane locates the storage location of the batch of steel pipes according to the records, retrieves the pipes, and transports them to the loading station of the first finishing line 5. Subsequently, the steel pipes enter the finishing line and pass through the straightener, flaw detector, saw, and collection and packaging machine in sequence. After processing, the rows of steel pipes are returned via the transport mechanism and stored again in the first automated storage and retrieval system 9 by the first stacker crane. If the batch of steel pipes requires further processing, it is retrieved from the automated storage and retrieval system and sent to the corresponding downstream production line; if all processes have been completed, it awaits release from the warehouse. This model of returning to the warehouse after each process completely decouples the production lines, making production scheduling extremely flexible.

[0050] When a heat treatment process is required, there are two paths to choose from: The first path: The first stacker crane removes rows of steel pipes from the first automated warehouse 9 and places them on the furnace-entry transverse conveyor chain of the second heat treatment line 4. This furnace-entry transverse conveyor chain transports the steel pipes to the furnace-entry lifting conveyor of the second heat treatment line 4, and then they are conveyed into the heating furnace of the second heat treatment line 4 by the furnace-entry wide roller conveyor. After heat treatment, the steel pipes are output from the furnace-exit wide roller conveyor, and then retrieved by the furnace-exit lifting conveyor chain and transversely moved to the furnace-exit transverse conveyor chain of the second heat treatment line 4. The first stacker crane removes the processed steel pipes from this conveyor chain and stores them in the first automated warehouse 9.

[0051] The second approach: When the first heat treatment line 3 is needed, the first stacker crane moves rows of steel pipes to the second automated warehouse 10 via the inter-warehouse lateral conveyor chain 11. The second stacker crane in the second automated warehouse 10 then transports the pipes to the furnace feed roller conveyor of the first heat treatment line 3. After processing by the first heat treatment line 3, the steel pipes are returned to the first automated warehouse 9 via its furnace discharge lateral conveyor chain. Both approaches can be flexibly selected to fully utilize the capacity of different heat treatment lines and avoid equipment idleness or congestion.

[0052] When the oil-immersion cold drawing process is required, the first stacker crane retrieves rows of steel pipes from the first automated storage and retrieval system 9 and places them on the inlet transverse conveyor chain of the first oil-immersion cold drawing production line 7 or the second oil-immersion cold drawing production line 8. The inlet transverse conveyor chain delivers the steel pipes to the bundled material baskets of that production line. After being collected and bundled, the steel pipes undergo sequential processes such as oil immersion, draining, cold drawing, and end cutting. The end-cut steel pipes are then grouped and sent to the outlet transverse conveyor chain of the same production line.

[0053] The export lateral conveyor chain returns the rows of steel pipes to the portal of the first automated storage and retrieval system (AS / RS) 9, where the first stacker crane stores them again. Because two parallel oil-immersion cold-drawing production lines are installed, the system can automatically select the most suitable line for processing based on the current workload, steel pipe specifications, and process requirements, achieving load balancing and rapid response. The entire oil-immersion cold-drawing process requires no manual handling of the steel pipes; it is entirely completed by the automated conveyor chain and stacker crane, avoiding surface contamination or damage to the steel pipes caused by manual handling before and after oil immersion.

[0054] When steel pipes need to be shipped out, the first stacker crane retrieves rows of steel pipes from the first automated warehouse 9 and places them on the corresponding transverse conveyor chain in the inbound / outbound area. They are then moved to a collection basket to await shipment. The inbound / outbound area equipment is located at one end of the workshop, such as... Figure 1 The area shown is located on the right side of the second oil-immersion cold drawing production line 8. This area is also equipped with mechanical devices for unbundling, separating, and aligning steel pipes. When external steel pipes need to enter this production system for further processing, bundled steel pipes are hoisted into unbundled material baskets. After unbundling, separating, and aligning, rows of steel pipes are transported to the transverse conveyor chain of the inbound / outbound warehouse area. The first stacker crane retrieves them and stores them in the first automated warehouse 9, thus entering the workshop production system. In this way, this system can process steel pipes produced by the upstream production line in this workshop, and can also accept external materials for processing, greatly improving the system's utilization rate and flexibility.

[0055] As described above, the flexible steel pipe production system provided by this invention uses the first automated warehouse 9 as its core, with all upstream and downstream production lines arranged around it. Fully automated material transfer is achieved through portal frames, transverse transport chains, and stacker cranes. This layout completely solves the problems of dispersed equipment, reliance on overhead cranes for transport, extremely large footprint of intermediate semi-finished products, and complex production scheduling in traditional steel pipe deep processing workshops.

[0056] In traditional workshops, steel pipes are stacked on the ground or simple racks after each process, occupying a significant amount of workshop space and easily damaged by overhead cranes during transport. In this method, all semi-finished steel pipes are stored vertically on cantilever racks in the first automated storage and retrieval system (AS / RS) 9, eliminating the need for ground storage and significantly improving workshop space utilization. Stacker cranes and transverse conveyor chains replace overhead cranes. Steel pipes come directly from upstream production lines, including seamless pipe production line 1 and welded pipe production line 2, into the first AS / RS 9, and are then automatically conveyed to the next process, maintaining a neat, orderly arrangement throughout. This avoids surface scratches and deformation caused by lifting and collisions, making it particularly suitable for precision steel pipes with high surface quality requirements.

[0057] Secondly, the system dynamically determines the processing route for each batch of steel pipes based on order demand and equipment load. Whether to perform heat treatment or cold drawing first, whether to use the first heat treatment line 3 or the second heat treatment line 4, and whether to proceed to the first oil-immersion cold drawing production line 7 or the second oil-immersion cold drawing production line 8, all can be flexibly configured. Since the semi-finished steel pipes return to the first automated warehouse 9 after each process instead of flowing directly to fixed equipment, the production lines are completely decoupled. Any equipment shutdown for maintenance or production change will not affect the continuous production of other lines. For orders with multiple varieties and small batches, this model allows for rapid switching of process routes without the need for manual adjustments to equipment layout or material handling, significantly improving scheduling efficiency.

[0058] Furthermore, the virtual material location and fragment sorting functions ensure that the first automated storage and retrieval system (AS / RS) 9 always maintains its maximum effective capacity, avoiding storage waste caused by scattered material locations. The system automatically distinguishes between high-turnover and low-turnover semi-finished steel pipes, storing frequently accessed pipes in shallow areas near the gate openings to reduce stacker crane travel distance and improve retrieval speed; while placing long-term temporarily stored semi-finished steel pipes in deeper areas to optimize overall operational efficiency. External materials can also be seamlessly integrated, being sorted by equipment in the inbound and outbound areas before being stored, thus integrating into the existing semi-finished steel pipe management system and expanding the system's processing capacity. The second automated storage and retrieval system (AS / RS) 10 and the first AS / RS 9 exchange materials via an inter-AS / RS lateral transport chain 11, further enhancing buffering capacity.

[0059] Finally, the system records key data such as the location, completed processes, and number of cold drawing passes for each batch of steel pipes, providing a basis for automated decision-making in subsequent processes. During multi-pass cold drawing, the system can accurately identify the current state of the steel pipes, avoiding duplicate processing or missed steps. This information-based management not only reduces the error rate of manual recording and judgment but also provides data support for production optimization and quality management.

[0060] In this embodiment, the single-aisle structure and cantilever rack design of the first automated storage and retrieval system (AS / RS) 9 enable the stacker crane to quickly access steel pipes at any location. The virtual storage location ensures maximum utilization of storage space. The second AS / RS 10, serving as supplementary storage and an upstream buffer, seamlessly connects with the first AS / RS 9 via an inter-AS / RS lateral transport chain 11, forming a two-tiered storage system that further enhances the system's buffering capacity and scheduling flexibility. The four upstream production lines and four downstream production lines are all independently connected to the AS / RS, with no direct material transport channels between them, avoiding logistics crossovers and interference and simplifying the transportation paths within the workshop. Each production line is equipped with a dedicated lateral transport chain, minimizing the transfer distance and time of materials from the AS / RS to the equipment loading point.

[0061] For the heat treatment process, this embodiment provides two independent processing lines, each equipped with a transverse conveyor chain for furnace entry and exit, achieving fully automated material handling during the heat treatment process. After being retrieved from the automated storage and retrieval system (AS / RS), the steel pipes pass through a transverse conveyor chain, a lifting chain conveyor, and a wide roller conveyor before entering the heating furnace. After heat treatment, they return to the AS / RS via the same route. Throughout the entire process, the steel pipes move along a fixed trajectory, preventing collisions with other equipment or objects and ensuring safe handling at high temperatures. For the oil-immersion and cold drawing process, the system also automatically bundles, immerses, cold draws, cuts, and rows the finished steel pipes. The exit transverse conveyor chain neatly rows the finished steel pipes and returns them to the AS / RS, avoiding the cumbersome manual placement and hoisting of the steel pipes after oil immersion in traditional processes.

[0062] The first finishing line 5 and the second finishing line 6 are each equipped with a slitting machine, which separates the rows of steel pipes brought in by the transverse conveyor chain into individual pipes, which are then sequentially fed into a straightening machine. The straightened steel pipes then undergo non-destructive testing by a flaw detector; defective pipes are automatically rejected, while qualified pipes are cut to length or trimmed by a saw, and finally packaged by a collection and packaging machine. Finished steel pipes can be put back into storage for shipment as needed, or shipped directly. The two finishing lines are arranged side-by-side, allowing for the simultaneous processing of steel pipes of different specifications or batches without interference, significantly improving the throughput of the finishing process.

[0063] From the perspective of the overall production process, this system supports multiple typical process routes. For example, steel pipes produced by seamless pipe production line 1 can directly enter the second automated storage and retrieval system 10, and then be conveyed by the second stacker crane to the first heat treatment line 3 for heat treatment. After heat treatment, the steel pipes are sent to the first automated storage and retrieval system 9, and then allocated to the first oil-immersion cold drawing production line 7 for cold drawing according to order requirements. Finally, they enter the first finishing line 5 for straightening and flaw detection before being released from the warehouse. As another example, steel pipes produced by welded pipe production line 2 can first be stored in the second automated storage and retrieval system 10, and then conveyed to the first automated storage and retrieval system 9 via the inter-warehouse lateral transport chain 11. They are then allocated to the second heat treatment line 4 for heat treatment, subsequently sent to the second oil-immersion cold drawing production line 8 for cold drawing, and finally enter the second finishing line 6 for finishing. Furthermore, externally sourced steel pipes can directly enter the first automated storage and retrieval system 9 through the inbound / outbound area equipment, and then flexibly select subsequent processes according to process requirements. All these paths are automatically planned and executed by the production management system without manual intervention or adjustment of equipment layout.

[0064] In traditional workshops, semi-finished steel pipes require multiple overhead crane lifts. Each lift can result in scratches, dents, or even bends due to collisions with wire ropes, hooks, or other pipes. In this system, after the steel pipes come off the upstream production line, they are first neatly arranged in rows and then smoothly transferred to a stacker crane or conveyor chain via a wide roller conveyor or collection platform. The stacker crane's forks employ a specially designed cantilever structure, with all contact points with the steel pipes made of soft materials or smooth surfaces to prevent scratches. When stored in the automated warehouse, the pipes on each cantilever rack are arranged parallel and separated, avoiding stacking and deformation. During heat treatment and oil immersion cold drawing processes, the steel pipes are always kept in rows as they pass through the equipment, preventing any individual pipes from falling off. These measures ensure that the final product meets the stringent surface quality requirements of the petrochemical, machinery, and other industries.

[0065] This system also has good scalability and maintainability. When a new production line needs to be added, simply install a new transverse conveyor chain at the door-shaped hole reserved on the corresponding side of the first automated warehouse 9 and connect the new production line to it without changing the overall layout.

[0066] In addition, the software architecture of the production management system supports multiple scheduling algorithms, which can continuously optimize the scheduling strategy based on actual production data to improve system efficiency.

[0067] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A flexible steel pipe production system, characterized in that, It includes a first automated warehouse, which extends along its own length direction. At least one upstream production line is arranged on one side of the first automated warehouse along its length direction, and at least one downstream production line is arranged on the other side of the first automated warehouse along its length direction. A second automated warehouse is arranged on the side of the end of the first automated warehouse. The first automated warehouse has multiple door-shaped openings along its length, and each door-shaped opening is equipped with a transport mechanism. Each transport mechanism is connected to the corresponding upstream or downstream production line. The first automated warehouse is equipped with a first stacker crane, which is connected to various transportation mechanisms.

2. The flexible steel pipe production system as described in claim 1, characterized in that, The upstream production line includes a seamless pipe production line, a welded pipe production line, a first heat treatment line, and a second heat treatment line. The seamless pipe production line, the welded pipe production line, the first heat treatment line, and the second heat treatment line all extend along the length direction of the first automated warehouse, and are arranged sequentially along the width direction of the first automated warehouse. The second heat treatment line is located close to the first automated storage and retrieval system, the first heat treatment line is located on the side of the first heat treatment line away from the first automated storage and retrieval system, the welded pipe production line is located on the side of the first heat treatment line away from the second heat treatment line, and the seamless pipe production line is located on the side of the welded pipe production line away from the first heat treatment line.

3. The flexible steel pipe production system as described in claim 1, characterized in that, The downstream production lines include a first finishing line, a second finishing line, a first oil-immersion cold drawing production line, and a second oil-immersion cold drawing production line. The first finishing line, the second finishing line, the first oil-immersion cold drawing production line, and the second oil-immersion cold drawing production line extend along the length of the first automated warehouse and are arranged sequentially.

4. The flexible steel pipe production system as described in claim 1, characterized in that, The second automated storage and retrieval system is located at the end of the first automated storage and retrieval system. The second automated storage and retrieval system is connected to the first automated storage and retrieval system via an inter-storage lateral transport chain. A second stacker crane is installed inside the second automated storage and retrieval system.

5. The flexible steel pipe production system as described in claim 1, characterized in that, The first automated storage and retrieval system is a single-lane automated storage and retrieval system with multiple cantilever racks inside, and the cantilever racks have multiple virtual material positions.

6. The flexible steel pipe production system as described in claim 1, characterized in that, The transport mechanism includes a furnace exit transverse transport chain for the first heat treatment line, a furnace inlet transverse transport chain for the second heat treatment line, and a furnace outlet transverse transport chain. The lateral transport chain of the first finishing line, and the lateral transport chain of the second finishing line; The inlet and outlet transverse transport chains of the first oil-immersion cold drawing production line, and the inlet and outlet transverse transport chains of the second oil-immersion cold drawing production line.

7. The working method of a flexible steel pipe production system as described in any one of claims 1-6, characterized in that, After the upstream production line completes processing, rows of steel pipes are transferred to the corresponding transportation mechanism; The first stacker crane in the first automated warehouse retrieves rows of steel pipes from the transport mechanism and stores them in the vacant material locations within the first automated warehouse; When a downstream process needs to be executed, the first stacker crane takes out a row of steel pipes from the corresponding material position and places them on the transport mechanism corresponding to the downstream process. The downstream production line receives the row of steel pipes for processing. After processing, the rows of steel pipes are returned by the transportation mechanism and stored again in the first automated warehouse by the first stacker crane. The first stacker crane performs debris sorting during the intervals when there are no transport tasks, moving semi-finished products from scattered idle material areas to continuous idle areas.

8. The working method of the flexible steel pipe production system as described in claim 7, characterized in that, When a heat treatment process is required, the first stacker crane takes out rows of steel pipes from the first automated warehouse and places them on the furnace-entry transverse conveyor chain of the second heat treatment line. After being treated by the second heat treatment line, the steel pipes are returned by the furnace-exit transverse conveyor chain of the second heat treatment line, and the first stacker crane stores them in the first automated warehouse. Alternatively, the first stacker crane will transfer rows of steel pipes to the second automated warehouse via a transverse transport chain between the automated warehouses, and the second stacker crane in the second automated warehouse will then transport them to the first heat treatment line.

9. The working method of the flexible steel pipe production system as described in claim 7, characterized in that, When the oil immersion and cold drawing process is required, the first stacker crane takes out the row of steel pipes from the first automated warehouse and places them on the inlet transverse conveyor chain of the first or second oil immersion and cold drawing production line. After the oil immersion and cold drawing process, the steel pipes are returned by the corresponding outlet transverse conveyor chain of the first or second oil immersion and cold drawing production line, and the first stacker crane puts them back into the first automated warehouse.

10. The working method of the flexible steel pipe production system as described in claim 7, characterized in that, When steel pipes need to be taken out of the warehouse, the first stacker crane will take out rows of steel pipes from the first automated warehouse, place them in the equipment in the warehouse entry and exit area, and move them to the collection basket. When external steel pipes enter the warehouse, the rows of steel pipes, after being loosely bundled, divided, and aligned, are placed in the equipment in the warehouse entry and exit area, and the first stacker crane takes them away and stores them in the first automated warehouse.

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