Ship outfitting integrated construction method and collaborative management system

Abstract

The application discloses a ship outfitting piece integrated construction method and a collaborative management system, and belongs to the technical field of ship construction; in view of the problems of multi-specialty cross interference, difficult overhead welding and vertical welding operation and low section transfer efficiency in traditional section outfitting, the application moves the installation process of the outfitting piece to the small group erection or middle group erection stage of the structure, and completes the flat welding, flat angle welding or horizontal welding of the outfitting pieces such as handrails, steps, supports and cable guides in the flat state of the structure plate; the application also comprises a collaborative management system, which realizes differentiated drawing distribution and accurate material distribution through a process planning module, a data collaboration module, a material tracking module and a progress monitoring module; the application converts the outfitting operation in a three-dimensional space into a plane operation, reduces the welding difficulty, shortens the section construction period, and is suitable for the construction of various ships.

Description

Technical Field

[0001] This invention relates to the field of shipbuilding technology, specifically to an integrated construction method for integrating and installing outfitting components during the initial or mid-stage assembly of a ship's hull structure, and a collaborative management system for implementing this method. Background Technology

[0002] Ship outfitting components are the core components for realizing various functions of a ship. Their installation workload usually accounts for more than 30% of the total construction time of the ship. Therefore, the efficiency and quality of outfitting operations directly affect the overall construction cycle and construction cost of the ship.

[0003] In the traditional shipbuilding model, the hull structure follows the process of "parts → sub-assembly → mid-assembly → section → main section → dock assembly". The installation of outfitting components is mainly concentrated in the "section outfitting" stage after the sections are formed. At this time, the sections have initially formed a three-dimensional box structure, and various professional construction teams need to carry out cross-operations in the same limited enclosed space.

[0004] However, as shipbuilding demands increasing precision and speed, the drawbacks of the traditional segmented outfitting method have become increasingly apparent, necessitating a systematic optimization of the outfitting and installation process.

[0005] The existing segmented outfitting methods mainly have the following technical defects and shortcomings:

[0006] 1. After segmented molding, the internal space is divided into narrow channels by structures such as longitudinal bones and ribs. The simultaneous entry of multiple professional teams leads to crisscrossing pipelines, overlapping work surfaces, and frequent interference, which causes a large amount of rework and waiting, resulting in logistics congestion and prominent safety hazards.

[0007] 2. Welding inside or at the bottom of a section often requires welding in difficult positions such as overhead welding and vertical welding. When welding overhead, the molten pool drops, which can easily cause defects such as incomplete fusion, porosity, or undercut. When welding vertically, the molten pool flows downward, making it difficult to control the weld formation. This places high demands on the welder's qualifications, and the welding quality fluctuates greatly, with a low first-pass yield, resulting in a large amount of subsequent repairs.

[0008] 3. The narrow space inside the segmented box requires workers to maintain a bent-over, squatting or even supine position for long periods of time, making it impossible to work upright continuously. This results in high physical exertion and short working hours. In addition, poor lighting and ventilation not only reduce efficiency but also increase health risks. Furthermore, the proportion of easily operable positions such as flat welding and flat fillet welding is extremely low, and a large number of high-difficulty welding operations further extend the outfitting cycle.

[0009] 4. All outfitting work is highly concentrated in the section stage. Coupled with cross-operations and welding difficulties, section outfitting has become a bottleneck in the process. This directly affects the utilization rate of dock and pier work positions, thus lengthening the shipbuilding cycle.

[0010] 5. In the traditional model, outfitting materials are centrally delivered to the section assembly site, where they are piled up haphazardly and have poor matching, often resulting in missing or incorrect parts, which further exacerbates construction delays.

[0011] In summary, there is an urgent need in the existing technology for a method that can move the outfitting and installation process from a crowded and difficult three-dimensional segmented space to an open and easy-to-construct planar operation stage, so as to fundamentally solve the problems of multi-disciplinary interference, welding difficulties and long cycles, realize the planarization, pre-positioning and collaborative management of outfitting operations, and thus build an integrated outfitting component construction model. Summary of the Invention

[0012] To address the problems of multi-disciplinary interference, welding difficulties, poor ergonomics, bottlenecks in segmented transfer, and inefficient material management in the traditional segmented outfitting model, this invention proposes an integrated construction method and collaborative management system for ship outfitting components.

[0013] The core idea of ​​this method is to move the installation process of outfitting components from the three-dimensional segmented space in the later stage to the stage before the construction of the structure. By using the flat state of the structural components, the welding position is made planar. At the same time, through differentiated drawing distribution and material delivery, as well as systematic collaborative management, the entire outfitting operation process is integrated.

[0014] To achieve the above objectives, the present invention provides an integrated construction method for ship outfitting components, which specifically includes the following steps:

[0015] S1. Process Analysis: Based on the shipbuilding process plan, first identify those outfitting components that can be installed in the early stages of structural construction.

[0016] The preceding construction phase includes the initial assembly phase of the structure and / or the intermediate assembly phase, while the subsequent construction phase includes the final assembly phase of the segments and / or the final closure phase of the segments.

[0017] This analysis allows us to identify which outfitting components are suitable for being moved forward from the source, laying the foundation for the design of subsequent forward processes.

[0018] S2. Process Shift Design: The installation process of the identified outfitting components is explicitly shifted to the preceding construction stage in the process plan, and a differentiated drawing distribution plan and material delivery plan are generated accordingly.

[0019] The differentiated drawing distribution plan requires the following: drawings for outfitting components installed in the preceding construction phase shall be distributed simultaneously with or in advance of the corresponding structural component drawings; drawings for outfitting components installed in the subsequent construction phase shall be distributed later than the structural component drawings.

[0020] The differentiated material distribution plan requires the following: outfitting materials should be precisely delivered to the corresponding construction site according to the preceding construction stage to which they are moved.

[0021] This ensures the smooth implementation of moving processes forward from the production preparation level.

[0022] S3. Pre-installation: In the pre-construction stage, the structural components are laid flat on the jig, and the planned outfitting components are installed and welded, so that the welding position is at least one of flat welding, flat fillet welding or horizontal welding.

[0023] The outfitting components involved in this step include handrails, steps, small brackets and / or cable trays; the welds formed by installation and welding are located at the positions indicated by the positioning lines of the structural panels.

[0024] Because the structural components are placed horizontally, workers can work upright, and the welding positions are flat welding, fillet welding, or horizontal welding, avoiding overhead welding and vertical welding, reducing the welding difficulty and the requirements for welder qualifications.

[0025] S4. Integrated Transfer: The structural components with installed outfitting parts are transferred as a whole unit to the subsequent construction stage (such as segment assembly, overall segment closure).

[0026] The structural unit with outfitting does not require a separate outfitting station during subsequent assembly, thus enabling the simultaneous progress of structural construction and outfitting operations.

[0027] S5. Subsequent supplementary installation: During the subsequent construction phase, only the remaining outfitting components that are not suitable for forward movement are installed.

[0028] These outfitting components typically involve complex system interfaces or are constrained by process requirements such as hoisting and painting, and must be completed at this stage.

[0029] Since some outfitting work has been completed in the preceding stages, the workload in the segmented or overall stages is reduced, thus providing more construction space and time for other disciplines.

[0030] To achieve efficient execution of the above methods, the present invention also provides an integrated collaborative management system for ship outfitting components, which includes a process planning module, a data collaboration module, a material tracking module, and a progress monitoring module.

[0031] The process planning module is configured to identify the forward installation stage to which each outfitting component belongs, that is, to determine whether each outfitting component should be installed in the group assembly stage, the intermediate assembly stage, or the subsequent segmentation stage, and to output this information digitally.

[0032] The data collaboration module is configured to associate the forward installation information of outfitting components with structural construction process data, and drive the differentiated issuance of drawings and bills of materials.

[0033] Specifically, the module is also configured to: when the forward installation stage of an outfitting component is determined to be a sub-assembly stage or a mid-assembly stage, bind the installation drawings of the outfitting component with the corresponding structural sub-assembly drawings or mid-assembly drawings and issue them in advance, thereby ensuring that the on-site team receives complete structural and outfitting operation instructions at the same time.

[0034] The material tracking module is configured to schedule and track outfitting materials to the corresponding construction site according to the forward installation phase.

[0035] Furthermore, the module is also configured to generate material delivery instructions accurate to the construction site based on information from the forward installation phase, and to provide real-time feedback on the arrival and consumption status of materials, thereby achieving refined and timely delivery of materials.

[0036] The progress monitoring module is configured to monitor the installation progress of the forward outfitting components in the preceding construction phase and compare it with the overall construction plan.

[0037] This module may include a progress comparison submodule, which is configured to display in real time the difference between the completion rate of outfitting installation in the previous construction phase and the planned completion rate, and issue an early warning when the deviation exceeds a threshold, so as to facilitate timely intervention by management personnel.

[0038] The above modules can interact with each other through the Enterprise Resource Planning (ERP) system or the Manufacturing Execution System (MES) to form a closed-loop collaborative management system from design, process, materials to on-site construction.

[0039] Compared with the prior art, the present invention has the following beneficial effects:

[0040] 1. By moving some outfitting operations from the sectioning stage to the group and mid-section erection stages, the workload of the section outfitting stage is reduced, the turnover speed of sections in key work positions such as docks and wharves is increased, and the overall shipbuilding cycle is shortened.

[0041] 2. Transforming overhead and vertical welding in three-dimensional space into flat welding, fillet welding, or horizontal welding in a planar state allows workers to work upright, improves the controllability of welding quality, increases the first-pass yield, and reduces the requirements for senior welder qualifications, thereby reducing labor costs.

[0042] 3. It reduces spatial conflicts between multiple disciplines working at different stages, allowing more space within each stage to be allocated to disciplines such as piping and electrical systems that must be completed at that stage; at the same time, the flat working environment eliminates safety hazards such as welding spatter and climbing in confined spaces.

[0043] 4. Through differentiated material distribution plans and material tracking modules, outfitting parts are delivered accurately by workstation and node, avoiding problems such as on-site clutter, missing or incorrect parts in the traditional model, and reducing waiting time.

[0044] 5. This invention integrates outfitting operations with structural construction, and through data collaboration and progress monitoring, it constructs an integrated construction mode for ship outfitting components, providing a technical path for intelligent ship manufacturing and digital shipbuilding.

[0045] In summary, this invention solves several technical problems existing in traditional segmented outfitting from two levels: process method and management system. It realizes planar, pre-positioned and collaborative management of outfitting operations, improves construction efficiency and reduces overall costs, and is applicable to the construction of various types of ships and marine engineering structures. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the workspace for the forward movement of the process in this invention;

[0047] Figure 2 A schematic diagram of the work space for traditional segmented outfitting;

[0048] Figure 3 This is a process flow diagram of the integrated construction method for ship outfitting components based on process shifting in the present invention;

[0049] Figure 4 A schematic diagram showing the position of the outfitting component as it is moved forward and installed on the structural panel;

[0050] Figure 5 This is a module architecture diagram of the integrated collaborative management system for ship outfitting components involved in this invention.

[0051] In the diagram: 1. Upright operation; 2. Frame; 3. Working from below; 4. Multiple intersecting pipelines; 5. Structural panels; 6. Handrail; 7. Steps; 8. Small support; 9. Cable tray; 10. Weld; 11. Positioning line. Detailed Implementation

[0052] To enhance understanding of the present invention, the invention will be further described in detail below with reference to embodiments and accompanying drawings. These embodiments are only for explaining the invention and do not constitute a limitation on the scope of protection of the invention.

[0053] like Figure 1 and Figure 3 As shown, this embodiment provides an integrated construction method for ship outfitting components. This method can pre-install some outfitting components in the early stages of ship structure construction (such as the sub-assembly stage or the mid-assembly stage), thereby reducing the amount of outfitting work in subsequent section stages.

[0054] During the process analysis phase, the first step is to screen all outfitting components of the ship based on the ship construction process planning documents, and identify those outfitting components that are suitable for installation in the preceding construction phase.

[0055] The preliminary construction phase includes at least one of the small assembly phase and the intermediate assembly phase of the structure. For example, outfitting components that are small in size, light in weight and do not depend on other professional interfaces (such as handrails 6, steps 7, small supports 8, cable trays 9) can be identified as suitable for forward movement.

[0056] The subsequent construction phase includes at least one of the segment assembly phase and the overall segment closure phase.

[0057] During the process shift design phase, the installation process of the identified outfitting components is clearly marked in the process plan as being shifted to the designated preceding construction phase. At the same time, a differentiated drawing distribution plan and material delivery plan are formulated based on this shift arrangement.

[0058] The drawing distribution plan stipulates that drawings for outfitting components installed in the preceding construction phase should be distributed simultaneously with or in advance of the structural component drawings for that phase, while drawings for outfitting components installed in the subsequent construction phase are allowed to be distributed later.

[0059] The material distribution plan stipulates that outfitting materials should be directly delivered to the corresponding construction site (e.g., the group site or the intermediate group site) according to the forward phase to which they belong.

[0060] During the pre-installation stage, the structural panel 5 to be constructed is placed flat on the jig 2 during the previous construction stage;

[0061] like Figure 4 As shown, positioning lines 11 are pre-marked on the structural plate 5. The operator determines the installation position of each outfitting component according to the positioning lines 11, and then places the outfitting components such as handrail 6, step 7, small bracket 8 and cable tray 9 in the corresponding positions and fixes them to the structural plate 5 through weld 10.

[0062] Since the structural plate 5 is in a horizontal position, the operator can maintain an upright working posture to perform welding. The welding positions are mainly flat welding, flat fillet welding or horizontal welding, and there is no need to perform overhead welding or vertical welding.

[0063] Figure 1 This invention demonstrates the workspace for forward-moving processes, where operators work upright, the support frame 2 supports the plates, and there is no interference from intersecting pipes. In contrast, Figure 2 The work space of traditional segmented outfitting is shown, where operators have to look up at the work area 3 and there are multiple intersecting pipelines 4, making the work environment crowded.

[0064] During the integration and transfer phase, the structural panel 5, after the outfitting components have been installed, together with the fixed handrails 6, steps 7, and other components, is hoisted to the subsequent construction site as a whole unit. This unit directly participates in the structural assembly during the mid-stage assembly, segment assembly, or overall section closure phases, without the need to arrange separate installation stations for these outfitting components.

[0065] In the subsequent supplementary installation phase, only those outfitting components that are not suitable for forward movement are installed in the segment or overall stage. These include components that need to be connected to piping, electrical and other systems on site, or components that are too large and affect hoisting. Since the previous stage has already absorbed some of the outfitting workload, the construction pressure in the segment stage is significantly reduced.

[0066] Reference Figure 5 This embodiment also provides an integrated collaborative management system for ship outfitting components. The system is used to execute the above method and includes a process planning module, a data collaboration module, a material tracking module, and a progress monitoring module.

[0067] The process planning module receives outfitting component lists and structural construction process data from the ship production design system. The module has preset judgment rules that can automatically or manually identify the forward installation stage (e.g., small group assembly stage, mid-stage assembly stage, or rear sectioning stage) to which each outfitting component belongs. The identification results are stored in digital form and output to other modules.

[0068] The data collaboration module is associated with structural construction process data (such as DAP, i.e., segmented construction plan). When it receives the information of the advance installation stage of a certain outfitting component, the data collaboration module binds the installation drawings of the outfitting component with the structural drawings of the corresponding stage.

[0069] If the preliminary installation stage of the outfitting component is determined to be either the small group erection stage or the medium group erection stage, the data collaboration module triggers a drawing issuance instruction, requiring the installation drawings of the outfitting component to be issued to the construction team simultaneously or in advance, along with the structural small group erection drawings or medium group erection drawings. At the same time, the module drives the bill of materials (BOM) to be split according to the new stage, generating a differentiated material requirements plan.

[0070] The material tracking module receives material delivery instructions from the data collaboration module. The instructions include the outfitting component's code, quantity, required construction site (e.g., a workstation in the group assembly workshop), and required arrival time. The material tracking module obtains the material's inventory, picking, transportation, and arrival status in real time through an interface with the enterprise resource planning system or production execution system. When the material arrives at the designated site, the operator confirms receipt by scanning a code or using RFID. The module automatically updates the material status and feeds it back to the progress monitoring module.

[0071] The progress monitoring module is used to track the actual installation progress of the forward outfitting components in the previous construction stage. It has a built-in progress comparison sub-module, which periodically compares the actual completed quantity with the planned completed quantity and generates a completion rate curve.

[0072] When the actual completion rate of a certain workstation is lower than the preset threshold of the planned completion rate (e.g., lower than 80%), the progress monitoring module issues an early warning signal, prompting management personnel to intervene and coordinate.

[0073] Data interaction between all modules is completed through an enterprise resource planning system or a production execution system, forming a closed-loop management system from design to construction.

[0074] Implementation Example

[0075] Taking a container ship as an example, a certain bulkhead of the ship is designed with multiple sets of handrails 6 and cable trays 9;

[0076] According to traditional processes, these handrails 6 and cable trays 9 should be installed after the bulkhead section is formed. At this time, the section has become a three-dimensional box shape, and workers need to work from inside the section while looking up 3. There are also multiple intersecting pipelines 4 around, which makes construction difficult.

[0077] This embodiment employs the method of the present invention, and the specific implementation is as follows:

[0078] First, based on the construction guidelines, the process engineers identified that the handrail 6 and cable tray 9 on the bulkhead were suitable for installation in the preliminary stage;

[0079] Subsequently, during the group erection phase, the bulkhead panel (i.e., structural panel 5) is laid flat on the jig 2;

[0080] like Figure 4 As shown, positioning lines 11 have been marked on the structural plate 5. Workers place the handrail 6 and cable tray 9 on the plate according to the position of the positioning lines 11, and weld them using fillet welding to form weld 10.

[0081] Throughout the process, workers maintain an upright working posture, without needing to tilt their heads back or bend over.

[0082] After welding is completed, the structural plate 5 with outfitting is used as a whole unit in the mid-assembly and segment assembly process;

[0083] In the subsequent sectional phases, only the remaining outfitting components, such as the piping interfaces related to the bulkhead, need to be installed. Furthermore, since the handrails and cable trays are already in place, the interior space of the sectional is more spacious, and conflicts between cross-operations are significantly reduced.

[0084] As can be seen from the above examples, the method and system of the present invention can advance some of the outfitting work that was originally carried out in the segmented stage to the group erection stage, thereby reducing the welding difficulty, improving the working environment and shortening the segmented construction cycle.

[0085] 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 integrated construction of ship outfitting components, characterized in that, Includes the following steps: S1. Process Analysis: Based on the shipbuilding process plan, identify the outfitting components that can be installed in the early stages of structural construction; S2. Process Shift Design: The installation process of the identified outfitting components is shifted to the preceding construction stage in the process plan, and a differentiated drawing distribution plan and material delivery plan are generated accordingly. S3. Pre-installation: In the preceding construction stage, the structural components are placed flat on the construction support device to complete the installation and welding of the outfitting components, so that the welding position is at least one of flat welding, flat fillet welding or horizontal welding. S4. Integrated Transfer: Structural components with installed outfitting parts are transferred as a whole unit to the subsequent construction stage; S5. Subsequent Supplementary Installation: During the subsequent construction phase, install any remaining outfitting components that are not suitable for forward movement.

2. The method according to claim 1, characterized in that, The preceding construction stage includes the initial assembly stage and / or the intermediate assembly stage of the structure; the subsequent construction stage includes the segmented assembly stage and / or the final closure stage of the segments; the construction support device is a formwork frame.

3. The method according to claim 1 or 2, characterized in that, The differentiated drawing distribution plan requires that: drawings for outfitting components installed in the preceding construction phase be issued simultaneously with or ahead of the corresponding structural component drawings; drawings for outfitting components installed in the subsequent construction phase are issued later than the structural component drawings.

4. The method according to claim 1, characterized in that, The differentiated material distribution plan requires that outfitting materials be precisely delivered to the corresponding construction site according to the preceding construction stage to which they are moved.

5. The method according to claim 1, characterized in that, In step S3, the outfitting components include handrails, steps, small brackets, and / or cable trays; the welds formed by the installation and welding are located at the positions indicated by the positioning lines of the structural plates.

6. An integrated collaborative management system for ship outfitting components, characterized in that, include: The module includes a process planning module, a data collaboration module, a material tracking module, and a progress monitoring module. The process planning module is configured to identify the forward installation stage to which each outfitting component belongs; The data collaboration module is configured to associate the forward installation information of outfitting components with structural construction process data, and drive the differentiated issuance of drawings and bills of materials; The material tracking module is configured to schedule and track outfitting materials to the corresponding construction site according to the forward installation phase; The progress monitoring module is configured to monitor the installation progress of the forward outfitting components in the preceding construction phase and compare it with the overall construction plan.

7. The system according to claim 6, characterized in that, The data collaboration module is also configured to: when it is determined that the forward installation stage of an outfitting component is a sub-assembly stage or a mid-assembly stage, bind the installation drawings of the outfitting component with the corresponding sub-assembly drawings or mid-assembly drawings and issue them in advance.

8. The system according to claim 6, characterized in that, The material tracking module is also configured to generate material delivery instructions accurate to the construction site based on information from the forward installation phase, and to provide real-time feedback on the arrival and consumption status of materials.

9. The system according to claim 6, characterized in that, The progress monitoring module includes a progress comparison submodule, which is configured to display the difference between the completion rate of outfitting installation in the previous construction stage and the planned completion rate in real time, and issue an early warning when the deviation exceeds a threshold.

10. The system according to claim 6, characterized in that, The process planning module, data collaboration module, material tracking module, and progress monitoring module interact with each other through an enterprise resource planning system or a production execution system.

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