A ship assembly electromagnetic induction deformation regulation and control system and a regulation and control method

Abstract

This invention discloses a ship assembly electromagnetic induction deformation control system and method. The system includes a control trolley, a cooling device, and a variable frequency and voltage power supply. The control trolley includes a body module with a moving drive module. A magnetic adsorption module and an electromagnetic induction heating module are respectively installed at the bottom of the body module. An onboard 3D scanning detection unit is located at the front of the body module. An onboard voltage power supply module, a process parameter generation unit, and a control module are integrated inside the body module. The control module is signal-connected to the onboard 3D scanning detection unit, the process parameter generation unit, the moving drive module, and the electromagnetic induction heating module. This invention obtains 3D deformation data before and after control through the onboard 3D scanning detection unit, and generates control process parameters and performs feedback correction by the process parameter generation unit, thereby improving the synergy between deformation detection, parameter generation, control execution, and feedback correction of ship assembly components.

Description

Technical Field

[0001] This invention relates to the field of ship assembly welding deformation control technology, and in particular to a ship assembly electromagnetic induction deformation control system and control method. Background Technology

[0002] During shipbuilding, the assembly phase typically requires welding and assembling plate, profile, frame, and their combined components. These components are prone to deformation after welding, affecting assembly accuracy, subsequent assembly quality, and segment manufacturing efficiency. To correct this welding deformation, back-heating is commonly used in engineering. Compared to traditional flame back-heating, electromagnetic induction back-heating utilizes an electromagnetic field to rapidly convert electrical energy into heat energy. This method offers advantages such as high heating efficiency, rapid temperature rise, high correction accuracy, cleanliness, environmental friendliness, and higher safety, making it more suitable for the welding deformation correction needs at ship assembly sites.

[0003] Patent CN115011781B discloses an electromagnetic induction back-heating robot. This robot moves via wheels and a drive motor, attaches to a steel plate surface via upper or lower electromagnetic strips, and can install coil assemblies on the top or bottom of a frame structure as needed to adapt to back-heating operations on flat steel plates (front and back) or vertically or obliquely. Its working method mainly includes determining the heating position, installing and fixing the coil assembly, using an electromagnetic adsorption winch to attach the robot to the steel plate surface, moving along a marked line and heating, and retrieving the robot after work. Patent CN115261593B discloses an intelligent electromagnetic induction back-heating device installed on a vehicle body. This solution includes a vehicle body, an electromagnetic induction system, a high-frequency power supply, and a control cabinet. The electromagnetic induction system is installed on the top of the vehicle body and includes coil assemblies, coil adapters, and a coaxial transformer. The vehicle body includes a floor plate, a top plate, electric servo cylinders, wheels, and a drive motor, and can be further equipped with cameras and collision avoidance radar. Its working method mainly includes: controlling the vehicle body to move to the back of the steel plate and identifying the weld or the chalk line; automatically adjusting the tilt of the top of the vehicle body according to the shape of the back of the steel plate so that the coil assembly is parallel to the steel plate and the distance is constant; setting the vehicle body moving speed according to the plate thickness and controlling the coil assembly to continuously heat along the weld or the chalk line.

[0004] However, the aforementioned existing technologies mainly focus on the structural design and operating methods of electromagnetic induction control robots or control devices, primarily addressing issues such as equipment adsorption, movement, heating execution, and on-site operation. For ship assembly scenarios, existing technologies still lack systematic solutions for how to obtain the post-weld deformation state of components through vehicle-mounted 3D scanning, and how to generate control processes by combining component material properties, plate thickness, stiffener spacing, and other parameters, as well as how to provide feedback corrections to process parameters based on the residual deformation detection results after control. Summary of the Invention

[0005] Purpose of the invention: To address the above-mentioned problems, the purpose of this invention is to provide a ship assembly electromagnetic induction deformation control system and control method, which can generate control process parameters based on component characteristics and three-dimensional deformation detection results, and further drive the control trolley to complete the actual deformation control operation.

[0006] Technical Solution: A ship assembly electromagnetic induction deformation control system includes a control trolley, a cooling device that provides circulating cooling medium for the control trolley, and a frequency converter and transformer power supply that provides electrical energy to the control trolley. The control trolley includes a body module, on which a walking drive module for movement is provided. A magnetic adsorption module and an electromagnetic induction heating module are respectively installed at the bottom of the body module. An on-board three-dimensional scanning detection unit is located at the front of the body module. An on-board transformer power supply module, a process parameter generation unit, and a control module are integrated inside the body module. The control module is connected to the on-board three-dimensional scanning detection unit, the process parameter generation unit, the walking drive module, and the electromagnetic induction heating module via signals.

[0007] The vehicle-mounted transformer power module is used to transform and distribute external electrical energy introduced from the rear of the vehicle body, so as to provide matching working power for the main control board, motor controller and related vehicle electrical components.

[0008] The cooling device, variable frequency power supply and control trolley are connected by an integrated water and electricity transmission structure, so that the circulating medium can carry away the working heat of the heating components while cooperating to realize energy transmission, thus forming an integrated working structure for energy supply and cooling.

[0009] Furthermore, the walking drive module includes two drive wheels respectively installed on opposite sides of the vehicle body module and a swivel wheel installed at the bottom rear of the vehicle body module. The two drive wheels are respectively connected to drive motors for driving the vehicle body forward, backward and differential steering. The drive motors are connected to the control module via signals.

[0010] Ideally, the magnetic adsorption module includes a magnet assembly, and the vehicle body module includes a frame. The frame is a hollow square box structure with a long protrusion on its bottom surface, making the vertical cross-section of the frame L-shaped. The magnet assembly is installed at the bottom of the protrusion, and the casters are installed at the bottom of the frame opposite to the protrusion. The protrusion compensates for the height difference formed by the casters at the bottom of the frame. The casters are installed at the bottom of the frame through an elastic clamping structure, and two drive wheels are installed on opposite sides of the frame at the protrusion.

[0011] The magnet assembly is used to attach the vehicle body to the steel plate surface, enabling the vehicle body to move stably on the steel plate surface and complete the adjustment operation.

[0012] Two drive wheels are used to propel the vehicle forward, backward, and for differential steering; swivel casters provide auxiliary support to the rear of the vehicle and steer accordingly during steering. To improve the contact stability between the rear swivel casters and the steel plate surface, the rear swivel casters are connected to the frame through an elastic clamping structure, enabling the control trolley to maintain good support stability even when there are local unevennesses on the steel plate surface or changes in the vehicle's posture.

[0013] Ideally, the electromagnetic induction heating module includes a coaxial transformer and dual heating heads. The coaxial transformer is installed inside the frame, and the dual heating heads are connected to the coaxial transformer. The dual heating heads are installed downwards and sequentially through the bottom of the frame and the protrusion, so that they face the side of the frame corresponding to the area to be controlled.

[0014] Furthermore, the control module includes a main control board and a motor controller connected to it via signals. The motor controller is connected to the walking drive module via signals. The main control board integrates a process parameter generation unit, an on-board 3D scanning detection unit, and an electromagnetic induction heating module, which are respectively connected to the main control board via signals.

[0015] The process parameter generation unit generates initial control process parameters based on the component material properties, plate thickness, stiffener spacing, and deformation data obtained by the vehicle-mounted 3D scanning detection unit before control. It also uses the residual deformation data obtained by the vehicle-mounted 3D scanning detection unit after control to provide feedback correction to the control process parameters, generating corrected control process parameters. The control process parameters include electromagnetic induction heating power, control time, control movement speed, induction heating power frequency, number of control channels, control path, and control sequence. The control module is located inside the control trolley and is connected to the vehicle-mounted 3D scanning detection unit, the process parameter generation unit, the walking drive module, and the electromagnetic induction heating module. It receives scanning detection data, initial control process parameters, or corrected control process parameters, and converts the corresponding process parameters into trolley movement control commands and electromagnetic induction heating control commands to control the control trolley to complete detection scanning, movement positioning, and deformation control operations.

[0016] Furthermore, the vehicle-mounted 3D scanning and detection unit includes a line laser 3D contour scanning sensor, a heat-insulating protective cover, a walking encoder, and a data processing module. The data processing module is connected to both the line laser 3D contour scanning sensor and the walking encoder, and is used to match the 3D contour data with the vehicle's movement position information to generate 3D point cloud data of the area to be controlled. The line laser 3D contour scanning sensor projects a line laser onto the surface of the steel plate to be controlled and collects the contour change information of the steel plate surface; the walking encoder records the position information of the control vehicle as it moves along the detection path; the data processing module matches the contour data collected by the line laser 3D contour scanning sensor with the position data collected by the walking encoder to form 3D point cloud data of the area to be controlled. The heat-insulating protective cover reduces the impact of high temperature, smoke, and splashes on the sensor during the control process.

[0017] The vehicle-mounted 3D scanning and detection unit is installed on the control trolley and is used to perform 3D scanning of the assembly component to be controlled before and after control, respectively, to obtain 3D point cloud data of the surface of the assembly component, and to extract the location, length, width, maximum deflection and residual deflection of the deformation area based on the 3D point cloud data.

[0018] A control method for the above-mentioned ship assembly electromagnetic induction deformation control system includes the following steps:

[0019] Step S1: The control module controls the adjustment trolley to move along the preset detection path, and the vehicle-mounted three-dimensional scanning detection unit performs a pre-adjustment scan of the area to be adjusted to obtain the three-dimensional point cloud data of the surface of the component to be adjusted.

[0020] Step S2: The process parameter generation unit inside the trolley establishes a target reference surface based on the three-dimensional point cloud data, calculates the height deviation of the scanning point relative to the target reference surface, and extracts the location, length, width and maximum deflection of the deformation area.

[0021] Step S3: The process parameter generation unit combines the material properties, plate thickness and stiffener spacing of the component to be assembled, and calculates the target compensation amount based on the maximum deflection and the target allowable residual deformation.

[0022] Step S4: The process parameter generation unit generates initial control process parameters based on the target compensation amount, material properties, plate thickness, stiffener spacing, and deformation area size; the initial control process parameters include control power, control time, control moving speed, induction heating power supply frequency, number of control channels, control path, and control sequence;

[0023] Step S5: The control module controls the control trolley to move to the control starting position according to the initial control process parameters, and moves along the generated control path. At the same time, it controls the electromagnetic induction heating module to perform electromagnetic induction control operation according to the set control power, control moving speed, control time and induction heating power frequency.

[0024] Step S6: After the adjustment is completed, after the adjustment area cools down to the preset detection temperature or after the preset cooling time, the control module controls the adjustment trolley to return along the original adjustment path or pass through the adjustment area again. The vehicle-mounted three-dimensional scanning detection unit rescans the surface of the adjusted component to obtain the residual deformation after adjustment.

[0025] Step S7: The process parameter generation unit compares the adjusted residual deformation with the target allowable residual deformation and calculates the residual deformation deviation;

[0026] Step S8: When the residual deformation is greater than the target allowable residual deformation, the process parameter generation unit corrects the control power, control time, control moving speed, control number of control channels, control path or control sequence according to the residual deformation deviation, and sends the corrected control process parameters to the control module.

[0027] In step S9, the control module controls the control trolley to perform the control operation again according to the corrected control process parameters, and repeats steps S6 to S8 until the residual deformation meets the target allowable residual deformation requirement or reaches the preset maximum number of control operations.

[0028] Furthermore, in step S2, the target reference surface is represented as:

[0029] ;

[0030] in, For the target reference plane in coordinate The height values ​​at the location, where a, b, and c are the fitting coefficients of the target reference surface;

[0031] For any scan point obtained from a 3D scan The height deviation of the scanning point relative to the target reference plane is expressed as:

[0032] ;

[0033] in, Let be the height deviation of the i-th scan point relative to the target reference plane. Let be the actual height of the i-th scan point, then the initial deformation is expressed as:

[0034] ;

[0035] in, This represents the initial deformation after welding.

[0036] The scan point is included in the deformation region when the height deviation of the scan point meets the following conditions:

[0037] ;

[0038] in, The threshold for deformation recognition;

[0039] Determine the length of the deformation region based on the coordinate range of the scan points within the deformation region. and the width of the deformation area , where the length of the deformed region Used to determine the length of the control path and the width of the deformation region. Used to determine the number of control channels;

[0040] In step S3, the target compensation amount is expressed as:

[0041] ;

[0042] in, For the target compensation amount, Allowable residual deformation for the target;

[0043] When the following conditions are met: When the current deformation of the component meets the target allowable residual deformation requirement, no adjustment operation is performed;

[0044] When the following conditions are met: At that time, the process parameter generation unit enters the process of generating control process parameters.

[0045] Ideally, the process parameter generation unit generates parameters based on the target compensation amount. The intensity of regulation is classified into levels:

[0046] When the following conditions are met: When the deformation is determined to be slight, a low heat input single-channel control parameter is generated.

[0047] When the following conditions are met: When the deformation is determined to be moderate, a dual-channel control parameter for moderate heat input is generated.

[0048] When the following conditions are met: When the deformation is deemed large, high-heat input multi-channel zone control parameters are generated.

[0049] in, The first compensation threshold is... The second compensation threshold is set in advance based on the thickness of the ship assembly components and the material type.

[0050] The process parameter generation unit determines the target unit length heat input based on the target compensation amount, material properties, plate thickness, and stiffener spacing. The target unit length heat input is expressed as:

[0051] ;

[0052] in, For the target unit length heat input, Based on the heat input per unit length, This is a material correction factor. This is the plate thickness correction factor. This is the correction factor for the stiffener spacing. This is the deformation correction factor;

[0053] The deformation correction coefficient can be determined according to the following formula:

[0054] ;

[0055] The plate thickness correction factor can be determined according to the following formula:

[0056] ;

[0057] The stiffener spacing correction factor can be determined according to the following formula:

[0058] ;

[0059] in, The coefficient representing the influence of deformation. The plate thickness influence coefficient is... The influence coefficient of stiffener spacing is... For the thickness of the component plate to be adjusted, Based on the plate thickness, This refers to the actual spacing between the stiffeners. The reference stiffener spacing;

[0060] In this way, when the target compensation amount increases, the plate thickness increases, or the stiffener spacing increases, the target heat input per unit length increases accordingly; when the target compensation amount decreases, the plate thickness decreases, or the stiffener spacing decreases, the target heat input per unit length decreases accordingly.

[0061] Ideally, the heat input per unit length should satisfy the following relationship with the controlled power and the controlled moving speed:

[0062] ;

[0063] in, To regulate power, To control movement speed;

[0064] The electromagnetic induction heating power is determined by the following formula:

[0065] ;

[0066] in, This refers to the power of electromagnetic induction heating. This represents the efficiency coefficient of electromagnetic induction heating. For output voltage, For output current;

[0067] When adjusting power Once determined, the process parameter generation unit adjusts the moving speed based on the target unit length heat input:

[0068] ;

[0069] When the calculated control moving speed exceeds the preset speed upper limit or falls below the preset speed lower limit, the process parameter generation unit jointly corrects the control power and control moving speed to meet the equipment operating capacity and control process requirements.

[0070] The adjustment period is determined by the following formula:

[0071] ;

[0072] in, The control time corresponding to a single control path. To control the path length, To control movement speed;

[0073] The number of control channels is determined by the following formula:

[0074] ;

[0075] in, To control the number of lanes, The width of the deformation region. The effective thermal influence width for single-channel control is shown in square brackets []. [] indicates rounding up.

[0076] When the stiffener spacing is small, the control path is arranged along the opposite side of the stiffener weld; when the stiffener spacing is large or the three-dimensional scanning results show that the deformation area is wide, the process parameter generation unit sets multiple control paths between adjacent stiffeners so that the heat action area of ​​the dual heating head covers the main deformation area.

[0077] The control path prioritizes the point of maximum deflection in the deformation region. When multiple local deformation peaks exist, the process parameter generation unit determines the control sequence according to the order of deformation from largest to smallest, that is, it prioritizes controlling the region with the largest deformation, and then compensates for the region with the second largest deformation.

[0078] The effective heating depth in the electromagnetic induction heating process is expressed by the following formula:

[0079] ;

[0080] in, For effective heating depth, The resistivity of the material The material's magnetic permeability, The frequency of the induction heating power supply;

[0081] Based on the target heating depth The frequency of the induction heating power supply can be determined according to the following formula:

[0082] ;

[0083] When the thickness of the component to be controlled is large, the process parameter generation unit reduces the frequency of the induction heating power supply to increase the effective heating depth; when the thickness of the component to be controlled is small, the process parameter generation unit increases the frequency of the induction heating power supply to reduce the heat-affected zone and improve the local heating accuracy.

[0084] Furthermore, after the adjustment is completed, once the adjusted area has cooled to the preset detection temperature or passed through the preset cooling time, the adjustment trolley returns along the original adjustment path or passes through the adjusted area again. The onboard 3D scanning detection unit then re-scans the surface of the adjusted component to obtain the residual deformation after adjustment. .

[0085] The process parameter generation unit calculates the residual deformation deviation based on the residual deformation and the target allowable residual deformation:

[0086] ;

[0087] in, This represents the residual deformation deviation. This refers to the residual deformation after adjustment. Allowable residual deformation for the target;

[0088] When the following conditions are met: When the residual deformation after adjustment meets the target compensation requirements, the adjustment operation ends.

[0089] When the following conditions are met: When this occurs, it indicates that the control compensation is insufficient, and the process parameter generation unit will correct the process parameters for the next control based on the residual deformation deviation;

[0090] The corrected heat input per unit length can be determined using the following formula:

[0091] ;

[0092] in, For the (n+1)th adjustment of movement speed, For the (n+1)th adjustment power, This represents the heat input per unit length for the (n+1)th adjustment.

[0093] When the residual deformation deviation is large, the process parameter generation unit prioritizes increasing the heat input per unit length, specifically by increasing the control power, reducing the control moving speed, extending the control time, or increasing the number of control channels; when the residual deformation deviation is small, the process parameter generation unit prioritizes small-scale correction by reducing the control moving speed or increasing the local compensation control path.

[0094] Beneficial effects: Compared with the prior art, the advantages of the present invention are:

[0095] Firstly, this invention integrates an on-board 3D scanning detection unit onto a control trolley, enabling the control trolley to acquire 3D deformation data of the component surface while moving to the area to be controlled, and to generate control process parameters based on the 3D scanning results, thereby improving the synergy between detection, positioning, and control execution.

[0096] Secondly, through the cooperation of the vehicle-mounted 3D scanning detection unit, the process parameter generation unit, and the control module, this invention can realize a continuous operation process of pre-control scanning, parameter generation, control execution, post-control re-scanning, and parameter feedback correction. This transforms the control process from traditional experience-based parameter setting to an iterative parameter correction process based on the vehicle-mounted 3D scanning detection results, thereby improving the accuracy of control compensation and process consistency.

[0097] Thirdly, the control trolley of the present invention adopts a three-wheel movement structure with two front drive wheels and a single rear universal wheel, and combines a magnetic adsorption module to improve the adhesion stability of the trolley on the steel plate surface; the rear universal wheel can be connected to the frame through an elastic clamping structure to improve the support stability of the trolley when moving on a locally uneven steel plate surface.

[0098] Fourth, the present invention uses a process parameter generation unit to correct the unit length heat input, control power, control moving speed, control time, control number of control channels and control path according to the residual deformation deviation, so that the control operation can be iteratively adjusted according to the actual correction effect, thereby improving the adaptability and reliability of ship assembly component control correction. Attached Figure Description

[0099] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0100] Figure 2 This is an isometric schematic diagram of the upper half of the control trolley of the present invention;

[0101] Figure 3 This is an isometric schematic diagram of the lower half of the control trolley of the present invention;

[0102] Figure 4 This is a flowchart of the method of the present invention. Detailed Implementation

[0103] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention.

[0104] A ship assembly electromagnetic induction deformation control system, such as Figure 1 As shown, it includes a cooling device 1, a variable frequency power supply 2, and a control trolley 3.

[0105] Cooling device 1 provides circulating cooling medium to cool the coaxial transformer and dual-channel heating head. Variable frequency power supply 2 provides the electrical energy required for induction heating to the electromagnetic induction heating module in the control trolley 3. The control trolley 3 moves on the surface of the steel plate to be controlled and performs electromagnetic induction control on the back side of the weld or the opposite side of the component via the dual-channel heating head.

[0106] like Figure 2 and Figure 3 As shown, the control trolley 3 includes drive wheels 301, a motor controller 302, a coaxial transformer 303, a main control board 304, an on-board transformer power supply module 305, a dual-channel heating head 306, a magnetic adsorption module 307, casters 308, and an on-board 3D scanning detection unit 309. The main control board 304 integrates a process parameter generation unit and a control module. The process parameter generation unit generates initial control process parameters based on the deformation data before control acquired by the on-board 3D scanning detection unit 309, and performs feedback correction on the control process parameters based on the residual deformation data after control. The control module controls the operation of the motor controller 302, drive wheels 301, and dual-channel heating head 306 based on the control process parameters output by the process parameter generation unit.

[0107] Two drive wheels 301 are located on both sides of the front of the vehicle body and are connected to drive motors respectively. The two drive wheels 301 control the forward, backward, and steering movements of the vehicle 3 through differential speed control. Universal casters 308 are located at the rear of the vehicle body to provide auxiliary support and steer accordingly during steering. To improve the contact stability between the rear universal casters 308 and the steel plate surface, the universal casters 308 can be connected to the frame through an elastic clamping structure, ensuring that the vehicle 3 maintains good support stability even when there are local unevennesses on the steel plate surface or changes in the vehicle's posture.

[0108] The magnetic adsorption module 307 is located at the bottom of the control trolley 3 to improve the adhesion stability between the control trolley 3 and the steel plate surface and reduce the slippage of the trolley during movement, detection and control.

[0109] The vehicle-mounted 3D scanning and inspection unit 309 is positioned above the front of the control trolley 3 and connected to the trolley frame via a detection bracket. The scanning direction of the vehicle-mounted 3D scanning and inspection unit 309 is towards the surface of the steel plate to be controlled, and it is used to collect 3D topographic data of the steel plate surface during the movement of the control trolley 3. The vehicle-mounted 3D scanning and inspection unit 309 is communicatively connected to the main control board 304 and transmits the scanned data to the process parameter generation unit in the main control board 304.

[0110] The vehicle-mounted 3D scanning and detection unit 309 includes a line laser 3D contour scanning sensor, a heat-insulating protective cover, a walking encoder, and a data processing module. The data processing module is connected to both the line laser 3D contour scanning sensor and the walking encoder, and is used to match the 3D contour data with the vehicle's movement position information to generate 3D point cloud data of the area to be controlled. The line laser 3D contour scanning sensor projects a line laser onto the surface of the steel plate to be controlled and collects contour change information of the steel plate surface; the walking encoder records the position information of the control vehicle as it moves along the detection path; the data processing module matches the contour data collected by the line laser 3D contour scanning sensor with the position data collected by the walking encoder to form 3D point cloud data of the area to be controlled. The heat-insulating protective cover reduces the impact of high temperature, smoke, and splashes on the sensor during the control process.

[0111] The coaxial transformer 303 and the dual-track heating head 306 together constitute the electromagnetic induction heating actuator. The dual-track heating head 306 is located at the bottom of the control trolley 3 or on one side near the area to be controlled, and is used to form an induction heating zone with two heating tracks in the area to be controlled. The dual-track heating head 306 can move continuously along the back of the weld or the opposite side of the component, thereby forming a continuous heat treatment range in the deformation area.

[0112] The vehicle-mounted transformer power supply module 305 is located inside the vehicle body and is used to transform and distribute the external electrical energy introduced from the rear of the vehicle body to provide matching working power for the main control board 304, motor controller 302, vehicle-mounted 3D scanning detection unit 309 and related vehicle-mounted electrical components.

[0113] Before adjustment, the control module in the main control board 304 controls the adjustment trolley 3 to move along the preset detection path. The vehicle-mounted three-dimensional scanning detection unit 309 scans the component to be adjusted and obtains the three-dimensional point cloud data of the component surface, and establishes a deformation evaluation coordinate system based on the target reference plane. By comparing the component surface point cloud data with the target reference plane, the vehicle-mounted three-dimensional scanning detection unit 309 extracts the deformation area location, deformation area length, deformation area width, and maximum deflection.

[0114] The above-mentioned control method for the ship assembly electromagnetic induction control system, such as Figure 4 As shown, it includes the following steps:

[0115] Step S1: The control module controls the adjustment trolley 3 to move along the preset detection path, and the vehicle-mounted three-dimensional scanning detection unit 309 performs a pre-adjustment scan of the area to be adjusted to obtain three-dimensional point cloud data of the surface of the component to be adjusted.

[0116] Step S2: The process parameter generation unit establishes the target reference surface based on the three-dimensional point cloud data, calculates the height deviation of the scanning point relative to the target reference surface, and extracts the location, length, width and maximum deflection of the deformation area.

[0117] Step S3: The process parameter generation unit combines the material properties, plate thickness and stiffener spacing of the component to be assembled, and calculates the target compensation amount based on the maximum deflection and the target allowable residual deformation.

[0118] Step S4: The process parameter generation unit generates initial control process parameters based on the target compensation amount, material properties, plate thickness, stiffener spacing, and deformation zone size.

[0119] Step S5: The control module controls the control trolley 3 to move to the control starting position according to the initial control process parameters, and moves along the generated control path. At the same time, it controls the dual-channel heating head 306 to perform electromagnetic induction control operation according to the set control power, control moving speed, control time and induction heating power frequency.

[0120] Step S6: After the adjustment is completed, once the adjusted area has cooled to the preset detection temperature or passed the preset cooling time, the control module controls the adjustment trolley 3 to return along the original adjustment path or pass through the adjustment area again. The vehicle-mounted three-dimensional scanning detection unit 309 performs a rescan on the surface of the adjusted component to obtain the residual deformation after adjustment.

[0121] Step S7: The process parameter generation unit compares the adjusted residual deformation with the target allowable residual deformation and calculates the residual deformation deviation.

[0122] Step S8: When the residual deformation is greater than the target allowable residual deformation, the process parameter generation unit corrects the control power, control time, control moving speed, control number of control channels, control path or control sequence according to the residual deformation deviation, and sends the corrected control process parameters to the control module.

[0123] Step S9: The control module controls the control trolley 3 to perform the control operation again according to the corrected control process parameters, and repeats steps S6 to S8 until the residual deformation meets the target allowable residual deformation requirements or reaches the preset maximum number of control operations.

[0124] In this embodiment, the target reference plane can be represented as:

[0125] ;

[0126] in, For the target reference plane in coordinate The height values ​​at the location, where a, b, and c are the fitting coefficients of the target reference surface.

[0127] For any scan point obtained from a 3D scan The height deviation of the scanning point relative to the target reference plane can be expressed as:

[0128] ;

[0129] The initial deformation after welding can be determined by the following formula:

[0130] ;

[0131] The target compensation amount can be determined using the following formula:

[0132] ;

[0133] The process parameter generation unit receives the pre-control deformation data output by the vehicle-mounted 3D scanning and detection unit 309, and generates initial control process parameters by combining the material properties, plate thickness, and stiffener spacing of the component to be assembled. Material properties include component material type, resistivity, magnetic permeability, and thermal conductivity. Initial control process parameters include control power, control time, control movement speed, induction heating power supply frequency, number of control channels, control path, and control sequence.

[0134] The process parameter generation unit determines the target unit length heat input based on the target compensation amount, material properties, plate thickness, and stiffener spacing.

[0135] ;

[0136] in, For the target unit length heat input, Based on the heat input per unit length, This is a material correction factor. This is the plate thickness correction factor. This is the correction factor for the stiffener spacing. This is the deformation correction factor.

[0137] The deformation correction coefficient can be determined according to the following formula:

[0138] ;

[0139] The plate thickness correction factor can be determined according to the following formula:

[0140] ;

[0141] The stiffener spacing correction factor can be determined according to the following formula:

[0142] ;

[0143] in, The coefficient representing the influence of deformation. The plate thickness influence coefficient is... The influence coefficient of stiffener spacing is... For the thickness of the component plate to be adjusted, Based on the plate thickness, This refers to the actual spacing between the stiffeners. The reference stiffener spacing.

[0144] The following relationship exists between heat input per unit length, control power, and control moving speed:

[0145] ;

[0146] in, To regulate power, To control movement speed.

[0147] The electromagnetic induction heating power can be determined using the following formula:

[0148] ;

[0149] in, This refers to the power of electromagnetic induction heating. This represents the efficiency coefficient of electromagnetic induction heating. For output voltage, This is the output current.

[0150] When adjusting power Once confirmed, adjust the movement speed:

[0151] ;

[0152] Furthermore, the adjustment time can be determined using the following formula:

[0153] ;

[0154] in, The control time corresponding to a single control path. To control the path length, To control movement speed.

[0155] The number of control channels can be determined using the following formula:

[0156] ;

[0157] in, To control the number of lanes, The width of the deformation region. The effective thermal influence width for single-channel control is shown in square brackets []. [] indicates rounding up.

[0158] The effective heating depth in the electromagnetic induction heating process can be expressed by the following formula:

[0159] ;

[0160] in, For effective heating depth, The resistivity of the material The magnetic permeability of the material, The frequency of the induction heating power supply.

[0161] Based on the target heating depth The frequency of the induction heating power supply can be determined according to the following formula:

[0162] ;

[0163] During the regulation process, the control module controls the motor controller 302 and the electromagnetic induction heating module to operate based on the initial regulation process parameters output by the process parameter generation unit. The motor controller 302 controls the drive wheel 301 to move along the regulation path at the set regulation speed; the electromagnetic induction heating module performs regulation heating according to the set regulation power, regulation time, and induction heating power supply frequency.

[0164] After the adjustment is completed, once the adjusted area has cooled to the preset detection temperature or passed the preset cooling time, the control module controls the adjustment trolley 3 to return along the original adjustment path or pass through the adjusted area again. The onboard 3D scanning detection unit 309 re-scans the assembled component after adjustment to obtain the residual deformation amount after adjustment. The process parameter generation unit calculates the residual deformation deviation based on the residual deformation amount after adjustment and the target allowable residual deformation amount.

[0165] ;

[0166] in, This represents the residual deformation deviation. This refers to the residual deformation after adjustment. Allow residual deformation for the target.

[0167] When the following conditions are met: When the residual deformation after adjustment meets the target compensation requirements, the adjustment operation ends.

[0168] When the following conditions are met: When the time is insufficient, it indicates that the control compensation is insufficient, and the process parameter generation unit will correct the process parameters for the next control based on the residual deformation deviation.

[0169] The corrected heat input per unit length can be determined using the following formula:

[0170] ;

[0171] in, For the (n+1)th adjustment of movement speed, For the (n+1)th adjustment power, This represents the heat input per unit length for the (n+1)th adjustment.

[0172] The corrected control process parameters are sent to the control module, which then controls the control trolley 3 to perform the control operation again. By repeating the on-board 3D scanning detection, parameter correction, and re-control process, the residual deformation amount continues until it meets the target allowable residual deformation requirement or reaches the preset maximum number of control operations.

Claims

1. A ship assembly electromagnetic induction deformation control system, comprising a control trolley (3) and a cooling device (1) providing circulating cooling medium for the control trolley (3), and a frequency converter and voltage converter power supply (2) providing electrical energy for the control trolley (3), characterized in that: The control trolley (3) includes a vehicle body module, on which a walking drive module for movement is provided. A magnetic adsorption module and an electromagnetic induction heating module are respectively installed at the bottom of the vehicle body module. An on-board three-dimensional scanning detection unit (309) is set at the front of the vehicle body module. An on-board transformer power supply module (305), a process parameter generation unit and a control module are integrated inside the vehicle body module. The control module is connected to the on-board three-dimensional scanning detection unit (309), the process parameter generation unit, the walking drive module and the electromagnetic induction heating module respectively.

2. The ship assembly electromagnetic induction deformation control system according to claim 1, characterized in that: The walking drive module includes two drive wheels (301) installed on opposite sides of the vehicle body module and a universal wheel (308) installed at the bottom rear of the vehicle body module. The two drive wheels (301) are connected to drive motors respectively for driving the vehicle body forward, backward and differential steering. The drive motors are connected to the control module signal.

3. The ship assembly electromagnetic induction deformation control system according to claim 2, characterized in that: The magnetic adsorption module includes a magnet assembly (307), and the vehicle body module includes a frame. The frame is a hollow square box structure with a long protrusion on its bottom surface, making the vertical cross-section of the frame L-shaped. The magnet assembly (307) is installed at the bottom of the protrusion, and the caster wheel (308) is installed at the bottom of the frame opposite to the protrusion. The protrusion compensates for the height difference formed by the caster wheel (308) at the bottom of the frame. The caster wheel (308) is installed at the bottom of the frame through an elastic clamping structure. Two drive wheels (301) are installed on opposite sides of the frame at the protrusion.

4. The ship assembly electromagnetic induction deformation control system according to claim 3, characterized in that: The electromagnetic induction heating module includes a coaxial transformer (303) and a dual-channel heating head (306). The coaxial transformer (303) is installed inside the frame, and the dual-channel heating head (306) is connected to the coaxial transformer (303). The dual-channel heating head (306) is installed downwards and sequentially through the bottom of the frame and the protrusion, so that it faces the side of the frame corresponding to the area to be controlled.

5. The ship assembly electromagnetic induction deformation control system according to claim 1, characterized in that: The control module includes a main control board (304) and a motor controller (302) connected to it by signals. The motor controller (302) is connected to the walking drive module by signals. The main control board (304) integrates a process parameter generation unit. The vehicle-mounted three-dimensional scanning detection unit (309) and the electromagnetic induction heating module are respectively connected to the main control board (304) by signals.

6. The ship assembly electromagnetic induction deformation control system according to claim 1, characterized in that: The vehicle-mounted three-dimensional scanning detection unit (309) includes a line laser three-dimensional contour scanning sensor, a heat insulation protective cover, a walking encoder, and a data processing module. The data processing module is connected to the line laser three-dimensional contour scanning sensor and the walking encoder respectively, and is used to match the three-dimensional contour data with the vehicle's movement position information and generate three-dimensional point cloud data of the area to be controlled.

7. A control method for a ship assembly electromagnetic induction deformation control system as described in any one of claims 1 to 6, characterized in that... Includes the following steps: Step S1: The control module controls the adjustment trolley to move along the preset detection path, and the vehicle-mounted three-dimensional scanning detection unit performs a pre-adjustment scan of the area to be adjusted to obtain the three-dimensional point cloud data of the surface of the component to be adjusted. Step S2: The process parameter generation unit inside the trolley establishes a target reference surface based on the three-dimensional point cloud data, calculates the height deviation of the scanning point relative to the target reference surface, and extracts the location, length, width and maximum deflection of the deformation area. Step S3: The process parameter generation unit combines the material properties, plate thickness and stiffener spacing of the component to be assembled, and calculates the target compensation amount based on the maximum deflection and the target allowable residual deformation. Step S4: The process parameter generation unit generates initial control process parameters based on the target compensation amount, material properties, plate thickness, stiffener spacing, and deformation area size; the initial control process parameters include electromagnetic induction heating power, control time, control moving speed, induction heating power supply frequency, number of control channels, control path, and control sequence; Step S5: The control module controls the control trolley to move to the control starting position according to the initial control process parameters, and moves along the generated control path. At the same time, it controls the electromagnetic induction heating module to perform electromagnetic induction deformation control operation according to the set electromagnetic induction heating power, control movement speed, control time and induction heating power frequency. Step S6: After the adjustment is completed, after the adjustment area cools down to the preset detection temperature or after the preset cooling time, the control module controls the adjustment trolley to return along the original adjustment path or pass through the adjustment area again. The vehicle-mounted three-dimensional scanning detection unit rescans the surface of the adjusted component to obtain the residual deformation after adjustment. Step S7: The process parameter generation unit compares the adjusted residual deformation with the target allowable residual deformation and calculates the residual deformation deviation; Step S8: When the residual deformation is greater than the target allowable residual deformation, the process parameter generation unit corrects the electromagnetic induction heating power, control time, control moving speed, control number, control path or control sequence according to the residual deformation deviation, and sends the corrected control process parameters to the control module. In step S9, the control module controls the control trolley to perform deformation control operation again according to the corrected control process parameters, and repeats steps S6 to S8 until the residual deformation meets the target allowable residual deformation requirement or reaches the preset maximum number of control operations.

8. The control method for a ship assembly electromagnetic induction deformation control system according to claim 7, characterized in that, In step S2, the target reference surface is represented as: ； in, For the target reference plane in coordinate The height values ​​at the location, where a, b, and c are the fitting coefficients of the target reference surface; For any scan point obtained from a 3D scan The height deviation of the scanning point relative to the target reference plane is expressed as: ； in, Let be the height deviation of the i-th scan point relative to the target reference plane. Let be the actual height of the i-th scan point, then the initial deformation is expressed as: ； in, This represents the initial deformation after welding. The scan point is included in the deformation region when the height deviation of the scan point meets the following conditions: ； in, The threshold for deformation recognition; Determine the length of the deformation region based on the coordinate range of the scan points within the deformation region. and the width of the deformation area , where the length of the deformed region Used to determine the length of the control path and the width of the deformation region. Used to determine the number of control channels; In step S3, the target compensation amount is expressed as: ； in, For the target compensation amount, Allowable residual deformation for the target; When the following conditions are met: When the current deformation of the component meets the target allowable residual deformation requirement, no adjustment operation is performed; When the following conditions are met: At that time, the process parameter generation unit enters the process of generating control process parameters.

9. The control method of a ship assembly electromagnetic induction deformation control system according to claim 8, characterized in that, The process parameter generation unit generates parameters based on the target compensation amount. The intensity of regulation is classified into levels: When the following conditions are met: When the deformation is determined to be slight, a low heat input single-channel control parameter is generated. When the following conditions are met: When the deformation is determined to be moderate, a dual-channel control parameter for moderate heat input is generated. When the following conditions are met: When the deformation is deemed large, high-heat input multi-channel zone control parameters are generated. in, The first compensation threshold is... The second compensation threshold is set in advance based on the thickness of the ship assembly components and the material type. The process parameter generation unit determines the target unit length heat input based on the target compensation amount, material properties, plate thickness, and stiffener spacing. The target unit length heat input is expressed as: ； in, For the target unit length heat input, Based on the heat input per unit length, This is a material correction factor. This is the plate thickness correction factor. This is the correction factor for the stiffener spacing. This is the deformation correction factor; The deformation correction coefficient can be determined according to the following formula: ； The plate thickness correction factor can be determined according to the following formula: ； The stiffener spacing correction factor can be determined according to the following formula: ； in, The coefficient representing the influence of deformation. The plate thickness influence coefficient is... The influence coefficient of stiffener spacing is... For the thickness of the component plate to be adjusted, Based on the plate thickness, This refers to the actual spacing between the stiffeners. The reference stiffener spacing; In this way, when the target compensation amount increases, the plate thickness increases, or the stiffener spacing increases, the target heat input per unit length increases accordingly; when the target compensation amount decreases, the plate thickness decreases, or the stiffener spacing decreases, the target heat input per unit length decreases accordingly.

10. The control method of a ship assembly electromagnetic induction deformation control system according to claim 9, characterized in that, The following relationship exists between heat input per unit length, control power, and control moving speed: ； in, To regulate power, To control movement speed; The electromagnetic induction heating power is determined by the following formula: ； in, This refers to the power of electromagnetic induction heating. This represents the efficiency coefficient of electromagnetic induction heating. For output voltage, For output current; When adjusting power Once determined, the process parameter generation unit adjusts the moving speed based on the target unit length heat input: ； When the calculated control moving speed exceeds the preset speed upper limit or falls below the preset speed lower limit, the process parameter generation unit jointly corrects the control power and control moving speed to meet the equipment operating capacity and control process requirements. The adjustment period is determined by the following formula: ； in, The control time corresponding to a single control path. To control the path length, To control movement speed; The number of control channels is determined by the following formula: ； in, To control the number of lanes, The width of the deformation region. The effective thermal influence width for single-channel control is shown in square brackets []. The effective heating depth in the electromagnetic induction heating process is expressed by the following formula: ； in, For effective heating depth, The resistivity of the material The magnetic permeability of the material, The frequency of the induction heating power supply; Based on the target heating depth The frequency of the induction heating power supply can be determined according to the following formula: ； The process parameter generation unit calculates the residual deformation deviation based on the residual deformation and the target allowable residual deformation: ； in, This represents the residual deformation deviation. This refers to the residual deformation after adjustment. Allowable residual deformation for the target; When the following conditions are met: When the residual deformation after adjustment meets the target compensation requirements, the adjustment operation ends. When the following conditions are met: When this occurs, it indicates that the control compensation is insufficient, and the process parameter generation unit will correct the process parameters for the next control based on the residual deformation deviation; The corrected heat input per unit length can be determined using the following formula: ； in, For the (n+1)th adjustment of movement speed, For the (n+1)th adjustment power, This represents the heat input per unit length for the (n+1)th adjustment.

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