Ultra-light yielding (ULY) steel frame fabrication and quality control method

Abstract

The application discloses a method for manufacturing and quality control of super-light yielding ULY steel frame. The method comprises the following steps: establishing a standard digital model of the super-light yielding ULY steel frame; determining detection feature points; obtaining measured data of the super-light yielding ULY steel frame after processing; calculating cross-section forming quality indexes, end processing quality indexes, surface defect quality indexes and longitudinal forming quality indexes; normalizing each quality index and calculating a comprehensive processing quality index; and feeding back and correcting forming parameters, cutting parameters, constraint parameters and feeding parameters in the processing of the super-light yielding ULY steel frame. The application adopts a standard cross-section contour, a standard component forming axis and a characteristic length normalization processing mode to establish a quality evaluation model, and through dimensionless calculation of each deviation index, the method can be applied to super-light yielding ULY steel frames of different sizes, different types and different design parameters, and has good universality and scalability.

Description

Technical Field

[0001] This invention relates to the field of underground engineering support technology, and in particular to the fabrication and quality control methods of ultra-lightweight pressure-relief ULY steel frames. Background Technology

[0002] Ultra-lightweight yielding (ULY) steel frames are widely used in underground engineering support systems for deep tunnels, tunnels, and underground chambers. Their manufacturing process typically includes uncoiling, roll forming, length sawing, roll bending, and finished product stacking. Because the components use open, thin-walled, irregularly shaped cross-sections and the material has high strength, they are susceptible to defects during processing due to factors such as material springback, roller wear, equipment precision, processing parameters, and process conditions. These defects can easily lead to problems such as cross-sectional profile deviations, poor fit at the press joints, end bursts, skewed cuts, surface bulges, longitudinal forming axis deviations, curvature fluctuations, unloading springback, and bending radius deviations. These defects affect the assembly quality, load-bearing capacity, and yielding stability of the components.

[0003] In existing technologies, the inspection of the processing quality of ultra-lightweight ULY steel frames mainly relies on manual visual inspection, sample comparison, or local dimensional measurement, and usually only evaluates a single dimension or local defect. At the same time, there is a lack of unified quantitative indicators and evaluation standards between different inspection items, making it difficult to objectively reflect the processing quality of the entire steel frame and the processing consistency along the length direction, which is not conducive to quality comparison between different batches of products and production process control.

[0004] Therefore, existing technologies lack a quality quantification evaluation method and feedback control mechanism applicable to the processing of ultra-lightweight pressure-reducing ULY steel frames. They cannot uniformly convert different types of processing defects into measurable, calculable, and comparable evaluation indicators, and optimize and adjust processing parameters based on the evaluation results. As a result, it is difficult to meet the requirements of high-quality and high-consistency manufacturing of ultra-lightweight pressure-reducing ULY steel frames. Summary of the Invention

[0005] To address the aforementioned issues, this invention provides a method for manufacturing and quality control of ultralight pressure-reducing ULY steel frames, aiming to solve the problems of difficulty in quantifying quality defects and difficulty in correcting processing parameters based on quality results during the processing of ultralight pressure-reducing ULY steel frames.

[0006] The present invention adopts the following technical solution:

[0007] The fabrication and quality control methods for ultra-lightweight, pressure-reducing ULY steel frames include the following steps:

[0008] S1. Establish a standard digital model of the ultra-lightweight ULY steel frame. The standard digital model includes the standard cross-sectional profile, the longitudinal forming axis of the standard components, and the end structural parameters.

[0009] S2. Determine the detection feature points based on the geometric abrupt change locations, connection and fitting areas, local easily deformable areas, end processing sensitive areas, and longitudinal forming control areas in the standard cross-sectional profile;

[0010] S3. Obtain the measured data of the ultra-lightweight ULY steel frame after processing. The measured data shall include at least the measured cross-sectional profile data, end shape data, longitudinal centerline data, mating area gap data, and surface defect data.

[0011] S4. Based on the deviation between the measured data and the standard digital model, calculate the cross-section forming quality index, end processing quality index, surface defect quality index and longitudinal forming quality index respectively.

[0012] S5. Normalize each quality indicator and calculate the comprehensive processing quality index based on the preset weighting coefficients.

[0013] S6. Based on the relationship between the comprehensive processing quality index or at least one individual quality indicator and the preset threshold, feedback correction is performed on the forming parameters, cutting parameters, constraint parameters and feeding parameters during the processing of the ultra-lightweight ULY steel frame.

[0014] According to the aforementioned method for manufacturing and quality control of ultra-lightweight ULY steel frames, in S2, the detection feature points include cross-sectional contour feature points, fitting area feature points, end feature points, surface bulge detection points, and component longitudinal centerline sampling points;

[0015] The ultra-lightweight ULY steel frame has a channel-shaped cross-section with an open top. It is formed by the oppositely arranged first side wall, second side wall and bottom connecting section. The top two sides of the channel are symmetrically arranged with pressing parts. The whole is a U-shaped or trapezoidal channel cross-section with outward pressing edges.

[0016] The cross-sectional profile feature points are arranged at the midpoint and two corners of the bottom connecting section, the upper and lower turning points of the first side wall and the second side wall, the transition fillet or bend between the first side wall and the pressing part, the transition fillet or bend between the second side wall and the pressing part, the end point of the outer contour of the pressing part, and the edge of the groove opening. These features are used to characterize the bottom wall width, side wall inclination angle, groove width, pressing part fitting shape, and overall cross-sectional forming deviation.

[0017] Feature points of the bonding area are set on the edges of the two pressing parts to be bonded;

[0018] End feature points are set at the end of the crimped part, the end of the side wall part, and the end of the bottom connecting section on the sawn end face;

[0019] Surface bulge detection points are set at the middle of the side wall, the bottom connecting section, and the root of the crimped part;

[0020] The sampling points along the longitudinal centerline of the component are set at intervals along the length of the component.

[0021] Furthermore, the measured data are obtained through non-contact measurement, contact measurement, or a combination of both.

[0022] Non-contact measurement methods include at least one of laser scanning, 3D optical measurement, machine vision inspection, and point cloud reconstruction.

[0023] Contact measurement methods include at least one of mechanical probe measurement and sample comparison testing;

[0024] The cross-sectional contour data, end shape data, longitudinal center trajectory data, mating area gap data, and surface bulge deformation data of the processed components are obtained through the above detection methods.

[0025] Furthermore, in S4, the cross-section forming quality indicators include cross-section profile deviation indicators, fitting state evaluation indicators, and cross-section consistency indicators;

[0026] The calculation method for the cross-sectional profile deviation index is as follows:

[0027] ;

[0028] In the formula, The cross-sectional profile deviation index of the j-th test section; j is the test section number set along the longitudinal direction of the ultra-lightweight ULY steel frame; k is the feature point number within a single test section; This is the position vector of the kth feature point of the standard cross-sectional profile; Let be the position vector of the k-th feature point corresponding to the j-th measured cross section; m is the total number of feature points contained in each detection cross section. This is the characteristic length of the standard cross section, used to perform dimensionless processing on the deviation value;

[0029] The bonding condition evaluation index is used to evaluate the actual bonding quality of the crimped parts on both sides of the ultra-lightweight ULY steel frame. The bonding condition evaluation index includes bonding rate and bonding defect index.

[0030] The method for calculating the fit rate is as follows:

[0031] ;

[0032] In the formula, For the fit rate; Position of the mating area along its length Local normal gap at the location, To allow the maximum clearance, It is an indicator function; This is the theoretical total length of the mating region to be evaluated in the standard cross section;

[0033] The calculation method for the bonding defect index is as follows:

[0034] ;

[0035] In the formula, To meet the defect indicators;

[0036] The calculation method for the cross-sectional consistency index is as follows:

[0037] ;

[0038] In the formula, For cross-sectional consistency index; This refers to the number of test sections selected along the length of the component. This is an index for the overall cross-sectional profile deviation.

[0039] Overall cross-sectional profile deviation index The calculation method is as follows:

[0040] .

[0041] Furthermore, the end processing quality indicators include the end burr index and the cut deviation index;

[0042] The calculation method for the end-burst index is as follows:

[0043] ;

[0044] In the formula, E0 is the end blast index; b e b0 is the amount of opening at the machined end; b0 is the standard amount of opening at the end; L0 is the standard characteristic length of the cross section.

[0045] The calculation method for the incision deviation index is as follows:

[0046] ;

[0047] In the formula, Indicator of incision deviation; This is the measured cut angle; This is the standard cutting angle.

[0048] Furthermore, in S4, the surface defect quality indicators include the percentage of bulge area and the maximum bulge index;

[0049] The method for calculating the percentage of bulge area is as follows:

[0050] ;

[0051] In the formula, This represents the percentage of the area of ​​the bulge. This is the normal bulge height value at the component's test surface position (x, y) relative to the standard surface reference; The allowable bulge height; A is the detection area;

[0052] The calculation method for the maximum bulge index is as follows:

[0053] ;

[0054] In the formula, This represents the maximum bulge index; This represents the maximum bulge height. This is the characteristic length of the standard cross-section.

[0055] Furthermore, in S4, the longitudinal forming quality indicators include forming axis deviation, longitudinal curvature fluctuation index, and unloading springback index;

[0056] The calculation method for the forming axis deviation is as follows:

[0057] ;

[0058] In the formula, This is due to deviation of the forming axis; The characteristic length of the forming axis is designed for the standard component; n is the number of sampling points for the longitudinal axis. Design the spatial coordinate vector of the i-th axis sampling point on the forming axis of the standard component; This is the spatial coordinate vector of the i-th corresponding sampling point on the actual longitudinal center trajectory of the processed component;

[0059] The calculation method for the longitudinal curvature fluctuation index is as follows:

[0060] ;

[0061] In the formula, This is a longitudinal curvature fluctuation index; The design curvature of the i-th point on the forming axis of the standard component; ε is the curvature of the i-th point on the longitudinal centerline of the measured component; ε is the correction amount to prevent the denominator from being zero.

[0062] The calculation method for the unloading rebound index is as follows:

[0063] ;

[0064] In the formula, For unloading and rebound indicators; Let be the position coordinate vector of the i-th axis sampling point of the component under the constraint of processing and forming; The position coordinate vector of the i-th free state axis sampling point after the component has been processed and the forming constraints have been released.

[0065] Furthermore, in S4, when the longitudinal design axis of the component is an arc, the longitudinal forming quality index also includes the bending radius deviation; the calculation method for the bending radius deviation is as follows:

[0066] ;

[0067] In the formula, E R R0 is the bending radius deviation; R0 is the theoretical bending radius obtained by fitting the design forming axis; Rbending radius m The measured bending radius is obtained by fitting the actual longitudinal center trajectory after processing.

[0068] When the longitudinal design axis of the component is not a circular arc or the bending radius does not need to be evaluated, E R It is zero.

[0069] Furthermore, in S5, the calculation method for the comprehensive processing quality index is as follows:

[0070] ;

[0071] In the formula, Q is the comprehensive processing quality index; to These are the weighting coefficients.

[0072] Furthermore, S6 specifically refers to the following: The main components of the ultra-lightweight ULY steel frame are formed by using a continuous roll forming equipment to perform multiple roll forming, edge rolling, straightening, and length cutting on steel plates or strips, so that the legs, steel trusses, or their main cross sections are formed continuously in one piece; and during the forming process, the roller spacing, pressing amount, forming passes, feeding speed, cutting parameters, or straightening parameters are corrected based on the cross section forming quality index, end processing quality index, surface defect quality index, longitudinal forming quality index, and comprehensive processing quality index.

[0073] Compared with the prior art, the present invention has the following beneficial effects:

[0074] (1) The present invention adopts the standard cross-sectional profile, standard component forming axis and characteristic length normalization method to establish a quality evaluation model. By performing dimensionless calculation on various deviation indicators, the quality evaluation results are not affected by changes in component cross-sectional size, component length and specifications. It can be applied to ultra-lightweight pressure-relief ULY steel frames of different sizes, models and design parameters. It has good versatility and scalability, which is conducive to establishing a unified processing quality evaluation standard.

[0075] (2) This invention establishes a multi-dimensional processing quality evaluation system consisting of cross-sectional profile deviation index, bonding defect index, end processing quality index, surface defect index and longitudinal forming quality index. It transforms empirical processing defects such as cross-sectional size deviation, poor bonding of the pressing part, end bursting, surface bulging, longitudinal forming deviation, curvature fluctuation, unloading springback and other empirical processing defects into measurable and calculable quantitative evaluation indicators. It realizes the digital evaluation of the processing quality of ultra-lightweight ULY steel frame, improves the objectivity, accuracy and repeatability of processing quality evaluation, and reduces the error caused by human judgment. Attached Figure Description

[0076] Figure 1 Flowchart of the fabrication and quality control methods for ultralight pressure-reducing ULY steel frames;

[0077] Figure 2 A three-dimensional structural diagram of the ultra-lightweight, pressure-reducing ULY steel frame;

[0078] Figure 3 A schematic diagram of the cross-section of the ultralight, pressure-reducing ULY steel frame;

[0079] Figure 4 A schematic diagram illustrating the quantification of cross-sectional forming quality and the arrangement of feature points;

[0080] Figure 5 This is a schematic diagram illustrating the evaluation of the deviation between the end blast opening and the cut.

[0081] Figure 6 A schematic diagram for evaluating the bonding quality of the crimped joint of the ultralight ULY steel frame; Figure 6 (a) shows the crimped parts fully fitted. Figure 6 (b) shows the crimped part not being properly fitted;

[0082] Figure 7 Schematic diagram for evaluating the surface bulge quality of the ultralight ULY steel frame; Figure 7 (a) shows the state without bulges. Figure 7 (b) is the bulging state.

[0083] Explanation of reference numerals in the attached figures:

[0084] 1. First sidewall portion; 2. Second sidewall portion; 3. Bottom connecting section; 4. Press-fit portion. Detailed Implementation

[0085] To make the technical problem to be solved, the technical solution and advantages of the present invention clearer, the following description will be provided in conjunction with the accompanying drawings. Figures 1 to 7 The technical solution of the present invention will be clearly and completely described in conjunction with specific embodiments.

[0086] The flowchart of the fabrication and quality control method for ultralight pressure-reducing ULY steel frames is as follows: Figure 1As shown, the fabrication and quality control method for the ultralight pressure-reducing ULY steel frame includes the following steps:

[0087] S1. Establish a standard digital model of the ultra-lightweight ULY steel frame. The standard digital model includes the standard cross-sectional profile, the longitudinal forming axis of the standard components, and the end structural parameters. The standard cross-sectional profile is not limited to specific dimensions, but is expressed in the form of outlines, feature points, feature segments, and allowable deviations.

[0088] S2. Determine the detection feature points based on the locations of geometric abrupt changes, connecting and fitting areas, locally deformable areas, end processing sensitive areas, and longitudinal forming control areas in the standard cross-sectional profile. Detection feature points include cross-sectional profile feature points, fitting area feature points, end feature points, surface bulge detection points, and component longitudinal centerline sampling points.

[0089] like Figure 2 and Figure 3 As shown, the cross-section of the ultra-lightweight ULY steel frame is a groove-shaped cross-section with an open top. The groove is formed by the oppositely arranged first side wall, second side wall and bottom connecting section. The top two sides of the groove are symmetrically arranged with pressing parts. The whole is a U-shaped or trapezoidal groove cross-section with outward pressing edges.

[0090] like Figure 4 As shown, the circled locations represent feature point locations, which are preferably placed at points where the cross-sectional geometry changes abruptly or where processing defects are prone to occur. Specifically, the cross-sectional profile feature points are placed at the midpoint and end corners of the bottom connecting section, the upper and lower turning points of the first and second sidewalls, the transition fillets or bends between the first and second sidewalls, the transition fillets or bends between the second and third sidewalls and the pressing part, the endpoints of the outer contour of the pressing part, and the edge of the groove opening. These feature points characterize the bottom wall width, sidewall inclination angle, groove width, pressing part fit shape, and overall cross-sectional forming deviation.

[0091] For thin-walled sections, matching points of the inner and outer contours can be set in the first sidewall, second sidewall, bottom connecting section, and pressing section areas to characterize local flattening, bulging, and internal cavity deformation. The arrangement of these feature points can cover the geometric change zone, the main stress zone, the fitting control zone, and the easily deformable zone, thereby improving the completeness of the evaluation of the section forming quality.

[0092] Feature points for the bonding area are set at the edges of the two sides of the pressing part to be bonded; feature points for the ends are set at the ends of the pressing part, the ends of the side wall part, and the ends of the bottom connecting section on the sawn end face; surface bulge detection points are set at the middle of the side wall part, the bottom connecting section, and the root of the pressing part; sampling points for the longitudinal center line of the component are set at intervals along the length of the component.

[0093] After roll forming, multiple inspection sections are selected along the length of the component, and on each inspection section, feature points of the cross-section contour and feature points of the mating area are collected according to the above feature point arrangement. The cross-section contour deviation, the mating defect index of the two ears, and the cross-section consistency index are calculated. After sawing and segmenting, end feature points are collected and the end burr index and cut deviation index are calculated. After roll bending, sampling points of the longitudinal centerline of the component are collected and the forming axis deviation, longitudinal curvature fluctuation index, and unloading springback index are calculated. When the longitudinal design axis of the component is an arc, the bending radius deviation is further calculated. In the finished product inspection stage, surface bulge detection points are collected and the surface bulge index and comprehensive processing quality index are calculated.

[0094] S3. Obtain measured data of the processed ultra-lightweight ULY steel frame. The measured data includes at least measured cross-sectional profile data, end shape data, longitudinal centerline data, mating area gap data, and surface defect data. The measured data is obtained through non-contact measurement, contact measurement, or a combination of both. Non-contact measurement methods include at least one of laser scanning, three-dimensional optical measurement, machine vision inspection, and point cloud reconstruction. Contact measurement methods include at least one of mechanical probe measurement and template comparison inspection. The cross-sectional profile data, end shape data, longitudinal centerline trajectory data, mating area gap data, and surface bulge deformation data of the processed component are obtained through the above inspection methods.

[0095] S4. Based on the deviation between the measured data and the standard digital model, calculate the cross-section forming quality index, end processing quality index, surface defect quality index and longitudinal forming quality index respectively.

[0096] S5. Normalize each quality indicator and calculate the comprehensive processing quality index based on the preset weighting coefficients.

[0097] S6. Based on the relationship between the comprehensive processing quality index or at least one individual quality indicator and the preset threshold, the forming parameters, cutting parameters, constraint parameters and feeding parameters in the ultra-lightweight ULY steel frame processing process are corrected.

[0098] Furthermore, in S4, the cross-section forming quality indicators include cross-section profile deviation indicators, fitting state evaluation indicators, and cross-section consistency indicators.

[0099] Among them, the cross-sectional profile deviation index is used to characterize the spatial offset of the actual profile of the j-th detection cross-section relative to the standard cross-sectional profile, and its calculation method is as follows:

[0100] ;

[0101] In the formula, The cross-sectional profile deviation index of the j-th detection section; The numbering of the inspection section set along the longitudinal direction of the ultralight pressure-relief ULY steel frame; Number the feature points within a single detection section; This is the position vector of the kth feature point of the standard cross-sectional profile; Let be the position vector of the k-th feature point corresponding to the j-th measured cross section; m is the total number of feature points contained in each detection cross section. This is the characteristic length of the standard cross section, used to perform dimensionless processing on the deviation value.

[0102] The bonding condition evaluation index is used to evaluate the actual bonding quality of the crimped parts on both sides of the ultra-lightweight ULY steel frame. The bonding condition evaluation index includes bonding rate and bonding defect index.

[0103] Adhesion rate is used to evaluate the overall continuous adhesion, and its calculation method is as follows:

[0104] ;

[0105] In the formula, For the fit rate; Position of the mating area along its length Local normal gap at the location, To allow the maximum clearance, It is an indicator function; This is the theoretical total length of the mating area to be evaluated in the standard cross section.

[0106] The bonding defect index characterizes the degree to which the area to be bonded fails to meet the design bonding requirements. It reflects the proportion of missing effective bonding length, that is, the proportion of the actual area that does not meet the allowable gap requirement to the theoretical bonding area. A smaller bonding defect index indicates better bonding quality; a larger index indicates more severe bonding defects. The calculation method for the bonding defect index is as follows:

[0107] .

[0108] In the formula, To meet the defect indicators;

[0109] The cross-sectional consistency index is used to evaluate the uniformity of forming quality and processing stability of each tested cross-section along the length of the component. Its calculation method is as follows:

[0110] ;

[0111] In the formula, For cross-sectional consistency index; This refers to the number of test sections selected along the length of the component. This is the overall cross-sectional profile deviation index.

[0112] Overall cross-sectional profile deviation index The calculation method is as follows:

[0113] .

[0114] Cross-sectional profile deviation index It can evaluate the forming accuracy of a single test section, while the section consistency index This allows for further evaluation of the dispersion in forming accuracy among multiple test sections. Combining these two methods enables the evaluation of the cross-sectional forming quality of the ultra-lightweight, pressure-relief ULY steel frame from both local accuracy and overall processing stability dimensions. This improves the comprehensiveness and reliability of the processing quality evaluation results and provides a basis for subsequent processing parameter feedback and correction.

[0115] Furthermore, the end processing quality indicators include the end burr index and the cut deviation index.

[0116] The calculation method for the end-burst index is as follows:

[0117] ;

[0118] In the formula, E0 is the end blast index; b e b0 is the amount of opening at the end after machining; b0 is the standard amount of opening at the end; L0 is the standard characteristic length of the cross section.

[0119] The calculation method for the incision deviation index is as follows:

[0120] ;

[0121] In the formula, E q β is an indicator of incision deviation. e β0 represents the measured incision angle; β0 represents the standard incision angle.

[0122] Furthermore, in S4, the surface defect quality indicators include the percentage of bulge area and the maximum bulge index.

[0123] The method for calculating the percentage of bulge area is as follows:

[0124] ;

[0125] In the formula, This represents the percentage of the area of ​​the bulge. This is the normal bulge height value at the component's test surface position (x, y) relative to the standard surface reference; The allowable bulge height; A is the area of ​​the detection zone.

[0126] The calculation method for the maximum bulge index is as follows:

[0127] ;

[0128] In the formula, This represents the maximum bulge index; This represents the maximum bulge height. This is the characteristic length of the standard cross-section.

[0129] Furthermore, in S4, the longitudinal forming quality indicators include forming axis deviation, longitudinal curvature fluctuation index, and unloading springback index.

[0130] The calculation method for the forming axis deviation is as follows:

[0131] ;

[0132] In the formula, This is due to deviation of the forming axis; The characteristic length of the forming axis is designed for the standard component; n is the number of sampling points for the longitudinal axis. Design the spatial coordinate vector of the i-th axis sampling point on the forming axis of the standard component; Let be the spatial coordinate vector of the i-th corresponding sampling point on the actual longitudinal center trajectory of the processed component.

[0133] The calculation method for the longitudinal curvature fluctuation index is as follows:

[0134] ;

[0135] In the formula, This is a longitudinal curvature fluctuation index; The design curvature of the i-th point on the forming axis of the standard component; ε is the curvature of the i-th point on the longitudinal centerline of the measured component; ε is the correction amount to prevent the denominator from being zero.

[0136] The calculation method for the unloading rebound index is as follows:

[0137] ;

[0138] In the formula, For unloading and rebound indicators; Let be the position coordinate vector of the i-th axis sampling point of the component under the constraint of processing and forming; The position coordinate vector of the i-th free state axis sampling point after the component has been processed and the forming constraints have been released.

[0139] Furthermore, in S4, when the longitudinal design axis of the component is an arc, the longitudinal forming quality index also includes the bending radius deviation; the calculation method for the bending radius deviation is as follows:

[0140] ;

[0141] In the formula, R0 is the bending radius deviation; R0 is the theoretical bending radius obtained by fitting the design forming axis; Rbending radius m The measured bending radius is obtained by fitting the actual longitudinal center trajectory after processing.

[0142] When the longitudinal design axis of the component is not a circular arc or the bending radius does not need to be evaluated, E R It is zero.

[0143] Furthermore, in S5, the calculation method for the comprehensive processing quality index is as follows:

[0144] ;

[0145] In the formula, Q is the comprehensive processing quality index; to These are the weighting coefficients for different indicators.

[0146] Furthermore, S6 specifically refers to the following: The main components of the ultra-lightweight ULY steel frame are formed by using a continuous roll forming equipment to perform multiple roll forming, edge rolling, straightening, and length cutting on steel plates or strips, so that the legs, steel trusses, or their main cross sections are formed continuously in one piece; and during the forming process, the roller spacing, pressing amount, forming passes, feeding speed, cutting parameters, or straightening parameters are corrected based on the cross section forming quality index, end processing quality index, surface defect quality index, longitudinal forming quality index, and comprehensive processing quality index.

[0147] If the overall cross-sectional profile deviation index If the gap is large, prioritize adjusting the roller clearance and pressing amount of the roll forming unit; if it meets the defect index... If the gap is large, prioritize adjusting the crimping constraint gap and the closing shaping pressure; if the end bursting index is large... If the deviation is large, prioritize adjusting the sawing clamping force, cutting speed, and end constraint method; if the forming axis deviation is large... Unloading rebound index Or bending radius deviation If the value is large, prioritize adjusting the bending amount and roller spacing of the roller bending forming mechanism.

[0148] Feedback correction can be achieved through manual, semi-automatic, or automatic parameter tuning. When using automatic parameter tuning, the data processing unit outputs the correction amount for the processing parameters based on the difference between a single indicator and a threshold, and sends the correction amount to the corresponding processing mechanism.

[0149] This invention establishes a quality evaluation model using standard cross-sectional profiles, standard component forming axes, and characteristic length normalization. By performing dimensionless calculations on various deviation indicators, the quality evaluation results are unaffected by changes in component cross-sectional dimensions, component length, and specifications. It is applicable to ultra-lightweight ULY steel frames of different sizes, models, and design parameters, exhibiting good versatility and scalability, and is conducive to establishing a unified processing quality evaluation standard.

[0150] This invention establishes a multi-dimensional processing quality evaluation system consisting of cross-sectional profile deviation index, bonding defect index, end processing quality index, surface defect index, and longitudinal forming quality index. It transforms empirical processing defects such as cross-sectional dimension deviation, poor bonding of the crimped part, end bursts, surface bulges, longitudinal forming deviation, curvature fluctuation, and unloading springback into measurable and calculable quantitative evaluation indicators. This realizes the digital evaluation of the processing quality of ultra-lightweight ULY steel frames, improves the objectivity, accuracy, and repeatability of processing quality evaluation, and reduces errors caused by human judgment.

[0151] This invention establishes a correspondence between processing quality evaluation indicators and processing control parameters, and directly uses the test results for processing control. This achieves closed-loop control of ultra-lightweight, pressure-reducing ULY steel frames from quality inspection and evaluation to processing parameter optimization. It changes the existing technology where processing quality inspection and processing technology adjustment are independent of each other, improves the adaptive adjustment capability of the processing process and the consistency between product batches, and is of great significance for realizing the digital, standardized and intelligent control of the ultra-lightweight, pressure-reducing ULY steel frame processing process.

[0152] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit them. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the scope of the technology disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention.

Claims

1. A method for manufacturing and quality control of ultralight pressure-reducing ULY steel frames, characterized in that, The design methodology includes the following steps: S1. Establish a standard digital model of the ultra-lightweight ULY steel frame; the standard digital model includes the standard cross-sectional profile, the longitudinal forming axis of the standard components, and the end structural parameters. S2. Determine the detection feature points based on the geometric abrupt change locations, connection and fitting areas, local easily deformable areas, end processing sensitive areas, and longitudinal forming control areas in the standard cross-sectional profile; S3. Obtain the measured data of the ultra-lightweight ULY steel frame after processing. The measured data shall include at least the measured cross-sectional profile data, end shape data, longitudinal centerline data, mating area gap data, and surface defect data. S4. Based on the deviation between the measured data and the standard digital model, calculate the cross-section forming quality index, end processing quality index, surface defect quality index and longitudinal forming quality index respectively. S5. Normalize each quality indicator and calculate the comprehensive processing quality index based on the preset weighting coefficients. S6. Based on the relationship between the comprehensive processing quality index or at least one individual quality indicator and the preset threshold, feedback correction is performed on the forming parameters, cutting parameters, constraint parameters and feeding parameters during the processing of the ultra-lightweight ULY steel frame.

2. The method for manufacturing and quality control of ultra-lightweight ULY steel frames according to claim 1, characterized in that, In S2, the detection feature points include cross-sectional contour feature points, fitting area feature points, end feature points, surface bulge detection points, and component longitudinal centerline sampling points; The ultra-lightweight ULY steel frame has a channel-shaped cross-section with an open top. It is formed by the oppositely arranged first side wall, second side wall and bottom connecting section. The top two sides of the channel are symmetrically arranged with pressing parts. The whole is a U-shaped or trapezoidal channel cross-section with outward pressing edges. The cross-sectional profile feature points are arranged at the midpoint and two corners of the bottom connecting section, the upper and lower turning points of the first side wall and the second side wall, the transition fillet or bend between the first side wall and the pressing part, the transition fillet or bend between the second side wall and the pressing part, the end point of the outer contour of the pressing part, and the edge of the groove opening. These features are used to characterize the bottom wall width, side wall inclination angle, groove width, pressing part fitting shape, and overall cross-sectional forming deviation. Feature points of the bonding area are set on the edges of the two pressing parts to be bonded; End feature points are set at the end of the crimped part, the end of the side wall part, and the end of the bottom connecting section on the sawn end face; Surface bulge detection points are set at the middle of the side wall, the bottom connecting section, and the root of the crimping part; The sampling points along the longitudinal centerline of the component are set at intervals along the length of the component.

3. The method for manufacturing and quality control of ultralight pressure-reducing ULY steel frames according to claim 2, characterized in that, The measured data were obtained through non-contact measurement, contact measurement, or a combination of both. Non-contact measurement methods include at least one of laser scanning, 3D optical measurement, machine vision inspection, and point cloud reconstruction. Contact measurement methods include at least one of mechanical probe measurement and sample comparison testing; The cross-sectional contour data, end shape data, longitudinal center trajectory data, bonding area gap data, and surface bulge deformation data of the processed components are obtained through the above detection methods.

4. The method for manufacturing and quality control of the ultralight pressure-reducing ULY steel frame according to claim 3, characterized in that, In S4, the cross-section forming quality indicators include cross-section profile deviation indicators, fitting state evaluation indicators, and cross-section consistency indicators. The calculation method for the cross-sectional profile deviation index is as follows: ； In the formula, The cross-sectional profile deviation index of the j-th test section; j is the test section number set along the longitudinal direction of the ultra-lightweight ULY steel frame; k is the feature point number within a single test section; The position vector of the kth feature point of the standard cross-sectional profile; Let be the position vector of the k-th feature point corresponding to the j-th measured section; m is the total number of feature points contained in each detection section. This is the standard cross-sectional characteristic length, used to perform dimensionless processing on deviation values; The evaluation indicators for bonding status include bonding rate and bonding defect indicators; The method for calculating the fit rate is as follows: ； In the formula, For the fit rate; Position of the mating area along its length Local normal gap at the location, To allow the maximum clearance, It is an indicator function; This is the theoretical total length of the mating area to be evaluated in the standard cross section; The calculation method for the fitting defect index is as follows: ； In the formula, To meet the defect indicators; The calculation method for the cross-sectional consistency index is as follows: ； In the formula, As a cross-sectional consistency index; This refers to the number of test sections selected along the length of the component. This is an index for the overall cross-sectional profile deviation. Overall cross-sectional profile deviation index The calculation method is as follows: 。 5. The method for manufacturing and quality control of the ultralight pressure-relief ULY steel frame according to claim 4, characterized in that, End processing quality indicators include end burr mark indicators and cut deviation indicators; The calculation method for the end-burst index is as follows: ； In the formula, For end-explosion indicators; This refers to the opening amount at the end after machining. Standard end opening amount; The characteristic length of the standard cross section; The calculation method for the incision deviation index is as follows: ； In the formula, Indicator of incision deviation; This is the measured cut angle; This is the standard cutting angle.

6. The method for manufacturing and quality control of the ultralight pressure-relief ULY steel frame according to claim 5, characterized in that, In S4, the surface defect quality indicators include the percentage of bulge area and the maximum bulge index; The method for calculating the percentage of bulge area is as follows: ； In the formula, This represents the percentage of the area of ​​the bulge. This is the normal bulge height value at the component's test surface position (x, y) relative to the standard surface reference; The allowable bulge height; A is the area of ​​the detection region; The calculation method for the maximum bulge index is as follows: ； In the formula, This represents the maximum bulge index; This represents the maximum bulge height. This is the characteristic length of the standard cross-section.

7. The method for manufacturing and quality control of ultralight pressure-reducing ULY steel frames according to claim 6, characterized in that, In S4, the longitudinal forming quality indicators include forming axis deviation, longitudinal curvature fluctuation index, and unloading springback index. The calculation method for the forming axis deviation is as follows: ； In the formula, This is due to deviation of the forming axis; The characteristic length of the forming axis is designed for the standard component; n is the number of sampling points for the longitudinal axis. Design the spatial coordinate vector of the i-th axis sampling point on the forming axis of the standard component; This is the spatial coordinate vector of the i-th corresponding sampling point on the actual longitudinal center trajectory of the processed component; The calculation method for the longitudinal curvature fluctuation index is as follows: ； In the formula, This is a longitudinal curvature fluctuation index; The design curvature of the i-th point on the forming axis of the standard component; Let be the curvature of the i-th point on the longitudinal centerline of the measured component; ε is a correction factor to prevent the denominator from being zero; The calculation method for the unloading rebound index is as follows: ； In the formula, For unloading and rebound indicators; Let be the position coordinate vector of the i-th axis sampling point of the component under the constraint of processing and forming; The position coordinate vector of the i-th free state axis sampling point after the component has been processed and the forming constraints have been released.

8. The method for manufacturing and quality control of ultralight pressure-reducing ULY steel frames according to claim 7, characterized in that, In S4, when the longitudinal design axis of the component is an arc, the longitudinal forming quality index also includes the bending radius deviation; the calculation method for the bending radius deviation is as follows: ； In the formula, E R R0 is the bending radius deviation; R0 is the theoretical bending radius obtained by fitting the design forming axis; R0 m The measured bending radius is obtained by fitting the actual longitudinal center trajectory after processing. When the longitudinal design axis of the component is not a circular arc or the bending radius does not need to be evaluated, E R It is zero.

9. The method for manufacturing and quality control of ultralight pressure-reducing ULY steel frames according to claim 8, characterized in that, In S5, the calculation method for the comprehensive processing quality index is as follows: ； In the formula, The overall processing quality index; to These are the weighting coefficients.

10. The method for manufacturing and quality control of the ultralight pressure-relief ULY steel frame according to claim 9, characterized in that, S6 specifically refers to the use of continuous roll forming equipment to perform multiple roll forming, edge rolling, straightening, and length cutting on steel plates or strips, so that the legs, steel trusses, or their main cross sections are formed continuously as a whole. During the forming process, the roller spacing, pressing amount, forming passes, feeding speed, cutting parameters, or straightening parameters are fed back and corrected according to the cross section forming quality index, end processing quality index, surface defect quality index, longitudinal forming quality index, and comprehensive processing quality index.

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