Electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipe

Abstract

This utility model discloses an electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes, belonging to the technical field of spiral welded pipe forming equipment. It includes an industrial control computer for system control of the entire device, and a front axle drive system. The front axle drive system includes two electro-hydraulic servo cylinders and a cross-hinged front axle, with the two electro-hydraulic servo cylinders symmetrically installed on both sides of the cross-hinged front axle. This utility model, through the coordinated operation of the industrial control computer, front axle drive system, multi-sensor fusion detection system, dual closed-loop servo control system, forming angle calculation model, and human-machine interface terminal, achieves automatic detection and shaping. Compared to traditional manual shaping, it is more efficient, simpler to operate, and allows for more precise control, improving the pipe diameter qualification rate and ensuring processing quality. Simultaneously, during production, it can compensate for springback deformation in real time and automatically generate shaping logs for subsequent traceability.

Description

Technical Field

[0001] This utility model belongs to the technical field of spiral welded pipe forming equipment, and in particular relates to an electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes. Background Technology

[0002] Large-diameter spiral welded steel pipes are formed by spirally coiling and welding strip steel plates. The main operating steps are as follows: First, the steel coil is hoisted onto an uncoiler and slowly unrolled. A leveler then eliminates the coiling stress and wavy bends of the steel plate, making it flat. After correction, it is fed into a forming machine via a delivery machine. Under the stable thrust of the delivery machine, the steel plate is forcibly bent, and the edges gradually curl up along a forming die, forming a stable spiral shape. During the delivery process, the diameter of the steel pipe is controlled by adjusting the angle of the forming machine and the speed of the delivery machine. Finally, a round pipe is formed through welding.

[0003] The forming of steel pipes requires adjustment using a front-swing unit. However, traditional front-swing units typically require three people to operate the hydraulic valves, with a single adjustment taking ≥180 minutes, which is too time-consuming and results in low processing efficiency. Furthermore, relying on manual experience to control the front axle swing leads to a forming angle error of ±0.5°, resulting in a pipe diameter deviation >10mm. Additionally, real-time compensation for springback deformation is impossible during production, resulting in an ellipticity exceeding the standard rate >30%. Moreover, the adjustment parameters are usually not digitally recorded during the adjustment process, making process optimization difficult and operation extremely inconvenient. Therefore, we propose an electro-hydraulic servo intelligent forming device for ultra-large diameter spiral steel pipes to solve the aforementioned problems. Summary of the Invention

[0004] In view of this, in order to solve the problems of low efficiency of manual operation, difficulty in controlling accuracy, poor dynamic response and lack of subsequent data traceability of traditional front-swing units, which lead to difficulties in process optimization and great inconvenience in operation, this utility model provides an electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes.

[0005] To achieve the above objectives, this utility model provides the following technical solution: an electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes, including an industrial control computer for system control of the entire device; It also includes a front axle drive system, which includes two electro-hydraulic servo cylinders and a cross-hinged front axle, with the two electro-hydraulic servo cylinders symmetrically mounted on both sides of the cross-hinged front axle. It also includes a multi-sensor fusion detection system, which includes multiple tilt sensors and a laser rangefinder. The multiple tilt sensors are all arranged on the cross hinge front axle to measure the tilt angle of the cross hinge front axle, and the laser rangefinder is used to monitor the gap between the tube blank and the forming roll in real time. It also includes a dual closed-loop servo control system, which comprises a position loop and a force loop; the position loop detects the position of the steel pipe through sensors to ensure that the position of the steel pipe is accurate during the forming process; the force loop detects the force on the steel pipe during the forming process through sensors to ensure that the force on the steel pipe during the forming process is uniform and meets the requirements; It also includes a forming angle calculation model, which automatically calculates the theoretical forming angle based on the steel pipe specifications; It also includes a human-machine interaction terminal, which includes a touch screen, an alarm, and a modeling log generation module; the touch screen is used to display the real-time forming angle θ, the theoretical value θ0, and the deviation Δθ; the alarm is used to alarm for forming angle deviation; and the modeling log generation module is used to automatically generate a modeling log.

[0006] Furthermore, the angle between the thrust axis of the electro-hydraulic servo cylinder and the center line of the tube body is 45°-60°.

[0007] Furthermore, the two electro-hydraulic servo cylinders are symmetrically mounted in a V-shape on both sides of the cross-hinged front axle.

[0008] Furthermore, the dual closed-loop servo control system has a built-in springback compensation database for storing springback correction curves for different steel grades.

[0009] Furthermore, the dual closed-loop servo control system automatically calls up the compensation curve through the springback compensation database and according to the steel grade code, with the compensation angle Δθ = k1·σ + k2·t; Where σ is the yield strength, t is the wall thickness, and k1 / k2 is the material coefficient.

[0010] Furthermore, the tuning log automatically generated by the tuning log generation module includes timestamps, operator information, and oil pressure curves.

[0011] Furthermore, a mechanical limit stop is provided that works in conjunction with the cross-hinged front axle for angle limiting.

[0012] Furthermore, an over-limit hydraulic pressure shutdown threshold is provided for use in conjunction with the electro-hydraulic servo cylinder and for protection.

[0013] The embodiments of this utility model have the following beneficial effects: This invention, through the coordinated operation of an industrial control computer, a front axle drive system, a multi-sensor fusion detection system, a dual closed-loop servo control system, a forming angle calculation model, and a human-machine interface terminal, achieves automatic detection and shaping. Compared to traditional manual shaping, it is more efficient, simpler to operate, and allows for more precise control, improving pipe diameter qualification rate and ensuring processing quality. Simultaneously, during production, it can compensate for springback deformation in real time and automatically generate shaping logs for subsequent data traceability, enabling better process optimization.

[0014] Other advantages, objectives, and features of this invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination and study, or may be learned from practice of this invention. The objectives and other advantages of this invention can be realized and obtained through the following description. Attached Figure Description

[0015] To make the objectives, technical solutions, and advantages of this utility model clearer, the preferred embodiments of this utility model will be described in detail below with reference to the accompanying drawings, wherein: Figure 1 This is a block diagram of the overall structure of the electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes of this utility model; Figure 2 This is a block diagram of the front axle drive system. Figure 3 This is a block diagram of a multi-sensor fusion detection system. Figure 4 This is a block diagram of a dual closed-loop servo control system. Figure 5 This is a structural block diagram of a human-computer interaction terminal.

[0016] In the diagram: 10, Industrial PC; 20, Front axle drive system; 201, Electro-hydraulic servo cylinder; 202, Cross-hinged front axle; 30, Multi-sensor fusion detection system; 301, Tilt sensor; 302, Laser rangefinder; 40, Dual closed-loop servo control system; 401, Position loop; 402, Force loop; 50, Forming angle calculation model; 60, Human-machine interface terminal; 601, Touch screen; 602, Alarm; 603, Adjustment log generation module. Detailed Implementation

[0017] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this utility model. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0018] Please see Figures 1-5 This embodiment provides an electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes, including an industrial control computer 10, a front axle drive system 20, a multi-sensor fusion detection system 30, a dual closed-loop servo control system 40, a forming angle calculation model 50, and a human-machine interaction terminal 60. The industrial control computer 10 is used for system control of the entire device. The front axle drive system 20 includes two electro-hydraulic servo cylinders 201 and a cross-hinged front axle 202. The two electro-hydraulic servo cylinders 201 are symmetrically installed on both sides of the cross-hinged front axle 202, adopting a thrust redundancy design and a V-shaped layout, with their thrust axis forming an angle of 45°-60° with the center line of the pipe body. By setting two electro-hydraulic servo cylinders 201 to replace the traditional single-cylinder design, the normal operation of the system or equipment can be effectively guaranteed. The electro-hydraulic servo cylinders 201 are of the 200t class. The cross-hinged front axle 202 is equipped with a cross universal hinge base, which can eliminate lateral force interference and make the swing plane accuracy ≤0.05mm / m. In addition, to enhance the safety protection of the device, an over-pressure shutdown threshold is set for use with the electro-hydraulic servo cylinder 201. This threshold is set to >31.5MPa. When this threshold is exceeded, the electro-hydraulic servo cylinder 201 automatically stops working. A mechanical limit block is also provided for use with the cross-hinged front axle 202. This mechanical limit block limits the rotation angle of the cross-hinged front axle 202, controlling its stroke within ±5°, thus achieving a limit protection effect.

[0019] In one aspect of this embodiment, the multi-sensor fusion detection system 30 includes multiple tilt sensors 301 and a laser rangefinder 302. The tilt sensors 301 are all arranged on the cross-hinged front axle 202 and are used to measure the tilt angle of the cross-hinged front axle 202 in real time during the rotation driven by the electro-hydraulic servo cylinder 201. The tilt sensors 301 are MEMS tiltmeters with a range of ±10° and a resolution of 0.001°. The laser rangefinder 302 is mounted via a bracket, which is installed close to the measuring tube to reduce measurement errors and is used for real-time monitoring of the gap between the tube blank and the forming roller. The accuracy of the laser rangefinder 302 is controlled within ±0.1 mm.

[0020] In one aspect of this embodiment, the dual-closed-loop servo control system 40 includes a position loop 401 and a force loop 402. The position loop 401 is controlled by hydraulic cylinder displacement with a control accuracy of ±0.05mm. The position loop 401 detects the position of the steel pipe using sensors to ensure accurate positioning during the forming process. The force loop 402 is controlled by hydraulic pressure balance with a control fluctuation ≤±2MPa. The force loop 402 detects the stress on the steel pipe during the forming process using sensors to ensure uniform and compliant stress distribution. Furthermore, the dual-closed-loop servo control system 40 also includes a built-in springback compensation database for storing springback correction curves for different steel grades (Q235-Q690). The dual-closed-loop servo control system 40 automatically retrieves the compensation curve from the springback compensation database based on the steel grade code. The compensation angle Δθ = k1·σ + k2·t; where σ is the yield strength, t is the wall thickness, and k1 / k2 is the material coefficient.

[0021] In one aspect of this embodiment, the forming angle calculation model 50 automatically calculates the theoretical forming angle θ = arcsin(plate width / πD) based on the steel pipe specifications. Assuming the plate width is 1500mm, then the θ corresponding to the Ф4220 pipe body is approximately 83.46°.

[0022] In one aspect of this embodiment, the human-machine interface terminal 60 includes a touchscreen 601, an alarm 602, and a molding log generation module 603. The touchscreen 601 displays the real-time molding angle θ, the theoretical value θ0, and the deviation Δθ. The alarm 602 is used for molding angle deviation alarms, with Δθ set to ≥0.3° and the alarm time set to 5 seconds, thereby further enhancing safety protection. The out-of-tolerance alarm threshold is controlled within ±0.1°. The molding log generation module 603 automatically generates a molding log containing timestamps, operator information, and hydraulic pressure curves, enabling subsequent data traceability, better process optimization, and more convenient operation.

[0023] This invention can be used in the field of electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes, and can also be applied to other fields of this invention.

[0024] This embodiment takes the production of Q355C spiral steel pipe with a diameter of Ф4220×24mm as an example. First, the pipe diameter of 4220mm and the plate width of 1500mm are input through the HMI interface on the touch screen 601. The system then automatically calculates the theoretical forming angle as 83.46°. Then, the electro-hydraulic servo cylinder 201 is activated to push the cross hinge front axle 202 to rotate to 83.98°, leaving a springback allowance of 0.52°. At this time, the tilt sensor 301 detects and feeds back the actual value of 83.97°, while the laser rangefinder 302 confirms that the roll gap is 40.2mm. After the first section of steel pipe is formed, if the ellipticity exceeds the standard, the system automatically adds a compensation angle of 0.15°, and the final forming angle stabilizes at 83.48°. Therefore, according to the adjustment, the control accuracy of the forming angle is |83.46°-83.48°|=0.02°, which is less than the allowable deviation of 0.5°, while the actual measured pipe diameter is 4218mm, which meets the Class I tolerance of GB / T 21835-2008.

[0025] Compared to traditional manual adjustments, the results are shown in the table below: As shown in the comparison table above, the intelligent forming device designed in this utility model can shorten the forming time by at least 2 hours compared to traditional manual forming, saving a significant amount of time and thus greatly improving work efficiency. Furthermore, the forming control accuracy can be improved by 25 times, with smaller errors, allowing for effective control of precision, greatly improving the pipe diameter qualification rate, and ensuring processing quality. Simultaneously, it can also automatically predict and compensate, achieving real-time compensation for springback deformation during production.

[0026] However, as is well known to those skilled in the art, the working principles and wiring methods of the industrial control computer 10, the electro-hydraulic servo cylinder 201, the tilt sensor 301, the laser rangefinder 302, and the human-machine interaction terminal 60 are commonplace and belong to conventional means or common knowledge. They will not be described in detail here. Those skilled in the art can make any selections according to their needs or convenience.

[0027] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of this technical solution, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. An electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes, characterized in that, include: The industrial control computer (10) is used for the system control of the entire device; The front axle drive system (20) includes a cross-hinged front axle (202) and two electro-hydraulic servo cylinders (201), which are symmetrically mounted on both sides of the cross-hinged front axle (202). The multi-sensor fusion detection system (30) includes multiple tilt sensors (301) and a laser rangefinder (302). The multiple tilt sensors (301) are evenly distributed on the cross-hinged front axle (202) to measure the tilt angle of the cross-hinged front axle (202). The laser rangefinder (302) is used to monitor the gap between the tube blank and the forming roll in real time. A dual closed-loop servo control system (40) includes a position loop (401) and a force loop (402). The position loop (401) detects the position of the steel pipe through a sensor to ensure that the position of the steel pipe is accurate during the forming process. The force loop (402) detects the force on the steel pipe during the forming process through a sensor to ensure that the force on the steel pipe during the forming process is uniform and meets the requirements. Forming angle calculation model (50), based on the theoretical forming angle automatically calculated according to steel pipe specifications; The human-computer interaction terminal (60) includes a touch screen (601), an alarm (602), and a modeling log generation module (603); the touch screen (601) is used to display the real-time forming angle θ, the theoretical value θ0, and the deviation Δθ; the alarm (602) is used to alarm the forming angle deviation; and the modeling log generation module (603) is used to automatically generate a modeling log.

2. The electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes as described in claim 1, characterized in that, The angle between the thrust axis of the electro-hydraulic servo cylinder (201) and the center line of the tube body is 45°-60°.

3. The electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes as described in claim 2, characterized in that, The two electro-hydraulic servo cylinders (201) are symmetrically mounted in a V-shape on both sides of the cross-hinged front axle (202).

4. The electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes as described in claim 1, characterized in that, The dual closed-loop servo control system (40) has a built-in springback compensation database for storing springback correction curves for different steel grades.

5. The electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes as described in claim 4, characterized in that, The dual closed-loop servo control system (40) automatically calls the compensation curve through the springback compensation database and according to the steel grade code, with a compensation angle Δθ = k1·σ + k2·t; Where σ is the yield strength, t is the wall thickness, and k1 / k2 is the material coefficient.

6. The electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes as described in claim 1, characterized in that, The tuning log automatically generated by the tuning log generation module (603) includes timestamps, operators, and oil pressure curves.

7. The electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes as described in claim 1, characterized in that, It is also provided with a mechanical limit stop that works in conjunction with the cross-hinged front axle (202) and is used for angle limiting.

8. The electro-hydraulic servo intelligent shaping device for ultra-large diameter spiral steel pipes as described in claim 1, characterized in that, It also includes a hydraulic pressure over-limit shutdown threshold that is used in conjunction with the electro-hydraulic servo cylinder (201) for protection.

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