Method and system for monitoring shipyard operation by using welding current data

Abstract

Provided are a method and system for monitoring a shipyard operation by using welding current data. In the method for monitoring welding operations according to an embodiment of the present invention, welding current data is acquired, total welding time is calculated from the acquired welding current, and the calculated total welding time is converted into a progress rate of welding operations. Accordingly, the present invention enables accurately identifying the progress in a ship block assembly operation in real time while minimizing additional costs and resources.

Description

Method and system for monitoring shipyard processes using welding current data

[0001] The present invention relates to a shipyard process management technology, and more particularly, to a method for monitoring in real time the progress of a ship block assembled through welding in a shipyard.

[0002] In shipyards, welding is a pivotal process in shipbuilding. However, with welding workshops spread across vast yards, monitoring the welding process is extremely difficult. Consequently, automated welding process monitoring technology is urgently needed.

[0003] Therefore, CCTV cameras are installed in each welding facility to monitor the progress of the welding process through video analysis. However, the large scale of the facility poses challenges, requiring a large number of CCTV cameras and a significant amount of video analysis.

[0004] Accordingly, there is a need for a method to monitor the progress of the welding process using data generated during the welding process while minimizing additional costs and resources.

[0005] The present invention has been devised to solve the above problems, and the purpose of the present invention is to provide a method and system for monitoring the welding process of a ship block in real time by collecting / analyzing welding current data as a means for understanding the assembly process of a ship block while minimizing additional costs and resources.

[0006] A welding process monitoring method according to one embodiment of the present invention for achieving the above object includes: a step of acquiring welding current data; a step of calculating a total welding time from the acquired welding current; and a step of converting a welding process progress rate from the calculated total welding time.

[0007] The acquisition step may include a step of collecting welding current data measured at multiple welding locations on a welding block; and a step of integrating the collected welding current data according to a measurement time.

[0008] The collection step can collect welding current data measured from welding current measuring devices installed on some of the plurality of pin jigs on which the welding blocks are placed.

[0009] The output step may include a step of detecting the number of welders used for welding from the integrated welding current data in the integration step; and a step of calculating the total welding time by adding up the values ​​obtained by multiplying the detected number of welders by the corresponding welding time.

[0010] The detection step can detect the number of welders by identifying discrete level changes in welding current data. The detection step can detect the number of welders by identifying changes in the corresponding section of welding current data.

[0011] The conversion step may include a step of estimating the welding material usage from the calculated total welding time; a step of calculating the welding material usage rate by dividing the estimated welding material usage by the total welding material requirement; and a step of converting the welding material usage rate into a welding process progress rate.

[0012] The conversion step may further include a step of estimating which welding process the converted welding process progress rate currently corresponds to.

[0013] And, the welding process monitoring method according to an embodiment of the present invention may further include a step of visualizing information about the converted welding process progress rate and the estimated welding process.

[0014] A welding process monitoring system according to another embodiment of the present invention includes: an acquisition unit for acquiring welding current data; a calculation unit for calculating a total welding time from the acquired welding current; and a conversion unit for calculating a welding process progress rate from the calculated total welding time.

[0015] A welding process monitoring method according to another embodiment of the present invention comprises: a step of measuring welding current data; a step of calculating a total welding time from the obtained welding current; a step of converting a welding process progress rate from the calculated total welding time; and a step of visualizing the converted welding process progress rate.

[0016] A welding process monitoring system according to another embodiment of the present invention includes: measuring devices for measuring welding current data; an analysis system for calculating a total welding time from the measured welding current, converting a welding process progress rate from the calculated total welding time, and visualizing the converted welding process progress rate.

[0017] As described above, according to embodiments of the present invention, the welding process of a ship block can be monitored in real time by collecting / analyzing welding current data, thereby enabling the progress of the ship block assembly process to be accurately identified in real time while minimizing additional costs and resources.

[0018] FIG. 1 is a diagram illustrating the configuration of a welding process monitoring system according to one embodiment of the present invention;

[0019] Figure 2 is a drawing showing the detailed configuration of a welding current measuring device;

[0020] Figure 3 is a diagram illustrating a current measurement method using a DC current sensor.

[0021] Figure 4 is a diagram for explaining the concept of a multi-welding current measuring device.

[0022] Figure 5 is a drawing showing the detailed configuration of the welding current analysis system.

[0023] Figure 6 is a diagram illustrating the concept of data integration and time synchronization.

[0024] Figures 7 and 8 are examples of welder logarithm detection by discrete level change detection.

[0025] Figure 9 is an example of welding process visualization.

[0026] Hereinafter, the present invention will be described in more detail with reference to the drawings.

[0027] An embodiment of the present invention proposes a method for monitoring the ship block welding process in real time by collecting and analyzing welding current data to minimize additional costs and resources while monitoring the ship block assembly process. Specifically, the technology determines the total welding time based on welding current data measured at the ship block workshop, and monitors the welding process progress based on the determined total welding time.

[0028] FIG. 1 is a diagram illustrating the configuration of a welding process monitoring system according to one embodiment of the present invention. As illustrated, the welding process monitoring system according to the embodiment of the present invention is configured to include a welding current measuring device (100) and a welding current analysis system (200).

[0029] Fig. 1 illustrates a situation in which a welding technician is performing welding work on a welding block (20) placed on pin jigs (31) installed on a worktable (32) using a welding machine. The welding machine is composed of a welding machine body (11, 12) that controls welding strength by adjusting current supply / strength, a feeder (13, 14) for organizing holder wires and ground wires, and a holder (15, 16) for mounting a welding rod.

[0030] During welding, the current applied from the welding machine body (11, 12) flows along a path that returns to the welding machine body (11, 12) through the feeder (13, 14) and holder (15, 16) and the pin jig (31) and work table (32), as indicated by the dotted line in Fig. 1.

[0031] The welding current measuring device (100) is installed in the pin jig (31), measures the current flowing in the above path in real time, and transmits the measured welding current data to the welding current analysis system (200).

[0032] Fig. 2 illustrates a detailed configuration of a welding current measuring device (100). As illustrated, the welding current measuring device (100) is configured to include a DC current sensor (110), a data collection unit (120), and a communication unit (130).

[0033] The DC current sensor (110) is a sensor that measures the magnetic field generated by the current flowing in the return path of the welding current, and can generate DC welding current data at a rate of more than 100 samples per second. A current measurement method using the DC current sensor (110) is schematically illustrated in Fig. 3.

[0034] The data collection unit (120) collects and stores welding current data generated by the DC current sensor (110). The communication unit (130) periodically transmits the welding current data stored in the data collection unit (120) to the welding current analysis system (200), for example, every second.

[0035] Meanwhile, as shown on the left side of Fig. 4, the size of the welding current data generated by the welding current measuring device (100) varies depending on the welding position. That is, the size of the welding current data measured by the welding current measuring device (100) at a close welding position (Pa) is large, but the size of the welding current data measured by the welding current measuring device (100) at a far welding position (Pb, Pc) is small. Accordingly, there is a possibility that the welding current data at the welding position (Pb, Pc) may not be reflected normally.

[0036] To solve this, it is required to uniformly install a plurality of welding current measuring devices (100) throughout the welding zone, i.e., the zone where the welding block is located, as shown on the right side of Fig. 4.

[0037] Referring again to Fig. 1, the description is made. The welding current analysis system (200) calculates the total welding time for the welding block based on the welding current data collected by the welding current measuring devices (100) to determine the progress rate of the welding process.

[0038] Fig. 5 is a drawing illustrating a detailed configuration of a welding current analysis system (200). As illustrated, the welding current analysis system (200) is configured to include a time series DB (210), a data integration unit (220), a welder logarithm detection unit (230), a welding time calculation unit (240), a welding process conversion unit (250), and a welding process visualization unit (260).

[0039] The time series DB (210) is a data storage that collects / stores welding current data received from welding current measuring devices (100). The data integration unit (220) integrates the welding current data collected in the time series DB (210) according to the measurement time. This allows for obtaining a single integrated set of welding current data for a single welding block.

[0040] Meanwhile, the data integration unit (220) can periodically or as needed transmit a time synchronization command to the welding current measuring devices (100) to synchronize the welding current data collected in the time series DB (210) as illustrated in FIG. 6.

[0041] The welder number detection unit (230) analyzes the welding current data integrated by the data integration unit (220) to detect the number of welders used for welding the welding block. Since the number of welders used changes over time, the number of welders over time is determined.

[0042] As described above, since the welding positions and the positions of the welding current measuring devices (100) do not completely match, calculating the total welding time by integrating the welding current data may be inaccurate.

[0043] Accordingly, the welder number detection unit (230) detects the number of welders by identifying the change in the corresponding section of the integrated welding current data as illustrated in Fig. 7. In Fig. 7, when the welding current data enters the Ic section, the number of welders is detected as 1, when it enters the Ib section, the number of welders is detected as 2, and when it enters the Ia section, the number of welders is detected as 3. Fig. 8 presents another example of detecting the number of welders.

[0044] In this way, it can be said that the welder number detection unit (230) detects the welder number by detecting discrete level changes in welding current data.

[0045] The welding time calculation unit (240) calculates the total welding time for the welding block from the welding current data detected by the welder number detection unit (230). This can be calculated using the following mathematical formula.

[0046] ∑ (number of welders) × (corresponding welding time)

[0047] The welding time corresponds to calculating the area in the graph shown on the right side of Fig. 7.

[0048] The welding process conversion unit (250) determines the welding process from the total welding time calculated by the welding time calculation unit (240). Specifically, the welding process conversion unit (250) estimates the welding material usage from the total welding time, calculates the welding material usage rate by dividing the estimated welding material usage by the total welding material requirement, and converts the welding material usage rate into a welding process progress rate.

[0049] Furthermore, the welding process conversion unit (250) can also estimate which welding process (attachment welding process, main welding process, confirmation / maintenance welding, etc.) the converted welding process progress rate currently corresponds to.

[0050] The welding process visualization unit (260) visualizes the welding process progress rate converted by the welding process conversion unit (250) and information on the estimated welding process so that the user can view it.

[0051] Figure 9 illustrates welding process visualization using a welding process visualization unit (260). As illustrated, information about the welding process can be additionally displayed in the welding current data. Furthermore, information used for welding process conversion, such as the total welding time for a welding block and the welding material usage rate for a welding block, can be visualized along with the welding process progress rate.

[0052] So far, a preferred embodiment of a shipyard process monitoring method and system utilizing welding current data has been described in detail.

[0053] In the above embodiment, as a means of understanding the assembly process of a ship block while minimizing additional costs and resources, a method is proposed of understanding the total welding time based on welding current data measured at a ship block workshop, and monitoring the progress rate of the welding process based on the understood total welding time.

[0054] Meanwhile, it goes without saying that the technical idea of ​​the present invention can also be applied to a computer-readable recording medium containing a computer program that performs the functions of the device and method according to the present embodiment. In addition, the technical idea according to various embodiments of the present invention can be implemented in the form of computer-readable code recorded on a computer-readable recording medium. The computer-readable recording medium can be any data storage device that can be read by a computer and store data. For example, the computer-readable recording medium can be a ROM, a RAM, a CD-ROM, a magnetic tape, a floppy disk, an optical disk, a hard disk drive, etc. In addition, the computer-readable code or program stored on the computer-readable recording medium can be transmitted through a network connected between computers.

[0055] In addition, although the preferred embodiments of the present invention have been illustrated and described above, the present invention is not limited to the specific embodiments described above, and various modifications can be made by a person having ordinary skill in the art to which the present invention pertains without departing from the gist of the present invention as claimed in the claims, and such modifications should not be understood individually from the technical idea or prospect of the present invention.

Claims

1. Step of acquiring welding current data; A step of calculating the total welding time from the obtained welding current; A welding process monitoring method, characterized by including a step of converting a welding process progress rate from the calculated total welding time.

2. In claim 1, The acquisition stage is, A step of collecting welding current data measured at multiple welding positions on a welding block; A welding process monitoring method, characterized by including a step of integrating collected welding current data according to a measurement time.

3. In claim 1, The collection phase is, A welding process monitoring method characterized by collecting welding current data measured from welding current measuring devices installed on some of a plurality of pin jigs on which welding blocks are placed.

4. In claim 2, The output stage is, A step of detecting the number of welders used for welding from the integrated welding current data in the integration step; A welding process monitoring method characterized by comprising a step of calculating the total welding time by adding up the values ​​obtained by multiplying the number of detected welders by the corresponding welding time.

5. In claim 4, The detection phase is, A welding process monitoring method characterized by detecting the number of welders by identifying discrete level changes in welding current data.

6. In claim 5, The detection phase is, A welding process monitoring method characterized in that the number of welders is detected by identifying changes in the corresponding section of welding current data.

7. In claim 5, The conversion step is, A step of estimating the welding material usage from the calculated total welding time; A step of calculating the welding material usage rate by dividing the estimated welding material usage by the total welding material requirement; A welding process monitoring method, characterized by including a step of converting a welding material usage rate into a welding process progress rate.

8. In claim 7, The conversion step is, A welding process monitoring method, further comprising a step of estimating which welding process the converted welding process progress rate currently corresponds to.

9. In claim 8, A welding process monitoring method, further comprising a step of visualizing information about the converted welding process progress rate and the estimated welding process.

10. Acquisition unit for acquiring welding current data; A calculation unit that calculates the total welding time from the obtained welding current; A welding process monitoring system, characterized in that it includes a conversion unit that converts a welding process progress rate from the calculated total welding time.

11. Step of measuring welding current data; A step of calculating the total welding time from the obtained welding current; A step of converting the welding process progress rate from the calculated total welding time; A welding process monitoring method, characterized by including a step of visualizing a converted welding process progress rate.

12. Measuring devices for measuring welding current data; A welding process monitoring system comprising: an analysis system for calculating a total welding time from a measured welding current, converting a welding process progress rate from the calculated total welding time, and visualizing the converted welding process progress rate.

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