Double-Curvature Ship Plate Forming via Integrated Thermal-Mechanical Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional forming methods for double-curvature ship plates, such as line heating and multi-point bending, face inefficiencies and material stress issues, particularly in processing large-curvature plates, and rely heavily on manual operations leading to uncertain quality and high equipment costs.
Innovation Solution
An automatic integral forming method combining line heating, force loading, and water cooling with a loading system and computer simulation technology, utilizing a control device and expert database optimized by artificial neural networks to precisely control heat, pressure, and cooling processes for precise deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If line heating method is used for forming double-curvature plates, then forming efficiency is improved, but processing temperature control becomes difficult and material properties are affected
Solution Approach 1:
The patent combines line heating method with multi-point bending method into an integrated forming system. The heating装置 and bending装置 are merged to work simultaneously, allowing thermal expansion to reduce material resistance while mechanical force applies the desired shape, achieving both high efficiency and precise control
Solution Approach 2:
The patent changes the physical state of the material by controlling temperature parameters during forming. By heating specific regions to optimal temperatures and maintaining them within controlled ranges, the material becomes more formable while preventing overheating that would damage material properties
2Manufacturing precision
If multi-point bending method is used for forming double-curvature plates, then forming precision is improved, but equipment cost and construction cost increase
Solution Approach 1:
The patent segments the forming process into discrete controllable points along the plate. Multiple bending points are distributed along the forming path, each independently controllable, allowing precise local deformation while using simple, standardized bending mechanisms rather than complex overall systems
Solution Approach 2:
The patent replaces complex mechanical forming systems with a combination of thermal field control and simplified mechanical bending. The heating system substitutes for much of the mechanical force needed, reducing the complexity and cost of the mechanical bending apparatus while maintaining high forming precision
3Device complexity
If manual operation is used for forming processing, then equipment cost is reduced, but quality becomes uncertain and processing efficiency decreases
Solution Approach 1:
The patent implements feedback control in the forming process by monitoring temperature, bending force, and forming progress in real-time. The system automatically adjusts heating power and bending force based on feedback from sensors, ensuring consistent quality without requiring complex manual operation while keeping equipment relatively simple
Solution Approach 2:
The patent enables the forming system to automatically control its own process parameters through integrated control systems. The heating and bending operations self-regulate based on pre-programmed parameters and real-time feedback, eliminating the need for complex manual intervention while maintaining high quality consistency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances processing efficiency, reduces material stress, and significantly improves precision and automation, enabling the formation of complex shapes like saddle-shaped and twisted plates with reduced equipment costs and operator intensity.
Implementation Method 1
The line heating method is to conduct partial and linear heating on plates via line heat source such as flame or high-frequency induction heaters based on a principle of thermal expansion and contraction, so that residual plastic deformation of a work piece appears
Implementation Method 2
During the process, water may be sprayed on heating lines for reducing temperature thereon after line heating according to requirement of ships' structure for properties of materials
Data Source
AI summary
The present invention provides an automatic integral forming method for a double-curvature plate of a ship, comprising: a) constructing a loading system for integral forming; b) establishing relationship between basic forming data and processing data of the plate according to a requirement for a forming process; c) making prototyping software according to the relationship between the basic data and the processing data, installing the prototyping software on the control device, starting the prototyping software to load the plate so that the plate is plastically deformed in double curvature. The present invention features easy operation, high intelligence, high precision and wide application range, and thus is especially applicable for automatic forming of large-curvature plates such as saddle-shaped plates, sail-shaped plates, twisted plates, plates combining shapes thereof and so on.