CN111872704A - High-flexibility high-efficiency pipe production line - Google Patents
High-flexibility high-efficiency pipe production line Download PDFInfo
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- CN111872704A CN111872704A CN202010776969.3A CN202010776969A CN111872704A CN 111872704 A CN111872704 A CN 111872704A CN 202010776969 A CN202010776969 A CN 202010776969A CN 111872704 A CN111872704 A CN 111872704A
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Abstract
A high-flexibility high-efficiency pipe production line comprises a pipe vertical warehouse (1) connected with a sand blasting machine (2) through a logistics system (10), the sand blasting machine connected with a shot blasting machine (3), the shot blasting machine (3) connected with a cutting machine (4), the cutting machine (4) respectively connected with a manual assembly area (5), a flange welding device (6), a pipe bending machine (7) and a beveling machine (8) in parallel through the logistics system (10); the flange welding equipment (6) is respectively connected with the manual assembly area (5) and the pipe bender (7) in parallel through a logistics system (10); the pipe bender (7) is respectively connected with the manual assembly area (5) in parallel through a logistics system (10); the beveling machine (8) is connected in parallel with the manual assembly area (5), the TIG/MAG automatic welding machine (9), the pipe bending machine (7) and the flange welding equipment (6) through a logistics system (10). The invention reduces the labor amount, improves the efficiency, improves the integral manufacturing precision and reduces the workload of tube calibration.
Description
Technical Field
The invention relates to a pipe production line with high flexibility and high efficiency.
Background
Firstly, the traditional pipe production line flow is large in labor amount, unclear in scheduling, extensive in overall management and control, mainly based on manual management and control, and incapable of guaranteeing efficiency.
1) Drawing decomposition plans and production completion plans need to be compiled according to project plans, intermediate schedule plans and drawing plans;
2) sleeving the technical pipe according to a drawing decomposition plan;
3) manually splitting a receipt graph and checking technical center blanking data on site;
4) drawings which cannot be made are removed through manual drawing screening, the drawn drawings are classified according to the pipe diameters of different sizes, and the following conditions that a plurality of batches are segmented and simultaneously trepanned and drawn need to be classified according to the pipe diameters of different sizes;
5) the whole process management and control is carried out through the machine account and the corresponding internal work contact list;
the blanking of the pipe is carried out according to the use of materials of a jacking table, the cutting length and the like are manually controlled, and the opening, the bending pipe, the branch and mother pipe and the like are manually rechecked for the size, the bending angle and the like. Then beveling and removing iron oxide on the blanking pipe according to the process requirements, which is also performed by traditional manpower, and wastes time and labor;
and thirdly, most of the traditional pipe processing pipe calibration work is carried out manually, pre-welding inspection is required after positioning and assembling, welding is carried out by a welder, the distribution of welding workers is also managed and distributed manually, and the welded pipe is polished according to the process requirements and is reported and inspected after welding.
And fourthly, carrying out pressure test and disc matching work on the whole, and sending the whole to a factory for surface treatment. The whole process flow arranges statistics personnel to collect statistics worker working hours, collect pipe production states and the like.
In conclusion, the traditional pipe production mode has certain defects and shortcomings, and because the manual quantity is large, the flow direction of the whole pipe production process is analyzed and decomposed manually, and then the process arrangement is carried out. Therefore, in the aspect of pipe processing, the traditional process is more passive, the process flow is manual, more manpower and energy are needed to be arranged to digest drawings and arrange the process, the precision inspection is needed to be carried out for multiple times in the aspect of quality control to ensure the manufacturing precision, the whole management and control and the whole process need to be arranged and scheduled manually, and the sorting efficiency is not high for manufacturing pipes with large volume and non-uniform manufacturing processes.
Disclosure of Invention
Aiming at the defects of the existing pipe manufacturing process, the automatic pipe manufacturing 3R assembly line is combined, pipes and manual lines are combined, the whole assembly is realized, the process control is carried out, the pipe manufacturing process is optimized through software calculation, the manual consumption is reduced, the manufacturing precision is optimized, the pipe fitting scheduling and production are carried out through a pipe family manufacturing method, and the whole pipe manufacturing process is optimized.
A high-flexibility high-efficiency pipe production line comprises a RAMP system, an enterprise ERP system, a ship intermediate-range planning and scheduling system, a supply chain system, a workshop MES system, an advanced scheduling APS system, an equipment monitoring SCADA system, a pipe vertical warehouse management WMS system and a workshop material pulling LES system, wherein all the systems are connected through internal ports in an information transmission mode. The RAMP system is a 3R self-contained production, manufacturing, management and execution system, and comprises a workshop MES system, an advanced scheduling APS system and an equipment monitoring SCADA system. The pipeline information management system is used for introducing design information, plan information and material information from a design/ERP in batches according to each ship-shaped segmented tray, designing and modifying information, automatically creating a pipe production task package, automatically performing high-level production scheduling, and automatically generating corresponding numerical control instructions for stations such as a three-dimensional library, cutting equipment, pipe bending equipment, welding equipment and the like after the task package is released to a workshop for production, matching corresponding tool fixtures, automatically selecting WPS (WPS) for pipes and the like; and simultaneously, task queues are generated for semi-automatic stations and manual stations in real time, production scheduling of the respective automatic stations is automatically carried out, and required materials are automatically distributed to a cache area of the stations through a logistics system. The pipe vertical warehouse is connected with a sand blasting machine through a logistics system, the sand blasting machine is connected with a shot blasting machine, the shot blasting machine is connected with a cutting machine, and the cutting machine is respectively connected with a manual assembly area, flange welding equipment, a pipe bending machine and a beveling machine in parallel through the logistics system; the flange welding equipment is respectively connected with the manual assembly area and the pipe bender in parallel through a logistics system; the pipe bending machines are respectively connected with the manual assembly areas in parallel through a logistics system; the beveling machine is connected in parallel with the manual assembly area, the TIG/MAG automatic welding machine, the pipe bender and the flange welding equipment through a logistics system.
The vertical tube stock is used for storing tubes and comprises a three-dimensional shelf and an automatic feeding and discharging system based on the first-in first-out principle. The pipes are conveyed to the loading lifter from the feeding platform of the feeding system, the pipes are placed on the pipe frame of the three-dimensional goods shelf, and when unloading, the pipes are conveyed to the logistics roller way through the unloading lifter of the discharging system and conveyed to the next sand blasting device.
The manual assembly area is a manual assembly pipe part welding assembly area, and the pipe parts assembled on the intelligent assembly line are assembled on the assembly workbench manually.
The flange welding equipment is provided with four welding guns (divided into two groups), a pipeline bracket and a rotary table. An operator places the flange in a rotary table for centering and adjusts the angle of the flange, the pipeline is transferred to a pipeline support of the machine from a logistics roller way through a movable transmission arm, the pipeline support connects the pipeline and the flange, and then a welding gun moves in place to weld the welding line. Compared with the traditional manual positioning and re-welding, the manual cost is saved, the welding quality of the machine is relatively high, and the working hours are saved.
The logistics system is used for automatic transportation of the straight pipes between the equipment and the stations. The system is controlled by an editable controller (PLC), and is conveyed by a roller way, a plate roller way and a chain roller way, and when the system reaches a workbench, a single pipe is moved to the workbench from the roller way or the roller way/machine from the workbench through a pusher and a separator. Through its automatic transportation, realize the automatic switch between individual station, reduce artifical transport.
The invention adopts advanced information management systems such as an enterprise ERP system, a ship intermediate schedule planning and scheduling system, a supply chain system, a workshop MES system, an advanced scheduling APS system, an equipment monitoring SCADA system, a three-dimensional library management WMS system, a workshop material pulling LES system and the like, and the production efficiency of the workshop is effectively improved by matching with advanced production equipment and reasonable production line arrangement.
Drawings
FIGS. 1-20 are schematic views of the production line of the present invention, Nos. 1-20, respectively.
FIG. 21 is a process flow diagram of the present invention.
In the figure, 1, a pipe vertical warehouse, 2, a sand blasting machine, 3, a shot blasting machine, 4, a cutting machine, 5, a manual assembly area, 6, flange welding equipment, 7, a pipe bending machine, 8, a beveling machine, 9, a TIG/MAG automatic welding machine, 10, a logistics system, 11, a RAMP system, 12, an enterprise ERP system, 13, a ship middle schedule planning and scheduling system, 14, a supply chain system, 15, a workshop MES system, 16, an advanced APS system, 17, an equipment monitoring SCADA system, 18, a pipe vertical warehouse management WMS system and 19, a workshop drawing LES system.
Detailed Description
As shown in fig. 1-20, a production line for high-flexibility high-efficiency pipes has the following specific flow process:
firstly, design preparation:
and the design software imports the design and model information into an ISO system and confirms the accuracy of the production information.
The system comprises a RAMP system 11, an enterprise ERP system 12, a ship mid-range planning and scheduling system 13, a supply chain system 14, a workshop MES system 15, an advanced scheduling APS system 16, an equipment monitoring SCADA system 17, a pipe vertical warehouse management WMS system 18, a workshop material pulling LES system 19, a pipe vertical warehouse 1, a sand blasting machine 2, a shot blasting machine 3, a cutting machine 4, a manual assembly area 5, a flange welding device 6, a pipe bender 7, a beveling machine 8 and a TIG/MAG automatic welding machine 9 which are applied to a production line.
Secondly, production scheduling:
the automatic production line is divided into 20 different automatic production lines:
line No. 1: pipe vertical warehouse 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot → cutting machine 4 → buffer area (straight pipe, finished pipe)
Line 2: pipe vertical warehouse 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot → cutting machine 4 → manual assembly 5 (straight pipe)
Line No. 3: pipe vertical warehouse 1 → sand blasting machine 2, shot blasting machine 3 sand blasting → cutting machine 4 → flange welding equipment 1 → buffer area (straight pipe, finished pipe, flange or sleeve pipe at one or both ends)
Line No. 4: pipe vertical warehouse 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot → cutting machine 4 → flange welding equipment 6 → artificial assembly area 5 (straight pipe, flange or sleeve pipe at one end or two ends, and fittings such as bracket or web plate)
Line No. 5: tube stand 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot blasting → cutting machine 4 → 4' tube bender → buffer zone (bend, finish tube, DN40-DN 100)
Line No. 6: tube stand 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot blasting → cutting machine 4 → 4' tube bender → manual assembly area 5 (bend, DN40-DN100, ready to process)
Line No. 7: tube stand 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot blasting → cutting machine 4 → 8' tube bender → buffer zone (bend, finish tube, DN80-DN 200)
Line No. 8: tube stand 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot blasting → cutting machine 4 → 8' tube bender → manual assembly area 5 (bend, DN80-DN200, ready to process)
Line No. 9: pipe vertical warehouse 1 → sand blasting machine 2, shot blasting machine 3 sand blasting and shot blasting → cutting machine 4 → beveling machine 8 → artificial assembly area (short straight pipe, need butt welding accessory three-way bend pipe, etc.)
Line No. 10: pipe vertical warehouse 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot → cutting machine 4 → beveling machine 8 → long pipe TIG/MAG automatic welding machine → buffer zone (long straight pipe, finished pipe, need butt welding accessory)
Line No. 11: pipe stand → sand blasting → cutting machine → beveling machine 8 → long pipe TIG/MAG automatic welding machine → manual assembly area (long straight pipe, need butt welding accessory three-way bend pipe, etc.)
Line No. 12: tube vertical warehouse 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot blasting → cutting machine 4 → beveling machine 8 → 4' tube bender → manual assembly area (short bend, DN40-DN100, need butt welding accessory three-way bend, etc.)
Line No. 13: tube vertical warehouse 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot blasting → cutting machine 4 → beveling machine 8 → 8' tube bender → manual assembly area (short bend, DN80-DN200, need butt welding accessory three-way bend, etc.)
Line No. 14: tube stand 1 → sandblaster 2, shot-blasting machine 3 sandblasting and shot-blasting → cutting machine 4 → flange welding equipment 6 → 4' tube bender → buffer zone (bend, DN40-DN100, finish tube, flange or sleeve at one or both ends)
Line No. 15: tube stand 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot blasting → cutting machine 4 → flange welding equipment 6 → 4' tube bender → manual assembly area (bend tube, DN40-DN100, one end or two ends are flange or sleeve)
Line No. 16: tube stand 1 → sandblaster 2, shot-blasting machine 3 sandblasting and shot-blasting → cutting machine 4 → flange welding equipment 6 → 8' tube bender → buffer zone (bend, DN80-DN200, finish tube, flange or sleeve at one or both ends)
Line No. 17: tube vertical warehouse 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot → cutting machine 4 → flange welding equipment 6 → 8' tube bender → manual assembly area (bend tube, DN80-DN200, one end or two ends are flange or sleeve)
Line No. 18: pipe vertical warehouse 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot → cutting machine 4 → beveling machine 8 → flange welding equipment 6 → artificial assembly area 5 (straight pipe, one end is flange or sleeve, and the other end is to be butt welded)
Line No. 19: tube stand 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot blasting → cutting machine 4 → beveling machine 8 → flange welding equipment 6 → 4' tube bender → manual assembly area 5 (bend, DN40-DN100, one end is flange or sleeve, one end is to be butt welded)
Line No. 20: tube stand 1 → sand blasting machine 2, shot blasting machine 3 sand blasting shot blasting → cutting machine 4 → beveling machine 8 → flange welding equipment 6 → 8' tube bender → manual assembly area 5 (bend, DN80-DN200, one end or two ends are flange or sleeve, one end is to be butt welded)
When the design information is released, the RAMP system 11 of the 3R software can decompose the production process of the pipes according to the characteristics of each pipe and distribute the decomposed production process to the corresponding pipe station line.
The RAMP system is used for identifying and dividing pipe manufacturing procedures to corresponding production lines, meanwhile, the automatic scheduling function of the RAMP system is used for optimizing production line load, and finally, the pipe parts produced by the production lines are assembled to each corresponding station for final assembly. Each manual station will be equipped with a corresponding end machine to guide the personnel at each station to assemble and weld.
Compared with the prior art, the invention has the following beneficial effects:
the pipe manufacturing process is optimized by combining the modern automatic production line technology, the labor amount is reduced, and the efficiency is improved.
1) The traditional production in the form of pipe sections is completely overturned by the automatic identification decomposition technology of the RAMP system. The pipe section is decomposed into smaller components, and the pipe is produced in a pipe part family mode, so that the workload of manual positioning and welding is reduced, and the production and manufacturing efficiency is improved;
2) because the cutting instruction is sent by the automatic cutting machine, the pipes are automatically delivered from the three-dimensional warehouse of the pipes, and the pipes are conveyed through the logistics system, so that the workload of manual checking and conveying is reduced;
the automatic equipment and the automatic calculation software thereof improve the integral manufacturing precision, reduce the error and reduce the workload of tube calibration
1) Cutting and welding instructions are directly controlled through software, and errors are reduced;
the pipe bending is carried out in a mode of welding before bending, the cutting amount is automatically calculated by software, and the precision is ensured;
because a series of automatic devices such as automatic cutting, flange welding devices, TIG/MAG automatic welding machines and the like are adopted, the inspection before welding is omitted, the precision is much more accurate than that of the traditional pipe production line, the automatic production process flow is combined with manual work in the whole production process, and the high-efficiency and high-precision production is realized.
Claims (4)
1. A pipe production line having high flexibility and high efficiency, characterized in that: the system comprises a RAMP system, an enterprise ERP system, a ship intermediate schedule planning and scheduling system, a supply chain system, a workshop MES system, an advanced scheduling APS system, an equipment monitoring SCADA system, a pipe vertical warehouse management WMS system and a workshop material pulling LES system, wherein all the systems are connected through internal ports for information transmission; the pipe vertical warehouse is connected with a sand blasting machine through a logistics system, the sand blasting machine is connected with a shot blasting machine, the shot blasting machine is connected with a cutting machine, and the cutting machine is respectively connected with a manual assembly area, flange welding equipment, a pipe bending machine and a beveling machine in parallel through the logistics system; the flange welding equipment is respectively connected with the manual assembly area and the pipe bender in parallel through a logistics system; the pipe bending machines are respectively connected with the manual assembly areas in parallel through a logistics system; the beveling machine is connected in parallel with the manual assembly area, the TIG/MAG automatic welding machine, the pipe bender and the flange welding equipment through a logistics system.
2. A pipe production line having high flexibility and high efficiency according to claim 1, wherein: the vertical tube stock comprises a three-dimensional shelf and an automatic feeding and discharging system with first-in first-out function.
3. A pipe production line having high flexibility and high efficiency according to claim 1, wherein: the flange welding equipment comprises a welding gun, a pipeline bracket and a rotary table; the pipe bracket connects the pipe and the flange.
4. A pipe production line having high flexibility and high efficiency according to claim 1, wherein: the logistics system is used for automatic transportation of the straight pipe between the equipment and the station; the system is controlled by a PLC (programmable logic controller) and is conveyed by a roller way, a plate roller way and a chain roller way, and when the system reaches a workbench, a single pipe is moved to the workbench from the roller way or a machine from the workbench through a pusher and a separator.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010776969.3A CN111872704A (en) | 2020-08-05 | 2020-08-05 | High-flexibility high-efficiency pipe production line |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010776969.3A CN111872704A (en) | 2020-08-05 | 2020-08-05 | High-flexibility high-efficiency pipe production line |
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| CN111872704A true CN111872704A (en) | 2020-11-03 |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113233163A (en) * | 2021-03-24 | 2021-08-10 | 银川隆基光伏科技有限公司 | Feeding and discharging system of slicing machine |
| CN114029739A (en) * | 2021-11-30 | 2022-02-11 | 天水锻压机床(集团)有限公司 | 5G rod combination intelligent production line and production method thereof |
-
2020
- 2020-08-05 CN CN202010776969.3A patent/CN111872704A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113233163A (en) * | 2021-03-24 | 2021-08-10 | 银川隆基光伏科技有限公司 | Feeding and discharging system of slicing machine |
| CN114029739A (en) * | 2021-11-30 | 2022-02-11 | 天水锻压机床(集团)有限公司 | 5G rod combination intelligent production line and production method thereof |
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