海洋平台导管架建造CAD/CAM技术研究
|
摘要
随着对近海油气资源开发力度的加大,近年来深水导管架建造成为海洋工程中重点发展的项目之一。随着导管架结构日益复杂,工程建造规模也逐渐庞大起来。为确保导管架工程在满足建造质量的前提下,在项目周期内顺利完工,有必要对海洋工程现有的设计制造工艺进行技术提升,以提高生产作业效率。本课题通过对海洋平台导管架的生产建造工艺进行分析,从管件切割图纸设计以及生产加工入手,开发管件切割设计系统和切管机数控系统,实现从设计到制造整个生产流程的技术提升。
以AutoCAD为系统设计平台,以导管架单线图为结构设计基础,开发管件切割设计系统。系统自动判断管节点类型并计算各种管节点设计参数,然后进行相贯线焊接坡口计算,依据所得数据绘制管件切割成型的单件图、样板图。同时为满足后续焊接工艺要求,系统通过绘制脚印图,确定焊接管件之间的相对位置关系,满足焊接装配的精度要求。在实现相贯线计算的基础上,进一步扩展系统功能,实现重心、重量计算以及焊材统计。系统具有良好的操作性,可以有效提升导管架平台生产设计效率。
为满足管件自动化切割的生产需求,基于对切管机割炬运动控制分析以及对管件火焰切割工艺的理解,开发切管机数控系统。在数控系统中输入管件几何、位置参数以及相关系统参数后,数控系统自动完成计算,并生成数控加工代码。同时为实现数控代码的验证,在系统中绘制管件切割成型图,并通过仿真技术,实现管件切割状态下的割炬位姿运动仿真。
两系统紧密配合实现系统功能,促使管件切割生产从设计到加工的整个制管工艺流程向自动化、集成化方向转变。课题工作与导管架工程实际生产需要紧密结合,研究成果直接应用在导管架管件生产加工中。实际应用表明,系统功能的运用可以有效提高管件切割精度与加工效率,在保证导管架建造质量的基础之上,促进了海洋工程建造技术水平的提升。
With the growing exploitation of offshore oil and gas resources, the construction of deep water jacket has become a key project in ocean engineering in recent years. Jacket structure is increasingly complicated. As a result, project scale is growing too. Under the premise of guaranteeing construction quality, in order to ensure completion of construction project in construction cycle, it is necessary to transform the current technology of production design, improve production efficiency and realize the technology level of ascension. Through systemic analysis of the technological process on the construction of offshore jacket, this paper started with pipe cutting design and production processing, developed Pipe Cutting Design System and CNC Pipe Cutting System, which realized comprehensive technology promotion of the whole production flow.
Based on offshore jacket single line diagram, the Pipe Cutting Design System was developed under the AutoCAD design platform. The system automatically implements the judgment of pipe joints type, calculation of node design parameters, then realizes calculation of intersecting curves with welding groove of many types of intersecting joints. On the basis of the computational data, system automatically generates pipe cutting sheet and template sheet. Meanwhile, in order to meet welding process requirements, footprint drawings are designed to determine the mutual position of welding pipes and meet the precision requirements of the welding assembly design. On the basis of calculation of intersecting curves, system function is further extended, which implements calculation of center of gravity and weight, statistics of welding materials. The system has good operability and is helpful to improve the manufacturing and design efficiency of offshore jacket platform.
To realize the production requirements of pipe automatic cutting processing, on the basis of mechanical structure motion analysis of Pipe Cutting Machine and flame cutting process, CNC Flame Pipe Cutting System was developed. After inputting of calculating parameters including pipes geometric parameters, location parameters and system parameters, system automatically calculates and generates NC code. Meanwhile in order to check NC code, cutting molding figure is drew in the system. Through simulation technology, pipe cutting process simulation is realized.
Cooperating together tightly, system function is implemented, which promotes the whole pipe cutting process from design to manufacture developing into automation and integration. The research is closely related with the production demand of ocean engineering, and research result is applied directly in jacket pipes production. The practical application showed that system functions implementation effectively improves the pipe processing precision and efficiency, which promotes the ascension of construction technology level on the basis of guarantee construction quality of offshore jacket.
以AutoCAD为系统设计平台,以导管架单线图为结构设计基础,开发管件切割设计系统。系统自动判断管节点类型并计算各种管节点设计参数,然后进行相贯线焊接坡口计算,依据所得数据绘制管件切割成型的单件图、样板图。同时为满足后续焊接工艺要求,系统通过绘制脚印图,确定焊接管件之间的相对位置关系,满足焊接装配的精度要求。在实现相贯线计算的基础上,进一步扩展系统功能,实现重心、重量计算以及焊材统计。系统具有良好的操作性,可以有效提升导管架平台生产设计效率。
为满足管件自动化切割的生产需求,基于对切管机割炬运动控制分析以及对管件火焰切割工艺的理解,开发切管机数控系统。在数控系统中输入管件几何、位置参数以及相关系统参数后,数控系统自动完成计算,并生成数控加工代码。同时为实现数控代码的验证,在系统中绘制管件切割成型图,并通过仿真技术,实现管件切割状态下的割炬位姿运动仿真。
两系统紧密配合实现系统功能,促使管件切割生产从设计到加工的整个制管工艺流程向自动化、集成化方向转变。课题工作与导管架工程实际生产需要紧密结合,研究成果直接应用在导管架管件生产加工中。实际应用表明,系统功能的运用可以有效提高管件切割精度与加工效率,在保证导管架建造质量的基础之上,促进了海洋工程建造技术水平的提升。
With the growing exploitation of offshore oil and gas resources, the construction of deep water jacket has become a key project in ocean engineering in recent years. Jacket structure is increasingly complicated. As a result, project scale is growing too. Under the premise of guaranteeing construction quality, in order to ensure completion of construction project in construction cycle, it is necessary to transform the current technology of production design, improve production efficiency and realize the technology level of ascension. Through systemic analysis of the technological process on the construction of offshore jacket, this paper started with pipe cutting design and production processing, developed Pipe Cutting Design System and CNC Pipe Cutting System, which realized comprehensive technology promotion of the whole production flow.
Based on offshore jacket single line diagram, the Pipe Cutting Design System was developed under the AutoCAD design platform. The system automatically implements the judgment of pipe joints type, calculation of node design parameters, then realizes calculation of intersecting curves with welding groove of many types of intersecting joints. On the basis of the computational data, system automatically generates pipe cutting sheet and template sheet. Meanwhile, in order to meet welding process requirements, footprint drawings are designed to determine the mutual position of welding pipes and meet the precision requirements of the welding assembly design. On the basis of calculation of intersecting curves, system function is further extended, which implements calculation of center of gravity and weight, statistics of welding materials. The system has good operability and is helpful to improve the manufacturing and design efficiency of offshore jacket platform.
To realize the production requirements of pipe automatic cutting processing, on the basis of mechanical structure motion analysis of Pipe Cutting Machine and flame cutting process, CNC Flame Pipe Cutting System was developed. After inputting of calculating parameters including pipes geometric parameters, location parameters and system parameters, system automatically calculates and generates NC code. Meanwhile in order to check NC code, cutting molding figure is drew in the system. Through simulation technology, pipe cutting process simulation is realized.
Cooperating together tightly, system function is implemented, which promotes the whole pipe cutting process from design to manufacture developing into automation and integration. The research is closely related with the production demand of ocean engineering, and research result is applied directly in jacket pipes production. The practical application showed that system functions implementation effectively improves the pipe processing precision and efficiency, which promotes the ascension of construction technology level on the basis of guarantee construction quality of offshore jacket.
引文
[1]吴应湘,李华,曾晓辉,深海采油平台发展现状和设计中的关键问题,中国造船,2002,43(10):80~86
[2]黄悦华,任克忍,我国海洋石油钻井平台现状与技术发展分析,石油机械,2007,35(09):157~161
[3]张用德,袁学强,我国海洋钻井平台发展现状与趋势,石油矿场机械,2008,37(09):14~17
[4] Vasconcellos, A decision support system for floating platform design, Ocean Engineering, 1999, 26: 865~889
[5]魏晓添,海洋导管架结构的现状研究及应用前景,山西建筑,2010,36(19):102~103
[6]刘放,海洋平台技术的现状及发展趋势,设计与计算,2009,06:1~3
[7]深水导管架海洋平台安全可靠性分析及优化设计:[博士学位论文],东营;中国石油大学(华东),2010
[8]魏爱民,番禺30-1亚洲最大导管架的重建,今日科苑,2011,18:87~89
[9] Jeong-Tae Kim and Norris Stubbs, Damage Detection in Offshore Jacket Structures from Limited Modal Information, International Journal of Offshore and Polar Engineering, 1995, 5(01)
[10]孔祥鼎,夏炳仁,海洋平台建造工艺,北京:人民交通出版社,1993,108~112
[11]王兆喆.新型数控火焰切割机ACS软件系统的研究:[硕士学位论文],天津;天津大学,2008
[12] Vernon Tool Company,4 and 5-Axis microprocessor pipe machine instruction manual,USA:Vernon Tool Company,2003
[13]王国栋,阎祥安,肖聚亮,管环相贯焊接坡口数控切割研究,中国机械工程,2005,16(06):561~563
[14]肖聚亮,阎祥安,王国栋,等,管锥相贯焊接坡口数控切割,焊接学报,2005,26(05):69~72
[15]李宝清,贾安东,多管、板相贯坡口切割的数学模型,2000,33(5),583~586
[16] Yasuhisa Okumoto, Kentaro Hiyoku, Noritaka Uesugi, Simulation Based Production Using 3-D CAD in Shipbuilding, International Journal of CAD/CAM, 2006, 6(1)
[17]初新杰,采油平台三维建模CAD系统的开发与应用,装备制造技术,2011,5:73~7
[18]张淑玉,谢永增,孙明凯,等,Xsteel在钢结构深化设计中的应用,冶金标准化与质量,2007,44(02):60~62
[19]李长锁,隋波,Xsteel软件在海洋工程加工设计中的首次应用,中国造船,2006,47(增刊):92~95
[20]周愫承,洪英,曾国鼎,等,计算机辅助海洋平台集成系统,中国海洋平台,1996,11(06):280~286
[21]白秉仁,陈汉松,深水导管架加工设计软件系统研制与应用,计算机应用,1991,04:35~38
[22]杨文友,李天斌,王文华,交管工字钢单件图自动绘制程序的编制及应用,中国造船,2009,50(增刊):491~497
[23]申国栋,基于多机器人的H型钢火焰切割系统的路径规划研究:[硕士学位论文],天津;天津大学,2010
[24] Weike Song, Gang Wang, Juliang Xiao et al, Research on multi-robot open architecture of an intelligent CNC system based on parameter-driven technology,Robotics and Computer-Integrated Manufacturing, In Press
[25]聂晓根,刘艳斌,范扬波,等,五轴数控火焰切管机床数控系统研制,机械科学与技术,2008,27(2):268~272
[26]张剑锋,新型管子定长切割机的研究,造船技术,2007,1:40-43
[27]上海宝业机电科技有限公司,BCNCG系列数控管道相贯线切割机技术规格书,2008
[28]葛国政,数控管子相贯线火焰切割机的研制,焊接设备与材料,2006,1(02):45~47
[29] Blackburn J, Advancements in Pipe Cutting Operations, The Fabricator, 1994, 09: 14~19
[30]李浩,海洋工程管子相贯线坡口切割专家FastCAM,焊接与切割,2009,20:14~15
[31]陈柳芸,海洋石油平台数控切割系统研究:[硕士学位论文],上海;上海交通大学,2010
[32]姜萌,近海工程结构物—导管架平台,大连:大连理工大学出版社,2009,18~20
[33]阳连丰,易建英,苗双喜,浅析海洋石油平台组块机械专业的加工设计,中国修船,2008,21(增刊),45~47
[34]张增华,导管架加工设计管理,中国海上油气(工程),1989,1(03):47~52
[35]应长春,朱成章,海洋平台管节点制造工艺的特点,中国海洋平台,1989,01:25~28
[36]肖聚亮,阎祥安,王国栋,等,火焰数控切管机割炬轨迹研究及仿真,机械工程学报,2005,41(04):234~238
[37]秦元飞,李权才,肖聚亮,等,五轴数控火焰切管机割炬位姿控制,中国机械工程,2011,22(8):922~925
[38] Leska M, Proper Preparation: The Key to Successful Pipe Welds, Welding Journal, 2009, 88(05): 50~51
[39]中华人民共和国能源部,SY/T 4802-92,海上固定平台规划、设计和建造的推荐作法,北京:中国石油工业标准化技术委员会,1992-10-01
[40]美国焊接学会,AWS 1.1/D1.1M:2008,钢结构焊接规范,美国:美国焊接学协会,2008-07-02
[41] Miyashita H, Katsuki M, Yoneyama T, et al, Development of Computer Controlled Pipe-Cutting Machine, Ishikawajima-Harima Eng, 1986, 26(04): 256~240
[42] Carlos Toro, Maite Termenón, Jorge Posada, et al, Ontology Supported Adaptive User Interfaces for Structural CAD Design, DIGITAL ENTERPRISE, 2007, 03: 283~290
[43]虞明星,李淑民,宋峥嵘,等,海洋平台导管架建造焊材消耗定额统计,焊接技术,2011,40(6):48~50
[44]董玉德,赵韩,CAD二次开发理论与技术,合肥:合肥工业大学出版社,2009,135~136
[45]周乐来,马婧,AutoCAD 2008 Visual LISP二次开发技术入门到精通,北京:机械工业出版社,2007,135~136
[46]中国机械工程学会焊接学会,焊接手册,北京:机械工业出版社,2007
[47]王晋涛,数控铣削加工过程仿真的研究与分析:[硕士学位论文],天津;天津大学,2007
[48] K.T. Lim, H. El-Mounayri, CAD/CAM BASED GEOMETRIC MODELING SIMULATION FOR VIRTUAL MANUFACTURING, Electrical Insulation Conference and Electrical Manufacturing & Coil Winding Conference, Cincinnati, OH, USA, 1999, Proceedings, 547~551
[49]李颖,薛海滨,朱伯立,等,OpenGL技术应用实例精粹,北京:国防工业出版社,5~6
[50] Yunching Huang, James H. Oliver, Integrated simulation, error assessment, and tool path correction for five-axis NC milling, 1995, 14(5): 331~344
[51]赵玉刚,宋现春,数控技术,北京:机械工业出版社,2007,19~20
[52] Edward Angel交互式计算机图形学(吴文国),北京:清华大学出版社,2006,130~140
[2]黄悦华,任克忍,我国海洋石油钻井平台现状与技术发展分析,石油机械,2007,35(09):157~161
[3]张用德,袁学强,我国海洋钻井平台发展现状与趋势,石油矿场机械,2008,37(09):14~17
[4] Vasconcellos, A decision support system for floating platform design, Ocean Engineering, 1999, 26: 865~889
[5]魏晓添,海洋导管架结构的现状研究及应用前景,山西建筑,2010,36(19):102~103
[6]刘放,海洋平台技术的现状及发展趋势,设计与计算,2009,06:1~3
[7]深水导管架海洋平台安全可靠性分析及优化设计:[博士学位论文],东营;中国石油大学(华东),2010
[8]魏爱民,番禺30-1亚洲最大导管架的重建,今日科苑,2011,18:87~89
[9] Jeong-Tae Kim and Norris Stubbs, Damage Detection in Offshore Jacket Structures from Limited Modal Information, International Journal of Offshore and Polar Engineering, 1995, 5(01)
[10]孔祥鼎,夏炳仁,海洋平台建造工艺,北京:人民交通出版社,1993,108~112
[11]王兆喆.新型数控火焰切割机ACS软件系统的研究:[硕士学位论文],天津;天津大学,2008
[12] Vernon Tool Company,4 and 5-Axis microprocessor pipe machine instruction manual,USA:Vernon Tool Company,2003
[13]王国栋,阎祥安,肖聚亮,管环相贯焊接坡口数控切割研究,中国机械工程,2005,16(06):561~563
[14]肖聚亮,阎祥安,王国栋,等,管锥相贯焊接坡口数控切割,焊接学报,2005,26(05):69~72
[15]李宝清,贾安东,多管、板相贯坡口切割的数学模型,2000,33(5),583~586
[16] Yasuhisa Okumoto, Kentaro Hiyoku, Noritaka Uesugi, Simulation Based Production Using 3-D CAD in Shipbuilding, International Journal of CAD/CAM, 2006, 6(1)
[17]初新杰,采油平台三维建模CAD系统的开发与应用,装备制造技术,2011,5:73~7
[18]张淑玉,谢永增,孙明凯,等,Xsteel在钢结构深化设计中的应用,冶金标准化与质量,2007,44(02):60~62
[19]李长锁,隋波,Xsteel软件在海洋工程加工设计中的首次应用,中国造船,2006,47(增刊):92~95
[20]周愫承,洪英,曾国鼎,等,计算机辅助海洋平台集成系统,中国海洋平台,1996,11(06):280~286
[21]白秉仁,陈汉松,深水导管架加工设计软件系统研制与应用,计算机应用,1991,04:35~38
[22]杨文友,李天斌,王文华,交管工字钢单件图自动绘制程序的编制及应用,中国造船,2009,50(增刊):491~497
[23]申国栋,基于多机器人的H型钢火焰切割系统的路径规划研究:[硕士学位论文],天津;天津大学,2010
[24] Weike Song, Gang Wang, Juliang Xiao et al, Research on multi-robot open architecture of an intelligent CNC system based on parameter-driven technology,Robotics and Computer-Integrated Manufacturing, In Press
[25]聂晓根,刘艳斌,范扬波,等,五轴数控火焰切管机床数控系统研制,机械科学与技术,2008,27(2):268~272
[26]张剑锋,新型管子定长切割机的研究,造船技术,2007,1:40-43
[27]上海宝业机电科技有限公司,BCNCG系列数控管道相贯线切割机技术规格书,2008
[28]葛国政,数控管子相贯线火焰切割机的研制,焊接设备与材料,2006,1(02):45~47
[29] Blackburn J, Advancements in Pipe Cutting Operations, The Fabricator, 1994, 09: 14~19
[30]李浩,海洋工程管子相贯线坡口切割专家FastCAM,焊接与切割,2009,20:14~15
[31]陈柳芸,海洋石油平台数控切割系统研究:[硕士学位论文],上海;上海交通大学,2010
[32]姜萌,近海工程结构物—导管架平台,大连:大连理工大学出版社,2009,18~20
[33]阳连丰,易建英,苗双喜,浅析海洋石油平台组块机械专业的加工设计,中国修船,2008,21(增刊),45~47
[34]张增华,导管架加工设计管理,中国海上油气(工程),1989,1(03):47~52
[35]应长春,朱成章,海洋平台管节点制造工艺的特点,中国海洋平台,1989,01:25~28
[36]肖聚亮,阎祥安,王国栋,等,火焰数控切管机割炬轨迹研究及仿真,机械工程学报,2005,41(04):234~238
[37]秦元飞,李权才,肖聚亮,等,五轴数控火焰切管机割炬位姿控制,中国机械工程,2011,22(8):922~925
[38] Leska M, Proper Preparation: The Key to Successful Pipe Welds, Welding Journal, 2009, 88(05): 50~51
[39]中华人民共和国能源部,SY/T 4802-92,海上固定平台规划、设计和建造的推荐作法,北京:中国石油工业标准化技术委员会,1992-10-01
[40]美国焊接学会,AWS 1.1/D1.1M:2008,钢结构焊接规范,美国:美国焊接学协会,2008-07-02
[41] Miyashita H, Katsuki M, Yoneyama T, et al, Development of Computer Controlled Pipe-Cutting Machine, Ishikawajima-Harima Eng, 1986, 26(04): 256~240
[42] Carlos Toro, Maite Termenón, Jorge Posada, et al, Ontology Supported Adaptive User Interfaces for Structural CAD Design, DIGITAL ENTERPRISE, 2007, 03: 283~290
[43]虞明星,李淑民,宋峥嵘,等,海洋平台导管架建造焊材消耗定额统计,焊接技术,2011,40(6):48~50
[44]董玉德,赵韩,CAD二次开发理论与技术,合肥:合肥工业大学出版社,2009,135~136
[45]周乐来,马婧,AutoCAD 2008 Visual LISP二次开发技术入门到精通,北京:机械工业出版社,2007,135~136
[46]中国机械工程学会焊接学会,焊接手册,北京:机械工业出版社,2007
[47]王晋涛,数控铣削加工过程仿真的研究与分析:[硕士学位论文],天津;天津大学,2007
[48] K.T. Lim, H. El-Mounayri, CAD/CAM BASED GEOMETRIC MODELING SIMULATION FOR VIRTUAL MANUFACTURING, Electrical Insulation Conference and Electrical Manufacturing & Coil Winding Conference, Cincinnati, OH, USA, 1999, Proceedings, 547~551
[49]李颖,薛海滨,朱伯立,等,OpenGL技术应用实例精粹,北京:国防工业出版社,5~6
[50] Yunching Huang, James H. Oliver, Integrated simulation, error assessment, and tool path correction for five-axis NC milling, 1995, 14(5): 331~344
[51]赵玉刚,宋现春,数控技术,北京:机械工业出版社,2007,19~20
[52] Edward Angel交互式计算机图形学(吴文国),北京:清华大学出版社,2006,130~140