船体分段三维测量及对位系统控制策略研究
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摘要
随着科技的发展和造船工艺的提高,为了提高造船效率和质量,造船模式正在向总段巨型化建造工艺方向发展,这对船舶设计水平和制造精度控制等环节都提出了更高的要求。如何快速准确地测量建造过程中船体分段产品与理论模型之间的误差,以及如何提高搭载时对接分段快速对位的效率,已经成为国内外船舶与海洋工程领域研究的热点,因此研究这些问题具有非常重要的理论意义和实际应用价值。
本文在掌握国内外相关问题的研究现状基础上,对这些关键问题展开了进一步的研究工作,主要研究内容包括：
(1)船体分段建造过程中变形与反变形措施方面的研究。在船舶建造过程中,焊接、搁墩、吊装、移位等过程都会引起船体分段的变形,本文详细分析了引起船体变形的原因,并针对不同的变形情况提出了相应的反变形工艺措施。
(2)基于全站仪的船体分段大尺度测量方法的研究。分析了分段建造及搭载过程中船体分段大尺度三维测量方法,讨论了理论点集的选取原则,理论点集和测量点集常用匹配方法,并结合船体分段三维测量的特点,针对对应点集匹配的三点对齐法的不足,提出了基于最小二乘法选择中心点的改进三点对齐法；针对非对应点集匹配常用的迭代最近点法(ICP),提出了先采用主成份分析(PCA)进行粗匹配,再利用ICP进行精匹配的两阶段匹配方法,有效地提高了匹配精度。
(3)船体分段合拢自动化系统及控制策略的研究。针对现有的搭载方式占用吊机时间过长,并且存在安全隐患问题,设计了一种用于船体分段合拢的三维可调平台系统,该系统由多个三自由度可调墩组成,单个可调墩可实现一定范围的三维运动,当采用群墩控制时,系统可实现多自由度运动,从而实现安全、高效和高精度控制的船体分段搭载对位和合拢的建造工艺。
(4)基于多新息(Multi-innovation)理论的船体分段对位控制方法研究。船体分段合拢对接过程是一个难以建立数学模型的非线性系统,针对这一特点深入研究了可调平台控制策略问题,理论证明了基于多新息理论的无模型控制律的收敛性问题,并对控制律中的参数采用遗传算法进行在线优化；提出了基于多新息理论的PID神经网络控制算法,并证明了该方法的收敛性。最后采用多个仿真实例对所提出的两种改进算法进行验证,结果表明,改进后的两种控制算法都比原算法收敛速度快,具有更强的鲁棒性。
(5)面向造船工程实际,采用自主发明专利技术制作了三自由度可调墩样机,提出了基于开放式控制系统开发规范的可调墩控制系统的框架结构,研制开发了可调墩控制系统的软硬件平台,并在平台控制算法库中,实现了本文提出的基于多新息理论的PIDNN控制算法,实际控制效果进一步验证了方法的有效性。本文研发了具有自主知识产权的船体分段大尺度测量误差分析系统和模拟搭载系统,实现了船体分段无余量建造误差分析和模拟搭载过程分析,以及有余量测量建造误差分析和模拟搭载功能,本研究成果已应用于广新海事重工股份有限公司的多艘实船建造中,取得了较好的实际工程应用效果。
With the development of science and shipbuilding technology, the shipbuilding mode is moving on the direction of gigantic block in order to improve the efficiency and quality of shipbuilding. Therefore it makes more demands of designing and manufacturing and other sectors. How to quickly and accurately measure the error between the theoretical model and real product in construction process, and how to increase positioning efficiency of docking in assembly process, have become the hotspot of academic research at home and abroad, so it has important theoretical significance and application value onstudying these issues.
This article launched further research work on these issues on the basis of the current research archeivement made by experts at home and abroad. The main research contents include:
(1) Study the deformation and the anti-deformation measures in the process of hull construction. In the process of hull construction, welding, placing on pier, lifting and shifting can cause deformation of hull block. This paper analyzes the cause of hull deformation, and propose corresponding measures against deformation according to different deformation type.
(2) Study the hull block large-scale measurement methods usingtotal station. This paper analyzes the large scale three-dimensional measurement method of hull block in the process of construction and assembly, discusses the selection principle of theoretical point set, and the matching method between theoretical point set and measurement point set, proposes the improved three point alignment method of selecting the central point based on least square method after taking the characteristics of three-dimensional measurement of hull block and aiming at the shortage of point set matching in alignment method,. About the IPC method frequently used in the matching of non-correspondence point set, this paper proposes a new way of matching the point set by PCA in general and then matching the point set by ICP finely, which can improve the matching accuracy effectively.
(3) Study the hull block assembly automation systems and control method. The existing assembly methods occupies long crane time and have security issues, this paper designes a three-dimensional adjustable platform used for hull block assembly. The system consists of several three degree of freedom adjustable pier, and using single pier can achieve a range of three-dimensional movement. When it turnsto group pier control mode, system can achieve multi degree of freedom of movement, and then realize a safe, efficient, high-accuracy technology of hull block assembly and positioning.
(4) Study the hull block positioning control method based on the theory of multi-innovation. It is difficult to establish mathematical model for the hull block docking as it is a nonlinear system, this paper deeply studies the adjustable platform control method issues, theoretically proves the convergence of the model free control based on the multi-innovation theory, optimizes the control parameters online by using genetic algorithms, proposes a PID neural network control algorithm based on multi-innovation theory, and proves its convergence. Finally, this paper use multiple simulation instancesto verify these two improved algorithms, and the results show that the improved two control algorithms converges faster with strong robustness.
(5) Oriented to the shipbuilding engineering practice, this paper makes a three degrees of freedom adjustable pier prototype, proposes adjustable pier control system frame structure based on the development of open control system specification., developes the hardware and software platform of adjustable the pier control system, and implement the proposed PIDNN control algorithm based on multi-innovation theory in platform control algorithm library, and the actual control results further validate the effectiveness of the proposed method. This paper also developes a hull block large-scale measurement error analysis system and an assembly simulation system, which achieved functions as error analysis and simulation analysis of hull block no-margin construction, margin measuring error analysis and assembly simulation. The results of this study have been applied to several shipbuilding projects in Guangxin Shipbuilding&Heavy Industry Co., Ltd., and acheives a good practical effect.
本文在掌握国内外相关问题的研究现状基础上,对这些关键问题展开了进一步的研究工作,主要研究内容包括：
(1)船体分段建造过程中变形与反变形措施方面的研究。在船舶建造过程中,焊接、搁墩、吊装、移位等过程都会引起船体分段的变形,本文详细分析了引起船体变形的原因,并针对不同的变形情况提出了相应的反变形工艺措施。
(2)基于全站仪的船体分段大尺度测量方法的研究。分析了分段建造及搭载过程中船体分段大尺度三维测量方法,讨论了理论点集的选取原则,理论点集和测量点集常用匹配方法,并结合船体分段三维测量的特点,针对对应点集匹配的三点对齐法的不足,提出了基于最小二乘法选择中心点的改进三点对齐法；针对非对应点集匹配常用的迭代最近点法(ICP),提出了先采用主成份分析(PCA)进行粗匹配,再利用ICP进行精匹配的两阶段匹配方法,有效地提高了匹配精度。
(3)船体分段合拢自动化系统及控制策略的研究。针对现有的搭载方式占用吊机时间过长,并且存在安全隐患问题,设计了一种用于船体分段合拢的三维可调平台系统,该系统由多个三自由度可调墩组成,单个可调墩可实现一定范围的三维运动,当采用群墩控制时,系统可实现多自由度运动,从而实现安全、高效和高精度控制的船体分段搭载对位和合拢的建造工艺。
(4)基于多新息(Multi-innovation)理论的船体分段对位控制方法研究。船体分段合拢对接过程是一个难以建立数学模型的非线性系统,针对这一特点深入研究了可调平台控制策略问题,理论证明了基于多新息理论的无模型控制律的收敛性问题,并对控制律中的参数采用遗传算法进行在线优化；提出了基于多新息理论的PID神经网络控制算法,并证明了该方法的收敛性。最后采用多个仿真实例对所提出的两种改进算法进行验证,结果表明,改进后的两种控制算法都比原算法收敛速度快,具有更强的鲁棒性。
(5)面向造船工程实际,采用自主发明专利技术制作了三自由度可调墩样机,提出了基于开放式控制系统开发规范的可调墩控制系统的框架结构,研制开发了可调墩控制系统的软硬件平台,并在平台控制算法库中,实现了本文提出的基于多新息理论的PIDNN控制算法,实际控制效果进一步验证了方法的有效性。本文研发了具有自主知识产权的船体分段大尺度测量误差分析系统和模拟搭载系统,实现了船体分段无余量建造误差分析和模拟搭载过程分析,以及有余量测量建造误差分析和模拟搭载功能,本研究成果已应用于广新海事重工股份有限公司的多艘实船建造中,取得了较好的实际工程应用效果。
With the development of science and shipbuilding technology, the shipbuilding mode is moving on the direction of gigantic block in order to improve the efficiency and quality of shipbuilding. Therefore it makes more demands of designing and manufacturing and other sectors. How to quickly and accurately measure the error between the theoretical model and real product in construction process, and how to increase positioning efficiency of docking in assembly process, have become the hotspot of academic research at home and abroad, so it has important theoretical significance and application value onstudying these issues.
This article launched further research work on these issues on the basis of the current research archeivement made by experts at home and abroad. The main research contents include:
(1) Study the deformation and the anti-deformation measures in the process of hull construction. In the process of hull construction, welding, placing on pier, lifting and shifting can cause deformation of hull block. This paper analyzes the cause of hull deformation, and propose corresponding measures against deformation according to different deformation type.
(2) Study the hull block large-scale measurement methods usingtotal station. This paper analyzes the large scale three-dimensional measurement method of hull block in the process of construction and assembly, discusses the selection principle of theoretical point set, and the matching method between theoretical point set and measurement point set, proposes the improved three point alignment method of selecting the central point based on least square method after taking the characteristics of three-dimensional measurement of hull block and aiming at the shortage of point set matching in alignment method,. About the IPC method frequently used in the matching of non-correspondence point set, this paper proposes a new way of matching the point set by PCA in general and then matching the point set by ICP finely, which can improve the matching accuracy effectively.
(3) Study the hull block assembly automation systems and control method. The existing assembly methods occupies long crane time and have security issues, this paper designes a three-dimensional adjustable platform used for hull block assembly. The system consists of several three degree of freedom adjustable pier, and using single pier can achieve a range of three-dimensional movement. When it turnsto group pier control mode, system can achieve multi degree of freedom of movement, and then realize a safe, efficient, high-accuracy technology of hull block assembly and positioning.
(4) Study the hull block positioning control method based on the theory of multi-innovation. It is difficult to establish mathematical model for the hull block docking as it is a nonlinear system, this paper deeply studies the adjustable platform control method issues, theoretically proves the convergence of the model free control based on the multi-innovation theory, optimizes the control parameters online by using genetic algorithms, proposes a PID neural network control algorithm based on multi-innovation theory, and proves its convergence. Finally, this paper use multiple simulation instancesto verify these two improved algorithms, and the results show that the improved two control algorithms converges faster with strong robustness.
(5) Oriented to the shipbuilding engineering practice, this paper makes a three degrees of freedom adjustable pier prototype, proposes adjustable pier control system frame structure based on the development of open control system specification., developes the hardware and software platform of adjustable the pier control system, and implement the proposed PIDNN control algorithm based on multi-innovation theory in platform control algorithm library, and the actual control results further validate the effectiveness of the proposed method. This paper also developes a hull block large-scale measurement error analysis system and an assembly simulation system, which achieved functions as error analysis and simulation analysis of hull block no-margin construction, margin measuring error analysis and assembly simulation. The results of this study have been applied to several shipbuilding projects in Guangxin Shipbuilding&Heavy Industry Co., Ltd., and acheives a good practical effect.
引文
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