High-purity ferrite heat exchanger welding system based on intelligent robot welding

Abstract

The invention belongs to the technical field of automatic welding, and particularly relates to a high-purity ferrite heat exchanger welding system based on intelligent robot welding, which comprises a belt-driven moving platform and a heat exchanger tube plate to be processed, and the surface of one side of the belt-driven moving platform is fixedly connected with a numerical control cabinet through a connecting rod; a supporting base is slidably clamped to the outer surface of a guide rail of the belt-driven moving platform, a welding mechanical arm is installed on the upper surface of the supporting base, meanwhile, a pretreatment mechanism is further arranged on the upper surface of the supporting base, and a clamping mechanism is arranged on the surface of the numerical control cabinet. According to the high-purity ferrite heat exchanger welding system based on intelligent robot welding, through multi-sensor data fusion and an intelligent image recognition system, the positions of a tube plate and holes can be accurately recognized, and real-time correction is carried out, so that welding defects such as cracks and air holes are avoided, errors caused by imperfect surfaces are overcome, and the welding precision is ensured.

Description

Technical Field

[0001] The invention relates to the technical field of automated welding, and in particular to a high-purity ferrite heat exchanger welding system based on intelligent robot welding. Background Art

[0002] High-purity ferrite heat exchanger is an important equipment widely used in high temperature, high pressure and corrosive environment. The welding quality of its tube sheet and tube hole directly affects the working performance and service life of the heat exchanger.

[0003] However, due to factors such as the ovality, cleanliness, burrs, incomplete rust removal and inaccurate groove processing of the holes on the heat exchanger tube sheet, traditional manual welding methods are difficult to ensure consistency and high quality. Although welding robots can provide a certain degree of accuracy, due to image recognition errors, position deviations, excessive heat input and other issues, welding accuracy and penetration often cannot meet the requirements of high-purity ferrite materials. Therefore, an automated welding system that can overcome existing problems is needed. Summary of the invention

[0004] Based on the above-mentioned existing technical problems, the present invention proposes a high-purity ferrite heat exchanger welding system based on intelligent robot welding.

[0005] The present invention proposes a high-purity ferrite heat exchanger welding system based on intelligent robot welding, comprising a belt-driven mobile platform and a heat exchanger tube sheet to be processed, wherein one side surface of the belt-driven mobile platform is fixedly connected to a numerical control cabinet via a connecting rod, and the outer surface of the guide rail of the belt-driven mobile platform is slidably connected to a support base, a welding robot arm is installed on the upper surface of the support base, and a pretreatment mechanism is also provided on the upper surface, and a clamping mechanism is provided on the surface of the numerical control cabinet.

[0006] Wherein, the pretreatment mechanism is arranged on one side of the welding robot arm, and processes the heat exchanger tube sheet prior to the welding robot arm.

[0007] Wherein, the clamping mechanism clamps the heat exchanger tube sheet and adjusts its flipping angle.

[0008] Preferably, the clamping mechanism includes a linkage frame fixedly connected to the outer surface of the output shaft of the CNC cabinet, the linkage frame is in an I-shape, and both side surfaces of one end of the linkage frame are rotatably connected to a pushing cylinder through a slide cylinder, and the surface of the piston rod of the pushing cylinder is fixedly connected to a telescopic frame through a connecting plate, and the outer surface of the heat exchanger tube sheet is in sliding contact with the surface of the telescopic frame.

[0009] Through the above technical scheme, in order to facilitate the rapid welding of the heat exchanger tube sheet and the tube hole, and at the same time facilitate the processing of the heat exchanger tube sheet surface, the heat exchanger tube sheet is placed horizontally on the telescopic frame. As the pushing cylinder is pushed, the telescopic frame contracts, so that the telescopic frame and the other side of the linkage frame clamp and fix the heat exchanger tube sheet at the same time. At the same time, the CNC cabinet can control its output shaft to drive the linkage frame to rotate, thereby driving the heat exchanger tube sheet on the telescopic frame to rotate, and then adjust the angle of the heat exchanger tube sheet to facilitate processing. The shape of the linkage frame makes it have the characteristics of double-station processing, so that the heat exchanger tube sheets on the two stations are switched when the linkage frame rotates.

[0010] Preferably, the clamping mechanism also includes a rotating motor fixedly connected to the two side surfaces of the other end of the linkage frame, the outer surface of the output shaft of the rotating motor is fixedly connected to an extrusion disk via a coupling, and one side surface of the extrusion disk is fixedly connected to the free end of the telescopic frame.

[0011] Through the above technical scheme, in order to adapt to the angle adjustment of the pretreatment mechanism when pretreating the surface of the heat exchanger tube sheet, the heat exchanger tube sheet is pushed by the pushing cylinder to make the surface of the extrusion plate come into contact with the extrusion plate, so that as the rotating motor is started, the heat exchanger tube sheet on one side of the workstation can be driven to adjust the angle.

[0012] Preferably, the clamping mechanism also includes a protective plate hinged to the upper and lower surfaces of the linkage frame through a hinge, and the upper and lower surfaces of the linkage frame are symmetrically hinged with push cylinders, and the piston rod surface of the push cylinder is hinged to a side surface corresponding to the protective plate.

[0013] Through the above technical scheme, in order to avoid mutual interference between the heat exchanger tube sheets on the two workstations on the linkage frame during processing, the two heat exchanger tube sheets are separated by a protective plate, and the protective angle of the protective plate is adjusted by the pushing cylinder to ensure the safety of the heat exchanger tube sheets during processing.

[0014] Preferably, the pretreatment mechanism includes a multi-axis robotic arm fixedly connected to the upper surface of the support base, the movable end of the multi-axis robotic arm is fixedly connected to a fixed block, and the lower surface of the fixed block is provided with an air gun, two polishing milling cutters and a brush roller in a clockwise direction.

[0015] Through the above technical scheme, in order to process the ovality, cleanliness, burrs and rust removal of the holes on the heat exchanger tube sheet, the multi-axis robotic arm can be adjusted at multiple angles and move flexibly, so that the angles of the air gun, polishing milling cutter and brush roller can be adjusted, so that the three pretreatment tools can be extended to the inner wall of the hole on the heat exchanger tube sheet to remove oxides and other dirt, and the geometry of the hole can be corrected. At the same time, the three processing tools can contact the surface of the heat exchanger tube sheet when horizontal, and the surface of the heat exchanger tube sheet can be cleaned as the multi-axis robotic arm moves.

[0016] Preferably, the pretreatment mechanism also includes a load-bearing block rotatably connected to the lower surface of the fixed block, the lower surface of the load-bearing block is fixedly connected to a mounting cover via a connecting rod, the outer surfaces of the connecting shafts of the air gun, polishing milling cutter and brush roller are rotatably sleeved with a support tube, the lower surface of the mounting cover is symmetrically fixedly connected with a support beam, a movable groove is penetrated through the upper surface of the support beam, and the outer surface of the support tube is slidably engaged with the inner wall of the movable groove.

[0017] Through the above technical scheme, in order to make the outer surfaces of the air gun, polishing milling cutter and brush roller contact the inner walls of the holes on the heat exchanger tube plate respectively to realize the processing action, the support beam is supported by the installation cover, so that the support tubes on the outer surfaces of the three processing tools can move horizontally in the corresponding moving grooves respectively, thereby adjusting the positions of the three processing tools so that they can fit the inner wall of the hole for operation, or detach from the inner wall of the hole for other operations.

[0018] Preferably, the pretreatment mechanism also includes an adjusting cylinder fixedly connected to the surface of the support beam, the piston rod surface of the adjusting cylinder is fixedly connected to the outer surface of the support tube, and the upper surface of the connecting shaft of the air gun, polishing milling cutter and brush roller is fixedly connected with a universal joint connecting shaft.

[0019] Through the above technical scheme, in order to adjust the contact degree between the three processing tools and the surface of the heat exchanger tube plate and the inner wall of the hole, the corresponding adjusting cylinder is actuated to make its piston rod adjust the displacement of the three processing tools. In order to maintain its rotation when adjusting the displacement of the processing tool to realize the processing action, the driving source is connected through the universal joint connecting shaft, and the rotation of the processing tool can be realized when the universal joint connecting shaft rotates.

[0020] Preferably, the interior of the fixed block is rotatably connected to a reduction motor, the outer surface of the output shaft of the reduction motor is fixedly connected to a driving gear, the surface of the load-bearing block is rotatably connected to a rotating shaft through a bearing, the outer surface of the lower end of the rotating shaft is fixedly sleeved with a driven gear, the driving gear is meshed with the driven gear, the lower surface of the rotating shaft is fixedly connected to the free end of the universal joint connecting shaft, and a linkage block is fixedly connected to one side surface of the fixed block.

[0021] Through the above technical scheme, in order to avoid waste of resources, a driving source is set to drive multiple processing tools to rotate, and the reduction motor drives the driving gear to rotate, so that the driven gear engaged with it drives the universal joint connecting shaft to rotate, and then controls the rotation of multiple processing tools to achieve burr processing, cleaning processing, correction processing, etc. of the heat exchanger tube sheet by the processing tools. At the same time, the gear group and the motor drive the reduction motor in the linkage block to drive the circumferential rotation of the structure on its lower surface, so that various pre-treatments can be achieved on the inner wall of the hole.

[0022] Preferably, laser sensors and infrared sensors are fixedly connected to both side surfaces of the welding head of the welding robot arm.

[0023] Through the above technical scheme, in order to achieve comprehensive recognition of the surface of the heat exchanger tube sheet, the position, size and groove of the holes, and improve the adaptability of the welding robot to the heat exchanger tube sheet, the laser sensor is installed near the welding head of the welding robot arm to directly scan the geometry of the welding area or the tube hole, which helps to calibrate the shape and size of the tube hole in real time before welding. During the operation of the welding robot arm, the laser sensor is synchronized with the position and posture information of the welding robot arm in real time to provide high-precision measurement data. The infrared sensor faces the surface of the heat exchanger tube sheet to be welded, which allows the sensor to detect whether there are pollutants such as oil and dust in the welding area before welding.

[0024] Preferably, ultrasonic sensors and visual cameras are fixedly connected to both side surfaces of the welding arm of the welding robot arm.

[0025] Through the above technical solution, in order to detect the welding quality, the ultrasonic sensors are installed on the welding arm of the welding robot arm and directly aimed at the groove of the welding joint. They can monitor the accuracy of the welding joint in real time and detect the changes in the groove during the welding process. The visual camera is installed on the welding arm of the welding robot arm, facing the surface of the heat exchanger tube sheet to be welded, so as to photograph the workpiece during the movement of the welding robot arm and perform real-time calibration. Multiple sensors are also integrated and installed in the same way on the multi-axis robot arm to control multiple processing tools to achieve precise processing of the heat exchanger tube sheet.

[0026] The beneficial effects of the present invention are:

[0027] 1. By setting up a clamping mechanism, the angle of the workpiece to be processed can be adjusted. During the adjustment process, the heat exchanger tube sheet is pushed by the cylinder to make it squeeze contact with the surface of the extrusion plate. As the rotating motor starts, the heat exchanger tube sheet on one side of the station can be driven to adjust the angle, making it convenient for the pretreatment of the heat exchanger tube sheet.

[0028] 2. By setting up a pretreatment mechanism, the ovality, cleanliness, burrs, rust removal and groove processing of the holes on the heat exchanger tube sheet can be pretreated. During the adjustment process, the corresponding adjustment cylinder is moved to make its piston rod pull the support tube on the outer surface of the air gun, change the displacement of the air gun, and make it close to the inner wall of the hole for air flow impact, so that the oxides and other dirt fall off, and then the polishing milling cutter moves to contact the inner wall of the hole, polishes and trims the inner wall of the hole, and finally cleans the inner wall with a brush roller. A variety of processing tools rotate clockwise first, so that the inner wall of the hole can be operated in a flow line, so that the robot integrates the cleaning and pretreatment system, automatically removes burrs, oxides and other dirt on the surface of the tube sheet, and ensures that the cleanliness of the tube sheet before welding meets the welding requirements.

[0029] 3. Through multi-sensor data fusion and intelligent image recognition system, the position of tube sheet and hole can be accurately identified and corrected in real time. Specifically, the welding robot can automatically optimize welding parameters according to real-time feedback to ensure the penetration of high-purity ferrite materials, weld quality and control of heat-affected zone, thereby avoiding welding defects such as cracks and pores, overcoming errors caused by surface imperfections and ensuring welding accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 A schematic diagram of a high-purity ferrite heat exchanger welding system based on intelligent robot welding proposed by the present invention;

[0031] Figure 2 A three-dimensional diagram of the welding robot arm structure of a high-purity ferrite heat exchanger welding system based on intelligent robot welding proposed by the present invention;

[0032] Figure 3 A three-dimensional diagram of the protective plate structure of a high-purity ferrite heat exchanger welding system based on intelligent robot welding proposed by the present invention;

[0033] Figure 4 A three-dimensional diagram of the telescopic frame structure of a high-purity ferrite heat exchanger welding system based on intelligent robot welding proposed by the present invention;

[0034] Figure 5 A three-dimensional diagram of the structure of a multi-axis mechanical arm of a high-purity ferrite heat exchanger welding system based on intelligent robot welding proposed by the present invention;

[0035] Figure 6 A three-dimensional diagram of the installation cover structure of a high-purity ferrite heat exchanger welding system based on intelligent robot welding proposed by the present invention;

[0036] Figure 7 A three-dimensional diagram of the support beam structure of a high-purity ferrite heat exchanger welding system based on intelligent robot welding proposed by the present invention;

[0037] Figure 8 This is a three-dimensional diagram of the universal joint connecting shaft structure of a high-purity ferrite heat exchanger welding system based on intelligent robot welding proposed by the present invention.

[0038] In the figure: 1. belt-driven mobile platform; 2. heat exchanger tube sheet; 3. CNC cabinet; 4. support base; 5. welding robot arm; 51. laser sensor; 52. infrared sensor; 53. ultrasonic sensor; 54. visual camera; 6. clamping mechanism; 61. linkage frame; 62. pushing cylinder; 63. telescopic frame; 64. rotating motor; 65. extrusion plate; 66. protective plate; 67. push cylinder; 7. pretreatment mechanism; 71. multi-axis robot arm; 72. fixed block; 73. air gun; 74. polishing milling cutter; 75. brush roller; 76. load-bearing block; 77. mounting cover; 78. support tube; 79. support beam; 80. moving groove; 81. adjusting cylinder; 82. universal joint connecting shaft; 83. reduction motor; 84. driving gear; 85. rotating shaft; 86. driven gear; 87. linkage block. DETAILED DESCRIPTION

[0039] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0040] Reference Figure 1-Figure 8 A high-purity ferrite heat exchanger welding system based on intelligent robot welding includes a belt-driven mobile platform 1 and a heat exchanger tube sheet 2 to be processed. A side surface of the belt-driven mobile platform 1 is fixedly connected to a CNC cabinet 3 through a connecting rod. A support base 4 is slidably connected to the outer surface of the guide rail of the belt-driven mobile platform 1. A welding robot arm 5 is installed on the upper surface of the support base 4. A pretreatment mechanism 7 is also provided on the upper surface of the support base 4. A clamping mechanism 6 is provided on the surface of the CNC cabinet 3.

[0041] The pretreatment mechanism 7 is arranged at one side of the welding robot arm 5 , and processes the heat exchanger tube sheet 2 prior to the welding robot arm 5 .

[0042] In order to facilitate the rapid welding of the heat exchanger tube sheet 2 and the tube holes, and to facilitate the surface processing of the heat exchanger tube sheet 2, the clamping mechanism 6 includes a linkage frame 61 fixedly connected to the outer surface of the output shaft of the numerical control cabinet 3, the linkage frame 61 is in an I-shape, and the two side surfaces of one end of the linkage frame 61 are rotatably connected to the push cylinder 62 through a slide cylinder, and the piston rod surface of the push cylinder 62 is fixedly connected to the telescopic frame 63 through a connecting plate. The outer surface of the heat exchanger tube sheet 2 is in sliding contact with the surface of the telescopic frame 63, and the heat exchanger tube sheet 2 is horizontally placed on the telescopic frame 63. The telescopic frame 63 is on the frame 63. With the push of the pushing cylinder 62, the telescopic frame 63 contracts, so that the telescopic frame 63 and the other side of the linkage frame 61 clamp and fix the heat exchanger tube sheet 2 at the same time. At the same time, the CNC cabinet 3 can control its output shaft to drive the linkage frame 61 to rotate, thereby driving the heat exchanger tube sheet 2 on the telescopic frame 63 to rotate, and then adjusting the angle of the heat exchanger tube sheet 2 to facilitate processing. The shape of the linkage frame 61 makes it have the characteristics of double-station processing, so that the heat exchanger tube sheets 2 on the two stations are switched when the linkage frame 61 rotates.

[0043] In order to adapt to the angle adjustment of the pretreatment mechanism 7 when pretreating the surface of the heat exchanger tube sheet 2, the clamping mechanism 6 also includes a rotating motor 64 fixedly connected to the two side surfaces of the other end of the linkage frame 61. The outer surface of the output shaft of the rotating motor 64 is fixedly connected to the extrusion plate 65 through a coupling. One side surface of the extrusion plate 65 is fixedly connected to the free end of the telescopic frame 63. The heat exchanger tube sheet 2 is squeezed and contacted with the surface of the extrusion plate 65 by the push of the pushing cylinder 62. As a result, as the rotating motor 64 is started, the heat exchanger tube sheet 2 on one side of the station can be driven to adjust the angle.

[0044] In order to avoid mutual interference between the heat exchanger tube sheets 2 on the two workstations on the linkage frame 61 during processing, the clamping mechanism 6 also includes a protective plate 66 hinged to the upper and lower surfaces of the linkage frame 61 through a hinge. The upper and lower surfaces of the linkage frame 61 are symmetrically distributed and hinged with push cylinders 67. The piston rod surface of the push cylinder 67 is hinged to the side surface of the corresponding protective plate 66. The two heat exchanger tube sheets 2 are separated by the protective plate 66. At the same time, the protective angle of the protective plate 66 is adjusted by the push cylinder 67 to ensure the safety of the heat exchanger tube sheet 2 during processing.

[0045] By setting up the clamping mechanism 6, the angle of the clamped workpiece to be processed can be adjusted. During the adjustment process, the heat exchanger tube sheet 2 is pushed and contacted with the surface of the extrusion plate 65 by the pushing of the pushing cylinder 62. As the rotating motor 64 is started, the heat exchanger tube sheet 2 on one side of the workstation can be driven to adjust the angle, making it convenient for the pretreatment of the heat exchanger tube sheet 2.

[0046] The clamping mechanism 6 clamps the heat exchanger tube sheet 2 and adjusts its flipping angle.

[0047] In order to process the ovality, cleanliness, burrs and rust removal of the holes on the heat exchanger tube sheet 2, the pretreatment mechanism 7 includes a multi-axis robot arm 71 fixedly connected to the upper surface of the support base 4, and the movable end of the multi-axis robot arm 71 is fixedly connected to a fixed block 72. The lower surface of the fixed block 72 is provided with an air gun 73, two polishing milling cutters 74, and a brush roller 75 in a clockwise direction. The multi-axis robot arm 71 can be adjusted at multiple angles and move flexibly, so that the angles of the air gun 73, the polishing milling cutter 74, and the brush roller 75 can be adjusted, so that the three pretreatment tools extend to the inner wall of the hole on the heat exchanger tube sheet 2 to remove oxides and other dirt, and correct the geometric shape of the hole. At the same time, the three processing tools can contact the surface of the heat exchanger tube sheet 2 when horizontal, and the surface of the heat exchanger tube sheet 2 is cleaned as the multi-axis robot arm 71 moves.

[0048] In order to make the outer surfaces of the air gun 73, the polishing milling cutter 74, and the brush roller 75 respectively contact the inner wall of the hole on the heat exchanger tube sheet 2 to realize the processing action, the pretreatment mechanism 7 also includes a load-bearing block 76 rotatably connected to the lower surface of the fixed block 72, and the lower surface of the load-bearing block 76 is fixedly connected to the mounting cover 77 through a connecting rod. The outer surfaces of the connecting shafts of the air gun 73, the polishing milling cutter 74, and the brush roller 75 are rotatably sleeved with support tubes 78. The lower surface of the mounting cover 77 is symmetrically distributed and fixedly connected with support beams 79. The upper surface of the support beam 79 is penetrated by a movable groove 80. The outer surface of the support tube 78 is slidably engaged with the inner wall of the movable groove 80. After the mounting cover 77 supports the support beam 79, the support tubes 78 on the outer surfaces of the three processing tools can be horizontally moved in the corresponding movable grooves 80, thereby adjusting the positions of the three processing tools so that they can fit the inner wall of the hole for operation, or detach from the inner wall of the hole for other operations.

[0049] In order to adjust the contact degree between the three processing tools and the surface of the heat exchanger tube sheet 2 and the inner wall of the hole, the pretreatment mechanism 7 also includes an adjusting cylinder 81 fixedly connected to the surface of the support beam 79, and the piston rod surface of the adjusting cylinder 81 is fixedly connected to the outer surface of the support tube 78. The corresponding adjusting cylinder 81 is actuated to make its piston rod adjust the displacement of the three processing tools. In order to keep the rotation of the processing tools when adjusting their displacement to realize the processing action, the upper surface of the connecting shaft of the air gun 73, the polishing milling cutter 74, and the brush roller 75 is fixedly connected with a universal joint connecting shaft 82, which is connected to the driving source through the universal joint connecting shaft 82. When the universal joint connecting shaft 82 rotates, the rotation of the processing tools can be realized.

[0050] In order to avoid waste of resources, a driving source is set to drive multiple processing tools to rotate. The internal rotation of the fixed block 72 is connected to a reduction motor 83, and the outer surface of the output shaft of the reduction motor 83 is fixedly connected to a driving gear 84. The surface of the load-bearing block 76 is rotatably connected to a rotating shaft 85 through a bearing. The outer surface of the lower end of the rotating shaft 85 is fixedly sleeved with a driven gear 86. The driving gear 84 is meshed with the driven gear 86. The lower surface of the rotating shaft 85 is fixedly connected to the free end of the universal joint connecting shaft 82. A linkage block 87 is fixedly connected to the surface of one side of the fixed block 72. The driving gear 84 is driven to rotate by the reduction motor 83, so that the driven gear 86 meshed with it drives the universal joint connecting shaft 82 to rotate, thereby controlling the rotation of multiple processing tools to realize burr processing, cleaning processing, correction processing, etc. of the heat exchanger tube sheet 2 by the processing tools. At the same time, the linkage block 87 drives the reduction motor 83 through the gear set and the motor to drive the structure of its lower surface to rotate circumferentially, so that various pretreatments can be achieved on the inner wall of the hole.

[0051] By setting up the pretreatment mechanism 7, the ovality, cleanliness, burr, rust removal and groove processing of the hole on the heat exchanger tube sheet 2 can be pretreated. During the adjustment process, the corresponding adjustment cylinder 81 is actuated to make its piston rod pull the support tube 78 on the outer surface of the air gun 73, change the displacement of the air gun 73, and make it close to the inner wall of the hole for air flow impact, so that the oxide and other dirt fall off, and then the polishing milling cutter 74 moves to contact the inner wall of the hole, polish and trim the inner wall of the hole, and finally the brush roller 75 cleans the inner wall. The various processing tools rotate clockwise first, so that the inner wall of the hole can be processed in a flow line, so that the robot integrates the cleaning and pretreatment system, automatically removes burrs, oxides and other dirt on the surface of the tube sheet, and ensures that the cleanliness of the tube sheet before welding meets the welding requirements.

[0052] In order to achieve comprehensive identification of the surface of the heat exchanger tube sheet 2, the position, size and groove of the holes, and improve the adaptability of the welding robot to the heat exchanger tube sheet 2, the surfaces on both sides of the welding head of the welding robot arm 5 are fixedly connected with a laser sensor 51 and an infrared sensor 52. The laser sensor 51 is installed near the welding head of the welding robot arm 5 so as to directly scan the geometric shape of the welding area or the tube hole, which helps to calibrate the shape and size of the tube hole in real time before welding. When the welding robot arm 5 is working, the laser sensor 51 is synchronized with the position and posture information of the welding robot arm 5 in real time to provide high-precision measurement data. The infrared sensor 52 faces the surface of the heat exchanger tube sheet 2 to be welded, which allows the sensor to detect whether there are pollutants such as oil and dust in the welding area before welding.

[0053] In order to detect the welding quality, ultrasonic sensors 53 and visual cameras 54 are fixedly connected to the surfaces of both sides of the welding arm of the welding robot arm 5. The ultrasonic sensors 53 are installed on the welding arm of the welding robot arm 5 and are directly aimed at the groove of the welding joint. They can monitor the accuracy of the welding joint in real time and detect the changes in the groove during the welding process. The visual camera 54 is installed on the welding arm of the welding robot arm 5 and faces the surface of the heat exchanger tube sheet 2 to be welded, so as to photograph the workpiece during the movement of the welding robot arm 5 and perform real-time calibration. Multiple sensors are also integrated and installed in the same way on the multi-axis robot arm 71, so as to control multiple processing tools to achieve precise processing of the heat exchanger tube sheet 2.

[0054] Through multi-sensor data fusion and intelligent image recognition systems, the positions of tube sheets and holes can be accurately identified and corrected in real time. Specifically, the welding robot can automatically optimize welding parameters based on real-time feedback to ensure the penetration of high-purity ferrite materials, weld quality and control of heat-affected zones, thereby avoiding welding defects such as cracks and pores, overcoming errors caused by surface imperfections and ensuring welding accuracy.

[0055] Working principle: In a specific embodiment of the present invention, the heat exchanger tube sheet 2 is placed on the telescopic frames 63 on both sides of the linkage frame 61. As the piston rod of the push cylinder 62 pushes, the telescopic frames 63 are retracted. At this time, one side surface of the heat exchanger tube sheet 2 is in compression contact with the surface of the pressure plate.

[0056] After the heat exchanger tube sheet 2 is clamped and fixed, the belt-driven mobile platform 1 drives the support base 4 to move horizontally on the outer surface of the guide rail. Since the multi-axis robot arm 71 is in front of the welding robot arm 5, the pretreatment mechanism 7 on the multi-axis robot arm 71 performs deburring, cleaning and correction on the surface of the heat exchanger tube sheet 2 and the inner wall of the hole;

[0057] When pre-processing the inner wall of the hole on the heat exchanger tube sheet 2, the multi-axis robot arm 71 drives an air gun 73, two polishing milling cutters 74, and a brush roller 75 to extend into the hole at the same time, and first drives the driving gear 84 to rotate through the reduction motor 83, so that the driven gear 86 meshing therewith drives the universal joint connecting shaft 82 to rotate, and then controls the self-rotation of various processing tools. At the same time, the linkage block 87 drives the reduction motor 83 through the gear set and the motor to drive the processing tools on its lower surface to revolve;

[0058] When the various processing tools rotate, the first one is actuated by the corresponding regulating cylinder 81, so that its piston rod pulls the support tube 78 on the outer surface of the air gun 73, changes the displacement of the air gun 73, and makes it close to the inner wall of the hole for air flow impact, so that the oxides and other dirt fall off, and then the polishing milling cutter 74 moves to contact the inner wall of the hole, polishes and trims the inner wall of the hole, and finally the brush roller 75 cleans the inner wall. The various processing tools rotate clockwise first, so that the inner wall of the hole can be processed in a continuous flow. At the same time, the integrated sensor can accurately analyze and control the pre-treatment operation, thereby ensuring that the cleanliness of the tube plate before welding meets the welding requirements;

[0059] After the multi-axis robot arm 71 completes the operation, the welding robot arm 5 starts to work. The laser sensor 51 is used to accurately identify the geometric shape of the tube hole and correct the ovality; the infrared sensor 52 determines the cleanliness of the tube sheet and avoids welding defects; the ultrasonic sensor 53 is used to detect the groove accuracy; the visual camera 54 is used to identify the position of the tube sheet and the hole. By fusing the data from different sensors, the comprehensive recognition of the tube sheet surface, the position, size and groove of the hole and the groove is realized, so as to improve the adaptability of the welding robot to the heat exchanger tube sheet 2. According to the real-time detected data such as the tube hole ovality, groove depth, tube sheet offset, etc., the welding parameters are automatically adjusted to ensure the best welding effect.

[0060] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A high-purity ferrite heat exchanger welding system based on intelligent robot welding, comprising a belt-driven mobile platform (1) and a heat exchanger tube sheet to be processed (2), characterized in that: A side surface of the belt-driven mobile platform (1) is fixedly connected to a numerical control cabinet (3) via a connecting rod, a support base (4) is slidably engaged with the outer surface of the guide rail of the belt-driven mobile platform (1), a welding robot arm (5) is installed on the upper surface of the support base (4), and a pretreatment mechanism (7) is also arranged on the upper surface thereof, and a clamping mechanism (6) is arranged on the surface of the numerical control cabinet (3); Wherein, the pretreatment mechanism (7) is arranged on one side of the welding mechanical arm (5), and processes the heat exchanger tube sheet (2) before the welding mechanical arm (5); The clamping mechanism (6) clamps the heat exchanger tube sheet (2) and adjusts its flipping angle.

2. According to claim 1, a high-purity ferrite heat exchanger welding system based on intelligent robot welding is characterized in that: The clamping mechanism (6) comprises a linkage frame (61) fixedly connected to the outer surface of the output shaft of the numerical control cabinet (3); the linkage frame (61) is in an I-shape; both side surfaces of one end of the linkage frame (61) are rotatably connected to a push cylinder (62) via a slide cylinder; the surface of the piston rod of the push cylinder (62) is fixedly connected to a telescopic frame (63) via a connecting plate; and the outer surface of the heat exchanger tube sheet (2) is in sliding contact with the surface of the telescopic frame (63).

3. The high-purity ferrite heat exchanger welding system based on intelligent robot welding according to claim 2 is characterized in that: The clamping mechanism (6) further comprises a rotating motor (64) fixedly connected to the two side surfaces of the other end of the linkage frame (61); the outer surface of the output shaft of the rotating motor (64) is fixedly connected to a pressing plate (65) via a coupling; and one side surface of the pressing plate (65) is fixedly connected to the free end of the telescopic frame (63).

4. The high-purity ferrite heat exchanger welding system based on intelligent robot welding according to claim 3 is characterized in that: The clamping mechanism (6) further comprises a protective plate (66) hinged to the upper and lower surfaces of the linkage frame (61) via a hinge, and the upper and lower surfaces of the linkage frame (61) are symmetrically hinged with a push cylinder (67), and the piston rod surface of the push cylinder (67) is hinged to a side surface corresponding to the protective plate (66).

5. The high-purity ferrite heat exchanger welding system based on intelligent robot welding according to claim 1 is characterized in that: The pretreatment mechanism (7) comprises a multi-axis mechanical arm (71) fixedly connected to the upper surface of the support base (4); the movable end of the multi-axis mechanical arm (71) is fixedly connected to a fixed block (72); and the lower surface of the fixed block (72) is provided with an air gun (73), two polishing milling cutters (74), and a brush roller (75) in a clockwise direction.

6. The high-purity ferrite heat exchanger welding system based on intelligent robot welding according to claim 5 is characterized in that: The pretreatment mechanism (7) also includes a load-bearing block (76) rotatably connected to the lower surface of the fixed block (72); the lower surface of the load-bearing block (76) is fixedly connected to a mounting cover (77) via a connecting rod; the outer surface of the connecting shaft of the air gun (73), the polishing milling cutter (74) and the brush roller (75) is rotatably sleeved with a support tube (78); the lower surface of the mounting cover (77) is symmetrically distributed and fixedly connected to a support beam (79); a movable groove (80) is penetrated through the upper surface of the support beam (79); the outer surface of the support tube (78) is slidably engaged with the inner wall of the movable groove (80).

7. The high-purity ferrite heat exchanger welding system based on intelligent robot welding according to claim 6 is characterized in that: The pretreatment mechanism (7) also includes an adjusting cylinder (81) fixedly connected to the surface of the support beam (79), the piston rod surface of the adjusting cylinder (81) is fixedly connected to the outer surface of the support tube (78), and the upper surface of the connecting shaft of the air gun (73), the polishing milling cutter (74), and the brush roller (75) is fixedly connected to a universal joint connecting shaft (82).

8. The high-purity ferrite heat exchanger welding system based on intelligent robot welding according to claim 7 is characterized in that: The fixed block (72) is rotatably connected to a reduction motor (83) inside, and the outer surface of the output shaft of the reduction motor (83) is fixedly connected to a driving gear (84). The surface of the load-bearing block (76) is rotatably connected to a rotating shaft (85) through a bearing. The lower end outer surface of the rotating shaft (85) is fixedly sleeved with a driven gear (86). The driving gear (84) is meshed with the driven gear (86). The lower surface of the rotating shaft (85) is fixedly connected to the free end of the universal joint connecting shaft (82). A linkage block (87) is fixedly connected to a side surface of the fixed block (72).

9. The high-purity ferrite heat exchanger welding system based on intelligent robot welding according to claim 1, characterized in that: The surfaces on both sides of the welding head of the welding mechanical arm (5) are respectively fixedly connected with a laser sensor (51) and an infrared sensor (52).

10. The high-purity ferrite heat exchanger welding system based on intelligent robot welding according to claim 1, characterized in that: Ultrasonic sensors (53) and visual cameras (54) are respectively fixedly connected to the surfaces on both sides of the welding arm of the welding mechanical arm (5).

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