Long-distance pipeline welding defect prevention and treatment device and method based on laser

Abstract

The invention discloses a laser-based long-distance pipeline welding defect prevention and treatment device and method, and belongs to the technical field of pipeline welding. The device comprises a welding power and power supply device, a welding master control device and a movement device moving in the circumferential direction of a to-be-welded pipeline; a welding device I, a welding device II and a welding seam scanning device are borne on the moving device, the welding device I and the welding device II are each provided with a welding gun, and a laser emitting device is installed on one side of each welding gun; the welding device II is further provided with an ultrasonic loader. The welding guns are calibrated through laser, the alignment degree between the welding guns is improved, meanwhile, through laser scanning, the parallelism between the welding guns and the grooves is improved, and the risk of welding deviation is reduced; the surface of the welding seam is scanned by the welding seam scanning device, so that welding defects on the surface are timely and comprehensively found; and according to the position of the welding defect, the molten pool is stirred or vibrated through the ultrasonic loader, the fluidity of the molten pool is improved, and the incomplete fusion or undercut defect is filled.

Description

Technical Field

[0001] The present invention mainly relates to the technical field of pipeline welding, and specifically to a laser-based long-distance pipeline welding defect prevention and treatment device and method. Background Art

[0002] In the welding operation of long-distance pipelines, it is very important to ensure the welding quality. At present, there are many problems that need to be solved in the practical application of long-distance pipeline welding systems. When the welding system is installed on the pipeline, it is difficult for the welding gun to remain absolutely parallel to the pipe mouth due to various factors such as measurement errors. There are slight deviations, which requires fine-tuning the welding gun during the welding process. It is required that the two welding guns are in a straight line and the straight line is parallel to the groove.

[0003] However, when welding pipelines in all positions, some positions are inconvenient to operate and have poor sight lines, which can easily cause visual errors and large measurement errors, which in turn cause the welding gun to deviate from the weld and cause unfusion defects. At the same time, due to the deviation of the pipeline groove and gap, the swing and amplitude of the welding gun need to be manually adjusted to adapt. However, if the amplitude is too small, it is easy to cause unfusion of the side wall, and if the amplitude is too large, the side wall will have undercuts, and the next layer of welding will not be able to penetrate the defect at this position, which will eventually lead to the generation of unfusion defects.

[0004] Therefore, it is necessary to develop a technology for preventing and treating welding defects in long-distance pipelines. Summary of the invention

[0005] The technical solution of the present invention aims at the technical problem that the existing technical solutions are too single, and provides a solution that is significantly different from the existing technologies. It mainly provides a laser-based long-distance pipeline welding defect prevention and treatment device and method, which is used to solve the technical problem that the existing long-distance pipeline welding is more prone to unfusion defects as mentioned in the above background technology.

[0006] The technical solution adopted by the present invention to solve the above technical problems is: A laser-based long-distance pipeline welding defect prevention and treatment device comprises a welding power and power supply device, a welding master control device and a motion device that moves along the circumferential direction of the pipeline to be welded, the motion device carries a welding device I, a welding device II and a weld scanning device located between the two welding devices, the welding device I and the welding device II are both provided with welding guns, and a laser emitting device is installed on one side of the welding gun; the welding device II is also provided with an ultrasonic loader for loading ultrasonic waves on the welding wire II.

[0007] Furthermore, the welding device I and the welding device II both include a welding gun fixing rod, a welding gun, a welding gun wire feeding mechanism, a welding gun wire box, welding wire and a laser emitting device, wherein the welding gun fixing rod is fixed on the moving device; the welding gun is located near the port side of the pipe to be welded, and the welding gun is clamped and connected to the welding gun fixing rod; the welding gun wire feeding mechanism is located on one side of the welding gun fixing rod, and the welding gun wire feeding mechanism is located on one side of the welding gun fixing rod; the welding gun wire box is located on the top of the welding gun wire feeding mechanism; the welding gun in the welding device I is connected to the welding gun wire feeding mechanism through a welding wire tube; in the welding device II, the ultrasonic loader is located on one side of the welding gun wire feeding mechanism, and the ultrasonic loader is connected to the welding gun wire feeding mechanism through a welding wire tube, and the welding gun is connected to the ultrasonic loader through a welding wire tube.

[0008] Furthermore, the weld scanning device comprises a weld scanning probe located between the two welding guns, and the weld scanning probe is connected to the moving device via a scanning device fixing rod.

[0009] Furthermore, the connection structure between the weld scanning probe and the scanning device fixing rod is provided with a height adjustment structure, and the height adjustment structure includes a ring body sleeved on the weld scanning probe, and a locking bolt threadedly connected to the ring body passes through one side of the ring body.

[0010] Furthermore, four magnetic universal wheels are installed at the bottom of the movement device.

[0011] Furthermore, the two welding guns are respectively aligned with the magnetic universal wheels on both sides in the length direction of the pipe to be welded.

[0012] Furthermore, the motion device is an arc-shaped plate structure.

[0013] Furthermore, the motion device includes two halves connected by a plug-in structure, the plug-in structure includes an arc guide groove and an arc plate adaptably inserted into the arc guide groove, and the motion device is connected to a fastening bolt that penetrates into the arc guide groove to lock the arc plate.

[0014] The present invention also provides a method for preventing and treating welding defects of long-distance pipelines based on laser, which is characterized by comprising the following steps: S1. After the pipes to be welded are paired, two laser emitting devices are turned on and emit line lasers, and the positions of the laser emitting devices and the welding gun are adjusted to ensure that the line lasers emitted by the two laser emitting devices are in a straight line, and the two welding wires are respectively on the line lasers emitted by the corresponding laser emitting devices; S2. Start the weld scanning device, scan the situation inside the groove of the pipe to be welded and display it on the welding master control device, adjust the two welding guns so that the line laser line is parallel to the groove of the pipe, and then start welding; S3. During welding, adjust the welding gun according to the display of the welding master control device to ensure that the straight line formed by the two welding guns is always parallel to the edge of the groove, so as to prevent welding deviation and the generation of unfusion defects; S4. After each weld is completed, the surface of the entire weld is scanned by a weld scanning device, and the scanning data and images are transmitted to the welding master control device to identify and analyze the location of suspected incomplete fusion defects and mark the corresponding welding position; S5. When the welding device II is about to weld to the welding position where the defect is located, turn on the ultrasonic loader to load ultrasonic waves on the welding wire II, and use the ultrasonically loaded welding wire II to stir or vibrate the molten pool to improve the fluidity of the molten pool, thereby filling the area of ​​the unfused defect and eliminating the defect.

[0015] Furthermore, in step S1, the positions of the two laser emitting devices are first adjusted to ensure that the two welding wires are respectively on the straight lines of the line lasers emitted by the corresponding laser emitting devices; then one of the welding guns is adjusted to ensure that the line lasers emitted by the two laser emitting devices are on a straight line.

[0016] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention arranges a laser emitting device on one side of the welding gun, and uses the line laser emitted by the laser emitting device to calibrate the position of the welding gun, thereby ensuring that the two welding guns are in a straight line; at the same time, the straight line formed by the line lasers of the two welding guns can be displayed on the welding master control device through a weld scanning device for comparison with the area line formed by the pipeline welding groove. By adjusting the position of the welding guns to keep them parallel to each other, the probability of welding deviation is reduced, the occurrence of side wall unfusion is reduced, and the effect of preventing long-distance pipeline welding defects is achieved.

[0017] (2) The present invention is provided with a weld scanning device. After each weld is completed, the weld scanning device scans the entire surface of the weld and marks the position of suspected lack of fusion defects, so as to timely and comprehensively discover surface welding defects, including minor defects, and realize welding and detection at any time. And through the setting of an ultrasonic loader, when the welding gun welds to the position of suspected lack of fusion defects, the ultrasonic loader loads ultrasonic waves on the welding wire to stir the molten pool, improve the fluidity of the molten pool, fill the lack of fusion or undercut defects, thereby eliminating the lack of fusion defects, achieving the effect of eliminating long-distance pipeline welding defects, and realizing welding, detection and processing at any time, improving welding quality and reducing rework costs.

[0018] (3) In the optimized solution of the present invention, the moving device is set as a length-adjustable structure, and the position of the welding gun is limited. A height-adjustable structure is also set for the weld scanning device, so that the device can be applied to pipes of more different diameters.

[0019] The present invention will be explained in detail below with reference to the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the three-dimensional structure when the present invention is applied; Figure 2 It is a schematic diagram of a three-dimensional structure from another viewing angle when the present invention is applied; Figure 3 It is a schematic diagram of the three-dimensional structure of the motion device in the second embodiment; Figure 4 is a longitudinal cross-sectional schematic diagram of the motion device in the second embodiment; Figure 5 It is a structural schematic diagram of the height adjustment structure in the second embodiment.

[0021] Figure numerals: 1. Pipe to be welded; 2. Magnetic universal wheel; 3. Welding gun wire feeding mechanism II; 4. Welding gun wire box II; 5. Ultrasonic loader; 6. Welding gun fixing rod II; 7. Welding gun II; 8. Weld seam scanning probe; 9. Welding gun I; 10. Moving device; 101. Arc guide groove; 102. Arc plate; 103. Fastening bolt; 11. Scanning device fixing rod; 111. Ring body; 112. Locking bolt; 12. Laser emitting device II; 13. Laser emitting device I; 14. Welding gun fixing rod I; 15. Welding gun wire box I; 16. Welding gun wire feeding mechanism I. DETAILED DESCRIPTION

[0022] To facilitate understanding of the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. Several embodiments of the present invention are given in the drawings, but the present invention can be implemented in different forms and is not limited to the embodiments described in the text. On the contrary, these embodiments are provided to make the content disclosed in the present invention more thorough and comprehensive.

[0023] It should be noted that when an element is referred to as being "fixed on" another element, it may be directly on the other element or there may be a central element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a central element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used in this article are for illustrative purposes only.

[0024] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly connected by technicians in the technical field to which the present invention belongs. The terminology used in the specification of the present invention is for the purpose of describing specific embodiments and is not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0025] Example 1: Please refer to the attached Figure 1 -Attached Figure 2 , a laser-based long-distance pipeline welding defect prevention and treatment device, comprising: The moving device 10 is an arc-shaped plate structure, and four magnetic universal wheels 2 are installed at the bottom thereof, which are used to be magnetically attracted to the surface of the pipe to be welded 1, and the moving device 10 moves along the circumference of the pipe to be welded 1; Welding device I, comprising: welding gun fixing rod I14, welding gun I9, welding gun wire feeding mechanism I16, welding gun wire box I15, laser emitting device I13, welding wire I; Welding device II, including: welding gun fixing rod II 6, welding gun II 7, welding gun wire feeding mechanism II 3, welding gun wire box II 4, laser emitting device II 12, ultrasonic loader 5, welding wire II; The welding gun fixing rod Ⅰ14 and the welding gun fixing rod Ⅱ6 are fixed on both sides of the motion device 10 respectively; the welding gun Ⅰ9 and the welding gun Ⅱ7 are both located near the end side of the pipe to be welded 1, the welding gun Ⅰ9 is clamped and connected to the welding gun fixing rod Ⅰ14, and the welding gun Ⅱ7 is clamped and connected to the welding gun fixing rod Ⅱ6; the welding gun wire feeding mechanism Ⅰ16 is located on one side of the welding gun fixing rod Ⅰ14, and the welding gun wire feeding mechanism Ⅱ3 is located on one side of the welding gun fixing rod Ⅱ6 (the connecting rod of the welding gun is integrated with the upper structure of the welding gun fixing rod, and can be rotatably connected to the lower structure of the welding gun fixing rod. At the same time, a motor is installed on the top of the upper structure of the welding gun fixing rod to control the rotation of the upper structure of the welding gun fixing rod and drive the welding gun to adjust its position. Since the lower structure of the welding gun fixing rod is fixed, the two welding guns can be rotated. The positions are almost fixed to each other, and only slight adjustments need to be made according to the pipeline, which can be satisfied by rotation adjustment); the welding gun wire box Ⅰ15 is located on the top of the welding gun wire feeding mechanism Ⅰ16, and the welding gun wire box Ⅱ4 is located on the top of the welding gun wire feeding mechanism Ⅱ3; the laser emitting device Ⅰ13 is connected to one side of the welding gun Ⅰ9, and the laser emitting device Ⅱ12 is connected to one side of the welding gun Ⅱ7 (the laser emitting device is connected to the welding gun in the form of a clamp, and the position of the laser emitting device can be adjusted by loosening the bolts of the clamp); the welding gun Ⅰ9 is connected to the welding gun wire feeding mechanism Ⅰ16 through a welding wire tube; the ultrasonic loader 5 is located on one side of the welding gun wire feeding mechanism Ⅱ3; the ultrasonic loader 5 is connected to the welding gun wire feeding mechanism Ⅱ3 through a welding wire tube, and the welding gun Ⅱ7 is connected to the ultrasonic loader 5 through a welding wire tube. The welding wire I passes through the welding gun wire box I15, passes through the welding gun wire feeding mechanism I16, and is then transported to the welding gun I9; the welding wire II passes through the welding gun wire box II4, passes through the welding gun wire feeding mechanism II3, and then passes through the ultrasonic loader 5 into the welding gun II7; A weld scanning device, comprising a weld scanning probe 8 and a scanning device fixing rod 11, wherein the weld scanning probe 8 is located between welding guns I9 and II7 and close to the end of the pipe 1 to be welded, and the weld scanning probe 8 is fixedly connected to the moving device 10 through the scanning device fixing rod 11; A welding power and power supply device (not shown in the figure) which provides power and power for all movements of the above-mentioned devices; The welding master control device (not shown in the figure) controls all movements and operations of the moving device 10, welding device I, welding device II and weld scanning device.

[0026] A laser-based method for preventing and treating long-distance pipeline welding defects comprises the following steps: (1) After the first pair of pipes to be welded is completed, the laser emitting device Ⅰ13 and the laser emitting device Ⅱ12 are turned on to emit line lasers, and the positions of the laser emitting device Ⅰ13 and the laser emitting device Ⅱ12 are adjusted to ensure that the welding wire Ⅰ is on the line laser straight line emitted by the laser emitting device Ⅰ13 and the welding wire Ⅱ is on the line laser straight line emitted by the laser emitting device Ⅱ12; then adjust the welding gun Ⅱ7 to ensure that the line laser emitted by the laser emitting device Ⅰ13 and the line laser emitted by the laser emitting device Ⅱ12 are on the same straight line; (2) Start the weld scanning probe 8, scan the situation inside the groove of the pipe 1 to be welded and display it on the welding master control device, adjust the welding gun I 9 and welding gun II 7 so that the line laser straight line is parallel to the pipe groove, and then start welding; (3) During welding, adjust welding gun II7 according to the display of the welding master control device to ensure that the straight line formed by welding guns I9 and II7 is always parallel to the edge of the groove, so as to prevent welding deviation and the occurrence of incomplete fusion defects; (4) After each weld is completed, the weld scanning probe 8 scans the surface of the entire weld, and transmits the scanning data and image to the welding master control device, manually identifies and analyzes the location of suspected lack of fusion defects, and marks the corresponding welding position; (5) When the welding device II is about to weld to the welding position where the defect is located, the ultrasonic loader 5 is turned on to load ultrasonic waves on the welding wire II, and the welding wire II loaded with ultrasonic waves is used to stir or vibrate the molten pool to improve the fluidity of the molten pool, thereby filling the area of ​​the unfused defect and eliminating the defect.

[0027] Embodiment 2: This embodiment differs from Embodiment 1 in that: Please refer to the attached Figure 3 -Attached Figure 4 In this embodiment, the length of the motion device 10 is adjustable. The specific structure is: It includes two halves connected by a plug-in structure, and the welding device I and the welding device II are respectively located on the two halves. The plug-in structure includes an arc-shaped guide groove 101 and an arc-shaped plate 102 that is adaptively inserted into the arc-shaped guide groove 101. The moving device 10 is connected with a fastening bolt 103 that penetrates into the arc-shaped guide groove 101, which is used to lock the arc-shaped plate 102, that is, to maintain the adjustment length of the moving device 10. By adjusting the length of the moving device 10, the spacing between the magnetic universal wheels 2 on both sides can be adjusted, so that the moving device 10 can be applied to pipes of more different diameters.

[0028] The welding guns I9 and II7 are respectively aligned with the magnetic universal wheels 2 on both sides in the length direction of the pipe to be welded 1, and the working ends of the welding guns I9 and II7 are flush with the bottom of the magnetic universal wheels 2. Then, when the length of the motion device 10 is adjusted to any state, as long as the magnetic universal wheels 2 are attached to the surface of the pipe to be welded 1, the working ends of the welding guns I9 and II7 can contact the groove without the need to lift and lower the welding guns I9 and II7, which is more convenient to use.

[0029] Please refer to the attached Figure 5 The connection structure between the weld scanning probe 8 and the scanning device fixing rod 11 is provided with a height adjustment structure to adapt to pipes of different diameters. The height adjustment structure specifically includes a ring body 111 sleeved on the weld scanning probe 8, and a locking bolt 112 threadedly connected to the ring body 111 is passed through one side of the ring body 111.

[0030] The rest is the same as the first embodiment.

[0031] The above is an exemplary description of the present invention in combination with the accompanying drawings. It is obvious that the specific implementation of the present invention is not limited to the above-mentioned method. As long as such non-substantial improvements are made by adopting the method concept and technical solution of the present invention, or the concept and technical solution of the present invention are directly applied to other occasions without improvement, they are all within the protection scope of the present invention.

Claims

1. A laser-based long-distance pipeline welding defect prevention and treatment device, characterized in that: The invention comprises a welding power and power supply device, a welding master control device and a motion device (10) that moves along the circumferential direction of a pipe to be welded (1), wherein the motion device (10) carries a welding device I, a welding device II and a weld scanning device located between the two welding devices, wherein both the welding device I and the welding device II are provided with welding guns, and a laser emitting device is installed on one side of the welding guns; the welding device II is also provided with an ultrasonic loader (5) for loading ultrasonic waves onto the welding wire II.

2. According to claim 1, a laser-based long-distance pipeline welding defect prevention and treatment device is characterized in that: The welding device I and the welding device II both comprise a welding gun fixing rod, a welding gun, a welding gun wire feeding mechanism, a welding gun wire box, welding wire and a laser emitting device, wherein the welding gun fixing rod is fixed to a moving device (10); the welding gun is located near the end of the pipe (1) to be welded, and the welding gun is clamped and connected to the welding gun fixing rod; the welding gun wire feeding mechanism is located on one side of the welding gun fixing rod, and the welding gun wire feeding mechanism is located on one side of the welding gun fixing rod; the welding gun wire box is located on the top of the welding gun wire feeding mechanism; the welding gun in the welding device I is connected to the welding gun wire feeding mechanism via a welding wire tube; in the welding device II, the ultrasonic loader (5) is located on one side of the welding gun wire feeding mechanism, and the ultrasonic loader (5) is connected to the welding gun wire feeding mechanism via a welding wire tube, and the welding gun is connected to the ultrasonic loader (5) via a welding wire tube.

3. According to claim 1, a laser-based long-distance pipeline welding defect prevention and treatment device is characterized in that: The weld scanning device comprises a weld scanning probe (8) located between two welding guns, and the weld scanning probe (8) is connected to the moving device (10) via a scanning device fixing rod (11).

4. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 3 is characterized in that: The connection structure between the weld scanning probe (8) and the scanning device fixing rod (11) is provided with a height adjustment structure, the height adjustment structure comprising a ring body (111) sleeved on the weld scanning probe (8), and a locking bolt (112) threadedly connected to the ring body (111) passes through one side of the ring body (111).

5. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 1 is characterized in that: Four magnetic universal wheels (2) are installed at the bottom of the movement device (10).

6. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 5 is characterized in that: The two welding guns are respectively aligned with the magnetic universal wheels (2) on both sides in the length direction of the pipe (1) to be welded.

7. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 1 is characterized in that: The motion device (10) is in the form of an arc-shaped plate structure.

8. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 7 is characterized in that: The motion device (10) comprises two halves connected by a plug-in structure, the plug-in structure comprising an arc-shaped guide groove (101) and an arc-shaped plate (102) adaptably inserted into the arc-shaped guide groove (101), and the motion device (10) is connected to a fastening bolt (103) that penetrates into the arc-shaped guide groove (101) and is used to lock the arc-shaped plate (102).

9. A laser-based method for preventing and treating long-distance pipeline welding defects, characterized in that: The steps include: S1. After the pipes to be welded (1) are paired, two laser emitting devices are turned on to emit line lasers, and the positions of the laser emitting devices and the welding gun are adjusted to ensure that the line lasers emitted by the two laser emitting devices are in a straight line, and the two welding wires are respectively in the line laser lines emitted by the corresponding laser emitting devices; S2. Start the weld scanning device to scan the situation inside the groove of the pipe (1) to be welded and display it on the welding master control device. Adjust the two welding guns so that the line laser line is parallel to the groove of the pipe before starting welding. S3. During welding, adjust the welding gun according to the display of the welding master control device to ensure that the straight line formed by the two welding guns is always parallel to the edge of the groove, so as to prevent welding deviation and the generation of unfusion defects; S4. After each weld is completed, the surface of the entire weld is scanned by a weld scanning device, and the scanning data and images are transmitted to the welding master control device to identify and analyze the location of suspected incomplete fusion defects and mark the corresponding welding position; S5. When the welding device II is about to weld to the welding position where the defect is located, the ultrasonic loader (5) is turned on to load ultrasonic waves on the welding wire II, and the welding wire II loaded with ultrasonic waves is used to stir or vibrate the molten pool to improve the fluidity of the molten pool, thereby filling the area of ​​the unfused defect and eliminating the defect.

10. A laser-based long-distance pipeline welding defect prevention and treatment method according to claim 9, characterized in that: In step S1, first adjust the positions of the two laser emitting devices to ensure that the two welding wires are respectively on the straight lines of the line lasers emitted by the corresponding laser emitting devices; then adjust one of the welding guns to ensure that the line lasers emitted by the two laser emitting devices are on a straight line.

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