Weld bead cleaning device and method based on diamond magnetic wheel layout and dual-frequency ultrasonic wave

Abstract

The present invention relates to a weld cleaning device based on a diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves, comprising a frame, two sets of short-axis magnetic wheels, two long-axis magnetic wheels, an adjustable clamping mechanism, a dual-frequency ultrasonic slag cleaning unit, a drive motor, a power supply, and a control module. The two sets of short-axis magnetic wheels are arranged front and back, each set including two short-axis magnetic wheels symmetrically arranged on the left and right sides of the frame. The drive motor is disposed within the frame and connected to the short-axis magnetic wheels. The two long-axis magnetic wheels are disposed on the front and back sides of the frame and connected to the frame via an adjustable connecting frame to adapt to pipes of different curvatures. The dual-frequency ultrasonic slag cleaning unit is mounted on the frame via an adjustable clamping mechanism, which can drive the dual-frequency ultrasonic slag cleaning unit to move horizontally and in depth, so that its working end is aligned with the pipe weld and extends into the weld groove. The device is not prone to slippage during operation, can adapt to pipes of different curvatures, is reliable and convenient to use, and has good cleaning effects, thereby improving weld cleaning efficiency.

Description

Technical Field

[0001] The present invention belongs to the technical field of post-welding processing, and specifically relates to a weld cleaning device and method based on a diamond magnetic wheel layout and dual-frequency ultrasound, which is suitable for the automated cleaning of welds on complex curved workpieces such as power plant pipelines. Background Art

[0002] After welding, power plant pipelines require weld cleaning. Traditional weld cleaning devices typically utilize a linear layout with two or four magnetic wheels, based on single-frequency ultrasonic technology. However, these devices suffer from insufficient and uneven magnetic density, resulting in poor adsorption and prone to slippage when used on curved pipes. Single-frequency ultrasonic technology, on the other hand, cannot simultaneously break up deep-seated weld slag and provide fine surface treatment. Consequently, existing weld cleaning devices are inconvenient to use, and their cleaning effectiveness needs to be improved. Summary of the Invention

[0003] The purpose of the present invention is to provide a weld cleaning device and method based on a diamond magnetic wheel layout and dual-frequency ultrasonic waves. The device is not prone to slippage during operation, can be adapted to pipes with different curvatures, is reliable and convenient to use, has good cleaning effects, and improves the efficiency of weld cleaning.

[0004] In order to achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a weld cleaning device based on a diamond magnetic wheel layout and dual-frequency ultrasonic waves, comprising a frame, two groups of short-axis magnetic wheels, two long-axis magnetic wheels, an adjustable clamping mechanism, a dual-frequency ultrasonic slag cleaning unit, a drive motor and a power supply and control module; the two groups of short-axis magnetic wheels are arranged front and back, each group includes two short-axis magnetic wheels and are symmetrically arranged on the left and right sides of the frame to form a double-row redundant adsorption surface, the drive motor is arranged in the frame and connected to the short-axis magnetic wheels on both sides to drive it to work, the two long-axis magnetic wheels are arranged on the front and back sides of the frame and are respectively connected to the frame through adjustable connecting frames to change The relative positions of the two long-axis magnetic wheels and the pipeline make it adaptable to pipelines with different curvatures; the dual-frequency ultrasonic slag cleaning unit is installed on the frame through an adjustable clamping mechanism, and the adjustable clamping mechanism can adjust the distance in the horizontal and depth directions to drive the dual-frequency ultrasonic slag cleaning unit to move, so that its working end is aligned with the pipeline weld and extends into the weld groove to perform slag crushing and cleaning work; the power supply and control module includes a power supply module and a control module, and the control module is electrically connected to the adjustable clamping mechanism, the dual-frequency ultrasonic slag cleaning unit and the drive motor respectively to control the operation of the entire device, and the power supply module supplies power to the entire device.

[0005] Furthermore, the two groups of short-axis magnetic wheels are adaptive to pipes with different curvatures; the adjustable connecting frame includes a fixed frame, a sliding frame and a threaded fastener, the rear end of the fixed frame is fixedly installed on the frame, the front end of the fixed frame is provided with a bolt through-hole, the long-axis magnetic wheel is rotatably connected to the front end of the sliding frame, and the rear section of the sliding frame is provided with a slide groove, and the threaded fastener includes a fastening bolt and a fastening nut, the fastening bolt passes through the slide groove and the bolt through-hole and is connected in cooperation with the fastening nut; by loosening the fastening bolt and allowing the sliding frame to slide and swing relative to the fixed frame, and then tightening the fastening bolt, the relative position of the long-axis magnetic wheel and the pipe can be adjusted to adapt to pipes with different curvatures.

[0006] Furthermore, the dual-frequency ultrasonic slag crushing and cleaning unit includes a dual-frequency probe and an amplitude variable rod. The dual-frequency probe includes a low-frequency transducer and a high-frequency transducer. The low-frequency transducer is used to crush deep-layer welding slag, the high-frequency transducer is used to refine surface treatment, and the amplitude variable rod is used to amplify the amplitude to improve the welding slag crushing and cleaning efficiency.

[0007] Furthermore, the horn adopts a titanium alloy stepped horn, the thick end of the titanium alloy stepped horn, that is, the input end, is connected to the dual-frequency probe through a flange, and the thin end of the titanium alloy stepped horn, that is, the output end, is inserted into the weld groove for slag crushing and cleaning.

[0008] The amplitude magnification of the horn is determined by the ratio of the cross-sectional area of ​​the input end to the cross-sectional area of ​​the output end:

[0009]

[0010] Where M is the amplitude magnification factor, A1 is the cross-sectional area of ​​the input end, and A2 is the cross-sectional area of ​​the output end.

[0011] Furthermore, the adjustable clamping mechanism includes a clamping frame, a horizontal adjustment mechanism, a depth adjustment mechanism and a working unit connecting frame. The rear end of the clamping frame is fixedly connected to the frame, the horizontal adjustment mechanism is installed at the front of the clamping frame, the depth adjustment mechanism is installed on the horizontal adjustment mechanism, and the rear end of the working unit connecting frame is installed on the depth adjustment mechanism. The dual-frequency ultrasonic debris cleaning unit is installed on the working unit connecting frame through the elastic connecting piece at the front of the working unit connecting frame, so that the dual-frequency ultrasonic debris cleaning unit is driven to move in the horizontal and depth directions through the cooperation of the horizontal adjustment mechanism and the depth adjustment mechanism.

[0012] Furthermore, the horizontal adjustment mechanism is a manual adjustment mechanism, including a first slider, a first screw rod and a screw rod fixing frame, the screw rod fixing frame is fixedly installed on the clamping frame, the first slider is slidingly connected to the clamping frame, the first screw rod is cooperatively connected to the screw rod fixing frame, the rear end of the first screw rod has an adjustment knob, and the front end of the first screw rod is rotatably connected to the first slider to drive the first screw rod to rotate in and out by rotating the adjustment knob, thereby driving the first slider to slide back and forth along the clamping frame; the depth adjustment mechanism is installed on the first slider.

[0013] Furthermore, the depth adjustment mechanism is an electric adjustment mechanism, including a vertical bracket, a second slider, a second screw rod, an adjusting motor and a motor fixing frame, the vertical bracket is fixedly installed on the horizontal adjustment mechanism, the adjusting motor is fixedly installed on the upper part of the vertical bracket through the motor fixing frame and is downwardly connected to the second screw rod, the second slider is slidably connected to the vertical bracket, and the second screw rod is cooperated with the second slider to drive the second screw rod to rotate by the adjusting motor, and convert the rotational movement of the second screw rod into the up and down sliding of the second slider; the rear end of the working unit connecting frame is fixedly connected to the second slider; the control module is electrically connected to the adjusting motor, and the control module controls the operation of the adjusting motor according to a preset working end downward distance, drives the second slider and the working unit connecting frame and the dual-frequency ultrasonic slag cleaning unit thereon to move downward a set distance, so that the working end of the dual-frequency ultrasonic slag cleaning unit extends into the weld groove to perform slag crushing and cleaning work.

[0014] Furthermore, it also includes a rotating brushing unit, which is arranged next to the dual-frequency ultrasonic debris cleaning unit and is installed on an adjustable clamping mechanism together with the dual-frequency ultrasonic debris cleaning unit; the control module is electrically connected to the rotating brushing unit to control its operation.

[0015] Furthermore, the frame includes a first shell and a second shell, two drive motors are arranged in the front and rear of the first shell, and the drive motor is installed in the first shell through a motor fixing bracket. The two driving ends of the drive motor respectively extend to the left and right sides of the first shell and are connected to the corresponding short-axis magnetic wheels to drive them to work; the two long-axis magnetic wheels are respectively connected to the first shell through adjustable connecting brackets; the second shell is fixedly installed on the upper part of the first shell, and the power supply and control module is installed in the second shell; the adjustable clamping mechanism is fixedly installed on the upper part of the second shell.

[0016] The present invention also provides a weld cleaning method based on the above device, comprising:

[0017] 1) The device is placed on the target pipe. The two sets of short-axis magnetic wheels adapt to pipes of different curvatures. The positions of the two long-axis magnetic wheels are adjusted until they reliably contact the target pipe, thereby adapting to the curvature of the target pipe.

[0018] 2) Adjust the horizontal and depth positions of the dual-frequency ultrasonic debris cleaning unit through the adjustable clamping mechanism so that the working end of the dual-frequency ultrasonic debris cleaning unit is aligned with the pipe weld and extends into the weld groove;

[0019] 3) Start the dual-frequency ultrasonic slag cleaning unit, first start the low-frequency mode to break up deep-layer welding slag, and then start the high-frequency mode for surface treatment;

[0020] 4) The short-axis magnetic wheel is driven by the driving motor to move along the weld track to complete the cleaning operation.

[0021] Compared with the existing technology, the present invention has the following beneficial effects: It provides a weld cleaning device and method based on a diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves. The device's diamond-shaped magnetic wheel layout design, with four short-axis wheels and two long-axis wheels, not only significantly improves the magnetic attraction force and its distribution uniformity, but also enables the device to be applied to pipes of varying curvatures, ensuring reliable attachment to the pipes during operation and avoiding the risk of slippage. Furthermore, the device achieves dual-frequency ultrasonic collaborative operation to simultaneously meet the requirements of weld slag crushing and surface refinement, significantly improving the cleaning effect and weld cleaning efficiency. Therefore, the present invention has strong practicality and broad application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a schematic diagram of the device structure of an embodiment of the present invention (front view);

[0023] Figure 2 is a schematic diagram of the device structure of an embodiment of the present invention (top view);

[0024] Figure 3 This is a schematic diagram of the working state of the device adapted to a pipe with a diameter of 400 mm in an embodiment of the present invention;

[0025] Figure 4 This is a schematic diagram of the working state of the device adapted to a pipe with a diameter of 260 mm in an embodiment of the present invention;

[0026] Figure 5 is a structural schematic diagram of an adjustable clamping mechanism in an embodiment of the present invention;

[0027] Figure 6 is a structural diagram of a depth adjustment mechanism in an embodiment of the present invention;

[0028] Figure 7 Schematic diagram of the installation structure of the dual-frequency ultrasonic debris cleaning unit and the rotary brushing unit in an embodiment of the present invention;

[0029] Figure 8 2 is a schematic structural diagram of a rotary scrubbing unit according to an embodiment of the present invention;

[0030] Figure 9 This is a block diagram of the implementation principle of the power supply and control module in an embodiment of the present invention. DETAILED DESCRIPTION

[0031] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0032] It should be noted that the following detailed descriptions are exemplary and are intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present application belongs.

[0033] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0034] like Figure 1-9 As shown, this embodiment provides a weld cleaning device based on a diamond magnetic wheel layout and dual-frequency ultrasonic waves, including a frame, two groups of short-axis magnetic wheels 1, two long-axis magnetic wheels 2, an adjustable clamping mechanism, a dual-frequency ultrasonic slag cleaning unit, a drive motor 3 and a power supply and control module 4; the two groups of short-axis magnetic wheels 1 are arranged front and back, each group includes two short-axis magnetic wheels and are symmetrically arranged on the left and right sides of the frame to form a double-row redundant adsorption surface, the drive motor 3 is arranged in the frame and connected to the short-axis magnetic wheels 1 on both sides to drive them to work, and the two long-axis magnetic wheels 2 are arranged on the front and back sides of the frame and are respectively connected to the frame through adjustable connecting frames to change the two long-axis magnetic wheels. The relative position of the wheel and the pipeline makes it adaptable to pipelines with different curvatures; the dual-frequency ultrasonic slag cleaning unit is installed on the frame through an adjustable clamping mechanism, and the adjustable clamping mechanism can adjust the distance in the horizontal direction and the depth direction to drive the dual-frequency ultrasonic slag cleaning unit to move, so that its working end is facing the pipeline weld 10 and extends into the weld groove to perform slag crushing and cleaning work; the power supply and control module 4 includes a power supply module and a control module, and the control module is electrically connected to the adjustable clamping mechanism, the dual-frequency ultrasonic slag cleaning unit and the drive motor respectively to control the operation of the entire device, and the power supply module supplies power to the entire device.

[0035] The composition of this device is further described below.

[0036] 1. Enhanced diamond-shaped magnetic wheel layout

[0037] Short-axis magnetic wheels (two groups of 4):

[0038] Two sets of short-axis magnetic wheels 1 adapt to pipes 5 of different curvatures. Each set of two short-axis magnetic wheels is symmetrically distributed on the left and right sides of the frame to form a "double-row redundant adsorption surface".

[0039] Long axis magnetic wheel (2 pieces):

[0040] Located at the front and rear ends of the bottom of the device, connected to the rack through adjustable connecting brackets.

[0041] The adjustable connecting frame includes a fixed frame 6, a sliding frame 7 and a threaded fastener. The rear end of the fixed frame 6 is fixedly installed on the frame. A bolt through-hole is provided at the front end of the fixed frame 6. The long-axis magnetic wheel 2 is rotatably connected to the front end of the sliding frame 7. A slide groove is provided at the rear end of the sliding frame 7. The threaded fastener includes a fastening bolt 8 and a fastening nut 9. The fastening bolt 8 passes through the slide groove and the bolt through-hole and is connected in conjunction with the fastening nut 9. By loosening the fastening bolt 8 and allowing the sliding frame to slide and swing relative to the fixed frame, and then tightening the fastening bolt 8, the relative position of the long-axis magnetic wheel 2 and the pipe 5 can be adjusted to adapt to pipes with different curvatures. The working conditions of this device for pipes with diameters of 400mm and 260mm are respectively as follows: Figure 3 、 4 shown.

[0042] In this embodiment, the diameter of the short-axis magnetic wheel and the long-axis magnetic wheel are both 60 mm, and NdFeB N52 grade magnets are used. The adsorption force of a single wheel is ≥150N, and the total adsorption force of the six magnetic wheels is ≥900N.

[0043] 2. Dual-frequency ultrasonic slag crushing unit

[0044] The dual-frequency ultrasonic slag crushing and cleaning unit includes a dual-frequency probe 11 and a horn 12. The dual-frequency probe 11 includes a low-frequency transducer and a high-frequency transducer. The low-frequency transducer is used to crush deep-layer welding slag, and the high-frequency transducer is used to refine the surface treatment. The horn 12 is used to amplify the amplitude to improve the welding slag crushing and cleaning efficiency.

[0045] In this embodiment, a 20kHz low-frequency transducer is used as the low-frequency transducer, and a 40kHz high-frequency transducer is used as the high-frequency transducer. The horn is a titanium alloy stepped horn. The thick end (i.e., the input end) of the horn has a diameter of 25mm and is connected to the dual-frequency probe via a flange. The thin end (i.e., the output end) of the horn has a diameter of 5mm and is inserted into the weld groove to break up slag and clean it.

[0046] The characteristic of the stepped horn is that the cross-sectional area changes in a stepped manner along the axial direction, which can effectively amplify the amplitude of the ultrasonic wave, thereby improving the working efficiency of the ultrasonic wave. The amplitude amplification factor of the horn is determined by the ratio of the cross-sectional area of ​​the input end to the cross-sectional area of ​​the output end:

[0047]

[0048] Where M is the amplitude magnification factor, A1 is the cross-sectional area of ​​the input end, and A2 is the cross-sectional area of ​​the output end.

[0049] 3. Adjustable clamping mechanism

[0050] like Figure 5 As shown, the adjustable clamping mechanism includes a clamping frame 13, a horizontal adjustment mechanism 14, a depth adjustment mechanism 15 and a working unit connecting frame 16. The rear end of the clamping frame 13 is fixedly connected to the frame, the horizontal adjustment mechanism 14 is installed at the front of the clamping frame 13, the depth adjustment mechanism 15 is installed on the horizontal adjustment mechanism 14, the rear end of the working unit connecting frame 16 is installed on the depth adjustment mechanism 15, and the front part of the working unit connecting frame 16 has an elastic connector for installing a dual-frequency ultrasonic debris cleaning unit. The dual-frequency ultrasonic debris cleaning unit is installed on the working unit connecting frame 16 through the elastic connector, so that the dual-frequency ultrasonic debris cleaning unit is driven to move in the horizontal and depth directions through the cooperation of the horizontal adjustment mechanism 14 and the depth adjustment mechanism 15.

[0051] In this embodiment, the elastic connector can be a double-ring elastic structure, with the inner and outer rings elastically connected by multiple springs arranged circumferentially. The inner ring is used to mount the working unit connecting frame 16, and the outer ring is fixed to the front of the working unit connecting frame 16. The dual-frequency ultrasonic slag cleaning unit is mounted on the working unit connecting frame 16 via an elastic connector because the weld surface has some ups and downs during device operation. Mounting the dual-frequency ultrasonic slag cleaning unit on the working unit connecting frame 16 via an elastic connector provides a certain elastic margin, thereby ensuring that the lower end of the horn maintains contact with the working surface during operation. A completely rigid connection prevents damage to the horn, adjustment motor, and other related components during adjustment and operation.

[0052] The horizontal adjustment mechanism 14 is a manual adjustment mechanism, including a first slider 17, a first screw rod 18 and a screw rod fixing frame 19. The screw rod fixing frame 19 is fixedly installed on the clamping frame 13. The first slider 17 is slidably connected to the clamping frame 13. The first screw rod 18 is cooperatively connected to the screw rod fixing frame 19. The rear end of the first screw rod 18 has an adjustment knob 20. The front end of the first screw rod 18 is rotatably connected to the first slider 17, so that the first screw rod 18 can be driven to rotate in and out by rotating the adjustment knob 20, thereby driving the first slider 17 to slide back and forth along the clamping frame 13; the depth adjustment mechanism 15 is installed on the first slider 17.

[0053] like Figure 6As shown, the depth adjustment mechanism 15 is an electric adjustment mechanism, including a vertical bracket 21, a second slider 22, a second screw rod 23, an adjustment motor 24 and a motor fixing bracket 25. The vertical bracket 21 is fixedly mounted on the first slider 17 of the horizontal adjustment mechanism 14. The adjustment motor 24 is fixedly mounted on the upper part of the vertical bracket 21 through the motor fixing bracket 25 and is downwardly connected to the second screw rod 23. The second slider 22 is slidably connected to the vertical bracket 21. The second screw rod 23 is cooperated with the second slider 22 to drive the second screw rod 23 to rotate through the adjustment motor 24, and the rotational motion of the second screw rod 23 is converted into the up and down sliding motion of the second slider 22; the rear end of the working unit connecting frame 16 is fixedly connected to the second slider 22; the control module 4 is electrically connected to the adjustment motor 24, and the control module 4 controls the adjustment motor 24 to work according to a preset working end downward movement distance, drives the second slider 22 and the working unit connecting frame 16 and the dual-frequency ultrasonic slag cleaning unit thereon to move downward a set distance, so that the working end of the dual-frequency ultrasonic slag cleaning unit extends into the weld groove to perform slag crushing and cleaning work. In addition, the regulating motor has a current overload protection function to prevent motor overload and damage to working components. In this embodiment, two left and right limiting guide rails 28 are vertically provided on the vertical bracket 21. The second slider 22 slides with both left and right limiting guide rails 28, thereby achieving a sliding connection between the second slider 22 and the vertical bracket 21. The limiting guide rails 28 guide the second slider 22 to limit its vertical sliding movement.

[0054] In order to enhance the support strength of the clamping frame, the adjustable clamping mechanism further includes a reinforcing rod 26 , one end of the reinforcing rod 26 is fixedly connected to the side of the frame, and the other end is fixedly connected to the lower side of the middle portion of the clamping frame 13 .

[0055] 4. Rotary brushing unit

[0056] In order to improve the cleaning effect, the device also includes a rotating brush unit 27, which is arranged beside the dual-frequency ultrasonic debris cleaning unit and is installed on the adjustable clamping mechanism together with the dual-frequency ultrasonic debris cleaning unit. Figure 7 As shown, two clamping seats are arranged side by side on the working unit connecting frame 16, one for installing the dual-frequency ultrasonic debris cleaning unit and the other for installing the rotating brushing unit 27. The control module 4 is electrically connected to the rotating brushing unit 27 to control its operation.

[0057] In this embodiment, the rotary brushing unit adopts a silicon carbide fiber brush head. The brush head of the rotary brushing unit can be replaced with a grinding head, a scraper, etc. according to the need for cleaning interlayer welding slag to improve the cleaning effect.

[0058] like Figure 8As shown, the rotary scrubbing unit 27 primarily consists of a brush motor 32 and a brush head 33. The clamping base holds the brush motor 32, which drives the brush head 33. The brush head can be replaced with other working components, such as a grinding head or scraper, through a quick-locking device 34 for quick replacement.

[0059] 5. Drive system

[0060] The device is equipped with two front and rear drive motors, each used to drive two sets of short-axis magnetic wheels. Both drive motors are servo motors, which drive the four short-axis magnetic wheels in the two sets to move synchronously, with stepless speed regulation and forward and reverse bidirectional drive.

[0061] 6. Lightweight frame

[0062] The frame includes a first housing 29 and a second housing 30. Two drive motors 3 are positioned front and rear within the first housing 29. The drive motors 3 are mounted within the first housing 29 via a motor mounting bracket 25. The two driving ends of the drive motors 3 extend outward from the left and right sides of the first housing 29 and connect to corresponding short-axis magnetic wheels 1 to drive the motors. The two long-axis magnetic wheels 2 are each connected to the first housing 29 via an adjustable connecting bracket. The second housing 30 is fixedly mounted on top of the first housing 29, and the power and control module 4 is mounted within the second housing 30. The second housing 30 serves as a transition piece between the first housing 29 and the clamping bracket 13. The adjustable clamping mechanism is fixedly mounted on top of the second housing 30.

[0063] In this embodiment, the frame adopts a carbon fiber frame with a total weight of ≤22 kg and a torsional rigidity of ≥200 N•m / rad.

[0064] The working unit connecting frame for clamping the dual-frequency ultrasonic debris cleaning unit and the rotary brushing unit adopts a magnesium alloy bracket, and the bracket is equipped with a reinforcing rod to improve rigidity and stability.

[0065] 7. Power supply and control module

[0066] In this device, the power supply and control module includes a power supply module and a control module.

[0067] The power module is connected to an external 220V AC power supply. After filtering, rectifying and voltage-regulating the 220V AC power supply, the power module supplies power to the power-consuming units in the device, including the two drive motors (24V), the regulating motor (24V), the brush head motor (24V), the low-frequency transducer (pulse voltage: 200V), and the high-frequency transducer (pulse voltage: 100V).

[0068] The control module integrates control functions for two drive motors, a regulating motor, a brush head motor, and high- and low-frequency transducers. These functions include: controlling the two drive motors for forward and reverse switching and inorganic speed regulation (50-3000 RPM); controlling the regulating motor for forward and reverse switching and deceleration to 3 mm / s for precise control; controlling the brush head motor for stepless speed regulation (50-3000 RPM); and controlling the low-frequency transducer and high-frequency transducer in the dual-frequency probe to work collaboratively (alternating between high and low frequencies) or independently at a low frequency of 20 kHz and a high frequency of 40 kHz, respectively. Furthermore, the control module includes an interactive module for user interaction.

[0069] In this embodiment, the power module and the control module are both disposed in the second housing 30 , and the interaction module is embedded in a side surface of the second housing 30 to facilitate user input of control commands and display of relevant working parameters.

[0070] This embodiment also provides a weld cleaning method based on the above device, and the specific implementation steps are as follows.

[0071] S1. Place the device on the target pipe. The two sets of short-axis magnetic wheels adapt to pipes with different curvatures. Adjust the positions of the two long-axis magnetic wheels until they reliably contact the target pipe, thereby adapting to the curvature of the target pipe.

[0072] S2. Adjust the horizontal and depth positions of the dual-frequency ultrasonic debris cleaning unit through the adjustable clamping mechanism so that the working end of the dual-frequency ultrasonic debris cleaning unit is aligned with the pipeline weld and extends into the weld groove.

[0073] In this embodiment, the device is also provided with a rotary brushing unit. Therefore, in the process of adjusting the horizontal and depth positions of the dual-frequency ultrasonic debris cleaning unit, the horizontal and depth positions of the rotary brushing unit are adjusted synchronously.

[0074] During this process, the horizontal direction is adjusted manually and the depth position is adjusted by a stepless motor, so that the amplitude rod moves downward a set distance until its thin end contacts the working surface.

[0075] S3. Start the dual-frequency ultrasonic slag cleaning unit. If the collaborative working mode is selected, first start the low-frequency mode (20kHz) to break up deep-layer welding slag, with a crushing depth of more than 1mm; then start the high-frequency mode (40kHz) for surface treatment. The surface roughness after treatment is Ra ≤ 6.3μm.

[0076] During this process, the rotary scrubbing unit works in conjunction with the dual-frequency ultrasonic debris removal unit. The high-frequency mode is activated for surface treatment while the scrubbing mode is activated simultaneously to enhance the cleaning effect.

[0077] S4. The short-axis magnetic wheel is driven by a driving motor to move along the weld track to complete the cleaning operation.

[0078] During this process, by changing the power supply voltage of the drive motor, the synchronous speed of the drive motor can be adjusted and forward and reverse switching can be performed, thereby realizing stepless speed regulation of the magnetic wheel rotation and forward and reverse drive of the device movement.

[0079] In step S1, after the device is installed on the target pipe, a magnetic wheel movement test is performed, assuming the working components (dual-frequency ultrasonic debris cleaning unit + rotary scrubbing unit) do not contact the working surface. First, start the drive motor, select the movement direction, and begin the magnetic wheel movement test at the minimum speed. Then, adjust the speed to the appropriate speed before proceeding to the next step.

[0080] In addition, the device has a safety protection mechanism that automatically stops when the dual-frequency ultrasonic debris cleaning unit overheats (>80°C).

[0081] Example 1:

[0082] Working conditions: Φ260mm×20 pipe, oxide layer depth 0.8mm;

[0083] set up:

[0084] The distance between the long axis magnetic wheels is 300mm, which is suitable for the pipe diameter;

[0085] Ultrasonic high frequency 40KHz, pulse voltage 100V;

[0086] Effect: No slippage during the whole process, and the surface Ra after cleaning is 5.5μm.

[0087] Example 2:

[0088] Working conditions: Φ400×35mm pipeline, multi-layer weld;

[0089] Setting: The distance between the long axis magnetic wheels is adjusted to 440mm to match the pipe diameter;

[0090] Ultrasonic low frequency 20KHz, pulse voltage 200V; ultrasonic high frequency 40KHz, pulse voltage 100V; start the brush head at the same time;

[0091] Effect: No slippage during the whole process, and good welding slag cleaning effect.

[0092] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any other manner. Any person skilled in the art may utilize the above-disclosed technical content to modify or modify the present invention into equivalent embodiments. However, any simple modifications, equivalent variations, and modifications to the above embodiments that do not depart from the technical content of the present invention and are based on the technical essence of the present invention remain within the scope of protection of the present invention.

Claims

1. A weld cleaning device based on a diamond magnetic wheel layout and dual-frequency ultrasonic waves, characterized in that: It includes a frame, two groups of short-axis magnetic wheels, two long-axis magnetic wheels, an adjustable clamping mechanism, a dual-frequency ultrasonic debris cleaning unit, a drive motor and a power supply and control module; the two groups of short-axis magnetic wheels are arranged front and back, each group includes two short-axis magnetic wheels and are symmetrically arranged on the left and right sides of the frame to form a double-row redundant adsorption surface, the drive motor is arranged in the frame and connected to the short-axis magnetic wheels on both sides to drive them to work, the two long-axis magnetic wheels are arranged on the front and back sides of the frame and are respectively connected to the frame through adjustable connecting frames to change the relative positions of the two long-axis magnetic wheels and the pipeline to adapt to different curves rate pipeline; the dual-frequency ultrasonic slag cleaning unit is installed on the frame through an adjustable clamping mechanism, and the adjustable clamping mechanism can adjust the distance in the horizontal direction and the depth direction to drive the dual-frequency ultrasonic slag cleaning unit to move, so that its working end is aligned with the pipeline weld and extends into the weld groove to perform slag crushing and cleaning work; the power supply and control module includes a power supply module and a control module, the control module is electrically connected to the adjustable clamping mechanism, the dual-frequency ultrasonic slag cleaning unit and the drive motor respectively to control the operation of the entire device, and the power supply module supplies power to the entire device; The dual-frequency ultrasonic slag cleaning unit includes a dual-frequency probe and an amplitude transformer. The dual-frequency probe includes a low-frequency transducer and a high-frequency transducer. The low-frequency transducer is used to break up deep-layer welding slag, the high-frequency transducer is used to refine the surface treatment, and the amplitude transformer is used to amplify the amplitude to improve the efficiency of welding slag breaking and cleaning. The horn adopts a titanium alloy stepped horn, the thick end of the titanium alloy stepped horn, that is, the input end, is connected to the dual-frequency probe through a flange, and the thin end of the titanium alloy stepped horn, that is, the output end, is inserted into the weld groove for slag crushing and cleaning. The amplitude magnification of the horn is determined by the ratio of the cross-sectional area of ​​the input end to the cross-sectional area of ​​the output end: Where M is the amplitude magnification factor, A1 is the cross-sectional area of ​​the input end, and A2 is the cross-sectional area of ​​the output end.

2. The weld cleaning device based on diamond magnetic wheel layout and dual-frequency ultrasonic wave according to claim 1 is characterized in that: The two groups of short-axis magnetic wheels are adaptive to pipes with different curvatures; the adjustable connecting frame includes a fixed frame, a sliding frame and a threaded fastener; the rear end of the fixed frame is fixedly installed on the frame, the front end of the fixed frame is provided with a bolt through-hole, the long-axis magnetic wheel is rotatably connected to the front end of the sliding frame, the rear section of the sliding frame is provided with a slide groove, and the threaded fastener includes a fastening bolt and a fastening nut, the fastening bolt passes through the slide groove and the bolt through-hole and is connected in cooperation with the fastening nut; by loosening the fastening bolt and allowing the sliding frame to slide and swing relative to the fixed frame, and then tightening the fastening bolt, the relative position of the long-axis magnetic wheel and the pipe can be adjusted to adapt to pipes with different curvatures.

3. The weld cleaning device based on diamond magnetic wheel layout and dual-frequency ultrasonic wave according to claim 1 is characterized in that: The adjustable clamping mechanism includes a clamping frame, a horizontal adjustment mechanism, a depth adjustment mechanism and a working unit connecting frame. The rear end of the clamping frame is fixedly connected to the frame, the horizontal adjustment mechanism is installed at the front of the clamping frame, the depth adjustment mechanism is installed on the horizontal adjustment mechanism, and the rear end of the working unit connecting frame is installed on the depth adjustment mechanism. The dual-frequency ultrasonic debris cleaning unit is installed on the working unit connecting frame through the elastic connecting piece at the front of the working unit connecting frame, so that the dual-frequency ultrasonic debris cleaning unit is driven to move in the horizontal and depth directions through the cooperation of the horizontal adjustment mechanism and the depth adjustment mechanism.

4. The weld cleaning device based on diamond magnetic wheel layout and dual-frequency ultrasonic wave according to claim 3 is characterized in that: The horizontal adjustment mechanism is a manual adjustment mechanism, including a first slider, a first screw rod and a screw rod fixing frame. The screw rod fixing frame is fixedly installed on the clamping frame. The first slider is slidably connected to the clamping frame. The first screw rod is cooperatively connected to the screw rod fixing frame. The rear end of the first screw rod has an adjustment knob. The front end of the first screw rod is rotatably connected to the first slider to drive the first screw rod to rotate in and out by rotating the adjustment knob, thereby driving the first slider to slide back and forth along the clamping frame; the depth adjustment mechanism is installed on the first slider.

5. The weld cleaning device based on diamond magnetic wheel layout and dual-frequency ultrasonic wave according to claim 3 is characterized in that: The depth adjustment mechanism is an electric adjustment mechanism, comprising a vertical bracket, a second slider, a second screw rod, an adjustment motor and a motor fixing bracket. The vertical bracket is fixedly mounted on the horizontal adjustment mechanism. The adjustment motor is fixedly mounted on the upper part of the vertical bracket through the motor fixing bracket and is downwardly connected to the second screw rod. The second slider is slidably connected to the vertical bracket. The second screw rod is cooperatively connected to the second slider, so that the second screw rod is driven to rotate by the adjustment motor and the rotational motion of the second screw rod is converted into an up and down sliding motion of the second slider. The rear end of the working unit connecting frame is fixedly connected to the second slider; the control module is electrically connected to the adjusting motor, and the control module controls the operation of the adjusting motor according to the preset downward distance of the working end, driving the second slider and the working unit connecting frame and the dual-frequency ultrasonic slag cleaning unit thereon to move downward a set distance, so that the working end of the dual-frequency ultrasonic slag cleaning unit extends into the weld groove to perform slag crushing and cleaning work.

6. The weld cleaning device based on diamond magnetic wheel layout and dual-frequency ultrasonic wave according to claim 1 is characterized in that: It also includes a rotating brushing unit, which is arranged next to the dual-frequency ultrasonic debris cleaning unit and is installed on an adjustable clamping mechanism together with the dual-frequency ultrasonic debris cleaning unit; the control module is electrically connected to the rotating brushing unit to control its operation.

7. The weld cleaning device based on diamond magnetic wheel layout and dual-frequency ultrasonic wave according to claim 1 is characterized in that: The frame includes a first shell and a second shell. Two drive motors are arranged in the front and rear of the first shell. The drive motors are installed in the first shell through a motor fixing frame. The two driving ends of the drive motor respectively extend to the left and right sides of the first shell and are connected to the corresponding short-axis magnetic wheels to drive them to work; the two long-axis magnetic wheels are respectively connected to the first shell through adjustable connecting frames; the second shell is fixedly installed on the upper part of the first shell, and the power supply and control module is installed in the second shell; the adjustable clamping mechanism is fixedly installed on the upper part of the second shell.

8. A weld cleaning method based on the device according to any one of claims 1 to 7, characterized in that: include: 1) The device is placed on the target pipe. The two sets of short-axis magnetic wheels adapt to pipes of different curvatures. The positions of the two long-axis magnetic wheels are adjusted until they reliably contact the target pipe, thereby adapting to the curvature of the target pipe. 2) Adjust the horizontal and depth positions of the dual-frequency ultrasonic debris cleaning unit through the adjustable clamping mechanism so that the working end of the dual-frequency ultrasonic debris cleaning unit is aligned with the pipe weld and extends into the weld groove; 3) Start the dual-frequency ultrasonic slag cleaning unit, first start the low-frequency mode to break up deep-layer welding slag, and then start the high-frequency mode for surface treatment; 4) The short-axis magnetic wheel is driven by the driving motor to move along the weld track to complete the cleaning operation.

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