Plasma welding device for electric pressure test pump shell

Abstract

According to the plasma welding device for the electric pressure test pump shell, intelligent welding is achieved through cooperation of hardware and software. Hardware comprises a moving and rotating mechanism composed of a master console, a straight line and a direct current motor to control the plasma welding device, and a bearing mechanism with magnetic attraction is used for stabilizing the shell. The software comprises a welding parameter self-adaption module, and parameters are automatically adapted and optimized according to shell attributes; the welding seam path planning module generates an accurate path according to the model or manual input; the real-time monitoring and early warning module monitors the welding temperature, the arc stability, the position of a plasma welder and the like and regulates and controls the welding temperature, the arc stability and the And the equipment state management module monitors equipment in real time, diagnoses faults and pushes maintenance suggestions. The device solves the problems that a traditional device is difficult in parameter adaptation, low in path planning efficiency and poor in precision, and not intelligent in process monitoring and equipment management, parameter optimal configuration and path precise planning are achieved, the welding quality stability, the operation efficiency and the equipment reliability are improved, and the efficient production requirement of the modern industry is met.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of welding equipment, in particular to a plasma welding device for an electric pressure test pump shell. BACKGROUND

[0002] In the manufacturing process of pressure equipment shell, the welding quality is crucial.

[0003] The conventional welding device is difficult to quickly and accurately match the optimal welding parameters when facing pressure equipment shells with different materials, structural thicknesses and weld structure types, and often needs manual repeated debugging, which is low in efficiency and unstable in welding quality.

[0004] At the same time, the monitoring and control means in the welding process are relatively single, and the temperature of the welding area, the arc stability and the position deviation of the welding execution component cannot be monitored in real time and comprehensively, and once an abnormal situation occurs, it is difficult to adjust in time and effectively, which is easy to cause welding defects.

[0005] In addition, the monitoring and management of the equipment running state are not intelligent enough, the prediction, recording and maintenance suggestion pushing of equipment failure lack systematicness, and cannot meet the requirements of modern industrial production on equipment reliability and maintenance convenience.

[0006] Therefore, it is necessary to provide a plasma welding device for an electric pressure test pump shell to solve the above technical problems. SUMMARY

[0007] The purpose of the present application is to provide a plasma welding device for pressure equipment shell, which realizes self-adaptive configuration of welding parameters, intelligent planning of welding path, real-time monitoring and control of welding process and effective management of equipment state through the built-in software system of the console, so as to improve the welding quality and efficiency, reduce the equipment failure rate, and improve the intelligent level and maintenance convenience of the equipment.

[0008] To solve the above technical problems, the present application provides a plasma welding device for an electric pressure test pump shell, which comprises a base, a moving mechanism, a rotating mechanism and a console for controlling the device, the rotating mechanism comprises a plasma welder, the console is built-in with a software system, the software system comprises a welding parameter self-adaptive module, a weld path planning module, a real-time monitoring and early warning module and an equipment state management module. The welding parameter self-adaptive module is used for automatically matching and generating optimal welding current, voltage, plasma gas flow and welding speed parameters according to the material, thickness and weld type of the electric pressure test pump shell. The weld path planning module is used for receiving shell three-dimensional model data or manually input weld trajectory information, automatically planning the movement path of the plasma welder, and synchronously sending to the moving mechanism and the rotating mechanism to control their actions. The real-time monitoring and early warning module is configured to collect temperature, arc stability, and plasma welder position deviation data during the welding process, generate a warning signal and trigger corresponding parameter adjustment or position correction instructions when the collected data exceeds a preset threshold value; The device state management module is configured to monitor the running state of the moving mechanism, rotating mechanism, supporting plate, and plasma welder in real time, record device fault information, and push maintenance recommendations.

[0009] Preferably, the welding parameter self-adaptive module includes an information interaction subunit, a multi-dimensional parameter database, a real-time sensing and collecting subunit, and a dynamic parameter correction subunit. The information interaction subunit is configured to receive information about the shell material characteristics, structure thickness, and weld structure type of the pressure-bearing device input by the staff through the main control system, perform numerical format verification on the input structure thickness information, and perform preset option range verification on the material characteristics and weld structure type information. When invalid input is detected, a prompt is triggered. The weld type information includes axial weld, circumferential weld, and corner weld. The multi-dimensional parameter database is configured to pre-store a basic welding parameter set corresponding to different shell material characteristics, different structure thicknesses, and different weld structure types. The basic welding parameter set includes a basic range of welding current, voltage, plasma gas flow rate, and welding travel speed, and the parameter mapping is established with the shell material characteristics, structure thickness, and weld structure type as joint indexes. The real-time sensing and collecting subunit is configured to collect arc current fluctuation, arc voltage fluctuation, and plasma gas flow stability data during the welding process through the sensing components built in the welding execution component. The dynamic parameter correction subunit is configured to retrieve the corresponding basic welding parameter set from the multi-dimensional parameter database, correct the parameter set in combination with the real-time sensing data, eliminate abnormal intervals, and generate optimal welding parameters composed of optimal welding current, voltage, plasma gas flow rate, and welding speed.

[0010] Preferably, the weld path planning module includes a data receiving and processing subunit, a path generation and optimization subunit, and an instruction conversion and sending subunit, and is provided with a path precision threshold value and a path smoothing coefficient. The data receiving and processing subunit is configured to receive shell three-dimensional model data or manually input weld trajectory information, and identify the model weld feature point set or convert the manually input information into a digitalized feature point set, respectively. The path generation and optimization subunit is configured to generate an initial path curve by fitting the feature points through an interpolation algorithm, check the path precision after smoothing processing, and adjust the parameters or add feature points for re-planning when the precision is not up to standard. The instruction conversion sending subunit is used for discretizing the planning path to obtain discrete path points containing space coordinates and rotation angles, and converting the discrete path points into displacement instructions of the displacement adjustment mechanism and angle instructions of the attitude control mechanism and sending the displacement instructions and the angle instructions synchronously.

[0011] As preferred, the real-time monitoring and early warning module comprises a multi-parameter acquisition subunit, a threshold comparison and analysis subunit, and a pre-warning control execution subunit, and preset thresholds of welding area temperature, arc stability, and welding execution component position deviation are provided. The multi-parameter acquisition subunit is used for acquiring welding area temperature, arc voltage fluctuation coefficient, and welding execution component position deviation data. The threshold comparison and analysis subunit is used for comparing the acquired data with corresponding thresholds to determine whether the acquired data exceeds the thresholds. The pre-warning control execution subunit is used for triggering a power reduction instruction when the welding area temperature exceeds the threshold, triggering a gas flow adjustment instruction when the arc voltage fluctuation exceeds the threshold, and triggering a position correction instruction when the welding execution component position deviation exceeds the threshold.

[0012] As preferred, the equipment state management module comprises a state data acquisition subunit, a fault determination and analysis subunit, an information storage and recording subunit, and a maintenance suggestion pushing subunit, preset thresholds of each equipment operation are provided, and a fault severity coefficient is defined. The state data acquisition subunit is used for acquiring displacement adjustment mechanism operation current, attitude control mechanism rotation speed deviation, shell support component fixing strength, and welding execution component temperature data. The fault determination and analysis subunit is used for comparing the data with the thresholds to determine the fault type, and calculating a fault severity value by pre-design. The information storage and recording subunit is used for structurally recording fault information and storing the fault information according to time. The maintenance suggestion pushing subunit is used for matching maintenance suggestions and pushing the maintenance suggestions according to fault severity classification.

[0013] As preferred, the moving mechanism comprises a first linear motor installed transversely on three support rods, a second linear motor installed longitudinally on the first linear motor, and a third linear motor installed transversely on the second linear motor.

[0014] As preferred, the rotating mechanism comprises a sliding block slidingly connected to the third linear motor and a first DC motor installed on the sliding block, a first turntable installed on an output shaft of the first DC motor, a support rod installed on an upper end of the first turntable through a flange, and a second DC motor installed inside one end of the support rod; a second turntable installed on an output shaft of the second DC motor, an electric push rod installed on the second turntable, and an installation position of the electric push rod connected to the plasma welder.

[0015] As preferred, two groups of driving rollers are rotatably installed on the first supporting plate, and a third DC motor is installed on the first supporting plate, and the output shaft of the third DC motor is connected with the rotating shaft of one group of driving rollers through a shaft coupling.

[0016] Compared with the related art, the plasma welding device for the electric pressure test pump shell has the following beneficial effects: 1. The welding parameter self-adaptive module automatically retrieves and dynamically corrects parameters according to the shell material, thickness and welding seam type, eliminates abnormal intervals to generate optimal parameters, avoids welding defects caused by improper parameters, ensures stable welding quality, and solves the problem of matching optimal parameters for different shell working conditions in traditional devices.

[0017] 2. The real-time monitoring and early warning module collects temperature, arc stability and plasma welding device position deviation data, generates early warning and triggers adjustment instructions when the threshold is exceeded, timely corrects power, gas flow or position, reduces welding quality problems caused by process abnormalities, and reduces welding risks.

[0018] 3. The equipment state management module of the present application real-time monitors the running state of the mechanism, automatically determines the fault type, calculates the severity, classifies and pushes the maintenance suggestions, and structures the fault information, which is convenient for quick positioning and maintenance, reduces the equipment downtime, and improves the maintenance convenience and equipment reliability.

[0019] In summary, the present application cooperates hardware mechanism and software system to solve the problems of parameter adaptation difficulty, low efficiency and poor precision of path planning, and unintelligent process monitoring and equipment management in traditional welding devices, realizes optimal parameter configuration, accurate path planning, dynamic process control and intelligent equipment management for electric pressure test pump shell welding, significantly improves the welding quality stability, operation efficiency and equipment reliability, and meets the modern industrial efficient production demand. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 The present application provides a schematic diagram of the overall appearance of a plasma welding device for an electric pressure test pump shell; Figure 2 The present application provides a schematic diagram of the moving mechanism structure; Figure 3 The present application provides a schematic diagram of the third linear motor structure; Figure 4 The present application provides a schematic diagram of the first supporting plate structure; Figure 5 The present application provides a schematic diagram of the second supporting plate structure; Figure 6 The present application provides a schematic diagram of the software system; Figure 7 Detailed schematic diagram of the software system proposed in the present application.

[0021] In the figure, 1 is a base, 2 is a bottom plate, 3 is a support rod, 4 is a first linear motor, 5 is a second linear motor, 6 is a third linear motor, 7 is a general control console, 8 is a sliding block, 9 is a first DC motor, 10 is a first rotary table, 11 is a support rod, 12 is a second DC motor, 13 is an electric push rod, 14 is a plasma welding device, 15 is a first supporting plate, 16 is a second supporting plate, 17 is a driving roller, 18 is a third DC motor, and 19 is an electromagnetic base. DETAILED DESCRIPTION

[0022] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of the present application.

[0023] The terms used in the present disclosure are merely for the purpose of describing specific embodiments and are not intended to limit the present disclosure. The singular forms "a," "an," and "the" used in the present disclosure and the appended claims are also intended to include the plural forms, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and includes any or all possible combinations of one or more associated listed items.

[0024] It should be understood that although the terms first, second, third, etc. can be used in this disclosure to describe various information, these information should not be limited to these terms. These terms are only used to distinguish information of the same type from each other. For example, without departing from the scope of the present disclosure, the first information can also be referred to as the second information, and similarly, the second information can also be referred to as the first information. Depending on the context, the word "if" as used herein can be interpreted as "when" or "upon determination" or "in response to determining".

[0025] Please refer to Figures 1-7 A plasma welding device for an electric pressure test pump shell includes a base 1, a bottom plate 2 and a plurality of support rods 3 are installed on the top surface of the base 1, the plurality of support rods 3 are located on one side of the bottom plate 2, a moving mechanism is installed on the support rod 3, a rotating mechanism is installed on the moving mechanism, and a first supporting plate 15 and a second supporting plate 16 that can be replaced are installed on the bottom plate 2; a general control console 7 for controlling the device is installed on one end of the top surface of the base 1; The general control console 7 is built-in with a software system, the software system includes a welding parameter self-adaptive module, a welding seam path planning module, a real-time monitoring and early warning module, and a device state management module; The welding parameter adaptive module is used to automatically match and generate optimal welding current, voltage, plasma gas flow and welding speed parameters according to the material, thickness and weld type of the electric pressure test pump shell; The weld path planning module is used to receive shell three-dimensional model data or manually input weld track information, automatically plan the motion path of the plasma welder 14, and synchronously send to the moving mechanism and the rotating mechanism to control their actions; The real-time monitoring and early warning module is used to collect temperature, arc stability and plasma welder 14 position deviation data during welding, generate a warning signal and trigger corresponding parameter adjustment or position correction instructions when the collected data exceeds the preset threshold; The device state management module is used to monitor the running state of the moving mechanism, rotating mechanism, support plate and plasma welder 14 in real time, record device fault information and push maintenance suggestions.

[0026] In this application, the welding parameter adaptive module includes an information interaction subunit, a multi-dimensional parameter database, a real-time sensing and collecting subunit, and a dynamic parameter correction subunit; The information interaction subunit is used to receive the pressure-containing equipment shell material characteristics, structure thickness and weld structure type information input by the staff through the main control system, perform numerical format verification on the input structure thickness information, and perform preset option range verification on the material characteristics and weld structure type information. When invalid input is triggered, a prompt is triggered; wherein the weld type information includes axial weld, circumferential weld and corner weld; The multi-dimensional parameter database is used to pre-store a basic welding parameter set corresponding to different shell materials M, different shell thicknesses H and different weld types W. The basic welding parameter set includes a welding current basic range , a voltage basic range , a plasma gas flow basic range and a welding speed basic range , and the shell material characteristics M, shell thickness H and weld type W are used as joint indexes to establish a parameter mapping relationship; and the current fluctuation threshold , the voltage fluctuation threshold , the gas flow stability threshold , the current correction weight α, the voltage correction weight β, the gas flow correction weight γ and the speed correction weight δ are defined; wherein, is the minimum basic current, is the maximum basic current, is the minimum basic voltage, is the maximum basic voltage, is the minimum basic gas flow, is the maximum basic gas flow, For minimum basic welding speed, Maximum basic welding speed; The real-time data acquisition subunit is used to acquire data on arc current fluctuations, arc voltage fluctuations, and plasma gas flow stability during the welding process through the sensing components built into the welding execution component. The sensing components include current, voltage, and gas flow sensors. Real-time instantaneous value of arc current is collected by a current sensor. t represents the acquisition time, and the arc current fluctuation data is calculated, including the instantaneous current fluctuation value. Current fluctuation amplitude ; Instantaneous fluctuation value of current The calculation formula is: , Represented as The interval mean, current fluctuation amplitude The calculation formula is: ; Real-time instantaneous value of arc voltage is collected by a voltage sensor. The calculated arc voltage fluctuation data includes instantaneous voltage fluctuation values. Voltage fluctuation amplitude ; Including instantaneous voltage fluctuation value The calculation formula is: , Represented as The interval mean, voltage fluctuation amplitude The calculation formula is: ; Real-time plasma gas flow rate was collected using a gas flow sensor. The plasma gas flow stability data SQ was calculated using the following formula: ( During the data collection period The maximum value, To be the minimum value, (as the average value), and temporarily stored in time series format; The dynamic parameter correction subunit is used to retrieve the corresponding set of basic welding parameters from the material-weld parameter database based on the shell material information M, shell thickness information H, and weld type information W received by the parameter input unit; and to process the data acquired by the real-time data acquisition unit. , SQ and , , If compared, Then calculate the abnormal current range. Remove The portion exceeding this range yields the corrected current baseline range. Similarly, the corrected voltage base range is obtained. Corrected basic range of gas flow rate If the fluctuation data does not exceed the corresponding threshold, the corrected base range will be consistent with the original base range. The parameter correction unit is also used for calculation. interval mean , interval mean , interval mean , interval mean The optimal welding parameters are generated using the following formula: Optimal welding current ; Optimal welding voltage ; Optimal plasma gas flow rate ; Optimal welding speed .

[0027] In this application, the weld path planning module includes a data receiving and processing subunit, a path generation and optimization subunit, and an instruction conversion and sending subunit, and has a preset path accuracy threshold. Path smoothing coefficient ( ); The data receiving and processing subunit is used to receive shell 3D model data or weld trajectory information manually input by workers through the main control console 7. When receiving shell 3D model data, it can automatically identify the set of weld feature points in the model. ( (The coordinates of the i-th weld feature point in three-dimensional space); when receiving manually input weld trajectory information, the input coordinate points and line information are converted into a digital set of weld feature points; The path generation and optimization subunit is used for path planning based on the weld feature point set P obtained by the data receiving unit. It uses a cubic spline interpolation algorithm to fit the feature points and generate an initial path curve C(j), where t is a parameter variable. Its expression is: ,in The coefficients of the cubic spline interpolation are obtained by satisfying the continuity conditions of the position and the first and second derivatives at the feature points; Then, a smoothing formula is introduced to optimize the initial path curve C(t) to improve its smoothness, resulting in the smoothed path curve C'(t), expressed as: ; Simultaneously, the accuracy of the smoothed path curve C'(t) is verified, and the curve and the characteristic points of each weld are calculated. distance ( for (Parameter values ​​corresponding to curve C'(t); set the distance deviation threshold) If all If C'(t) is the planned path, then C'(t) is determined; if there exists If so, adjust the interpolation algorithm parameters or increase the number of feature points, and re-plan the path until the accuracy requirements are met. The instruction conversion and transmission subunit is used to discretize the planned path C'(t) to obtain a series of discrete path points. , ,in Let n be the spatial coordinates of the nth discrete point. The rotation angle of the plasma welder 14 about the vertical axis. The rotation angle around the horizontal axis is converted into displacement commands for controlling the first linear motor 4, the second linear motor 5, and the third linear motor 6 of the moving mechanism and angle commands for controlling the first DC motor 9 and the second DC motor 12 of the rotating mechanism. These commands are then sent synchronously to the moving mechanism and the rotating mechanism to control the plasma welder 14 to move along the planned path.

[0028] In this application, the real-time monitoring and early warning module includes a multi-parameter acquisition subunit, a threshold comparison and analysis subunit, and an early warning and control execution subunit, and is preset with a temperature threshold. Arc stability threshold Position deviation threshold ; The multi-parameter acquisition subunit is used to acquire process data during the welding process. It acquires the real-time temperature T(t) of the welding area through a temperature sensor, where t is the acquisition time. Arc voltage fluctuation coefficient is collected using an arc monitoring sensor. The calculation formula is as follows: ,in For real-time arc voltage, for The average value within the data collection period; The real-time position coordinates of the plasma welder 14 are collected by a position sensor. and the preset target position coordinates In comparison, the positional deviation D(t) is calculated using the following formula: ; The threshold comparison analysis subunit is used to compare the real-time temperature T(t) and arc voltage fluctuation coefficient acquired by the data acquisition unit. , the position deviation D(t) respectively and the corresponding preset threshold 、 、 are compared to determine whether the preset threshold is exceeded; The early warning control execution subunit is configured to generate a temperature early warning signal and trigger an adjustment instruction to reduce the welding power when T(t) is detected The adjusted welding power The calculation formula is: wherein, is the current welding power, is a preset temperature adjustment coefficient 0 <1, is the maximum temperature allowed in the welding area; When D(t) > is detected, an arc stability early warning signal is generated, and an instruction to adjust the plasma gas flow is triggered. The adjusted plasma gas flow The calculation formula is wherein is the current plasma gas flow, is an arc adjustment coefficient 0 <1, is the maximum value of the arc voltage fluctuation coefficient allowed, is the gas flow step size of each adjustment; When D(t) is detected, a position deviation early warning signal is generated, and an instruction to control the moving mechanism to correct the position of the plasma welder (14) is triggered, so that the plasma welder 14 moves towards the target position. The displacement amount of the movement is proportional to the position deviation , and the proportional coefficient is , that is, .

[0029] In the present application, the device state management module includes a state data acquisition subunit, a fault determination and analysis subunit, an information storage and recording subunit, and a maintenance suggestion pushing subunit. The mobile mechanism running current threshold , the rotating mechanism rotating speed deviation threshold , the supporting plate magnetic attraction intensity threshold , the plasma welder temperature threshold , the fault severity coefficient is defined, 0 <1, the larger the value, the more serious the fault; State data acquisition subunit, for collecting displacement adjustment mechanism running current, attitude control mechanism speed deviation, shell support component fixation strength and welding execution component temperature data: collecting real-time running current of moving mechanism (first linear motor 4, second linear motor 5, third linear motor 6) through current sensor (t is acquisition time); collecting real-time rotating speed n(t) of rotating mechanism (first direct current motor 9, second direct current motor 12) through rotating speed sensor, and calculating speed deviation (pre-set target rotating speed of rotating mechanism); collecting real-time magnetic attraction strength F(t) of electromagnetic base 19 on second support plate 16 through pressure sensor; collecting real-time temperature of plasma welder 14 through temperature sensor Fault determination analysis subunit, for comparing real-time data collected by state data acquisition subunit with corresponding pre-set threshold value, determining whether the equipment has faults: if , determining that moving mechanism has current overload fault; if , determining that rotating mechanism has speed abnormality fault; if , determining that support plate magnetic attraction strength is insufficient fault; if , determining that plasma welder 14 has temperature too high fault At the same time, calculating severity value S of each type of fault through fault severity formula, formula is ; wherein is real-time data (such as , ) exceeding threshold value or real-time data (such as , ) below threshold value is corresponding pre-set threshold value, and is maximum (or minimum) limit value allowed by equipment (such as maximum running current allowed by moving mechanism, minimum magnetic attraction strength allowed by support plate) Information storage recording subunit, for structurally recording determined fault information, recording content including fault equipment type (moving mechanism / rotating mechanism / support plate / plasma welder 14), fault occurrence time , fault corresponding real-time data , fault severity value S and fault duration (time interval from fault occurrence to fault elimination), and storing recorded data to fault database built in module in time sequence ​​The maintenance suggestion push sub-unit is used to match the corresponding maintenance suggestions from the preset maintenance solution library according to the faulty equipment type and the fault severity value S (such as matching the mobile mechanism current overload fault with suggestions to check the motor load and clean the motor heat dissipation channel; matching the plasma welder 14 temperature too high fault with suggestions to check the cooling system and reduce the welding power). Fault severity value S and preset severe fault threshold General fault threshold Comparison, when When a serious malfunction is detected, an audible and visual alarm will be immediately triggered on the main control panel, and an emergency repair notification will be sent to the maintenance personnel's smart terminal; when If the fault is indicated by a general fault, only the fault message and maintenance suggestions will be displayed on the main control panel 7; when... If the fault is minor, only the repair suggestion will be stored in the information recording unit, and you will be prompted to check it after the equipment is shut down.

[0030] In this application, the moving mechanism includes a first linear motor 4 that is horizontally mounted on three support rods 3, a second linear motor 5 that is vertically mounted on the first linear motor 4, and a third linear motor 6 that is horizontally mounted on the second linear motor 5.

[0031] In this application, the rotating mechanism includes a slider 8 slidably connected to a third linear motor 6 and a first DC motor 9 mounted on the slider 8. A first turntable 10 is mounted on the output shaft of the first DC motor 9. A support rod 11 is mounted on the upper end of the first turntable 10 via a flange. A second DC motor 12 is installed inside one end of the support rod 11. A second turntable is mounted on the output shaft of the second DC motor 12. An electric push rod 13 is mounted on the second turntable. The output end of the electric push rod 13 is connected to the mounting position of the plasma welder 14.

[0032] In this application, the base plate 2 is provided with a slot, the bottom end of the first support plate 15 and the second support plate 16 are both provided with a sliding groove for the matching slot, and multiple electromagnetic bases 19 are installed on the top surface of the second support plate 16.

[0033] In this application, two sets of drive rollers 17 are rotatably mounted on the first support plate 15, and a third DC motor 18 is mounted on the first support plate 15. The output shaft of the third DC motor 18 is connected to the rotating shaft of one of the drive rollers 17 through a coupling.

[0034] This plasma welding device for electric pressure testing pump housings achieves intelligent control of the welding process through the synergy of hardware and software systems. The specific working principle is as follows: I. Parameter Configuration The staff inputs the shell material, thickness, and weld type axial / circumferential / angle weld through the master console 7, and the information interaction subunit checks the information validity. The welding parameter adaptive module takes the material, thickness, and weld type as the index, retrieves the basic welding parameters from the multi-dimensional parameter database, combines the arc current / voltage fluctuation and plasma gas stability data collected by the built-in sensor of the plasma welder 14, eliminates the abnormal parameter interval, and generates the optimal welding parameters.

[0035] II. Path planning and mechanism action The weld path planning module receives the shell three-dimensional model or manual trajectory information, converts it into a digitalized weld feature point set, fits and optimizes the planning path through the interpolation algorithm, discretizes it into path points containing coordinates and plasma welder 14 rotation angles, converts it into displacement instructions of the mobile mechanism first linear motor 4, second linear motor 5, and third linear motor 6 and angle instructions of the rotating mechanism first DC motor 9 and second DC motor 12, and controls the plasma welder 14 to move according to the path.

[0036] III. Process monitoring and control The multi-parameter acquisition subunit acquires the welding area temperature, arc voltage fluctuation coefficient, and plasma welder 14 position deviation. The threshold comparison and analysis subunit determines whether the parameters exceed the preset threshold. When the threshold is exceeded, the early warning and control execution subunit triggers the corresponding instructions: the temperature exceeds the threshold to reduce the welding power, the arc fluctuation exceeds the threshold to adjust the plasma gas flow, and the position deviation exceeds the threshold to control the mobile mechanism to correct the plasma welder 14 position.

[0037] IV. Equipment state management The state data acquisition subunit acquires the mobile mechanism running current, rotating mechanism speed deviation, second support plate 16 electromagnetic base 19 magnetic attraction strength, and plasma welder 14 temperature. The fault determination and analysis subunit compares the threshold to determine the fault type and calculate the severity. The information storage and recording subunit records the fault information, and the maintenance suggestion pushing subunit pushes the suggestions according to the severity classification. In case of serious fault, the master console 7 will sound and light alarm and push an emergency notification.

[0038] All formulas in this scheme are calculated based on the de-dimensioned values. The specific de-dimensioning can be realized by standardization, normalization, and other conventional means in the field, which will not be elaborated here. The formulas are obtained through software simulation iteration optimization based on a large number of electric pressure test pump shell welding working condition data, which can best fit the parameter correlation law of the actual welding scene. The preset parameters in the formulas (such as current fluctuation threshold, path precision threshold, fault severity coefficient, etc.) can be flexibly set by the technical personnel in the field combined with the specific shell material, welding process requirements, and equipment performance parameters.

[0039] The implementation of the present scheme can be realized by software, hardware, firmware or any combination thereof. When realized by software, it can be presented in the form of a computer program product, which contains computer instructions loaded or executed on a computer (which can be a built-in processor of the total control console 7 or an external control terminal) to realize the functions of parameter calculation, path planning, fault determination and the like in the present scheme. The computer instructions can be stored in a computer readable storage medium (such as a built-in storage module of the total control console 7 or an external U disk, solid state disk, etc.), or transmitted between storage media in a wired / wireless manner.

[0040] It should be understood that the execution order of each functional module in the present scheme is determined according to its inherent logic and the requirements of the welding process, and is not affected by the sequence number of the process description; the division of each module is only a logical functional division, which can be integrated or split in actual implementation, for example, the welding parameter self-adaptive module and the real-time monitoring and early warning module can share part of the sensor data interface, which does not affect the overall function implementation.

[0041] Each functional unit in the present scheme can be integrated into the built-in processing unit of the total control console 7, or separately physically deployed and communicated through a data interface; the coupling of the hardware mechanisms (such as the moving mechanism, the rotating mechanism) and the software modules is realized through the instruction transmission interface of the total control console 7, which can adopt the form of electrical connection or industrial bus communication.

[0042] When the functions of the present scheme are realized in the form of software functional units and applied as independent modules, they can be stored in a computer readable storage medium built-in or external to the total control console 7, which includes a U disk, a mobile hard disk, a ROM, a RAM, a magnetic disk, an optical disk and other media that can store program codes, and is called and executed through the program loading function of the total control console 7 to realize the corresponding control process.

[0043] Other embodiments of the application will be apparent to those skilled in the art from consideration of the specification and practice of the application disclosed herein. It is intended that the application be limited only by the scope of the claims, including all variations and equivalents of the generic principles disclosed and underlying principles and details thereof. The specification and examples given are considered exemplary only, with the true scope and spirit of the application indicated by the following claims.

[0044] It should be understood that the present application is not limited to the precise construction which has been described above and illustrated in the accompanying drawings, and that various modifications and changes can be made by those skilled in the art without departing from the scope of the application. The scope of the application is indicated only by the scope of the claims which follow.

Claims

1. A plasma welding device for the electrically powered pressure test pump housing, comprising a base (1), a moving mechanism, a rotating mechanism and a general control console (7) for the control of the device, the rotating mechanism comprising a plasma welder (14), the base (1) having a top surface on which a base plate (2) is mounted, and the base plate (2) having a first replaceable support plate (15) and a second replaceable support plate (16) mounted thereon, characterized in that, The total console (7) is internally provided with a software system, which comprises a welding parameter adaptive module, a weld path planning module, a real-time monitoring and early warning module, and a device state management module; The welding parameter adaptive module is used for automatically matching and generating optimal welding current, voltage, plasma gas flow and welding speed parameters according to the material, thickness and weld type of the electric pressure test pump shell; The weld path planning module is used for receiving shell three-dimensional model data or manually input weld track information, automatically planning the motion path of the plasma welder (14), and synchronously sending to the moving mechanism and the rotating mechanism to control the action thereof; The real-time monitoring and early warning module is used for collecting temperature, arc stability and plasma welder (14) position deviation data in the welding process, generating a warning signal and triggering corresponding parameter adjustment or position correction instructions when the collected data exceeds the preset threshold value; The device state management module is used for real-time monitoring of the running state of the moving mechanism, the rotating mechanism, the supporting plate and the plasma welder (14), recording device fault information and pushing maintenance suggestions.

2. A plasma welding apparatus for an electrically powered pressure testing pump housing according to claim 1, wherein, The welding parameter adaptive module comprises an information interaction subunit, a multi-dimensional parameter database, a real-time sensing acquisition subunit and a dynamic parameter correction subunit; The information interaction subunit is used for receiving the pressure equipment shell material characteristics, structure thickness and weld structure type information input by the staff through the main control system, performing numerical format verification on the input structure thickness information, and performing preset option range verification on the material characteristics and weld structure type information, and triggering a prompt when invalid input is detected; The weld type information includes axial weld, circumferential weld and corner weld; The multi-dimensional parameter database is used for pre-storing a basic welding parameter set corresponding to different shell material characteristics, different structure thicknesses and different weld structure types, wherein the basic welding parameter set comprises a basic range of welding current, voltage, plasma gas flow and welding speed, and the parameter mapping is established with the shell material characteristics, structure thickness and weld structure type as joint indexes; The real-time sensing acquisition subunit is used for collecting arc current fluctuation, arc voltage fluctuation and plasma gas flow stability data in the welding process through the sensing components built in the welding execution component; The dynamic parameter correction subunit is used for calling the corresponding basic welding parameter set from the multi-dimensional parameter database, correcting the parameter set in combination with the real-time sensing data, eliminating abnormal intervals, and generating optimal welding parameters composed of optimal welding current, voltage, plasma gas flow and welding speed.

3. A plasma welding apparatus for an electrically powered pressure testing pump housing according to claim 1, wherein, The weld path planning module comprises a data receiving and processing subunit, a path generation and optimization subunit, and an instruction conversion and sending subunit, and is provided with a path precision threshold and a path smoothing coefficient; The data receiving and processing subunit is used for receiving shell three-dimensional model data or manually input weld track information, and identifying model weld feature point sets or converting manual input into digitalized feature point sets, respectively; The path generation optimization subunit is configured to generate an initial path curve by fitting feature points through an interpolation algorithm, check path accuracy after smoothing processing, and adjust parameters or add feature points to re-plan when the accuracy is not up to standard; The instruction conversion and sending subunit is configured to discretize the planned path to obtain discrete path points containing spatial coordinates and rotation angles, convert the discrete path points into displacement instructions of the displacement adjustment mechanism and angle instructions of the posture control mechanism, and synchronously send the displacement instructions and the angle instructions.

4. A plasma welding apparatus for an electrically powered pressure testing pump housing according to claim 1, wherein, The real-time monitoring and early warning module includes a multi-parameter acquisition subunit, a threshold comparison and analysis subunit, and a pre-warning control execution subunit, and is preconfigured with thresholds of welding area temperature, arc stability, and position deviation of the welding execution component. The multi-parameter acquisition subunit is configured to acquire welding area temperature, arc voltage fluctuation coefficient, and welding execution component position deviation data. The threshold comparison and analysis subunit is configured to compare the acquired data with corresponding thresholds to determine whether the thresholds are exceeded. The pre-warning control execution subunit is configured to trigger a power reduction instruction when the temperature exceeds the threshold, trigger a gas flow adjustment instruction when the arc fluctuation exceeds the threshold, and trigger a position correction instruction when the position deviation exceeds the threshold.

5. A plasma welding apparatus for an electrically powered pressure testing pump housing according to claim 1, wherein, The equipment state management module includes a state data acquisition subunit, a fault determination and analysis subunit, an information storage and recording subunit, and a maintenance suggestion pushing subunit, and is preconfigured with equipment operation thresholds and a fault severity coefficient. The state data acquisition subunit is configured to acquire displacement adjustment mechanism operating current, posture control mechanism speed deviation, shell support component fixing strength, and welding execution component temperature data. The fault determination and analysis subunit is configured to compare the data with the thresholds to determine the fault type, and calculate the fault severity value. The information storage and recording subunit is configured to record fault information in a structured manner and store the information according to time. The maintenance suggestion pushing subunit is configured to match maintenance suggestions and push the suggestions according to fault severity classification.

6. A plasma welding apparatus for an electrically powered pressure testing pump housing according to claim 1, wherein, The moving mechanism includes a first linear motor (4) transversely installed on three support rods (3), a second linear motor (5) longitudinally installed on the first linear motor (4), and a third linear motor (6) transversely installed on the second linear motor (5).

7. A plasma welding apparatus for an electrically powered pressure testing pump housing according to claim 1, wherein, The rotating mechanism includes a slider (8) slidingly connected to the third linear motor (6) and a first DC motor (9) installed on the slider (8), a first turntable (10) installed on the output shaft of the first DC motor (9), a support rod (11) installed on the upper end of the first turntable (10) through a flange, and a second DC motor (12) installed inside one end of the support rod (11); a second turntable is installed on the output shaft of the second DC motor (12), an electric push rod (13) is installed on the second turntable, and the output end of the electric push rod (13) is connected to the installation position of the plasma welder (14).

8. A plasma welding apparatus for an electrically powered pressure testing pump housing according to claim 1, wherein, Two groups of drive rollers (17) are rotatably installed on the first support plate (15), a third DC motor (18) is installed on the first support plate (15), and the output shaft of the third DC motor (18) is connected to the shaft of one of the drive rollers (17) through a coupling.

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