Intelligent welding thick workpiece adaptive bottom layer groove group error device and method

Abstract

This invention discloses an intelligent welding device and method for adaptive beveling and alignment errors in the welding process technology of large equipment manufacturing, specifically for welding thick workpieces. It includes: a welding power source, a gas-shielded welding mechanism, a control mechanism, and a wire feeding mechanism. The gas-shielded welding mechanism includes a welding torch traveling device, a shielding gas device, a camera, a weld seam tracker, and a welding torch. The camera and weld seam tracker are connected to the welding end of the welding torch. The camera is used to acquire real-time welding images and transmit them to the control mechanism. The welding torch traveling device and the shielding gas device are connected to the welding torch. The control mechanism includes a manual controller and a remote controller. The manual controller is connected to the weld seam tracker and is used to control the welding current, arc voltage, welding speed, and the mechanical actions of the welding torch. The wire feeding mechanism is connected to the gas-shielded welding mechanism. This invention can adapt to beveling and alignment errors caused by workpiece processing, enabling welding on both the front and back sides, thus improving welding efficiency and quality.

Description

Technical Field

[0001] This invention relates to an intelligent welding thick workpiece adaptive bottom beveling assembly error correction device and method, belonging to the field of welding process technology for large equipment manufacturing. Background Technology

[0002] The welding of the main body welds of large, thick-walled pressure vessels and critical equipment, such as chemical high-pressure vessels and nuclear power pressure vessels, involves a large workload and requires high quality. Therefore, the application of efficient and reliable automated welding methods is an inevitable trend in the development of intelligent manufacturing. With the development of robotics and automated tooling, it is now feasible to automate a large amount of welding work by replacing manual labor with machines. Furthermore, laser vision sensors make automated welding positioning and even automatic weld seam tracking possible. Currently, the main method for automated welding of large workpieces is to rotate the workpiece and fix the welding torch on top for horizontal welding. This automated welding requires the design and fabrication of complex gantry cranes and other process equipment.

[0003] Thick and large workpieces differ from small, precision workpieces, often exhibiting significant dimensional errors in the pre-welding beveling assembly. Common errors caused by welding beveling assembly include: lateral and vertical deviations in the welding torch's movement trajectory, unevenness at both ends of the bevel leading to misalignment, and excessively large or small root gaps. Currently, a major challenge hindering the adoption of automated welding in the manufacturing of large pressure vessels and equipment is the difficulty in ensuring consistent pre-welding beveling assembly dimensions during the forming process, such as cutting and rolling on large plate rolling machines. Uneven gap sizes and non-roundness in the bevels result in radial deviations and misalignment. This directly leads to defects in the automated welding process, especially in the root pass of critical welds, such as incomplete root penetration, unstable torch height, and poor weld formation, ultimately resulting in substandard main weld quality. While weld tracking can mitigate welding torch movement deviation to some extent, it only allows for minor adjustments in horizontal and vertical directions, making it unsuitable for thick and large workpieces with significant dimensional errors, and it also fails to address the problems of bevel misalignment and excessive root gaps. Meanwhile, as welding progresses, the electric arc heating continuously causes localized thermal deformation of the workpiece, further exacerbating the bevel alignment error and causing deviations from the design dimensions. Compared to the remaining weld passes in multi-layer welding, the root pass requires extremely high precision in bevel dimensions and is often the key factor determining the overall weld quality.

[0004] To overcome these challenges, manufacturers are forced to resort to inefficient manual welding for the initial pass, requiring manual adjustments based on observation as the welding progresses, followed by submerged arc welding for the filler passes. Manual welding is time-consuming and labor-intensive, typically taking 2-3 months, significantly delaying the manufacturing cycle. Furthermore, manual welding cannot be performed continuously; tungsten inert gas (TIG) welding requires periodic replacement of the welding wire, and shielded metal arc (SMAW) welding requires periodic replacement of the welding rod, resulting in low efficiency, poor process stability, and high skill requirements for manual operation. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide an intelligent welding device and method for adaptive beveling error correction of thick workpieces. By setting a manual controller to control and adjust the welding current, arc voltage, welding speed and mechanical action of the welding torch, the welding torch can be controlled to adaptively swing, deflect, move laterally and vertically according to different working conditions during the welding process. This solves the technical problem of how to eliminate the influence of thick workpiece assembly deviation on the root pass weld to a large extent.

[0006] To achieve the above objectives, the present invention is implemented using the following technical solution:

[0007] In a first aspect, the present invention provides an intelligent welding thick workpiece adaptive bottom beveling error correction device, comprising: a welding power source, a gas shielded welding mechanism, a control mechanism, and a wire feeding mechanism.

[0008] The gas-shielded welding mechanism includes a welding torch traveling device, a shielding gas device, a camera, a weld seam tracker, and a welding torch. The camera and the weld seam tracker are connected to the welding end of the welding torch. The camera is used to acquire real-time welding images of the welding torch and transmit these images to the control mechanism. The weld seam tracker is used to monitor and track the weld seam in real time and adjust the welding torch traveling deviation in both horizontal and vertical directions. The welding torch traveling device is connected to the welding torch to move the welding torch along the side of the workpiece bevel. The shielding gas device is connected to the welding torch through a shielding gas passage to deliver shielding gas to the welding area during the welding process.

[0009] The control mechanism includes a manual controller and a remote controller; the remote controller is used to receive the real-time welding images transmitted by the camera and output the real-time welding images to the remote controller screen; the manual controller is connected to the weld tracker and is used to control and adjust the welding current, arc voltage, welding speed and the mechanical action of the welding torch, so as to realize the swing, deflection, lateral movement and vertical up and down movement of the welding torch;

[0010] The wire feeding mechanism is connected to the gas-shielded welding mechanism and is used to provide the welding wire required for welding to the gas-shielded welding mechanism.

[0011] Optionally, the camera employs a laser imaging system, which is also used to measure and display workpiece bevel deviation data, and transmit the workpiece bevel deviation data to the remote controller.

[0012] Optionally, when the camera displays that the root gap of the welded workpiece assembly exceeds the design specification by 1mm, the manual controller controls the welding torch to swing back and forth in a "Z" or "semi-circular" shape and reduces the welding current; when the camera displays that the root gap of the welded workpiece assembly is less than the design specification by 1mm, the manual controller increases the welding current and decreases the welding speed; when the camera displays that the two ends of the workpiece bevel assembly are uneven, forming a misalignment of more than 2mm, the manual controller controls the welding torch to deflect 0-20 degrees toward the workpiece with the lower misalignment, forming an inclined weld; when the camera displays that the welding wire end is not aligned with the center position of the workpiece bevel and exceeds the horizontal automatic adjustment limit of the weld tracker by ±0.5mm, the manual controller controls the welding torch to move laterally so that the welding wire is aligned with the center of the workpiece bevel; when the camera displays that the welding voltage is too low and the welding torch height exceeds the vertical automatic adjustment limit of the weld tracker by ±0.5mm, the manual controller controls the welding torch to move longitudinally and adjust the welding torch height until the arc voltage returns to normal.

[0013] Optionally, the intelligent welding thick workpiece adaptive bottom beveling error correction device can perform bottom beveling on both the front and back sides of the workpiece beveling.

[0014] Optionally, the welding torch traveling device may be a welding trolley that travels along a track or a trackless welding trolley.

[0015] Optionally, the weld seam tracker uses laser-based non-contact sensing, with an effective scanning distance range of 90–130 mm.

[0016] Secondly, the present invention provides an adaptive error method based on the aforementioned intelligent welding thick workpiece adaptive bottom beveling assembly error correction device, comprising:

[0017] The camera captures real-time images of the welding process using the welding torch;

[0018] Based on the real-time welding images, the camera measures and displays workpiece bevel deviation data;

[0019] The camera transmits the real-time welding image and the workpiece bevel deviation data to the remote controller;

[0020] When the camera shows that the gap between the roots of the welding workpieces exceeds the design specification of 1mm, the manual controller controls the welding torch to swing back and forth in a "Z" or "semi-circular arc" shape and reduces the welding current.

[0021] When the camera shows that the root gap between the welding workpieces is less than 1mm as specified in the design, the manual controller increases the welding current and decreases the welding speed.

[0022] When the camera shows that the two ends of the workpiece bevel assembly are uneven, forming a misalignment of more than 2mm, the manual controller controls the welding torch to deflect 0-20 degrees toward the workpiece with the lower misalignment, forming an inclined weld.

[0023] When the camera shows that the tip of the welding wire is not aligned with the center of the workpiece bevel and exceeds the horizontal automatic adjustment limit of ±0.5mm of the weld tracker, the manual controller controls the lateral displacement of the welding gun to align the welding wire with the center of the workpiece bevel.

[0024] When the camera displays that the welding voltage is too low and the welding torch height exceeds the vertical automatic adjustment limit of ±0.5mm of the weld seam tracker, the manual controller controls the longitudinal displacement of the welding torch to adjust the welding torch height until the arc voltage returns to normal.

[0025] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0026] This invention employs an intelligent adaptive beveling device and method for welding thick workpieces to correct errors in the root pass. By setting a manual controller, the welding current, arc voltage, welding speed, and mechanical actions of the welding torch are controlled and adjusted. During the welding process, the welding torch is controlled to adaptively swing, deflect, move laterally, and move vertically up and down according to different working conditions. This can better adapt to the influence of unavoidable workpiece beveling size errors on the weld quality in the root pass welding of thick workpieces, and can effectively eliminate various forming defects such as incomplete penetration, burn-through, and weld beads at the weld root.

[0027] Meanwhile, this invention enables clean and automated welding, replacing manual welding operations in harsh on-site environments. It also enables automated welding of both the front and back sides, replacing the complex process of traditional front welding and back carbon arc gouging + welding formation. This simplifies the root pass welding process and greatly improves welding efficiency and quality. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the intelligent welding thick workpiece adaptive bottom beveling error correction device described in one embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram illustrating the adjustment of the gap C error of the workpiece bevel assembly in one embodiment of the present invention;

[0030] Figure 3 This is a schematic diagram of the adjustment of misalignment error of the workpiece bevel group in one embodiment of the present invention;

[0031] Figure 4 This is a schematic diagram of the lateral error adjustment of the workpiece welding torch in one embodiment of the present invention;

[0032] Figure 5This is a schematic diagram of workpiece welding torch height error adjustment in one embodiment of the present invention. Detailed Implementation

[0033] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments and specific features in the embodiments are detailed descriptions of the technical solution of the present application, rather than limitations thereof. In the absence of conflict, the embodiments and technical features in the embodiments can be combined with each other.

[0034] In this article, the term "and / or" is merely a description of the relationship between related objects, indicating that there can be three kinds of relationships. For example, A and / or B can mean: A exists alone, A and B exist simultaneously, or B exists alone.

[0035] The application principle of the present invention will be described in detail below with reference to the accompanying drawings. Example

[0036] This invention provides an intelligent welding device for adaptive bottom beveling of thick workpieces to correct errors, such as... Figure 1 As shown, it includes: welding power source, gas shielded welding mechanism, control mechanism and wire feeding mechanism;

[0037] The gas-shielded welding mechanism includes a welding torch traveling device, a shielding gas device, a camera, a weld seam tracker, and a welding torch. The camera and the weld seam tracker are connected to the welding end of the welding torch. The camera is used to acquire real-time welding images of the welding torch and transmit these images to the control mechanism. The weld seam tracker is used to monitor and track the weld seam in real time and adjust the welding torch traveling deviation in both horizontal and vertical directions. The welding torch traveling device is connected to the welding torch to move the welding torch along the side of the workpiece bevel. The shielding gas device is connected to the welding torch through a shielding gas passage to deliver shielding gas to the welding area during the welding process.

[0038] The control mechanism includes a manual controller and a remote controller; the remote controller is used to receive the real-time welding images transmitted by the camera and output the real-time welding images to the remote controller screen; the manual controller is connected to the weld tracker and is used to control and adjust the welding current, arc voltage, welding speed and the mechanical action of the welding torch, so as to realize the swing, deflection, lateral movement and vertical up and down movement of the welding torch;

[0039] The wire feeding mechanism is connected to the gas-shielded welding mechanism and is used to provide the welding wire required for welding to the gas-shielded welding mechanism.

[0040] By setting a manual controller to control and adjust the welding current, arc voltage, welding speed, and mechanical actions of the welding torch, the welding torch can be controlled to adapt to different working conditions during the welding process by swinging, deflecting, moving laterally, and moving vertically. This can better adapt to the influence of unavoidable workpiece bevel size errors on weld formation during the root pass welding of thick workpieces, and can effectively eliminate various forming defects such as incomplete penetration, burn-through, and weld beads at the weld root, greatly improving welding efficiency and welding quality.

[0041] In one specific embodiment of the present invention, the camera employs a laser imaging system, and is also used to measure and display workpiece bevel deviation data, and transmit the workpiece bevel deviation data to the remote controller. For example... Figure 2 As shown, when the camera displays that the root gap between the welded workpieces exceeds the design specification of 1mm, the manual controller controls the welding torch to swing back and forth in a "Z" or "semi-circular" shape and reduces the welding current; Figure 2 As shown, when the camera displays that the root gap between the welded workpiece assembly is less than the designed 1mm, the manual controller increases the welding current and decreases the welding speed; for example... Figure 3 As shown, when the camera displays that the two ends of the workpiece bevel assembly are uneven, forming a misalignment exceeding 2mm, the manual controller controls the welding torch to deflect 0-20 degrees towards the workpiece with the lower misalignment, forming an inclined weld; as Figure 4 As shown, when the camera indicates that the welding wire tip is not aligned with the center of the workpiece bevel and exceeds the automatic horizontal adjustment limit of the weld tracker by ±0.5mm, the manual controller controls the lateral displacement of the welding torch to align the welding wire with the center of the workpiece bevel; Figure 5 As shown, when the camera displays that the welding voltage is too low and the welding torch height exceeds the vertical automatic adjustment limit of the weld tracker by ±0.5mm, the manual controller controls the longitudinal displacement of the welding torch to adjust the welding torch height until the arc voltage returns to normal.

[0042] In one specific embodiment of the present invention, the intelligent welding thick workpiece adaptive bottom beveling error correction device can perform bottom beveling on both the front and back sides of the workpiece beveling.

[0043] In one specific embodiment of the present invention, the welding torch traveling device adopts a welding carriage that travels along a track or a trackless welding carriage. The welding method is a welding method in which the welding carriage travels and drives the filler wire, including gas shielded welding, tungsten inert gas welding, gas metal arc welding, CO2 gas shielded welding, and mixed gas shielded welding. The welding equipment includes a welding power source, a wire feeding mechanism, a shielding gas supply mechanism, a welding carriage and its traveling mechanism, and a welding torch fixing device.

[0044] In one specific embodiment of the present invention, the weld seam tracker uses laser-based non-contact sensing, and the effective scanning distance range is 90-130 mm.

[0045] In one specific embodiment of the present invention, before welding, the rust in the bevel area to be welded is removed with sandpaper or a grinding wheel, and oil stains are removed with organic solvents. The welding wire used for welding must be free of rust, oil stains, moisture, or other contaminants.

[0046] The following detailed description of the embodiment of the present invention uses the specific implementation of circumferential welding of the vessel shell of a propane dehydrogenation high-temperature reactor as an example. This reactor is the core device for propane dehydrogenation. The shell is made of 304H high-temperature stainless steel, with an outer diameter of Ф3200mm and a wall thickness of 40mm. During manufacturing, a flat plate is first rolled sequentially into shape on a large rolling machine, and then the end face is milled and beveled using a super-large machining center. The bevel is a double V-shape, with a straight edge dimension of 6mm in the middle and a 2mm gap at the root of the V-shape. To automate the root pass welding and replace the previous manual welding, an automatic root pass weld layer is applied using tungsten inert gas (TIG) welding. Because the TIG weld bead is too thin, a metal arc welding (MAG) is used to fill and reinforce the weld bead, forming a double bottom pass bead 3-4mm wide and 4-5mm thick. Afterwards, the main circumferential weld seam can be completed using high-energy submerged arc automatic multi-layer welding with the aid of a weld seam tracker. For tungsten inert gas (TIG) welding, use 1.2mm diameter 304H special coiled wire. For metal inert gas (MIG) welding, use 1.2mm diameter 304H special layered wire. Before welding, clean the rust from the bevel area with sandpaper or a grinding wheel, and remove oil stains with organic solvents. The welding wire must be free of rust, oil, moisture, or other contaminants. Use TIG welding for the root pass, followed by MIG welding to widen and thicken the root pass. Use 1.2mm diameter 304H special coiled wire. During welding, when the camera screen displays a misalignment exceeding 2mm at both ends of the workpiece bevel assembly, activate the manual controller to deflect the welding torch 15° towards the workpiece with the lower misalignment, creating an inclined weld. This will also create a certain penetration depth at the bottom of the workpiece with the higher misalignment, thus compensating for the root misalignment and ensuring complete penetration at the bevel root. When the camera screen displays that the welding wire tip is not aligned with the center of the bevel, exceeding the automatic adjustment limit of ±0.5mm by the weld tracker, the manual controller is activated to control the lateral displacement of the welding torch, ensuring that the welding wire is aligned with the center of the workpiece bevel. When the camera screen displays that the welding voltage is too low and the welding torch height exceeds the adjustment range of ±0.5mm by the weld tracker, the manual controller is activated to control the vertical distance adjustment function of the welding torch, adjusting the welding torch height until the arc voltage returns to normal. The results show that, under the conditions of misalignment of the cylinder bevel, uneven root gap, and radial dimension height variation during assembly, the root pass weld is well formed, without porosity, incomplete penetration, inclusions, or other forming defects. After the entire main circumferential weld is completed by submerged arc multi-pass welding, the weld flaw detection and mechanical properties meet the quality requirements of pressure vessels for pressure equipment.

[0047] The following detailed description of the embodiment of the present invention uses the specific implementation of the melon-shaped end cap welding of a laterite acid leaching reactor as an example. This reactor is a key large, thick-walled vessel for nickel extraction from laterite. The end cap material is a titanium / carbon steel composite plate, with a diameter of Ф5570mm and a wall thickness of 128mm. Due to the large size and thickness of the plate, a melon-shaped local hydraulic curvature is used during manufacturing, followed by welding to form an integral end cap. Before welding, the titanium layer on both sides of the bevel to be welded is removed to expose the carbon steel substrate. The end face bevel is milled using a super-large machining center, resulting in a double V-shaped bevel with a straight edge dimension of 18mm at the root of the V-shape and a 2mm gap. The weld trajectory is complex during the end cap welding process, and the bevel size error is relatively large. To automate the root pass welding and replace the previous manual root pass welding, an automatic root pass weld layer is applied using carbon steel CO2 gas shielded welding, followed by a filler weld to form a double bottom pass weld bead 3-4mm wide and 4-5mm thick. The main circumferential weld can then be completed using high-energy submerged arc automatic multi-layer welding with the aid of a weld seam tracker. A Ф1.2mm H08Mn2SiA disc-wound CO2 welding wire is used. Before welding, rust in the bevel area to be welded is removed with sandpaper or a grinding wheel, and oil is removed with organic solvents. The welding wire must be free of rust, oil, moisture, and other contaminants. The root pass is welded using CO2 gas shielded welding, followed by a thicker root pass. After completing the root pass, the carbon steel weld is completed using high-efficiency submerged arc welding with the aid of a weld seam tracker. During welding, when the camera screen displays a misalignment exceeding 2mm at both ends of the bevel assembly, the manual controller is activated to control the welding torch deflection function, causing the torch to deflect 15° towards the workpiece with the lower misalignment to form an inclined weld. This creates a certain penetration depth at the bottom of the workpiece with the higher misalignment, thereby compensating for the root misalignment and ensuring complete penetration at the root of the bevel. When the camera screen displays that the welding wire tip is not aligned with the center of the bevel, exceeding the weld tracker's automatic adjustment limit of ±0.5mm, the manual controller is activated to control the lateral displacement of the welding torch, ensuring the welding wire is aligned with the center of the workpiece bevel. When the camera screen displays that the welding voltage is too low and the welding torch height exceeds the weld tracker's adjustment range of ±0.5mm, the manual controller is activated to control the welding torch's vertical distance adjustment function, adjusting the torch height until the arc voltage returns to normal. Finally, the titanium layer is welded using tungsten inert gas welding with titanium plate strips. The results show that, even with misalignment of the cylinder bevel, uneven root gap, and radial dimension height variation during assembly, the root pass weld is well-formed, without porosity, incomplete penetration, or inclusions. After completing the entire main circumferential weld using submerged arc multi-pass welding, the weld flaw detection and mechanical properties meet the quality requirements for pressure vessels of pressure equipment.

[0048] The following detailed description of the embodiment of the present invention uses the welding of the longitudinal weld seam of the outer shell of an ultra-large heat exchange feed heat exchanger as a specific example. This shell system is a large propane dehydrogenation heat exchange vessel, with a cylindrical body made of 304H high-temperature stainless steel, an outer diameter of Ф3000mm, a wall thickness of 50mm, and a length of 20900mm. During manufacturing, a flat plate is first rolled sequentially into shape on a large rolling machine, and then the longitudinal bevel is milled using an ultra-large machining center. The bevel is V-shaped, leaving a 3mm gap at the root. To automate the root pass welding, replacing the previous manual welding, an automatic root pass weld layer is applied using tungsten inert gas (TIG) welding. Because the TIG weld bead is too thin, a metal arc welding (MAG) is used to fill and reinforce the weld bead, forming a double bottom pass bead 3-4mm wide and 4-5mm thick. Afterwards, the main circumferential weld seam can be completed using high-energy submerged arc automatic multi-layer welding with the aid of a weld seam tracker. For tungsten inert gas (TIG) welding, use 1.2mm diameter 304H special coiled wire. For metal inert gas (MIG) welding, use 1.2mm diameter 304H special layered wire. Before welding, clean the rust from the bevel area with sandpaper or a grinding wheel, and remove oil stains with organic solvents. The welding wire must be free of rust, oil, moisture, and other contaminants. Use TIG welding for the root pass, followed by MIG welding to widen and thicken the root pass. Use 1.2mm diameter 304H special coiled wire. During welding, when the camera screen displays a misalignment exceeding 2mm at both ends of the bevel assembly, activate the manual controller to deflect the welding torch 15° towards the workpiece with the lower misalignment, creating an inclined weld. This will also create a certain penetration depth at the bottom of the workpiece with the higher misalignment, thus compensating for the root misalignment and ensuring full penetration at the bevel root. When the camera screen displays that the welding wire tip is not aligned with the center of the bevel, exceeding the automatic adjustment limit of ±0.5mm by the weld tracker, the manual controller is activated to control the lateral displacement of the welding torch, ensuring that the welding wire is aligned with the center of the workpiece bevel. When the camera screen displays that the welding voltage is too low and the welding torch height exceeds the adjustment range of ±0.5mm by the weld tracker, the manual controller is activated to control the vertical distance adjustment function of the welding torch, adjusting the welding torch height until the arc voltage returns to normal. The results show that, under the conditions of misalignment of the cylinder bevel, uneven root gap, and radial dimension height variation during assembly, the root pass weld is well formed, without porosity, incomplete penetration, inclusions, or other forming defects. After the entire main circumferential weld is completed by submerged arc multi-pass welding, the weld flaw detection and mechanical properties meet the quality requirements of pressure vessels for pressure equipment. Example

[0049] This invention provides an adaptive error method using the intelligent welding thick workpiece adaptive beveling error correction device described in Example 1, comprising:

[0050] The camera captures real-time images of the welding process using the welding torch;

[0051] Based on the real-time welding images, the camera measures and displays workpiece bevel deviation data;

[0052] The camera transmits the real-time welding image and the workpiece bevel deviation data to the remote controller;

[0053] When the camera shows that the gap between the roots of the welding workpieces exceeds the design specification of 1mm, the manual controller controls the welding torch to swing back and forth in a "Z" or "semi-circular arc" shape and reduces the welding current.

[0054] When the camera shows that the root gap between the welding workpieces is less than 1mm as specified in the design, the manual controller increases the welding current and decreases the welding speed.

[0055] When the camera shows that the two ends of the workpiece bevel assembly are uneven, forming a misalignment of more than 2mm, the manual controller controls the welding torch to deflect 0-20 degrees toward the workpiece with the lower misalignment, forming an inclined weld.

[0056] When the camera shows that the tip of the welding wire is not aligned with the center of the workpiece bevel and exceeds the horizontal automatic adjustment limit of ±0.5mm of the weld tracker, the manual controller controls the lateral displacement of the welding gun to align the welding wire with the center of the workpiece bevel.

[0057] When the camera displays that the welding voltage is too low and the welding torch height exceeds the vertical automatic adjustment limit of ±0.5mm of the weld seam tracker, the manual controller controls the longitudinal displacement of the welding torch to adjust the welding torch height until the arc voltage returns to normal.

[0058] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0059] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0060] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0061] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0062] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A smart welding thick workpiece adaptive bottom beveling assembly error correction device, characterized in that, It includes: welding power source, gas shielded welding mechanism, control mechanism and wire feeding mechanism; The gas-shielded welding mechanism includes a welding torch traveling device, a shielding gas device, a camera, a weld seam tracker, and a welding torch; the camera and the weld seam tracker are connected to the welding end of the welding torch; the camera is used to acquire real-time welding images of the welding torch and transmit the real-time welding images to the control mechanism; The weld seam tracker is used to monitor and track the weld seam in real time and adjust the welding torch travel deviation in the horizontal and vertical directions; the welding torch travel device is connected to the welding torch to drive the welding torch to move on the side of the workpiece bevel; the shielding gas device is connected to the welding torch through the shielding gas passage to deliver shielding gas to the welding area during the welding process. The control mechanism includes a manual controller and a remote controller; the remote controller is used to receive the real-time welding images transmitted by the camera and output the real-time welding images to the remote controller screen; the manual controller is connected to the weld tracker and is used to control and adjust the welding current, arc voltage, welding speed and the mechanical action of the welding torch, so as to realize the swing, deflection, lateral movement and vertical up and down movement of the welding torch; The wire feeding mechanism is connected to the gas-shielded welding mechanism to provide the welding wire required for welding. When the camera displays that the root gap between the welding workpiece pairs exceeds the design specification by 1mm, the manual controller controls the welding torch to swing back and forth in a "Z" or "semi-circular" shape and reduces the welding current. When the camera displays that the root gap between the welding workpiece pairs is less than the design specification by 1mm, the manual controller increases the welding current and decreases the welding speed. When the camera displays that the two ends of the workpiece bevel pair are uneven, forming a misalignment of more than 2mm, the welding current is increased. The manual controller controls the welding torch to deflect 0-20 degrees toward the workpiece with a low misalignment, forming an inclined weld. When the camera shows that the welding wire tip is not aligned with the center of the workpiece bevel and exceeds the horizontal automatic adjustment limit of the weld tracker by ±0.5mm, the manual controller controls the welding torch to move laterally so that the welding wire is aligned with the center of the workpiece bevel. When the camera shows that the welding voltage is too low and the welding torch height exceeds the vertical automatic adjustment limit of the weld tracker by ±0.5mm, the manual controller controls the welding torch to move longitudinally and adjust the welding torch height until the arc voltage returns to normal.

2. The intelligent welding thick workpiece adaptive bottom beveling error correction device according to claim 1, characterized in that, The camera employs a laser imaging system and is also used to measure and display workpiece bevel deviation data, and transmit the workpiece bevel deviation data to the remote controller.

3. The intelligent welding thick workpiece adaptive bottom beveling and error correction device according to claim 1, characterized in that, The intelligent welding thick workpiece adaptive bottom beveling error correction device can perform bottom beveling on both the front and back sides of the workpiece beveling.

4. The intelligent welding thick workpiece adaptive bottom beveling and error correction device according to claim 1, characterized in that, The welding torch traveling device is either a welding trolley that travels along a track or a trackless welding trolley.

5. The intelligent welding thick workpiece adaptive bottom beveling and error correction device according to claim 1, characterized in that, The weld seam tracker uses laser-based non-contact sensing, and the effective scanning distance range is 90–130 mm.

6. An adaptive error method based on the intelligent welding thick workpiece adaptive beveling error correction device according to any one of claims 1 to 5, characterized in that, include: The camera captures real-time images of welding with the welding torch; Based on the real-time welding images, the camera measures and displays workpiece bevel deviation data; The camera transmits the real-time welding image and the workpiece bevel deviation data to the remote controller; When the camera shows that the gap between the roots of the welding workpieces exceeds the design specification of 1mm, the manual controller controls the welding torch to swing back and forth in a "Z" or "semi-circular arc" shape and reduces the welding current. When the camera shows that the root gap between the welding workpieces is less than 1mm as specified in the design, the manual controller increases the welding current and decreases the welding speed. When the camera shows that the two ends of the workpiece bevel assembly are uneven, forming a misalignment of more than 2mm, the manual controller controls the welding torch to deflect 0-20 degrees toward the workpiece with the lower misalignment, forming an inclined weld. When the camera shows that the tip of the welding wire is not aligned with the center of the workpiece bevel and exceeds the horizontal automatic adjustment limit of ±0.5mm of the weld tracker, the manual controller controls the lateral displacement of the welding gun to align the welding wire with the center of the workpiece bevel. When the camera displays that the welding voltage is too low and the welding torch height exceeds the vertical automatic adjustment limit of ±0.5mm of the weld seam tracker, the manual controller controls the longitudinal displacement of the welding torch to adjust the welding torch height until the arc voltage returns to normal.

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