A straight-bend pipe position welding system and method

Abstract

The application discloses a straight-bend pipe variable-position welding system and method, which comprises a robot unit, a welding unit, a movable rail unit and a variable-position machine system. The robot unit comprises a welding robot, a control cabinet and an anti-collision sensor. The welding unit comprises a welding power source, a wire feeder, a welding gun and a gun cleaner. The movable rail unit comprises a movable rail and an equipment mounting table. The variable-position machine system comprises a main variable-position machine, a slave variable-position machine, a three-jaw chuck and a rotary motor. When pipe welding is performed, the main variable-position machine and the slave variable-position machine can cooperate with different angle bend pipes to meet the fixing requirements of two ends of the pipes, so that the pipe welding end faces of the two ends are located at the center positions of the variable-position machines and the end faces are perpendicular to the horizontal plane. The movable rail and the robot are cooperated to realize full-position automatic welding of the pipes, the adaptability and flexibility of the welding fastening tool for different angle bend pipes are improved, the bend pipe welding operation efficiency is improved, the operation strength of manual bend pipe welding is reduced, and the operation intelligent level is improved.

Description

Technical Field

[0001] This invention relates to the field of welding straight pipes to straight pipes and straight pipes to bends, and particularly to a straight-bend displacement welding system and method. Background Technology

[0002] In the shipbuilding process, the piping process in the outfitting process requires the use of a large number of pipes. Pipes account for a large amount of usage in both the pre-outfitting and final assembly processes of shipbuilding. The welding workload of pipes is huge. Traditional manual welding operations are inefficient, costly, and inconsistent in quality, which is not conducive to improving the precision of ship pipe manufacturing.

[0003] To save on pipe welding costs, control welding deformation, and improve production efficiency, automated pipe welding technology is being increasingly used. With the mature application of positioner systems, the combination of automated welding robots and positioners has become an important method for welding pipe fittings. However, even in more advanced domestic shipyards such as Nantong COSCO Kawasaki and Dalian COSCO Kawasaki Shipyards, most automated pipe processing production lines are designed for straight pipe-to-straight pipe / flange welding. Automated welding platforms for straight pipe-to-bend pipes are not yet mature, mainly due to a lack of adaptability research for positioner systems in bending pipe clamping, making it impossible to guarantee fully automated welding of straight and bent pipes in all positions during the welding process.

[0004] Application No. 201911420488.2, entitled "An Automatic Welding Auxiliary Device for Pipe Bending," includes a rotary drive device for driving a rectangular frame to rotate in a plane parallel to the vertical frame, a position adjustment device for driving an angle adjustment device to reciprocate along the length of the rectangular frame, an angle adjustment device for adjusting the angle between the three-jaw chuck and the rectangular frame, a counterweight balancing device installed on the rectangular frame and located at the end away from the three-jaw chuck, and a welding torch fixing device installed on the bottom frame. The welding torch fixing device is used to install the welding torch and enables the welding torch to move in both the horizontal and vertical directions. However, this device is suitable for laboratory welding and is not suitable for welding large outfitting process pipe fittings. Summary of the Invention

[0005] To address the aforementioned issues, this invention provides a straight-to-bend pipe displacement welding system and method, enabling rapid tooling for bends, improving the adaptability, intelligence, and efficiency of pipe welding, and achieving automated welding of straight-to-bend pipes.

[0006] To achieve the above objectives, the present invention employs the following technical means:

[0007] A straight-bend pipe positioning and welding system includes a robot unit, a welding unit, a moving ground rail unit, and a positioner system. The positioner system includes a master positioner, a slave positioner, and a positioner ground rail. The master positioner fixes the straight pipe, and the slave positioner fixes the bend pipe. The master positioner and the slave positioner can automatically adjust the distance between themselves through the positioner ground rail, so that the welding end faces of the two pipes are at the center position of the master and slave positioners, and the end faces are perpendicular to the horizontal plane.

[0008] Furthermore, the main positioner includes a main positioner body, a main turntable, a main three-jaw chuck, an axial motor, and a three-jaw chuck connecting seat; the main positioner body is connected to the main turntable via gears, and the main turntable rotates forward and backward via the axial motor; the three-jaw chuck connecting seat is fastened to the center of the main turntable with bolts; the main three-jaw chuck is fastened to the center of the three-jaw chuck connecting seat with fixing bolts, and the three-jaw chuck rotates around the center of the main turntable via the axial motor; the main positioner body moves horizontally along the positioner's ground rail via a transverse motor.

[0009] Furthermore, the slave positioner includes a slave positioner body, a slave turntable, a slave three-jaw chuck, a three-jaw chuck rotating seat, a rotary motor, and a three-jaw chuck connecting component; the slave turntable is connected to the slave positioner body via gears; the three-jaw chuck rotating seat is connected to the slave turntable via a rotating shaft; the three-jaw chuck is connected to the three-jaw chuck rotating seat via the three-jaw chuck connecting component, and the three-jaw chuck rotates by rotating the three-jaw chuck rotating seat around the motor axis via the rotary motor, thereby allowing the slave three-jaw chuck to tilt to adapt to different pipe bending angles; the slave positioner body moves horizontally along the positioner's ground rail via a transverse motor.

[0010] Furthermore, the rotary motor mounting brackets are installed symmetrically at both ends of the turntable, and the rotary motor mounting brackets are used to install the rotary motor.

[0011] Furthermore, a symmetrical three-jaw chuck connector is fixed to the inner side of the three-jaw chuck rotating seat in the vertical direction. The three-jaw chuck connector is connected to the connecting rod of the three-jaw chuck, and the connection position of the two is adjustable. The adjustment is made to adjust the center position of the three-jaw chuck relative to the three-jaw chuck rotating seat to adapt to the change of the spatial position of the bent pipe.

[0012] Furthermore, both the three-jaw chuck connector and the connecting rod of the three-jaw chuck are provided with slots on the outside. A retractable slot component adapted to the slot is installed in the slot. One end of the retractable slot component is fixed in the slot of the three-jaw chuck connecting rod, and the other end is inside the slot of the three-rotor chuck connector. The three-rotor chuck connector can move relative to the retractable slot component to achieve the center position of the three-rotor chuck relative to the three-jaw chuck rotating seat. The retractable slot component is fixed and loosened by a positioning and fastening device.

[0013] Furthermore, the robot unit includes a welding robot, a control cabinet, and anti-collision sensors.

[0014] Furthermore, the welding unit includes a welding power source, a wire feeder, a welding torch, and a torch cleaner.

[0015] Furthermore, the mobile ground rail unit includes a ground rail and an equipment mounting platform.

[0016] A welding method based on the straight-bend pipe displacement welding system, comprising:

[0017] The main positioner fixes a section of pipe with a main three-jaw chuck; the slave positioner fixes a section of bent pipe with a three-jaw chuck, so that the welding end faces of the two pipe assemblies are in the center position of the positioner and the end faces are perpendicular to the horizontal plane; by adjusting the distance between the main positioner and the slave positioner in the horizontal direction of the positioner ground rail, the welding straight pipe and straight / bent pipe can be fixed.

[0018] The welding robot unit moves to the designated welding position between straight pipes via a moving ground rail unit. Through welding commands and the welding unit, in coordination with the synchronous rotation of the main positioner and the slave positioner, it performs all-position welding operations between straight pipes and straight pipes / bends.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention, through a positioner system, can achieve tooling fixation for the spatial position of bent pipes at different angles by means of the three-rotor chuck rotating seat and retractable slot of the positioner. By adjusting the position of the master and slave positioners on the positioner ground rail, it can adapt to the fixation of the two ends of the straight-bent pipe. With the cooperation of the robot and welding unit, it can realize full-position automatic welding of straight-bent pipes, improve the automation, intelligence and efficiency of the pipe bending welding process, reduce the hazards suffered by workers in the welding operation, and save operating costs. Attached Figure Description

[0020] Figure 1 This is a diagram of a straight-to-bend pipe displacement welding system.

[0021] Figure 2 A schematic diagram of the main positioner structure.

[0022] Figure 3 Side view of the main positioner structure.

[0023] Figure 4 This is a schematic diagram of the positioner structure.

[0024] Figure 5 This is a side view of the positioner structure.

[0025] Figure 6 This is a schematic diagram of the transverse movement device from the three-jaw chuck of the positioner.

[0026] Figure 7 This is a schematic diagram of the three-turn chuck connector structure.

[0027] Figure 8 This is a schematic diagram showing the relative position of the three-rotor chuck connector and the three-grip chuck connecting rod.

[0028] Figure 9 This is a schematic diagram of the retractable card slot structure.

[0029] In the diagram: 1. Welding robot, 2. Control cabinet, 3. Welding power supply, 4. Welding torch, 5. Torch cleaner, 6. Ground rail, 7. Equipment mounting platform, 8. Main positioner, 81. Main positioner body, 82. Main turntable, 83. Main three-jaw chuck, 84. Three-jaw chuck rotating seat, 9. Slave positioner, 91. Slave positioner body, 92. Slave turntable, 93. Slave three-jaw chuck, 931. Three-jaw chuck connecting rod, 94. Three-jaw chuck rotating seat, 95. Rotary motor, 951. Rotary motor mounting base, 96. Three-jaw chuck connector, 97. Telescopic chuck, 98. Positioning and fastening device. Detailed Implementation

[0030] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0031] Based on the shortcomings of existing technologies, this invention has conducted research on straight-to-bend pipe displacement welding systems, and invented a displacement machine system with universal adaptability to straight / bend pipes, realizing the universal adaptability of straight-to-bend pipe displacement machine tooling and the automation of the welding process. Figure 1 As shown, this embodiment provides a straight-to-bend pipe positioning welding system, including a robot unit, a welding unit, a mobile ground rail unit, and a positioner system. The robot unit includes a welding robot 1, a control cabinet 2, and an anti-collision sensor. The welding unit includes a welding power source 3, a wire feeder, a welding torch 4, and a torch cleaner 5. The mobile ground rail unit includes a ground rail 6 and an equipment mounting platform 7. The positioner system includes a master positioner 8 and a slave positioner 9, which together form the positioner system. Automatic distance adjustment can be achieved through the positioner ground rail 10.

[0032] Combination Figures 2-3The main positioner 8 includes a main positioner body 81, a main turntable 82, a main three-jaw chuck 83, and a three-jaw chuck connecting seat 84. The main positioner body 81 is connected to the main turntable 82 by gears, and the main turntable 82 can rotate forward and backward by an axial motor. The three-jaw chuck connecting seat 84 is fastened to the center of the main turntable 82 by bolts. The main three-jaw chuck 83 is fastened to the center of the three-jaw chuck connecting seat 84 by fixing bolts, and the three-jaw chuck 83 can rotate around the center of the main turntable 82 by an axial motor. The main positioner body 81 can move horizontally on the positioner ground rail 10 by a transverse motor.

[0033] Combination Figures 4-9 The slave positioner 9 includes a slave positioner body 91, a slave turntable 92, a slave three-jaw chuck 93, a three-jaw chuck rotating seat 94, a rotary motor 95, a three-jaw chuck connector 96, a retractable slot 97, and a positioning and fastening device 98. The slave turntable 92 is connected to the slave positioner body 91 via gears; the three-jaw chuck rotating seat 94 is connected to the slave turntable 92 via a rotating shaft; the three-jaw chuck 93 is connected to the three-jaw chuck rotating seat 94 via the three-jaw chuck connector 96 and the retractable slot 97. The slave positioner body 91 can move horizontally along the positioner ground rail 10 via a transverse motor; the slave turntable 92 is connected to the slave positioner body 91 via gears and rotates at its center via an axial motor. The rotary motor mounting bases 951 are symmetrically installed at both ends of the turntable 92. The rotary motor 95 is mounted on the rotary motor mounting bases 951. The rotary motor 95 is connected to the three-jaw chuck rotating seat 94 through gears, realizing the rotation of the three-jaw chuck rotating seat 94 around the motor axis. Symmetrical three-jaw chuck connecting parts 96 are fixed to the inner side of the three-jaw chuck rotating seat 94 in the vertical direction. T-shaped movable slots are provided on the outer sides of the three-jaw chuck connecting parts 96 and the three-jaw chuck connecting rod 931. One end of the retractable slot 97 is fixed to one side of the movable slot of the three-jaw chuck connecting rod 931, and the other end is inside the movable slot of the three-jaw chuck connecting part 96. The three-jaw chuck connecting part 96 can move relative to the three-jaw chuck 93 through the retractable slot 97. The retractable slot 97 is fixed and loosened by a movable positioning and fastening device 98. The positioner 9 uses a rotary motor 95 to tilt the three-jaw chuck 93 to adapt to different bending angles; the three-jaw chuck 93 can be adjusted by the synchronous loosening of the positioning and fastening devices 98 at both ends, along the telescopic slot 97, to achieve the center position of the three-jaw chuck 93 relative to the three-jaw chuck rotating seat 94, adapting to changes in the spatial position of the bending pipe.

[0034] A welding method based on the aforementioned straight-to-bend pipe positioning welding system includes: the main positioner 8 fixing a section of pipe using a main three-jaw chuck 83; the slave positioner 9 fixing the spatial position of a section of bend pipe using a slave three-jaw chuck 93; ensuring the welding end faces of the two pipe pairs are positioned at the center of the positioner and perpendicular to the horizontal plane; and fixing the straight pipe to be welded with the straight / bend pipe by adjusting the horizontal distance between the main positioner 8 and the slave positioner 9 on the positioner ground rail 10. The welding robot 1 moves to an appropriate welding position between the straight pipe and the straight / bend pipe via the ground rail 6. By writing welding instructions and coordinating with the synchronous rotation of the main positioner 8 and the slave positioner 9, all-position welding of straight pipe to straight / bend pipe is achieved. This method is based on the aforementioned system and includes all the technical features described in the system, which will not be repeated here.

[0035] This invention utilizes the relative positions of positioner systems to achieve positioning fixtures for straight-to-bend pipes within a certain angle range, based on the rotation angle of the positioners. A welding platform, in conjunction with the positioner systems, enables intelligent operation of the welding process. This provides rapid fixtures for bends, improves the adaptability, intelligence, and efficiency of pipe welding, and achieves automated welding of straight-to-bend pipes.

[0036] It should be noted that the connection relationships between the components in the robot unit, welding unit, and mobile track unit are common knowledge to those skilled in the art and will not be elaborated here.

Claims

1. A straight-to-bend pipe displacement welding system, comprising a robot unit, a welding unit, and a moving ground rail unit, characterized in that: It also includes a positioner system; the positioner system includes a main positioner (8), a slave positioner (9) and a positioner ground rail (10). The main positioner (8) fixes the straight pipe and the slave positioner (9) fixes the bent pipe. The main positioner (8) and the slave positioner (9) can automatically adjust the distance through the positioner ground rail (10) so that the welding end faces of the pipes at both ends are at the center of the main and slave positioners and the end faces are perpendicular to the horizontal plane. The slave positioner (9) includes a slave positioner body (91), a slave turntable (92), a slave three-jaw chuck (93), a three-jaw chuck rotating seat (94), a rotary motor (95), and a three-jaw chuck connector (96). The slave turntable (92) is connected to the slave positioner body (91) via gears. The three-jaw chuck rotating seat (94) is connected to the slave turntable (92) via a rotating shaft. The slave three-jaw chuck (93) is connected to the three-jaw chuck rotating seat (94) via the three-jaw chuck connector (96). The three-jaw chuck rotating seat (94) is connected to the rotary motor (95). The rotary motor (95) rotates the three-jaw chuck rotating seat (94) around the motor axis to drive the slave three-jaw chuck (93) to rotate, so that the angle of the slave three-jaw chuck (93) can be tilted to adapt to different pipe bending angles. The slave positioner body (91) moves horizontally on the positioner ground rail (10) via a transverse motor. The three-jaw chuck rotating seat (94) has a symmetrical three-jaw chuck connector (96) fixed on its inner side in the vertical direction. The three-jaw chuck connector (96) is connected to the connecting rod of the three-jaw chuck (93). The connection position of the two can be adjusted to adjust the center position of the three-jaw chuck (93) relative to the three-jaw chuck rotating seat (94) to adapt to the change of the spatial position of the bent pipe.

2. The straight-bend pipe displacement welding system according to claim 1, characterized in that: The main positioner (8) includes a main positioner body (81), a main turntable (82), a main three-jaw chuck (83), an axial motor, and a three-jaw chuck connecting seat (84). The main positioner body (81) is connected to the main turntable (82) by gears, and the main turntable (82) is rotated forward and backward by the axial motor. The three-jaw chuck connecting seat (84) is fastened to the center of the main turntable (82) by bolts. The main three-jaw chuck (83) is fastened to the center of the three-jaw chuck connecting seat (84) by fixing bolts, and the main three-jaw chuck (83) is rotated around the center of the main turntable (82) by the axial motor. The main positioner body (81) moves horizontally on the positioner ground rail (10) by a transverse motor.

3. The straight-bend pipe displacement welding system according to claim 1, characterized in that: The rotary motor mounting base (951) is installed symmetrically at both ends of the turntable (92), and the rotary motor (95) is installed on the rotary motor mounting base (951). The rotary motor (95) is connected to the three-jaw chuck rotary seat (94) through gears.

4. The straight-bend pipe displacement welding system according to claim 1, characterized in that: The three-jaw chuck connector (96) and the connecting rod from the three-jaw chuck (93) are both provided with slots. A retractable slot piece (97) adapted to the slot is installed in the slot. One end of the retractable slot piece (97) is fixed in the slot of the three-jaw chuck connecting rod (931), and the other end is inside the slot of the three-jaw chuck connector (96). The three-jaw chuck connector (96) can move relative to the retractable slot piece (97) and be fixed and loosened by the positioning fastening device (98).

5. The straight-bend pipe displacement welding system according to claim 1, characterized in that: The robot unit includes a welding robot (1), a control cabinet (2), and anti-collision sensors.

6. The straight-bend pipe displacement welding system according to claim 1, characterized in that: The welding unit includes a welding power source (3), a wire feeder, a welding torch (4), and a torch cleaner (5).

7. The straight-bend pipe displacement welding system according to claim 1, characterized in that: The mobile ground rail unit includes a ground rail (6) and an equipment mounting platform (7).

8. A welding method based on the straight-bend pipe displacement welding system according to any one of claims 1-7, characterized in that: include: The main positioner fixes a section of pipe with a main three-jaw chuck; the slave positioner fixes a section of bent pipe with a three-jaw chuck, so that the welding end faces of the two pipe assemblies are in the center position of the positioner and the end faces are perpendicular to the horizontal plane; by adjusting the distance between the main positioner and the slave positioner in the horizontal direction of the positioner ground rail, the welding straight pipe is fixed to the straight pipe or bent pipe. The welding robot unit moves to the designated welding position between straight pipes via a moving ground rail unit. Through welding commands and the welding unit, in coordination with the synchronous rotation of the main positioner and the slave positioner, it performs all-position welding operations between straight pipes and straight pipes / bends.

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