Rootless welding method and device

Abstract

The application discloses a kind of rootless welding method and device, the method includes: step S1, to be welded steel plate is wound to form cylinder, and the argon protection of to be welded part of the to be welded steel plate is carried out;Step S2, the first camera is used to photograph the to be welded part, and the first welding parameter of the to be welded part is determined, to execute first welding operation according to the first welding parameter on the outside of the to be welded steel plate the to be welded part;Step S3, the second camera is used to photograph the to be welded part, and the first welding parameter of the to be welded part is determined, to execute second welding operation according to the second welding parameter on the outside of the to be welded steel plate the to be welded part;Step S4, third welding operation is carried out on the inside of the to be welded steel plate the to be welded part, and the cylinder of welding completion is obtained.The application does not need to carry out root cleaning treatment to weld, reduces environmental pollution, improves welding quality.

Description

Technical Field

[0001] This invention relates to the field of welding technology, and specifically to a root-cleaning-free welding method and apparatus. Background Technology

[0002] Shell-and-tube heat exchangers are widely used in industries such as oil refining and chemical processing, offering advantages such as high reliability, strong adaptability, and ease of design, manufacturing, and use. A shell-and-tube heat exchanger typically consists of components such as a tube box, shell, and tube bundles, all connected by welding. The quality of this welding determines the lifespan of the equipment. In particular, the longitudinal and circumferential butt welds of the tube box and shell are full-penetration welds, usually employing a double-sided welding method. This involves welding on one side using shielded metal arc welding (SMAW) or submerged arc welding (SAW), followed by root cleaning on the other side before continuing welding. Root cleaning methods include carbon rod gouging and grinding. Carbon rod gouging produces significant spatter, causing substantial environmental pollution and easily creating a carburized layer on the base material surface, affecting weld quality. This carburized layer must be removed to prevent further carburization during gouging and subsequent welding cracks. Grinding is time-consuming and potentially dangerous. Summary of the Invention

[0003] This invention aims to at least partially solve one of the technical problems in related technologies. Therefore, one object of this invention is to provide a root-cleaning-free welding method, comprising:

[0004] Step S1: The steel plate to be welded is wound into a cylindrical shape, and the welding part of the steel plate to be welded is protected by argon.

[0005] Step S2: Use a first camera to photograph the part to be welded and determine the first welding parameters of the part to be welded, so as to perform a first welding operation on the part to be welded on the outside of the steel plate to be welded according to the first welding parameters;

[0006] Step S3: Use a second camera to photograph the part to be welded and determine the first welding parameters of the part to be welded, so as to perform a second welding operation on the part to be welded on the outside of the steel plate to be welded according to the second welding parameters;

[0007] Step S4: Perform a third welding operation on the part to be welded on the inside of the steel plate to be welded to obtain a welded cylinder.

[0008] Preferably, step S2 includes:

[0009] Step S21: Use the first camera to capture the area to be welded and determine the image information of the area to be welded;

[0010] Step S22: Determine the welding area of ​​the part to be welded based on the image information corresponding to the part to be welded;

[0011] Step S23: Determine the corresponding first welding parameters based on the welding area of ​​the part to be welded, so as to perform a first welding operation on the part to be welded on the outside of the steel plate to be welded according to the first welding parameters; the first welding parameters are used to control the first welding torch to perform the first welding operation.

[0012] Preferably, step S23 includes:

[0013] Step S231: If the welding area of ​​the part to be welded satisfies a preset relationship with the preset welding area, determine the first welding parameter corresponding to the preset welding area;

[0014] Step S232: Control the working state of the first welding torch according to the first welding parameters, so that the first welding torch performs the first welding operation on the part to be welded on the outside of the steel plate to be welded.

[0015] Preferably, step S231 includes:

[0016] If the welding area of ​​the part to be welded is equal to or less than the preset welding area, determine the first welding time corresponding to the preset welding area;

[0017] If the welding area of ​​the part to be welded is greater than the preset welding area, determine the second welding time corresponding to the preset welding area.

[0018] Preferably, step S3 includes:

[0019] Step S31: Use the second camera to capture the area to be welded, and determine the image information corresponding to the weld in the area to be welded;

[0020] Step S32: Determine the locations of each defect point in the weld based on the image information corresponding to the weld.

[0021] Step S33: Determine the corresponding second welding parameters based on each defect point in the weld, and perform a second welding operation on the part to be welded on the outside of the steel plate to be welded according to the second welding parameters; the second welding parameters are used to control the second welding gun to perform the second welding operation.

[0022] Preferably, step S33 includes:

[0023] Step S331: Determine the second welding parameters corresponding to the preset defect points based on the quantitative relationship between each defect point in the weld and the preset defect points;

[0024] Step S332: Control the working state of the second welding torch according to the second welding parameters so that the second welding torch performs a second welding operation on the part to be welded on the outside of the steel plate to be welded.

[0025] Preferably, step S331 includes:

[0026] If the number of defect points in the weld is greater than the number of preset defect points, determine the second welding parameters corresponding to the preset defect points.

[0027] Another object of the present invention is to provide a welding apparatus for performing the above-described root-cleaning-free welding method, comprising:

[0028] The first protective mechanism is used to install and fix the steel plate to be welded, and to provide argon protection to the steel plate to be welded in a first direction.

[0029] The second protective mechanism is located on one side of the first protective mechanism and provides argon protection to the steel plate to be welded in the second direction.

[0030] A welding mechanism, located on the opposite side from the second protective mechanism, is used to weld the steel plate to be welded.

[0031] Preferably, the welding mechanism includes:

[0032] frame;

[0033] A first welding assembly, movably mounted on the frame, is used to perform a first welding operation on the steel plate to be welded;

[0034] A second welding assembly, movably mounted on the frame and adjacent to the first welding assembly, is used to perform a second welding operation on the steel plate to be welded;

[0035] A control system is mounted on the frame and connected to the first welding assembly and the second welding assembly, and is used to control the operation of the first welding assembly and the second welding assembly respectively.

[0036] The above-described solution of the present invention has at least the following beneficial effects:

[0037] The root-cleaning-free welding method provided by this invention first involves winding a steel plate to be welded into a cylindrical shape and then argon-protecting the welding area of ​​the steel plate. A first camera is used to photograph the welding area and determine first welding parameters for that area. Based on these first welding parameters, a first welding operation is performed on the welding area on the outside of the steel plate. Then, a second camera is used to photograph the welding area and determine the first welding parameters for that area. Based on these second welding parameters, a second welding operation is performed on the welding area on the outside of the steel plate. Finally, a third welding operation is performed on the welding area on the inside of the steel plate, resulting in a welded cylindrical body. This produces a double-sided weld, eliminating the need for root cleaning, reducing environmental pollution, and improving welding quality.

[0038] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0039] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0040] Figure 1 This is a flowchart of the root-cleaning-free welding method provided in the embodiments of the present invention;

[0041] Figure 2 This is a schematic diagram of step S2 provided in an embodiment of the present invention;

[0042] Figure 3 This is a schematic diagram of step S23 provided in an embodiment of the present invention;

[0043] Figure 4 This is a schematic diagram of step S3 provided in an embodiment of the present invention;

[0044] Figure 5 This is a schematic diagram of step S33 provided in the embodiment of the present invention;

[0045] Figure 6 This is a schematic diagram of the structure of the root-cleaning-free welding device provided in the embodiment of the present invention.

[0046] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0047] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0048] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "circumferential," and "radial," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0049] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0050] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0051] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0052] The root-cleaning-free welding method and apparatus of the present invention are described in detail below with reference to the accompanying drawings.

[0053] like Figures 1 to 6 As shown, the root-cleaning-free welding method provided in this embodiment of the invention includes:

[0054] Step S1: The steel plate 4 to be welded is wound into a cylindrical shape, and the welding part of the steel plate 4 to be welded is protected by argon.

[0055] In this embodiment, when processing the shell-and-tube heat exchanger, the steel plate 4 to be welded can be used to weld the corresponding shell first, and then the shell and the tube box can be welded together. Therefore, when welding the shell, the steel plate 4 to be welded can be rolled into a cylindrical shape so that there is no gap at the joint of the steel plate 4 to be welded, so that the joint of the steel plate 4 to be welded can be welded. It can be understood that argon protection means purging the back of the part to be welded with protective gas, so that the part to be welded can be protected from oxidation during the welding process.

[0056] Step S2: Use the first camera 5 to photograph the part to be welded and determine the first welding parameters of the part to be welded, so as to perform the first welding operation on the outside of the steel plate 4 to be welded according to the first welding parameters.

[0057] In this embodiment, the first camera 5 can be the camera corresponding to the first welding gun 6, the first welding gun 6 can be a plasma arc welding gun, and the first welding parameter can be expressed as the welding time corresponding to the first welding gun 6, etc. The first welding parameter can be obtained by manual input or by calculation by the control system 9, so that the first welding gun 6 can weld the part to be welded according to the first welding parameter; wherein, the first welding operation means performing self-fusion welding on the steel plate 4 to be welded without filler wire.

[0058] Specifically, step S2 above includes:

[0059] Step S21: Use the first camera 5 to capture the area to be welded and determine the image information of the area to be welded;

[0060] Step S22: Determine the welding area of ​​the part to be welded based on the image information corresponding to the part to be welded;

[0061] Step S23: Determine the corresponding first welding parameters based on the welding area of ​​the part to be welded, so as to perform the first welding operation on the outside of the steel plate 4 to be welded according to the first welding parameters; the first welding parameters are used to control the first welding torch 6 to perform the first welding operation.

[0062] In this embodiment, the first camera 5 can be controlled by the control system 9 to capture images of the part to be welded, thereby determining the image information of the part to be welded. The image information of the part to be welded can be formed as a straight line. By recognizing the image information of the part to be welded, the corresponding pixel points can be determined. Thus, the corresponding welding area can be calculated based on the pixel points of the part to be welded. Thus, the corresponding first welding parameters can be determined based on the welding area. Then, the first welding gun 6 can be controlled by the first welding parameters to perform self-fusion welding on the outside of the steel plate 4 to be welded.

[0063] Furthermore, step S23 above includes:

[0064] Step S231: If the welding area of ​​the part to be welded satisfies the preset relationship with the preset welding area, determine the first welding parameter corresponding to the preset welding area;

[0065] Step S232: Control the working state of the first welding torch 6 according to the first welding parameters so that the first welding torch 6 performs the first welding operation on the outside of the steel plate 4 to be welded.

[0066] In this embodiment, the preset welding area and the first welding parameters can be pre-set to have a corresponding relationship. By determining the welding area of ​​the part to be welded, it can be determined whether the welding area of ​​the part to be welded and the preset welding area meet the preset relationship. Then, the corresponding first welding parameters can be determined according to different preset relationships. Optionally, the first welding parameters may include a first welding time and a second welding time. The first welding gun 6 is controlled to perform welding according to the first welding parameters to ensure higher quality when performing self-fusion welding on the steel plate 4 to be welded.

[0067] In an optional embodiment, step S231 includes: if the welding area of ​​the part to be welded is equal to or less than a preset welding area, determining a first welding time corresponding to the preset welding area; if the welding area of ​​the part to be welded is greater than the preset welding area, determining a second welding time corresponding to the preset welding area; wherein the first welding time and the second welding time are preset and have a corresponding relationship with the preset welding area. By comparing the welding area of ​​the part to be welded with the preset welding area, it can be determined that when welding the part to be welded, the first welding can be performed using the first welding time or the second welding time, ensuring that the welding time of the steel plate 4 to be welded is more accurate and improving its welding quality.

[0068] Step S3: Use the second camera 7 to photograph the part to be welded and determine the first welding parameters of the part to be welded, so as to perform the second welding operation on the outside of the steel plate 4 to be welded according to the second welding parameters.

[0069] Specifically, step S3 above includes:

[0070] Step S31: Use the second camera 7 to capture images of the area to be welded and determine the image information corresponding to the weld seam in the area to be welded;

[0071] Step S32: Based on the image information corresponding to the weld, determine the location of each defect point in the weld;

[0072] Step S33: Determine the corresponding second welding parameters based on each defect point in the weld, so as to perform a second welding operation on the outside of the steel plate 4 to be welded according to the second welding parameters; the second welding parameters are used to control the second welding torch 8 to perform the second welding operation.

[0073] In this embodiment, after the first welding torch 6 completes the autofusion welding, a weld can be formed at the part to be welded. Therefore, the control system 9 can control the second camera 7 to take pictures of the weld completed by autofusion welding, thereby determining the image information of the weld. By identifying the image information of the part to be welded, the corresponding defect point is determined. Thus, the second welding parameters can be determined based on the defect point of the weld. Then, the second welding torch 8 can be controlled to perform filler wire welding on the outside of the steel plate 4 to be welded using the second welding parameters.

[0074] Specifically, step S33 above includes:

[0075] Step S331: Determine the second welding parameters corresponding to the preset defect points based on the quantitative relationship between each defect point in the weld and the preset defect points;

[0076] Step S332: Control the working state of the second welding torch 8 according to the second welding parameters so that the second welding torch 8 performs the second welding operation on the outside of the steel plate 4 to be welded.

[0077] Furthermore, step S331 includes: if the number of each defect point in the weld is greater than the number of preset defect points, determining the second welding parameters corresponding to the preset defect points. The second welding parameters can be represented by the temperature of the second welding torch 8, and the defect points represent porosity or collapse in the weld. By determining the quantitative relationship between each defect point and the preset defect points, it can be determined whether the number of each defect point in the weld is greater than the number of preset defect points. If it is greater, the second welding torch 8 can be controlled according to the second welding parameters corresponding to the preset defect points, so that after the second welding torch 8 welds the weld with filler wire, root cleaning is not required, ensuring better weld quality.

[0078] Step S4: Perform the third welding operation on the inner side of the steel plate 4 to be welded to obtain the welded cylinder.

[0079] In this embodiment, the third welding operation refers to submerged arc welding of the part to be welded. Submerged arc welding is used to weld the inner side of the cylinder that has been welded on the outside. After welding, the weld can be radiographically inspected to ensure that the weld meets the qualified standard.

[0080] The welding apparatus for performing the above-described root-cleaning-free welding method proposed in the embodiments of the present invention includes a first protective mechanism, a second protective mechanism, and a welding mechanism. The first protective mechanism is used to install and fix the steel plate 4 to be welded and to perform argon blasting protection on the steel plate 4 in a first direction. The second protective mechanism is located on one side of the first protective mechanism and to perform argon blasting protection on the steel plate 4 to be welded in a second direction. The welding mechanism is located on the other side opposite to the second protective mechanism and is used to weld the steel plate 4 to be welded.

[0081] Furthermore, the welding mechanism includes a frame 10; a first welding assembly, a second welding assembly, and a control system 9. The first welding assembly is movably mounted on the frame 10 and is used to perform a first welding operation on the steel plate 4 to be welded. The second welding assembly is movably mounted on the frame 10 and adjacent to the first welding assembly, and is used to perform a second welding operation on the steel plate 4 to be welded. The control system 9 is mounted on the frame 10 and connected to the first welding assembly and the second welding assembly, and is used to control the operation of the first welding assembly and the second welding assembly respectively.

[0082] In this embodiment, the first protection mechanism includes a support platform 3 and a protection device 2 for protecting the cylinder in the radial direction. The second protection mechanism can protect the cylinder in the circumferential direction. The first welding assembly includes a first welding torch 6 and a first camera 5. The second welding assembly includes a second welding torch 8 and a second camera 7. When welding the steel plate 4 to be welded, the first protection mechanism can purge the back of the steel plate 4 to be welded with protective gas. Then, the control system 9 controls the first camera 5 and the first welding torch 6 to perform the first welding operation. After the first welding torch 6 completes the self-fusion welding of the steel plate 4 to be welded, the control system 9 can control the second camera 7 and the second welding torch 8 to perform the second welding operation. After the welding is completed, submerged arc welding can be used to weld inside the cylinder, thereby eliminating the need for root cleaning of the weld and ensuring better welding quality.

[0083] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0084] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A root-cleaning-free welding method, characterized in that, include: Step S1: The steel plate to be welded is wound into a cylindrical shape, and the welding part of the steel plate to be welded is protected by argon. Step S2: Use a first camera to photograph the part to be welded and determine the first welding parameters of the part to be welded, so as to perform a first welding operation on the part to be welded on the outside of the steel plate to be welded according to the first welding parameters; Step S3: Use a second camera to photograph the part to be welded and determine the second welding parameters of the part to be welded, so as to perform a second welding operation on the part to be welded on the outside of the steel plate to be welded according to the second welding parameters; Step S4: Perform a third welding operation on the part to be welded on the inside of the steel plate to be welded to obtain a welded cylinder. Step S2 includes: Step S21: Use the first camera to capture the area to be welded and determine the image information of the area to be welded; Step S22: Determine the welding area of ​​the part to be welded based on the image information corresponding to the part to be welded; Step S23: Determine the corresponding first welding parameters based on the welding area of ​​the part to be welded, and perform a first welding operation on the part to be welded on the outside of the steel plate to be welded according to the first welding parameters; the first welding parameters are used to control the first welding torch to perform the first welding operation. Step S23 includes: Step S231: If the welding area of ​​the part to be welded satisfies a preset relationship with the preset welding area, determine the first welding parameter corresponding to the preset welding area; Step S232: Control the working state of the first welding torch according to the first welding parameters so that the first welding torch performs the first welding operation on the part to be welded on the outside of the steel plate to be welded. The first welding parameters include the first welding duration and the second welding duration; Step S3 includes: Step S31: Use the second camera to capture the area to be welded, and determine the image information corresponding to the weld in the area to be welded; Step S32: Based on the image information corresponding to the weld, determine the location of each defect point in the weld, where the defect point represents the porosity or collapse of the weld. Step S33: Determine the corresponding second welding parameters based on each defect point in the weld, and perform a second welding operation on the part to be welded on the outside of the steel plate to be welded according to the second welding parameters; the second welding parameters are used to control the second welding torch to perform the second welding operation; Step S33 includes: Step S331: Determine the second welding parameters corresponding to the preset defect points based on the quantitative relationship between each defect point in the weld and the preset defect points; Step S332: Control the working state of the second welding torch according to the second welding parameters so that the second welding torch performs a second welding operation on the part to be welded on the outside of the steel plate to be welded. Step S331 includes: If the number of defect points in the weld is greater than the number of preset defect points, determine the second welding parameter corresponding to the preset defect point. The second welding parameter is the temperature of the second welding torch. The first welding operation is autofusion welding, the second welding operation is filler wire welding, and the third welding operation is submerged arc welding.

2. The root-cleaning-free welding method according to claim 1, characterized in that, Step S231 includes: If the welding area of ​​the part to be welded is equal to or less than the preset welding area, determine the first welding time corresponding to the preset welding area; If the welding area of ​​the part to be welded is greater than the preset welding area, determine the second welding time corresponding to the preset welding area.

3. The root-cleaning-free welding method according to claim 1, characterized in that, It also includes welding equipment, which includes: The first protective mechanism is used to install and fix the steel plate to be welded, and to provide argon protection to the steel plate to be welded in a first direction. The second protective mechanism is located on one side of the first protective mechanism and provides argon protection to the steel plate to be welded in the second direction. A welding mechanism, located on the opposite side from the second protective mechanism, is used to weld the steel plate to be welded.

4. The root-cleaning-free welding method according to claim 3, characterized in that, The welding mechanism includes: frame; A first welding assembly, movably mounted on the frame, is used to perform a first welding operation on the steel plate to be welded; A second welding assembly, which is movably mounted on the frame and adjacent to the first welding assembly, is used to perform a second welding operation on the steel plate to be welded. A control system is mounted on the frame and connected to the first welding assembly and the second welding assembly, for controlling the operation of the first welding assembly and the second welding assembly respectively.

Images