A large-diameter super-long common-base tank vertical friction stir welding assembly welding system

Abstract

The present application belongs to the technical field of large-scale storage tank assembly and welding automation equipment for launch vehicles, and particularly relates to a large-diameter and ultra-long common-base storage tank vertical friction stir welding assembly and welding system. The system comprises a vertical welding jig, a tank body lifting system, an outer clamping ring mechanism, a large-diameter high-precision heavy-load hollow rotary platform, a large-thickness high-strength aluminum alloy heavy-load constant-pressure constant-displacement friction stir welding spindle system, an inner support mechanism, a cylinder segment product feeding system, a tank bottom product feeding system, an in-situ phased array automatic detection system, a control system, an elevator and a safety passage. The beneficial effects are that the system can realize the integration of functions such as assembly, welding, detection, repair welding, lifting and unloading in the manufacturing process of launch vehicle storage tank products, meet the development and support requirements of the new generation manned launch vehicle 5m diameter ultra-long common-base storage tank, and improve the technical level of ultra-long and large-thickness storage tank assembly and friction stir welding in the field of Chinese aerospace.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of large-scale storage tank assembly welding automation equipment of a carrier rocket, and particularly relates to a large-diameter super-long common-base storage tank vertical friction stir welding assembly and welding system. BACKGROUND

[0002] The storage tank of a carrier rocket is a main component of the rocket body structure, and its main function is to serve as a thin-walled pressure-bearing container for storing oxidizing agents and combustion agents during the flight of the rocket, and to stabilize the main structure of the rocket as a "ridge beam". The storage tank generally adopts a high-strength aluminum alloy tailor-welded structure, and the surface thereof is distributed with complex and diverse weld seam tracks. In addition, the storage tank has the structural characteristics of super large size, poor overall rigidity, and strong local rigidity. The assembly and welding forming of the storage tank is considered as one of the most difficult links in the entire development process of the carrier rocket.

[0003] The new generation of manned carrier rockets have made a great leap in carrying capacity compared with the currently serving carrier rockets. Along with the several-fold increase in carrying capacity, the storage tank of the carrier rocket also presents the characteristics of super length, large thickness, and new structure. The storage tank of the new generation of manned carrier rockets in China has a diameter of Φ5m, a maximum length of nearly 37m, and a welding thickness of more than 20mm. The storage tank structure adopts the latest common-base structure internationally, and the tank body ring seam assembly process has the characteristics of large structure size, weak overall rigidity, strong local rigidity, and complex and difficult assembly and welding.

[0004] In view of the above product structure characteristics and manufacturing difficulties, the welding process needs to adopt advanced friction stir welding technology. However, the horizontal friction stir welding system is not suitable for products with super long size and poor rigidity. The new generation of manned carrier rockets need to break through the traditional mode of manufacturing space storage tanks in the actual production process, and a new vertical storage tank assembly and welding system is invented to meet the needs of product manufacturing. SUMMARY

[0005] The application aims to provide a large-diameter super-long common-base storage tank vertical friction stir welding assembly and welding system, which can realize the overall welding mode of one-time clamping, sequential welding, and in-situ detection, and break through the traditional mode of manufacturing space storage tanks in the actual production process in view of the characteristics of the new generation of manned carrier rockets, such as large size, weak overall rigidity, strong local rigidity, and complex and difficult assembly and welding.

[0006] The technical scheme of the present application is as follows: a large-diameter super-long common-bottom storage tank vertical friction stir welding assembly and welding system, comprising a vertical welding jig, a tank lifting system, an outer clamping ring mechanism, a large-diameter high-precision heavy-load hollow rotary platform, a large-thickness high-strength aluminum alloy heavy-load constant-pressure constant-displacement friction stir welding spindle system, an inner support mechanism, a cylinder segment product feeding system, a tank bottom product feeding system, an in-situ phased array automatic detection system, a control system, and an elevator and safety channel. The vertical welding jig is arranged on a base platform, the side end of the vertical welding jig on the base platform is provided with an elevator and safety channel, the two sides of the vertical welding jig on the base platform are respectively provided with a cylinder segment product feeding system and a tank bottom product feeding system, the tank bottom product feeding system is provided with an inner support mechanism, the in-situ phased array automatic detection system, the control system, the large-diameter high-precision heavy-load hollow rotary platform, and the large-thickness high-strength aluminum alloy heavy-load constant-pressure constant-displacement friction stir welding spindle system are arranged on the large-diameter high-precision heavy-load hollow rotary platform, the outer clamping ring mechanism is arranged in the middle of the outer clamping ring base at the lower part of the vertical welding jig, and the tank lifting system is arranged in the vertical welding jig.

[0007] The vertical welding jig comprises an upper jig layer, an upper outer clamping ring base, an outer clamping ring base support column, a lower outer clamping ring base, and a lower jig layer, the upper jig layer is arranged on the upper outer clamping ring base, the lower part of the upper outer clamping ring base is provided with the outer clamping ring base support column, the outer clamping ring base support column is arranged on the lower outer clamping ring base, and the top of the lower jig layer is arranged on the lower outer clamping ring base.

[0008] The tank lifting system comprises a lifting ring assembly, a lifting ring assembly, a aligning mechanism, a lifting module, a laser ranging generator, and a taper pin, the lifting ring assembly has a disc structure with four protruding parts, each protruding part is fixedly connected with the lifting ring assembly, each protruding part is fixed with the aligning mechanism and a lifting module through the taper pin, and the lower part of the lifting module is provided with the laser ranging generator for part leveling detection.

[0009] The outer clamping ring mechanism comprises an upper outer clamping ring assembly, an outer pressing claw, a lower outer clamping ring assembly, an upper clamping ring moving seat, an upper outer clamping ring lifting driving assembly, an outer pressing claw driving assembly, and a lower outer clamping ring fixed seat, the outer side of the upper clamping ring moving seat is connected with a plurality of upper outer clamping ring lifting driving assemblies, the upper clamping ring moving seat is arranged on the outer pressing claw driving assembly and is driven by the outer pressing claw driving assembly, the outer pressing claw driving assembly is arranged on the lower outer clamping ring fixed seat, and the inner side of the upper clamping ring moving seat is sequentially provided with the upper outer clamping ring assembly, the outer pressing claw, and the lower outer clamping ring assembly.

[0010] The large-diameter high-precision heavy-load hollow rotary platform comprises a large slider assembly, a rotary platform driving assembly, an annular connecting beam, a guide rail base, a small slider assembly, an outer annular guide rail, an inner annular guide rail, a large gear ring, a guide roller assembly and a step platform support, the annular connecting beam is an annular component, a plurality of small slider assemblies are fixed on the upper end surface of the annular connecting beam through the guide roller assembly, the large slider assembly is installed on the upper end surface of the annular connecting beam, the rotary platform driving assembly is installed on both sides of the large slider assembly, the guide rail base is installed in the annular space of the annular connecting beam, the outer annular guide rail and the inner annular guide rail are installed on the guide rail base, the outer annular guide rail and the inner annular guide rail are respectively located on the outer side and the inner side of the annular space of the annular connecting beam, and the large gear ring is installed below the inner annular guide rail on the inner side of the annular space of the annular connecting beam.

[0011] The large-thickness high-strength aluminum alloy heavy-load constant-pressure constant-displacement friction stir welding spindle system comprises an X-axis movement device, a Y-axis movement device, a Y-axis driving device, a large-torque output heavy-load friction stir welding spindle, a stirring head and an A-axis adjusting and locking device, the X-axis movement device is installed on a base, the Y-axis movement device is installed on the X-axis movement device, the Y-axis movement device is driven through the Y-axis driving device, the large-torque output heavy-load friction stir welding spindle is installed on the side surface of the Y-axis movement device, the stirring head is installed on the large-torque output heavy-load friction stir welding spindle, and the A-axis adjusting and locking device is installed on the upper portion of the Y-axis movement device.

[0012] The inner support mechanism comprises a box cylinder segment butt joint fixed inner support device, a cylinder segment common bottom locking bottom welding inner support device and a box sealing welding inner support supporting device.

[0013] The cylinder segment product feeding system comprises a cylinder segment fixed inner support device, an outer sliding box, a pneumatic supporting disc, a pneumatic supporting disc lifting driving device, an outer sliding box base, a movable welding base and a quadrant alignment mechanism, the quadrant alignment mechanism is installed on the lower portion of the movable welding base, the outer sliding box base is installed on the upper portion of the movable welding base, the pneumatic supporting disc lifting driving device is installed on the outer sliding box base, the pneumatic supporting disc is installed on the outer side of the pneumatic supporting disc lifting driving device, the outer sliding box is installed on the upper portion of the outer sliding box base, and the cylinder segment fixed inner support device is installed on the outer sliding box.

[0014] The box bottom product feeding system comprises a common bottom fixed inner support device, an inner sliding box, a middle sliding box, a fixed outer sliding box, a movable welding base, a quadrant alignment mechanism and a detachable box sealing inner support device, the quadrant alignment mechanism is installed in the movable welding base, the fixed outer sliding box is installed on the movable welding base, the middle sliding box is sleeved in the fixed outer sliding box, the inner sliding box is sleeved in the middle sliding box, the detachable box sealing inner support device is installed on the top of the inner sliding box, and the common bottom fixed inner support device is installed below the edge of the detachable box sealing inner support device.

[0015] The beneficial effects of the present application are: 1. The present application proposes a large-diameter common-bottom storage tank friction stir welding assembly welding system suitable for vertical assembly welding mode of the storage tank, according to the analysis of the vertical assembly welding requirement of the storage tank, the system mainly comprises a vertical welding jig, a tank body lifting system, a large-thickness high-strength aluminum alloy friction welding outer clamping ring mechanism, a large-diameter high-precision heavy-load hollow rotary platform, a large-thickness high-strength aluminum alloy heavy-load constant pressure constant displacement friction stir welding spindle system, a large-thickness high-strength aluminum alloy friction welding inner support mechanism, a tank bottom and cylinder segment product feeding system, etc., which can realize the integration of functions such as assembly, welding, detection, repair welding, lifting and unloading in the manufacturing process of the launch vehicle storage tank, meet the development support requirements of the new generation manned launch vehicle 5m diameter ultra-long common-bottom storage tank, and improve the technical level of ultra-long and large-thickness storage tank assembly and friction stir welding in the field of aerospace in China.

[0016] 2. The system is suitable for the following overall process route of large-diameter common-bottom storage tank body ring joint friction stir welding: the vertical assembly welding mode is adopted as a whole, the product is fixed with the inner support tooling system, the welding machine rotates around the product on the system frame to complete the friction stir welding of the product, after welding a ring joint, the product is lifted for the next ring joint welding after detection, and after all the ring joints are welded, the tank body is lifted to the unloading position and is hoisted out for unloading.

[0017] 3. A multi-column form vertical welding jig is provided, which serves as the basis of the tank body vertical assembly welding system, provides support and motion guidance for the parts, the system frame has sufficient rigidity to prevent the occurrence of track deviation and distortion, the opening of the circular arc frame leaves a channel for hoisting and transferring the storage tank, and the hoisting and transferring of the storage tank is realized.

[0018] 4. The split combined tank body lifting system can stably and reliably lift the storage tank product, and has the function of automatically identifying emergency situations and taking braking. The lifting ring assembly also has synchronous lifting motion with the upper clamping ring to realize the function of lifting the cylinder segment (or tank bottom) and the upper tank structure in the welding area. The lifting ring driving device laser ranging leveling device can adjust the parallelism of the lifting ring mounting surface according to the real-time position feedback, ensure that the product is parallel to the reference horizontal plane, and realize automatic leveling of the tank body. The lifting ring centering device can realize the coaxiality of the product lifting ring rotary center and the outer clamping ring pressure block rotary center through the automatic adjustment of the X-direction and Y-direction servo motors, so that the lifting ring has the function of adjusting the concentricity of the storage tank axis and the outer clamping ring axis.

[0019] 5. An external pressure holding ring device for precise control of the pressing force and displacement of the ring seam welding of a tank body, the external ring assembly pressing block being driven by a respective servo motor, with the functions of synchronous pressing and independent driving and adjustment of the pressing, the pressing force being adjustable, the pressing block pressing movement being perpendicular to the product arc surface, and the pressing position being steplessly adjustable within the pressing stroke. The structure of the driving part ensures that the friction resistance torque generated after the external ring assembly presses the product is completely greater than the driving torque applied to the product by the welding machine, thereby ensuring that the product does not rotate relative to the upper and lower external ring assemblies during the entire welding process.

[0020] 6. A large-diameter high-precision heavy-load hollow rotary platform device, which solves the technical problem of precise and stable rotation of a stirring main machine around a large-diameter tank body to complete the stirring and welding of the entire circumference of the tank ring seam in a vertical assembly state. A large-torque output driving device is designed by using an inner-outer double-layer split combined high-precision high-strength bearing steel circumferential motion guide rail, the axial stress depth is increased, the rotation rigidity is strong, and it can resist larger axial and tangential dynamic loads; a double-servo motor anti-backlash device is used, the backlash of the gear is eliminated by adjusting the tensioning torque between the two motors, the positioning accuracy and overall transmission rigidity are improved. The technical problem of precise and stable rotation of a stirring main machine around a large-diameter tank body to complete the stirring and welding of the entire circumference of the tank ring seam in a vertical assembly state is innovatively solved.

[0021] 7. A large-thickness high-strength aluminum alloy heavy-load constant-pressure constant-displacement friction stir welding spindle system structure is proposed, a spindle motor synchronous large-torque output mechanical transmission device is designed, the heavy-load stirring welding power and torque are stably output, the spindle radial feeding is driven by a servo motor ball screw nut, a high-precision pressure sensor and a grating ruler (displacement sensor) are configured to realize constant-pressure constant-displacement full-closed-loop control of the shaft shoulder pressure feeding motion, and the numerical control system realizes the function of real-time adjustment of the spindle axial displacement adjustment. A heavy-load electric servo precise displacement control stirring pin retracting device is designed, a servo torque motor + planetary roller screw suitable for heavy-load working conditions is used for driving, a highly integrated retracting driving device is configured with a high-precision encoder to realize semi-closed-loop control and ensure the retracting servo accuracy, and the weld keyhole is cleaned with high quality. The above system solves the problems of continuous constant heavy load, high rigidity, large torque output, and keyhole-free friction stir welding equipment development in the forming process of thick plate high-strength aerospace aluminum alloy friction stir welding, and realizes high-quality, efficient and reliable automatic welding forming of a new generation of manned launch vehicle fuel tank.

[0022] 8. The inner support mechanism for thick high-strength aluminum alloy stirring welding, the inner support system includes three structural forms, namely, the butt joint of the box cylinder section, the bottom welding of the cylinder section, and the sealing box welding inner support supporting device, each inner support device is used for the whole different butt joint ring seam of the storage box. The intersection surface between the inner support blocks is at a certain angle in the radial direction, and is in the "male and female mold fitting" mode, which can realize the 360° full adhesion of the product inner surface and the back backing plate, and avoid the welding defects caused by the non-adhesion of the back of the welding area. Through the above three sets of inner support systems with different structures, the system can realize one-time clamping and sequential welding, and the product does not need to be reloaded during the period, realizing high-efficiency welding processing of the storage box product.

[0023] 9. The cylinder section product feeding system meets the height lifting locking requirement of the 5m diameter 0-7m long bottomed storage box cylinder section ring seam assembly welding; the feeding system can realize the pre-assembly of the open-type frame outside the cylinder section product and the automatic locking position lifting product loading driving mechanism inside the frame; the mechanism can realize the automatic matching of the 0-7m long cylinder section upper welding area and the fixed inner support backing plate height; a pneumatic inner support positioning clamping device is arranged at the lower welding area of the cylinder section; a double-servo driving quadrant angle automatic alignment mechanism is invented; a three-layer sliding box precise driving guide device is invented, realizing the accurate lifting of the cylinder section product and the fixed inner support as a whole.

[0024] 10. The automatic positioning, clamping and lifting feeding device suitable for the "hat-shaped" bottomed assembly and "bowl-shaped" box bottom assembly in the vertical state. The system can realize the pre-assembly of the open-type frame outside the box bottom product and the automatic locking position lifting product loading driving inside the frame, meets the height lifting locking requirement of the 5m diameter bottomed and front and back bottom ring seam assembly welding; can realize the automatic clamping and positioning of the "hat-shaped" bottomed assembly outside the frame, the lifting of the bottomed assembly and the fixed inner support tool inside the frame to meet the bottomed assembly and cylinder section bottom ring seam welding requirement; can realize the installation and positioning of the "bowl-shaped" box bottom assembly outside the frame, the lifting of the box bottom assembly and the detachable inner support tool inside the frame to meet the box bottom assembly and cylinder section sealing ring seam welding requirement; a double-servo driving quadrant angle automatic alignment mechanism is invented; a three-layer sliding box precise driving guide device is invented, realizing the accurate lifting of the box bottom product and the inner support device as a whole.

[0025] 11. In-situ phased array automatic detection in the system after the welding and polishing operation is completed. The phased array automatic detection device is installed on the rotating platform, the probe device is installed through the column and beam, and the different height welding seam detection function can be realized. After the welding seam is polished, the detection system automatically contacts the welding seam surface through the telescopic shaft, the probe tool is designed as a follow-up, the system automatically detects and collects data, and the telescopic shaft returns to the original position after the detection is completed, so that the online data collection, analysis and report generation can be realized, and therefore the system can realize the in-situ detection of the welding seam and improve the product production and detection efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 A large-diameter super-long common-base tank vertical mixing friction welding assembly and welding system provided by the present application is shown in the general schematic diagram;

[0027] Figure 2 A front view of the vertical welding jig is shown in the diagram;

[0028] Figure 3 A top view of the vertical welding jig is shown in the diagram;

[0029] Figure 4 A schematic diagram of the tank lifting system is shown in the diagram;

[0030] Figure 5 A schematic diagram of the outer clamping ring mechanism is shown in the diagram;

[0031] Figure 6 A large-diameter high-precision heavy-load hollow rotary platform structure diagram is shown in the diagram;

[0032] Figure 7 A large-thickness high-strength aluminum alloy heavy-load constant-pressure constant-displacement friction welding spindle system schematic diagram is shown in the diagram;

[0033] Figure 8 A schematic diagram of the tank cylinder segment butt joint fixing internal support device in the internal support mechanism is shown in the diagram;

[0034] Figure 9 A schematic diagram of the cylinder segment common base locking bottom welding internal support device in the internal support mechanism is shown in the diagram;

[0035] Figure 10 A schematic diagram of the sealing and welding internal support tightening device in the internal support mechanism is shown in the diagram;

[0036] Figure 11 A schematic diagram of the 7m long cylinder segment in the cylinder segment product feeding system is shown in the diagram;

[0037] Figure 12 A schematic diagram of the short cylinder segment in the cylinder segment product feeding system is shown in the diagram;

[0038] Figure 13 A schematic diagram of the common base assembly lifting in the tank bottom product feeding system is shown in the diagram;

[0039] Figure 14 A schematic diagram of the tank bottom assembly lifting in the tank bottom product feeding system is shown in the diagram.

[0040] In the figure: 1 vertical welding jig, 2 box lifting system, 3 outer ring mechanism, 4 large-diameter high-precision heavy-load hollow rotary platform, 5 large-thickness high-strength aluminum alloy heavy-load constant-pressure constant-displacement friction stir welding spindle system, 6 inner support mechanism, 7 cylinder segment product feeding system, 8 box bottom product feeding system, 9 in-situ phased array automatic detection system, 10 control system, 11 elevator and safety passage, 12 upper layer of jig, 13 upper outer ring base, 14 outer ring base support column, 15 lower outer ring base, 16 lower layer of jig, 17 hanging ring assembly, 18 lifting ring assembly, 19 aligning mechanism, 20 lifting module, 21 laser ranging generator, 22 taper pin, 23 upper outer ring assembly, 24 outer pressure claw, 25 lower outer ring assembly, 26 upper ring moving seat, 27 upper outer ring lifting driving assembly, 28 outer pressure claw driving assembly, 29 lower outer ring fixed seat, 30 large slider assembly, 31 rotary platform driving assembly, 32 ring-shaped connecting beam, 33 guide rail base, 34 small slider assembly, 35 outer ring-shaped guide rail, 36 inner ring-shaped guide rail, 37 large gear ring, 38 guide roller assembly, 39 stepped platform support, 40 X-axis movement device, 41 Y-axis movement device, 42 Y-axis driving device, 43 large-torque output heavy-load friction stir welding spindle, 44 stirring head, 45 A-axis adjusting and locking device, 46 cylinder segment inner support base, 47 cylinder segment inner support outer support block assembly, 48 cylinder segment inner support inner support fast assembly, 49 cylinder segment inner support wedge block assembly, 50 common bottom inner support leveling assembly, 51 common bottom inner support inner support fast assembly, 52 common bottom inner support outer support block assembly, 53 common bottom inner support wedge block assembly, 54 common bottom inner support base, 55 boxed inner support lower lifting seat assembly, 56 personnel operation platform assembly, 57 boxed inner support upper support disc, 58 cylinder segment fixed inner support device, 59 outer sliding box, 60 pneumatic support disc, 61 pneumatic support disc lifting driving device, 62 outer sliding box base, 63 movable welding base, 64 quadrant alignment mechanism, 65 common bottom fixed inner support device, 66 inner sliding box, 67 middle sliding box, 68 fixed outer sliding box, 69 movable welding base, 70 quadrant alignment mechanism, 71 detachable boxed inner support device. DETAILED DESCRIPTION

[0041] The application will be described in further detail below in conjunction with the accompanying drawings and specific embodiments.

[0042] The large-diameter super-long common bottom storage tank vertical friction stir welding assembly and welding system provided by the application can realize the overall welding mode of one-time clamping, sequential welding and in-situ detection, and can break through the traditional aerospace storage tank manufacturing mode in the actual production process in view of the characteristics of the new generation manned launch vehicle storage tank, such as large size, weak overall rigidity, strong local rigidity and complex and difficult welding.

[0043] The overall idea of the large-diameter co-bottom storage tank body ring joint friction welding system is a vertical assembly welding mode. The product is fixed and does not rotate with the inner support and external pressing mechanism during welding. The welding machine rotates around the product on the system welding jig to complete the friction welding of the product and realize the welding of the ring joint.

[0044] As shown in Figure 1 A large-diameter super-long co-bottom storage tank vertical friction stir welding assembly welding system, the vertical welding jig is the main support part of the entire system, and four racks are arranged on four columns to provide guidance and driving support for the lifting system. The lifting system can be quickly connected with the product, and the product moves upward as the lifting system rises. The inner support mechanism can be quickly installed on the tank bottom product feeding system, and different inner support mechanisms can be quickly replaced to facilitate the fixation of different tank bottoms on the tank bottom product feeding system. After the tank bottom product is fixed on the tank bottom product feeding system, the tank bottom product feeding system starts to move along the ground rail to the bottom of the vertical welding jig, adjusts the centering, lifts the tank bottom to quickly connect with the lifting system, loosens the inner support mechanism on the tank bottom product feeding system, and lifts the tank bottom product feeding system. The tank bottom product feeding system is lowered and moved out of the vertical jig. The cylinder segment product is installed and fixed on the inner support of the cylinder segment product feeding system, and moves to the bottom of the jig to adjust the centering. The cylinder segment is lifted to the welding position, and the outer wrapping ring system is actuated to tightly hold the cylinder segment on the tank bottom and cylinder segment product feeding system connected with the lifting system. The welding spindle works and starts welding. After one revolution on the rotating platform, the welding spindle stops working, and the welding of the first ring joint is completed. The phased array detector starts working to check the weld quality and decide whether to repair. When the requirements are met, the second weld is confirmed to be correct and the next step is performed. The inner support of the cylinder segment product feeding system is loosened, the outer wrapping ring system is loosened, and the welded product is lifted to the next welding position with the lifting system. The cylinder segment product feeding system is moved out of the vertical jig, the next cylinder segment is assembled and fixed, and then moved back to the bottom of the vertical jig. The centering is adjusted, the cylinder segment is lifted to the welding position, and the outer wrapping ring system is actuated to tightly hold the cylinder segment on the tank bottom and cylinder segment product feeding system connected with the lifting system. The welding spindle works and starts welding. After one revolution on the rotating platform, the welding spindle stops working, and the welding of the second ring joint is completed. The phased array detector starts working to check the weld quality and decide whether to repair. When the requirements are met, the second weld is confirmed to be correct and the next step is performed. The process is repeated until all cylinder segment products and tank bottom products are accurately welded, and the storage tank welding is completed. The lifting ring assembly in the lifting system is separated from the lifting ring assembly, the lifting ring assembly in the lifting system is lifted using the workshop overhead crane, and the storage tank is translated out of the opening of the vertical jig, completing the welding of the storage tank.

[0045] The electrical control system is the most powerful brain of the welding system, and it completes the instruction sending and state detection of all the above-mentioned action steps through preset programs. In addition, the welding system is also equipped with a lifting elevator and a safety passage for the operator to enter the vertical type frame to observe the system state and the system maintenance at any time.

[0046] As shown in Figure 1 , a large-diameter super-long common-bottom tank vertical friction stir welding assembly welding system includes a vertical welding jig 1, a tank lifting system 2, an outer ring mechanism 3, a large-diameter high-precision heavy-load hollow rotary platform 4, a large-thickness high-strength aluminum alloy heavy-load constant-pressure constant-displacement friction stir welding spindle system 5, an inner support mechanism 6, a cylinder segment product feeding system 7, a tank bottom product feeding system 8, an in-situ phased array automatic detection system 9, a control system 10, and an elevator and safety passage 11. The vertical welding jig 1 is installed on a base platform, the elevator and safety passage 11 are installed on the side end of the vertical welding jig 1 on the base platform, the cylinder segment product feeding system 7 and the tank bottom product feeding system 8 are respectively installed on both sides of the vertical welding jig 1 on the base platform, the inner support mechanism 6 is installed on the tank bottom product feeding system 8, the in-situ phased array automatic detection system 9, the control system 10, the large-diameter high-precision heavy-load hollow rotary platform 4, and the large-thickness high-strength aluminum alloy heavy-load constant-pressure constant-displacement friction stir welding spindle system 5 are installed on the lower part of the vertical welding jig 1, the outer ring mechanism 3 is installed at the middle position of the lower part of the vertical welding jig 1, and the tank lifting system 2 is installed on the upper part of the vertical welding jig 1.

[0047] As shown in Figure 2 and 3 , the vertical welding jig 1 is the basis of the tank vertical assembly welding system, and provides support and motion guidance for the parts. In order to ensure that the position distance relationship between the multiple columns does not change, the columns are designed to be connected to form a closed structure, ensuring the rigidity of the frame and preventing the deviation and distortion of the lifting system guide rail. In order to improve the rigidity of the system frame, a multiple column combination form is adopted. It includes a jig upper layer 12, an outer ring base 13, an outer ring base support column 14, a lower outer ring base 15, and a jig lower layer 16. The jig upper layer 12 is installed on the outer ring base 13, the outer ring base support column 14 is installed on the lower outer ring base 15, and the top of the jig lower layer 16 is installed on the lower outer ring base 15.

[0048] Considering the need to hoist and transport the storage tank after welding is completed, the vertical welding jig 1 cannot be completely closed, and the closed structure needs to be cancelled on one side to leave a tank transfer outlet, that is, the opening of the circular arc frame is in the shape of C, serving as a channel for hoisting and transporting. The vertical welding jig 1 body includes two parts, one part is installed between the lower outer ring base and the foundation, used to support and position the entire welding system (except the bed body); the other part is installed on the upper outer ring base, used to support and position the lifting system + product. The two parts are connected by the upper and lower outer ring base structure to form a rigid whole.

[0049] As shown in Figure 4 , the tank lifting system 2 includes a lifting ring assembly 17, a lifting ring assembly 18, a centering mechanism 19, a lifting module 20, a laser ranging generator 21 and a taper pin 22. The lifting ring assembly 17 is a disc-shaped structure with four protruding parts, each of which is fixedly connected with the lifting ring assembly 18. Each protruding part is fixed with a centering mechanism 19 and a lifting module 20 through a taper pin 22, and the lower part of the lifting module 20 is provided with a laser ranging generator 21.

[0050] The function of the lifting ring assembly 18 is to provide driving force for the lifting of the storage tank product, and has the function of automatically identifying emergency situations and taking braking. At the same time, the four lifting modules 20 have the function of adjusting the level of the entire lifting ring. The lifting ring assembly 18 also has the function of synchronous lifting with the upper outer ring to realize the function of sewing the upper tank structure of the welding area with the lower cylinder segment (or tank bottom) of the welding area. The lifting ring assembly is connected with the super-high vertical jig through heavy-load linear guide rails, and can move up and down in the vertical jig structure through high-precision gear and rack drive.

[0051] The laser ranging generator 21 on the lifting ring assembly 18 is installed below the lifting module 20, and the laser receiver is installed on the ground and calibrated during equipment assembly. In this way, the lifting ring can adjust the parallelism and height position of the lifting ring mounting surface according to the real-time position feedback, ensure that the product is parallel to the reference horizontal plane, and realize automatic leveling of the tank end frame (connected with the lifting ring), that is, the axis of the storage tank is perpendicular to the horizontal plane.

[0052] The lifting ring assembly 17 is driven by the lifting ring assembly and directly connected with the storage tank product. The lifting ring assembly 17 is connected with the lifting ring assembly through four centering mechanisms located at the top of the lifting ring. The lifting ring and the lifting ring mechanism are connected through taper pin bolts, which can realize separation of feeding and separation of unloading. The centering device can realize coaxiality of the product lifting ring rotation center and the outer ring pressing block rotation center reference through automatic adjustment of X direction and Y direction servo motors, so that the lifting ring has the function of adjusting the concentricity of the storage tank axis and the outer ring axis.

[0053] After the whole box welding is completed, the lifting system can lift the product to the highest position of the mold frame, so that the lower end of the product is higher than the welding processing area. The overhead crane of the factory is connected with the lifting ring. At this time, the lifting ring assembly and the lifting ring assembly can be separated by loosening the taper pin bolt connection. The lifting ring runs downward on the mold frame to the lower end of the box body. The overhead crane of the factory hoists the lifting ring together with the product to the mold frame.

[0054] As shown in Figure 5 The outer clamping ring mechanism 3 includes an upper outer clamping ring assembly 23, an outer pressing claw 24, a lower outer clamping ring assembly 25, an upper clamping ring moving seat 26, an upper outer clamping ring lifting driving assembly 27, an outer pressing claw driving assembly 28, and a lower outer clamping ring fixed seat 29. The outer side of the upper clamping ring moving seat 26 is connected with a plurality of upper outer clamping ring lifting driving assemblies 27. The upper clamping ring moving seat 26 is installed on the outer pressing claw driving assembly 28 and is driven by the outer pressing claw driving assembly 28. The outer pressing claw driving assembly 28 is installed on the lower outer clamping ring fixed seat 29. The inner side of the upper clamping ring moving seat 26 is sequentially provided with the upper outer clamping ring assembly 23, the outer pressing claw 24, and the lower outer clamping ring assembly 25.

[0055] The outer clamping ring mechanism 3 is driven by respective servo motors, has synchronous pressing and independent driving adjustment pressing functions, the pressing force is adjustable, the pressing direction of the pressing block is perpendicular to the arc surface of the product (the product is pressed in the same direction), and the pressing position is steplessly adjustable within the pressing stroke. The outer pressing mechanism radially presses the outer wall of the cylinder segment of the product by a plurality of outer pressing claw units. Each outer pressing claw is driven by a servo motor to control the lead screw, so that synchronous control and independent control of the plurality of pressing claws can be realized.

[0056] Each outer pressing claw 24 has independent driving adjustment pressing function, the pressing force is adjustable, the pressing direction of the pressing block is perpendicular to the arc surface of the product, and the stroke is 150 mm (satisfying the thickness of 4 mm to 30 mm of the product). The pressing position is steplessly adjustable within the pressing stroke. The displacement control accuracy of the outer pressing claw 24 can reach 0.2 mm.

[0057] The rated output pressure of each outer pressing claw 24 driving part is 80 KN (calculated according to the output torque of the servo motor), the friction resistance torque generated by the cooperation of the outer clamping ring assembly and the inner support pressing device after pressing the product is completely greater than the driving torque applied to the product by the welding machine, so that the relative rotation between the product and the upper and lower outer clamping ring assemblies during the whole welding process is prevented.

[0058] The upper outer clamping ring assembly has a 300 mm lifting capacity and can be linked with the lifting system to realize downward movement to box ring joint and joint force greater than 80 KN. The lifting system of the upper clamping ring realizes linear motion driving through a servo motor + a reducer + a screw lifter + a screw nut seat. A linear guide rail is arranged between the base ring and the moving ring of the upper clamping ring to realize guiding.

[0059] As shown in Figure 6As shown, the large-diameter, high-precision, heavy-duty hollow rotary platform 4 includes a large slider assembly 30, a rotary platform drive assembly 31, an annular connecting beam 32, a guide rail base 33, a small slider assembly 34, an outer annular guide rail 35, an inner annular guide rail 36, a large gear ring 37, a guide roller assembly 38, and a step platform support 39. The annular connecting beam 32 is an annular component, and multiple small slider assemblies 34 are fixed to its upper end face through the guide roller assembly 38. The large slider assembly 30 is installed on the upper end face of the annular connecting beam 32. The rotary platform drive assembly 31 is installed on both sides of the large slider assembly 30. The guide rail base 33 is installed in the annular space of the annular connecting beam 32. The outer annular guide rail 35 and the inner annular guide rail 36 are installed on the guide rail base 33. The outer annular guide rail 35 and the inner annular guide rail 36 are located on the outer and inner sides of the annular space of the annular connecting beam 32, respectively. The large gear ring 37 is installed below the inner annular guide rail 36 on the inner side of the annular space of the annular connecting beam 32.

[0060] The large-diameter, high-precision, heavy-duty hollow rotary platform 4 solves the technical challenge of accurately and stably rotating the mixing host around a large-diameter box in a vertical assembly state to complete the full circumference mixing and welding of the box's circumference seam. It features a double-layered, split-type, high-precision, high-strength bearing steel circumferential motion guide rail and a high-torque output drive device, increasing the axial force depth and rotational rigidity to resist large axial and tangential dynamic loads. It employs a dual-servo motor backlash elimination device, adjusting the tension torque between the two motors to eliminate gear backlash, improving positioning accuracy and overall transmission rigidity. The hollow structure solves the problem of space constraints for motion accommodation. The large-diameter, high-precision, heavy-duty hollow rotary platform 4 is a modular device, installed on the lower outer ring base ring, matching the spatial dimensions of the outer ring to ensure that various movements of the welding machine and the product do not interfere with each other.

[0061] like Figure 7 As shown, the heavy-duty constant pressure constant displacement friction stir welding spindle system 5 of thick, high-strength aluminum alloy includes an X-axis motion device 40, a Y-axis motion device 41, a Y-axis drive device 42, a high-torque output heavy-duty friction stir welding spindle 43, a stirring head 44, and an A-axis adjustment and locking device 45. The X-axis motion device 40 is mounted on a base, and the Y-axis motion device 41 is mounted on the X-axis motion device 40. The Y-axis motion device 41 is driven by the Y-axis drive device 42. The high-torque output heavy-duty friction stir welding spindle 43 is mounted on the side of the Y-axis motion device 41, and the stirring head 44 is mounted on the high-torque output heavy-duty friction stir welding spindle 43. The A-axis adjustment and locking device 45 is mounted on the upper part of the Y-axis motion device 41.

[0062] The heavy load constant pressure constant displacement friction stir welding spindle system 5 of the large thickness high strength aluminum alloy adopts the friction stir welding process to continuously and stably output heavy load pressure and large torque power to maintain the welding process, so the rigidity and torque power output of the spindle system are required to be high, which is the most significant feature distinguishing from other machining processes. The heavy load constant pressure constant displacement friction stir welding spindle system is located on the hollow rotary table, a spindle motor synchronous large torque output mechanical transmission device is designed to realize the stable output of heavy load stirring welding power and torque, the spindle is driven by a servo motor ball screw and nut along the product top radial feed to realize the constant pressure constant displacement full closed loop control of the shaft shoulder pressure feed motion, the high precision pressure sensor and grating ruler (displacement sensor) are configured to realize the function of real-time adjustment of the spindle axial displacement adjustment, the numerical control system realizes the function of real-time adjustment of the spindle axial displacement adjustment. A heavy load electric servo precise displacement control stirring needle retracting device is designed, a servo torque motor + planetary roller screw suitable for heavy load working condition is adopted to realize the driving, and a highly integrated retracting driving device is configured with a high precision encoder to realize semi-closed loop control and ensure the retracting servo precision. During the ring seam welding process of the storage tank, the stirring needle retracting motion and the welding execution mechanism rotating around the ring seam can realize linkage control, the retracting action is smooth without jamming under the stirring condition, the retracting force meets the requirements of 30mm thickness 2219, 2195 and other aerospace high strength aluminum alloy keyhole-free welding, and the keyhole of the weld is removed with high quality. The above system solves the technical problems of continuous constant heavy load, high rigidity, large torque output and keyhole-free friction stir welding in the forming process of thick plate high strength aerospace aluminum alloy friction stir welding, and realizes the high quality, efficient and reliable automatic welding forming of the new generation manned launch vehicle fuel storage tank.

[0063] As shown in Figures 8-10 , the inner support mechanism 6 includes a tank cylinder segment butt joint fixed inner support device, a cylinder segment common bottom locking bottom welding inner support device and a tank sealing welding inner support tightening device.

[0064] As shown in Figure 8 , the tank cylinder segment butt joint fixed inner support device includes a cylinder segment inner support base 46, a cylinder segment inner support outer support block assembly 47, a cylinder segment inner support inner support fast assembly 48 and a cylinder segment inner support wedge block assembly 49. The cylinder segment inner support base 46 is an annular part, a plurality of cylinder segment inner support outer support block assemblies 47 and cylinder segment inner support inner support fast assemblies 48 are installed at the edge of the cylinder segment inner support base 46 in intervals, and a plurality of cylinder segment inner support wedge block assemblies 49 are installed at the lower end of the cylinder segment inner support base 46.

[0065] As shown in Figure 9As shown, the common bottom locking bottom welding inner support device includes a common bottom inner support leveling assembly 50, a common bottom inner support inner support quick assembly 51, a common bottom inner support outer support block assembly 52, a common bottom inner support wedge block assembly 53, and a common bottom inner support base 54. The common bottom inner support base 54 is an annular component, and a plurality of common bottom inner support inner support quick assemblies 51 and common bottom inner support outer support block assemblies 52 are installed at intervals on the edge of the common bottom inner support base 54. A plurality of common bottom inner support leveling assemblies 50 are installed on the outside of the edge of the common bottom inner support base 54, and a plurality of common bottom inner support wedge block assemblies 53 are installed on the lower part of the edge of the common bottom inner support base 54.

[0066] As shown, Figure 10 The box sealing welding inner support tightening device includes a box sealing inner support lower layer lifting seat assembly 55, a personnel operation platform assembly 56, and a box sealing inner support upper layer support disc 57. The box sealing inner support upper layer support disc 57 is installed on the box sealing inner support lower layer lifting seat assembly 55, and the personnel operation platform assembly 56 is installed between the box sealing inner support lower layer lifting seat assembly 55 and the box sealing inner support upper layer support disc 57.

[0067] The inner support system includes three structural forms, namely, the box body cylinder segment butt joint, the cylinder segment common bottom locking bottom welding, and the box sealing welding inner support tightening device. Each inner support device is used for different butt joint ring seams of the whole storage box. The intersection surface between the inner support blocks has a certain angle in the radial direction, and is in a "male and female mold fitting" mode. The theoretical outer diameter of all the inner support blocks after being supported is 1-2 mm larger than the theoretical inner diameter of the storage box product. On the one hand, when the support blocks move to the final state, the gap between the split support blocks is kept at a small position, and on the other hand, the pressing allowance of the product is increased. The inner support has sufficient rigidity and radial micro-adjustment function, can realize 360° full adhesion of the inner surface of the product and the back backing plate, and avoid welding defects caused by the non-adhesion of the back part in the welding area. Through the above three sets of inner support systems with different structures, the system can realize one-time clamping and sequential welding, and the product does not need to be reloaded during the period, realizing high-efficiency welding processing of the storage box product. The inner support system is installed on the cylinder segment or box bottom feeding mechanism described below.

[0068] As shown, Figures 11-12 The cylinder segment product feeding system 7 includes a cylinder segment fixed inner support device 58, an outer sliding box 59, a pneumatic support disc 60, a pneumatic support disc lifting driving device 61, an outer sliding box base 62, a movable welding base 63, and a quadrant alignment mechanism 64. The movable welding base 63 is installed with the quadrant alignment mechanism 64 on the lower part, and the outer sliding box base 62 on the upper part. The outer sliding box base 62 is installed with the pneumatic support disc lifting driving device 61, and the pneumatic support disc lifting driving device 61 is installed with the pneumatic support disc 60 on the outside. The outer sliding box base 62 is installed with the outer sliding box 59 on the upper part, and the outer sliding box 59 is installed with the cylinder segment fixed inner support device 58,

[0069] The cylinder segment product feeding system 7 does not include a movable welding base, a fixed inner stand, an outer sliding box, four outer sliding seats, a pneumatic support disc assembly and a fixed inner support tooling assembly, meets the height lifting and locking requirements of the ring seam assembly and welding of the 5m diameter 0-7m long common bottom storage tank cylinder segment, the feeding system can realize the pre-assembly of the open-type frame outside the cylinder segment product and the automatic locking position lifting product loading driving mechanism inside the frame, the mechanism can realize the automatic matching of the height of the 0-7m long cylinder segment upper welding area and the fixed inner support pad, the cylinder segment lower welding area pneumatic inner support positioning and clamping device is configured, the quadrant angle automatic alignment mechanism of the double servo drive cylinder segment is invented, and the two-layer sliding box precise driving guide device is invented to realize the overall upward precise lifting of the cylinder segment product and the fixed inner support.

[0070] As shown in Figure 13 and 14 , the tank bottom product feeding system 8 includes a common bottom fixed inner support device 65, an inner sliding box 66, a middle sliding box 67, a fixed outer sliding box 68, a movable welding base 69, a quadrant alignment mechanism 70 and a detachable tank sealing inner support device 71, the quadrant alignment mechanism 70 is installed in the movable welding base 69, the fixed outer sliding box 68 is installed on the movable welding base 69, the middle sliding box 67 is sleeved in the fixed outer sliding box 68, the inner sliding box 66 is sleeved in the middle sliding box 67, the detachable tank sealing inner support device 71 is installed on the top of the inner sliding box 66, and the common bottom fixed inner support device 65 is installed below the edge of the detachable tank sealing inner support device 71.

[0071] The tank bottom product feeding system 8 is suitable for the automatic positioning, clamping and lifting of the "hat-shaped" common bottom assembly and the "bowl-shaped" tank bottom assembly in a vertical state. The system can realize the pre-assembly of the open-type frame outside the tank bottom product and the automatic locking position lifting product loading driving inside the frame, meets the height lifting and locking requirements of the ring seam assembly and welding of the 5m diameter common bottom and the front and rear bottom, can realize the automatic clamping and positioning of the "hat-shaped" common bottom assembly outside the frame, lifts the common bottom assembly and the fixed inner support tooling inside the frame to meet the common bottom assembly and the cylinder segment bottom ring seam welding requirements, can realize the installation and positioning of the "bowl-shaped" tank bottom assembly outside the frame, lifts the tank bottom assembly and the detachable inner support tooling inside the frame to meet the tank bottom assembly and the cylinder segment sealing ring seam welding requirements, invents the quadrant angle automatic alignment mechanism of the double servo drive cylinder segment, and invents the three-layer sliding box precise driving guide device to realize the overall upward precise lifting of the tank bottom product and the inner support device.

[0072] In the phase array automatic detection system 9, the system has the function of automatic detection in situ after the polishing work is completed. The phase array automatic detection device is installed on the rotating platform, and the probe device is installed through the column and the beam, which can realize the detection function of different height welds. After the weld is polished, the detection system automatically contacts the telescopic shaft to the surface of the weld to ensure that the coupling is good. The probe tool is designed to follow the movement, and the coupling agent automatic spraying device is installed in front of the probe tool. After the surface is coupled with the weld, the rotating platform is rotated, the rotating platform needs to provide a code signal, the system starts to detect and collect data, and the telescopic shaft returns to the original position after the detection is completed. The phase array automatic detection device includes an ultrasonic phased array detection system and an ultrasonic phased array data acquisition and data analysis system. The interface can realize fast and convenient connection, online data acquisition, analysis and report generation, so that the system can realize in-situ detection of the weld and improve the production and detection efficiency of the product.

Claims

1. A large diameter, ultra-long, co-bonded tank, vertical friction stir welding assembly welding system, characterized by: The application relates to a vertical welding jig, a box lifting system, an outer embracing ring mechanism, a large-diameter high-precision heavy-load hollow rotary platform, a heavy-load constant-pressure constant-displacement friction stir welding spindle system of a high-strength thick aluminum alloy, an inner supporting mechanism, a cylinder segment product feeding system, a box bottom product feeding system, an in-situ phased array automatic detection system, a control system, an elevator and a safety channel, wherein the vertical welding jig is arranged on a base platform, the side end of the vertical welding jig on the base platform is provided with the elevator and the safety channel, the two sides of the vertical welding jig on the base platform are respectively provided with the cylinder segment product feeding system and the box bottom product feeding system, the inner supporting mechanism is arranged on the box bottom product feeding system, the in-situ phased array automatic detection system is arranged on the large-diameter high-precision heavy-load hollow rotary platform, the control system, the large-diameter high-precision heavy-load hollow rotary platform and the heavy-load constant-pressure constant-displacement friction stir welding spindle system of the high-strength thick aluminum alloy, the outer embracing ring mechanism is arranged at the middle position of the outer embracing ring base in the lower part of the vertical welding jig, and the box lifting system is arranged in the vertical welding jig.

2. A system for assembly welding of large diameter, ultra-long common-wall tanks by vertical friction stir welding as defined in claim 1, characterized in that: The vertical welding jig comprises an upper jig layer, an upper outer embracing ring base, an outer embracing ring base supporting column, a lower outer embracing ring base and a lower jig layer, the upper jig layer is arranged on the upper outer embracing ring base, the outer embracing ring base supporting column is arranged on the lower outer embracing ring base, and the top of the lower jig layer is arranged on the lower outer embracing ring base.

3. A system for assembly welding of large diameter, ultra-long common-wall tanks by vertical friction stir welding as defined in claim 1, characterized in that: The box lifting system comprises a lifting ring assembly, a lifting ring assembly, a aligning mechanism, a lifting module, a laser ranging generator and a taper pin, the lifting ring assembly is a disc type structure with four protruding parts, each protruding part is fixedly connected with the lifting ring assembly, each protruding part is fixed with the aligning mechanism and one lifting module through the taper pin, and the lower part of the lifting module is provided with the laser ranging generator.

4. A system for assembly welding of large diameter, ultra-long common-wall tanks by friction stir welding in a vertical position, according to claim 1, characterized in that: The outer embracing ring mechanism comprises an upper outer embracing ring assembly, an outer pressing claw, a lower outer embracing ring assembly, an upper embracing ring moving seat, an upper outer embracing ring lifting driving assembly, an outer pressing claw driving assembly and a lower outer embracing ring fixing seat, the outer side of the upper embracing ring moving seat is connected with a plurality of upper outer embracing ring lifting driving assemblies, the upper embracing ring moving seat is arranged on the outer pressing claw driving assembly and is driven by the outer pressing claw driving assembly, the outer pressing claw driving assembly is arranged on the lower outer embracing ring fixing seat, and the inner side of the upper embracing ring moving seat is sequentially provided with the upper outer embracing ring assembly, the outer pressing claw and the lower outer embracing ring assembly.

5. A system for assembly welding of large diameter, ultra-long common-wall tanks by vertical friction stir welding as defined in claim 1, characterized in that: The large-diameter high-precision heavy-load hollow rotary platform comprises a large slider assembly, a rotary platform driving assembly, an annular connecting beam, a guide rail base, a small slider assembly, an outer annular guide rail, an inner annular guide rail, a large gear ring, a guide roller assembly and a step platform support.

6. A system for assembly welding of large diameter, ultra-long common-wall tanks by vertical friction stir welding as defined in claim 1, characterized in that: The inner support mechanism comprises a box cylinder segment butt joint fixed inner support device, a cylinder segment common bottom locking and welding inner support device and a box sealing welding inner support supporting device.

7. A system for assembly welding of large diameter, ultra-long common-wall tanks by vertical friction stir welding as defined in claim 1, characterized in that: The cylinder segment product feeding system comprises a cylinder segment fixed inner support device, an outer sliding box, a pneumatic supporting disc, a pneumatic supporting disc lifting driving device, an outer sliding box base, a movable welding base and a quadrant alignment mechanism.

8. A system for assembly welding of large diameter, ultra-long common-wall tanks by vertical friction stir welding as defined in claim 1, characterized in that: The box bottom product feeding system comprises a common bottom fixed inner support device, an inner sliding box, a middle sliding box, a fixed outer sliding box, a movable welding base, a quadrant alignment mechanism and a detachable box sealing inner support device.

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