A pipeline all-position welding process parameter optimization device and method

Abstract

This invention provides a device and method for optimizing process parameters in all-position pipeline welding, which can ensure weld formation quality and joint performance, while simplifying welding operations and saving testing costs. It includes a front assembly device, a rear assembly device, a rotary deceleration device, a lifting and attitude adjustment device, a fixing frame, a hydraulic system, and a control system. The front and rear assembly devices are coaxially connected, with one end of the rear assembly device connected to the rotary deceleration device. The fixing frame includes a column and a base plate. The rotary deceleration device is mounted on the column, and the lifting and attitude adjustment device is mounted on the base plate. The lifting and attitude adjustment device is used to adjust the height and angle of the welding torch. The output end of the hydraulic system is connected to both the front and rear assembly devices to provide power. The control end of the control system is connected to the switching units of the rotary deceleration device, the lifting and attitude adjustment device, and the hydraulic system.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of pipeline welding process, in particular to a pipeline all-position welding process parameter optimization device and method. BACKGROUND

[0002] The welding requirement of pipeline girth weld welding belongs to multi-layer multi-pass all-position welding, which is divided into flat welding, vertical welding and overhead welding, and the welding process parameters are different in different positions. The all-position welding process is complex, and the welding specification is difficult to control, so it is difficult to ensure the stability of the weld quality. During the welding process, the pipeline remains stationary at a fixed position, and the welding posture of each layer is from flat welding to vertical welding and then to overhead welding. The welding current, welding voltage and welding speed and other process parameters change with the position, and the appropriate welding process parameters can be adjusted only after multiple welding through welding gun movement (manual or welding trolley).

[0003] In order to ensure the performance and welding quality of the pipeline girth weld joint, process parameter test and process evaluation test need to be carried out during the formal construction of the pipeline. At present, a section of pipeline is usually used to carry out girth welding simulation test after being paired. Since the pipeline is fixed, the lengths of flat welding, vertical welding and overhead welding positions are also limited, and a large number of different position welding tests need to be carried out to find out the appropriate welding process parameters and the welding of process evaluation samples. It consumes a lot of manpower and material resources, the operation is complex, there are many important parameters, and it is impossible to ensure the stability of the weld forming quality and joint performance. SUMMARY

[0004] In order to solve the problems in the prior art, the present application provides a pipeline all-position welding process parameter optimization device and method, which can ensure the weld forming quality and joint performance, simplify the welding operation and save test cost.

[0005] To achieve the above-mentioned purpose, the present application provides the following technical scheme:

[0006] A pipeline all-position welding process parameter optimization device, comprising a front pairing device, a rear pairing device, a rotary speed reduction device, a lifting and posture adjusting device, a fixed frame, a hydraulic system and a control system.

[0007] The front pairing device and the rear pairing device are coaxially connected, one end of the rear pairing device is connected with the rotary speed reduction device, the fixed frame comprises a stand and a bottom plate, the rotary speed reduction device is installed on the stand, the lifting and posture adjusting device is installed on the bottom plate, the lifting and posture adjusting device is used for adjusting the height and angle of the welding gun, the output ends of the hydraulic system are connected with the front pairing device and the rear pairing device respectively for providing power, and the control ends of the control system are connected with the rotary speed reduction device, the lifting and posture adjusting device and the switch unit of the hydraulic system.

[0008] Preferably, the lifting and posture adjusting device comprises a lifting frame, a lifting motor, a lifting screw, a sliding plate, a telescopic beam, a welding gun positioner, a guide pulley and a locking mechanism.

[0009] The bottom of the lifting frame is fixed on one side surface of the bottom plate, one side of the lifting frame is connected with the lifting screw, and the bottom of the lifting frame is provided with the lifting motor connected with the lifting screw. The lifting screw is in sliding connection with the sliding plate, one end of the sliding plate is provided with the guide pulley and the locking mechanism, the telescopic beam is installed on the guide pulley, the telescopic direction of the telescopic beam is perpendicular to the sliding direction of the sliding plate, and one end of the telescopic beam is provided with the welding gun positioner.

[0010] Preferably, the front pairing device comprises a front pairing disc, a front hydraulic cylinder, a front cage, a front supporting rod and a front guide wheel.

[0011] The tail end of the front pairing disc is provided with the front hydraulic cylinder, the front cage is coaxially connected with the front pairing disc, the front pairing disc is circumferentially distributed with a plurality of pairs of front supporting rods, the plurality of pairs of front supporting rods form an umbrella-shaped structure, the connecting end points of the front supporting rods are connected with the piston rods of the front hydraulic cylinder, and the front cage is circumferentially distributed with a plurality of groups of front guide wheels.

[0012] The rear pairing device comprises a rear pairing disc, a rear hydraulic cylinder, a rear cage, a rear supporting rod and a rear adjusting rod.

[0013] The head end of the rear pairing disc is provided with the rear hydraulic cylinder, the rear cage is coaxially connected with the rear pairing disc, the rear pairing disc is circumferentially distributed with a plurality of pairs of rear supporting rods, the plurality of pairs of rear supporting rods form an umbrella-shaped structure, the connecting end points of the rear supporting rods are connected with the piston rods of the rear hydraulic cylinder, and the rear cage is circumferentially distributed with a plurality of groups of rear adjusting rods.

[0014] Preferably, the front pairing disc and the rear pairing disc are both in a horn-shaped structure, and the front cage and the rear cage are both in a cylindrical support.

[0015] Preferably, the front guide wheel is provided with two groups, and the two groups of front guide wheels are perpendicular to each other.

[0016] Preferably, the rear adjusting rod is provided with two groups, and the two groups of rear adjusting rods are perpendicular to each other.

[0017] Preferably, the hydraulic system is connected with the front pairing device and the rear pairing device in sequence through a hydraulic pump and a hydraulic pipe, and a rotatable joint is arranged in the middle of the hydraulic pipe.

[0018] Preferably, the control system comprises an input unit, and the input unit is used for inputting basic information of a pipeline to be welded, and the basic information comprises pipeline material, wall thickness, welding process and groove shape.

[0019] A pipeline all-position welding process parameter optimization method, comprising the following steps:

[0020] Starting the hydraulic system, placing the pipeline to be welded on the front set of aligning devices and the rear set of aligning devices, adjusting the placement position of the pipeline to be welded and fixing;

[0021] Fixing the welding torch on the lifting and posture adjusting device, and adjusting the lifting and posture adjusting device to make the welding torch be at the corresponding welding position according to different welding position requirements;

[0022] The control system sets the welding parameters according to the current welding position;

[0023] The control system controls the starting hydraulic system and the rotary speed reducer to perform welding, and adjusts the welding parameters according to the arc stability and the weld forming condition during the welding process until the weld forming meets the processing requirements;

[0024] The control system saves the welding parameters of the current welding position, and completes the welding process parameter optimization at the current welding position;

[0025] The above steps are repeated to continue welding at the next welding position until the welding process parameter optimization at all welding positions is completed.

[0026] Preferably, the welding parameters include the rotary speed, the welding current, the welding voltage and the welding torch swing mode.

[0027] Compared with the prior art, the present application has the following beneficial effects:

[0028] The present application provides a pipeline all-position welding process parameter optimization device, which fixes the pipeline to be welded on the front set of aligning devices and the rear set of aligning devices, changes the difficulty of keeping the pipeline in a fixed position in the traditional way, adopts the cooperation of the pipeline and the welding torch, adjusts the rotary speed of the pipeline through the rotary speed reducer and adjusts the position of the welding torch through the lifting and posture adjusting device, can realize welding at any position of the pipeline girth weld, and can adjust the welding current, the welding voltage and other welding process parameters in real time through the control system according to the observed weld forming quality during the welding process, so as to obtain reasonable welding process and quickly obtain optimized all-position welding process parameters.

[0029] Furthermore, the lifting and posture adjustment device described in this invention is used to adjust the welding height, welding posture, and angle of the welding torch during welding. Specifically, the lifting frame is vertically mounted on one side of the base plate of the fixed frame to maintain the overall stability of the lifting and posture adjustment device. A lifting screw is installed in the middle of the lifting frame, and a lifting motor connected to the lifting screw is installed at the bottom of the lifting frame. The lifting motor provides power to the lifting and posture adjustment device. The sliding plate is mounted on the lifting screw and can slide along the columns of the fixed frame on both sides of the lifting frame. When the lifting motor is running, the lifting screw rotates to raise and lower the sliding plate and the telescopic beam, thereby adjusting the vertical height of the welding torch. One end of the sliding plate is equipped with a guide wheel and a locking mechanism. The telescopic beam is mounted on the guide wheel, and the locking mechanism can fix and lock the telescopic beam to maintain stability. The guide wheel can be used to adjust the position of the telescopic beam, and the telescopic beam is set in a direction perpendicular to the sliding direction of the sliding plate, allowing it to extend and retract horizontally. One end of the telescopic beam is equipped with a welding torch positioner for placing the welding torch. The welding torch positioner can rotate at any angle in the vertical plane to adjust the posture and angle of the welding torch, thereby enabling welding of any position of the pipe circumferential weld, optimizing the welding process parameters in all positions, and is simple and feasible to operate.

[0030] Furthermore, the front and rear assembly devices of the present invention are used to place and fix the pipe to be welded, and the pipe itself is rotated by rotating the front and rear assembly devices, overcoming the welding difficulty caused by the pipe being fixed. The front and rear assembly devices are coaxially connected, and one end of the rear assembly device is connected to a rotary deceleration device to achieve synchronous rotation of the front and rear assembly devices. In addition, the welding process parameter optimization device of the present invention can be used to optimize the welding process parameters of pipes with various diameters and wall thicknesses in all positions by replacing the front and rear support rods of different heights. It has a wide range of applications. Using the device of the present invention can not only ensure the weld formation quality and joint performance, but also save a lot of test costs and manpower. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of the pipe all-position welding process parameter optimization device of the present invention;

[0032] Figure 2 This is a schematic diagram illustrating the adjustment of the welding torch height and posture position according to the present invention;

[0033] Figure 3 This is a schematic diagram of the structure of the front assembly device of the present invention;

[0034] Figure 4 This is a schematic diagram of the structure of the rear assembly device of the present invention;

[0035] Figure 5 This is a schematic diagram of the lifting and posture adjustment device of the present invention.

[0036] In the diagram, 1. Front assembly device; 1-1. Front assembly disc; 1-2. Front hydraulic cylinder; 1-3. Front cage frame; 1-4. Front strut; 1-5. Front guide wheel;

[0037] 2. Rear assembly device; 2-1. Rear assembly disc; 2-2. Rear hydraulic cylinder; 2-3. Rear cage frame; 2-4. Rear support rod; 2-5. Rear adjusting rod;

[0038] 3. Rotational speed reduction device;

[0039] 4. Lifting and posture adjustment device; 4-1. Lifting frame; 4-2. Lifting motor; 4-3. Lifting screw; 4-4. Slide plate; 4-5. Telescopic beam; 4-6. Welding torch positioner; 4-7. Guide pulley; 4-8. Locking mechanism;

[0040] 5. Fixing frame; 5-1. Upright; 5-2. Base plate;

[0041] 6. Hydraulic system; 7. Control system. Detailed Implementation

[0042] The present invention will be further described in detail below with reference to specific embodiments. These descriptions are for explanation purposes only and are not intended to limit the scope of the invention.

[0043] like Figure 1 As shown, the present invention provides a pipeline all-position welding process parameter optimization device, which includes a front assembly device 1, a rear assembly device 2, a rotary deceleration device 3, a lifting and attitude adjustment device 4, a fixing frame 5, a hydraulic system 6, and a control system 7.

[0044] The front assembly device 1 and the rear assembly device 2 are coaxially connected. One end of the rear assembly device 2 is connected to the rotary speed reducer 3. The fixed frame 5 includes a column 5-1 and a base plate 5-2. The rotary speed reducer 3 is installed on the column 5-1. The lifting and posture adjustment device 4 is installed on the base plate 5-2. The lifting and posture adjustment device 4 is used to adjust the height and angle of the welding torch. The output end of the hydraulic system 6 is connected to the front assembly device 1 and the rear assembly device 2 respectively to provide power. The control end of the control system 7 is connected to the switching unit of the rotary speed reducer 3, the lifting and posture adjustment device 4 and the hydraulic system 6 respectively.

[0045] This invention provides a device for optimizing process parameters for all-position welding of pipelines. The pipeline to be welded is fixed on the front assembly device 1 and the rear assembly device 2 described in this invention. This overcomes the difficulty of traditional methods where the pipeline remains stationary. By employing a combined approach of the pipeline and welding torch, the pipeline rotation speed is adjusted via a rotary deceleration device 3, and the welding torch position is adjusted via a lifting and posture adjustment device 4. This allows for welding at any position of the circumferential weld seam. Simultaneously, during the welding process, based on the observed weld formation quality, the welding current, welding voltage, and other welding process parameters can be adjusted in real time via a control system 7 to obtain a reasonable welding process and quickly achieve optimized all-position welding process parameters. In actual pipeline welding process planning, the pipeline's rotational speed is simply converted into the linear velocity at the welding bevel and set as the actual travel speed of the welding carriage. This allows for the rapid acquisition of optimized welding process parameters, which, together with the measured and displayed welding current and welding voltage parameters, serve as the optimized process parameters for actual all-position pipeline welding.

[0046] Furthermore, such as Figure 5 As shown, the lifting and attitude adjustment device 4 includes a lifting frame 4-1, a lifting motor 4-2, a lifting screw 4-3, a sliding plate 4-4, a telescopic beam 4-5, a welding torch positioning platform 4-6, a guide pulley 4-7, and a locking mechanism 4-8.

[0047] The lifting frame 4-1 is fixed at its bottom to one side of the base plate 5-2. A lifting screw 4-3 is connected to one side of the lifting frame 4-1. A lifting motor 4-2 connected to the lifting screw 4-3 is provided on one side of the bottom of the lifting frame 4-1. One end of the lifting screw 4-3 is slidably connected to the slide plate 4-4. One end of the slide plate 4-4 is provided with a guide pulley 4-7 and a locking mechanism 4-8. A telescopic beam 4-5 is installed on the guide pulley 4-7. The telescopic direction of the telescopic beam 4-5 is perpendicular to the sliding direction of the slide plate 4-4. One end of the telescopic beam 4-5 is provided with a welding torch positioning platform 4-6, which is used to place the welding torch.

[0048] The lifting and posture adjustment device 4 described in this invention is used to adjust the welding height, welding posture, and angle of the welding torch during welding. Specifically, the lifting frame 4-1 is vertically mounted on one side of the base plate 5-2 of the fixed frame 5 to maintain the overall stability of the lifting and posture adjustment device 4. A lifting screw 4-3 is provided at the middle position of the lifting frame 4-1, and a lifting motor 4-2 connected to the lifting screw 4-3 is provided at the bottom of the lifting frame 4-1. The lifting motor 4-2 provides power to the lifting and posture adjustment device 4. The sliding plate 4-4 is mounted on the lifting screw 4-3 and can slide along the columns 5-1 on both sides of the lifting frame 4-1. When the lifting motor 4-2 is running, the lifting screw 4-3 rotates to raise and lower the sliding plate 4-4 and the telescopic beam 4-5, thereby realizing the adjustment of the vertical position of the welding torch. One end of the sliding plate 4-4 is equipped with a guide pulley 4-7 and a locking mechanism 4-8. The telescopic beam 4-5 is mounted on the guide pulley 4-7. The locking mechanism 4-8 can fix and lock the telescopic beam 4-5 to maintain stability. The guide pulley 4-7 can be used to adjust the position of the telescopic beam 4-5. The telescopic beam 4-5 is set in a direction perpendicular to the sliding direction of the sliding plate 4-4, and can extend and retract in the horizontal direction. One end of the telescopic beam 4-5 is equipped with a welding torch positioning platform 4-6 for placing the welding torch. The welding torch positioning platform 4-6 can rotate at any angle in the vertical plane to adjust the posture and angle of the welding torch, thereby realizing welding at any position of the pipe circumferential weld, optimizing the welding process parameters in all positions, and is simple and feasible to operate.

[0049] Furthermore, such as Figure 3 As shown, the front assembly device 1 of the present invention includes a front assembly disc 1-1, a front hydraulic cylinder 1-2, a front cage frame 1-3, a front row support rod 1-4, and a front guide wheel 1-5;

[0050] The front set of discs 1-1 is provided with a front hydraulic cylinder 1-2 at its tail end. The front cage 1-3 is coaxially connected to the front set of discs 1-1. The front set of discs 1-1 is circumferentially distributed with multiple pairs of front row support rods 1-4. The multiple pairs of front row support rods 1-4 form an "inverted umbrella" type linkage structure as the frame of the umbrella. The connecting end of the front row support rods 1-4 is connected to the piston rod of the front hydraulic cylinder 1-2. The front cage 1-3 is circumferentially distributed with multiple sets of front guide wheels 1-5.

[0051] like Figure 4 As shown, the rear assembly device 2 includes a rear assembly disc 2-1, a rear hydraulic cylinder 2-2, a rear cage frame 2-3, a rear support rod 2-4, and a rear adjusting rod 2-5;

[0052] The rear pair of discs 2-1 is provided with a rear hydraulic cylinder 2-2 at its first end. The rear cage frame 2-3 is coaxially connected to the rear pair of discs 2-1. The rear pair of discs 2-1 is circumferentially distributed with multiple pairs of rear support rods 2-4. The multiple pairs of rear support rods 2-4 form an "inverted umbrella" type linkage structure as the frame of the umbrella. The connecting end of the rear support rods 2-4 is connected to the piston rod of the rear hydraulic cylinder 2-2. The rear cage frame 2-3 is circumferentially distributed with multiple sets of rear adjustment rods 2-5.

[0053] The front assembly device 1 and rear assembly device 2 of this invention are used to place and fix the pipe to be welded, and the pipe itself is rotated by rotating the front assembly device 1 and rear assembly device 2, thus overcoming the welding difficulty caused by the pipe being fixed. The front assembly device 1 and rear assembly device 2 are coaxially connected, and one end of the rear assembly device 1 is connected to the rotary deceleration device 3 to achieve synchronous rotation of the front assembly device 1 and rear assembly device 2. In addition, the welding process parameter optimization device of this invention can be used to optimize the welding process parameters of pipes with various diameters and wall thicknesses in all positions by replacing the front row support rods 1-4 and the rear row support rods 2-4 with different heights. It has a wide range of applications. Using the device of this invention can not only ensure the weld formation quality and joint performance, but also save a lot of test costs and manpower.

[0054] Preferably, the front pair of discs 1-1 and the rear pair of discs 2-1 are both trumpet-shaped structures, and the front cage frame 1-3 and the rear cage frame 2-3 are both cylindrical supports.

[0055] In this embodiment, the front guide wheels 1-5 are provided in two sets. The two sets of front guide wheels 1-5 are evenly distributed in the circumferential direction of the middle part of the front cage 1-3. The two sets of front guide wheels 1-5 are perpendicular to each other. One set is located in the vertical direction and the other set is located in the horizontal direction (the vertical direction is the height direction of the welding gun. Based on this, the horizontal direction is the plane perpendicular to the direction of the welding gun's lifting).

[0056] In this embodiment, there are eight pairs of front row support rods 1-4, which are evenly distributed around the front group disc 1-1.

[0057] In this embodiment, the rear adjustment rod 2-5 is provided in two sets. The two sets of rear adjustment rods 2-5 are evenly distributed in the circumferential direction of the middle part of the rear cage 2-3. The two sets of rear adjustment rods 2-5 are perpendicular to each other, with one set located in the vertical direction and the other set located in the horizontal direction.

[0058] In this embodiment, there are eight pairs of rear support rods 2-4, which are evenly distributed around the rear assembly disc 2-1.

[0059] Furthermore, the hydraulic system 6 is connected to the front assembly device 1 and the rear assembly device 2 in sequence through a hydraulic pump and hydraulic pipes, and is used to provide the required power to the front hydraulic cylinder 1-2, the rear hydraulic cylinder 2-2, the front guide wheel 1-5, and the rear adjusting rod 2-5. The hydraulic pipes are provided with a rotatable joint in the middle, which facilitates the corresponding rotational position adjustment according to the position setting.

[0060] Furthermore, the control system 7 includes an input unit for inputting basic information about the pipe to be welded, including pipe material, wall thickness, welding process, and bevel shape. In this invention, the control system 7 can control the start and stop of the rotary reduction device 3, the lifting motor 4-2, and the hydraulic system 6, thereby achieving synchronous rotation of the front assembly device 1 and the rear assembly device 2. Simultaneously, it controls the extension and retraction of the front support rod 1-4, the front guide wheel 1-5, the rear support rod 2-4, and the rear adjusting rod 2-5, as well as the lifting and lowering of the welding torch and the posture adjustment device 4. Furthermore, by inputting the basic information about the pipe to be welded through a programmer, it adjusts the rotation speed of the rotary reduction device 3 in real time, thereby adjusting the rotation speed of the pipe to be welded.

[0061] This invention also provides a method for optimizing process parameters of all-position welding of pipelines, comprising the following steps:

[0062] Start the hydraulic system 6, place the pipe to be welded on the front assembly device 1 and the rear assembly device 2, adjust the position of the pipe to be welded and fix it.

[0063] The welding torch is fixed on the lifting and posture adjustment device 4. According to different welding position requirements, the lifting and posture adjustment device 4 is adjusted to make the welding torch in the corresponding welding position. The telescopic beam 4-5 in the lifting and posture adjustment device 4 is locked by the locking mechanism 4-8 in the lifting and posture adjustment device 4.

[0064] Control system 7 sets welding parameters based on the current welding position;

[0065] The control system 7 controls the start of the hydraulic system 6 and the rotary deceleration device 3 to perform welding. During the welding process, the welding parameters are adjusted according to the arc stability and weld formation until the weld formation meets the processing requirements.

[0066] The control system 7 saves the welding parameters of the current welding position and optimizes the welding process parameters at the current welding position.

[0067] Repeat the above steps to continue welding at the next welding position until the welding process parameters at all welding positions have been optimized.

[0068] The welding parameters include: rotation speed, welding current, welding voltage, and welding torch oscillation mode.

[0069] The specific implementation steps of the pipeline all-position welding process parameter optimization device of the present invention are as follows:

[0070] The first step is to adjust the height of the front strut 1-4, rear strut 2-4, front guide wheel 1-5, and rear adjusting rod 2-5. Adjust the height of these components to an appropriate level, within their effective travel range, based on the diameter of the steel pipe.

[0071] The second step is the installation and assembly of the steel pipes. The steel pipes are divided into two sections, namely pipe section A and pipe section B. Start the hydraulic system 6. First, pass pipe section A, with its welded bevel, through the front cage 1-3 and place it on the rear cage 2-3. Adjust the position of pipe section A using the rear adjusting rod 2-5 so that the bevel end face of pipe section A is at the junction of the front assembly plate 1-1 and the rear assembly plate 2-1. Press the lifting button on the rear support rod 2-4 to fix pipe section A. Next, place pipe section B, with its welded bevel, on the front cage 1-3. Adjust pipe section B to a suitable relative position with pipe section A using the front guide wheel 1-5. Press the lifting button on the front support rod 1-4 to fix pipe section B.

[0072] The third step is to adjust the height and posture of the welding torch. First, fix the welding carriage on the welding torch positioner 4-6, start the lifting motor 4-2, and use the lifting screw 4-3, sliding plate 4-4 and telescopic beam 4-5 in the lifting and posture adjustment device 4 to raise the welding torch to a certain welding position (such as the flat welding position). Then, adjust the angle of the welding torch positioner 4-6 so that the welding torch is in the corresponding welding posture position, and lock the telescopic beam 4-5 with the locking mechanism 4-8.

[0073] The fourth step is to initially set the welding parameters. Based on the position to be welded, initially set parameters such as rotation speed, welding current, welding voltage, and welding torch oscillation mode.

[0074] Step 5: Optimize welding process parameters. Control system 7 starts the welding power supply and the power supply to the rotary deceleration device 3, then presses the welding start button. During welding, based on the stability of the arc and the weld formation, adjust parameters such as rotation speed, welding current, welding voltage, and welding torch oscillation appropriately until the weld formation achieves satisfactory results. Record and save the welding parameters at that welding position, and continue welding until reaching the starting position, thus completing the optimization of the process parameters for one weld.

[0075] Step 6: Repeat steps 3 to 5 to continue optimizing the welding process parameters for vertical welding, overhead welding, or other clock positions.

[0076] Example

[0077] Taking the optimization of process parameters for all-position automatic welding of circumferential welds in a Φ1219×22.0mmX80 pipe as an example.

[0078] The first step is to adjust the height of the front strut 1-4, rear strut 2-4, front guide wheel 1-5, and rear adjusting rod 2-5. By adding shims or replacing the front strut 1-4 and rear strut 2-4, the distance between the tops of each set of symmetrical struts after they are extended to their maximum height should be 1219mm (i.e., the outer diameter of the pipe), and the initial distance between the center-symmetrical front guide wheel 1-5 and rear adjusting rod 2-5 should be 1165mm (i.e., the outer diameter of the steel pipe - 2 times the wall thickness - 5mm).

[0079] The second step is the installation and assembly of the steel pipes. Start the hydraulic system 6. First, pass the pre-welded beveled section A through the front cage 1-3 and place it on the rear cage 2-3. Adjust the position of section A using the rear adjusting rod 2-5 so that the beveled end face of section A is at the junction of the front and rear assembly plates. Press the lifting button on the rear support rod 2-4 to fix section A. Next, place the pre-welded beveled section B on the front cage 1-3. Adjust section B to a suitable relative position with section A using the front guide wheel 1-5. Press the lifting button on the front support rod 1-4 to fix section B.

[0080] The third step is to adjust the height and posture of the welding torch. First, fix the welding carriage on the welding torch positioner 4-6, start the lifting motor 4-2, and use the lifting screw 4-3, sliding plate 4-4 and telescopic beam 4-5 in the lifting and posture adjustment device 4 to raise the welding torch to the flat welding position (12 o'clock to 2 o'clock position), and adjust the angle of the welding torch positioner 4-6 so that the welding torch is in the corresponding welding posture position.

[0081] The fourth step is to initially set the welding parameters. Based on the position to be welded, the rotation speed, welding current, welding voltage, and welding torch oscillation mode are initially set. Table 1 shows the initial welding parameters for the 5th weld pass of the filler layer in the flat welding position.

[0082] Table 1 Preliminary welding parameters for the 5th weld pass of the filler layer at the flat weld position

[0083]

[0084] Step 5: Welding process parameter optimization. Control system 7 starts the welding power supply and the rotary deceleration device 3, then presses the welding start button. During welding, based on the stability of the arc and the weld formation, adjust parameters such as rotation speed, welding current, welding voltage, and welding torch oscillation appropriately until the weld formation achieves satisfactory results. Record and save the welding parameters for the flat welding position, and continue welding until the welding start position is reached, completing the process parameter optimization for one weld. Table 2 shows the optimized welding parameters for the 5th weld pass of the filler layer at the flat welding position.

[0085] Table 2. Optimized welding parameters for the 5th weld pass of the filler layer at the flat weld position.

[0086]

[0087] Step 6: Repeat steps 3 to 5 to optimize the welding process parameters for vertical welding, overhead welding, or other clock positions.

[0088] A comparison of the data in Tables 1 and 2 shows that, after adopting the welding process optimization device and method described in this invention, the values ​​of various welding process parameters, such as wire feeding speed, rotation speed, and welding torch oscillation speed, have been improved to a certain extent. This enables the optimization of weld formation quality and joint performance, while simplifying welding operations and further improving welding efficiency.

[0089] To achieve the above objectives, the main technical means adopted in this invention are described clearly, completely, and accurately, and the substantive content of the invention is explained. The degree of disclosure is such that it is sufficient for a person skilled in the art to understand and implement the invention.

Claims

1. A device for optimizing process parameters of all-position welding of pipelines, characterized in that, It includes a front assembly device (1), a rear assembly device (2), a slewing deceleration device (3), a lifting and attitude adjustment device (4), a fixed frame (5), a hydraulic system (6), and a control system (7); The front assembly device (1) and the rear assembly device (2) are coaxially connected. One end of the rear assembly device (2) is connected to the rotary deceleration device (3). The fixed frame (5) includes a column (5-1) and a base plate (5-2). The rotary deceleration device (3) is installed on the column (5-1). The lifting and posture adjustment device (4) is installed on the base plate (5-2). The lifting and posture adjustment device (4) is used to adjust the height and angle of the welding torch. The output end of the hydraulic system (6) is connected to the front assembly device (1) and the rear assembly device (2) respectively to provide power. The control end of the control system (7) is connected to the switching unit of the rotary deceleration device (3), the lifting and posture adjustment device (4) and the hydraulic system (6) respectively. The lifting and attitude adjustment device (4) includes a lifting frame (4-1), a lifting motor (4-2), a lifting screw (4-3), a sliding plate (4-4), a telescopic beam (4-5), a welding torch positioner (4-6), a guide pulley (4-7), and a locking mechanism (4-8). The lifting frame (4-1) is fixed at its bottom to one side of the base plate (5-2). A lifting screw (4-3) is connected to one side of the lifting frame (4-1). A lifting motor (4-2) connected to the lifting screw (4-3) is provided on one side of the bottom of the lifting frame. The lifting screw (4-3) is slidably connected to the slide plate (4-4). One end of the slide plate (4-4) is provided with a guide pulley (4-7) and a locking mechanism (4-8). A telescopic beam (4-5) is installed on the guide pulley (4-7). The telescopic direction of the telescopic beam (4-5) is perpendicular to the sliding direction of the slide plate (4-4). One end of the telescopic beam (4-5) is provided with a welding torch positioning platform (4-6). The welding torch positioning platform (4-6) is used to place the welding torch. The front assembly device includes a front assembly disc (1-1), a front hydraulic cylinder (1-2), a front cage frame (1-3), a front strut (1-4), and a front guide wheel (1-5). The front set of discs (1-1) is provided with a front hydraulic cylinder (1-2) at its tail end. The front cage (1-3) is coaxially connected to the front set of discs (1-1). The front set of discs (1-1) is circumferentially distributed with multiple pairs of front row support rods (1-4). The multiple pairs of front row support rods (1-4) form an umbrella-shaped structure. The connecting end of the front row support rods (1-4) is connected to the piston rod of the front hydraulic cylinder (1-2). The front hydraulic cylinder (1-2) and the front cage (1-3) are circumferentially distributed with multiple sets of front guide wheels (1-5). The rear assembly device (2) includes a rear assembly plate (2-1), a rear hydraulic cylinder (2-2), a rear cage frame (2-3), a rear support rod (2-4), and a rear adjustment rod (2-5). The rear pair of discs (2-1) is provided with a rear hydraulic cylinder (2-2) at its first end. The rear cage frame (2-3) is coaxially connected to the rear pair of discs (2-1). The rear pair of discs (2-1) is circumferentially distributed with multiple pairs of rear support rods (2-4). The multiple pairs of rear support rods (2-4) form an umbrella-shaped structure. The connecting end of the rear support rods (2-4) is connected to the piston rod of the rear hydraulic cylinder (2-2). The rear cage frame (2-3) is circumferentially distributed with multiple sets of rear adjusting rods (2-5).

2. The device for optimizing pipeline welding process parameters according to claim 1, characterized in that, The front pair of discs (1-1) and the rear pair of discs (2-1) are both horn-shaped structures, and the front cage frame (1-3) and the rear cage frame (2-3) are both cylindrical supports.

3. The device for optimizing pipeline welding process parameters according to claim 1, characterized in that, The front guide wheel (1-5) is provided in two sets, and the two sets of front guide wheels (1-5) are perpendicular to each other.

4. The device for optimizing pipeline welding process parameters according to claim 1, characterized in that, The rear adjustment rod (2-5) is provided in two sets, and the two sets of rear adjustment rods (2-5) are perpendicular to each other.

5. The device for optimizing pipeline welding process parameters according to claim 1, characterized in that, The hydraulic system (6) is connected to the front assembly device (1) and the rear assembly device (2) in sequence through a hydraulic pump and a hydraulic pipe, wherein a rotatable joint is provided in the middle of the hydraulic pipe.

6. The device for optimizing pipeline welding process parameters according to claim 1, characterized in that, The control system (7) includes an input unit, which is used to input various basic information of the pipe to be welded, including: pipe material, wall thickness, welding process and bevel shape.

7. A method for optimizing process parameters of all-position welding of pipelines, characterized in that, The optimized apparatus based on any one of claims 1-6 includes the following steps: Start the hydraulic system (6), place the pipe to be welded on the front assembly device (1) and the rear assembly device (2), adjust the position of the pipe to be welded and fix it; The welding torch is fixed on the lifting and posture adjustment device (4). According to different welding position requirements, the lifting and posture adjustment device (4) is adjusted to make the welding torch in the corresponding welding position. The control system (7) sets the welding parameters according to the current welding position; The control system (7) controls the start of the hydraulic system (6) and the rotary deceleration device (3) to perform welding. During the welding process, the welding parameters are adjusted according to the arc stability and weld formation until the weld formation meets the processing requirements. The control system (7) saves the welding parameters of the current welding position and completes the optimization of the welding process parameters at the current welding position; Repeat the above steps to continue welding at the next welding position until the welding process parameters at all welding positions have been optimized.

8. The method for optimizing pipeline welding process parameters according to claim 7, characterized in that, The welding parameters include: rotation speed, welding current, welding voltage, and welding torch oscillation mode.

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