Flange copying positioning welding tool and welding method for large-diameter steel pipe

Abstract

A flange copying positioning welding tool for large diameter steel pipe comprises a support roller frame pair (10) and a female flange frame pair (20), the support roller frame pair (10) is used for supporting the steel pipe in the axial direction of the steel pipe with a span L mm, a steel pipe is placed on the support roller frame pair (10), the levelness H of the steel pipe is adjusted to meet H <= 0.03 mm / L mm, and a standard flange (1) is spot-welded and positioned at both ends of the steel pipe respectively, the female flange frame pair (20) is fixedly installed on the steel pipe with a distance S in the axial direction outside the steel pipe based on the perpendicularity and horizontal axis of the standard flange (1). The flange copying positioning welding tool for large diameter steel pipe and the welding method have high flange positioning precision, are convenient for on-site operation, do not need to pay attention to the levelness of the foundation, and are suitable for steel pipes with any section.

Description

Technical Field

[0001] This invention relates to the field of steel pipe flange welding, specifically to a flange replication and positioning welding fixture and welding method for large-diameter steel pipes. Background Technology

[0002] Steel pipes with a diameter of DN500 or larger are called large-diameter steel pipes. The accuracy of flange connections for large-diameter steel pipes is a prerequisite for the straight installation of long-distance prefabricated pipelines in a single on-site installation. The accuracy of steel pipe flange connections includes: ① Perpendicularity of the flange to the pipe's rotation axis. This perpendicularity ensures the entire pipeline can be installed in a straight line and guarantees the tightness of the flange gap. In special cases, when the pipeline pressure is high and the required service life is long, metal gaskets are usually used between the flanges at both ends. Metal gaskets have poor elasticity and, unlike rubber gaskets, cannot compensate for insufficient perpendicularity between the flange and the pipe. Therefore, the perpendicularity requirement between the flange and the pipe's rotation axis is even higher. Large-diameter steel pipes with a diameter of DN500 or larger have a large diameter, and both the flange and the pipe are heavy. The alignment and welding processes of the flange and the pipe can easily affect the perpendicularity between the flange and the pipe. ② Concentricity of the flange and the pipe end, i.e., the annular gap between them must be uniform. This annular gap is the width of the subsequent weld. If the annular gap is uneven, the weld will be narrow where the gap is small and wide where the gap is large, or even unable to form a continuous weld, resulting in a positioning failure and scrap.

[0003] Existing technologies for welding flanges to large-diameter steel pipes typically employ specialized machine tools. These tools include a fixed seat and a sliding seat that slide relative to each other on a horizontal guide rail. A ring clamp for fixing the flange is mounted on the sliding seat, ensuring the flange is perpendicular to the horizontal guide rail after installation. For example, Nippon Steel Corrosion Protection Co., Ltd. disclosed a steel pipe flange welding device (JP Patent Application Publication No. 8-174282A, Publication Date: July 9, 1996). The machine tool 3 has a horizontal guide rail 4, with fixed seats 2a and movable seats 2b on both sides, respectively, positioned on the guide rail 4. Seats 2a and 2b vertically fix clamping panels 1a and 1b. The flange 31 is fixed to the clamping panels 1a and 1b, ensuring it is perpendicular to the guide rail 4. The steel pipe 30 is then hoisted onto support rollers 5a and 5b. Then, the center axis is aligned, and the lifting handwheel 12 is operated to align the steel pipe 30, horizontally supported on the left and right rollers 5a and 5b, with the center of the left and right panels 1a and 1b. ② The flange is positioned at the center, and the two protrusions 15 are respectively inserted into the two radially opposite bolt holes 32 of the end flange 31. The end flange 31 is attracted and supported on the front surface of the panel 1 by the magnet 19; ③ At the end, the fixed bases 2a and 2b move towards the end of the steel pipe, so that the gasket 20 installed on the front surface of the fixed side plates 1a and 1b contacts the thick end face of the steel pipe 30. As a result, the flange 31 is positioned at a right angle to the outer periphery of the edge of the steel pipe 30, and the flange center hole 31a protrudes outward by the thickness of the gasket 20 compared to the end face of the steel pipe 30 to form an inner weld 34. Obviously, it is impossible to have such a closely level guide rail on the installation site. The above-mentioned steel pipe flange welding device must be completed with the help of professional machine tools and high-level guide rails. If it is used for on-site installation, professional transportation equipment is required, and a level installation foundation must be made and the on-site installation must be completed. The cost is high, and the location cannot be changed at will.

[0004] There are also flanges that are welded by hand. The disadvantages of hand welding of flanges are: a) inaccurate positioning; b) positioning and welding quality vary from person to person, are unstable and difficult to control.

[0005] Therefore, there is an urgent need in this field for a welding fixture for steel pipe end flanges that can quickly and accurately position the perpendicularity of the end flange to the steel pipe axis at the pipeline installation site, reducing the skill requirements and labor intensity of operators. This is a pressing problem that needs to be solved in the field of steel pipe end flange welding. Summary of the Invention

[0006] To address the shortcomings of the existing technology, the present invention aims to provide a flange replication positioning welding fixture and welding method for large-diameter steel pipes, solving the technical problem of "achieving high-precision, simple and quick positioning of the end flange perpendicular to the steel pipe axis at the pipeline installation site, reducing the skill requirements and labor intensity of operators."

[0007] The objective of this invention is achieved by providing a flange replication and positioning welding fixture for large-diameter steel pipes, comprising:

[0008] A pair of support rollers is used to support the steel pipe in a straight-moving manner along the axis of the steel pipe with a span of Lmm; a steel pipe is placed on the pair of support rollers, and the levelness H of the steel pipe is adjusted to meet H≤0.06mm / Lmm; a standard flange is spot-welded to each end of the steel pipe for positioning.

[0009] The female flange pair is fixedly installed at both ends of the steel pipe with an axial outward displacement distance S, based on the verticality and horizontal axis of the standard flange.

[0010] Furthermore, the mother flange frame includes a vertical back integrated component, a mother flange, and a fixing frame. The vertical back integrated component includes a vertically integrated vertical support beam and a back beam. The fixing frame is hinged at both ends of the vertical support beam, allowing the vertical back integrated component to be rotated and adjusted in a vertical plane.

[0011] Furthermore, the fixed frame includes a horizontal support beam, and fulcrum blocks and tail telescopic seats are provided perpendicular to the horizontal support beam at intervals. The fulcrum blocks are fixed between the horizontal support beam and the vertical support beam. The extension and retraction of the tail telescopic seats can allow the vertical support beam to rotate around the fulcrum blocks in the vertical plane, thereby allowing the back beam to gradually press against the mother flange.

[0012] Furthermore, the self-adjusting level includes a main body of the same length as the span, a glass tube containing liquid and air bubbles, a scale in the middle of the glass tube, a support rod slidably mounted on one end of the main body perpendicular to the extension direction of the main body, a screw pair connected to one end of the support rod, and a scale on the side of the support rod indicating its length extending out of the main body, with the scale unit being mm / Lmm.

[0013] Furthermore, the main body is mounted on the positioning frame pair. The bottom surface of the positioning frame pair has an abutting arc surface with the same radius as the outer circumference of the steel pipe. The side surface of the positioning frame pair has a horizontal level. When the abutting arc surface of the positioning frame pair abuts against the top of the steel pipe and the bubbles of the front and rear horizontal levels are both located at the middle scale, the glass tube axis of the self-adjusting level is parallel to the axis of the steel pipe and located at the highest point of the steel pipe.

[0014] Furthermore, the support roller frame includes a support steel beam, two inclined support seats are fixedly installed on the support steel beam, the roller seats are installed perpendicular to the inclined plane, and the roller seats are equipped with support rollers. The rotation of the support rollers can make the steel pipe move linearly left and right along the axial direction.

[0015] Furthermore, the support roller frame also includes a central positioning beam, which includes an end abutment section that abuts against the support steel beams laterally and a side positioning section that presses against the top surface of the support steel beams. The central positioning beam has a central surface π1 perpendicular to the centerline of the cross-section. The straight-line installation and positioning of the support roller frame is achieved as follows: the support roller frame fixes the central positioning beam between two sets of parallel support steel beams according to the span Lmm, and the side positioning surfaces of the two inclined support seats are fixed to the top surface of the support steel beams by abutting the side positioning sections, ensuring that the front and rear support rollers of the support roller frame are symmetrically arranged on both sides of the central positioning rod, and ensuring that the axis of the steel pipe is coplanar with the central surface π1.

[0016] Furthermore, the vertical backrest assembly includes a vertical triangular frame and a backrest triangular frame. The backrest triangular frame is vertically connected to the support side of the vertical triangular frame. A fulcrum block is of the same length as the support side and is rotatably supported below the support side. A bottom positioning beam extends outward perpendicularly to the support side. The apex of the vertical triangular frame opposite to the support side is supported on the tail telescopic seat. Positioning protrusions are provided at both ends of the fulcrum block, and the support side is rotatably supported on the positioning protrusions. Positioning bosses are provided at the three corners of the backrest triangular frame. The perpendicularity of the plane containing the positioning bosses to the top surface of the bottom positioning beam is less than or equal to 0.01.

[0017] A welding positioning method using a flange replication positioning welding fixture for the large-diameter steel pipe.

[0018] S1, fixed support roller frame pair, standard flange fabrication;

[0019] The support roller frame is fixed in the same straight line, the steel pipe is hoisted onto the support roller frame, and the levelness H of the steel pipe is adjusted to meet H≤0.06mm / Lmm;

[0020] Standard flanges are welded at both ends of the steel pipe to ensure that the perpendicularity of the plane of the standard flange to the axis of the steel pipe is less than 0.01, and at the same time, the concentricity of the standard flange and the steel pipe is ensured.

[0021] S2, using the verticality and horizontal axis of the standard flange as a reference, fix and install the mother flange frame pair, and hoist the standard steel pipe off the production line;

[0022] S3, Copy the positioning of the mother flange

[0023] A mating flange F is fixedly connected to the female flange of the two female flange brackets using connecting bolts;

[0024] The steel pipes are hoisted to the support roller frame pair;

[0025] Move the steel pipe to the left until it stops at the limit block at the end, spot weld the left-side flange in place, and loosen the connecting bolts; move the steel pipe to the right until it stops at the limit block at the end, place at least 3 shims between the outer circumference of the steel pipe and the inner hole of the flange F to adjust the concentricity, spot weld the right-side flange in place; loosen the connecting bolts and lift the steel pipe away.

[0026] S4, the steel pipe is hoisted and lowered to the full welding operation area for full welding operation;

[0027] S5, repeat steps S3 and S4.

[0028] The welding positioning method using the flange replication positioning welding fixture of the large-diameter steel pipe, wherein the fixing and installation of the mother flange frame with the verticality and horizontal axis of the standard flange as a reference includes the following steps.

[0029] S31, Standard flange and mother flange are fixedly connected by overlapping.

[0030] The boss ring face of the mother flange abuts against the boss ring face of the standard flange, which is tightly connected to the ground by multiple connecting bolts, and moves outward a distance S along the axial direction together with the steel pipe W.

[0031] S32, fabricate a vertical back piece

[0032] The back beam is welded to the top surface of the vertical support beam. At the same time, the top surface of the end of the vertical support beam and the front surface of the back beam are ground to finish the horizontal reference surface A and the abutment surface B, so that the perpendicularity of the abutment surface B relative to the horizontal reference surface A is less than or equal to 0.01.

[0033] S33, Fixed female flange pair

[0034] a. Calculate the height of the fulcrum block and manufacture the fulcrum block according to this height;

[0035] b. Fix the horizontal support beam and the tail telescopic seat

[0036] A horizontal support beam is fixed approximately perpendicular to the steel pipe axis direction by offsetting the back beam thickness outward in the direction directly below the mother flange. A fulcrum block is fixed on the top surface of the middle part of the horizontal support beam, and a tail telescopic seat is fixed along the steel pipe axis direction by a span of Lmm.

[0037] c. Fixed vertical back integrated component

[0038] The vertical support beam of the vertical backrest assembly is fixedly connected to the fulcrum block and the top surface of the tail telescopic seat. The height of the tail telescopic seat is adjusted, and the vertical support beam is rotated with the top surface of the fulcrum block as the fulcrum until the abutment surface B of the backrest beam is completely in contact with the plane ring surface of the mother flange. The height of the tail telescopic seat is locked, and the vertical support beam is fixed to the tail telescopic seat. At the same time, the mother flange is welded and fixed to the abutment surface of the backrest beam.

[0039] Compared with existing technologies, the flange replication positioning welding fixture and welding method for large-diameter steel pipes can be assembled and fixed on-site, achieving high positioning accuracy of flange welding positioning at extremely low cost. This reduces the skill requirements and labor intensity of operators, resulting in extremely high efficiency, and is applicable to steel pipes of any cross-section. Attached Figure Description

[0040] Figure 1 This is a main sectional view of Embodiment 1 of the flange replication positioning welding fixture for large-diameter steel pipes according to the present invention;

[0041] Figure 2 This is a left view of the support roller frame 10 of Embodiment 1 of the flange replication positioning welding fixture for a large-diameter steel pipe according to the present invention.

[0042] Figure 3 This is a front sectional view of the support roller frame 10 of an embodiment 1 of a flange replication positioning welding fixture for a large-diameter steel pipe according to the present invention.

[0043] Figure 4 This is a main sectional view of another example of the support roller frame 10 of the flange replication positioning welding fixture for a large-diameter steel pipe according to the present invention.

[0044] Figure 5 This is a front sectional view of the middle positioning beam 16 in another example of the support roller frame pair 10 of the flange replication positioning welding fixture for a large-diameter steel pipe according to the present invention.

[0045] Figure 6 This is a left view of the mother flange frame 20 in Embodiment 1 of the flange replication positioning welding fixture for a large-diameter steel pipe according to the present invention.

[0046] Figure 7 This is a main sectional view of the support roller frame 10 of Embodiment 1 of the flange replication positioning welding fixture for large-diameter steel pipes of the present invention.

[0047] Figure 8 This is a main sectional view of the height-adjustable support roller frame 10 of an embodiment 1 of a flange replication positioning welding fixture for a large-diameter steel pipe according to the present invention.

[0048] Figure 9 This is a schematic diagram of step S1 of an embodiment 1 of the flange replication positioning welding fixture for a large-diameter steel pipe according to the present invention;

[0049] Figure 10 This is a partial sectional view of Embodiment 2 of the flange replication positioning welding fixture for large-diameter steel pipes according to the present invention;

[0050] Figure 11 This is a front view of Embodiment 2 of the flange replication positioning welding fixture for large-diameter steel pipes according to the present invention.

[0051] The reference numerals in the above figure:

[0052] 10. Support roller frame pair; 11. Support steel beam; 12. Inclined support seat; 13. Roller assembly; 14. Support roller; 15. Support busbar; 16. Center positioning beam; 17. Strip level; 18. Laser emitter; 19. Laser receiver.

[0053] 20. Female flange bracket pair; 21. Vertical back integrated piece; 22. Female flange; 23. Fixing bracket; 24. Horizontal support beam; 25. Support block; 26. Tail telescopic seat; 27. Diagonal brace; 28. Connecting bolt; 29. ​​Limiting block.

[0054] 21.1 Vertical support beam, 21.2 Backing beam, 21.3 Concave arc surface, 25.1 Circular arc top surface, Nut 35.1, 35.2 Threaded rod

[0055] 30 Telescopic base, 31 Support platform, 32 Support ramp, 33 Inclined slide, 34 Slider seat, 35 Screw pair, 36 Rotary handwheel

[0056] F-type flange, W-type steel pipe, π1 mid-plane Detailed Implementation

[0057] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings, but are not intended to limit the scope of the present invention.

[0058] Example 1

[0059] A flange replication positioning welding fixture for large-diameter steel pipes, including

[0060] A support roller pair 10 is used to support the steel pipe linearly along its axis with a span of L mm. A steel pipe is placed on the support roller pair 10, and the pipe's horizontality H is adjusted to satisfy H≤0.06mm / Lmm. A standard flange 1 is spot-welded to both ends of the steel pipe for positioning. The span L satisfies: L≥0.5L. 管 , where L 管 The length of the steel pipe;

[0061] The female flange pair 20 is fixedly installed at both ends of the steel pipe by an outward displacement distance S, with the verticality and horizontal axis of the standard flange 1 as the reference.

[0062] The verticality and horizontal axis of standard flange 1 are used as a reference to achieve the following:

[0063] The mother flange bracket 20 includes a vertical back integral component 21, a mother flange 22, and a fixing bracket 23. The vertical back integral component 21 includes a vertically integrated vertical support beam 21.1 and a back support beam 21.2. The mother flange 22 is fixedly connected to the standard flange 1. The vertical back integral component 21 is positioned by the plane ring surface and center line of the mother flange 22 and placed on the top surface of the fixing bracket 23 for support and fixation to the foundation.

[0064] The support roller frame pair 10 includes support steel beams 11 and a central positioning beam 16. The central positioning beam 16 includes an end abutment section 16.1 that abuts laterally between the support steel beams 11, a side positioning section 16.2 that presses against the top surface of the support steel beams 11, and a connecting part 16.3 located between the support roller frames. The central positioning beam 16 has a central surface π1 perpendicular to the centerline of its cross-section. Two inclined support seats 12 are symmetrically arranged on the top surfaces of the two support steel beams 11 along both sides of the central surface π1. Roller assemblies 13 are installed perpendicular to the inclined top surfaces of the inclined support seats 12. Roller shafts are rotatably arranged parallel to the inclined surfaces within the roller assemblies 13. Support rollers 14 are fixed to the roller shafts. The support rollers 14 include convex arc roller surfaces, and the highest point of the roller surface forms a support generatrix 15. The support generatrix 15 is symmetrically arranged on both sides of the central surface π1, that is, two roller assemblies 13 are symmetrically arranged on both sides of the central surface π1 of the support rollers 14. The rotation of the support roller 14 enables the steel pipe to move linearly left and right along the axial direction. The central positioning beam 16 only serves to position the central surface π1 and does not function as a force-applying structural component.

[0065] In the cross-section of the support roller pair 10, the included angle between the straight lines from the center of the steel pipe to the contact point of the support roller 14 is the support angle β, where β ≥ 60°. Two support roller pairs 10 are spaced apart on the foundation, one of which is fixed and the other is height-adjustable. A strip-type level 17 with the same span as the two support roller pairs 10 is provided at the top of the steel pipe to adjust the levelness of the steel pipe.

[0066] The height-adjustable support roller frame 10 replaces the support steel beam 11 with a telescopic base 30. The telescopic base 30 includes a support platform 31, the bottom of which has two support inclined surfaces 32. Each of the two support inclined surfaces 32 has an inclined slide rail 33, and a slider seat 34 is slidably mounted on the inclined slide rail 33. The two slider seats 34 are connected to the same helical pair 35, which is driven by a rotating handwheel 36. The helical pair 35 includes a nut 35.1 and a screw 35.2. The screw 35.2 is fixedly connected to the rotating handwheel 36.

[0067] The straight-line installation and positioning of the support roller frame 10 is completed before the leveling installation. The straight-line fixed installation is achieved as follows: the support roller frame 10 fixes the center positioning beam 16 between two sets of parallel support steel beams 11 and the support roller 14 according to the span Lmm. The side positioning surfaces of the two inclined support seats 12 are fixed to the top surface of the support steel beam 11 by abutting the side positioning section 16.2. This ensures that the front and rear support rollers of the support roller frame 10 are symmetrically arranged on both sides of the center positioning rod 16, ensuring that the axis of the steel pipe is coplanar with the center plane π1, while reducing the parallelism requirement of the support steel beam 11.

[0068] For the positioning design of the vertical back integral component to the mother flange:

[0069] The fixed frame 23 includes a horizontal support beam 24 fixedly installed on the foundation perpendicular to the axis of the steel pipe. Support blocks 25 and tail telescopic seats 26 are spaced perpendicular to the horizontal support beam. The support blocks 25 are fixed to the top surface of the middle part of the horizontal support beam 24. The top surface of the front end of the vertical support beam 21.1 has a horizontal reference surface A. The surface of the back beam 21.2 facing the axis of the steel pipe has an abutment surface B. Both the horizontal reference surface A and the abutment surface B are ground to ensure that the perpendicularity of the abutment surface B relative to the horizontal reference surface A is less than or equal to 0.01. The vertical support beam 21.1 of the vertical back beam 21 overlaps the top surfaces of the support blocks 25 and the tail telescopic seats 26. The support blocks 25 are hinged structures, including an upper support block and a lower support block, which are connected by a pivot hinge. A diagonal brace 27 is fixed between the top of the back beam 21.2 and the tail of the vertical support beam 21.1. The abutment surface B of the back beam 21.2 is integrally welded with a female flange 22. The lower part of the female flange 22 abuts against the horizontal reference plane A of the vertical support beam 21.1, thereby achieving the abutment. The height H of the fulcrum block 25 is calculated to satisfy H. 支 =H 母 -S 竖 -S 横 H 母 S is the height of the lowest point of the female flange 22 from the foundation. 竖 S represents the Z-axis thickness of the vertical support beam, and S represents the Z-axis thickness of the horizontal support beam 24. Preferably, diagonal braces 27 are fixedly connected to both sides of the vertical I-beam 21.1 and both ends of the horizontal support beam 24. Multiple flange fixing holes are provided on the female flange 22 corresponding to the flange fixing holes. That is, the female flange 22 is positioned by tightly fitting against the upper and lower points of the beam.

[0070] More preferably, the vertical support beam 21.1 and the back beam 21.2 are two perpendicular triangular frames sharing a support edge. Each triangular frame has three positioning points at its three vertices. The perpendicularity between the plane containing the three positioning points of the vertical support beam 21.1 and the plane containing the three positioning points of the back beam 21.2 is less than or equal to 0.01. Two support blocks 25 are provided, each supporting a bottom positioning beam with a flange extending outward perpendicular to the support edge. The vertex of the vertical support beam 21.1 opposite to the support edge is supported by the tail telescopic seat 26.

[0071] The standard flange 1, the female flange 22, and the mating flange F are all the same flange component, each including a planar annular surface 2 and a boss annular surface 3 in the axial direction. The supporting steel beam 11, the horizontal supporting beam 24, the vertical supporting beam 21.1, and the backrest beam 21.2 are all standard I-beams.

[0072] Three limiting blocks 29 are fixedly connected to the inner circumferential wall of the mother flange 22. Each limiting block 29 protrudes from the annular surface 3 of the boss by a clearance distance S1. When the mating flange F is fixedly connected to the mother flange 22 in a stacked manner, when the steel pipe moves along its axial direction and its end abuts against the limiting block 29, the end of the steel pipe enters the inner hole of the mating flange F by a fixed distance. The fixed connection between the mating flange F and the mother flange 22 is configured such that their annular surfaces 3 abut against each other, and the connecting bolts 28 pass through the flange fixing holes 22.1 and are tightened with nuts.

[0073] The installation process of fixing the mother flange to flange 20 with the verticality and horizontal axis of standard flange 1 as the reference is as follows:

[0074] ①Standard flange 1 and female flange 22 are fixedly connected by overlapping.

[0075] The boss ring face of the female flange 22 abuts against the boss ring face of the standard flange and is fixedly connected by multiple connecting bolts 28, and moves outward a distance S along the axial direction together with the steel pipe W.

[0076] ② Fabricate a vertical back piece

[0077] The back beam 21.2 is welded to the top surface of the vertical support beam 21.1. At the same time, the top surface of the end of the vertical support beam and the front surface of the back beam are ground to finish the horizontal reference surface A and the abutment surface B, so that the perpendicularity of the abutment surface B to the horizontal reference surface A is less than or equal to 0.01.

[0078] ③Fixed female flange for 20

[0079] a. Calculate the height of the fulcrum block 25 and manufacture the fulcrum block 25 according to this height;

[0080] b. Fix the horizontal support beam and the tail telescopic seat

[0081] A horizontal support beam 24 is fixed approximately perpendicular to the direction of the steel pipe axis by offsetting the back beam thickness from the direction directly below the mother flange. A fulcrum block 25 is fixed on the top surface of the middle part of the horizontal support beam 24. A tail telescopic seat 26 is fixed along the direction of the steel pipe axis by a span of Lmm.

[0082] c. Fixed vertical back integrated component

[0083] The vertical support beam 21.1 of the vertical backrest integrated component is fixedly connected to the fulcrum block 25 and the tail telescopic seat 26. The height of the tail telescopic seat 26 is adjusted, and the vertical support beam 21.1 is rotated with the top surface of the fulcrum block 25 as the fulcrum until the abutment surface B of the backrest beam 21.2 is completely in contact with the plane annular surface of the mother flange 22. The height of the tail telescopic seat 26 is locked, and the vertical support beam 21.1 is fixed to the tail telescopic seat 26. At the same time, the mother flange 22 is welded and fixed to the abutment surface of the backrest beam 21.2.

[0084] Alternatively, the tail telescopic seat 26 can be replaced with a fulcrum block 25, which is a cylinder or cuboid of a certain height. The two fulcrum blocks 25 are then attached to the front and rear ends of the vertical support beam 21.1 and welded together for fixation.

[0085] The large-diameter steel pipe refers to a steel pipe with a diameter greater than or equal to Ф500mm.

[0086] A method for flange replication and positioning welding of large-diameter steel pipes includes the following steps.

[0087] S1, same as the linear fixed support roller frame 10, standard flange 1 made.

[0088] The support roller frame 10 is fixedly installed in the same straight line. The steel pipe is hoisted onto the support roller frame 10 and the levelness H of the steel pipe is adjusted to meet H≤0.06mm / Lmm.

[0089] Standard flanges are welded at both ends of the steel pipe to ensure that the perpendicularity of the plane of the standard flange to the axis of the steel pipe is less than 0.01, and at the same time, the concentricity of the standard flange and the steel pipe is ensured.

[0090] S2, using the verticality and horizontal axis of standard flange 1 as a reference, fix and install the mother flange bracket 20, and hoist the standard steel pipe off the line;

[0091] S3, Copy the positioning of the mother flange

[0092] A mating flange F is fixedly connected to the female flange 22 of the two female flange brackets 20 using connecting bolts 28;

[0093] The steel pipe is hoisted to the support roller frame 10;

[0094] The steel pipe is moved to the left until it reaches the limit block at the end, and the left-side connecting flange is spot-welded in place. The connecting bolts are then loosened. The steel pipe is moved to the right until it reaches the limit block at the end, and at least three shims are placed between the outer circumference of the steel pipe and the inner hole of the connecting flange F to adjust concentricity. The right-side connecting flange is spot-welded in place, and the connecting bolts are then loosened. The automation of the left or right movement of the steel pipe is achieved by connecting a motor to one of the support roller pairs 10 to drive the support roller 14 to rotate. That is, one of the support roller pairs 10 is the driving roller, and the other is the driven roller.

[0095] S4, the steel pipe is hoisted and lowered to the full welding operation area for full welding operation;

[0096] S5, repeat steps S3 and S4.

[0097] In step S1, the horizontality H of the steel pipe axis is ensured to be H≤0.06mm / Lmm by a bar level, the perpendicularity of the annular plane of the standard flange to the steel pipe axis is less than or equal to 0.01 by a plumb line, and the concentricity of the flange and the steel pipe is ensured by a gasket placed between the standard flange and the steel pipe.

[0098] Before spot welding in step S3, there is a step S31 to adjust the concentricity. Step S31 includes setting at least 3 shims between the outer periphery of the steel pipe and the inner hole of the connecting flange F when the gap between the outer periphery of the steel pipe W and the inner hole of the connecting flange F is not uniform.

[0099] The steel pipe is preferably a spiral welded pipe. The maximum diameter is 500 mm or greater, and the span L of the support roller frame is greater than or equal to 2 / 3 of the span L. The standard spiral welded pipe length is 12 meters, and the span L of the support roller frame is at least 8 meters.

[0100] Example 2

[0101] The positioning of the additional support roller frame for the straight-line fixed installation of 10 is the same as in Example 1.

[0102] A flange replication and positioning welding fixture for large-diameter steel pipes includes a laser emitter 18 on the inclined support seat 12 of the support roller assembly 13 of the other support roller assembly 10. The laser emitter 18 automatically adjusts its level and emits a horizontal beam tangentially to the support busbar 15. A laser receiver 19 is positioned at the corresponding location on the inclined support seat 12 of the other support roller assembly 13 of the support roller assembly 10 where the laser beam strikes. The laser receiver 19 is a reflective surface perpendicular to the horizontal plane. Two laser emitters 18 and two laser receivers 19 are provided corresponding to the two inclined support seats 12 of the two support roller assemblies 13.

[0103] The steel pipe leveling is achieved as follows: the laser emitter 18 emits a laser beam 18.1 horizontally, and the laser beam 18.1 is simultaneously tangent to the support generatrix 15 of the front and rear support rollers of the support roller frame pair 10, which means that the support rollers are level, that is, the steel pipe is level.

[0104] The support roller pair is fixedly installed in a straight line as follows: the laser emitter 18 emits a laser beam 18.1 horizontally tangentially to the support busbar 15, and the infrared beams 18.1 from the two infrared emitters 18 are simultaneously received by the two infrared receivers 19. The support roller pair 10 also includes a control device and an alarm. If either one fails to receive a signal, it indicates that the fixed installation in a straight line cannot be achieved, and the control device triggers the alarm to sound.

[0105] Due to the weight of the steel pipe, the impact on the support roller frame 10 is significant, especially on the roller shaft of the support roller assembly. When the roller shaft deforms slightly while the steel pipe is moving forward, the roundness of the support roller rotation will be deformed. At a certain position on the support busbar, the infrared ray 146 will be blocked and cannot be received by the corresponding infrared receiver 19, triggering an alarm. After the alarm, the deformed support roller assembly should be replaced entirely or only the roller shaft should be replaced. The horizontality of the steel pipe should be readjusted to ensure that both infrared rays 18.1 are received simultaneously. The standard flange 1 should be manually repositioned, and its axis and perpendicularity should be copied to the mother flange 22. Then, the mother flange should be re-fixed to the mother flange frame 20 so that the positioning of the butt flange F can be copied to the mother flange and welded to the end of the new steel pipe.

[0106] The flange replication positioning welding fixture and welding method for the large-diameter steel pipe solves the technical problem of "achieving high-precision, simple, and rapid positioning of the flange perpendicular to the steel pipe axis under the premise of on-site installation, reducing the skill requirements and labor intensity of operators" by abandoning the positioning method of large slide rail machine tools and adopting the following inventive points:

[0107] (1) Replication and positioning of the mating flange

[0108] The support roller frame positions the horizontal axis of the 10 positioning steel pipe, and the mother flange frame positions the 20 replica standard flange 1. At the same time, it completes the verticality positioning and concentricity positioning of the flange perpendicular to the steel pipe axis, achieving the goal in one go and reducing the difficulty of operation.

[0109] The support roller frame 10 is installed and positioned in a straight line. After the steel pipe is supported by the support roller frame, the level is adjusted to meet the requirement of H≤0.06mm / spanLmm. The support roller frame 10 positions the axis of the steel pipe. The female flange frame 20 is fixedly installed at both ends of the steel pipe. The female flanges are opposite to the standard flanges and fixed to the female flange frame 20 with the verticality and horizontal axis of the standard flanges as the reference. When installing flanges on each steel pipe, it is only necessary to stack the mating flange F opposite to the female flange 22, copy the axis of the female flange 22 and the perpendicularity of the annular plane perpendicular to the axis of the steel pipe to the mating flange F, hoist the steel pipe to the support roller frame 10, move it to the mating flange F, and perform spot welding.

[0110] The bubble level has an accuracy of 0.03 mm per division, and the 0.06 mm accuracy is achieved because the length is relatively long, and even a small adjustment would have a significant impact. Example 2 improves upon this by using an electronic laser level, which does not measure the steel pipe itself, but rather measures whether the support points of the front and rear support rollers are level, resulting in higher accuracy and better operability.

[0111] (2) The support busbars of the two support rollers are simultaneously calibrated by a horizontal laser beam to achieve straight-line fixed installation and horizontal leveling.

[0112] In Example 1, the steel pipe is adjusted to be absolutely horizontal using a bubble level, and the inclined support seat 12 of the two roller assembly 13 simultaneously abuts against both sides of the central positioning beam 16 to achieve a straight-line fixed installation.

[0113] In Example 2, two laser levels 18 simultaneously emit horizontal laser beams 18.1, with each laser beam 18.1 tangent to the support generatrix 15 of the front and rear support rollers, thus leveling the support rollers and the steel pipes supported on them. The straight-line fixed installation of the support roller frame 10 is achieved by the laser emitter 18 horizontally emitting laser beams 18.1 tangent to the support generatrix 15, and the infrared beams 18.1 from the two infrared emitters 18 are simultaneously received by two infrared receivers 19. The support generatrix of the two support rollers is simultaneously calibrated by the horizontal laser beams, achieving straight-line fixed installation and leveling. The leveling and straight-line fixed installation in Example 2 are more convenient.

[0114] The flange replication positioning welding fixture and welding method for large-diameter steel pipes have the following advantages compared with existing technologies:

[0115] (1) There is no need to pay attention to the levelness of the foundation. The large slide rail type machine tool method is abandoned. As long as the local foundation of the support roller frame to 10 and the mother flange frame to 20 base can be firmly and horizontally fixed and supported.

[0116] This application utilizes a bar level or laser level to adjust the levelness of the steel pipe, achieving a levelness of H≤0.06mm / Lmm, while neglecting the levelness of the foundation itself. Using only two easily portable support rollers (pair 10), two female flanges (pair 20), and a laser level, the pipe can be loaded onto a truck and transported to the installation site. A local foundation is first constructed, followed by rapid installation and positioning. This achieves high-precision flange welding positioning at extremely low cost, reducing the skill requirements and labor intensity for operators, and resulting in significantly higher efficiency.

[0117] (2) Applicable to steel pipes of any cross section.

[0118] Regardless of whether the steel pipe has a circular cross-section, a square cross-section, or any other cross-section, it will not affect the left and right linear movement of the steel pipe along the axis of the steel pipe on the support roller frame 10, nor will it affect the positioning of the mother flange 22 replicating the standard flange 1 and the installation of the fixing frame 23. Therefore, the above-mentioned flange replication positioning welding fixture and welding method for large-diameter steel pipes are applicable to the positioning welding of steel pipes and flanges of any cross-section.

Claims

1. A flange replication and positioning welding fixture for large-diameter steel pipes, characterized in that, include A support roller pair (10) is fixedly installed on a local foundation without a sliding rail in a straight line. It is used to support the steel pipe and level the horizontality of the steel pipe axis in a straight movement along the steel pipe axis with a span of Lmm. A steel pipe is placed on the support roller pair (10) and the steel pipe is leveled until the horizontality H meets H≤0.06mm / Lmm. A standard flange (1) is spot welded to both ends of the steel pipe to ensure that the perpendicularity between the plane of the standard flange and the axis of the steel pipe is less than 0.01, and at the same time, the concentricity between the standard flange and the steel pipe is ensured to obtain a standard version of the steel pipe. The mother flange pair (20) is fixed to the local foundation without a sliding rail, and is fixedly installed at both ends of the steel pipe with an axial outward displacement distance S. The mother flange pair (20) includes a vertical back integral component (21) and a mother flange (22). The vertical back integral component (21) includes a vertically integrated vertical support beam (21.1) and a back beam (21.2). The top surface of the end of the vertical support beam (21.1) is provided with a horizontal reference surface A, and the front of the back beam (21.2) is provided with an abutment surface B. The horizontal reference surface A of the vertical support beam (21.1) is abutted against the lowest point of the mother flange (22), and the abutment surface B is completely fitted to the plane ring surface of the mother flange (22) to obtain the positioning I of the vertical back integral component (21). The replication positioning and fixed installation is achieved as follows: taking the verticality and horizontal axis of the standard flange (1) as a reference, the mother flange (22) and the standard flange (1) are stacked and fixedly connected, and the vertical back integral piece (21) and the mother flange (22) are welded and fixed with positioning I, while the vertical back integral piece (21) is supported and fixed with positioning I; the standard flange (1) is disassembled.

2. The flange replication and positioning welding fixture for large-diameter steel pipes as described in claim 1, characterized in that, The mother flange bracket (20) also includes a fixing bracket (23) to position and support the vertical back integral component (21) as follows: the front and rear ends of the vertical support beam (21.1) are respectively hinged to the fixing bracket (23), so that the vertical back integral component (21) can be rotated and adjusted in the vertical plane; or after the back beam (21.2) is closely attached to the mother flange and integrally welded, the front and rear ends of the vertical support beam (21.1) are supported and integrally welded to the fixing bracket (23) at a fixed height.

3. The flange replication and positioning welding fixture for large-diameter steel pipes as described in claim 2, characterized in that, The fixed frame (23) includes a horizontal support beam (24), which is fixedly installed perpendicular to the axis of the steel pipe; a fulcrum block (25) and a tail telescopic seat (26) are provided perpendicular to the horizontal support beam at intervals. The fulcrum block (25) is hinged between the top surface of the horizontal support beam (24) and the position of the vertical support beam (21.1) located directly below the back beam. The tail telescopic seat (26) is hinged at the tail end of the vertical support beam (21.1). The extension and retraction of the tail telescopic seat (26) can make the vertical support beam (21.1) rotate around the fulcrum block (25) in the vertical plane, thereby making the back beam (21.2) gradually close to the mother flange (22). Alternatively, after the back beam (21.2) is closely attached to the mother flange and integrally welded, the tail telescopic seat (26) is replaced with a fulcrum block (25). The fulcrum block (25) is integrally welded between the top surface of the horizontal support beam (24) and the vertical support beam (21.1) located directly below the back beam. Another fulcrum block (25) is integrally welded to the lower surface of the tail end of the vertical support beam (21.1).

4. The flange replication and positioning welding fixture for large-diameter steel pipes as described in claim 3, characterized in that, The mother flange (22) includes a rear positioning ring and a raised ring. The mother flange bracket (20) is implemented with the verticality and horizontal axis of the standard flange (1) as a reference: the mother flange (22) and the standard flange (1) are fixedly connected by multiple bolts (28), the tail telescopic seat (26) is raised, and the vertical back integrated piece (21) is rotatably adjustable so that the back beam (21.2) is tightly positioned against the rear positioning ring of the mother flange. Then the mother flange is welded to the back beam (21.2). The standard flange includes a rear positioning face and a raised annular face. The mother flange (22) and the standard flange are fixedly connected by stacking relative to each other as follows: the raised annular face of the mother flange (22) abuts against the raised annular face of the standard flange and is fixedly connected by multiple connecting bolts (28).

5. The flange replication and positioning welding fixture for large-diameter steel pipes as described in any one of claims 1-4, characterized in that, The support roller frame pair (10) includes two support steel beams (11), and two inclined support seats (12) are fixedly installed on the support steel beams (11). The inclined support seats (12) are installed with roller seats (13) perpendicular to the inclined surface. The roller seats (13) are provided with support rollers (14). One of the support roller frame pairs (10) is the driving roller. The support roller (14) is connected to a rotation drive source. The rotation of the support roller (14) can make the steel pipe move linearly left and right along the axial direction.

6. The flange replication and positioning welding fixture for large-diameter steel pipes as described in claim 5, characterized in that, The support roller pair (10) also includes a central positioning beam (16). The central positioning beam (16) includes an end abutment section (16.1) that abuts against the support steel beam (11) laterally and a side positioning section (16.2) that presses against the top surface of the support steel beam (11). The central positioning beam (16) has a central surface (π1) perpendicular to the center line of the cross section. The straight-line installation and positioning of the support roller pair (10) is achieved as follows: the support roller pair (10) fixes the central positioning beam (16) between two sets of parallel support steel beams (11) with a span of Lmm. The side positioning surfaces of the two inclined support seats (12) are fixed to the top surface of the support steel beam (11) by abutting the side positioning section (16.2). This ensures that the front and rear support rollers of the support roller pair (10) are symmetrically arranged on both sides of the central positioning beam (16) and that the axis of the steel pipe is coplanar with the central surface π1.

7. The flange replication and positioning welding fixture for large-diameter steel pipes as described in claim 5, characterized in that, The support roller (14) includes a convex circular arc roller surface, and the highest point of the roller surface forms a support generatrix (15). The support generatrix (15) is symmetrically arranged on both sides of the mid-plane π1. It also includes a laser emitter (18), which can emit a laser beam (18.1) tangentially to the support generatrix (15). The leveling of the steel pipe axis is achieved by the laser beam (18.1) being tangential to the support generatrix (15) of the front and rear support rollers of the support roller frame pair (10).

8. The flange replication and positioning welding fixture for large-diameter steel pipes as described in any one of claims 1-4, characterized in that, After the steel pipe is leveled, a laser receiver (19) is set at the laser irradiation point position on the other roller seat of the support roller pair (10); the support roller pair (10) is fixedly installed in a straight line as follows: the laser emitter (18) emits a laser beam (18.1) tangentially to the support busbar (15), and the laser beams (18.1) of the two laser emitters (18) are simultaneously received by the two laser receivers (19).

9. A welding positioning method using a flange replication positioning welding fixture for large-diameter steel pipes as described in any one of claims 1-8, characterized in that, S1, fix the support roller frame pair (10), and make a standard flange (1); The support roller frame (10) is fixedly installed in the same straight line. The steel pipe is hoisted onto the support roller frame (10). The horizontality H of the steel pipe axis is adjusted to meet H≤0.06mm / Lmm. Standard flanges are welded at both ends of the steel pipe to ensure that the perpendicularity of the plane of the standard flange to the axis of the steel pipe is less than 0.01, and at the same time, the concentricity of the standard flange and the steel pipe is ensured. S2, fix the mother flange bracket (20) with the verticality and horizontal axis of the standard flange (1) as the reference, and hoist the standard steel pipe off the line; S3, Copy the positioning of the mother flange A mating flange (F) is fixedly connected to the mother flange pair (20) using connecting bolts (28); The steel pipe is hoisted to the support roller frame 10; Move the steel pipe to the left until it stops at the end of the limiting block, spot weld the left-side flange, and loosen the connecting bolts; move the steel pipe to the right until it stops at the end of the limiting block, place at least 3 shims between the outer circumference of the steel pipe and the inner hole of the flange (F) to adjust the concentricity, spot weld the right-side flange; loosen the connecting bolts and lift the steel pipe away. S4, the steel pipe is hoisted and lowered to the full welding operation area for full welding operation; S5, repeat steps S3 and S4.

10. The welding positioning method using the flange replication positioning welding fixture for large-diameter steel pipes as described in claim 9, characterized in that, The process of fixing and installing the female flange bracket (20) based on the verticality and horizontal axis of the standard flange (1) includes the following steps: S31, the standard flange (1) and the mother flange (22) are fixedly connected by overlapping. The boss ring face of the mother flange (22) abuts against the boss ring face of the standard flange and is fixedly connected by multiple connecting bolts (28), and moves outward a distance S along the axial direction together with the steel pipe W; S32, fabricate a vertical back piece The back beam (21.2) is welded to the top surface of the vertical support beam (21.1). At the same time, the top surface of the end of the vertical support beam and the front surface of the back beam are ground to finish the horizontal reference surface A and the abutment surface B, so that the perpendicularity of the abutment surface B to the horizontal reference surface A is less than or equal to 0.

01. S33, Fixed female flange pair a. Calculate the height of the fulcrum block (25) and manufacture the fulcrum block (25) according to this height; b. Fix the horizontal support beam and the tail telescopic seat A horizontal support beam (24) is fixed perpendicular to the steel pipe axis direction by offsetting the back beam thickness outward in the direction directly below the mother flange. A fulcrum block (25) is fixed between the top surface of the middle part of the horizontal support beam (24) and the vertical support beam (21.1). A tail telescopic seat 26 is fixed along the steel pipe axis direction by a span of Lmm. c. Fixed vertical back integrated component The vertical support beam (21.1) of the vertical back integrated component is fixedly connected to the top surface of the fulcrum block (25) and the tail telescopic seat (26). The height of the tail telescopic seat (26) is adjusted, and the vertical support beam (21.1) rotates with the top surface of the fulcrum block (25) as the fulcrum until the abutment surface B of the back beam (21.2) is completely in contact with the plane ring surface of the mother flange (22). The height of the tail telescopic seat (26) is locked, and the vertical support beam (21.1) is fixed to the tail telescopic seat (26). At the same time, the abutment surface of the mother flange (22) and the back beam (21.2) are welded and fixed.

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