An automatic welding system for a photothermal power generation main beam steel pipe and a flange

Abstract

The application discloses a kind of photothermal power generation girder steel pipe and flange automatic welding system, including the photothermal girder steel pipe is divided into three stations step-by-step welding: first, first station 8 flanges are according to specified position and are sleeved on steel pipe, then 1# welding robot is moved by servo motor, respectively 5 positions are spot welded on 8 flanges, flange is preliminarily fixed on steel pipe, to facilitate the second station repair welding;After first station spot welding is finished, it is conveyed to second station by conveying belt, welding arm is close to the contact surface of flange and steel pipe by lifting cylinder, servo motor is automatically rotated and positioned to the 5 positions of spot welding, 40mm repair welding is covered on welding arm, after second station is welded, it is conveyed to third station by conveying belt, third station carries out the welding of steel pipe middle fixed arm, servo motor is automatically rotated and positioned to multiple specified positions, 3# welding robot starts welding until end.

Description

Technical Field

[0001] This invention relates to the field of solar energy utilization technology, and more specifically, to an automatic welding system for the main beam steel pipe and flange of a solar thermal power generation system. Background Technology

[0002] Concentrated solar power (CSP) is a novel way to utilize solar energy. It is a green, clean, and renewable energy source with good sustainable power output capabilities. The construction of a CSP plant requires the installation of numerous solar thermal mirror field devices. These devices use steel pipes as main beams, with multiple fixed flanges welded onto the beams to support the mirror devices on top. Each main beam steel pipe has eight flanges, and each flange requires five arc-shaped weld points at designated locations.

[0003] After reviewing relevant materials, it was found that current welding systems are inefficient, have few welding stations, and only allow for the welding of two flanges on a single steel pipe. This invention, however, utilizes three welding stations to weld multiple flanges onto a steel pipe. The number and position of the flanges are selectable and adjustable, and precise positioning welding can be achieved on each flange.

[0004] To address the shortcomings of the existing technology, this invention is proposed. Summary of the Invention

[0005] The present invention provides an automatic welding system that can weld multiple flanges onto a steel pipe through three welding stations, with the number and position of the flanges being selectable and adjustable, and can precisely position and weld the solar thermal power generation main beam steel pipe and flange on each flange.

[0006] To achieve the objective of this invention, the technical solution provided by this invention is as follows:

[0007] An automated welding system for the main beam steel pipe and flanges of a solar thermal power generation system includes three stations for step-by-step welding of the main beam steel pipe: First, at the first station, eight flanges are fitted onto the steel pipe at designated positions. Then, a servo motor moves a welding robot (number 1) to spot weld five positions on each of the eight flanges, initially fixing the flanges to the steel pipe for subsequent welding at the second station. After spot welding at the first station, the pipe is conveyed to the second station via a conveyor belt. Welding machines are located on both sides of the second station. Two servo motors move the welding machines to the positions of the eight flanges. A lifting cylinder brings the welding arm close to the contact surface between the flange and the steel pipe. The servo motor automatically rotates and positions the steel pipe to the five spot-welded positions. The welding arm covers a 40mm section for further welding, further fixing the flange and steel pipe to meet mechanical load requirements. After welding at the second station, the pipe is conveyed to the third station via a conveyor belt. At the third station, the intermediate fixing arm of the steel pipe is welded. A servo motor automatically rotates and positions the steel pipe to multiple designated positions, and a welding robot (number 3) begins welding until completion. The specific welding process is as follows:

[0008] Step S1, the first workstation begins operation;

[0009] Step S11: Place the 8 flanges onto the steel pipe at the designated positions;

[0010] Step S12: The welding robot at station #1 is fixed on the mobile platform and moved to three positions by a servo motor. When it reaches the first position, the welding robot will spot weld the first, second and third flange pieces.

[0011] In step S13, the welding robot at the second position can spot weld the 4th and 5th flange pieces.

[0012] In step S14, the welding robot at the third position can spot weld the 6th, 7th, and 8th flange pieces;

[0013] Step S2, the second workstation begins operation;

[0014] The welding system at station #2 is equipped with welding machines and welding arms on both the left and right sides. The welding arms can be moved to the designated positions in the steel pipe by servo motors. The motors on the left and right sides can be controlled independently. There are 8 flange welding positions in the steel pipe. The servo motor on the left side is responsible for welding 1-4 flanges, and the servo motor on the right side is responsible for welding 5-8 flanges. The positions of flanges 1-8 are as follows.

[0015] The #2 rotary servo motor is responsible for rotating the steel pipe. There are 5 welding points on the flange, located at 0°, 45°, and 135° on the flange.

[0016] The welding arc length at each of the 225° and 315° positions is 40mm. The zero point position of the steel pipe is the position where the proximity switch detects the flange protrusion, and this position is set to 0°. When the steel pipe rotates to the welding position, the rotation speed is reduced to 8° / s. When the welding is completed, the speed is increased to 15° / s. When rotating to the next welding position, the speed is reduced to 8° / s again. This process is repeated until all 5 welding points are welded.

[0017] Step S2 specifically includes:

[0018] Step S201: Transport the steel pipe with the flange initially spot-welded to station #2;

[0019] Step S202: The propulsion cylinder of station #2 is started, and the gripper cylinder is started;

[0020] Step S203: The servo motor at station #2 drives the steel pipe to start rotating clockwise;

[0021] Step S204: The proximity switch detects the flange;

[0022] Step S205: Stop the motor and set this position to zero.

[0023] Step S206: Select the position on the steel pipe that needs to be welded. The left motor is responsible for flanges 1, 2, 3, and 4, and the right motor is responsible for flanges 5, 6, 7, and 8.

[0024] In step S207, the left and right servo motors M1 and M2 move to position 1 and position 5 respectively;

[0025] Step S208: Rotate the steel pipe clockwise to a position of 175°;

[0026] Step S209: The welding arm at station #2 descends;

[0027] Step S210: Rotate the steel pipe counterclockwise to the target position of 180°, and set the rotation speed to 8° / s to start the first section of welding;

[0028] Step S211: When the steel pipe rotates to 185°, the first section of welding is completed. The rotation speed is set to 15° / s, and the process begins to move to the next section of welding position.

[0029] In step S212, when the steel pipe is rotated to 225°, the second section welding begins, the rotation speed is set to 15° / s, and it begins to move to the next section welding position;

[0030] Step S213, continue with the other three welding operations;

[0031] In step S214, when the steel pipe rotates counterclockwise to 180°, the welding of all five positions around the circle is completed;

[0032] In step S215, the left and right servo motors M1 and M2 move to position 2 and position 6 respectively, and repeat steps S210-S214 to weld the second flange.

[0033] Step S216: Repeat step 215 until all flanges are welded and the steel pipe welding is completed.

[0034] Step S217: The welding arm at station #2 is raised;

[0035] Step S218, the servo motor of station #2 returns to the zero position;

[0036] Step S219: The gripper cylinder at station #2 retracts, and the push cylinder retracts.

[0037] Step S3, work begins at the third workstation;

[0038] The welding robot at station #3 is responsible for welding the fixed arm in the middle of the steel pipe. The steel pipe is rotated to 0°, 90° and 225° by the servo motor #3. After the welding robot completes the welding at these three positions, the overall welding of the main beam steel pipe is completed.

[0039] Step S3 specifically includes:

[0040] Step S301: Transport the welded steel pipe to station #3.

[0041] Step S302: The propulsion cylinder of station #3 is started, and the gripper cylinder is started;

[0042] In step S303, the servo motor at station #3 drives the steel pipe to start rotating clockwise;

[0043] Step S304: The proximity switch detects the flange;

[0044] Step S305: Stop the motor and set this position to zero.

[0045] Step S306: Welding robot #3 begins welding the steel pipe support arm at the first position;

[0046] Step S307: Servo motor #3 rotates to the second position;

[0047] Step S308: Welding robot #3 begins welding the steel pipe support arm at the second position;

[0048] Step S309: Servo motor #3 rotates to the third position;

[0049] Step S310: Welding robot #3 begins welding the steel pipe support arm at the third position;

[0050] Step S311, welding complete.

[0051] The beneficial effects of this invention are:

[0052] This invention fulfills the need for multi-piece, multi-point welding of steel pipe flanges. It is designed with three workstations for step-by-step welding. The first workstation performs spot welding to initially fix the flange; the second workstation performs full welding with a set arc to meet the flange's load-bearing requirements; and the third workstation performs supplementary welding of the intermediate fixed arm. This design method can greatly save labor costs, shorten welding time, and improve production efficiency. Attached Figure Description

[0053] Figure 1 This is a schematic diagram of the overall process flow of the present invention;

[0054] Figure 2 This is a schematic diagram of the overall structure of the present invention;

[0055] Figure 3 for Figure 2 Another perspective illustration;

[0056] In the diagram, 1: The servo motor for the welding robot at station 1; 2: The moving platform for the welding robot at station 1; 3: The steel pipe flange; 4: Welding station 1; 5: The servo motor for the steel pipe rotation at station 2; 6: Welding station 2; 7: The steel pipe conveyor belt; 8: The servo motor for the steel pipe rotation at station 3; 9: Welding station 3; 10: The support frame for the welding robot at station 3; 11: The welding robot at station 3; 12: The welding arm at station 2; 13: The servo motor for the welding machine at station 2; 14: The lifting cylinder for the welding arm at station 2; 15: The welding machine at station 2; 16: The welding robot at station 1; 17: The motor for the steel pipe conveyor belt. Detailed Implementation

[0057] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings.

[0058] Combined with appendix Figure 2 , Figure 3 As shown, the automatic welding system for the main beam steel pipe and flange of a solar thermal power generation system of the present invention includes a welding robot moving servo motor 1 at station 1, a welding robot moving platform 2 at station 1, a steel pipe flange 3, a welding station 4 at station 1, a steel pipe rotating servo motor 5 at station 2, a steel pipe conveyor belt 6 at station 2, a steel pipe rotating servo motor 8 at station 3, a welding station 9 at station 3, a welding robot support frame 10 at station 3, a welding robot 11 at station 3, a welding arm 12 at station 2, a welding machine moving servo motor 13 at station 2, a welding arm lifting cylinder 14 at station 2, a welding machine 15 at station 2, a welding robot 16 at station 1, and a steel pipe conveyor belt motor 17.

[0059] The No. 1 welding robot 16 is fixed on the No. 1 welding robot mobile platform 2. Through the No. 1 welding robot mobile servo motor 1, it is positioned and moved to three positions of the No. 1 welding station 4. The No. 1 welding robot 16 completes the spot welding of all 8 steel pipe flange pieces 3.

[0060] Welding station 6 #2 is equipped with welding machines 15 and welding arms 12 on both the left and right sides. These arms can be moved to designated positions within the steel pipe via servo motors 13. The left and right servo motors 13 can be controlled independently. The steel pipe has eight flange welding positions; the left servo motor handles welding flanges 1-4, and the right servo motor handles welding flanges 5-8.

[0061] The servo motor 5 at station #2 rotates the steel pipe. There are five welding points on the flange, located at 0°, 45°, 135°, 225°, and 315°. The welding arc length at each position is 40mm. The zero point of the steel pipe is the position where the proximity switch detects the flange protrusion, and this position is set to 0°. When the steel pipe rotates to the welding position, the rotation speed is reduced to 8° / s. When welding is completed, the speed is increased to 15° / s. When rotating to the next welding position, the speed is reduced to 8° / s again. This cycle repeats until all five welding points are welded.

[0062] The support frame 10 of the No. 3 welding robot located at welding station 9 of No. 3 has a No. 3 welding robot 11. The No. 3 welding robot 11 is responsible for welding the fixed arm in the middle of the steel pipe. The No. 3 welding robot 11 rotates the steel pipe to 0°, 90° and 225° respectively through the steel pipe rotation servo motor 8 of No. 3 station. After the welding robot completes the welding at these three positions, the overall welding of the main beam steel pipe is completed.

[0063] The steel pipe conveyor belt motor 17 drives the steel pipe conveyor belt 7 to complete the transportation and transmission of steel pipes.

[0064] The solar thermal main beam steel pipe is welded in three steps at three stations: First, at the first station, eight flanges are evenly distributed and fitted onto the steel pipe. Then, a servo motor moves welding robot #1 to spot weld five positions on each of the eight flanges, fixing the flanges to the steel pipe. After the spot welding at the first station is completed, the pipe is conveyed to the second station via a conveyor belt. Welding machines are arranged on both sides of the second station. Two servo motors move the welding machines to the positions of the eight flanges, and the five spot welded positions are covered with a 40mm full weld to further fix the flanges to the steel pipe and meet the mechanical load requirements. The third station performs the supplementary welding of the intermediate fixing arm.

[0065] The specific welding process is detailed in the appendix. Figure 1 The explanation is as follows:

[0066] Step S1, the first workstation begins operation;

[0067] Step S11: Place the 8 flanges onto the steel pipe at the designated positions;

[0068] Step S12: The welding robot at station #1 is fixed on the mobile platform and moved to three positions by a servo motor. When it reaches the first position, the welding robot will spot weld the first, second and third flange pieces.

[0069] In step S13, the welding robot at the second position can spot weld the 4th and 5th flange pieces.

[0070] In step S14, the welding robot at the third position can spot weld the 6th, 7th, and 8th flange pieces;

[0071] Step S2, the second workstation begins operation;

[0072] Step S2 specifically includes:

[0073] Step S201: Transport the steel pipe with the flange initially spot-welded to station #2;

[0074] Step S202: The propulsion cylinder of station #2 is started, and the gripper cylinder is started;

[0075] Step S203: The servo motor at station #2 drives the steel pipe to start rotating clockwise;

[0076] Step S204: The proximity switch detects the flange;

[0077] Step S205: Stop the motor and set this position to zero.

[0078] Step S206: Select the position on the steel pipe that needs to be welded. The left motor is responsible for flanges 1, 2, 3, and 4, and the right motor is responsible for flanges 5, 6, 7, and 8.

[0079] In step S207, the left and right servo motors M1 and M2 move to position 1 and position 5 respectively;

[0080] Step S208: Rotate the steel pipe clockwise to a position of 175°;

[0081] Step S209: The welding arm at station #2 descends;

[0082] Step S210: Rotate the steel pipe counterclockwise to the target position of 180°, and set the rotation speed to 8° / s to start the first section of welding;

[0083] Step S211: When the steel pipe rotates to 185°, the first section of welding is completed. The rotation speed is set to 15° / s, and the process begins to move to the next section of welding position.

[0084] In step S212, when the steel pipe is rotated to 225°, the second section welding begins, the rotation speed is set to 15° / s, and it begins to move to the next section welding position;

[0085] Step S213, continue with the other three welding operations;

[0086] In step S214, when the steel pipe rotates counterclockwise to 180°, the welding of all five positions around the circle is completed;

[0087] In step S215, the left and right servo motors M1 and M2 move to position 2 and position 6 respectively, and repeat steps S210-S214 to weld the second flange.

[0088] Step S216: Repeat step 215 until all flanges are welded and the steel pipe welding is completed.

[0089] Step S217: The welding arm at station #2 is raised;

[0090] Step S218, the servo motor of station #2 returns to the zero position;

[0091] Step S219: The gripper cylinder at station #2 retracts, and the push cylinder retracts.

[0092] Step S3, work begins at the third workstation;

[0093] Step S3 specifically includes:

[0094] Step S301: Transport the welded steel pipe to station #3.

[0095] Step S302: The propulsion cylinder of station #3 is started, and the gripper cylinder is started;

[0096] In step S303, the servo motor at station #3 drives the steel pipe to start rotating clockwise;

[0097] Step S304: The proximity switch detects the flange;

[0098] Step S305: Stop the motor and set this position to zero.

[0099] Step S306: Welding robot #3 begins welding the steel pipe support arm at the first position;

[0100] Step S307: Servo motor #3 rotates to the second position;

[0101] Step S308: Welding robot #3 begins welding the steel pipe support arm at the second position;

[0102] Step S309: Servo motor #3 rotates to the third position;

[0103] Step S310: Welding robot #3 begins welding the steel pipe support arm at the third position;

[0104] Step S311, welding complete.

[0105] The described embodiments are merely some, not all, of the embodiments in this application. All other embodiments obtained by those skilled in the art based on the embodiments in this application without inventive effort are within the scope of protection of this application.

Claims

1. An automatic welding method for the steel pipe and flange of a solar thermal power generation main beam, characterized in that: The process involves welding the solar thermal main beam steel pipe in three stages at three different workstations: First, at the first workstation, eight flanges are fitted onto the steel pipe at designated positions. Then, a servo motor moves welding robot #1 to spot weld five points on each of the eight flanges, initially fixing them to the steel pipe for subsequent welding at the second workstation. After spot welding at the first workstation, the pipe is conveyed to the second workstation. Welding machines are positioned on both sides of the second workstation. Two servo motors move the welding machines to the positions of the eight flanges. A lifting cylinder brings the welding arm close to the contact surface between the flange and the steel pipe. The servo motor automatically rotates and positions the steel pipe to the five spot-welded locations. The welding arm then covers a 40mm section for further welding, further securing the flange to the steel pipe to meet mechanical load requirements. After welding at the second workstation, the pipe is conveyed to the third workstation. At the third workstation, the middle fixing arm of the steel pipe is welded. A servo motor automatically rotates and positions the steel pipe to multiple designated locations, and welding robot #3 begins welding until completion. The specific welding process is as follows: Step S1, the first workstation begins operation; Step S11: Place the 8 flanges onto the steel pipe at the designated positions; Step S12: The welding robot at station #1 is fixed on the mobile platform and moved to three positions by a servo motor. When it reaches the first position, the welding robot will spot weld the first, second and third flange pieces. In step S13, the welding robot at the second position will spot weld the 4th and 5th flange pieces; In step S14, the welding robot at the third position will spot weld the 6th, 7th, and 8th flange pieces; Step S2, the second workstation begins operation; The welding system at station #2 is equipped with welding machines and welding arms on both the left and right sides. These arms can be moved to designated positions within the steel pipe via servo motors. The motors on the left and right sides can be controlled independently. There are 8 flange welding positions on the steel pipe. The servo motor on the left is responsible for welding 1-4 flanges, and the servo motor on the right is responsible for welding 5-8 flanges. The positions of flanges 1-8 are as follows. #2 rotary servo motor is responsible for rotating the steel pipe. There are 5 welding points on the flange, located at 0°, 45°, 135°, 225°, and 315° on the flange, with a welding arc length of 40mm at each position. The zero point position of the steel pipe is the position where the proximity switch detects the flange protrusion, and this position is set to 0°. When the steel pipe rotates to the welding position, the rotation speed is reduced to 8° / s. When the welding is completed, the speed is increased to 15° / s until it rotates to the next welding position, at which point the speed is reduced to 8° / s again. This cycle repeats until all 5 welding points are welded. Step S2 specifically includes: Step S201: Transport the steel pipe with the flange initially spot-welded to station #2; Step S202: The propulsion cylinder of station #2 is started, and the gripper cylinder is started; Step S203: The servo motor at station #2 drives the steel pipe to start rotating clockwise; Step S204: The proximity switch detects the flange; Step S205: Stop the motor and set this position to zero. Step S206: Select the position on the steel pipe that needs to be welded. The left motor is responsible for flanges 1, 2, 3, and 4, and the right motor is responsible for flanges 5, 6, 7, and 8. In step S207, the left and right servo motors M1 and M2 move to position 1 and position 5 respectively; Step S208: Rotate the steel pipe clockwise to a position of 175°; Step S209: The welding arm at station #2 descends; Step S210: Rotate the steel pipe counterclockwise to the target position of 180°, and set the rotation speed to 8° / s to start the first section of welding; Step S211: When the steel pipe rotates to 185°, the first section of welding is completed. The rotation speed is set to 15° / s, and the process begins to move to the next section of welding position. In step S212, when the steel pipe is rotated to 225°, the second section welding begins, the rotation speed is set to 15° / s, and it begins to move to the next section welding position; Step S213, continue with the other three welding operations; In step S214, when the steel pipe rotates counterclockwise to 180°, the welding of all five positions around the circle is completed; In step S215, the left and right servo motors M1 and M2 move to position 2 and position 6 respectively, and repeat steps S210-S214 to weld the second flange. Step S216: Repeat step 215 until all flanges are welded and the steel pipe welding is completed. Step S217: The welding arm at station #2 is raised; Step S218, the servo motor of station #2 returns to the zero position; Step S219: The gripper cylinder at station #2 retracts, and the push cylinder retracts. Step S3, work begins at the third workstation; The welding robot at station #3 is responsible for welding the fixed arm in the middle of the steel pipe. The steel pipe is rotated to 0°, 90° and 225° by the servo motor #3. After the welding robot completes the welding at these three positions, the overall welding of the main beam steel pipe is completed.

2. The automatic welding method for the main beam steel pipe and flange of a solar thermal power generation system according to claim 1, characterized in that: Step S3 specifically includes: Step S301: Transport the welded steel pipe to station #3. Step S302: The propulsion cylinder of station #3 is started, and the gripper cylinder is started; In step S303, the servo motor at station #3 drives the steel pipe to start rotating clockwise; Step S304: The proximity switch detects the flange; Step S305: Stop the motor and set this position to zero. Step S306: Welding robot #3 begins welding the steel pipe support arm at the first position; Step S307: Servo motor #3 rotates to the second position; Step S308: Welding robot #3 begins welding the steel pipe support arm at the second position; Step S309: Servo motor #3 rotates to the third position; Step S310: Welding robot #3 begins welding the steel pipe support arm at the third position; Step S311, welding complete.

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