An underwater multifunctional all-position welding repair system and method

Abstract

The application provides an underwater multifunctional all-position welding repair system and method; wherein the system comprises a magnetic adsorption mobile robot for walking on a metal surface in a magnetic adsorption mode, a welding repair mechanical arm for implementing underwater welding repair, an underwater wire feeding system for feeding welding wire, a dry drainage cover and a local drainage cover; the dry drainage cover is connected with the magnetic adsorption mobile robot through a lifting mechanism; the welding repair mechanical arm and the underwater wire feeding system are located in the dry drainage cover; and the local drainage cover is arranged at an execution end of the welding repair mechanical arm. The system can adopt three underwater welding repair schemes including dry method, local dry method and dry method-local dry method composite, simultaneously has the advantages of the dry method and the local dry method, can automatically match the best repair scheme through an underwater welding repairability evaluation and decision method, and realizes underwater welding repair of various damage types and all positions.

Description

Technical Field

[0001] This invention relates to the field of underwater welding repair technology, and more specifically, to an underwater multifunctional all-position welding repair system and method. Background Technology

[0002] The demand for underwater manufacturing and repair of underwater structures for marine equipment is increasing. These structures are subject to heavy workloads, harsh operating environments, and unpredictable loads such as wind, waves, and earthquakes, making them highly susceptible to damage and serious hazards. Underwater welding technology is a crucial method for the underwater manufacturing and repair of underwater structures for high-end marine equipment such as ships, offshore engineering projects, and offshore wind power.

[0003] Underwater welding methods mainly include three categories: wet welding, dry welding, and partially dry welding. Wet welding is done directly in seawater. While this method has the advantages of simple welding equipment, flexible operation, and low cost, the welding arc is completely exposed to the water environment, resulting in poor weld quality. Dry welding uses a large working chamber to completely drain the water from the area to be welded, creating a dry working environment similar to that on land. This results in high weld quality, but the equipment is complex and expensive, the welding cost is extremely high, and the operating efficiency is low. Partial dry welding technology uses small / micro-drainage devices to separate the welding arc from the water environment, combining the advantages of high quality of dry welding and low cost and high efficiency of wet welding. However, the high pressure inside and outside the drainage cover, rapid cooling, and strong airflow interference in the micro-area of ​​the welding process make the welding process extremely complex due to the coupling of multiple physical fields of heat, magnetism, electricity, and force. Summary of the Invention

[0004] To overcome the shortcomings and deficiencies of the existing technology, the present invention aims to provide an underwater multifunctional all-position welding repair system and method. The system can adopt three underwater welding repair schemes, including dry method, partial dry method and dry-partial dry method composite method, and has the advantages of both dry method and partial dry method. It can automatically match the best repair scheme through underwater welding repairability evaluation and decision-making method, and realize underwater welding repair of various damage types and all positions (overhead welding, vertical welding and flat welding).

[0005] To achieve the above objectives, the present invention provides a multi-functional underwater all-position welding repair system, comprising:

[0006] A magnetic adsorption mobile robot used to walk on metal surfaces by magnetic adsorption;

[0007] A robotic arm for underwater welding repair;

[0008] Underwater wire feeding system for conveying welding wire;

[0009] In addition to dry drainage covers and local drainage covers;

[0010] The dry drainage cover is connected to the magnetic adsorption mobile robot via a lifting mechanism to achieve lifting; the welding repair robotic arm and the underwater wire feeding system are located in the dry drainage cover; the partial drainage cover is set at the execution end of the welding repair robotic arm.

[0011] Preferably, the magnetic adsorption mobile robot includes a magnetic adsorption walking mechanism and an underwater welding robot chassis; a passage position is opened in the middle of the underwater welding robot chassis; a dry drainage cover is installed in the passage position and is connected to the underwater welding robot chassis through a lifting mechanism.

[0012] Preferably, the lower part of the dry drainage cover and the bottom of the partial drainage cover are made of soft material to ensure close contact with the surface of the underwater damaged area; the upper part of the dry drainage cover is made of hard material to provide impact protection for the underwater wire feeding system and the welding repair robotic arm.

[0013] The welding repair method of the underwater multifunctional all-position welding repair system includes the following steps:

[0014] S1. Based on the underwater damage area, set an underwater welding repair plan; the set underwater welding repair plans include a dry welding repair plan that uses only a dry drainage cover for drainage, a local dry welding repair plan that uses only a local drainage cover for drainage, and a dry-local dry composite welding repair plan that uses both a dry drainage cover and a local drainage cover for drainage.

[0015] S2. Control the magnetic adsorption mobile robot to move to the underwater damaged area, so that the underwater damaged area is within the reach of the welding repair robot arm;

[0016] S3. Create a dry welding environment according to the underwater welding repair plan set in step S1;

[0017] When the dry welding repair scheme is set, the dry drainage cover sinks, and the underwater damaged area is located within the coverage area of ​​the dry drainage cover; the water inside the dry drainage cover is drained to create a dry welding environment.

[0018] When the local dry welding repair scheme is set, the welding repair robotic arm controls the local drainage cover to sink and cover the underwater damaged area, draining the water inside the local drainage cover and creating a dry environment in the welding micro-area.

[0019] When the dry-partial dry composite welding repair scheme is set, the dry drainage cover is first lowered, and the underwater damaged area is located within the coverage area of ​​the dry drainage cover; the water inside the dry drainage cover is drained; then the welding repair robotic arm controls the partial drainage cover to lower and cover the underwater damaged area, draining the water inside the partial drainage cover and creating a dry environment in the welding micro-area.

[0020] S4. Conduct underwater welding repair work.

[0021] Preferably, in step S1, the method for setting the underwater welding repair scheme is as follows: The size, curvature, surface flatness, and location of the underwater damaged area are obtained; based on the location of the underwater damaged area, the welding position is set to one of overhead welding, vertical welding, flat welding, or horizontal welding; the size, curvature, and surface flatness of the underwater damaged area are compared with the application threshold of the dry drainage cover: if they are greater than the application threshold of the dry drainage cover, a local dry welding repair scheme is set; if they are less than or equal to the application threshold of the dry drainage cover, based on the welding position, when the welding position is flat welding, a dry-local dry composite welding repair scheme is set; for other welding position methods, a dry welding repair scheme is set.

[0022] Preferably, in step S3, when the dry-partial dry composite welding repair scheme is set, the air pressure inside the local drainage hood is 0.5 standard atmospheres higher than that inside the dry drainage hood.

[0023] Preferably, step S2 includes the following steps:

[0024] S21. Establish communication between the underwater multi-functional all-position welding repair system and the client;

[0025] S22. Land operators use the client to control the magnetic adsorption mobile robot to move to the damaged area and adjust the position of the magnetic adsorption mobile robot so that the underwater damaged area is within the coverage of the dry drainage cover.

[0026] Preferably, step S4, performing underwater welding repair work, refers to: planning the motion trajectory of the welding repair robot arm and adjusting the process parameters; the process parameters include welding current and voltage, duty cycle, and wire feeding speed; and performing underwater welding repair work according to the motion trajectory of the welding repair robot arm and the process parameters.

[0027] The planned motion trajectory of the welding repair robot arm refers to: planning the path of the welding repair robot arm according to the shape, type and depth of the underwater damage area, so that the motion trajectory of the welding repair robot arm can cover the entire underwater damage area, and setting the welding angle of the welding gun of the welding repair robot arm.

[0028] Preferably, after step S4, step S5 is further included: the dry drainage cover and / or the partial drainage cover move upwards, and the magnetic adsorption mobile robot moves back to its initial position.

[0029] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0030] 1. The underwater multifunctional all-position welding repair system of the present invention is equipped with a dry drainage cover and a local drainage cover. It can adopt three underwater welding repair schemes, including dry method, local dry method, and dry-local dry method composite method. Through underwater welding repairability evaluation and decision-making methods, it can automatically match the best repair scheme to realize underwater welding repair of various damage types and all positions (overhead welding, vertical welding, flat welding). The present invention combines the advantages of dry method and local dry method and has significant advantages in automation, intelligence and multifunctionality.

[0031] 2. The present invention, a dry-partial dry composite welding repair scheme, can separate the local drainage cover from the external seawater by a dry drainage cover, avoiding direct impact of external seawater on the local drainage cover. This solves the problem of multi-physical field coupling factors of heat, magnetism, electricity and force in the welding micro-area under high pressure, rapid cooling and strong airflow interference inside and outside the local dry drainage cover in traditional local dry welding technology. It can also solve the problem that seawater remains in the lower part of the dry drainage cover due to gravity during flat welding, resulting in incomplete drainage and the inability to form a dry welding environment on the surface to be welded.

[0032] 3. The dry drainage hood provided by this invention covers the area to be welded but does not cover the entire underwater multifunctional all-position welding repair system. It effectively reduces the internal space of the dry drainage hood without reducing the welding operation space, greatly saving the flow of drainage gas and protective gas, and has better performance under continuous operation conditions. In terms of safety, the dry drainage hood provided by this invention adopts a double-layer structure design. The lower part of the dry drainage device is used to sink and adsorb the surface to be repaired, and the upper part can be used to prevent underwater wire feeding system, welding repair robotic arm and other structures from being hit by underwater organisms.

[0033] 4. The local dry drainage device provided by the present invention fully considers various working conditions such as cover plate welding repair and crack repair, and designs a lower soft material to ensure that the welding area is uneven, curved or has steps, thus ensuring the multifunctionality of the present invention. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the underwater multifunctional all-position welding repair system of the present invention;

[0035] Figure 2 This is a schematic diagram of the underwater multifunctional all-position welding repair system of the present invention, with the upper part of the dry drainage cover hidden.

[0036] Figure 3 This is a schematic diagram of the dry drainage cover of the underwater multifunctional all-position welding repair system of the present invention;

[0037] Figure 4 This is a schematic diagram of the partial drainage cover of the underwater multifunctional all-position welding repair system of the present invention;

[0038] Figure 5 This is a flowchart of the welding repair method of the present invention;

[0039] In this diagram, 1 represents the magnetic adsorption walking mechanism; 2 represents the underwater welding robot chassis; 3 represents the lifting mechanism; 4 represents the dry drainage hood; 5 represents the dry drainage hood drain valve; 6 represents the controller; 7 represents the underwater wire feeding system; 8 represents the underwater wire feeding system drive motor; 9 represents the welding repair robotic arm; 10 represents the bottom water inlet; 11 represents the controller interface; 12 represents the upper part of the dry drainage hood; 13 represents the lower part of the dry drainage hood; 14 represents the drain valve of the partial drainage hood; 15 represents the bottom of the partial drainage hood; and 16 represents the bottom water inlet. Detailed Implementation

[0040] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0041] Example

[0042] This embodiment describes an underwater multifunctional all-position welding repair system, such as... Figure 1 and Figure 2 As shown, it includes: a magnetic adsorption mobile robot for walking on a metal surface by magnetic adsorption; a welding repair robotic arm 9 for performing underwater welding repair; an underwater wire feeding system 7 for conveying welding wire; and a dry drainage cover 4 and a local drainage cover.

[0043] The magnetic adsorption mobile robot includes a magnetic adsorption walking mechanism 1 and an underwater welding robot chassis 2. A passageway is provided in the middle of the underwater welding robot chassis 2. A dry drainage cover 4 is installed in the passageway and connected to the underwater welding robot chassis via a lifting mechanism 3 to achieve lifting. A welding repair robotic arm 9 and an underwater wire feeding system 7 are located within the dry drainage cover 4. A partial drainage cover is installed at the end effector of the welding repair robotic arm 9.

[0044] like Figure 3 As shown, the lower part 13 of the dry drainage cover is made of soft material to ensure close contact with the surface of the underwater damaged area; the upper part 12 of the dry drainage cover is made of hard material to provide impact protection for the underwater wire feeding system 7 and the welding repair robotic arm 9.

[0045] like Figure 4 As shown, the partial drainage cover is an improvement on the existing technology. The bottom 15 of the partial drainage cover is made of soft material to achieve close contact with the surface where the underwater damage area is located.

[0046] The welding repair method of the underwater multifunctional all-position welding repair system, such as Figure 5 As shown, it includes the following steps:

[0047] S1. Based on the underwater damage area, set an underwater welding repair scheme; the set underwater welding repair schemes include a dry welding repair scheme that uses only the dry drainage cover 4 for drainage, a partial dry welding repair scheme that uses only the partial drainage cover for drainage, and a dry-partial dry composite welding repair scheme that uses both the dry drainage cover 4 and the partial drainage cover for drainage.

[0048] Specifically, the method for setting an underwater welding repair scheme is as follows: Obtain the size, curvature, surface flatness, and location of the underwater damaged area; based on the location of the underwater damaged area, set the welding position to one of overhead welding, vertical welding, flat welding, or horizontal welding; compare the size, curvature, and surface flatness of the underwater damaged area with the application threshold of the dry drainage cover 4: if it exceeds the application threshold of the dry drainage cover 4, meaning the underwater damaged area does not support the use of the dry drainage cover, then a partial dry welding repair scheme is set; if it is less than or equal to the application threshold of the dry drainage cover 4, then based on the welding position, when the welding position is flat welding, there is a lot of seawater residue inside the dry drainage cover 4, so a dry-partial dry composite welding repair scheme is set; for other welding position methods, a dry welding repair scheme is set.

[0049] S2. Control the magnetic adsorption mobile robot to move to the underwater damaged area, so that the underwater damaged area is within the reach of the welding repair robotic arm 9.

[0050] Step S2 includes the following steps:

[0051] S21. Establish communication between the underwater multi-functional all-position welding repair system and the client;

[0052] S22. Land operators use the client to control the magnetic adsorption mobile robot to move to the damaged area and adjust the position of the magnetic adsorption mobile robot so that the underwater damaged area is within the coverage area of ​​the dry drainage cover 4.

[0053] S3. Create a dry welding environment according to the underwater welding repair plan set in step S1;

[0054] When the dry welding repair scheme is set, the dry drainage cover 4 sinks, and the underwater damaged area is located within the coverage area of ​​the dry drainage cover 4; the water inside the dry drainage cover 4 is drained to create a dry welding environment.

[0055] When the local dry welding repair scheme is set, the welding repair robotic arm 9 controls the local drainage cover to sink and cover the underwater damaged area, draining the water inside the local drainage cover and creating a dry environment in the welding micro-area.

[0056] When the dry-partial dry composite welding repair scheme is set, the dry drainage cover 4 is first lowered, and the underwater damaged area is located within the coverage area of ​​the dry drainage cover 4; the water inside the dry drainage cover 4 is drained; then the welding repair robotic arm 9 controls the partial drainage cover to lower and cover the underwater damaged area, draining the water inside the partial drainage cover and creating a dry environment in the welding micro-area; the air pressure inside the partial drainage cover is 0.5 standard atmospheres higher than the air pressure inside the dry drainage cover 4.

[0057] The water inside the dry drainage hood 4 is drained by introducing high-pressure drainage gas into the dry drainage hood and draining the seawater through the dry drainage hood drainage valve 5; the water inside the partial drainage hood is drained by introducing high-pressure drainage gas into the partial drainage hood and draining the seawater through the partial drainage hood drainage valve 14.

[0058] S4. Perform underwater welding repair work: Plan the motion trajectory of the welding repair robot arm 9 and adjust the process parameters; the process parameters include welding current and voltage, duty cycle, and wire feeding speed; perform underwater welding repair work according to the motion trajectory of the welding repair robot arm 9 and the process parameters.

[0059] Planning the motion trajectory of the welding repair robot arm 9 refers to: planning the path of the welding repair robot arm 9 based on the shape, type, and depth of the underwater damage area, so that the motion trajectory of the welding repair robot arm 9 can cover the entire underwater damage area, and setting the welding angle of the welding torch of the welding repair robot arm 9.

[0060] After completing the path planning of the welding repair robot arm and adjusting the process parameters such as welding current, voltage, duty cycle, and wire feeding speed, the robot arm control command is issued through the client. The command is transmitted to the robot-end controller through the communication bus, which controls the movement of the welding repair robot arm to perform underwater arc initiation, welding, wire feeding and other operations, so as to realize the automated welding repair of underwater damaged areas.

[0061] After completing the welding repair, the following steps may also be included:

[0062] The dry drainage cover 4 and / or the partial drainage cover move upwards, and the magnetic adsorption mobile robot moves back to its initial position.

[0063] This invention employs a strong magnetic wheel adsorption motion mode, equipped with both underwater dry and partial dry drainage covers. It possesses all-position underwater movement capability and dry and partial dry welding functions. Based on different types of damage to underwater structures, it can formulate underwater dry and partial dry welding repair solutions, achieving high-quality, high-efficiency, high-reliability, and high-performance underwater damage welding repair for marine equipment.

[0064] The above embodiments are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the spirit and principle of the present invention shall be considered equivalent substitutions and shall be included within the protection scope of the present invention.

Claims

1. A multi-functional underwater all-position welding repair method, characterized in that: For underwater multi-functional all-position welding repair system; The underwater multifunctional all-position welding repair system includes: A magnetic adsorption mobile robot used to walk on metal surfaces by magnetic adsorption; A robotic arm for underwater welding repair; Underwater wire feeding system for conveying welding wire; In addition to dry drainage covers and local drainage covers; The dry drainage cover is connected to the magnetic adsorption mobile robot via a lifting mechanism to achieve lifting; the welding repair robotic arm and the underwater wire feeding system are located in the dry drainage cover; the partial drainage cover is set at the execution end of the welding repair robotic arm; The underwater multi-functional all-position welding repair method includes the following steps: S1. Based on the underwater damage area, set an underwater welding repair plan; the underwater welding repair plan includes a dry welding repair plan that uses only a dry drainage cover for drainage, a local dry welding repair plan that uses only a local drainage cover for drainage, and a dry-local dry composite welding repair plan that uses both a dry drainage cover and a local drainage cover for drainage. S2. Control the magnetic adsorption mobile robot to move to the underwater damaged area, so that the underwater damaged area is within the reach of the welding repair robot arm; S3. Create a dry welding environment according to the underwater welding repair plan set in step S1; When the dry welding repair scheme is set, the dry drainage cover sinks, and the underwater damaged area is located within the coverage area of ​​the dry drainage cover; the water inside the dry drainage cover is drained to create a dry welding environment. When the local dry welding repair scheme is set, the welding repair robotic arm controls the local drainage cover to sink and cover the underwater damaged area, draining the water inside the local drainage cover and creating a dry environment in the welding micro-area. When the dry-partial dry composite welding repair scheme is set, the dry drainage cover is first lowered, and the underwater damaged area is located within the coverage area of ​​the dry drainage cover; the water inside the dry drainage cover is drained; then the welding repair robotic arm controls the partial drainage cover to lower and cover the underwater damaged area, draining the water inside the partial drainage cover and creating a dry environment in the welding micro-area. S4. Perform underwater welding repair work; Step S1, the method for setting the underwater welding repair scheme, is as follows: obtain the size, curvature, surface flatness, and location of the underwater damaged area; based on the location of the underwater damaged area, set the welding position method to one of overhead welding, vertical welding, flat welding, and horizontal welding; compare the size, curvature, and surface flatness of the underwater damaged area with the application threshold of the dry drainage cover: if it is greater than the application threshold of the dry drainage cover, then set it as a local dry welding repair scheme; if it is less than or equal to the application threshold of the dry drainage cover, then based on the welding position method, when the welding position method is flat welding, set it as a dry-local dry composite welding repair scheme; for other welding position methods, set it as a dry welding repair scheme.

2. The underwater multifunctional all-position welding repair method according to claim 1, characterized in that: The magnetic adsorption mobile robot includes a magnetic adsorption walking mechanism and an underwater welding robot chassis; a passage position is opened in the middle of the underwater welding robot chassis; a dry drainage cover is installed in the passage position and is connected to the underwater welding robot chassis through a lifting mechanism.

3. The underwater multifunctional all-position welding repair method according to claim 1, characterized in that: The lower part of the dry drainage cover and the bottom of the partial drainage cover are made of soft material to ensure close contact with the surface of the underwater damaged area; the upper part of the dry drainage cover is made of hard material to provide impact protection for the underwater wire feeding system and the welding repair robotic arm.

4. The underwater multifunctional all-position welding repair method according to claim 1, characterized in that: In step S3, when the dry-partial dry composite welding repair scheme is set, the air pressure inside the local drainage hood is 0.5 standard atmospheres higher than that inside the dry drainage hood.

5. The underwater multifunctional all-position welding repair method according to claim 1, characterized in that: Step S2 includes the following steps: S21. Establish communication between the underwater multi-functional all-position welding repair system and the client; S22. Land operators use the client to control the magnetic adsorption mobile robot to move to the damaged area and adjust the position of the magnetic adsorption mobile robot so that the underwater damaged area is within the coverage of the dry drainage cover.

6. The underwater multifunctional all-position welding repair method according to claim 1, characterized in that: Step S4, performing underwater welding repair work, refers to: planning the motion trajectory of the welding repair robotic arm and adjusting the process parameters; Process parameters include welding current and voltage, duty cycle, and wire feed speed; Underwater welding repair work is carried out based on the motion trajectory and process parameters of the welding repair robot arm. The planned motion trajectory of the welding repair robot arm refers to: planning the path of the welding repair robot arm according to the shape, type and depth of the underwater damage area, so that the motion trajectory of the welding repair robot arm can cover the entire underwater damage area, and setting the welding angle of the welding gun of the welding repair robot arm.

7. The underwater multifunctional all-position welding repair method according to claim 1, characterized in that: After step S4, step S5 is also included: the dry drainage cover and / or the partial drainage cover move upwards, and the magnetic adsorption mobile robot moves back to its initial position.

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