An automatic control system for pipe welding

Abstract

The present invention belongs to the technical field of pipe welding control, and discloses a pipe welding automation control system, which includes a fixing mechanism setting module, a pipe position fixing module, a welding parameter setting module, a welding operation execution module, a welding quality analysis module, and a welding abnormality identification module. When performing a feasibility analysis of the welding operation of a target pipe group, the present invention automatically collects the abnormal conditions of the gap width of the target pipe group, and then determines whether the welding operation is allowed. This analysis method adopts an automated intelligent judgment method, which ensures the reliability and safety of the welding product and improves the overall welding efficiency. At the same time, when performing the pipe welding operation, the present invention analyzes the pipe parameters and then sets the welding parameters adaptively. This analysis method can obtain adaptive welding parameters based on the actual pipe parameters, ensures the welding quality, and improves the adaptability of the welding system.

Description

Technical Field

[0001] The invention belongs to the technical field of pipe fitting welding control and relates to an automatic control system for pipe fitting welding. Background Art

[0002] Pipe welding is a common industrial processing technology used to connect different components in a pipeline system. Pipe welding can ensure the structural integrity and safe operation of the pipeline system, while improving the efficiency and reliability of fluid transmission, providing solid support for various industrial applications. In actual production, welding quality defects may occur due to improper manual operation or long reaction time, which will directly affect the performance and safety of the pipeline system. Therefore, the automated control of pipe welding is of great significance.

[0003] Pipe welding mainly includes the steps of fixing, welding and post-processing, among which the fixing and welding operations of pipes are important steps to ensure the quality of the finished welded products.

[0004] In the traditional pipe welding process, the feasibility of pipe welding is usually judged manually. This process based on manual judgment and operation reduces the efficiency of pipe welding and significantly increases the time cost of the overall welding process. At the same time, manual operation is highly subjective, which may lead to poor consistency in pipe fixation, affecting the welding quality and the overall reliability of the project. When high-precision alignment and fixation cannot be achieved, it may cause displacement or deviation during the welding operation, affecting the quality and strength of the weld.

[0005] In the traditional pipe welding operation process, relatively fixed welding parameters are usually used, ignoring the differences in the required welding parameters caused by the different parameters of each position of the pipe. This analysis method may cause the welding parameters to be incompatible with the pipe parameters, which in turn leads to an increase in welding defects and even pipe breakdown or deformation, affecting the stability and safety of the overall structure of the finished pipe welding product. At the same time, the use of incompatible welding parameters may lead to reduced production efficiency and the need for rework due to insufficient welding, increasing time and cost. Summary of the invention

[0006] In view of this, in order to solve the problems raised in the above background technology, a pipe welding automatic control system is now proposed.

[0007] The objective of the present invention can be achieved through the following technical scheme: a pipe welding automation control system, the system comprising: a fixing mechanism setting module, used to set the fixing mechanism, the fixing mechanism comprising a first fixing device and a second fixing device, wherein the first fixing device is used to fix the first pipe, and the second fixing device is used to fix the second pipe.

[0008] The pipe position fixing module is used to record the first pipe and the second pipe to be welded as a target pipe group, fix the target pipe group using a fixing mechanism, and scan the fixed target pipe group using a three-dimensional scanning device, analyze the abnormality of the seam width of the target pipe group according to the scanning result, and judge whether the welding operation is allowed. When it is judged that the welding operation is not allowed, adjust the fixing mechanism to fix the position of the target pipe group again.

[0009] The welding parameter setting module is used to collect the pipe wall thickness of the target pipe group when judging whether the welding operation is allowed, and then judge whether it is necessary to set the welding parameters by region. If it is judged to be necessary, the welding parameters are set by region for the target pipe group. If it is judged not to be necessary, the welding parameters are set based on the average pipe thickness of the target pipe group.

[0010] The welding operation execution module is used to perform welding operations on pipe fittings after the welding parameters are set.

[0011] The welding quality analysis module is used to perform quality inspection on the target pipe group after welding, specifically including weld quality inspection and pipe quality inspection, and then analyze the welding operation quality based on the quality inspection results.

[0012] The welding anomaly identification module is used to determine whether there is a quality abnormality in the welding operation based on the quality of the welding operation, and identify the specific abnormal direction when it is determined to be present, wherein the abnormal direction includes position fixation abnormality and welding parameter abnormality.

[0013] In a preferred embodiment of the present invention, the analysis of the abnormal situation of the gap width of the target pipe group is specifically as follows: extracting the scanning data of the target pipe group obtained by using a three-dimensional scanning device, and then constructing a three-dimensional contour of the target pipe group, recording the area of ​​the target pipe group corresponding to the first pipe and the second pipe to be connected as the area to be welded, locating the area to be welded of the target pipe group, and arranging a number of detection points at equal distances in the area to be welded of the target pipe group, and obtaining the monitoring width corresponding to each detection point.

[0014] The monitoring width corresponding to each detection point is compared with the preset reference monitoring width to obtain the deviation of each monitoring width, and the mean of each monitoring width deviation is calculated to obtain the deviation of the gap width of the target pipe group.

[0015] The deviations of the monitored widths are compared to obtain the maximum monitored width deviation and the minimum distance deviation, and then compared to obtain the difference in the width of the gaps of the target pipe group.

[0016] The gap width deviation and gap width difference of the target pipe fitting group are accumulated and calculated according to the weight to obtain the gap width anomaly index of the target pipe fitting group.

[0017] In a preferred embodiment of the present invention, the determination of whether the welding operation is allowed is specifically as follows: comparing the gap width abnormality index of the target pipe group with the preset allowable gap width abnormality index; when the gap width abnormality index of the target pipe group is greater than the allowable gap width abnormality index, determining that the welding operation is not allowed; and when the gap width abnormality index of the target pipe group is less than or equal to the allowable gap width abnormality index, determining that the welding operation is allowed.

[0018] In a preferred embodiment of the present invention, the determination of whether it is necessary to perform regional welding parameter setting is specifically as follows: extracting three-dimensional data information of the target pipe group obtained by using a three-dimensional scanning device, and then locating the area to be welded of the target pipe group, and arranging a number of acquisition points at equal distances along the extension direction of the weld in the area to be welded of the target pipe group, and obtaining the first pipe wall thickness and the second pipe wall thickness corresponding to each acquisition point.

[0019] The first pipe wall thickness and the second pipe wall thickness of each collection point are compared, and the smaller pipe wall thickness is selected as the effective pipe wall thickness of the corresponding collection point.

[0020] The effective wall thickness of each acquisition point is compared to obtain the maximum wall thickness and the minimum wall thickness of the target pipe group, and then the differential wall thickness is obtained by comparison. The differential wall thickness of the target pipe group is compared with the preset allowable differential wall thickness to obtain a judgment result on whether it is necessary to set the welding parameters for each area.

[0021] In a preferred embodiment of the present invention, the regional welding parameter setting is specifically as follows: the effective wall thickness of each collection point of the target pipe fitting group is compared with the effective wall thickness of the adjacent collection point to obtain the wall thickness similarity of each collection point and the adjacent collection point, and then compared with the preset similarity of the qualified wall thickness. If the wall thickness similarity of a certain collection point and the adjacent collection point is greater than or equal to the qualified wall thickness similarity, it is judged that the collection point and the corresponding adjacent collection point belong to the same collection area. If the wall thickness similarity of a certain collection point and the adjacent collection point is less than the qualified wall thickness similarity, it is judged that the collection point and the corresponding adjacent collection point do not belong to the same collection area, and then the collection points of the target pipe fitting group are divided into several collection areas.

[0022] The effective pipe wall thickness of the corresponding collection points in each collection area is averaged to obtain the monitored pipe wall thickness of each collection area.

[0023] Based on the monitored pipe wall thickness corresponding to each acquisition area, the welding parameters of the target pipe group corresponding to each acquisition area are obtained.

[0024] In a preferred embodiment of the present invention, the weld quality inspection and analysis steps are as follows: using a laser scanning sensor to move horizontally along the weld surface of the target pipe group after the welding operation, obtaining three-dimensional data of the weld surface and generating a three-dimensional contour map of the weld surface weld layer.

[0025] Several monitoring points are set at equal distances along the extension direction of the weld layer, each monitoring point corresponds to the midpoint of the weld layer in the extension direction perpendicular to the weld layer, and the weld layer information of each monitoring point is obtained from the three-dimensional contour map of the weld layer surface of the target pipe group, specifically including the weld layer width and weld layer thickness.

[0026] The weld layer width and weld layer thickness of each monitoring point are compared respectively to obtain the fluctuation of weld layer width and weld layer thickness of the target pipe assembly.

[0027] The weld layer width fluctuation and weld layer thickness fluctuation of the target pipe fitting group are summed up according to the weights to obtain the weld quality anomaly index of the target pipe fitting group.

[0028] In a preferred embodiment of the present invention, the pipe quality inspection and analysis steps are as follows: using a high-definition camera to obtain an image of the welding area after the welding operation of the target pipe group, the welding area includes the weld area and the area within a pre-set monitoring distance at both ends of the weld.

[0029] The damage position in the welding area image is located, the number of damages in the welding area is counted, and then compared with the preset reference damage number to obtain the abnormality of the damage number.

[0030] The damage position in the welding area is located, and then the damage position area is obtained using image processing software. The average area of ​​each damage position is calculated to obtain the monitored damage area, and the monitored damage area is compared with the welding area to obtain the abnormality of the damage degree.

[0031] The abnormality of the damage quantity and the abnormality of the damage degree are summed up according to the weights to obtain the pipe quality abnormality index of the target pipe group.

[0032] In a preferred embodiment of the present invention, the analysis of welding operation quality is specifically as follows: a welding operation quality index of the target pipe fitting group is obtained based on a weld quality anomaly index and a pipe quality anomaly index of the target pipe fitting group.

[0033] In a preferred embodiment of the present invention, the determination of whether there is a quality abnormality in the welding operation is specifically as follows: the welding operation quality index of the target pipe fitting group is compared with a preset standard welding operation quality index; when the welding operation quality index of the target pipe fitting group is greater than or equal to the standard welding operation quality index, it is determined that there is no quality abnormality in the welding operation; when the welding operation quality index of the target pipe fitting group is less than the standard welding operation quality index, it is determined that there is a quality abnormality in the welding operation.

[0034] In a preferred embodiment of the present invention, the specific abnormal direction of identification is specifically as follows: the target pipe group judged to have quality abnormalities in the welding operation is recorded as the abnormal pipe group.

[0035] The weld quality abnormality index and the pipe quality abnormality index of the abnormal pipe fitting group are compared with the preset allowable weld quality abnormality index and the allowable pipe quality abnormality index to obtain the specific abnormal direction of the abnormal pipe fitting group.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) When performing a feasibility analysis on the welding operation of a target pipe group, the present invention automatically collects abnormal conditions of the seam width of the target pipe group, and then determines whether the welding operation is allowed. This analysis method adopts an automated intelligent judgment method, which can accurately measure and analyze the seam width, avoiding errors that may occur in manual measurement, thereby improving the quality of subsequent welding operations and ensuring the reliability and safety of welding products. At the same time, the automated identification method improves the overall welding efficiency.

[0037] (2) When performing pipe welding operations, the present invention first analyzes the pipe wall thickness and then obtains appropriate welding parameters based on the pipe wall thickness. This analysis method can reduce welding defects, thereby ensuring welding quality. At the same time, the welding parameters are automatically adjusted according to different pipe parameters, thereby improving the adaptability and versatility of the welding system, avoiding excessively long or short welding time due to inappropriate parameters, improving welding efficiency, shortening production cycles, reducing welding costs, and also reducing rework and material loss caused by welding defects.

[0038] (3) The present invention performs weld quality inspection and pipe quality inspection on the finished product after the welding operation, and then conducts abnormality pointing analysis on the situation of welding abnormality based on the monitoring results, and then forms a closed loop with position fixation and welding parameter analysis. This analysis method can timely discover abnormalities in the welding process, accurately point out the problem through quality inspection feedback, promote the optimization of welding parameters and pipe fixing strategy, so as to continuously improve the quality of welding products. The data collected by the closed-loop analysis can be used for long-term process optimization. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for describing the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0040] Figure 1 It is a schematic diagram of the connection of each module of the system of the present invention.

[0041] Figure 2 It is a schematic diagram of the welding area of ​​the present invention.

[0042] Reference numerals: 1 - monitoring distance, 2 - weld seam, 3 - welding area. DETAILED DESCRIPTION

[0043] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0044] See also Figure 1 As shown, the present invention provides a pipe welding automation control system, which includes a fixing mechanism setting module, a pipe position fixing module, a welding parameter setting module, a welding operation execution module, a welding quality analysis module and a welding abnormality identification module, wherein the fixing mechanism setting module is connected to the pipe position fixing module, the pipe position fixing module is connected to the welding parameter setting module, the welding parameter setting module is connected to the welding operation execution module, the welding operation execution module is connected to the welding quality analysis module, and the welding quality analysis module is connected to the welding abnormality identification module.

[0045] The fixing mechanism setting module is used to set a fixing mechanism, and the fixing mechanism includes a first fixing device and a second fixing device, wherein the first fixing device is used to fix the first pipe, and the second fixing device is used to fix the second pipe.

[0046] It should be noted that the reasons for fixing pipe fittings are: fixing pipe fittings can ensure the precise alignment of two or more pipe fittings during the welding process, help ensure the straightness and flatness of the weld, and reduce the workload of post-weld correction; the thermal stress generated during the welding process may cause slight movement or deformation of the pipe fittings, and fixing can limit this movement and ensure that the position of the pipe fittings remains unchanged during the welding process.

[0047] Exemplarily, the fixing device may be a mechanical arm or a mechanical clamp.

[0048] The pipe position fixing module is used to record the first pipe and the second pipe to be welded as a target pipe group, fix the target pipe group using a fixing mechanism, and scan the fixed target pipe group using a three-dimensional scanning device, analyze the abnormality of the seam width of the target pipe group according to the scanning result, and judge whether the welding operation is allowed. When it is judged that the welding operation is not allowed, adjust the fixing mechanism to fix the position of the target pipe group again.

[0049] It should be noted that the gap width between the pipes to be welded affects the welding quality: too large a gap may result in the molten metal being unable to fully fill the gap, causing the weld to be irregular in shape or even forming weld nodules or pits. In order to fill the gap that is too large, more welding materials are needed, which not only increases the cost but may also affect the weld performance.

[0050] Preferably, the analysis of the abnormal situation of the gap width of the target pipe group is specifically as follows: extracting the scanning data of the target pipe group obtained by using a three-dimensional scanning device, and then constructing a three-dimensional contour of the target pipe group, recording the area of ​​the target pipe group corresponding to the first pipe and the second pipe to be connected as the area to be welded, locating the area to be welded of the target pipe group, and arranging a number of detection points at equal distances in the area to be welded of the target pipe group, and obtaining the monitoring width corresponding to each detection point.

[0051] The monitoring width corresponding to each detection point is compared with the preset reference monitoring width to obtain the deviation of each monitoring width, and the mean of each monitoring width deviation is calculated to obtain the deviation of the gap width of the target pipe group.

[0052] Exemplarily, the reference monitoring width is .

[0053] It should be added that the monitoring width deviation analysis steps are: the monitoring width corresponding to each detection point is calculated by difference with the reference monitoring width to obtain the monitoring width deviation value, and then the absolute value of each monitoring width deviation value is calculated by ratio with the reference monitoring width to obtain the monitoring width deviation.

[0054] It should be noted that the specific impact of the gap width deviation on the gap width anomaly index of the target pipe group is: a large gap width deviation may lead to excessive use of welding materials and increase costs; an inappropriate gap width will complicate the welding process and may require multiple fillings and adjustments, reducing the welding speed and overall efficiency; the gap width deviation affects the predictability and quality control of the welding process and may lead to an increase in the defective rate.

[0055] The monitoring width deviation values ​​are compared to obtain the maximum monitoring width deviation and the minimum monitoring width deviation, and then compared to obtain the gap width difference of the target pipe group.

[0056] It should be added that the steps for analyzing the difference in width of gaps of the target pipe fitting group are as follows: compare the maximum monitoring width deviation with the minimum monitoring width deviation; if both the maximum monitoring width deviation and the minimum monitoring width deviation are positive or negative, sum the absolute values ​​of the maximum monitoring width deviation and the minimum monitoring width deviation to obtain the difference in width of gaps of the target pipe fitting group; if the maximum monitoring width deviation and the minimum monitoring width deviation are one positive and one negative, sum the maximum monitoring width deviation and the minimum monitoring width deviation to obtain the difference in width of gaps of the target pipe fitting group.

[0057] It should be noted that the difference in seam width reflects the consistency and stability of the seam width of the target pipe group. The specific impact is: the stability of the seam width is crucial to the welding process. Small difference means that the welding conditions are more controllable, which can reduce welding defects such as lack of fusion, cracks, pores and slag inclusions, thereby improving the overall quality of welding.

[0058] The gap width deviation and gap width difference of the target pipe fitting group are accumulated and calculated according to the weight to obtain the gap width anomaly index of the target pipe fitting group.

[0059] For example, the weights of the gap width deviation and the gap width difference are: .

[0060] Preferably, the determination of whether the welding operation is allowed is specifically as follows: comparing the gap width abnormality index of the target pipe group with the preset allowable gap width abnormality index; when the gap width abnormality index of the target pipe group is greater than the allowable gap width abnormality index, determining that the welding operation is not allowed; and when the gap width abnormality index of the target pipe group is less than or equal to the allowable gap width abnormality index, determining that the welding operation is allowed.

[0061] For example, the allowable gap width abnormality index is .

[0062] It should be noted that, when conducting a feasibility analysis on the welding operation of a target pipe group, the present invention automatically collects abnormal conditions of the seam width of the target pipe group, and then determines whether the welding operation is allowed. This analysis method adopts an automated intelligent judgment method, which can accurately measure and analyze the seam width, avoiding errors that may occur in manual measurement, thereby improving the quality of subsequent welding operations and ensuring the reliability and safety of welding products. At the same time, the automated identification method improves the overall welding efficiency.

[0063] The welding parameter setting module is used to collect the pipe wall thickness of the target pipe group when it is judged that the welding operation is allowed, and then judge whether it is necessary to set the welding parameters by region. If it is judged that it is necessary, the welding parameters are set by region for the target pipe group; if it is judged that it is not necessary, the welding parameters are set based on the average pipe thickness of the target pipe group.

[0064] Exemplarily, the welding parameters may be welding current and welding speed.

[0065] It should be noted that the reasons for selecting welding speed and welding current as the monitored welding parameters are: the welding current directly affects the penetration depth and width of the weld, and the current has a direct impact on the penetration ability and shape of the weld; the welding speed is closely related to heat input and directly affects the performance of the weld and its surrounding materials.

[0066] Preferably, the determination of whether it is necessary to perform regional welding parameter setting is specifically as follows: extracting three-dimensional data information of the target pipe group obtained by using a three-dimensional scanning device, and then locating the area to be welded of the target pipe group, and arranging a number of acquisition points at equal distances along the extension direction of the weld in the area to be welded of the target pipe group, and obtaining the first pipe wall thickness and the second pipe wall thickness corresponding to each acquisition point.

[0067] The first pipe wall thickness and the second pipe wall thickness of each collection point are compared, and the smaller pipe wall thickness is selected as the effective pipe wall thickness of the corresponding collection point.

[0068] It should be noted that the reason for selecting a smaller pipe wall thickness as the effective pipe wall thickness of the corresponding collection point is that excessive welding parameters may cause the pipe wall with a lower thickness to be punctured or deformed. Therefore, it is more appropriate to select a smaller pipe wall thickness as an influencing factor for the selection of welding parameters, which can ensure the quality of the welded products.

[0069] The effective wall thickness of each acquisition point is compared to obtain the maximum wall thickness and the minimum wall thickness of the target pipe group, and then the differential wall thickness is obtained by comparison. The differential wall thickness of the target pipe group is compared with the preset allowable differential wall thickness to obtain a judgment result on whether it is necessary to set the welding parameters for each area.

[0070] It should be noted that the reason for using the pipe wall thickness as a basis for determining whether it is necessary to perform regional welding parameter setting is that different pipe wall thicknesses have different requirements for welding parameters.

[0071] For example, the allowed difference in pipe wall thickness is .

[0072] It should be added that when the differential wall thickness of the target pipe group is greater than the allowable differential wall thickness, it is determined that regional welding parameter setting is required; when the differential wall thickness of the target pipe group is less than or equal to the allowable differential wall thickness, it is determined that regional welding parameter setting is not required.

[0073] Preferably, the regional welding parameter setting is specifically as follows: the effective wall thickness of each collection point of the target pipe fitting group is compared with the effective wall thickness of the adjacent collection point to obtain the wall thickness similarity of each collection point and the adjacent collection point, and then compared with the preset similarity of the qualified wall thickness. If the wall thickness similarity of a certain collection point and the adjacent collection point is greater than or equal to the qualified wall thickness similarity, it is judged that the collection point and the corresponding adjacent collection point belong to the same collection area. If the wall thickness similarity of a certain collection point and the adjacent collection point is less than the qualified wall thickness similarity, it is judged that the collection point and the corresponding adjacent collection point do not belong to the same collection area, and then the collection points of the target pipe fitting group are divided into several collection areas.

[0074] For example, the similarity of the qualified pipe wall thickness is .

[0075] It should be added that the steps of analyzing the similarity of pipe wall thickness are as follows: the effective pipe wall thickness of a certain collection point is subtracted from the effective pipe wall thickness of the adjacent collection point, and then the result of the difference calculation is ratio-calculated with the effective pipe wall thickness of the collection point to obtain the difference of pipe wall thickness, and 1 is subtracted from the difference of pipe wall thickness between the collection point and the adjacent collection point to obtain the similarity of pipe wall thickness.

[0076] The effective pipe wall thickness of the corresponding collection points in each collection area is averaged to obtain the monitored pipe wall thickness of each collection area.

[0077] It should be noted that the reason for being able to perform mean calculation is that a preliminary similarity analysis has been conducted to ensure that the pipe wall thickness in the same area is similar. Therefore, selecting welding parameters based on the results of the average value analysis will not cause the pipe wall at each collection point to be punctured or deformed.

[0078] Based on the monitored pipe wall thickness corresponding to each acquisition area, the welding parameters of the target pipe group corresponding to each acquisition area are obtained.

[0079] It should be noted that, since different pipe wall thicknesses have different requirements for welding parameters, there is a corresponding relationship between pipe wall thickness and welding parameters, so the corresponding adaptive welding parameters can be obtained through the pipe wall thickness.

[0080] It should be noted that, when performing pipe welding operations, the present invention first analyzes the pipe wall thickness, and then obtains adaptive welding parameters based on the pipe wall thickness. This analysis method can reduce welding defects, thereby ensuring welding quality. At the same time, the welding parameters are automatically adjusted according to different pipe parameters, thereby improving the adaptability and versatility of the welding system, avoiding excessively long or short welding time due to improper parameters, improving welding efficiency, shortening production cycles, reducing welding costs, and also reducing rework and material losses caused by welding defects.

[0081] The welding operation execution module is used to perform welding operations on the pipe fittings after the welding parameters are set.

[0082] The welding quality analysis module is used to perform quality inspection on the target pipe group after welding, specifically including weld quality inspection and pipe quality inspection, and then analyze the welding operation quality based on the quality inspection results.

[0083] Preferably, the weld quality inspection and analysis steps are as follows: using a laser scanning sensor to move horizontally along the weld surface of the target pipe group after the welding operation, obtaining three-dimensional data of the weld surface and generating a three-dimensional contour map of the weld surface weld layer.

[0084] Several monitoring points are set at equal distances along the extension direction of the weld layer, each monitoring point corresponds to the midpoint of the weld layer in the extension direction perpendicular to the weld layer, and the weld layer information of each monitoring point is obtained from the three-dimensional contour map of the weld layer surface of the target pipe group, specifically including the weld layer width and weld layer thickness.

[0085] It should be noted that the weld layer thickness refers to the distance from the tube surface to the highest point of the weld layer.

[0086] The weld layer width and weld layer thickness of each monitoring point are compared respectively to obtain the fluctuation of weld layer width and weld layer thickness of the target pipe assembly.

[0087] It should be noted that the reasons for selecting the fluctuation of weld layer width and weld layer thickness as influencing factors of weld quality abnormality index are: 1. Fluctuation of weld layer width: affects the appearance and internal structure of the weld. The inconsistency of weld width will cause local stress concentration, which may affect the strength and toughness of the weld. Welds with large width fluctuations may require more solder filling, which increases material cost and welding time. 2. Fluctuation of weld layer thickness: The thickness of the weld layer directly reflects the depth of penetration during the welding process. Large thickness fluctuations may mean unstable penetration, affecting the strength and durability of the weld. Insufficient weld layer thickness may result in incomplete fusion, while excessive thickness may cause overheating of the weld, resulting in degradation of the performance of the heat-affected zone or deformation of the weld.

[0088] The weld layer width fluctuation and weld layer thickness fluctuation of the target pipe fitting group are summed up according to the weights to obtain the weld quality anomaly index of the target pipe fitting group.

[0089] Exemplarily, the weights of the fluctuation of the welding layer width and the fluctuation of the welding layer thickness are .

[0090] Preferably, see Figure 2 As shown, the pipe quality inspection and analysis steps are as follows: a high-definition camera is used to obtain an image of the welding area of ​​the target pipe group after the welding operation, and the welding area includes the weld area and the area within a pre-set monitoring distance at both ends of the weld.

[0091] For example, the monitoring distance is .

[0092] It should be noted that during welding operation, the influence range of welding operation on pipe fittings is limited due to the attenuation of heat conduction. Therefore, only monitoring the damage condition in the welding area can more accurately reflect the actual damage condition.

[0093] The damage position in the welding area image is located, the number of damages in the welding area is counted, and then compared with the preset reference damage number to obtain the abnormality of the damage number.

[0094] It should be noted that damage types include but are not limited to undercut, penetration and cracks.

[0095] The damage position in the welding area is located, and then the damage position area is obtained using image processing software. The average area of ​​each damage position is calculated to obtain the monitored damage area, and the monitored damage area is compared with the welding area to obtain the abnormality of the damage degree.

[0096] The abnormality of the damage quantity and the abnormality of the damage degree are summed up according to the weights to obtain the pipe quality abnormality index of the target pipe group.

[0097] For example, the weights of the abnormality of the number of injuries and the abnormality of the degree of injury are .

[0098] Further preferably, the analyzing of the welding operation quality is specifically as follows: obtaining the welding operation quality index of the target pipe fitting group based on the weld quality abnormality index and the pipe quality abnormality index of the target pipe fitting group.

[0099] It should be added that the weld quality abnormality index of the target pipe group and pipe quality abnormality index Substitute into the analysis formula Get the welding operation quality index of the target pipe group ,in Respectively represent the weights of the weld quality abnormality index and the pipe quality abnormality index, .

[0100] For example, .

[0101] The welding anomaly identification module is used to determine whether there is a quality abnormality in the welding operation based on the quality of the welding operation, and identify the specific abnormal direction when it is determined to exist, and the abnormal direction includes position fixation abnormality and welding parameter abnormality.

[0102] Preferably, the determination of whether there is a quality abnormality in the welding operation is specifically as follows: comparing the welding operation quality index of the target pipe fitting group with a preset standard welding operation quality index; when the welding operation quality index of the target pipe fitting group is greater than or equal to the standard welding operation quality index, it is determined that there is no quality abnormality in the welding operation; when the welding operation quality index of the target pipe fitting group is less than the standard welding operation quality index, it is determined that there is a quality abnormality in the welding operation.

[0103] Exemplarily, the qualified welding operation quality index is .

[0104] Preferably, the identification of specific abnormal directions is specifically as follows: the target pipe group judged to have quality abnormalities in the welding operation is recorded as an abnormal pipe group.

[0105] The weld quality abnormality index and the pipe quality abnormality index of the abnormal pipe fitting group are compared with the preset allowable weld quality abnormality index and the allowable pipe quality abnormality index to obtain the specific abnormal direction of the abnormal pipe fitting group.

[0106] It should be added that, when the weld quality abnormality index of the abnormal pipe fitting group is greater than the allowable weld quality abnormality index, the specific abnormality of the abnormal pipe fitting group is judged to be a position fixed abnormality; when the pipe quality abnormality index of the abnormal pipe fitting group is greater than the allowable pipe quality abnormality index, the specific abnormality of the abnormal pipe fitting group is judged to be a welding parameter abnormality.

[0107] For example, the allowable weld quality abnormality index and the allowable pipe quality abnormality index are respectively .

[0108] It should be noted that the present invention performs weld quality inspection and pipe quality inspection on the finished product after the welding operation, and then performs abnormality pointing analysis on the situation where welding abnormalities occur based on the monitoring results, and then forms a closed loop with position fixation and welding parameter analysis. This analysis method can timely discover abnormalities in the welding process, promote the optimization of welding parameters and pipe fixing strategies, and thus continuously improve the quality of welded products. The data collected by the closed-loop analysis can be used for long-term process optimization to promote continuous improvement and innovation of welding technology.

[0109] The above contents are merely examples and explanations of the concept of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the concept of the invention or exceed the scope defined by the present invention, they shall all fall within the protection scope of the present invention.

Claims

1. A pipe welding automation control system, characterized in that: The system includes: A fixing mechanism setting module, used for setting a fixing mechanism, wherein the fixing mechanism comprises a first fixing device and a second fixing device, wherein the first fixing device is used for fixing the first pipe fitting, and the second fixing device is used for fixing the second pipe fitting; A pipe fitting position fixing module is used to record the first pipe fitting and the second pipe fitting to be welded as a target pipe fitting group, fix the target pipe fitting group using a fixing mechanism, and scan the fixed target pipe fitting group using a three-dimensional scanning device, analyze the abnormality of the seam width of the target pipe fitting group according to the scanning result, and judge whether the welding operation is allowed, and when it is judged that the welding operation is not allowed, adjust the fixing mechanism to fix the position of the target pipe fitting group again; A welding parameter setting module is used to collect the pipe wall thickness of the target pipe group when it is determined that the welding operation is allowed, and then determine whether it is necessary to set the welding parameters by region. If it is determined that it is necessary, the welding parameters are set by region for the target pipe group. If it is determined that it is not necessary, the welding parameters are set based on the average pipe thickness of the target pipe group. A welding operation execution module is used to perform welding operations on pipe fittings after welding parameters are set; The welding quality analysis module is used to perform quality inspection on the target pipe group after welding, including weld quality inspection and pipe quality inspection, and then analyze the welding operation quality based on the quality inspection results; A welding anomaly identification module is used to determine whether there is a quality anomaly in the welding operation based on the quality of the welding operation, and identify specific anomaly directions when it is determined that there is an abnormality, wherein the abnormality directions include position fixation abnormality and welding parameter abnormality; The abnormal situation of the gap width of the target pipe group to be analyzed is as follows: Extract the scanning data of the target pipe group obtained by using the three-dimensional scanning device, and then construct the three-dimensional contour of the target pipe group, record the area of ​​the target pipe group corresponding to the first pipe and the second pipe to be connected as the area to be welded, locate the area to be welded of the target pipe group, and arrange a number of detection points at equal distances in the area to be welded of the target pipe group, and obtain the monitoring width corresponding to each detection point; The monitoring width corresponding to each detection point is compared with the preset reference monitoring width to obtain the deviation of each monitoring width, and the deviation of each monitoring width is averaged to obtain the deviation of the gap width of the target pipe group; The deviations of each monitoring width are compared to obtain the maximum monitoring width deviation and the minimum distance deviation, and then compared to obtain the difference in the width of the gaps of the target pipe group; The gap width deviation and gap width difference of the target pipe group are accumulated and calculated according to the weight to obtain the gap width anomaly index of the target pipe group; The determination of whether it is necessary to perform regional welding parameter setting is as follows: Extracting the three-dimensional data information of the target pipe group obtained by using the three-dimensional scanning device, and then locating the area to be welded of the target pipe group, and arranging a number of acquisition points at equal distances along the extension direction of the weld in the area to be welded of the target pipe group, and obtaining the wall thickness of the first pipe and the wall thickness of the second pipe corresponding to each acquisition point; Compare the first pipe wall thickness of each sampling point with the second pipe wall thickness, and select the smaller pipe wall thickness as the effective pipe wall thickness of the corresponding sampling point; The effective wall thickness of each acquisition point is compared to obtain the maximum wall thickness and the minimum wall thickness of the target pipe group, and then the difference wall thickness is obtained by comparison. The difference wall thickness of the target pipe group is compared with the preset allowable difference wall thickness to obtain the judgment result of whether it is necessary to set the welding parameters for each area; The specific setting of the regional welding parameters is as follows: The effective wall thickness of each collection point of the target pipe fitting group is compared with the effective wall thickness of the adjacent collection point to obtain the wall thickness similarity of each collection point and the adjacent collection point, and then compared with the preset similarity of the qualified wall thickness. If the wall thickness similarity of a certain collection point and the adjacent collection point is greater than or equal to the qualified wall thickness similarity, it is judged that the collection point and the corresponding adjacent collection point belong to the same collection area. If the wall thickness similarity of a certain collection point and the adjacent collection point is less than the qualified wall thickness similarity, it is judged that the collection point and the corresponding adjacent collection point do not belong to the same collection area, and then the collection points of the target pipe fitting group are divided into several collection areas; The effective pipe wall thickness of the corresponding collection points in each collection area is averaged to obtain the monitoring pipe wall thickness of each collection area; Based on the monitored pipe wall thickness corresponding to each acquisition area, the welding parameters of the target pipe group corresponding to each acquisition area are obtained.

2. The pipe welding automation control system according to claim 1, characterized in that: The determination of whether the welding operation is allowed is specifically as follows: The gap width abnormality index of the target pipe fitting group is compared with the preset allowable gap width abnormality index. When the gap width abnormality index of the target pipe fitting group is greater than the allowable gap width abnormality index, it is judged that the welding operation is not allowed. When the gap width abnormality index of the target pipe fitting group is less than or equal to the allowable gap width abnormality index, it is judged that the welding operation is allowed.

3. The pipe welding automation control system according to claim 1, characterized in that: The weld quality inspection and analysis steps are as follows: A laser scanning sensor is used to horizontally move along the weld surface of the target pipe group after the welding operation to obtain three-dimensional data of the weld surface and generate a three-dimensional contour map of the weld layer on the weld surface; A number of monitoring points are set at equal distances along the extension direction of the weld layer, each monitoring point corresponds to the midpoint of the weld layer in the extension direction perpendicular to the weld layer, and the weld layer information of each monitoring point is obtained from the three-dimensional contour map of the weld layer surface of the target pipe group, specifically including the weld layer width and the weld layer thickness; The weld layer width and weld layer thickness of each monitoring point are compared to obtain the fluctuation of weld layer width and weld layer thickness of the target pipe assembly; The weld layer width fluctuation and weld layer thickness fluctuation of the target pipe fitting group are summed up according to the weights to obtain the weld quality anomaly index of the target pipe fitting group.

4. The pipe welding automation control system according to claim 3, characterized in that: The pipe quality inspection and analysis steps are as follows: Using a high-definition camera to obtain an image of the welding area of ​​the target pipe assembly after the welding operation, the welding area includes the weld area and areas within a preset monitoring distance at both ends of the weld; Locate the damage position in the welding area image, count the number of damages in the welding area, and then compare it with the preset reference damage number to obtain the abnormality of the damage number; Locate the damage position in the welding area, and then use image processing software to obtain the damage position area, and then calculate the average of the areas of each damage position to obtain the monitored damage area, and compare the monitored damage area with the welding area to obtain the abnormality of the damage degree; The abnormality of the damage quantity and the abnormality of the damage degree are summed up according to the weights to obtain the pipe quality abnormality index of the target pipe group.

5. The pipe welding automation control system according to claim 4, characterized in that: The analysis of welding operation quality is as follows: The welding operation quality index of the target pipe fitting group is obtained based on the weld quality abnormality index and the pipe quality abnormality index of the target pipe fitting group.

6. A pipe welding automation control system as claimed in claim 5, characterized in that: The specific details of judging whether there is quality abnormality in welding operation are as follows: The welding operation quality index of the target pipe fitting group is compared with the preset standard welding operation quality index. When the welding operation quality index of the target pipe fitting group is greater than or equal to the standard welding operation quality index, it is judged that there is no quality abnormality in the welding operation. When the welding operation quality index of the target pipe fitting group is less than the standard welding operation quality index, it is judged that there is quality abnormality in the welding operation.

7. The pipe welding automation control system according to claim 4, characterized in that: The specific abnormality points to be identified are as follows: The target pipe fitting group judged to have quality abnormalities in welding operation is recorded as an abnormal pipe fitting group; The weld quality abnormality index and the pipe quality abnormality index of the abnormal pipe fitting group are compared with the preset allowable weld quality abnormality index and the allowable pipe quality abnormality index to obtain the specific abnormality direction of the abnormal pipe fitting group.

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