A stainless steel pipe welding machine

Abstract

The present invention relates to a stainless steel pipe welding machine applied to the technical field of welding machines. Through the differential pair coil technology, the thickness of the steel pipe and the width of the welding area are measured, and the welding parameters are adaptively adjusted. Secondly, through the cooperation of the first detection component, the second detection component and the piezoelectric ceramic stack, the real-time dynamic adjustment of the distance between the welding gun and the surface of the steel pipe is realized, and the precise control of the arc length is ensured. In addition, the stacked first detection component and the second detection component are used to detect the slight defects in the weld, and the defect information is fed back instantly by non-destructive detection to avoid potential safety hazards. The weld preheating function accurately controls the temperature of the heating area through the preheating coil to create ideal conditions for welding, optimize welding performance, and reduce thermal cracks and metal embrittlement. Finally, the wire drying function uses the waste heat of the heat dissipation gas to effectively remove moisture from the surface of the welding wire, avoid the generation of spatter and pores during welding, improve welding stability, and ensure welding quality and welding accuracy.

Description

Technical Field

[0001] This invention relates to stainless steel pipe welding machines, and more particularly to a stainless steel pipe welding machine applied in the field of welding machine technology. Background Technology

[0002] Welding technology plays a crucial role in modern manufacturing, especially in fields such as pipeline construction, petrochemicals, shipbuilding, and aerospace. Welding stainless steel pipes is a critical process due to the unique properties of the material. Traditional stainless steel pipe welding techniques often rely on manual operation, which is not only inefficient but also results in weld quality that is highly dependent on the operator's skill level, making it difficult to guarantee consistency. Furthermore, the instability of the arc length during manual welding often leads to fluctuations in weld quality, increasing the likelihood of welding defects such as porosity, cracks, and lack of fusion.

[0003] Chinese invention patent CN109794726B discloses a stainless steel pipe welding machine, including a spot welding machine, a frame, a support plate, a first bracket, a second bracket, bearings, threaded pipes, openings, threaded pipe sleeves, a driven pulley, a transmission belt, a driving pulley, a motor, a chassis, pipe bodies, a housing, an air inlet pipe, an air outlet, an activated carbon filter, and a fan. The motor in this invention can drive the threaded pipes to rotate via the driving pulley, transmission belt, and driven pulley. Furthermore, the two threaded pipes can engage with the two pipe bodies to be welded under the action of the threaded sleeve, facilitating welding while the two pipe bodies are rotating. The fan effectively draws the welding fumes into the housing, and the activated carbon filter inside the housing removes harmful components from the fumes.

[0004] Although the above design achieves rotary welding of stainless steel pipe fittings and removes harmful components generated during welding through a filter, it still has certain limitations, such as low welding quality, insufficient welding precision, and lack of defect detection process. Summary of the Invention

[0005] In view of the above-mentioned prior art, the technical problem to be solved by the present invention is how to provide a stainless steel pipe welding machine that uses a composite multifunctional coil to adaptively adjust welding parameters, adjust the arc length in real time, preheat the weld, and detect weld defects, thereby improving welding quality, ensuring precise control of the arc length, promoting the formation of uniform and beautiful welds, reducing welding stress and deformation, using non-destructive detection of defects in the weld, providing immediate feedback on defect information, facilitating rapid repair, and avoiding potential safety hazards.

[0006] To address the aforementioned problems, this invention provides a stainless steel pipe welding machine, comprising a welding torch, an adjusting ring fixedly connected to the outer end of the welding torch, a piezoelectric ceramic stack fixedly connected to the bottom end of the adjusting ring, a heat insulation layer fixedly connected to the inner wall of the piezoelectric ceramic stack, a heat dissipation ring fixedly connected to the outer wall of the piezoelectric ceramic stack, a support ring fixedly connected to the bottom end of the piezoelectric ceramic stack, and the support ring being slidably connected to the welding torch; the bottom end of the heat dissipation ring being fixedly connected to the support ring; a support plate slidably connected to the outer wall of the adjusting ring; a drying ring fixedly connected to the top end of the support plate; an annular frame fixedly connected to the outer end of the support ring; a preheating coil wound around the outer end of the annular frame; a cooling ring fixedly connected to the bottom end of the annular frame; an inner shell fixedly connected to the outer end of the support plate; and a detection device fixedly connected to the outer end of the inner shell.

[0007] As a further improvement of this application, the detection device includes a first detection component and a second detection component fixedly connected to the outer end of the inner shell. The first detection component includes a detection frame fixedly connected to the outer end of the inner shell. A silicon steel sheet is fixedly connected to the inner wall of the detection frame, and a detection coil is wound around the outer wall of the detection frame. The first detection component and the second detection component have the same structure.

[0008] As a further improvement of this application, the first detection component and the second detection component are stacked and aligned axially, the distance between the first detection component and the second detection component is 20-30mm, and the coils of the first detection component and the second detection component are wound in opposite directions.

[0009] As a further improvement of this application, the detection frame is arc-shaped and the curvature is close to that of a stainless steel tube. The outer end of the first detection component is fixedly connected to an outer shell, and the outer shell is fixedly connected to the outer end of the second detection component. The top of the outer shell is fixedly connected to a plurality of symmetrically arranged condensation inlet pipes.

[0010] As another improvement of this application, the outer end of the detection frame is provided with a plurality of uniformly distributed through holes, and the through holes are interconnected with the condenser inlet pipe. The through holes on the detection frame are interconnected with the cooling ring, and the cooling ring is interconnected with the annular frame.

[0011] As a further improvement to this application, the inner wall of the annular frame is provided with multiple through holes, and the annular frame is connected to the cavity formed by the support ring, the support plate, and the inner shell. The top of the support plate is provided with a through hole, and the cavity formed by the support ring, the support plate, and the inner shell is connected to the drying ring through the through hole. The outer end of the drying ring is fixedly connected to a condenser outlet pipe, and the condenser outlet pipe is connected to the drying ring.

[0012] As a further improvement to this application, the heat insulation layer is made of boron nitride ceramic, the heat dissipation ring is made of copper and filled with phase change material, the annular frame is made of polyimide material and is arc-shaped with a curvature close to that of stainless steel tube, the inner shell is a magnetic shielding layer made of permalloy or ferrite material, and the cooling ring is made of engineering plastic polyimide.

[0013] As another improvement of this application, the piezoelectric ceramic stack is made of lead zirconate titanate material, with a single layer thickness of 0.1-0.2 mm, 100-200 layers, an inner electrode thickness of 1-2 μm, an outer electrode thickness of 10-20 μm, and a driving voltage of 100 V.

[0014] Includes the following steps;

[0015] S1. Adaptive adjustment of welding parameters;

[0016] The thickness of the stainless steel pipe and the width of the weld are detected by using a first and second detection component arranged in a stack. After signal processing and analysis, the control system adjusts the welding current, voltage, welding speed, wire feeding speed and other parameters according to the detected signals to ensure welding quality and efficiency.

[0017] S2, Real-time adjustment of arc length;

[0018] By detecting the real-time distance between the welding torch and the surface of the steel pipe and adjusting the position of the welding torch, the arc length is kept constant. The changes in the magnetic field are monitored by using stacked differential coils, and the actual distance is calculated after signal processing, so as to achieve real-time and precise control of the welding arc length.

[0019] S3. Weld defect detection;

[0020] After welding is completed, the changes in the electromagnetic properties of the weld are analyzed. The amplitude, frequency and phase information of the signal are used to identify and locate potential defects in the weld. Combined with machine learning algorithms, pattern recognition is performed to output the specific type, location and severity of the defects, so as to ensure the integrity and safety of the welded structure.

[0021] S4. Heat dissipation and welding wire drying;

[0022] During the welding process, a circulating cooling gas system effectively dissipates heat from the piezoelectric ceramic stack, preheating coil, first detection component, and second detection component. Simultaneously, the dissipated gas is used to dry the welding wire, cool the weld, and clean the welding slag, thereby optimizing welding quality, improving process stability and weld performance, and ensuring the integrity and aesthetics of the welded structure.

[0023] In summary, the application has the following beneficial effects:

[0024] 1. Adaptive adjustment of welding parameters: Utilizing differential coil technology, the thickness of the steel pipe and the width of the welding area are accurately measured, and the welding parameters are automatically adjusted to ensure the stability of the welding process and the consistency of the weld, significantly improving welding quality, while greatly increasing production efficiency, reducing welding problems caused by material differences, and achieving efficient and stable mass production.

[0025] 2. Real-time adjustment of arc length: The distance between the welding torch and the steel pipe surface is dynamically adjusted in real time through the first detection component, the second detection component and the piezoelectric ceramic stack, ensuring precise control of the arc length, promoting the formation of uniform and beautiful welds, reducing welding stress and deformation, improving the mechanical properties and service life of the finished product. At the same time, the closed-loop control mechanism enhances the controllability and repeatability of the welding process, reduces operator dependence and improves the level of automation.

[0026] 3. Weld quality inspection: The first and second inspection components are stacked to detect minute defects in the weld, such as cracks, lack of fusion, and porosity. Non-destructive testing of weld defects is used to provide real-time feedback on defect information, which facilitates rapid repair and avoids potential safety hazards. At the same time, the accumulated inspection data provides valuable information for continuous improvement of welding processes and promotes the iterative upgrading of welding technology.

[0027] 4. Weld preheating: The preheating coil precisely controls the temperature of the heating zone, creating ideal conditions for welding, optimizing welding performance, reducing hot cracking and metal embrittlement, and preheating can significantly improve the toughness of the welded joint, extend the product service life, and reduce maintenance costs.

[0028] 5. Welding wire drying: Utilizing the residual heat of the cooling gas, the moisture on the surface of the welding wire is effectively removed, avoiding spatter and porosity during welding, improving welding stability. At the same time, dried welding wire helps reduce welding defects, ensures the strength and corrosion resistance of the weld, and improves the reliability of the final product. Attached Figure Description

[0029] Figure 1 This is a first partial drawing of this application;

[0030] Figure 2 This is a second partial drawing of this application;

[0031] Figure 3 This is a third partial drawing of this application;

[0032] Figure 4 This is the fourth partial drawing of this application;

[0033] Figure 5 This is the fifth partial drawing of this application;

[0034] Figure 6 This is the sixth partial drawing of this application;

[0035] Figure 7 This is the seventh partial drawing of this application;

[0036] Figure 8 This is the front view of this application;

[0037] Figure 9 This is a cross-sectional view (AA) of this application;

[0038] Figure 10 This is a BB cross-sectional view of this application;

[0039] Figure 11 This is a schematic diagram of the overall structure of this application.

[0040] Description of the numbers in the figure:

[0041] 1. Welding torch; 2. Adjusting ring; 3. Piezoelectric ceramic stack; 4. Insulation layer; 5. Heat dissipation ring; 6. Support ring; 7. Support plate; 8. Drying ring; 9. Annular frame; 10. Preheating coil; 11. Cooling ring; 12. Inner shell; 13. First detection component; 14. Second detection component; 15. Detection frame; 16. Silicon steel sheet; 17. Detection coil; 18. Outer shell; 19. Condensate inlet pipe; 20. Condensate outlet pipe. Detailed Implementation

[0042] The three embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0043] The first implementation method:

[0044] Figure 1-11 A stainless steel pipe welding machine is shown, comprising a welding torch 1, an adjusting ring 2 fixedly connected to the outer end of the welding torch 1, a piezoelectric ceramic stack 3 fixedly connected to the bottom end of the adjusting ring 2, a heat insulation layer 4 fixedly connected to the inner wall of the piezoelectric ceramic stack 3, a heat dissipation ring 5 fixedly connected to the outer wall of the piezoelectric ceramic stack 3, a support ring 6 fixedly connected to the bottom end of the piezoelectric ceramic stack 3, and the support ring 6 slidably connected to the welding torch 1. The bottom end of the heat dissipation ring 5 is fixedly connected to the support ring 6. A support plate 7 is slidably connected to the outer wall of the adjusting ring 2. A drying ring 8 is fixedly connected to the top end of the support plate 7. An annular frame 9 is fixedly connected to the outer end of the support ring 6. A preheating coil 10 is wound around the outer end of the annular frame 9. A cooling ring 11 is fixedly connected to the bottom end of the annular frame 9. An inner shell 12 is fixedly connected to the outer end of the support plate 7. A detection device is fixedly connected to the outer end of the inner shell 12.

[0045] The welding torch 1 is used to generate an electric arc and feed the welding wire. The adjusting ring 2 connects the welding torch 1 and the piezoelectric ceramic stack 3, providing a mechanism and rigid support for adjusting the position of the welding torch, allowing the welding torch 1 to be finely adjusted as needed, ensuring the accurate distance between the welding torch 1 and the surface of the stainless steel pipe during the welding process. The piezoelectric ceramic stack 3 is used to adjust the position of the welding torch 1 in real time according to the detection signal, control the arc length, improve the automation level and welding quality of the welding process, ensure a constant arc length, and reduce manual intervention. The heat insulation layer 4 is located inside the piezoelectric ceramic stack 3 to prevent the heat of the welding torch 1 from being conducted to the piezoelectric ceramic stack 3, protecting the piezoelectric ceramic stack 3 from the high temperature during the welding process and extending its service life. A heat dissipation ring 5 surrounds the outside of the piezoelectric ceramic stack 3 to absorb the heat generated during operation, keeping the operating temperature of the piezoelectric ceramic stack 3 within a safe range and improving its operational stability and efficiency. A support ring 6 provides support for the piezoelectric ceramic stack 3, while keeping the welding torch 1 in a radial position and allowing the welding torch 1 to slide on the support ring 6. The sliding connection design of the support ring 6 makes the position adjustment of the welding torch 1 more flexible. A support plate 7 connects the drying ring 8 and the inner shell 12, providing support for the entire equipment and providing a path for the flow of cooling gas. The drying ring 8 is used to dry the welding wire, removing moisture from the surface of the welding wire. The dried welding wire can reduce spatter and porosity during the welding process, improving welding quality. The annular frame 9 carries the preheating coil 10 and also serves as the connection point for the cooling ring 11. The preheating coil 10 is used to preheat the welding area. Preheating can improve the welding performance of the welding material, reduce welding defects, and improve weld quality. The cooling ring 11 surrounds the bottom of the annular frame 9 and serves as a cooling channel to cool the preheating coil 10. The inner shell 12 is used to protect the internal components, provide structural support, and also has a magnetic shielding function.

[0046] The second implementation method:

[0047] Figure 1-11 The detection device shown includes a first detection component 13 and a second detection component 14 fixedly connected to the outer end of the inner housing 12. The first detection component 13 includes a detection frame 15 fixedly connected to the outer end of the inner housing 12. A silicon steel sheet 16 is fixedly connected to the inner wall of the detection frame 15, and a detection coil 17 is wound around the outer wall of the detection frame 15. The first detection component 13 and the second detection component 14 have the same structure.

[0048] The first detection component 13 and the second detection component 14 are stacked and aligned axially. The distance between the first detection component 13 and the second detection component 14 is 20-30mm. The coils of the first detection component 13 and the second detection component 14 are wound in opposite directions.

[0049] The detection frame 15 is arc-shaped and its curvature is close to that of a stainless steel pipe. The outer end of the first detection component 13 is fixedly connected to the outer shell 18, and the outer shell 18 is fixedly connected to the outer end of the second detection component 14. The top of the outer shell 18 is fixedly connected to a plurality of symmetrically arranged condensation inlet pipes 19.

[0050] The outer end of the detection frame 15 has multiple evenly distributed through holes, and the through holes are connected to the condenser inlet pipe 19. The through holes on the detection frame 15 are connected to the cooling ring 11, and the cooling ring 11 is connected to the annular frame 9.

[0051] The inner wall of the annular frame 9 has multiple through holes, and the annular frame 9 is connected to the cavity formed by the support ring 6, the support plate 7, and the inner shell 12. The top of the support plate 7 has a through hole, and the cavity formed by the support ring 6, the support plate 7, and the inner shell 12 is connected to the drying ring 8 through the through hole. The outer end of the drying ring 8 is fixedly connected to the condenser outlet pipe 20, and the condenser outlet pipe 20 is connected to the drying ring 8.

[0052] The heat insulation layer 4 is made of boron nitride ceramic, the heat dissipation ring 5 is made of copper and filled with phase change material, the annular frame 9 is made of polyimide material and is arc-shaped with a curvature close to that of stainless steel tube, the inner shell 12 is a magnetic shielding layer made of permalloy or ferrite material, the cooling ring 11 is made of engineering plastic polyimide, the piezoelectric ceramic stack 3 is made of lead zirconate titanate material, the thickness of a single piezoelectric ceramic layer is 0.1-0.2 mm, the number of layers is 100-200, the thickness of the inner electrode is 1-2 μm, the thickness of the outer electrode is 10-20 μm, and the driving voltage is 100V.

[0053] The first detection component 13 and the second detection component 14 are stacked and have the same structure. The detection frame 15 contains a silicon steel sheet 16, and the outer wall is wound with a detection coil 17. The coils are wound in opposite directions. This design can improve the sensitivity and accuracy of magnetic field induction. The opposite direction of coil winding helps to cancel background noise and enhance signal contrast. The detection frame 15 is designed as an arc, with a curvature close to that of a stainless steel tube. It has a through hole at the outer end. The arc design allows the detection component to fit tightly to the object to be detected, improving detection accuracy. The through hole design facilitates the flow of cooling medium and enhances thermal management. The outer shell 18 connects the first detection component 13 and the second detection component 14. It has a condenser inlet pipe 19 at the top, which provides overall structural stability. The condenser inlet pipe 19 introduces cooling medium to ensure the stable operating temperature of the detection component. The cooling ring 11 is connected to the through hole of the detection frame 15. The inner wall of the ring frame 9 has The through-hole and drying ring 8 connect to the condenser outlet pipe 20, forming a complete cooling circulation path to effectively remove the heat generated during the detection process. The drying ring 8 dries the welding wire. The heat insulation layer 4 is made of boron nitride ceramic, and the heat dissipation ring 5 is made of copper and phase change material. The inner shell 12 is a magnetic shielding layer made of permalloy or ferrite material. Boron nitride ceramic has excellent thermal insulation properties, copper and phase change material have efficient heat dissipation, and the magnetic shielding layer reduces external magnetic field interference, ensuring the accuracy and stability of the detection. The piezoelectric ceramic stack 3 is made of lead zirconate titanate material, with a single layer thickness of 0.1-0.2 mm and a total of 100-200 layers. The thickness of the inner electrode and the outer electrode are 1-2 μm and 10-20 μm, respectively. The driving voltage is 100V. The piezoelectric ceramic stack provides high-precision, high-response displacement output for real-time adjustment of the distance between the welding torch 1 and the steel pipe surface, ensuring a constant arc length.

[0054] The third implementation method:

[0055] Figure 1-11 The present invention illustrates a method of using a stainless steel pipe welding machine, including the following steps;

[0056] S1. Adaptive adjustment of welding parameters;

[0057] The welding equipment uses a welding robotic arm connected to the outer casing 18 to perform rotary welding on stainless steel pipes. Before welding begins, the width and thickness of the weld joint are measured. A first detection component 13 acts as a transmitting coil, and a second detection component 14 acts as a receiving coil, forming a differential pair. The first and second detection components 13 and 14 are designed to match the curvature of the steel pipe surface. The control system controls the detection frame 15 on the first detection component 13 to receive alternating current, generating an alternating magnetic field. This alternating magnetic field passes through the stainless steel pipe, generating eddy currents inside. These eddy currents then generate their own magnetic fields, which in turn react on the second detection component 14, changing its magnetic flux and consequently its impedance and induced voltage. The second detection component 14 detects the changes in the magnetic field caused by the stainless steel pipe and collects the signal of the induced voltage change. This data is then compared... The output signals of the two sets of coils in the first detection component 13 and the second detection component 14 can eliminate the influence of background noise and environmental factors, retaining only the signals related to the thickness of the stainless steel tube and the width of the weld. The original signal is first filtered to remove high-frequency noise and other irrelevant signals, and then the amplitude of the signal is increased by an amplifier to convert the analog signal into a digital signal, which is then transmitted to the processor. The amplitude, frequency or phase changes related to the thickness of the stainless steel tube and the width of the weld are extracted from the signal. Algorithms such as Fourier transform, wavelet transform, and neural network are used to identify specific patterns in the signal, which are compared with known data on the thickness of the stainless steel tube and the width of the weld. The analyzed data is converted into specific thickness and width values ​​and displayed on the operation interface. Finally, the detection results are fed back to the welding control system, which automatically adjusts the welding current, voltage, welding speed and wire feeding speed to optimize the welding effect.

[0058] The system utilizes a stacked first detection component 13 and a second detection component 14 to detect the thickness of the stainless steel pipe and the width of the weld before welding, providing high-resolution detection capabilities. The system can monitor the thickness of the stainless steel pipe and the width of the weld in real time, allowing welding parameters to be adjusted immediately to adapt to real-time changes in the stainless steel pipe material. This ensures the stability of the welding process and the consistency of the weld. Furthermore, the ability to adaptively adjust welding parameters improves the controllability and predictability of the welding process, reduces human error, directly optimizes welding parameters, increases welding speed, shortens the production cycle, and improves overall production efficiency. Additionally, the system can collect a large amount of welding data, which can be used for further analysis and improvement of the welding process.

[0059] S2, Real-time adjustment of arc length;

[0060] After the welding parameters are adjusted, the welding robotic arm drives the welding equipment to weld the stainless steel pipe. At the same time, the control system energizes the preheating coil 10 to preheat the welding area. By adjusting the power and frequency of the preheating coil 10, the temperature of the heating area is precisely controlled to ensure that the welding point reaches the ideal preheating temperature. Then, the detection frame 15 in the first detection component 13 and the second detection component 14 generates an alternating magnetic field. The second detection component 14 detects the change in magnetic field caused by the change in distance between the welding torch 1 and the surface of the steel pipe. The closer the distance, the stronger the magnetic field, and vice versa. This change will be reflected as the fluctuation of the induced voltage in the receiving coil. The acquired signal is first amplified by the preamplifier to enhance the signal strength. Then, the signal enters the filter to remove high-frequency noise and unwanted signal components. The filtered signal is sent to the analog-to-digital converter to convert the analog signal into a digital signal. The digital signal is input to the signal processing software for further analysis and processing to extract distance information. The signal processing system calculates the actual distance from the welding torch 1 to the surface of the steel pipe based on the change in the induced voltage of the receiving coil and the pre-calibrated voltage-distance relationship.

[0061] The calculated distance information is sent to the feedback loop of the control system and compared with the set target distance. Welding torch 1 is placed in the preset initial position, at which point the piezoelectric ceramic stack 3 is in the preset voltage state. The distance between welding torch 1 and the steel pipe surface is consistent with the target distance. After receiving the distance signal, the control system compares the actual measured distance with the preset target distance and calculates the deviation between the actual and target distances. Based on the magnitude of the deviation, the control system uses a PID control algorithm to calculate the voltage change to be applied to the piezoelectric ceramic stack 3. The control algorithm ensures that the adjustment of the welding torch 1 position is smooth and rapid, avoiding over-adjustment or oscillation. The control system applies the adjusted voltage to the piezoelectric ceramic stack 3. If the actual distance is greater than the target distance, the voltage increases, causing the piezoelectric ceramic stack 3 to... The piezoelectric ceramic stack 3 contracts, causing the adjusting ring 2 to move downwards, making the welding torch 1 slide along the support ring 6. The welding torch 1 approaches the surface of the steel pipe. If the actual distance is less than the target distance, the voltage decreases, the piezoelectric ceramic stack 3 extends, and the extension of the piezoelectric ceramic stack 3 causes the adjusting ring 2 to move upwards, making the welding torch 1 slide along the support ring 6. The welding torch 1 moves away from the surface of the steel pipe. The piezoelectric ceramic stack 3 responds to the voltage change, and the position of the welding torch 1 is adjusted accordingly. During the adjustment process, the differential coil continuously detects the new distance between the welding torch 1 and the surface of the steel pipe. The control system calculates and adjusts again based on the new signal to form a closed-loop control. When the position of the welding torch 1 is adjusted to be near the target distance, the control system continues to monitor the distance between the welding torch 1 and the surface of the steel pipe to ensure that the position of the welding torch 1 is stable at the target distance and that there is no unnecessary shaking or drifting.

[0062] Real-time adjustment of the distance between the welding torch 1 and the steel pipe surface ensures a constant arc length, which is conducive to forming a stable and high-quality weld. Precise temperature control in the preheating zone can improve the welding performance of stainless steel pipes, reduce welding stress and deformation, and improve the mechanical properties of the weld. Closed-loop control ensures precise adjustment of welding parameters. Even if there are slight fluctuations during the welding process, it can quickly return to the set ideal state. The fast-response piezoelectric ceramic stack 3 can quickly adjust the position of the welding torch 1, reducing errors caused by adjustment time. The use of PID control algorithms for welding preparation and adjustment time makes the adjustment of the welding torch 1 position smoother, avoiding over-adjustment and oscillation, and improving the stability and predictability of the welding process.

[0063] S3. Weld quality inspection;

[0064] After welding is completed, the weld is inspected for quality. The control system applies an alternating current to the first detection component 13, generating an alternating magnetic field. The magnetic field penetrates the weld and affects the induced voltage in the second detection component 14. The second detection component 14 captures magnetic field disturbances caused by changes in conductivity, permeability, or defects in the weld. These changes are reflected in the induced voltage of the second detection component 14. By analyzing the amplitude, frequency, and phase changes of the signal, the type and location of defects in the weld are reflected. Machine learning technology is applied to identify abnormal patterns in the signal. The location and type of defects are determined through signal analysis. The results are then compared with known standards or databases to determine the severity and type of defects. Features related to defects, such as signal bursts, distortions, or missing values, are extracted from the signal. A pattern recognition algorithm is used to identify defect patterns in the signal. The detected defect information, including defect type, location, and severity, is output.

[0065] Stacked differential coils can provide higher detection sensitivity and resolution, accurately identifying minute defects in welds such as cracks, lack of fusion, and porosity. This detection method is non-destructive, allowing inspection without damaging the weld structure. Immediate inspection after welding can promptly detect defects, avoiding waste in subsequent processes and reducing rework and repair costs. The inspection results can generate detailed data reports, facilitating quality control departments to analyze trends, identify potential problem areas, and implement preventative maintenance and process improvements. Early detection of potential weld defects can prevent safety hazards in stainless steel pipe equipment and reduce the risk of accidents caused by welding problems.

[0066] S4. Heat dissipation and welding wire drying;

[0067] During the welding process, heat dissipation is required for the piezoelectric ceramic stack 3, preheating coil 10, first detection component 13, second detection component 14, and the entire welding equipment. Cooling gas enters through multiple condenser inlet pipes 19. First, the cooling gas enters the detection frame 15 through the through hole to cool the first detection component 13. After passing through the first detection component 13, the cooling gas enters the second detection component 14 to cool the second detection component 14. After flowing out of the second detection component 14, the cooling gas enters the cooling ring 11 and the annular frame 9 to cool the preheating coil 10, while simultaneously isolating the heat generated by the welding torch 1. After flowing out through the through hole in the inner wall of the annular frame 9, the cooling gas absorbs the heat generated by the heat dissipation ring 5, indirectly cooling the piezoelectric ceramic stack 3. After cooling, the gas enters the drying ring 8 through the through hole on the support plate 7, and then flows out through the condenser outlet pipe 20. Finally, the gas flowing through the drying ring 8 has a certain temperature, which can dry the welding wire on the welding torch 1. The gas flowing out through the condenser outlet pipe 20 can cool the weld and clean the welding slag.

[0068] The cooled gas has a certain temperature, which can remove residual moisture and humidity from the surface of the welding wire, reduce spatter and porosity during welding, improve the stability of the welding process and the mechanical properties of the weld. The cooling gas can quickly remove some of the heat from the weld, promote rapid cooling of the weld, help control the microstructure of the weld, reduce the risk of hot cracking and deformation, and the gas flow can remove welding spatter and slag, keep the weld surface clean, which is beneficial for subsequent inspection and processing, and improve the appearance of the weld.

[0069] In light of current practical needs, the above-described embodiments adopted in this application are not limited to these. Any changes made within the scope of knowledge possessed by those skilled in the art without departing from the concept of this application still fall within the protection scope of this invention.

Claims

1. A stainless steel pipe welding machine, Features: The invention comprises a welding gun (1), wherein the outer end of the welding gun (1) is fixedly connected to an adjustment ring (2), the bottom end of the adjustment ring (2) is fixedly connected to a piezoelectric ceramic stack (3), the inner wall of the piezoelectric ceramic stack (3) is fixedly connected to a heat insulation layer (4), the outer wall of the piezoelectric ceramic stack (3) is fixedly connected to a heat dissipation ring (5), the bottom end of the piezoelectric ceramic stack (3) is fixedly connected to a support ring (6), and the support ring (6) is slidably connected to the welding gun (1), and the bottom end of the heat dissipation ring (5) is fixedly connected to the support ring (6). The outer wall of the adjusting ring (2) is slidably connected to a support plate (7), the top of the support plate (7) is fixedly connected to a drying ring (8), the outer end of the support ring (6) is fixedly connected to an annular frame (9), the outer end of the annular frame (9) is wound with a preheating coil (10), the bottom end of the annular frame (9) is fixedly connected to a cooling ring (11), the outer end of the support plate (7) is fixedly connected to an inner shell (12), and the outer end of the inner shell (12) is fixedly connected to a detection device; The detection device comprises a first detection component (13) and a second detection component (14) fixedly connected to the outer end of the inner shell (12); the first detection component (13) comprises a detection frame (15) fixedly connected to the outer end of the inner shell (12); a silicon steel sheet (16) is fixedly connected to the inner wall of the detection frame (15); a detection coil (17) is wound around the outer wall of the detection frame (15); the first detection component (13) and the second detection component (14) have the same structure; The detection frame (15) is arc-shaped, and its curvature is close to that of the stainless steel tube; the outer end of the first detection component (13) is fixedly connected to an outer shell (18), and the outer shell (18) is fixedly connected to the outer end of the second detection component (14); the top end of the outer shell (18) is fixedly connected to a plurality of symmetrically arranged condensation inlet pipes (19); The outer end of the detection frame (15) is provided with a plurality of evenly distributed through holes, and the through holes are interconnected with the condensation inlet pipe (19), the through holes on the detection frame (15) are interconnected with the cooling ring (11), and the cooling ring (11) is connected with the annular frame (9); The inner wall of the annular frame (9) is provided with a plurality of through holes, and the annular frame (9) is in communication with a cavity surrounded by the support ring (6), the support plate (7), and the inner shell (12); a through hole is provided at the top end of the support plate (7), and the cavity surrounded by the support ring (6), the support plate (7), and the inner shell (12) is in communication with the drying ring (8) through the through hole; a condensation outlet pipe (20) is fixedly connected to the outer end of the drying ring (8), and the condensation outlet pipe (20) is in communication with the drying ring (8).

2. A stainless steel pipe welding machine according to claim 1, Features: The first detection component (13) and the second detection component (14) are stacked and arranged, and the first detection component (13) and the second detection component (14) are aligned in the axial direction, the distance between the first detection component (13) and the second detection component (14) is 20-30 mm, and the coils of the first detection component (13) and the second detection component (14) are wound in opposite directions.

3. A stainless steel pipe welding machine according to claim 1, Features: The heat insulation layer (4) is made of boron nitride ceramics, the heat dissipation ring (5) is made of copper and is filled with phase change material, the annular frame (9) is made of polyimide material and is arc-shaped with a curvature close to that of a stainless steel tube, the inner shell (12) is a magnetic shielding layer, and the magnetic shielding layer is made of permalloy or ferrite material, and the cooling ring (11) is made of engineering plastic polyimide.

4. A stainless steel pipe welding machine according to claim 1, Features: The piezoelectric ceramic stack (3) is made of lead zirconate titanate material, the thickness of a single layer of piezoelectric ceramic is 0.1-0.2 mm, the number of layers is 100-200, the thickness of the inner electrode is 1-2 μm, the thickness of the outer electrode is 10-20 μm, and the driving voltage is 100 V.

5. A method for using a stainless steel pipe welding machine according to any one of claims 1 to 4, Features: The steps include: S1, adaptive adjustment of welding parameters; The thickness of the stainless steel pipe and the width of the weld are detected by using a first detection component (13) and a second detection component (14) arranged in a stacked manner. After signal processing and analysis, the control system adjusts the welding current, voltage, welding speed, wire feeding speed, etc. according to the detected signals to ensure welding quality and efficiency; S2, real-time adjustment of arc length; By detecting the real-time distance between the welding gun (1) and the surface of the steel pipe and adjusting the position of the welding gun (1), the arc length is ensured to be constant, and the stacked differential coil is used to monitor the magnetic field change, and the actual distance is calculated after signal processing, so as to achieve real-time and accurate control of the welding arc length; S3, weld defect detection; After welding is completed, the electromagnetic characteristics of the weld are analyzed, and the potential defects in the weld are identified and located using the amplitude, frequency and phase information of the signal. The machine learning algorithm is combined for pattern recognition to output the specific type, location and severity of the defect to ensure the integrity and safety of the welded structure. S4, heat dissipation and wire drying; During the welding process, the piezoelectric ceramic stack (3), the preheating coil (10), the first detection component (13), and the second detection component (14) are effectively cooled by the circulating cooling gas system. At the same time, the heat-dissipated gas is used to dry the welding wire, cool the weld, and clean the welding slag, thereby optimizing the welding quality, improving the process stability and weld performance, and ensuring the integrity and aesthetics of the welded structure.

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