Double-gun four-wire pipeline all-position automatic welding system and method

Abstract

The invention discloses a double-gun four-wire pipeline all-position automatic welding system and method. The system comprises a control system, a mechanical system and a welding power supply system, the welding power supply system comprises a wire feeding module and a welding power supply module which are connected; the mechanical system comprises a welding tractor, a first double-wire welding gun and a second double-wire welding gun; the gun tail of the first double-wire welding gun is provided with a first main gun barrel and a first auxiliary gun barrel. The gun tail of the second double-wire welding gun is provided with a second main gun barrel and a second auxiliary gun barrel. The control system comprises a main control box; the main control box is used for controlling the wire feeding module to feed wires to the first double-wire welding gun through the first main gun barrel and / or the first auxiliary gun barrel, controlling the wire feeding module to feed wires to the second double-wire welding gun through the second main gun barrel and / or the second auxiliary gun barrel, controlling the welding trolley to move and controlling welding operation of the first double-wire welding gun and the second double-wire welding gun. The system not only can adapt to different welding construction conditions, but also improves the welding efficiency and the welding quality.

Description

Technical Field

[0001] The invention relates to the field of long-distance pipeline welding, and in particular to a double-gun four-wire pipeline full-position automatic welding system and method. Background Art

[0002] With the rapid development of my country's oil and gas industry, the construction of long-distance pipeline projects has developed rapidly. As a key technology for the construction of long-distance pipeline projects, pipeline welding technology directly affects the construction quality, efficiency and cost of pipeline projects. With the continuous improvement of pipeline construction quality, in order to further meet the requirements of pipeline construction and the continuous development of advanced pipeline welding technology, pipeline construction welding technology has gradually developed from traditional manual arc welding and semi-automatic welding to pipeline full-position automatic welding technology. The application of automatic welding technology has opened an accelerator for long-distance pipeline construction, which has greatly improved the efficiency and quality of pipeline construction.

[0003] At present, the commonly used pipeline automatic welding process is narrow gap single welding gun or double welding gun gas shielded automatic welding. Based on this technology, in order to improve the efficiency of pipeline construction welding, further reducing the groove width or increasing the number of welding guns will greatly increase the difficulty of welder operation, which is not conducive to on-site application. Summary of the invention

[0004] In order to enrich the types of pipeline welding systems and increase the selection space of pipeline all-position automatic welding methods, an embodiment of the present invention provides a dual-gun four-wire pipeline all-position automatic welding system and method.

[0005] In a first aspect, an embodiment of the present invention provides a dual-gun four-wire pipeline full-position automatic welding system, including a control system, a mechanical system and a welding power supply system;

[0006] The welding power supply system includes a wire feeding module and a welding power supply module connected;

[0007] The mechanical system comprises a welding carriage, a first double-wire welding gun and a second double-wire welding gun; the first double-wire welding gun and the second double-wire welding gun are fixed to the welding carriage;

[0008] The gun tail of the first double-wire welding gun is respectively provided with a first main gun barrel and a first auxiliary gun barrel;

[0009] The gun tail of the second double-wire welding gun is respectively provided with a second main gun barrel and a second auxiliary gun barrel;

[0010] The wire feeding module is respectively connected to the first main gun barrel, the first auxiliary gun barrel, the second main gun barrel and the second auxiliary gun barrel;

[0011] The control system includes a main control box;

[0012] The main control box is respectively connected to the welding carriage and the wire feeding module, and is used to control the wire feeding module to feed wire to the first twin-wire welding gun through the first main gun barrel and / or the first auxiliary gun barrel, control the wire feeding module to feed wire to the second twin-wire welding gun through the second main gun barrel and / or the second auxiliary gun barrel, control the movement of the welding carriage, and control the welding operations of the first twin-wire welding gun and the second twin-wire welding gun.

[0013] In one or some optional embodiments, the gun head of the first twin-wire welding gun is provided with a first conductive nozzle and a second conductive nozzle, and the angle between the first conductive nozzle and the second conductive nozzle is adjustable;

[0014] The gun head of the second twin-wire welding gun is provided with a third conductive nozzle and a fourth conductive nozzle, and the angle between the third conductive nozzle and the fourth conductive nozzle is adjustable.

[0015] In one or some optional embodiments, a first feedback line, a first wire feeding tube, a first water cooling tube and a first protective gas tube are arranged in the first main gun barrel, and the first conductive nozzle is connected to the first wire feeding tube;

[0016] A second feedback line and a second wire feeding tube are arranged in the first secondary gun barrel, and the second conductive nozzle is connected to the second wire feeding tube;

[0017] A third feedback line, a third wire feeding tube, a second water cooling tube and a second protective gas tube are arranged in the second main gun barrel, and the third conductive nozzle is connected to the third wire feeding tube;

[0018] A fourth feedback line and a fourth wire feeding tube are arranged in the second sub-barrel, and the fourth conductive nozzle is connected to the fourth wire feeding tube.

[0019] In one or some optional embodiments, the wire feeding module includes a first wire feeding box, a second wire feeding box, a third wire feeding box, a fourth wire feeding box, a first protective gas bottle, a second protective gas bottle, a first water cooling box and a second water cooling box;

[0020] The first protective gas cylinder and the first water cooling box are respectively connected to the first wire feeding box;

[0021] The first wire feeding box is connected to the first main barrel;

[0022] The second wire feeding box is connected to the first auxiliary barrel;

[0023] The second protective gas cylinder and the second water cooling box are respectively connected to the third wire feeding box;

[0024] The third wire feeding box is connected to the second main barrel;

[0025] The fourth wire feeding box is connected to the second auxiliary gun barrel.

[0026] In one or some optional embodiments, the first main gun barrel and the gun head direction of the first twin-wire welding gun form an angle of 145° to 175°;

[0027] The first secondary gun barrel and the gun head direction of the first double-wire welding gun form an angle of 145° to 175°;

[0028] The second main gun barrel and the gun head direction of the second double-wire welding gun form an angle of 145° to 175°;

[0029] The second auxiliary gun barrel and the gun head direction of the second twin-wire welding gun form an angle of 145° to 175°.

[0030] In one or some optional embodiments, the tail of the first twin-wire welding gun is provided with a first interface;

[0031] The first interface is suitable for connecting the first auxiliary barrel so that the first auxiliary barrel can be detachably mounted on the first double-wire welding gun;

[0032] The tail of the second twin-wire welding gun is provided with a second interface;

[0033] The second interface is suitable for connecting the second auxiliary gun barrel so that the second auxiliary gun barrel can be detachably installed on the second twin-wire welding gun.

[0034] In one or some optional embodiments, the control system further comprises a laser vision tracker;

[0035] The laser vision tracker is fixed to the forward end of the welding carriage and is used to scan the width and depth of the pipeline groove and transmit the scanning signal to the main control box.

[0036] In one or some optional embodiments, the control system further comprises a position sensor;

[0037] The position sensor is arranged in the welding carriage, and is used for obtaining the position of the welding carriage, and transmitting the obtained position signal to the main control box.

[0038] In one or some optional embodiments, the control system further comprises a handheld box;

[0039] The handheld box is connected to the main control box and is used to send an operation signal to the main control box.

[0040] In one or some optional embodiments, the mechanical system further comprises a guide track;

[0041] The guide track is annular and can be sleeved on the pipeline.

[0042] In one or some optional embodiments, the welding carriage comprises a first welding gun clamping mechanism, a second welding gun clamping mechanism, a welding gun vertical adjustment mechanism, a welding gun horizontal adjustment mechanism and a carriage base;

[0043] The first welding gun clamping mechanism, the second welding gun clamping mechanism, the welding gun vertical adjustment mechanism and the welding gun horizontal adjustment mechanism are respectively arranged above the trolley base;

[0044] The first welding gun clamping mechanism is used to clamp the first double-wire welding gun;

[0045] The second welding gun clamping mechanism is used to clamp the second double-wire welding gun;

[0046] The welding gun vertical adjustment mechanism and the welding gun horizontal adjustment mechanism are used to adjust the positions of the first twin-wire welding gun and the second twin-wire welding gun.

[0047] In one or some optional embodiments, the welding carriage further includes a traveling mechanism and a clamping mechanism;

[0048] The clamping mechanism clamps the guide rail and can move relative to the guide rail;

[0049] The traveling mechanism is used to drive the welding carriage to slide along the guide track.

[0050] In a second aspect, an embodiment of the present invention provides a dual-gun four-wire pipeline full-position automatic welding method, which uses the dual-gun four-wire pipeline full-position automatic welding system described in the first aspect, including:

[0051] Controlling the wire feeding module to feed wire to the first double-wire welding gun through the first main gun barrel and / or the first auxiliary gun barrel;

[0052] Controlling the wire feeding module to feed wire to the second double-wire welding gun through the second main gun barrel and / or the second auxiliary gun barrel;

[0053] The first twin-wire welding gun and / or the second twin-wire welding gun are controlled to perform pipeline all-position welding operation, and the welding carriage is controlled to move around the pipeline.

[0054] The beneficial effects of the above technical solution provided in the embodiments of the present invention include at least:

[0055] The double-gun four-wire pipeline full-position automatic welding system provided in the embodiment of the present invention is configured by respectively arranging the first main gun barrel and the first auxiliary gun barrel at the gun tail of the first double-wire welding gun, and respectively arranging the second main gun barrel and the second auxiliary gun barrel at the gun tail of the second double-wire welding gun, so that the first double-wire welding gun and the second double-wire welding gun can switch between the double-wire welding state and the single-wire welding state at any time, thereby being able to adapt to different welding construction conditions and improving welding efficiency and welding quality; by cooperating with the first double-wire welding gun and the second double-wire welding gun to jointly perform pipeline full-position welding, the wire feeding speed is improved, thereby improving the welding speed and construction efficiency; because the two welding wires of the double-wire welding heat each other, the arc energy can be fully utilized, and the deposition efficiency is higher than that of the single-wire welding, thereby improving the construction efficiency of pipeline full-position welding; and because the welding molten width and the molten pool length of the double-wire welding are increased, the first double-wire welding gun and the second double-wire welding gun do not need to swing or only need to slightly swing during the process of pipeline full-position welding, effectively improving the situation of the groove side wall not being fused and the appearance of pores in narrow gap welding, and improving the welding construction quality of pipeline full-position automatic welding.

[0056] Other features and advantages of the present invention will be described in the following description, and partly become apparent from the description, or understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the written description and the accompanying drawings.

[0057] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0059] Figure 1 It is a structural schematic diagram of a dual-gun four-wire pipeline full-position automatic welding system provided in an embodiment of the present invention;

[0060] Figure 2 It is a schematic structural diagram of a first double-wire welding gun head provided in an embodiment of the present invention;

[0061] Figure 3 It is a structural schematic diagram of the tail portion of a first twin-wire welding gun provided in an embodiment of the present invention;

[0062] Figure 4 A schematic diagram of a welding carriage provided in an embodiment of the present invention;

[0063] Figure 5 A control schematic diagram of a dual-gun four-wire pipeline full-position automatic welding system provided in an embodiment of the present invention;

[0064] Figure 6 This is a schematic diagram of a Φ1219 pipe groove with a wall thickness of 18.4 mm provided in an embodiment of the present invention.

[0065] In the figure:

[0066] 1 is a welding power supply system, 11 is a wire feeding module, 111 is a first wire feeding box, 112 is a second wire feeding box, 113 is a third wire feeding box, 114 is a fourth wire feeding box, 115 is a first shielding gas cylinder, 116 is a second shielding gas cylinder, 12 is a welding power supply module, 121 is a first welding power supply, 122 is a second welding power supply, 123 is a third welding power supply, and 124 is a fourth welding power supply;

[0067] 2 is a mechanical system, 21 is a welding carriage, 211 is a first welding gun clamping mechanism, 212 is a second welding gun clamping mechanism, 213 is a welding gun vertical adjustment mechanism, 214 is a welding gun horizontal adjustment mechanism, 215 is a carriage base, 216 is a walking mechanism, 217 is a clamping mechanism, 22 is a first double-wire welding gun, 221 is a first conductive nozzle, 222 is a second conductive nozzle, 223 is a first fastening screw, 224 is a first interface, and 23 is a guide rail;

[0068] 24 is the first main gun barrel, 241 is the first wire feeding tube, 242 is the first water cooling tube, 243 is the first protective gas tube, 25 is the first auxiliary gun barrel, 251 is the second wire feeding tube, 26 is the second main gun barrel, and 27 is the second auxiliary gun barrel;

[0069] 3 is a control system, 31 is a main control box, 32 is a laser vision tracker, and 33 is a handheld box. DETAILED DESCRIPTION

[0070] The exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although the exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art.

[0071] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", "far", "near", "front", "back" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0072] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0073] The inventors have found that the existing single-torch and double-torch automatic welding technologies both use high-frequency swing welding due to the small welding arc melting width, which is prone to side wall unfusion problems caused by insufficient swinging, affecting the pipeline welding quality; in addition, when welding thick-walled pipes, the external filling layer requires a large swing width, and the swing parameters are difficult to match with other welding parameters, which is prone to near-surface unfusion defects.

[0074] Based on this, an embodiment of the present invention provides a dual-gun four-wire pipeline all-position automatic welding system and method, which are described in detail below through specific embodiments.

[0075] Embodiment 1

[0076] The embodiment of the present invention provides a dual-gun four-wire pipeline full-position automatic welding system, referring to Figure 1-Figure 4 As shown, it includes a welding power supply system 1, a mechanical system 2 and a control system 3;

[0077] The welding power supply system 1 comprises a wire feeding module 11 and a welding power supply module 12 connected;

[0078] The mechanical system 2 includes a welding carriage 21, a first double-wire welding gun 22 and a second double-wire welding gun (not shown in the figure); the first double-wire welding gun 22 and the second double-wire welding gun are fixed to the welding carriage 21;

[0079] The first double-wire welding gun 22 is provided with a first main gun barrel 24 and a first auxiliary gun barrel 25 at the gun tail.

[0080] The second double-wire welding gun has a second main gun barrel 26 and a second auxiliary gun barrel 27 at its gun tail.

[0081] The wire feeding module 11 is respectively connected to the first main gun barrel 24, the first auxiliary gun barrel 25, the second main gun barrel 26 and the second auxiliary gun barrel 27;

[0082] The control system 3 includes a main control box 31;

[0083] The main control box 31 is respectively connected to the welding carriage 21 and the wire feeding module 11, and is used to control the wire feeding module 11 to feed wire to the first twin-wire welding gun 22 through the first main gun barrel 24 and / or the first auxiliary gun barrel 25, control the wire feeding module 11 to feed wire to the second twin-wire welding gun through the second main gun barrel 26 and / or the second auxiliary gun barrel 27, control the movement of the welding carriage 21, and control the welding operations of the first twin-wire welding gun 22 and the second twin-wire welding gun.

[0084] In an embodiment of the present invention, the wire feeding module 11 is connected to the welding power supply module 12, the welding power supply module 12 receives the feedback signal of the wire feeding module 11, and the welding power supply module 12 performs output voltage and waveform control; the welding power supply module 12 controls the wire feeding motor of the wire feeding module 11 and accurately controls the wire feeding speed of the wire feeding module 11.

[0085] In a specific embodiment, referring to Figure 1 As shown, the wire feeding module 11 includes a first wire feeding box 111, a second wire feeding box 112, a third wire feeding box 113, a fourth wire feeding box 114, a first protective gas bottle 115, a second protective gas bottle 116, a first water cooling box (not shown in the figure) and a second water cooling box (not shown in the figure). The first wire feeding box 111 and the second wire feeding box 112 are used to provide welding wire to the first double-wire welding gun 22, the first protective gas bottle 115 is used to provide protective gas to the first double-wire welding gun 22, the first water cooling box is used to provide cooling water to the first double-wire welding gun 22, and the first wire feeding box 111 is respectively connected to the first protective gas bottle 115 and the first water cooling box; the first wire feeding box 111 is connected to the first main gun barrel 24, and the second wire feeding box 112 is connected to the first auxiliary gun barrel. The third wire feeding box 113 and the fourth wire feeding box 114 are used to provide welding wire to the second twin-wire welding gun, the second shielding gas cylinder 116 is used to provide shielding gas to the second twin-wire welding gun, the second water cooling box is used to provide cooling water to the second twin-wire welding gun, and the third wire feeding box 113 is connected to the second shielding gas cylinder 116 and the second water cooling box respectively; the third wire feeding box 113 is connected to the second main gun barrel 26, and the fourth wire feeding box 114 is connected to the second auxiliary gun barrel 27.

[0086] In a specific implementation, the first water cooling box circulates cooling water to the gun head of the first twin-wire welding gun 22 through the first wire feeding box 111 and the first main gun barrel 24, and the second water cooling box circulates cooling water to the welding gun head of the second twin-wire welding gun through the third wire feeding box 113 and the second main gun barrel 26, thereby reducing the gun head temperature of the first twin-wire welding gun 22 and the second twin-wire welding gun during the welding process.

[0087] In a specific embodiment, the protective gas in the first protective gas cylinder 115 and the second protective gas cylinder 116 may be a mixed gas of argon and carbon dioxide.

[0088] In the embodiment of the present invention, refer to Figure 1-Figure 3As shown, the first main gun barrel 24 has a first feedback line (not shown in the figure), a first wire feeding tube 241, a first water cooling tube 242 and a first shielding gas tube 243 built in. The first feedback line can transmit electrical signals such as current, voltage and power to the first twin-wire welding gun 22, and the first wire feeding tube 241, the first water cooling tube 242 and the first shielding gas tube 243 can respectively provide welding wire, shielding gas and cooling water to the first twin-wire welding gun 22; the first auxiliary gun barrel 25 has a second feedback line (not shown in the figure) and a second wire feeding tube 251 built in. The second feedback line can transmit electrical signals such as current, voltage and power to the first twin-wire welding gun 22, and the second wire feeding tube 251 can provide welding wire to the first twin-wire welding gun 22.

[0089] In the embodiment of the present invention, the second main gun barrel 26 is built-in with a third feedback line (not shown in the figure), a third wire feeding tube (not shown in the figure), a second water cooling tube (not shown in the figure) and a second shielding gas tube (not shown in the figure). The third feedback line can transmit electrical signals such as current, voltage and power to the second twin-wire welding gun, and the third wire feeding tube, the second water cooling tube and the second shielding gas tube can respectively provide welding wire, shielding gas and cooling water to the second twin-wire welding gun; the second auxiliary gun barrel 27 is built-in with a fourth feedback line (not shown in the figure) and a fourth wire feeding tube (not shown in the figure). The fourth feedback line can transmit electrical signals such as current, voltage and power to the second twin-wire welding gun, and the fourth wire feeding tube can provide welding wire to the second twin-wire welding gun.

[0090] In a specific embodiment, referring to Figure 1-Figure 3 As shown, the gun head of the first twin-wire welding gun 22 is provided with a first conductive nozzle 221 and a second conductive nozzle 222, and the first conductive nozzle 221 and the second conductive nozzle 222 are installed on the gun head of the first twin-wire welding gun 22 through a first fastening screw 223. The orientation of the first conductive nozzle 221 and the second conductive nozzle 222 can be adjusted through the first fastening screw 223, so that the angle between the first conductive nozzle 221 and the second conductive nozzle 222 can be adjusted. By reasonably determining the angle between the first conductive nozzle 221 and the second conductive nozzle 222 and the dry extension of the welding wire sent out by the first conductive nozzle 221 and the second conductive nozzle 222, the spacing between the vertices of the two welding wires can be adjusted, so that the first twin-wire welding gun 22 can be applied to welding conditions in different situations. When the first twin-wire welding gun 22 is used for pipeline welding, since two welding wires form a common welding pool during welding, the gun head of the first twin-wire welding gun 22 can swing freely in the pipeline groove with narrow gap and large depth, and the molten width and length of the welding pool of twin-wire welding are increased, which can effectively improve the problems of unfused side wall of the groove and air holes during narrow gap welding. During the welding process, the first twin-wire welding gun 22 does not need to swing or only needs to swing slightly to ensure that the grooves on both sides are completely fused. Under the same deposition efficiency conditions, twin-wire welding has a higher arc heat utilization rate, which is more conducive to ensuring joint performance.

[0091] In a specific embodiment, referring to Figure 1-Figure 3 As shown, the first main gun barrel 24 and the first auxiliary gun barrel 25 respectively form an angle of 145° to 175° with the direction of the gun head of the first twin-wire welding gun 22; the first wire feeding tube 241 is connected to the first conductive nozzle 221, and the first wire feeding box 111 provides welding wire to the first conductive nozzle 221; the second wire feeding tube 251 is connected to the second conductive nozzle 222, and the second wire feeding box 112 provides welding wire to the second conductive nozzle 222. The first water cooling box and the first shielding gas cylinder 115 can respectively provide cooling water and shielding gas to the first twin-wire welding gun 22 through the first wire feeding box 111, so as to reduce the gun head temperature during welding and provide gas shielding to the welding molten pool.

[0092] In the embodiment of the present invention, a first interface 224 is provided at the tail of the first twin-wire welding gun 22, and the first interface 224 is suitable for connecting the first auxiliary barrel 25, so that the first auxiliary barrel 25 can be detachably mounted on the first twin-wire welding gun 22. The first interface 224 can be a quick-insert fastening threaded port to achieve a detachable connection between the first interface 224 and the first auxiliary barrel 25, and because the first conductive nozzle 221 and the second conductive nozzle 222 are provided with welding wire by different wire feeding tubes, the first twin-wire welding gun 22 can switch to a single-wire welding structure at any time, thereby being able to adapt to different welding construction conditions, and improving welding efficiency and welding quality.

[0093] In a specific embodiment, the structure of the second twin-wire welding gun is the same as that of the first twin-wire welding gun 22, and the gun head thereof is provided with a third conductive nozzle (not shown in the figure) and a fourth conductive nozzle (not shown in the figure), and the third conductive nozzle and the fourth conductive nozzle are installed on the gun head of the second twin-wire welding gun through a second fastening screw (not shown in the figure), and the orientation of the third conductive nozzle and the fourth conductive nozzle can be adjusted through the second fastening screw, so that the angle between the third conductive nozzle and the fourth conductive nozzle can be adjusted. By reasonably determining the angle between the third conductive nozzle and the fourth conductive nozzle and the dry extension length of the welding wire sent out by the third conductive nozzle and the fourth conductive nozzle, the spacing adjustment of the two welding wire vertices can be achieved, so that the second twin-wire welding gun can be suitable for welding conditions in different situations. When the second twin-wire welding gun is used for pipeline welding, since the two welding wires form a common welding molten pool during welding, the gun head of the second twin-wire welding gun can swing freely in the pipeline groove with a narrow gap and a large depth, and the molten width and length of the welding molten pool of the twin-wire welding are increased, which can effectively improve the problems of unfused side walls of the groove and porosity during narrow gap welding. During the welding process, the second twin-wire welding gun does not need to swing or only needs to swing slightly to ensure that the grooves on both sides are completely fused.

[0094] In a specific embodiment, the second main gun barrel 26 and the second auxiliary gun barrel 27 respectively form an angle of 145° to 175° with the direction of the gun head of the second twin-wire welding gun. The third wire feeding tube is connected to the third conductive nozzle, and the third wire feeding box 113 provides welding wire to the third conductive nozzle; the fourth wire feeding tube is connected to the fourth conductive nozzle, and the fourth wire feeding box 114 provides welding wire to the fourth conductive nozzle. The second water cooling box and the second shielding gas cylinder 116 can respectively provide cooling water and shielding gas to the second twin-wire welding gun 113 through the third wire feeding box, so as to reduce the gun head temperature during welding and provide gas shielding to the welding molten pool.

[0095] In the embodiment of the present invention, a second interface (not shown in the figure) is provided at the tail of the second twin-wire welding gun, and the second interface is suitable for connecting the second auxiliary gun barrel 27, so that the second auxiliary gun barrel 27 can be detachably mounted on the second twin-wire welding gun. The second interface can be a quick-insert fastening threaded port to achieve detachable connection between the second interface and the second auxiliary gun barrel 27, and because the third conductive nozzle and the fourth conductive nozzle are provided with welding wire by different wire feeding tubes, the second twin-wire welding gun can switch to a single-wire welding structure at any time, thereby being able to adapt to different welding construction conditions, and improving welding efficiency and welding quality.

[0096] The inventors have found that most of the existing twin-wire welding guns are connected to industrial robots for lap welding and fillet welding in industrial production such as automobiles and ships. The welding gun head is thick and cannot penetrate into the bottom of the narrow gap groove. In addition, due to the large size of the welding gun and the long gun body, it is difficult to adapt to the environmental conditions of pipeline full-position welding. The first twin-wire welding gun 22 and the second twin-wire welding gun provided in the embodiment of the present invention have a light gun body and a gun head structure, which can meet the requirements of pipeline welding space size and narrow gap groove welding, and can realize the rapid conversion of single and double wire welding gun structures, thereby improving welding operation efficiency.

[0097] In a specific embodiment, referring to Figure 1 As shown, the welding power supply module 12 includes a first welding power supply 121, a second welding power supply 122, a third welding power supply 123 and a fourth welding power supply 124. The first welding power supply 121 is connected to the first wire feeding box 111 through a relay line, and is used to provide welding energy for the arc of the first conductive nozzle 221 of the first twin-wire welding gun 22; the second welding power supply 122 is connected to the second wire feeding box 112 through a relay line, and is used to provide welding energy for the arc of the second conductive nozzle 222 of the first twin-wire welding gun 22; the third welding power supply 123 is connected to the third wire feeding box 113 through a relay line, and is used to provide welding energy for the arc of the third conductive nozzle of the second twin-wire welding gun; the fourth welding power supply 124 is connected to the fourth wire feeding box 114 through a relay line, and is used to provide welding energy for the arc of the fourth conductive nozzle of the second twin-wire welding gun.

[0098] In a specific embodiment, referring to Figure 1As shown, the mechanical system 2 further includes a guide rail 23, which is annular and can be sleeved on the pipeline. The welding trolley 21 can move on the guide rail 23 to reach different positions of the pipeline and weld the pipeline groove.

[0099] In a specific embodiment, referring to Figure 4 As shown, the welding carriage 21 includes a first welding gun clamping mechanism 211, a second welding gun clamping mechanism 212, a welding gun vertical adjustment mechanism 213, a welding gun horizontal adjustment mechanism 214 and a carriage base 215. The first welding gun clamping mechanism 211, the second welding gun clamping mechanism 212, the welding gun vertical adjustment mechanism 213 and the welding gun horizontal adjustment mechanism 214 are respectively arranged above the carriage base 215; the first welding gun clamping mechanism 211 is used to clamp the first double-wire welding gun 22, and the second welding gun clamping mechanism 212 is used to clamp the second double-wire welding gun. The welding gun vertical adjustment mechanism 213 and the welding gun horizontal adjustment mechanism 214 are used to adjust the positions of the first twin-wire welding gun 22 and the second twin-wire welding gun. The welding gun vertical adjustment mechanism 213 can adjust the vertical distance between the first twin-wire welding gun 22 and the second twin-wire welding gun relative to the pipeline so that the height distance between the welding wire and the weld reaches the target distance; the welding gun horizontal adjustment mechanism 214 can adjust the horizontal distance between the first twin-wire welding gun 22 and the second twin-wire welding gun relative to the pipeline so that the welding wire is located in the center of the weld.

[0100] In a specific embodiment, referring to Figure 4 As shown, the welding carriage 21 also includes a traveling mechanism 216 and a clamping mechanism 217. The clamping mechanism 217 clamps the guide rail 23 and can move relative to the guide rail 23. The traveling mechanism 216 can drive the welding carriage 21 to slide along the guide rail 23 as a whole, that is, to make a circular motion around the pipeline.

[0101] In a specific embodiment, referring to Figure 1As shown, the first wire feeding box 111, the second wire feeding box 112, the third wire feeding box 113 and the fourth wire feeding box 114 are connected to the main control box 31 through control lines respectively. The first wire feeding box 111, the second wire feeding box 112, the third wire feeding box 113 and the fourth wire feeding box 114 can collect welding data (welding current, welding voltage, etc.) of the welding power module 12 during welding, and transmit the collected welding data to the main control box 31, so as to realize the real-time monitoring of the welding current and welding voltage by the main control box 31. The main control box 31 accurately determines the state of the droplet transfer according to the received welding data, and sends a control signal to the wire feeding module 11 and the welding power module 12 according to the preset welding program. After receiving the control signal of the main control box 31, the welding power module 12 accurately controls the welding parameters in the welding process according to the received control signal, and the welding parameters include current, voltage and welding time, etc., so as to control the arcs of the two welding wires to periodically complete the droplet transfer process according to the preset phase difference, thereby ensuring the stability of the arc and the welding accuracy. After the first wire feeding box 111, the second wire feeding box 112, the third wire feeding box 113 and the fourth wire feeding box 114 receive the control signal of the main control box 31, they provide welding wire, shielding gas and cooling water to the first twin-wire welding gun 22 and the second twin-wire welding gun according to the control signal of the main control box 31.

[0102] In a specific embodiment, referring to Figure 1 As shown, the control system 3 also includes a laser vision tracker 32, which is fixed to the forward end of the welding carriage 21 and perpendicular to the surface of the pipeline groove, and is used to scan the width and depth of the pipeline groove, and transmit the scanning signal to the main control box 31. Compared with the traditional arc tracking, the laser vision tracker 32 greatly improves the accuracy of the welding tracking technology and reduces manual interference. The main control box 31 is connected to the welding carriage 21 through a control line. The main control box 31 sends a control signal to the welding carriage 21 and the first double-wire welding gun 22 according to the scanning signal transmitted by the laser vision tracker 32. The welding carriage 21 adjusts its own movement speed and the position of the first double-wire welding gun 22 and the second double-wire welding gun according to the control signal to ensure that the gun head of the first double-wire welding gun 22 is always located in the center of the groove corner line during welding, and the position of the second double-wire welding gun can cooperate with the first double-wire welding gun 22; the first double-wire welding gun 22 adjusts its swing width and wire dry extension according to the control signal. The main control box 31 sends a control signal to the second twin-wire welding gun according to the scanning signal transmitted by the laser vision tracker 32 and the welding thickness of the first twin-wire welding gun 22. The second twin-wire welding gun adjusts its swing width and welding wire dry extension according to the control signal.

[0103] In a specific embodiment, the control system 3 also includes a position sensor (not shown in the figure), which is arranged in the welding trolley 21, for obtaining the position of the welding trolley 21 and transmitting the obtained position signal to the main control box 31, and the main control box 31 controls and adjusts the position of the welding trolley 21 according to the position signal.

[0104] In a specific embodiment, the control system 3 further includes a handheld box 33, which is connected to the main control box 31 and is used to send an operation signal to the main control box 31. The panel of the handheld box 33 includes a welding layer indicator, a welding layer selection button, a first double-wire welding gun 22 and a second double-wire welding gun switching button, a welding gun up / down / left / right motion control button, a swing width increase / decrease button (the multiplexing function in the non-welding state is main barrel wire feeding / secondary barrel wire feeding), a welding carriage 21 forward / backward button (the multiplexing function in the welding state is welding stop / welding stop), a jog welding wire button (the multiplexing function in the welding state is welding speed increase), a jog gas test button (the multiplexing function in the welding state is welding speed reduction), a single arc start, a double arc start and a stop button.

[0105] In the embodiment of the present invention, refer to Figure 5 As shown, the main control box 31 calls various parameters in the database according to the preset program, and sends control signals to the dual-gun welding trolley 21, the power module, and the wire feeding module 11 according to the scanning signals of the laser vision tracker 32 on the width and depth of the welding groove, thereby controlling the welding trolley 21, the welding power module 12 and the wire feeding module 11 to perform corresponding actions and adjustments, and is responsible for the digital communication of the entire dual-gun four-wire pipeline full-position automatic welding system.

[0106] In a specific embodiment, the dual-gun four-wire pipeline full-position automatic welding system further includes a power supply box (not shown in the figure) for supplying power to the dual-gun four-wire pipeline full-position automatic welding system. The power supply box includes a 5V power supply module and a 24V power supply module, and the 5V power supply module supplies power to the handheld box 33, the position sensor, and the main control box 31. The 24V power supply module supplies power to the welding trolley 21.

[0107] The inventors found that twin-wire welding, as an advanced and efficient welding technology, has been increasingly used in industrial production due to its advantages of high welding speed and deposition efficiency. It has also become a research hotspot in the current welding field and has been applied in manufacturing fields such as automobiles, ships, and steel structures. However, in the field of pipeline welding, due to the particularity of pipeline welding, welding is performed in all positions, including horizontal, vertical, and overhead. Precise control of the molten droplet transition is required to ensure the upward face formation and welding quality. Therefore, it has not been applied and promoted. The dual-gun four-wire full-position automatic welding system for pipelines provided in an embodiment of the present invention collects signals of the welding process through a laser vision tracker 32, a position sensor, a first wire feeding box 111, a second wire feeding box 112, a third wire feeding box 113 and a fourth wire feeding box 114, performs signal processing through a main control box 31, and accurately feeds wires to the gun heads of the first dual-wire welding gun 22 and the second dual-wire welding guns through the first main gun barrel 24, the first auxiliary gun barrel 25, the second main gun barrel 26 and the second auxiliary gun barrel 27, as well as accurately controls the droplet transition through the welding power supply module 12, thereby realizing the application of dual-wire welding in full-position welding of pipelines and significantly improving the welding efficiency and welding quality of pipeline welding.

[0108] In order to more clearly illustrate the specific implementation process of the embodiment of the present invention, the following embodiments are provided to describe the specific implementation process of the present invention in detail as follows:

[0109] Take the welding of Φ1219 pipe with a wall thickness of 18.4mm as an example. The reference for the welded pipe groove is Figure 6 As shown, root welding, hot welding, filling welding and cap welding are performed on the pipeline respectively, wherein the root welding adopts an internal welding machine with model CPP900-IW1219; the hot welding, filling welding and cap welding adopt the double-gun four-wire pipeline all-position welding system provided by the embodiment of the present invention.

[0110] During root welding, the pipes are degreased and rusted within 100mm of the groove to avoid welding defects caused by contamination of the groove during welding. The two pipes are assembled without gaps, and the misalignment range is 0-1.5mm. The high-frequency induction heating method is used to preheat the welded pipes, and the preheating temperature range is 80-120℃. The root welding parameters of the internal welding machine are adjusted according to the diameter of the welding pipe and the form of the internal rupture, and the root welding is completed. Specifically, it may include: adjusting the rotation speed of the internal welding machine rotating disk to 11-12mm / s, the overlap amount of the upper joint of the welding unit to 3-5mm, the overlap amount of the lower joint of the welding unit to 25-30mm, the overlap amount of the joints on both sides of the welding unit to 15-20mm, the welding voltage to 20-22V, the welding current to 180-220A, the wire feeding speed to 900-1000mm / min, the mixed shielding gas ratio CO2 / Ar=(15~25)% / (75~85)%, the shielding gas flow rate to 20-30L / min, and the wire dry extension to 9-11mm.

[0111] The embodiment of the present invention provides a dual-gun four-wire pipeline full-position automatic welding system for hot welding, filling and capping of narrow gap "V" type composite groove after root welding, until the surface excess height of the butt-jointed pipeline groove connection is within 0-2mm. The process specifications of hot welding, filling and capping welding are: welding method GMAW downward welding, welding speed 700-900mm / min, single main / auxiliary barrel wire feeding speed of the first dual-wire welding gun and the second dual-wire welding gun 6000-10000mm / min, welding current 140-300A, welding voltage 20-26V, mixed shielding gas ratio CO2 / Ar=(15-25)% / (75-85)%, shielding gas flow rate 20-30L / min, welding wire dry extension 8-10mm, dual wire vertex spacing 2mm, swing frequency 150-200ms / time, edge dwell time 20-100ms. According to the welding at different groove depths, the welding process is adjusted accordingly due to changes in groove width and depth.

[0112] The first double-wire welding gun 22 is used for hot welding, and only the first main gun barrel 24 of the first double-wire welding gun 22 is enabled for wire feeding welding. The first sub-gun barrel 25 of the first double-wire welding gun 22 is not operated at this time to avoid excessive welding heat input from the first double-wire welding gun 22 during hot welding, which may burn through the root weld and cause root weld burn-through defects. For filling welding, fix the welding trolley 21 on the guide rail 23, adjust the first double-wire welding gun 22 on the welding trolley 21 to the 0 point position of the pipeline, and adjust the dry extension length of the first double-wire welding gun 22 and the first double-wire welding gun 22 to the left and right center position of the groove; the welding wire vertex height of the second double-wire welding gun is 5-6mm higher than the position of the first double-wire welding gun 22 to avoid the conductive nozzle burning caused by the welding gun being too low. When the second double-wire welding gun moves to the arc starting position of the first double-wire welding gun 22, it automatically starts the arc, and the first double-wire welding gun automatically extinguishes the arc when it moves to 6 o'clock. When the second double-wire welding gun moves to 6 o'clock, 5mm from the arc ending position of the first double-wire welding gun 22, the arc is automatically extinguished. During welding, the width and depth of the pipeline groove are scanned by the laser vision tracker 32, and the scanning signal is transmitted to the main control box 31. The first twin-wire welding gun 22 automatically adjusts the welding position according to the control signal of the main control box 31 to ensure that the first twin-wire welding gun 22 is always located at the center of the groove corner line during welding, and the dry extension length of the first twin-wire welding gun 22 is adjusted in real time; the second twin-wire welding gun automatically adjusts the swing width and dry extension length according to the scanning signal of the laser vision tracker 32 and the weld thickness of the first twin-wire welding gun.

[0113] During filling and capping welding, the two welding wires of the first main barrel 24 and the first auxiliary barrel 25 of the first double-wire welding gun 22 heat each other and make full use of the arc energy, and the two welding wires of the second main barrel 26 and the second auxiliary barrel 27 of the second double-wire welding gun heat each other and make full use of the arc energy. Compared with single-wire welding, the deposition efficiency is high and the welding speed is fast, which improves the welding efficiency and welding quality. The inventors have found through comparison that the welding efficiency of the double-gun four-wire pipeline automatic welding can be improved by more than 30% compared with the double-gun pipeline full-position automatic welding efficiency. Due to the increase in the molten width and the length of the molten pool, the double-wire welding will effectively improve the problems of the side wall of the groove not being fused and the pores during narrow gap welding. During the welding process, the welding gun does not need to swing or only needs to be slightly swung to ensure that the grooves on both sides are completely fused.

[0114] Embodiment 2

[0115] Based on the same inventive concept, an embodiment of the present invention further provides a dual-gun four-wire pipeline full-position automatic welding method, which uses the dual-gun four-wire pipeline full-position automatic welding system described in Embodiment 1, including:

[0116] Control the wire feeding module 11 to feed wire to the first double-wire welding gun 22 through the first main gun barrel 24 and / or the first auxiliary gun barrel 25;

[0117] Control the wire feeding module 11 to feed wire to the second double-wire welding gun through the second main gun barrel 26 and / or the second auxiliary gun barrel 27;

[0118] The first twin-wire welding gun 22 and / or the second twin-wire welding gun are controlled to perform pipeline all-position welding operations, and the welding carriage 21 is controlled to move around the pipeline.

[0119] In the embodiment of the present invention, the double-gun four-wire pipeline full-position automatic welding method corresponds to the double-gun four-wire pipeline full-position automatic welding system described in Example 1. Its specific implementation process can refer to the process of using the double-gun four-wire pipeline full-position automatic welding system in Example 1 to realize pipeline full-position automatic welding. The repeated parts will not be repeated here.

[0120] Obviously, various changes and modifications may be made to the present invention by those skilled in the art without departing from the spirit and scope of the present invention. The present disclosure is not limited to the precise structure described above and shown in the accompanying drawings, and various changes and modifications may be made without departing from the scope thereof. The scope of the present disclosure is limited only by the appended claims. Thus, if these changes and modifications of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these changes and modifications.

Claims

1. A dual-gun four-wire pipeline full-position automatic welding system, characterized in that: Including control system, mechanical system and welding power supply system; The welding power supply system includes a wire feeding module and a welding power supply module connected; The mechanical system comprises a welding carriage, a first double-wire welding gun and a second double-wire welding gun; the first double-wire welding gun and the second double-wire welding gun are fixed to the welding carriage; The gun tail of the first double-wire welding gun is respectively provided with a first main gun barrel and a first auxiliary gun barrel; The gun tail of the second double-wire welding gun is respectively provided with a second main gun barrel and a second auxiliary gun barrel; The wire feeding module is respectively connected to the first main gun barrel, the first auxiliary gun barrel, the second main gun barrel and the second auxiliary gun barrel; The control system includes a main control box; The main control box is respectively connected to the welding carriage and the wire feeding module, and is used to control the wire feeding module to feed wire to the first twin-wire welding gun through the first main gun barrel and / or the first auxiliary gun barrel, control the wire feeding module to feed wire to the second twin-wire welding gun through the second main gun barrel and / or the second auxiliary gun barrel, control the movement of the welding carriage, and control the welding operations of the first twin-wire welding gun and the second twin-wire welding gun.

2. The double-gun four-wire pipeline all-position automatic welding system according to claim 1 is characterized in that: The gun head of the first twin-wire welding gun is provided with a first conductive nozzle and a second conductive nozzle, and the angle between the first conductive nozzle and the second conductive nozzle is adjustable; The gun head of the second twin-wire welding gun is provided with a third conductive nozzle and a fourth conductive nozzle, and the angle between the third conductive nozzle and the fourth conductive nozzle is adjustable.

3. The double-gun four-wire pipeline all-position automatic welding system according to claim 2 is characterized in that: A first feedback line, a first wire feeding tube, a first water cooling tube and a first protective gas tube are arranged in the first main gun barrel, and the first conductive nozzle is connected to the first wire feeding tube; A second feedback line and a second wire feeding tube are arranged in the first secondary gun barrel, and the second conductive nozzle is connected to the second wire feeding tube; A third feedback line, a third wire feeding tube, a second water cooling tube and a second protective gas tube are arranged in the second main gun barrel, and the third conductive nozzle is connected to the third wire feeding tube; A fourth feedback line and a fourth wire feeding tube are arranged in the second sub-barrel, and the fourth conductive nozzle is connected to the fourth wire feeding tube.

4. The double-gun four-wire pipeline full-position automatic welding system according to claim 3 is characterized in that: The wire feeding module includes a first wire feeding box, a second wire feeding box, a third wire feeding box, a fourth wire feeding box, a first protective gas cylinder, a second protective gas cylinder, a first water cooling box and a second water cooling box; The first protective gas cylinder and the first water cooling box are respectively connected to the first wire feeding box; The first wire feeding box is connected to the first main barrel; The second wire feeding box is connected to the first auxiliary barrel; The second protective gas cylinder and the second water cooling box are respectively connected to the third wire feeding box; The third wire feeding box is connected to the second main barrel; The fourth wire feeding box is connected to the second auxiliary gun barrel.

5. The double-gun four-wire pipeline all-position automatic welding system according to claim 1 is characterized in that: The first main gun barrel and the gun head direction of the first double-wire welding gun form an angle of 145° to 175°; The first secondary gun barrel and the gun head direction of the first double-wire welding gun form an angle of 145° to 175°; The second main gun barrel and the gun head direction of the second double-wire welding gun form an angle of 145° to 175°; The second auxiliary gun barrel and the gun head direction of the second twin-wire welding gun form an angle of 145° to 175°.

6. The dual-gun four-wire pipeline all-position automatic welding system according to claim 1 is characterized in that: The tail of the first twin-wire welding gun is provided with a first interface; The first interface is suitable for connecting the first auxiliary barrel so that the first auxiliary barrel can be detachably mounted on the first double-wire welding gun; The tail of the second twin-wire welding gun is provided with a second interface; The second interface is suitable for connecting the second auxiliary gun barrel so that the second auxiliary gun barrel can be detachably installed on the second twin-wire welding gun.

7. The double-gun four-wire pipeline all-position automatic welding system according to claim 1 is characterized in that: The control system also includes a laser vision tracker; The laser vision tracker is fixed to the forward end of the welding carriage and is used to scan the width and depth of the pipeline groove and transmit the scanning signal to the main control box.

8. The dual-gun four-wire pipeline all-position automatic welding system according to claim 1 is characterized in that: The control system also includes a position sensor; The position sensor is arranged in the welding carriage, and is used for obtaining the position of the welding carriage, and transmitting the obtained position signal to the main control box.

9. The double-gun four-wire pipeline all-position automatic welding system according to claim 1 is characterized in that: The control system also includes a handheld box; The handheld box is connected to the main control box and is used to send an operation signal to the main control box.

10. According to the double-gun four-wire pipeline all-position automatic welding system according to claim 1, it is characterized in that: The mechanical system also includes a guide rail; The guide track is annular and can be sleeved on the pipeline.

11. The double-gun four-wire pipeline all-position automatic welding system according to claim 1 is characterized in that: The welding carriage comprises a first welding gun clamping mechanism, a second welding gun clamping mechanism, a welding gun vertical adjustment mechanism, a welding gun horizontal adjustment mechanism and a carriage base; The first welding gun clamping mechanism, the second welding gun clamping mechanism, the welding gun vertical adjustment mechanism and the welding gun horizontal adjustment mechanism are respectively arranged above the trolley base; The first welding gun clamping mechanism is used to clamp the first double-wire welding gun; The second welding gun clamping mechanism is used to clamp the second double-wire welding gun; The welding gun vertical adjustment mechanism and the welding gun horizontal adjustment mechanism are used to adjust the positions of the first twin-wire welding gun and the second twin-wire welding gun.

12. The dual-gun four-wire pipeline all-position automatic welding system according to claim 10 is characterized in that: The welding carriage also includes a traveling mechanism and a clamping mechanism; The clamping mechanism clamps the guide rail and can move relative to the guide rail; The traveling mechanism is used to drive the welding carriage to slide along the guide track.

13. A dual-gun four-wire pipeline full-position automatic welding method, using the dual-gun four-wire pipeline full-position automatic welding system according to any one of claims 1 to 12, characterized in that: include: Controlling the wire feeding module to feed wire to the first double-wire welding gun through the first main gun barrel and / or the first auxiliary gun barrel; Controlling the wire feeding module to feed wire to the second double-wire welding gun through the second main gun barrel and / or the second auxiliary gun barrel; The first twin-wire welding gun and / or the second twin-wire welding gun are controlled to perform pipeline all-position welding operation, and the welding carriage is controlled to move around the pipeline.

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