Flange short pipe accurate welding device based on detection and correction and operation method

Abstract

The invention provides a flange short pipe accurate welding device based on detection correction and an operation method, the flange short pipe accurate welding device is used for correcting and welding a flange plate and a short pipe, and the flange short pipe accurate welding device comprises a workbench, a flange plate fastening device, a lifting device, a grinding mechanism, an operation arm and a detection aligner. The workbench is arranged on the horizontal plane and provided with a finished product containing area and a machining area. The finished product placing area is used for placing processed finished products; the flange plate fastening device is arranged in the machining area of the workbench. The lifting device is arranged above the flange plate fastening device; the grinding mechanism comprises a grinding disc and a grinding motor; the grinding disc is connected with an output shaft of the grinding motor; the grinding disc is lifted and rotated through a lifting device and a grinding motor respectively; the operation arm comprises a clamping mechanical arm and a welding mechanical arm which are used for clamping a short pipe and welding the short pipe and a flange plate correspondingly. And the detection aligner is arranged around the flange plate fastening device and is in communication connection with the control system.

Description

Technical Field

[0001] The present invention relates to the technical field of flange and short pipe welding, and in particular to a flange short pipe precision welding device and an operating method based on detection and correction. Background Art

[0002] In electromechanical systems, pipes and equipment ports or components (such as various valves) are connected through flanges. The traditional method involves assembling the flanges and performing extensive manual measurements. After the flanges and short pipe sections are precisely aligned, they are spot welded. Automatic or manual welding is then performed to weld the flange inner ring to the pipe in all positions.

[0003] The above work has the following defects:

[0004] (1) After the tooling is assembled, a large number of tools are used to check the horizontality and verticality of all directions to ensure the precise angle of the connection between the flange and the short pipe. This will avoid the flange and short pipe modules not being accurately assembled or having gaps in the middle, which will lead to rework or scrapping of module components. This process takes a lot of time and is highly dependent on the skills and quality of the workers.

[0005] (2) After the simple tool set is assembled, it can only be temporarily fixed by spot welding. Then the temporarily fixed short pipe and flange module are taken out and sent to the automatic welding machine for welding, which requires a lot of handling work. At the same time, even if the automatic welding machine is used, it is time-consuming and laborious to assemble the module on the machine and adjust the welding gun angle.

[0006] (3) After the general modules are temporarily fixed and assembled, two welding processes need to be performed on the automatic welding machine. One is the welding between the inside of the flange and the bottom of the pipe groove, and the other is the welding between the inner ring of the upper end face of the flange and the pipe wall. Due to mechanical limitations, the two welding processes need to be performed separately, and a large amount of manual transfer and manual adjustment are required during this period, which affects efficiency. Summary of the Invention

[0007] The purpose of the present invention is to provide a flange short pipe precision welding device based on detection and correction that can realize integrated operations such as automatic handling, precise matching, and automatic welding, integrate module functions, and maximize the use of automation and intelligent technology in measurement, matching, and welding links.

[0008] In order to achieve the above object, the present invention adopts the following technical solutions:

[0009] A flange short pipe precision welding device based on detection and correction is used to correct and weld flanges and short pipes, including a workbench, a flange fastening device, a lifting device, a grinding mechanism, an operating arm and a detection aligner;

[0010] The workbench is arranged on a horizontal plane and is used to provide a processing base; the workbench is provided with a finished product placement area and a processing area; the finished product placement area is used to place the processed finished products;

[0011] The flange fastening device is arranged in the processing area of ​​the workbench and is used to place and clamp the flange;

[0012] The lifting device is arranged above the flange fastening device and is used to control the grinding mechanism to rise and fall above the flange fastening device;

[0013] The grinding mechanism includes a grinding disc and a grinding motor; the grinding disc is connected to the output shaft of the grinding motor; the grinding disc is lifted and rotated by the lifting device and the grinding motor, respectively, and is used to press and limit the surface of the flange on the flange fastening device and grind it;

[0014] The operating arm includes a clamping mechanical arm and a welding mechanical arm, which are respectively used for clamping the short pipe and welding the short pipe and the flange;

[0015] The detection aligner is arranged around the flange fastening device and is connected to the control system for real-time feedback of the flange's own state and the welding process with the short pipe.

[0016] Preferably, the flange fastening device comprises a base, a clamping head and a horizontal displacement mechanism;

[0017] The base is arranged on the central axis of the workbench, and a plurality of waist-shaped holes are radially provided on the base. A clamping head with a silicone pad is respectively passed through the plurality of waist-shaped holes. One end of the clamping head is arranged on the workbench for radially clamping the flange after displacement; the other end of the clamping head is controlled and driven by the horizontal displacement mechanism to realize displacement in the waist-shaped hole.

[0018] Preferably, the horizontal displacement mechanism comprises a horizontal lead screw, a vertical pinion and a horizontal gear;

[0019] The horizontal large gear is arranged at the center of the base, and the horizontal large gear is driven by the driving unit. Several vertical small gears are engaged on the horizontal large gear. The number of the vertical small gears is the same as the number of the chuck heads. The bottom of the chuck head is arranged on the horizontal lead screw through a horizontal nut. One end of the horizontal lead screw is connected to the small gear, and the other end of the horizontal lead screw is arranged in the base.

[0020] Preferably, it further comprises a plurality of dust suction devices, wherein the plurality of dust suction devices are evenly distributed around the flange fastening device;

[0021] The dust collection device includes a dust collector and a sub-extraction pipe. The dust collector is arranged on the workbench and located on one side of the flange fastening device, and is used to collect welding slag and floating dust caused by welding the flange and the short pipe.

[0022] A dust collecting hopper is provided at the bottom of the flange fastening device, the bottom of the dust collector is connected to the dust collecting hopper through a branch exhaust pipe, and the dust collecting hopper is connected to the dust collecting box through a main exhaust pipe.

[0023] Preferably, the lifting device comprises a rectangular lifting top plate, a lifting motor, a screw mounting seat, a lifting screw, a lifting frame and a support column;

[0024] The lifting top plate is arranged above the flange fastening device through support columns to provide stable support required for lifting movement;

[0025] Two lifting screws are respectively arranged on the workbench through screw mounting seats and located on both sides of the flange fastening device. One end of each lifting screw is connected to a lifting motor arranged on the top of the lifting top plate to provide power for the lifting screw.

[0026] The lifting nuts on the two lifting screws are connected to the grinding disc via a lifting frame, so as to drive the lifting movement of the grinding disc.

[0027] Preferably, four support columns are used to support the four corners of the lifting top plate respectively. Auxiliary cameras are provided on the support columns. The cameras are respectively connected to the control system for real-time auxiliary feedback of the processing process.

[0028] Preferably, the welding robot arm includes a first robot arm and a second robot arm connected by a rotating shaft; the first robot arm is arranged on one side of the flange fastening device through a rotatable base; the second robot arm is connected to a welding gun, and the welding gun is connected to an electric welder through a line for welding the short pipe and the flange;

[0029] The clamping robot arm includes a first robot arm and a second robot arm connected by a rotating shaft; the first robot arm is arranged on one side of the flange fastening device through a rotatable base; the second robot arm is connected to a V-shaped clamping mechanism through a rotating mechanism, which is used to clamp the short tube and place the short tube in connection with the flange, and the V-shaped clamping mechanism connected by the rotating mechanism can achieve 180° rotation.

[0030] Preferably, an equipment top cover is installed on the top of the lifting device on the workbench, and a radiation shield is laid on all sides of the equipment top cover in contact with the workbench to form a processing chamber, which is used to suppress the radiation brought to the surrounding environment by the detection aligner during real-time shooting.

[0031] Preferably, an exhaust port is provided on the top cover of the equipment to discharge the fume during the welding process to avoid high temperature processing in the processing chamber.

[0032] The present invention also provides an operating method of a flange short pipe precision welding device based on detection and correction, comprising the following steps:

[0033] Step S0: According to the data thresholds of the flange and the short pipe preset in the control system;

[0034] Step S1: Flange processing

[0035] Step S11: placing the flange: the operator places the flange on the base;

[0036] Step S12: Pressing the flange: The two lifting motors of the lifting device respectively drive the screws of the two lifting screws to rotate, so that the lifting frame with the grinding disc descends toward the flange fastening device and presses the flange on the base. Then, the screws of the two lifting screws rotate in opposite directions, so that the lifting frame with the grinding disc ascends away from the flange fastening device.

[0037] Step S13: Clamping the flange: The control system controls the drive unit to rotate the horizontal large gear, and the plurality of vertical small gears meshing with the horizontal large gear drive the corresponding screw of the horizontal lead screw to rotate, thereby driving the horizontal nut on the screw to drive the clamping head connected thereto to move within the waist-shaped hole of the base. The plurality of clamping heads radially displace on the base, thereby clamping the outer ring of the flange;

[0038] Step S14: First filming: The flange is photographed using a number of detection and alignment devices located around the pedestal, including the flange's model specifications, placement status, and surface flatness. This information is fed back to the control system to generate a 3D surface model of the flange. The control system processes and analyzes the model, calculates the flatness error, and identifies the position and angle where the error exceeds the threshold. If it is determined that the surface flatness of the model does not meet the flatness threshold requirement in the control system, the control system generates a correction angle and polishing strategy; then the process proceeds to step S15; otherwise, the process proceeds to step S2.

[0039] Step S15: Grinding process: The two lifting motors of the lifting device respectively drive the screws of the two lifting screws to rotate, so that the lifting frame and the grinding disc are lowered toward the flange fastening device and contact the flange. Then, the grinding disc is controlled to rotate by the grinding motor, thereby grinding the surface of the flange according to the grinding strategy;

[0040] Step S16: Second filming: Use several detection aligners to film the flange again, confirm that the surface flatness of the flange meets the flatness requirement of the threshold, and then proceed to step S2. Otherwise, repeat steps S15 and S16.

[0041] Step S2: Short tube processing:

[0042] Step S21: Clamping and positioning the short pipe: The gripping arm of the operating arm rotates through the base to pick up the material from one side of the flange fastening device. The V-shaped gripping mechanism is controlled by the control system to grip the short pipe and rotates with the base. The distance between the second arm and the first arm is opened according to the threshold of the control system, and the short pipe gripped by the gripping arm is adjusted to the welding processing position on the flange.

[0043] Step S22: Third filming: The flange and short tube are photographed before welding using several detection and alignment devices, and the images are fed back to the control system to generate 3D surface models of the flange and short tube. The control system processes and analyzes the models to confirm whether the distance between the bottom of the short tube and the flange welding surface is uniform, and calculates the angular deviation between the central axis of the short tube and the central axis of the flange to ensure that the coaxiality of the two is within the control range. At the same time, the offset between the circumference of the short tube and the flange welding surface is confirmed.

[0044] The control system generates a deviation map of the relative positions of the short tube and the flange. If the deviation exceeds a set threshold, an adjustment command is issued, and the control system controls the gripping robot arm to reposition the short tube. If the position is correct, the control system generates a welding path based on the contact surface shape of the short tube and the flange, and the control system issues a welding permission signal, and then enters step S3.

[0045] Step S3: Welding process:

[0046] Step S31: Outer ring welding: The first welding path is to connect the short pipe and the flange around the outer circumference. The welding gun heats the welding electrode or welding wire to a specified temperature and starts welding.

[0047] The welding gun of the welding robot arm moves smoothly along the set path under the command of the control system. The welding arc forms a molten pool in the contact area between the short pipe and the flange, gradually filling the material to form a weld. The control system controls the welding speed and temperature to avoid overheating or welding defects. After welding is completed, the welding area is naturally cooled for 10 minutes.

[0048] Step S32: short tube flipping:

[0049] The V-shaped clamping mechanism on the clamping robot arm opens to clamp the outer wall of the semi-finished short pipe to avoid squeezing or damaging the weld

[0050] The V-shaped clamping mechanism of the clamping robot rotates, turning the semi-finished short tube 180 degrees and ensuring that the axis of the semi-finished short tube is aligned with the central axis of the base;

[0051] Step S33: Inner Ring Welding: The second welding path is to connect the short pipe and the flange around the inner circumference. The welding torch 75 heats the welding electrode or welding wire to a specified temperature and begins welding. During the inner ring welding process, the clamping robot arm always holds the semi-finished short pipe. Similarly, after welding is completed, the weld area is naturally cooled for 30 minutes.

[0052] If the non-standard short pipe flange module has flanges at both ends of the short pipe, repeat steps 1 to S3 to weld the flange at the other end of the short pipe.

[0053] Step S4: Final filming: Use the detection aligner to conduct a full-scale inspection of the finished short pipe and flange to ensure there is no welding leakage and avoid potential defects;

[0054] Step S5: The finished short pipe and flange are clamped by the clamping robot arm and then rotated by the base to place them in the finished product placement area on the workbench to complete the processing;

[0055] Step S6: Use professional weld quality testing equipment to test the quality of the two welds to confirm that the welding quality meets the standards and avoids potential defects, providing quality assurance for product delivery;

[0056] In addition, all film images and test analysis data are saved in the control system to the database to form a traceable quality file. The test data of each finished product is associated with the production batch to facilitate quality tracking and subsequent optimization.

[0057] Compared with the prior art, the present invention has the following beneficial effects:

[0058] (1) The present invention provides real-time radiographic feedback of the flange and short tube positions through a detection aligner, and simultaneously facilitates accurate positioning of the flange and short tube based on accurate information and automatic adjustment strategies based on computer detection analysis.

[0059] (2) The present invention uses a clamping robot arm and a welding robot arm. The clamping robot arm clamps the short pipe, and then the welding robot arm welds the short pipe and the flange. Two welding robot arms and two welding guns are set to perform two semicircular welding at the same time, which speeds up the production efficiency and avoids a large number of repeated handling and reassembly links.

[0060] In summary, this invention achieves integrated operations such as automated handling, precise alignment, and automated welding, integrating modular functions and resolving the space-consuming problem of multiple, dispersed devices and instruments with different functions in traditional technologies. It maximizes the use of automation and intelligent technologies in the measurement, alignment, and welding processes, alleviating the constraints of technical expertise and experience in the modular prefabrication of pipe fittings. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Figure 1 A schematic diagram of the three-dimensional structure of a flange short pipe precision welding device based on detection and correction provided by an embodiment of the present invention Figure 1 ;

[0062] Figure 2 A schematic diagram of the three-dimensional structure of a flange short pipe precision welding device based on detection and correction provided by an embodiment of the present invention Figure 2 ;

[0063] Figure 3 A schematic front view of a flange short pipe precision welding device based on detection and correction provided by an embodiment of the present invention;

[0064] Figure 4 for Figure 3 Schematic diagram of the cross-sectional structure of AA;

[0065] Figure 5 for Figure 4 A schematic diagram of the partially enlarged structure of the middle part;

[0066] Figure 6 A schematic diagram of the three-dimensional structure of a flange short pipe precision welding device based on detection and correction provided by an embodiment of the present invention Figure 3 ;

[0067] Figure 7 for Figure 6 A schematic diagram of the partially enlarged structure of B in the middle;

[0068] Figure 8 Schematic diagram of the bottom three-dimensional structure of a flange short pipe precision welding device based on detection and correction provided by an embodiment of the present invention Figure 4 ;

[0069] Figure 9 A schematic flow chart of an operating method of a flange short pipe precision welding device based on detection and correction provided by an embodiment of the present invention.

[0070] The serial numbers in the figure are as follows:

[0071] 1. Workbench; 2. Flange fastening device; 2-1. Base; 2-2. Chuck; 2-3. Silicone pad; 2-4. Horizontal screw; 2-5. Horizontal nut; 2-6. Vertical small gear; 2-7. Horizontal large gear; 3. Lifting device; 3-1. Lifting top plate; 3-2. Lifting motor; 3-3. Screw mounting base; 3-4. Lifting screw; 3-5. Lifting frame; 3-6. Support column; 3-7. Lifting screw nut; 4. Grinding mechanism; 4-1. Grinding disc; 4-2. Grinding motor; 5. Detection aligner; 6. Dust collector; 7. Operating arm; 7-1. Base; 7-2. First robotic arm; 7-3. Second robotic arm; 7-4. Clamping mechanism; 7-5; Welding gun; 8. Equipment top cover; 9. Radiation shield; 10. Dust hopper; 11. Branch exhaust pipe; 12. Main exhaust pipe; 13. Dust collection box; 14. Exhaust port. DETAILED DESCRIPTION

[0072] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0073] like Figures 1 to 8 As shown, a flange short pipe precision welding device based on detection and correction disclosed by the present invention is used to correct and weld flanges and short pipes, including a workbench 1, a flange fastening device 2, a lifting device 3, a grinding mechanism 4, an operating arm 7 and a detection aligner 5.

[0074] The workbench 1 is set on a horizontal plane and is used to provide a processing base; a finished product placement area and a processing area are provided on the workbench 1; and the finished product placement area is used to place the processed finished products.

[0075] The flange fastening device 2 is located in the processing area of ​​the workbench 1 and is used to place and clamp the flange. The flange fastening device 2 comprises a base 2-1, a clamping head 2-2, and a horizontal displacement mechanism. The base 2-1 is located on the central axis of the workbench 1 and is radially provided with a plurality of waist-shaped holes. Each of these waist-shaped holes is penetrated by a clamping head 2-2 with a silicone pad 2-3. One end of the clamping head 2-2 is located on the workbench 1 and is used to radially clamp the flange after displacement. The other end of the clamping head 2-2 is driven by the horizontal displacement mechanism to achieve displacement within the waist-shaped holes.

[0076] like Figure 5As shown in the partial enlarged view of A, the horizontal displacement mechanism includes a horizontal lead screw 2-4, a vertical pinion 2-6 and a horizontal gear 2-7; the horizontal gear 2-7 is arranged at the center of the base, and the horizontal gear 2-7 is driven by the drive unit. Several vertical pinions 2-6 are engaged on the horizontal gear 2-7. The number of vertical pinions 2-6 is the same as the number of the chuck head 2-2. The bottom of the chuck head 2-2 is set on the horizontal lead screw 2-4 through the horizontal nut 2-5. One end of the horizontal lead screw 2-4 is connected to the pinion 2-6, and the other end of the horizontal lead screw 2-4 is set in the base 2-1.

[0077] The lifting device 3 is arranged above the flange fastening device 2, and is used to control the lifting and lowering of the grinding mechanism 4 above the flange fastening device 2; the lifting device 3 includes a rectangular lifting top plate 3-1, a lifting motor 3-2, a screw mounting seat 3-3, a lifting screw 3-4, a lifting frame 3-5 and a support column 3-6.

[0078] The lifting top plate 3-1 is arranged above the flange fastening device 2 through the support column 3-6 to provide the stable support required for the lifting movement;

[0079] Two lifting screws 3-4 are used, which are respectively set on the workbench 1 through the screw mounting base 3-3 and located on both sides of the flange fastening device 2. One end of each lifting screw 3-4 is connected to the lifting motor 3-2 set on the top of the lifting top plate 3-1 to provide power for the lifting screw 3-4.

[0080] The grinding mechanism 4 includes a grinding disc 4-1 and a grinding motor 4-2. The grinding disc 4-1 is connected to the output shaft of the grinding motor 4-2. The lifting nuts 3-7 on the two lifting screws 3-4 are connected to the grinding disc 4-1 via a lifting frame 3-5, driving the lifting motion of the grinding disc 4-1. The output shaft of the grinding motor 4-2 is connected to the top of the grinding disc 4-1 to control the grinding disc 4-1 to grind the surface of the flange.

[0081] like Figure 7 As shown in the partial enlarged view of B, the operating arm 7 includes a clamping robot arm and a welding robot arm, which are respectively used to clamp the short pipe and weld the short pipe to the flange; the welding robot arm includes a first robot arm 7-2 and a second robot arm 7-3 connected by a rotating shaft; the first robot arm 7-2 is set on one side of the flange fastening device 2 through a rotatable base 7-1; the second robot arm 7-3 is connected to the welding gun 7-5, and the welding gun 7-5 is connected to the electric welding machine through a line for welding the short pipe to the flange.

[0082] The clamping robot arm includes another group of first robot arms 7-2 and second robot arms 7-3 connected by a rotating shaft; the first robot arm 7-2 is arranged on one side of the flange fastening device 2 through a rotatable base 7-1; the second robot arm 7-3 is connected to the V-shaped clamping mechanism 7-4 through a rotating mechanism, which is used to clamp the short tube and place the short tube in connection with the flange, and the V-shaped clamping mechanism 7-4 connected by the rotating mechanism can achieve 180° rotation.

[0083] The rotatable base 7-1 of the clamping robot arm and the welding robot arm has the same structure as the movable robot arm. The only difference is the connection welding gun 7-5 or the clamping mechanism 7-4. During welding, the two welding robots on both sides of the clamping robot arm work simultaneously, and the two welding guns perform two semicircular weldings at the same time, which speeds up the production efficiency and avoids a large number of repeated handling and reassembly links.

[0084] The present invention uses a clamping robot arm and a welding robot arm. The clamping robot arm clamps the short pipe, and then the welding robot arm welds the short pipe and the flange. Two welding robot arms are set to work simultaneously, and two welding guns perform two semicircular weldings at the same time, which speeds up production efficiency and avoids a large number of repeated handling and reassembly links.

[0085] The detection and alignment device 5 is positioned around the flange fastening device 2 and communicates with the control system, providing real-time feedback on the flange's position and the progress of its welding with the short pipe. The detection and alignment device captures the position of the flange and short pipe in real time and provides feedback to the control system. The precise information generated by computer detection and analysis, along with automatic adjustment strategies, facilitates precise positioning of the flange and short pipe.

[0086] Several dust collection devices 6 are evenly distributed around the flange fastening device 2, with the flange fastening device 2 as the center. These devices include a dust collector 6 and a branch exhaust pipe 11. The dust collector 6 is positioned on the workbench 1, located to one side of the flange fastening device 2, to collect welding slag and floating dust from welding the flange to the short pipe. A dust hopper 10 is provided at the bottom of the flange fastening device 2. The bottom of the dust collector 6 is connected to the dust hopper 10 via the branch exhaust pipe 11. The dust hopper 10 is then connected to a dust collection box 13 via a main exhaust pipe 12.

[0087] Furthermore, in this embodiment, four support columns 3-6 are used to support the four corners of the lifting top plate 3-1 respectively. Auxiliary cameras are provided on the support columns 3-6, and the cameras are respectively communicated with the control system and used for real-time auxiliary feedback of the processing process.

[0088] Furthermore, in this embodiment, a device top cover 8 is installed on the top of the lifting device 3 on the workbench 1. The four sides of the device top cover 8 are connected to the workbench 1 and are paved with radiation protection covers 9 to form a processing room, which is used to suppress the radiation brought to the surrounding environment by the detection aligner 5 during real-time shooting.

[0089] Furthermore, in this embodiment, in order to avoid the generation of smoke and high temperature during welding, an exhaust port 14 is provided on the top cover 8 of the equipment to exhaust the smoke during the welding process.

[0090] like Figure 9 As shown, this embodiment provides an operating method of the flange short pipe precision welding device based on detection and correction, including the following steps:

[0091] Step S0: Based on the various data thresholds of the flange and the short pipe preset in the control system; including but not limited to the control threshold during welding, the control threshold of the detection aligner during light detection, the workpiece adjustment and feedback threshold after welding is completed, and the final product quality detection threshold.

[0092] Step S1: Flange processing

[0093] Step S11: placing the flange: the operator places the flange on the base 2-1;

[0094] Step S12: Pressing the flange: The two lifting motors 3-2 of the lifting device 3 respectively drive the screws of the two lifting screws 3-4 to rotate, so that the lifting frame 3-5 with the grinding disc 4-1 descends toward the flange fastening device 2 and presses the flange on the base 2-1. Then, the screws of the two lifting screws 3-4 rotate in the opposite direction, so that the lifting frame 3-5 with the grinding disc 4-1 ascends away from the flange fastening device 2;

[0095] Step S13: Clamping the flange: The control system controls the driving unit to drive the horizontal large gear 2-7 to rotate, and the plurality of vertical small gears 2-6 meshing with the horizontal large gear 2-7 drive the corresponding screw of the horizontal lead screw 2-4 to rotate, thereby driving the horizontal nut 2-5 on the screw to drive the clamping head 2-2 connected thereto to move in the waist-shaped hole of the base 2-1, and the plurality of clamping heads radially displace on the base 1, thereby clamping the outer ring of the flange;

[0096] Step S14: First filming: The flange is photographed by a plurality of detection aligners 5 located around the pedestal 2-1, including the model specifications, placement status and surface flatness of the flange, and the data is fed back to the control system to generate a 3D surface model of the flange. The control system processes and analyzes the model, calculates the flatness error, and identifies the position and angle where the error exceeds the threshold. When it is determined that the surface flatness of the model does not meet the flatness requirement of the threshold in the control system, the control system generates a correction angle and a polishing strategy; then the process proceeds to step S15; otherwise, the process proceeds to step S2;

[0097] The details are as follows:

[0098] Step S141: Generate a 3D surface model of the flange, and the control system processes and analyzes the model, and generates point cloud data or a thickness distribution map based on the thickness data of the flange surface.

[0099] Record the thickness data (x,y,z)(x,y,z)(x,y,z) coordinates of each sampling point.

[0100] The data is stored in matrix form:

[0101] T[i][j]=t ij

[0102] Among them, i, j are the sampling point indexes on the flange surface, t ij is the thickness at that point.

[0103] Step S142: Analyze the collected thickness data to identify uneven areas and their characteristics (position, thickness difference).

[0104] Input: thickness data matrix T[i][j]; design thickness t0 of flange.

[0105] Output: thickness difference matrix D[i][j], uneven area location list (x,y).

[0106] Calculate the thickness difference:

[0107] Calculate the difference between actual thickness and design thickness point by point:

[0108] D[i]j]=T[i][j]-t0

[0109] The thickness difference matrix D[i][j] that exceeds the tolerance range [Δ min , Δ max ] are marked as uneven areas.

[0110] Use image processing algorithms (such as contour detection or region segmentation) to extract the boundaries and center points of the uneven regions from D[i][j].

[0111] Step S143: generating a grinding path and parameters (position, force, angle) according to the uneven area.

[0112] Input: thickness difference matrix D[i][j], uneven area information.

[0113] Output: grinding path (x, y, z) and corresponding grinding parameters.

[0114] Step S144: performing a grinding operation according to the path planning and adjusting grinding parameters in real time.

[0115] For each uneven area, plan the grinding path in layers:

[0116]

[0117] Among them, z k is the grinding depth of the kth layer, and n is the number of grinding times.

[0118] Step S15: Grinding process: The two lifting motors 3-2 of the lifting device 3 respectively drive the screws of the two lifting screws 3-4 to rotate, so that the lifting frame 3-5 and the grinding disc 4-1 are lowered toward the flange fastening device 2 and contact the flange. Then, the grinding motor 4-2 controls the rotation of the grinding disc 4-1, thereby grinding the surface of the flange according to the grinding strategy;

[0119] Step S151: Dynamically adjust the polishing strategy through real-time data feedback to ensure accuracy and consistency.

[0120] Step S16: Second filming: The flange is filmed again by using several detection aligners 5 to confirm that the surface flatness of the flange meets the flatness requirement of the threshold, and then step S2 can be entered. Otherwise, steps S15 to S16 are repeated;

[0121] Step S2: Short tube processing:

[0122] Step S21: Clamping and positioning the short tube: The clamping arm of the operating arm 7 rotates through the base 7-1 to pick up the material from one side of the flange fastening device 2. The V-shaped clamping mechanism 7-4 is controlled by the control system to clamp the short tube and rotate with the base 7-1. The distance between the second arm 7-3 and the first arm 7-2 is opened according to the threshold of the control system, and the short tube clamped by the clamping arm is adjusted to the welding processing position on the flange.

[0123] Step S22: Third filming: The flange and the short tube are photographed before welding using a plurality of detection aligners 5, and the images are fed back to the control system to generate 3D surface models of the flange and the short tube. The control system processes and analyzes the models to confirm whether the distance between the bottom of the short tube and the welding surface of the flange is uniform, and calculates the angular deviation between the central axis of the short tube and the central axis of the flange to ensure that the coaxiality of the two is within the control range; at the same time, the offset between the circumference of the short tube and the welding surface of the flange is confirmed;

[0124] The control system generates a deviation map of the relative positions of the short tube and the flange. If the deviation exceeds a set threshold, an adjustment command is issued, and the control system controls the gripping robot arm to reposition the short tube. If the position is correct, the control system generates a welding path based on the contact surface shape of the short tube and the flange, and the control system issues a welding permission signal, and then enters step S3.

[0125] Step S3: Welding process:

[0126] Step S31: Outer ring welding: The first welding path is to connect the short pipe and the flange around the outer circumference. The welding gun 7-5 heats the welding electrode or welding wire to a specified temperature and starts welding.

[0127] The welding gun 7-5 of the welding robot arm moves smoothly along the set path under the command of the control system. The welding arc forms a molten pool in the contact area between the short pipe and the flange, gradually filling the material to form a weld. The control system controls the welding speed and temperature to avoid overheating or welding defects. After welding is completed, the welding area is naturally cooled for 30 minutes.

[0128] Furthermore, sensors such as temperature sensors and visual sensors can be set to monitor the temperature, weld shape and quality of the welding area in real time.

[0129] If anomalies such as excessive temperature or weld seam deviation are detected, the control system automatically adjusts welding parameters or pauses welding.

[0130] Step S32: short tube flipping:

[0131] The V-shaped clamping mechanism 7-4 on the clamping robot arm opens to clamp the outer wall of the semi-finished short pipe to avoid squeezing or damaging the weld.

[0132] The V-shaped clamping mechanism 7-4 of the clamping robot rotates, flipping the semi-finished short tube 180 degrees, and ensuring that the axis of the semi-finished short tube is aligned with the central axis of the base 2-1;

[0133] Step S33: Inner Ring Welding: The second welding path is to connect the short pipe and the flange around the inner circumference. The welding gun 7-5 heats the welding electrode or welding wire to a specified temperature and begins welding. During the inner ring welding process, the clamping robot arm always holds the semi-finished short pipe. Similarly, after welding is completed, the welding area is naturally cooled for 30 minutes.

[0134] If the non-standard short pipe flange module has flanges at both ends of the short pipe, repeat steps 1 to S3 to weld the flange at the other end of the short pipe.

[0135] Step S4: Final filming: Perform a full-scale inspection of the finished short pipe and flange using the detection aligner 5 to ensure there is no welding leakage and avoid potential defects;

[0136] Step S5: The finished short pipe and flange are clamped by the clamping robot arm and then rotated by the base 7-1 to be placed in the finished product placement area on the workbench 1 to complete the processing;

[0137] Step S6: Professional weld quality testing instruments are used to test the quality of the two welds to confirm that the welding quality meets the standards and avoids potential defects, providing quality assurance for product delivery.

[0138] In addition, all film images and test analysis data are saved in the control system to the database to form a traceable quality file. The test data of each finished product is associated with the production batch to facilitate quality tracking and subsequent optimization.

[0139] The real-time film feedback of the flange and short pipe position by the detection aligner, as well as the precise information and automatic adjustment strategy based on computer detection analysis, help to accurately position the flange and short pipe.

[0140] In summary, this embodiment achieves integrated operations such as automated handling, precise alignment, and automated welding, integrating modular functions and resolving the space-consuming problem of multiple, dispersed devices and instruments with different functions in traditional technologies. It maximizes the use of automation and intelligent technologies in the measurement, alignment, and welding processes, alleviating the constraints of technical expertise and experience in the modular prefabrication of pipe fittings.

[0141] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like to indicate orientations or positional relationships based on the orientations 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 should not be understood as limiting the present invention.

[0142] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature identified as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, "plurality" means two or more, unless otherwise specifically defined.

[0143] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A flange short pipe precision welding device based on detection and correction, used for correcting and welding flanges and short pipes, characterized in that: It comprises a workbench (1), a flange fastening device (2), a lifting device (3), a grinding mechanism (4), an operating arm (7) and a detection aligner (5); The workbench (1) is arranged on a horizontal plane and is used to provide a processing base; a finished product placement area and a processing area are provided on the workbench (1); the finished product placement area is used to place the processed finished product; The flange fastening device (2) is arranged in the processing area of ​​the workbench (1) and is used for placing and clamping the flange; The lifting device (3) is arranged above the flange fastening device (2) and is used to control the grinding mechanism (4) to rise and fall above the flange fastening device (2); The grinding mechanism (4) comprises a grinding disc (4-1) and a grinding motor (4-2); the grinding disc (4-1) is connected to the output shaft of the grinding motor (4-2); the grinding disc (4-1) is lifted and rotated respectively by the lifting device (3) and the grinding motor (4-2), and is used to press and limit and grind the surface of the flange on the flange fastening device (2); The operating arm (7) comprises a clamping mechanical arm and a welding mechanical arm, which are respectively used for clamping the short pipe and welding the short pipe and the flange; The detection aligner (5) is arranged around the flange fastening device (2) and is communicatively connected with the control system for real-time feedback of the flange's own position status and the welding process with the short pipe.

2. According to claim 1, a flange short pipe precision welding device based on detection and correction is characterized in that: The flange fastening device (2) comprises a base (2-1), a clamping head (2-2) and a horizontal displacement mechanism; The base (2-1) is arranged on the central axis of the workbench (1); a plurality of waist-shaped holes are radially arranged on the base (2-1); a plurality of waist-shaped holes are respectively penetrated by a chuck head (2-2) with a silicone pad (2-3); one end of the chuck head (2-2) is arranged on the workbench (1) for radially clamping a flange after displacement; the other end of the chuck head (2-2) is controlled and driven by the horizontal displacement mechanism to achieve displacement in the waist-shaped hole.

3. The flange short pipe precision welding device based on detection and correction according to claim 2 is characterized in that: The horizontal displacement mechanism comprises a horizontal lead screw (2-4), a vertical small gear (2-6) and a horizontal large gear (2-7); The transverse large gear (2-7) is arranged at the center of the pedestal, and the transverse large gear (2-7) is driven by a driving unit. A plurality of the vertical small gears (2-6) are meshed on the transverse large gear (2-7), and the number of the vertical small gears (2-6) is the same as the number of the chuck heads (2-2). The bottom of the chuck heads (2-2) is arranged on the horizontal lead screw (2-4) through a horizontal nut (2-5), one end of the horizontal lead screw (2-4) is connected to the small gear (2-6), and the other end of the horizontal lead screw (2-4) is arranged in the pedestal (2-1).

4. The flange short pipe precision welding device based on detection and correction according to claim 1 is characterized in that: It also includes a plurality of dust suction devices, wherein the plurality of dust suction devices are evenly distributed around the flange fastening device (2); The dust collecting device comprises a dust collecting device (6) and a sub-exhaust pipe (11); the dust collecting device (6) is arranged on the workbench (1) and located on one side of the flange fastening device (2), and is used to collect welding slag and floating dust caused by welding the flange and the short pipe; A dust hopper (10) is provided at the bottom of the flange fastening device (2), the bottom of the dust collector (6) is connected to the dust hopper (10) via a branch exhaust pipe (11), and the dust hopper (10) is connected to a dust collection box (13) via a main exhaust pipe (12).

5. The flange short pipe precision welding device based on detection and correction according to claim 1 is characterized in that: The lifting device (3) comprises a rectangular lifting top plate (3-1), a lifting motor (3-2), a screw mounting seat (3-3), a lifting screw (3-4), a lifting frame (3-5) and a support column (3-6); The lifting top plate (3-1) is arranged above the flange fastening device (2) via a support column (3-6) to provide stable support required for lifting movement; Two lifting screws (3-4) are provided on the workbench (1) through screw mounting seats (3-3) and are located on both sides of the flange fastening device (2); one end of each lifting screw (3-4) is connected to a lifting motor (3-2) provided on the top of the lifting top plate (3-1) to provide power for the lifting screw (3-4); The lifting nuts (3-7) on the two lifting screws (3-4) are connected to the grinding disc (4-1) via a lifting frame (3-5) to drive the lifting movement of the grinding disc (4-1).

6. The flange short pipe precision welding device based on detection and correction according to claim 5 is characterized in that: Four support columns (3-6) are used to support the four corners of the lifting top plate (3-1) respectively. Auxiliary cameras are provided on the support columns (3-6). The cameras are respectively connected to the control system for real-time auxiliary feedback of the processing process.

7. The flange short pipe precision welding device based on detection and correction according to claim 1 is characterized in that: The welding mechanical arm comprises a first mechanical arm (7-2) and a second mechanical arm (7-3) connected by a rotating shaft; the first mechanical arm (7-2) is arranged on one side of the flange fastening device (2) via a rotatable base (7-1); the second mechanical arm (7-3) is connected to a welding gun (7-5), and the welding gun (7-5) is connected to an electric welder via a line for welding a short pipe and a flange; The clamping mechanical arm comprises a first mechanical arm (7-2) and a second mechanical arm (7-3) connected by a rotating shaft; the first mechanical arm (7-2) is arranged on one side of the flange fastening device (2) via a rotatable base (7-1); the second mechanical arm (7-3) is connected to a V-shaped clamping mechanism (7-4) via a rotating mechanism, and a rubber pad is provided on the clamping mechanism (7-4) for clamping a short pipe and placing the short pipe in connection with the flange, and the V-shaped clamping mechanism (7-4) connected via the rotating mechanism can realize a 180° rotation.

8. The flange short pipe precision welding device based on detection and correction according to claim 1 is characterized in that: A device top cover (8) is installed on the top of the lifting device (3) on the workbench (1), and a radiation protection cover (9) is laid on the four sides of the device top cover (8) in contact with the workbench (1) to form a processing room for suppressing the radiation brought to the surrounding environment by the detection aligner (5) during real-time shooting.

9. The flange short pipe precision welding device based on detection and correction according to claim 8 is characterized in that: An exhaust port (14) is provided on the top cover (8) of the equipment for exhausting smoke during the welding process to avoid high-temperature processing in the processing chamber.

10. An operating method of a flange short pipe precision welding device based on detection and correction according to any one of claims 1 to 9, characterized in that: The steps include: Step S0: according to various data thresholds of the flange and the short pipe preset in the control system; Step S1: Flange processing Step S11: placing the flange: the operator places the flange on the base (2-1); Step S12: Pressing the flange: The two lifting motors (3-2) of the lifting device (3) respectively drive the screws of the two lifting screws (3-4) to rotate, so that the lifting frame (3-5) with the grinding disc (4-1) descends in the direction close to the flange fastening device (2), and the flange on the base (2-1) is pressed and limited, so that the bottom of the flange is completely in contact with the surface of the flange fastening device (2), thereby preventing the flange from being slightly warped; then the screws of the two lifting screws (3-4) rotate in the opposite direction, so that the lifting frame (3-5) with the grinding disc (4-1) rises in the direction away from the flange fastening device (2); Step S13: Clamping the flange: The control system controls the driving unit to drive the horizontal large gear (2-7) to rotate, and a plurality of vertical small gears (2-6) meshing with the horizontal large gear (2-7) drive the corresponding screw of the horizontal lead screw (2-4) to rotate, thereby driving the horizontal nut (2-5) on the screw to drive the clamping head (2-2) connected thereto to move in the waist-shaped hole of the base (2-1), and the plurality of clamping heads radially move on the base (1), thereby clamping the outer ring of the flange; Step S14: First filming: The flange is photographed by a plurality of detection aligners (5) located around the pedestal (2-1), including the model and specifications of the flange, the placement status and the flatness of its surface, and the data are fed back to the control system to generate a 3D surface model of the flange. The control system processes and analyzes the model, calculates the flatness error, and identifies the position and angle where the error exceeds the threshold. When it is determined that the surface flatness of the model does not meet the flatness requirement of the threshold in the control system, the control system generates a correction angle and a polishing strategy; the process proceeds to step S15, otherwise it proceeds to step S2; Step S15: grinding process: the two lifting motors (3-2) of the lifting device (3) respectively drive the screws of the two lifting screws (3-4) to rotate, so that the lifting frame (3-5) brings the grinding disc (4-1) down toward the flange fastening device (2) and contacts the flange, and then the grinding motor (4-2) controls the grinding disc (4-1) to rotate, so as to grind the surface of the flange according to the grinding strategy; Step S16: Second filming: The flange is filmed again by using a plurality of detection aligners (5) to confirm that the surface flatness of the flange reaches the flatness requirement of the threshold value, and then the process proceeds to step S2. Otherwise, steps S15 to S16 are repeated; Step S2: Short tube processing: Step S21: clamping and positioning the short tube: the clamping mechanical arm of the operating arm (7) rotates through the base (7-1) to pick up the material from one side of the flange fastening device (2), the V-shaped clamping mechanism (7-4) is controlled by the control system to clamp the short tube and rotates with the base (7-1), the distance between the second mechanical arm (7-3) and the first mechanical arm (7-2) is opened according to the threshold of the control system, and the short tube clamped by the clamping mechanical arm is adjusted to the welding processing position on the flange; Step S22: The third filming: The flange and the short tube are photographed before welding by a plurality of detection aligners (5), and the images are fed back to the control system to generate 3D surface models of the flange and the short tube. The control system processes and analyzes the models of the two to confirm whether the distance between the bottom of the short tube and the welding surface of the flange is uniform, and calculates the angular deviation between the central axis of the short tube and the central axis of the flange to ensure that the coaxiality of the two is within the control range; at the same time, the offset between the circumference of the short tube and the welding surface of the flange is confirmed; The control system generates a deviation diagram of the relative position of the short tube and the flange; if the deviation exceeds the set threshold, an adjustment instruction is issued, and the control system controls the clamping robot arm to reposition the short tube; if the position is correct, the control system generates a welding path based on the contact surface shape of the short tube and the flange, and the control system issues a welding permission signal to enter step S3; Step S3: Welding process: Step S31: outer ring welding: the first welding path is to connect the short pipe and the flange plate around the outer circumference, and the welding gun (7-5) heats the welding electrode or welding wire to a specified temperature and starts welding; The welding gun (7-5) of the welding robot arm moves smoothly along the set path under the command of the control system, and the welding arc forms a molten pool in the contact area between the short pipe and the flange, gradually filling the material to form a weld; the control system controls the welding speed and temperature to avoid welding overheating or welding defects; after the welding is completed, the welding area is naturally cooled for 30 minutes; Step S32: short tube flipping: The V-shaped clamping mechanism (7-4) on the clamping mechanical arm opens to clamp the outer wall of the semi-finished short pipe to avoid squeezing or damaging the weld. The V-shaped clamping mechanism (7-4) of the clamping robot arm rotates to turn the semi-finished short tube 180 degrees and ensure that the axis of the semi-finished short tube is aligned with the central axis of the pedestal (2-1); Step S33: Inner circle welding: The second welding path is to connect the short pipe and the flange plate around the inner circle, and the welding gun (7-5) heats the welding electrode or welding wire to a specified temperature and starts welding; during the inner circle welding process, the clamping robot arm always clamps the semi-finished short pipe; similarly, after the welding is completed, the welding area is naturally cooled for 30 minutes; When the non-standard short tube flange module has flanges at both ends of the short tube, repeat the above steps 1 to S3 to weld the flange at the other end of the short tube; Step S4: Final filming: Perform a full-scale inspection of the finished short pipe and flange plate through the detection aligner (5) to ensure that there is no leakage and avoid potential defects; Step S5: clamping the finished short pipe and the flange by a clamping robot arm and then rotating them through the base (7-1) to place them in the finished product placement area on the workbench (1), completing the processing; Step S6: Use professional weld quality testing instruments to test the quality of the two welds to confirm that the welding quality meets the standards and avoids potential defects, providing quality assurance for product delivery; In addition, all film images and test analysis data are saved in the control system to the database to form a traceable quality file. The test data of each finished product is associated with the production batch to facilitate quality tracking and subsequent optimization.

Images