A flange short tube precise welding device based on detection correction and an operating method thereof

Abstract

The application provides a flange short pipe accurate welding device based on detection correction and an operating method, which is used for correcting and welding a flange and a short pipe and comprises a workbench, a flange fastening device, a lifting device, a polishing mechanism, an operating arm and a detection aligner. The workbench is arranged on a horizontal plane, and the workbench is provided with a finished product placing area and a processing area; the finished product placing area is used for placing finished products after processing; the flange fastening device is arranged in the processing area of the workbench; the lifting device is arranged above the flange fastening device; the polishing mechanism comprises a polishing disc and a polishing motor; the polishing disc is connected with the output shaft of the polishing motor; the polishing disc is lifted and rotated by the lifting device and the polishing motor respectively; the operating arm 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; and the detection aligner is arranged around the flange fastening device and is in communication connection with a control system, so that integrated operation is realized.

Description

Technical Field

[0001] This invention relates to the technical field of flange and short pipe welding, and more particularly to a precision welding device and operating method for flanges and short pipes based on detection and correction. Background Technology

[0002] In electromechanical systems, pipes and equipment ports or components (such as various valves) are connected via flanges. The traditional method involves assembling the components with tooling, performing extensive manual measurements, precisely assembling the flange and short pipe sections, spot welding for fixation, and then performing automatic or manual welding to weld the upper and lower layers of 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 horizontal and verticality of each direction to ensure the precise angle of the connection between the flange and the short pipe. This is to avoid rework or scrapping of the module due to inaccurate assembly or gaps between the flange and the short pipe module during installation. This process takes a lot of time and is highly dependent on the skills and qualifications of the workers.

[0005] (2) After the simple tools are assembled, they 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. This 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 and adjust the welding gun angle on the machine.

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

[0007] The purpose of this invention is to provide a precision welding device for flange short pipes based on detection and correction that can achieve integrated operations such as automatic handling, precise alignment, and automatic welding, integrates modular functions, and maximizes the use of automation and intelligent technologies in the measurement, alignment, and welding processes.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

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

[0010] The workbench is set on a horizontal plane 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 located in the processing area of ​​the workbench and is used to place and clamp the flange.

[0012] The lifting device is located above the flange fastening device and is used to control the grinding mechanism to move up and down 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, limit and grind the surface of the flange on the flange fastening device respectively;

[0014] The operating arm includes a clamping robotic arm and a welding robotic arm, which are used to clamp short pipes and weld short pipes to flanges, respectively.

[0015] The detection aligner is positioned around the flange fastening device and is connected in communication with the control system to provide real-time feedback on the flange's own status and the welding process with the short pipe.

[0016] Preferably, the flange fastening device includes a base, a clamp, and a horizontal displacement mechanism;

[0017] The platform is set on the central axis of the workbench. The platform has a plurality of oblong holes radially arranged on it. Each of the oblong holes is fitted with a clamping head with a silicone pad. One end of the clamping head is set 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 achieve displacement within the oblong holes.

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

[0019] The large horizontal gear is located at the center of the base and is driven by a drive unit. Several small vertical gears mesh on the large horizontal gear. The number of small vertical gears is the same as the number of chuck heads. The bottom of the chuck head is mounted on the horizontal lead screw by 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 located inside the base.

[0020] Preferably, it also includes a plurality of dust collection devices, which are evenly distributed around the flange fastening device;

[0021] The dust collection device includes a dust collector and a separate suction pipe. The dust collector is set on the workbench and located on one side of the flange fastening device, and is used to collect welding slag and dust brought in during the welding of the flange and the short pipe.

[0022] The bottom of the flange fastening device is equipped with a dust collection hopper, and the bottom of the dust collector is connected to the dust collection hopper through a branch exhaust pipe. The dust collection hopper is connected to the dust collection box through a main exhaust pipe.

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

[0024] The lifting top plate is mounted above the flange fastening device via a support column to provide stable support for the lifting movement;

[0025] Two lifting screws are used, which are respectively mounted on the worktable via 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 located on the top of the lifting plate to provide power to the lifting screw.

[0026] The grinding disc is connected to the two lifting screws via a lifting frame, which drives the grinding disc to move up and down.

[0027] Preferably, four support columns are used to support the four corners of the lifting top plate. Each support column is equipped with an auxiliary camera, which is connected to the control system and used to provide real-time feedback on the processing.

[0028] Preferably, the welding robotic arm includes a first robotic arm and a second robotic arm connected by a rotating shaft; the first robotic arm is mounted on one side of the flange fastening device via a rotatable base; the second robotic arm is connected to a welding torch, which is connected to an electric welding machine via a circuit for welding short pipes to flanges;

[0029] The clamping robotic arm includes a first robotic arm and a second robotic arm connected by a pivot. The first robotic arm is mounted on one side of the flange fastening device via a rotatable base. The second robotic arm is connected to a V-shaped clamping mechanism via a rotating mechanism for clamping short pipes and placing short pipes to connect with the flange. The V-shaped clamping mechanism can be rotated 180° via the rotating mechanism.

[0030] Preferably, the lifting device on the workbench is equipped with a top cover, and the top cover is connected to the workbench by a radiation shield to form a processing chamber, which is used to suppress the radiation emitted by the detector during real-time shooting.

[0031] Preferably, the top cover of the equipment is provided with an exhaust port for discharging fumes during the welding process, thereby preventing high-temperature processing in the processing chamber.

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

[0033] Step S0: Based on the preset data thresholds for the flange and short pipe in the control system;

[0034] Step S1: Flange processing

[0035] Step S11: Placing the flange: The operator places the flange on the pedestal;

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

[0037] Step S13: Clamping the flange: The control system controls the drive unit to drive the horizontal large gear to rotate. Several vertical small gears meshing with the horizontal large gear drive the corresponding horizontal screw screw to rotate, thereby driving the horizontal nut on the screw to drive the clamping head connected to it to move in the waist-shaped hole of the platform. Several clamping heads move radially on the platform, thereby clamping the outer ring of the flange.

[0038] Step S14: First image capture: The flange is imaged using several detectors located around the platform, including the flange's model and specifications, placement status, and surface flatness. This image is then 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 locations and angles where the error exceeds a threshold. If the surface flatness of the model does not meet the flatness requirement of the control system threshold, the control system generates a correction angle and a grinding strategy; proceed to step S15; otherwise, proceed to step S2.

[0039] Step S15: Grinding process: The two lifting motors of the lifting device drive the screws of the two lifting screws to rotate, thereby causing the lifting frame to descend towards the flange fastening device and contact the flange. Then, the grinding motor controls the rotation of the grinding disc to grind the surface of the flange according to the grinding strategy.

[0040] Step S16: Second filming: The flange is filmed again using several detectors to confirm that the surface flatness of the flange meets the threshold flatness requirement. Then proceed to step S2. Otherwise, repeat steps S15 and S16.

[0041] Step S2: Short pipe treatment:

[0042] Step S21: Clamping and positioning the short pipe: The clamping robotic 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 clamping mechanism is controlled by the control system to clamp the short pipe and rotate with the base. The distance between the second robotic arm and the first robotic arm is opened according to the threshold of the control system. The short pipe clamped by the clamping robotic arm is adjusted to be located at the welding processing position on the flange.

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

[0044] The control system generates a deviation diagram of the relative position of the short pipe and the flange; if the deviation exceeds the set threshold, an adjustment command is issued, and the control system controls the gripping robotic arm to reposition the short pipe; if the position is correct, the control system combines the contact surface shape of the short pipe and the flange to generate a welding path, and the control system issues a welding permission signal to proceed to step S3.

[0045] Step S3: Welding process:

[0046] Step S31: Outer ring welding: The first welding path is the outer circumference of the connection between the short pipe and the flange. Heat the welding electrode or welding wire with the welding gun to the specified temperature and start welding.

[0047] Under the command of the control system, the welding torch of the welding robot arm moves smoothly along the set path. The welding arc forms a molten pool in the contact area between the short pipe and the flange, gradually filling the pool with 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 welded area is allowed to cool naturally for 10 minutes.

[0048] Step S32: Short tube flipping:

[0049] The V-shaped gripping mechanism on the robotic arm opens to clamp the outer wall of the semi-finished short pipe, preventing compression or damage to the weld.

[0050] The V-shaped gripping mechanism of the gripping robot arm rotates, causing the semi-finished short tube to rotate 180°, and ensuring that the axis of the semi-finished short tube is aligned with the central axis of the platform;

[0051] Step S33: Inner ring welding: The second welding path is the inner circumference of the connection between the short pipe and the flange. The welding torch heats the welding electrode or welding wire to the specified temperature and welding begins. During the inner ring welding process, the clamping robotic arm always holds the semi-finished short pipe. Similarly, after the welding is completed, the welding area is allowed to cool naturally for 30 minutes.

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

[0053] Step S4: Final inspection: Use a probe alignment device to perform a full-range inspection of the finished short pipe and flange to ensure there are no missed welds and avoid potential defects;

[0054] Step S5: After clamping the finished product short pipe and flange with the gripping robotic arm, the finished product is placed on the finished product placement area on the worktable by rotating the base, thus completing the processing;

[0055] Step S6: The quality of the two welds is inspected by professional weld quality inspection instruments to confirm that the welding quality meets the standards and avoid potential defects, thus providing quality assurance for product delivery;

[0056] In addition, all radiographic images and detection analysis data are saved to a database in the control system to form a traceable quality file. The detection data of each finished product is associated with the production batch, which facilitates 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 on the position of the flange and short pipe through a detection alignment device, and at the same time, based on the accurate information and automatic adjustment strategy of computer detection analysis, it helps to accurately position the flange and short pipe.

[0059] (2) The present invention uses a clamping robotic arm and a welding robotic arm. The clamping robotic arm clamps the short pipe, and the welding robotic arm welds the short pipe and the flange. The two welding robotic arms and two welding guns simultaneously perform two semi-circular welding, which speeds up the production efficiency and avoids a lot of repetitive handling and reassembly matching.

[0060] In summary, this invention achieves integrated operations such as automatic handling, precise alignment, and automatic welding, integrating modular functions and solving the problem of large footprint caused by the dispersed use of multiple devices and instruments with different functions in traditional technologies. It maximizes the use of automation and intelligent technologies in the measurement, assembly, and welding stages, alleviating the constraints of technology and experience in the modular prefabrication of pipe fittings. Attached Figure Description

[0061] Figure 1 A three-dimensional structural diagram of a precision welding device for flange short pipes based on detection correction, provided for embodiments of the present invention. Figure 1 ;

[0062] Figure 2 A three-dimensional structural diagram of a precision welding device for flange short pipes based on detection correction, provided for embodiments of the present invention. Figure 2 ;

[0063] Figure 3 A front view schematic diagram of a precision welding device for flange short pipe based on detection correction provided for 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 magnified schematic diagram of the structure of part A in the diagram;

[0066] Figure 6 A three-dimensional structural diagram of a precision welding device for flange short pipes based on detection correction, provided for embodiments of the present invention. Figure 3 ;

[0067] Figure 7 for Figure 6 A magnified schematic diagram of the partial structure of B in the diagram;

[0068] Figure 8 A schematic diagram of the bottom three-dimensional structure of a precision welding device for flange short pipes based on detection and correction, provided for embodiments of the present invention. Figure 4 ;

[0069] Figure 9 This is a flowchart illustrating the operation method of a precision welding device for flange short pipes based on detection and correction, provided as an embodiment of the present invention.

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

[0071] 1. Workbench; 2. Flange fastening device; 2-1. Base; 2-2. Clamping head; 2-3. Silicone pad; 2-4. Horizontal lead screw; 2-5. Horizontal nut; 2-6. Vertical pinion; 2-7. Horizontal gear; 3. Lifting device; 3-1. Lifting top plate; 3-2. Lifting motor; 3-3. Lead screw mounting base; 3-4. Lifting lead screw; 3-5. Lifting frame; 3-6. Support column; 3-7. Lifting screw 4. Grinding mechanism; 4-1. Grinding disc; 4-2. Grinding motor; 5. Detector alignment device; 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 torch; 8. Equipment top cover; 9. Radiation shield; 10. Dust collection hopper; 11. Branch exhaust pipe; 12. Main exhaust pipe; 13. Dust collection box; 14. Exhaust port. Detailed Implementation

[0072] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0073] like Figures 1 to 8 As shown, this invention discloses a precision welding device for flange short pipes based on detection and correction, used for correcting and welding 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 to provide a processing base; the workbench 1 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.

[0075] The flange fastening device 2 is installed in the processing area of ​​the workbench 1 for placing and clamping the flange. The flange fastening device 2 includes 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. The base 2-1 has several oblong holes radially arranged on it. Each oblong hole has a clamping head 2-2 with a silicone pad 2-3 inserted into it. One end of the clamping head 2-2 is mounted on the workbench 1 for radially clamping 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 oblong holes.

[0076] like Figure 5As shown in the enlarged view of part A, the horizontal displacement mechanism includes a horizontal lead screw 2-4, a vertical pinion 2-6, and a transverse large gear 2-7. The transverse large gear 2-7 is located at the center of the base and is driven by a drive unit. Several vertical pinions 2-6 mesh on the transverse large gear 2-7. The number of vertical pinions 2-6 is the same as the number of chuck heads 2-2. The bottom of the chuck head 2-2 is mounted on the horizontal lead screw 2-4 by a 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 located inside the base 2-1.

[0077] The lifting device 3 is located 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 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 mounted above the flange fastening device 2 via the support column 3-6 to provide stable support for the lifting movement;

[0079] Two lifting screws 3-4 are used, which are respectively set on the workbench 1 through screw mounting base 3-3 and located on both sides of 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 to 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 grinding disc 4-1 is connected to the two lifting screws 3-4 via lifting nuts 3-7 through a lifting frame 3-5, which drives the lifting movement 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, which controls the grinding disc 4-1 to grind the surface of the flange.

[0081] like Figure 7 As shown in the enlarged view of section B, the operating arm 7 includes a clamping robotic arm and a welding robotic arm, used for clamping short pipes and welding short pipes to flanges, respectively; the welding robotic arm includes a first robotic arm 7-2 and a second robotic arm 7-3 connected by a rotating shaft; the first robotic arm 7-2 is mounted on one side of the flange fastening device 2 via a rotatable base 7-1; the second robotic arm 7-3 is connected to a welding torch 7-5, which is connected to an electric welding machine via wiring, for welding short pipes to flanges.

[0082] The clamping robotic arm includes another set of first robotic arms 7-2 and second robotic arms 7-3 connected by a rotating shaft; the first robotic arm 7-2 is set on one side of the flange fastening device 2 via a rotatable base 7-1; the second robotic arm 7-3 is connected to a V-shaped clamping mechanism 7-4 via a rotating mechanism, used to clamp short pipes and place short pipes to connect with the flange, and the V-shaped clamping mechanism 7-4 can be rotated 180° via the rotating mechanism.

[0083] The rotating base 7-1 of the clamping robotic arm and the welding robotic arm have the same structure as the movable robotic arm. The only difference is that it connects to the welding torch 7-5 or the clamping mechanism 7-4. During welding, the two welding robotic arms on both sides of the clamping robotic arm work simultaneously, and the two welding torches perform two semi-circular welding simultaneously, which speeds up production efficiency and avoids a lot of repetitive handling and reassembly matching.

[0084] This invention utilizes a clamping robotic arm and a welding robotic arm. The clamping robotic arm holds the short pipe, and the welding robotic arm welds the short pipe and flange. Two welding robotic arms work simultaneously, and two welding torches perform two semi-circular welds at the same time, which speeds up production efficiency and avoids a large number of repetitive handling and reassembly matching steps.

[0085] The detector alignment device 5 is positioned around the flange fastening device 2 and is connected to the control system to provide real-time feedback on the flange's position and the welding process with the short pipe. By taking images of the flange and short pipe positions in real time and feeding them back to the control system, the precise information and automatic adjustment strategies based on computer detection and analysis contribute to the accurate 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. Each device includes a dust collector 6 and a branch extraction pipe 11. The dust collector 6 is positioned on the workbench 1 and located on one side of the flange fastening device 2, used to collect welding slag and dust generated during the welding of the flange and short pipe. A dust collection hopper 10 is located at the bottom of the flange fastening device 2. The bottom of the dust collector 6 is connected to the dust collection hopper 10 via the branch extraction pipe 11. The dust collection hopper 10 is connected to the dust collection box 13 via the main extraction 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. Each support column 3-6 is equipped with an auxiliary camera, which is connected to the control system and used to provide real-time auxiliary feedback on the processing process.

[0088] Furthermore, in this embodiment, a top cover 8 is installed on the top of the lifting device 3 on the workbench 1. The top cover 8 is connected to the workbench 1 around the perimeter and a radiation shield 9 is laid to form a processing chamber, which is used to suppress the radiation brought to the surrounding environment by the detector alignment device 5 during real-time shooting.

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

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

[0091] Step S0: Based on the preset data thresholds for the flange and short pipe in the control system, including but not limited to the control thresholds during the welding process, the control thresholds for the detector alignment during the optical detection process, the workpiece adjustment and feedback thresholds after welding, and the final product quality inspection thresholds.

[0092] Step S1: Flange processing

[0093] Step S11: Place 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 drive the screws of the two lifting screws 3-4 to rotate, so that the lifting frame 3-5 carries the grinding disc 4-1 down toward the flange fastening device 2 and presses the flange on the platform 2-1. Then the screws of the two lifting screws 3-4 rotate in opposite directions, so that the lifting frame 3-5 carries the grinding disc 4-1 up away from the flange fastening device 2.

[0095] Step S13: Clamping the flange: The control system controls the drive unit to drive the horizontal large gear 2-7 to rotate. Several vertical small gears 2-6 meshing with the horizontal large gear 2-7 drive the screw of the corresponding 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 to it to move in the waist-shaped hole of the base 2-1. Several clamping heads move radially on the base 1, thereby clamping the outer ring of the flange.

[0096] Step S14: First image capture: The flange is imaged using several detectors 5 located around the platform 2-1, including the flange's model and specifications, placement status, and surface flatness. The image is then 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 positions and angles where the error exceeds the threshold. If 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 grinding strategy; proceed to step S15; otherwise, proceed to step S2.

[0097] Specifically as follows:

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

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

[0100] Data is stored in matrix form:

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

[0102] Where i and j are the sampling point indices on the flange surface, and t ij The thickness at that point.

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

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

[0105] Output: Thickness difference matrix D[i][j], list of uneven region locations (x, y).

[0106] Calculate the thickness difference:

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

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

[0109] The thickness difference matrix D[i][j] contains elements exceeding the tolerance range [Δ]. min Δ max Points marked with ] are considered 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: Generate a sanding path and parameters (position, pressure, angle) based on the uneven area.

[0112] Input: Thickness difference matrix D[i][j], information on uneven areas.

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

[0114] Step S144: Perform the grinding operation according to the path planning and adjust the grinding parameters in real time.

[0115] For each uneven area, a layered polishing path is planned:

[0116]

[0117] Among them, z k Let n be the polishing depth of the k-th layer, and n be the number of polishing passes.

[0118] Step S15: Grinding: The two lifting motors 3-2 of the lifting device 3 drive the screws of the two lifting screws 3-4 to rotate, so that the lifting frame 3-5 carries the grinding disc 4-1 down toward the flange fastening device 2 and contacts the flange. Then, the grinding motor 4-2 controls the grinding disc 4-1 to rotate, 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 using several detectors 5 to confirm that the surface flatness of the flange meets the threshold flatness requirement. Then, proceed to step S2. Otherwise, repeat steps S15-S16.

[0121] Step S2: Short pipe treatment:

[0122] Step S21: Clamping and positioning the short pipe: The clamping robotic 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 pipe and rotate with the base 7-1. The distance between the second robotic arm 7-3 and the first robotic arm 7-2 is opened according to the threshold of the control system, and the short pipe clamped by the clamping robotic arm is adjusted to be located at the welding processing position on the flange.

[0123] Step S22: Third imaging: Several detectors 5 are used to take pictures of the flange and short pipe in their pre-welding state, and the images are fed back to the control system to generate 3D surface models of the flange and short pipe. The control system processes and analyzes the models to confirm whether the distance between the bottom of the short pipe and the flange welding surface is uniform, and calculates the angular deviation between the central axis of the short pipe and the central axis of the flange to ensure that their coaxiality is within the control range; at the same time, it confirms the offset between the circumference of the short pipe and the flange welding surface.

[0124] The control system generates a deviation diagram of the relative position of the short pipe and the flange; if the deviation exceeds the set threshold, an adjustment command is issued, and the control system controls the gripping robotic arm to reposition the short pipe; if the position is correct, the control system combines the contact surface shape of the short pipe and the flange to generate a welding path, and the control system issues a welding permission signal to proceed to step S3.

[0125] Step S3: Welding process:

[0126] Step S31: Outer ring welding: The first welding path is the outer circumference of the connection between the short pipe and the flange. Heat the welding electrode or welding wire to the specified temperature with the welding torch at 7-5 and start welding.

[0127] Under the command of the control system, the welding torch 7-5 of the welding robot arm moves smoothly along the set path. 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 cools naturally for 30 minutes.

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

[0129] If an anomaly is detected, such as excessively high temperature or weld misalignment, the control system will automatically adjust the welding parameters or suspend welding.

[0130] Step S32: Short tube flipping:

[0131] The V-shaped gripping mechanism 7-4 on the gripping robotic arm opens to grip the outer wall of the semi-finished short pipe, preventing compression or damage to the weld.

[0132] The V-shaped gripping mechanism 7-4 of the gripping robot arm rotates, causing the semi-finished short tube to rotate 180°, and ensuring that the axis of the semi-finished short tube is aligned with the central axis of the platform 2-1;

[0133] Step S33: Inner ring welding: The second welding path is the inner circumference of the connection between the short pipe and the flange. The welding torch heats the welding electrode or welding wire to the specified temperature and welding begins. During the inner ring welding process, the clamping robotic arm always holds the semi-finished short pipe. Similarly, after the welding is completed, the welding area is allowed to cool naturally for 30 minutes.

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

[0135] Step S4: Final inspection: Use the detector alignment device 5 to perform a full-range inspection of the finished short pipe and flange to ensure there are no missed welds and avoid potential defects;

[0136] Step S5: After clamping the finished product short pipe and flange with the clamping robotic arm, the finished product is rotated and placed on the finished product placement area on the worktable 1 via the base 7-1 to complete the processing;

[0137] Step S6: The quality of the two welds is inspected by professional weld quality inspection instruments to confirm that the welding quality meets the standards and avoid potential defects, thus providing quality assurance for product delivery.

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

[0139] The real-time imaging feedback of the flange and short pipe positions via the detection alignment device, combined with precise information from computer detection analysis and automatic adjustment strategies, helps to accurately position the flange and short pipe.

[0140] In summary, this embodiment achieves integrated operations such as automatic handling, precise alignment, and automatic welding, integrating modular functions and solving the problem of large footprint caused by the dispersed use of multiple devices and instruments with different functions in traditional technologies. It maximizes the use of automation and intelligent technologies in the measurement, assembly, and welding stages, alleviating the constraints of technology and experience in the modular prefabrication of pipe fittings.

[0141] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this 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 technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0143] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A precision welding device for flange short pipes based on detection and correction, used for correcting and welding flanges and short pipes, characterized in that, It includes a workbench (1), a flange fastening device (2), a lifting device (3), a grinding mechanism (4), an operating arm (7), a detection aligner (5), and several dust collection devices; The workbench (1) is set on a horizontal surface and is used to provide a processing base; the workbench (1) 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; The flange fastening device (2) is set in the processing area of ​​the workbench (1) for placing and clamping the flange; The lifting device (3) is located 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) 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 grinding disc (4-1) is lifted and rotated by the lifting device (3) and the grinding motor (4-2) respectively, and is used to press, limit and grind the surface of the flange on the flange fastening device (2); The operating arm (7) includes a clamping robotic arm and a welding robotic arm, which are used to clamp short pipes and weld short pipes and flanges, respectively. The detection aligner (5) is arranged around the flange fastening device (2) and is connected to the control system for real-time feedback of the flange's own position status and the welding process with the short pipe. Several of the aforementioned dust collection devices are evenly distributed around the flange fastening device (2); The dust collection device includes a dust collector (6) and a separate suction pipe (11). The dust collector (6) is set on the workbench (1) and located on one side of the flange fastening device (2) for collecting welding slag and dust brought in during the welding of the flange and the short pipe. The bottom of the flange fastening device (2) is provided with a dust collection hopper (10), the bottom of the dust collector (6) is connected to the dust collection hopper (10) through a branch air extraction pipe (11), and the dust collection hopper (10) is connected to the dust collection box (13) through a main air extraction pipe (12). The lifting device (3) includes a rectangular lifting top plate (3-1), a lifting motor (3-2), a screw mounting base (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 mounted above the flange fastening device (2) via a support column (3-6) to provide stable support for the lifting movement; Two lifting screws (3-4) are used, which are respectively set on the workbench (1) through 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 to the lifting screw (3-4). The two lifting screws (3-4) are connected to the grinding disc (4-1) via the lifting frame (3-5) through the lifting nuts (3-7), which is used to drive the lifting movement of the grinding disc (4-1); The welding robotic arm includes a first robotic arm (7-2) and a second robotic arm (7-3) connected by a rotating shaft; the first robotic arm (7-2) is mounted on one side of the flange fastening device (2) via a rotatable base (7-1); the second robotic arm (7-3) is connected to a welding torch (7-5), which is connected to an electric welding machine via a line for welding short pipes to flanges; The clamping robotic arm includes a first robotic arm (7-2) and a second robotic arm (7-3) connected by a rotating shaft; the first robotic arm (7-2) is mounted on one side of the flange fastening device (2) via a rotatable base (7-1); the second robotic arm (7-3) is connected to a V-shaped clamping mechanism (7-4) via a rotating mechanism. The clamping mechanism (7-4) is provided with a rubber pad for clamping short pipes and placing short pipes to connect with the flange. The V-shaped clamping mechanism (7-4) can be rotated 180° via the rotating mechanism.

2. The precision welding device for flange short pipes based on detection correction according to claim 1, characterized in that, The flange fastening device (2) includes a base (2-1), a clamp (2-2), and a horizontal displacement mechanism; The platform (2-1) is set on the central axis of the workbench (1). The platform (2-1) has a plurality of oblong holes radially arranged on it. Each of the oblong holes is fitted with a clamping head (2-2) with a silicone pad (2-3). One end of the clamping head (2-2) is set on the workbench (1) for radially clamping the flange after displacement. The other end of the clamping head (2-2) is controlled and driven by the horizontal displacement mechanism to achieve displacement within the oblong holes.

3. The precision welding device for flange short pipes based on detection and correction according to claim 2, characterized in that, The horizontal displacement mechanism includes a horizontal lead screw (2-4), a vertical pinion (2-6), and a horizontal large gear (2-7). The transverse large gear (2-7) is located at the center of the platform. The transverse large gear (2-7) is driven by a drive unit. Several vertical small gears (2-6) mesh on the transverse large gear (2-7). The number of vertical small gears (2-6) is the same as the number of chuck heads (2-2). The bottom of the chuck head (2-2) is set on the horizontal lead screw (2-4) by 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 located inside the platform (2-1).

4. The precision welding device for flange short pipes based on detection correction according to claim 1, characterized in that, The support columns (3-6) consist of four columns, which are used to support the four corners of the lifting top plate (3-1). Each support column (3-6) is equipped with an auxiliary camera, which is connected to the control system and is used to provide real-time auxiliary feedback on the processing.

5. The precision welding device for flange short pipes based on detection correction according to claim 1, characterized in that, The lifting device (3) on the workbench (1) is equipped with a top cover (8). The top cover (8) is connected to the workbench (1) and a radiation shield (9) is laid around it to form a processing room, which is used to suppress the radiation of the detector (5) to the surrounding environment during real-time shooting.

6. The precision welding device for flange short pipes based on detection correction according to claim 5, characterized in that, The equipment top cover (8) is provided with an exhaust port (14) for discharging the fumes during the welding process and avoiding high-temperature processing in the processing chamber.

7. A method for operating the precision welding device for flange short pipes based on detection correction as described in any one of claims 1-6, characterized in that, Includes the following steps: Step S0: Based on the preset data thresholds for the flange and short pipe in the control system; Step S1: Flange processing Step S11: Place 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) drive the screws of the two lifting screws (3-4) to rotate, so that the lifting frame (3-5) carrying the grinding disc (4-1) descends towards the flange fastening device (2) and presses and limits the flange on the platform (2-1), so that the bottom of the flange is completely in contact with the surface of the flange fastening device (2) to prevent the flange from warping slightly; then the screws of the two lifting screws (3-4) rotate in opposite directions, so that the lifting frame (3-5) carrying the grinding disc (4-1) rises away from the flange fastening device (2); Step S13: Clamping the flange: The control system controls the drive unit to drive the horizontal large gear (2-7) to rotate. Several vertical small gears (2-6) meshing with the horizontal large gear (2-7) drive the screw of the corresponding horizontal lead screw (2-4) to rotate, thereby driving the horizontal nut (2-5) on the screw to drive the chuck (2-2) connected to it to move in the waist-shaped hole of the base (2-1). Several chucks move radially on the base (2-1), thereby clamping the outer ring of the flange. Step S14: First image capture: The flange is captured by several detectors (5) located around the platform (2-1), including the flange model and specifications, placement status and surface flatness, and 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 grinding strategy; proceed to step S15, otherwise proceed to step S2. Step S15: Grinding: The two lifting motors (3-2) of the lifting device (3) drive the screws of the two lifting screws (3-4) to rotate, thereby causing the lifting frame (3-5) to lower the grinding disc (4-1) towards the flange fastening device (2) and contact the flange. Then, the grinding motor (4-2) controls the grinding disc (4-1) to rotate, thereby grinding the surface of the flange according to the grinding strategy. Step S16: Second filming: The flange is filmed again by several detectors (5) to confirm that the surface flatness of the flange meets the threshold flatness requirement. Then, proceed to step S2. Otherwise, repeat steps S15-S16. Step S2: Short pipe treatment: Step S21: Clamping and positioning the short pipe: The clamping robotic 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) clamps the short pipe through the control system and rotates with the base (7-1). The distance between the second robotic arm (7-3) and the first robotic arm (7-2) is opened according to the threshold of the control system. The short pipe clamped by the clamping robotic arm is adjusted to be located at the welding processing position on the flange. Step S22: Third filming: The flange and short pipe are filmed before welding using several detectors (5), and the images are fed back to the control system to generate 3D surface models of the flange and short pipe. The control system processes and analyzes the models of both to confirm whether the distance between the bottom of the short pipe and the welding surface of the flange is uniform, calculates the angular deviation between the central axis of the short pipe and the central axis of the flange, and ensures that the coaxiality of the two is within the control range. At the same time, the offset between the circumference of the short pipe and the welding surface of the flange is confirmed. The control system generates a deviation diagram of the relative position of the short pipe and the flange; if the deviation exceeds the set threshold, an adjustment command is issued, and the control system controls the gripping robotic arm to reposition the short pipe; if the position is correct, the control system combines the contact surface shape of the short pipe and the flange to generate a welding path, and the control system issues a welding permission signal to proceed to step S3. Step S3: Welding process: Step S31: Outer ring welding: The first welding path is the outer circumference of the connection between the short pipe and the flange. Heat the welding electrode or welding wire with the welding gun (7-5) to the specified temperature and start welding. Under the command of the control system, the welding torch (7-5) of the welding robot arm moves smoothly along the set path. 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 cools naturally for 30 minutes. Step S32: Short tube flipping: The V-shaped clamping mechanism (7-4) on the clamping robotic arm opens to clamp the outer wall of the semi-finished short pipe, preventing compression or damage to the weld. The V-shaped gripping mechanism (7-4) of the gripping robot arm rotates, causing the semi-finished short tube to flip 180°, and ensuring that the axis of the semi-finished short tube is aligned with the central axis of the platform (2-1); Step S33: Inner ring welding: The second welding path is the inner circumference of the connection between the short pipe and the flange. The welding torch (7-5) heats the welding electrode or welding wire to the specified temperature and starts welding. During the inner ring welding process, the clamping robotic arm always clamps the semi-finished short pipe. Similarly, after the welding is completed, the welding area is allowed to cool naturally for 30 minutes. When a non-standard short pipe flange module has flanges at both ends of the short pipe, repeat steps 1 to S3 above to weld the flange at the other end of the short pipe. Step S4: Final inspection: Use the detector alignment device (5) to perform a full inspection of the finished short pipe and flange to ensure that there are no missed welds and avoid potential defects; Step S5: After clamping the finished product short pipe and flange with the clamping robotic arm, the finished product is rotated and placed on the finished product placement area on the worktable (1) through the base (7-1) to complete the processing; Step S6: The quality of the two welds is inspected by professional weld quality inspection instruments to confirm that the welding quality meets the standards and avoid potential defects, thus providing quality assurance for product delivery; In addition, all imaging images and detection analysis data are saved to a database in the control system to form a traceable quality file. The detection data of each finished product is associated with the production batch, which facilitates quality tracking and subsequent optimization.

Images