Butt welding method for pipeline installation in pipe ditch

Abstract

A butt welding method for pipeline installation in a pipe ditch relates to the technical field of pipe ditch pipeline welding, and comprises the following steps: S1, pipeline hoisting preparation; s2, pipeline hoisting and positioning; s3, pipe ditch pipeline butt joint adjustment; s4, welding preparation is conducted; s5, pipeline welding; s6, evaluating the calibration detection quality; equipment composition and a control system are adopted; the equipment composition comprises full-automatic hoisting equipment, welding equipment and calibration detection equipment. The control system comprises a central control system, an equipment control module, a communication module and a data transmission module. The pipeline butt welding device has the beneficial effects that the automation degree is high, accurate positioning can be achieved, all devices are controlled in a centralized and unified mode, the collaboration is better, butt welding of pipelines can be repeatedly and circularly conducted, and the efficiency of installation and butt welding of the pipelines in the pipe ditch is greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of trench pipeline welding, and in particular to a pipeline installation butt welding method in a trench. Background Art

[0002] A trench is an underground channel structure used to accommodate pipelines. It can protect pipelines from external damage and reduce the impact of environmental factors such as temperature changes and ultraviolet rays on pipelines. The materials of trench pipes are diverse, the most common ones are carbon steel, stainless steel, alloy steel, plastic, etc. Pipes of different materials are suitable for different media transportation and working conditions.

[0003] When laying existing pipelines, especially metal pipelines, docking and welding are usually required, which mainly includes the following steps: pipeline hoisting and installation, pipeline docking and pipeline welding. When lifting the pipeline, it is currently mainly carried out manually by cranes or hoisting machines, and the control of position and lifting requires command and cooperation to complete; when docking the pipelines, the pipeline docking device is used to install the docking and then weld. Each step cannot be used in a coherent manner, the accuracy is difficult to control, the degree of automation is low, and the positioning usually relies on manual lifting, which is time-consuming and labor-intensive, and the work efficiency is not high. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides a method for butt welding of pipelines in a trench to solve the above problems.

[0005] The present invention provides a method for butt welding of pipelines in a trench, the method comprising the following steps:

[0006] S1: Preparation for pipeline hoisting; install fully automatic hoisting equipment on both sides of the trench, connect the control system, and debug; install fully automatic welding equipment in the trench, connect the control system, and debug, prepare for pipeline hoisting, and clean the pipeline opening; install positioning sensors on the hoisting pipelines, connect the positioning sensors to the control system, calibrate and test the sensors, install electromagnetic suction docking devices at the docking pipe openings, connect the control system, and debug;

[0007] S2: Pipeline lifting and positioning: The fully automatic lifting equipment clamps the pipeline with a lifting device and lifts the pipeline above the trench. During the lifting process, the positioning sensor monitors the position and posture of the pipeline in real time and feeds back the information to the control system. The control system makes precise position adjustments based on the sensor feedback information to accurately move the pipeline above the docking position, and then slowly lowers the pipeline to bring the pipeline port close to the docking position.

[0008] S3: Pipeline butt adjustment in trenches; when the pipe port approaches the butt joint position, the weld tracking sensor of the fully automatic welding equipment is started, the weld tracking sensor scans the pipe port, identifies the position and angle of the port, and transmits the information to the control system. The control system adjusts the position and posture of the pipe through the fully automatic lifting equipment according to the information of the weld tracking sensor, so that the pipe ports are completely aligned, and the electromagnetic suction type butt jointer is opened through the control system to position and fix the hoisted pipe and the butt joint pipe;

[0009] S4: Welding preparation: After the pipeline is butt-jointed, preparatory work before welding is carried out, including cleaning the oil, rust and other impurities at the pipeline port, installing the welding protective gas device, adjusting the parameters of the welding equipment, and ensuring that the fully automatic welding equipment maintains communication connection with the control system;

[0010] S5: Pipeline welding: Start the fully automatic welding equipment and start the pipeline butt welding. During the welding process, the weld tracking sensor monitors the position change of the weld in real time. The control system automatically adjusts the position of the welding gun according to the feedback information of the weld tracking sensor. The automatic hoisting equipment adjusts the position and posture of the pipeline in time through the control system according to the welding progress and the requirements of the welding equipment until the welding is completed.

[0011] S6: Calibration and inspection quality assessment; after welding is completed, the weld is visually inspected by a scanner, and the weld is internally inspected by non-destructive testing methods. The scanned image and non-destructive testing data are sent to the control system for quality assessment, and welds with unqualified welding quality are repaired; after the welding acceptance is completed, the hoisting equipment and positioning sensors are removed, and the fully automatic hoisting equipment is moved to the next pipeline hoisting position for hoisting and butt welding of the next section of the pipeline.

[0012] Furthermore, before the fully automatic lifting equipment in S2 lifts, the pipeline is positioned, and the position of the target pipeline is determined by the laser displacement sensor of the fully automatic lifting equipment. The height of the hook from the target pipeline and the height of the reference plane are accurately transmitted to the control system for analysis and control of the fully automatic lifting equipment. During the lifting process of the fully automatic lifting equipment in S2, the height, horizontal position and swing of the target pipeline are monitored in real time by the laser displacement sensor of the fully automatic lifting equipment, and the control system corrects the deviation in time to lift the pipeline smoothly.

[0013] Furthermore, the scanner in S6 scans and checks whether there are defects such as cracks, pores, slag inclusions, and undercuts on the weld surface, and whether the weld size meets the design requirements; the non-destructive testing method is ultrasonic testing.

[0014] The method adopts an equipment composition and a control system; the equipment composition includes fully automatic lifting equipment, welding equipment and calibration and testing equipment; the control system includes a controller, a human-machine interface, an equipment control module, a communication module and a data transmission module; the fully automatic lifting equipment includes a gantry crane, a lifting device and a positioning device; the welding equipment includes a welding robot, a weld tracking sensor and a protective gas device; the calibration and testing equipment includes non-destructive testing equipment and a data acquisition module; the equipment control module includes a lifting equipment control module, a docking equipment control module, a welding equipment control module and a calibration and testing equipment control module.

[0015] Furthermore, the welding robot comprises a welding robot body and a walking mechanism. The welding robot body comprises a mechanical structure, a welding gun and a wire feeding mechanism. The walking mechanism is a magnetic walking mechanism.

[0016] Furthermore, the mechanical structure is composed of a multi-joint robotic arm with high-degree-of-freedom movement capability, which can accurately position the welding gun in three-dimensional space. Each joint is driven by a high-precision servo motor and cooperates with a precision reducer to achieve precise position control and motion trajectory planning.

[0017] Furthermore, the walking mechanism adopts a magnetic walking mechanism. The welding robot is adsorbed on the surface of the pipeline by a powerful magnet and can move freely in the circumference and axial direction of the pipeline. The magnetic walking mechanism is equipped with an anti-slip device to ensure that the robot walks stably on the surface of the pipeline.

[0018] Furthermore, the weld tracking sensor uses a laser vision sensor to monitor the position and shape changes of the weld in real time.

[0019] The beneficial effects of the present invention are: in a space-constrained trench, it has high flexibility, a high degree of automation, precise positioning, centralized and unified control of various devices, better coordination, and the butt welding of pipelines can be repeated and cyclically performed, greatly improving the efficiency of butt welding of pipeline installation in the trench. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 The present invention is a flow chart of the method. DETAILED DESCRIPTION

[0021] Example 1

[0022] like Figure 1As shown, the present invention provides a method for butt welding of pipelines in a trench, the method comprising: S1: preparation for pipeline hoisting; installing fully automatic hoisting equipment on both sides of the trench, connecting the control system, and debugging; installing fully automatic welding equipment in the trench, connecting the control system, and debugging, preparing for pipeline hoisting, and cleaning the pipeline opening; installing a positioning sensor on the hoisting pipeline, connecting the positioning sensor to the control system, calibrating and testing the sensor, installing an electromagnetic suction type butt joint device at the butt joint pipeline opening, connecting the control system, and debugging;

[0023] S2: Pipeline lifting and positioning: The fully automatic lifting equipment clamps the pipeline with a lifting device and lifts the pipeline above the trench. During the lifting process, the positioning sensor monitors the position and posture of the pipeline in real time and feeds back the information to the control system. The control system makes precise position adjustments based on the sensor feedback information to accurately move the pipeline above the docking position, and then slowly lowers the pipeline to bring the pipeline port close to the docking position.

[0024] S3: Pipeline butt adjustment in trenches; when the pipe port approaches the butt joint position, the weld tracking sensor of the fully automatic welding equipment is started, the weld tracking sensor scans the pipe port, identifies the position and angle of the port, and transmits the information to the control system. The control system adjusts the position and posture of the pipe through the fully automatic lifting equipment according to the information of the weld tracking sensor, so that the pipe ports are completely aligned, and the electromagnetic suction type butt jointer is opened through the control system to position and fix the hoisted pipe and the butt joint pipe;

[0025] S4: Welding preparation: After the pipeline is butt-jointed, preparatory work before welding is carried out, including cleaning the oil, rust and other impurities at the pipeline port, installing the welding protective gas device, adjusting the parameters of the welding equipment, and ensuring that the fully automatic welding equipment maintains communication connection with the control system;

[0026] S5: Pipeline welding: Start the fully automatic welding equipment and start the pipeline butt welding. During the welding process, the weld tracking sensor monitors the position change of the weld in real time. The control system automatically adjusts the position of the welding gun according to the feedback information of the weld tracking sensor. The automatic hoisting equipment adjusts the position and posture of the pipeline in time through the control system according to the welding progress and the requirements of the welding equipment until the welding is completed.

[0027] S6: Calibration and inspection quality assessment; after welding is completed, the weld is visually inspected by a scanner, and the weld is internally inspected by non-destructive testing methods. The scanned image and non-destructive testing data are sent to the control system for quality assessment, and welds with unqualified welding quality are repaired; after the welding acceptance is completed, the hoisting equipment and positioning sensors are removed, and the fully automatic hoisting equipment is moved to the next pipeline hoisting position for hoisting and butt welding of the next section of the pipeline.

[0028] Before the fully automatic lifting equipment in S2 is lifted, the pipeline is positioned, and the position of the target pipeline is determined by the laser displacement sensor of the fully automatic lifting equipment. The height of the hook from the target pipeline and the height of the reference surface are accurately transmitted to the control system for analysis and control of the fully automatic lifting equipment. During the lifting process of the fully automatic lifting equipment in S2, the height, horizontal position and swing of the target pipeline are monitored in real time by the laser displacement sensor of the fully automatic lifting equipment, and the control system corrects the deviation in time to ensure smooth lifting of the pipeline.

[0029] In S6, the scanner scans and checks whether there are cracks, pores, slag inclusions, undercut defects on the weld surface, and whether the weld size meets the design requirements; the non-destructive testing method is ultrasonic testing.

[0030] Example 2

[0031] The present invention provides a device for a method for butt welding of pipes installed in a pipe trench, the device comprising: fully automatic lifting equipment, welding equipment and calibration detection equipment; the control system comprises a controller, a human-machine interface, an equipment control module, a communication module and a data transmission module; the fully automatic lifting equipment comprises a gantry crane, a hanger device and a positioning device; the welding equipment comprises a welding robot, a weld tracking sensor and a protective gas device; the welding robot comprises a welding robot body and a walking mechanism, the welding robot body comprises a mechanical structure, a welding gun and a wire feeding mechanism, and the walking mechanism is a magnetic walking mechanism; the mechanical structure consists of a multi-joint mechanical arm, has a high degree of freedom of movement, and can accurately move in three-dimensional space The welding gun is positioned on the ground, and each joint is driven by a high-precision servo motor, which is matched with a precision reducer to achieve precise position control and motion trajectory planning; the walking mechanism adopts a magnetic walking mechanism. The welding robot is adsorbed on the surface of the pipeline by a powerful magnet and can move freely in the circumference and axial direction of the pipeline. The magnetic walking mechanism is equipped with an anti-skid device to ensure that the robot can walk stably on the surface of the pipeline; the weld tracking sensor adopts a laser vision sensor to monitor the position and shape changes of the weld in real time; the calibration and detection equipment includes non-destructive testing equipment and data acquisition modules; the equipment control modules include hoisting equipment control module, docking equipment control module, welding equipment control module and calibration and detection equipment control module.

Claims

1. A method for butt welding of pipelines in a trench, characterized in that: The method comprises the following steps: S1: Preparation for pipeline hoisting; install fully automatic hoisting equipment on both sides of the trench, connect the control system, and debug; install fully automatic welding equipment in the trench, connect the control system, and debug, prepare for pipeline hoisting, and clean the pipeline opening; install positioning sensors on the hoisting pipelines, connect the positioning sensors to the control system, calibrate and test the sensors, install electromagnetic suction docking devices at the docking pipe openings, connect the control system, and debug; S2: Pipeline lifting and positioning: The fully automatic lifting equipment clamps the pipeline with a lifting device and lifts the pipeline above the trench. During the lifting process, the positioning sensor monitors the position and posture of the pipeline in real time and feeds back the information to the control system. The control system makes precise position adjustments based on the sensor feedback information to accurately move the pipeline above the docking position, and then slowly lowers the pipeline to bring the pipeline port close to the docking position. S3: Pipeline butt adjustment in trenches; when the pipe port approaches the butt joint position, the weld tracking sensor of the fully automatic welding equipment is started, the weld tracking sensor scans the pipe port, identifies the position and angle of the port, and transmits the information to the control system. The control system adjusts the position and posture of the pipe through the fully automatic lifting equipment according to the information of the weld tracking sensor, so that the pipe ports are completely aligned, and the electromagnetic suction type butt jointer is opened through the control system to position and fix the hoisted pipe and the butt joint pipe; S4: Welding preparation: After the pipeline is butt-jointed, preparatory work before welding is carried out, including cleaning the oil, rust and other impurities at the pipeline port, installing the welding protective gas device, adjusting the parameters of the welding equipment, and ensuring that the fully automatic welding equipment maintains communication connection with the control system; S5: Pipeline welding: Start the fully automatic welding equipment and start the pipeline butt welding. During the welding process, the weld tracking sensor monitors the position change of the weld in real time. The control system automatically adjusts the position of the welding gun according to the feedback information of the weld tracking sensor. The automatic hoisting equipment adjusts the position and posture of the pipeline in time through the control system according to the welding progress and the requirements of the welding equipment until the welding is completed. S6: Calibration and inspection quality assessment; after welding is completed, the weld is visually inspected by a scanner, and the weld is internally inspected by non-destructive testing methods. The scanned image and non-destructive testing data are sent to the control system for quality assessment, and welds with unqualified welding quality are repaired; after the welding acceptance is completed, the hoisting equipment and positioning sensors are removed, and the fully automatic hoisting equipment is moved to the next pipeline hoisting position for hoisting and butt welding of the next section of the pipeline.

2. A method for butt welding of pipes in a pipe trench according to claim 1, characterized in that: Before the fully automatic lifting equipment in S2 is lifted, the pipeline is positioned, and the position of the target pipeline is determined by the laser displacement sensor of the fully automatic lifting equipment. The height of the hook from the target pipeline and the height of the reference surface are accurately transmitted to the control system for analysis and control of the fully automatic lifting equipment. During the lifting process of the fully automatic lifting equipment in S2, the height, horizontal position and swing of the target pipeline are monitored in real time by the laser displacement sensor of the fully automatic lifting equipment, and the control system corrects the deviation in time to ensure smooth lifting of the pipeline.

3. A method for butt welding of pipes in a pipe trench according to claim 1, characterized in that: In S6, the scanner scans and checks whether there are cracks, pores, slag inclusions, undercut defects on the weld surface, and whether the weld size meets the design requirements; the non-destructive testing method is ultrasonic testing.

4. A method for butt welding of pipes in a pipe trench according to claim 1, characterized in that: The method adopts an equipment composition and a control system; the equipment composition includes fully automatic lifting equipment, welding equipment and calibration and testing equipment; the control system includes a controller, a human-machine interface, an equipment control module, a communication module and a data transmission module; the fully automatic lifting equipment includes a gantry crane, a lifting device and a positioning device; the welding equipment includes a welding robot, a weld tracking sensor and a protective gas device; the calibration and testing equipment includes non-destructive testing equipment and a data acquisition module; the equipment control module includes a lifting equipment control module, a docking equipment control module, a welding equipment control module and a calibration and testing equipment control module.

5. A method for butt welding of pipes in a pipe trench according to claim 4, characterized in that: The welding robot comprises a welding robot body and a walking mechanism. The welding robot body comprises a mechanical structure, a welding gun and a wire feeding mechanism. The walking mechanism is a magnetic walking mechanism.

6. A method for butt welding of pipes in a pipe trench according to claim 4, characterized in that: The mechanical structure is composed of a multi-joint robotic arm with high-degree-of-freedom movement capability, which can accurately position the welding gun in three-dimensional space. Each joint is driven by a high-precision servo motor and cooperates with a precision reducer to achieve precise position control and motion trajectory planning.

7. A method for butt welding of pipes in a pipe trench according to claim 5, characterized in that: The walking mechanism adopts a magnetic walking mechanism. The welding robot is adsorbed on the surface of the pipeline by a powerful magnet and can move freely in the circumference and axial direction of the pipeline. The magnetic walking mechanism is equipped with an anti-slip device to ensure that the robot walks stably on the surface of the pipeline.

8. A method for butt welding of pipes in a pipe trench according to claim 4, characterized in that: The weld tracking sensor adopts a laser vision sensor to monitor the position and shape changes of the weld in real time.

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