Welding gun regulation and control method and system applied to spiral welded pipe welding operation environment

Abstract

The invention discloses a welding gun regulation and control method and system applied to a spiral welded pipe welding operation environment, and relates to the technical field of spiral welded pipes. Secondly, welding gun deviation and welding area parameters are obtained; step 3, modeling; fourthly, the welding gun set adjustment amount, the angle after first gun adjustment and the adjustment amount of each wire are calculated; and fifthly, welding control is conducted. The welding device has the effect of improving the welding work quality.

Description

Technical Field

[0001] The present application relates to the technical field of spiral welded pipes, and in particular to a welding gun control method and system applied to a spiral welded pipe welding operation environment. Background Art

[0002] In the existing spiral welded pipe welding process, one welding method is: use multiple welding wires to weld the weld. During welding, the mounting base of the welding gun is usually adjusted to the same angle as the spiral angle, and then a certain position is adjusted along the radial direction of the steel pipe to make the weld a downhill weld.

[0003] Since the welding position of each wire must be located on the spiral line, there is a certain angle between each wire welding point and the vertical line of the steel pipe axis. The current welding method only divides the deviation angle of each wire equally among multiple wires. If the angle is not adjusted, the bottom of the weld pool may be tilted and the weld morphology may be high on one side and low on the other side. Figure 8 As shown, in severe cases, even major quality accidents such as lack of fusion may occur, so the present application proposes a new technical solution. Summary of the invention

[0004] In order to improve the welding quality of spiral welded pipes, the present application provides a welding gun control method and system applied to a spiral welded pipe welding operation environment.

[0005] In the first aspect, the present application provides a welding gun control method and system applied to a spiral welded pipe welding operation environment, which adopts the following technical solutions: A welding gun control method applied to a spiral welded pipe welding operation environment, comprising: Step 1: Obtain the fixed parameters of the spiral welded pipe, which include: Obtaining and recording the plate width B of the substrate used to form the pipe, the diameter D of the pipe, and the weld spiral line distribution data of the pipe; Step 2: Obtain welding gun offset and welding zone parameters, including: The number of welding guns is defined as n, and the feeding direction of each welding wire corresponds to the center line of each welding gun or intersects with the center line of the welding gun; Define multiple welding guns to be arranged linearly to form a welding gun group, and the welding gun located at the outermost side is the first gun; Obtain and define the distance between two adjacent welding points on the spiral line as A, which is called welding point distance; Get the distance W between the first gun and the mid-perpendicular line when viewing the pipe end, which is called the first wire offset distance; Step 3: Modeling, which includes: generating a three-dimensional model based on the plate width B of the base plate of the pipe, the diameter D of the pipe, and the weld spiral line distribution data of the pipe; Step 4: Calculate the welding gun group adjustment amount, the angle after the first gun is adjusted, and the adjustment amount of each wire; The helix angle α is obtained based on the plate width B and the pipe diameter D as the adjustment amount of the welding gun group; Based on the first wire offset distance W, the rotation angle β when the first gun is offset is analyzed as the adjustment amount of the first gun; The theoretical offset angle θ is analyzed based on the welding point distance A as the adjustment amount of each wire; wherein the theoretical offset angle θ is the angle of each welding wire relative to the welding position of the first wire and the vertical line between the central axis of the steel pipe; Step 5: Perform welding control; Based on the calculated welding gun group adjustment amount, the angle after the first gun adjustment and the adjustment amount of each wire, the welding gun is adjusted and welding work is performed.

[0006] Optionally, the helix angle α is obtained based on the plate width B and the diameter D of the tube, which includes: The 3D model generates the center line of the pipe and defines it as line 1 M1; The three-dimensional model generates the center line of the substrate and is defined as line 2 M2; The angle between line 1 M1 and line 2 M2 of the unwound section of the substrate is measured to obtain an angle which is defined as the helix angle α.

[0007] Optionally, the calculation of the rotation angle β when the first gun is offset based on the first wire offset distance W includes: In the three-dimensional model, two endpoints corresponding to the first wire offset distance W are defined as point 1 D1 and point 2 D2 respectively; Generate a perpendicular line between point 1 D1 and line 1 M1, and a perpendicular line between point 2 D2 and line 1 M1 in the three-dimensional model, and define them as line 3 M3 and line 4 M4 respectively; The angle between line three M3 and line four M4 is measured, and the angle is obtained and defined as the rotation angle β when the welding gun is offset.

[0008] Optionally, the analyzing the theoretical offset angle θ based on the welding point distance A includes: In the three-dimensional model, the welding area is calibrated based on the first wire welding point and the welding point distance A, and the two end points of the welding area on the spiral line are generated and defined as point three D3 and point four D4 respectively; Generate a perpendicular line between point three D3 and line one M1, and a perpendicular line between point four D4 and line one M1 in the three-dimensional model, and define them as line five M5 and line six M6 respectively; The angle between line five M5 and line six M6 is measured to obtain an angle which is defined as a theoretical offset angle θ.

[0009] In the second aspect, the present application provides a welding gun control method and system applied to a spiral welded pipe welding operation environment, which adopts the following technical solutions: A welding gun control system applied to a spiral welded pipe welding operation environment, characterized in that it includes a movable mechanism and a controller, the movable mechanism includes a base, a movable plate one, a movable plate two, a linear drive unit and a rotation drive unit, the movable plate one is multiple and the number is equal to the welding gun / welding wire, the movable plate one is slidably connected to the base and the multiple movable plates one are parallel to each other, one movable plate two matches one movable plate one, the movable plate two is slidably connected to the movable plate one, the sliding direction of the movable plate two is perpendicular to the sliding direction of the matching movable plate one, the movable plate two is used to install the welding gun and is rotationally connected to the welding gun, the linear drive unit is installed on the base and is used to drive each movable plate one and movable plate two to slide respectively, the rotation drive unit is installed on the movable plate two and is used to drive the welding gun to rotate, the linear drive unit and the rotation drive unit are electrically connected to the controller respectively, and the controller is configured to load and execute a computer program for the welding gun control method applied to a spiral welded pipe welding operation environment as described in any one of claims 1 to 4.

[0010] Optionally, the rotation drive unit includes multiple groups of sub-units, each of which includes a rotating shaft, a gear set and a motor, the gear set includes a first gear and a second gear, the first gear is meshed with the second gear, the diameter of the first gear is smaller than the diameter of the second gear, the motor is fixed to the first gear, the second gear is fixed to the rotating shaft, the rotating shaft is used to fix the welding gun and is rotatably connected to the movable plate 2.

[0011] Optionally, the controller is configured as: Obtain the current actual weld position and determine whether it matches the weld spiral line distribution data. If yes, end the process; if not, calculate the weld torsion size L based on the current actual weld position and the theoretical position in the weld spiral line distribution data. Get the current first shot position; The first gun lateral adjustment dimension L1 is calculated based on the first gun position and weld torsion dimension L; Get the distance from the rotation axis of the first shot at the current position to the steel pipe and define it as H1; Based on the first gun, the horizontal adjustment dimension L1 is adjusted to make the linear drive unit work; Get the distance from the rotation axis of the first shot at the new position to the steel pipe and define it as H2; The longitudinal adjustment dimension H3 of the first gun is calculated based on the difference between H1 and H2; Based on the first gun longitudinal adjustment dimension H3, the linear drive unit works.

[0012] Optionally, the controller is configured as: Get the current first shot position and the axis of the first shot rotation axis, and generate a point based on the axis, and define it as point five D5; Obtain the position of the first gun after the linear drive unit is horizontally adjusted and the axis of the first gun rotation axis at this position, and generate a point based on the axis, and define it as point six D6; Generate a perpendicular line between point five D5 and line one M1, and a perpendicular line between point six D6 and line one M1 in the three-dimensional model, and define them as line seven M7 and line eight M8 respectively; The angle between line seven M7 and line eight M8 is measured to obtain the angle and define the welding gun deflection angle E.

[0013] To summarize, the present application includes the following beneficial technical effects: adjusting the position of the welding gun group to align it with the weld position and adjusting the angle of the welding gun can make the welding position of the welding gun more accurate, reduce the deflection of the bottom of the weld pool, and improve the welding quality by reducing the situation where one side of the weld is high and the other side is low after welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 is a schematic diagram of the method flow of the present application; Figure 2 is a schematic diagram of the helix angle α of the present application; Figure 3 is a schematic diagram of the rotation angle β when the first shot is offset in the present application; Figure 4 is a schematic diagram of the theoretical offset angle θ of the present application; Figure 5 It is a schematic diagram of the structure of the activity mechanism of this application; Figure 6 It is a schematic diagram of the structure of the system of the present application; Figure 7 is a schematic diagram of the weld torsion dimension L of the present application; Figure 8 It is a schematic diagram of the weld morphology.

[0015] Explanation of the reference numerals: 1. movable mechanism; 11. base; 12. movable plate 1; 13. movable plate 2; 14. linear drive unit; 15. rotation drive unit. DETAILED DESCRIPTION

[0016] The following is combined with Figure 1-8 This application is described in further detail.

[0017] The embodiments of the present application disclose a welding gun control method and system applied to a spiral welded pipe welding operation environment.

[0018] Reference Figure 1 The welding gun control method applied to the spiral welded pipe welding working environment includes the following steps: Step 1: Obtain the fixed parameters of the spiral welded pipe, which include: The plate width B of the substrate used to form the plate, the diameter D of the pipe, and the weld spiral line distribution data of the pipe are obtained and recorded.

[0019] Step 2: Obtain welding gun offset and welding zone parameters, including: The number of welding guns is defined as n, and the feeding direction of each welding wire corresponds to the center line of each welding gun or intersects with the center line of the welding gun; wherein, it is defined as n because the number of welding guns is multiple and at least two.

[0020] Define multiple welding guns to be arranged linearly to form a welding gun group, and the welding gun located at the outermost side is the first gun.

[0021] The distance between two adjacent welding points on the spiral line is obtained and defined as A, which is called welding point distance; the two welding points are the first welding point and the second welding point.

[0022] The distance W between the first gun and the mid-perpendicular line of the pipe when viewed from the end is called the first wire offset distance. When the welding gun group is at the initial position, W can be calculated based on the position of the first gun and the mid-perpendicular line of the pipe when viewed from the end.

[0023] Step 3: Modeling, which includes: A three-dimensional model is generated based on the plate width B of the base plate of the pipe, the diameter D of the pipe, and the weld spiral line distribution data of the pipe; wherein the three-dimensional model is generated by a three-dimensional modeling software, and the three-dimensional modeling software may be: Solidworks, Rhino.

[0024] Step 4: Calculate the welding gun group adjustment amount, the angle after the first gun is adjusted, and the adjustment amount for each wire.

[0025] Reference Figure 2 , based on the plate width B and the tube diameter D, the helix angle α is obtained as the adjustment amount of the welding gun group, which includes: The 3D model generates the center line of the pipe and defines it as line 1 M1; The three-dimensional model generates the center line of the substrate and is defined as line 2 M2; The angle between line 1 M1 and line 2 M2 of the unwound section of the substrate is measured to obtain an angle and define it as the helical angle α. The angle between line 1 M1 and line 2 M2 is measured using the angle measurement tool provided by the 3D modeling software, and the helical angle α is used to adjust the angle of the entire welding gun assembly.

[0026] Reference Figure 3 , based on the first wire offset distance W, the rotation angle β when the first gun is offset is analyzed as the adjustment amount of the first gun, which includes: In the three-dimensional model, two endpoints corresponding to the first wire offset distance W are defined as point 1 D1 and point 2 D2 respectively; Generate a perpendicular line between point 1 D1 and line 1 M1, and a perpendicular line between point 2 D2 and line 1 M1 in the three-dimensional model, and define them as line 3 M3 and line 4 M4 respectively; The angle between line 3 M3 and line 4 M4 is measured, and the angle is defined as the rotation angle β when the welding gun is offset. After adjusting the angle of the entire welding gun group, adjust the rotation of the first gun, where the rotation angle is β.

[0027] Reference Figure 4 , based on the welding point distance A, the theoretical offset angle θ is analyzed as the adjustment amount of each wire; wherein the theoretical offset angle θ is the angle of the vertical line between the welding position of each welding wire and the central axis of the steel pipe, which includes: In the three-dimensional model, the welding area is calibrated based on the first wire welding point and the welding point distance A, and the two end points of the welding area on the spiral line are generated and defined as point three D3 and point four D4 respectively; Generate a perpendicular line between point 3 D3 and line 1 M1 in the 3D model. Generate a perpendicular line between point 4 D4 and line 1 M1 and define them as line 5 M5 and line 6 M6 respectively. The angle between line 5 M5 and line 6 M6 is measured to obtain an angle and defined as a theoretical offset angle θ. After adjusting the angle of the first welding gun, the next welding gun is rotated and adjusted, wherein the rotation angle is θ, and the subsequent welding guns are adjusted in turn according to this method.

[0028] Step 5: Perform welding control; Based on the calculated welding gun group adjustment amount, the angle after the first gun adjustment and the adjustment amount of each wire, the welding gun is adjusted and welding work is performed.

[0029] The embodiment of the present application also discloses a welding gun control system applied to a spiral welded pipe welding operation environment.

[0030] Reference Figure 5 and Figure 6 A welding gun control system applied to a spiral welded pipe welding working environment includes a movable mechanism 1 and a controller. The movable mechanism 1 includes a base 11, a movable plate 12, a movable plate 2 13, a linear drive unit 14 and a rotation drive unit 15.

[0031] The movable plate 12 is slidably connected to the base 11. There are multiple movable plates 12 and the number is equal to the number of welding guns / welding wires. The multiple movable plates 12 are parallel to each other. There are also multiple movable plates 13, and one movable plate 13 matches one movable plate 12. The movable plate 13 is slidably connected to the movable plate 12, and the sliding direction of the movable plate 13 is perpendicular to the sliding direction of the movable plate 12 matched with it. The welding gun is installed on the movable plate 13, and the welding gun and the movable plate 13 are rotatably connected. The linear drive unit is installed on the base 11 and is used to drive each movable plate 12 and movable plate 13 to slide respectively. The linear drive unit 14 includes multiple electric cylinders, and the positions of the movable plates 12 and 13 can be changed by retracting the electric cylinders, thereby changing the position of the welding gun.

[0032] The rotation drive unit 15 is mounted on the movable plate 2 13 and is used to drive the welding gun to rotate. The rotation drive unit 15 includes multiple groups of sub-units, each of which includes a rotating shaft, a gear set and a motor. The rotating shaft is used to fix the welding gun and is rotationally connected to the movable plate 2 13. The gear set includes a first gear and a second gear. The diameter of the first gear is smaller than the diameter of the second gear. The motor is fixed to the first gear and drives the first gear to rotate. The first gear and the second gear are meshed. When the first gear rotates, it will push the second gear to rotate. The second gear is also fixed to the rotating shaft, and the welding gun can be driven to rotate through the rotating shaft.

[0033] Reference Figure 6 and Figure 7 , the linear drive unit 14 and the rotation drive unit 15 are electrically connected to the controller, and the configuration of the controller is: The current actual weld position is obtained (for example, by taking a photo with a camera and obtaining image positioning), and it is determined whether it matches the weld spiral line distribution data. If so, the process ends; if not, the weld torsion dimension L is calculated based on the current actual weld position and the theoretical position in the weld spiral line distribution data; Get the current first shot position; The first gun lateral adjustment dimension L1 is calculated based on the first gun position and weld torsion dimension L; Get the distance from the rotation axis of the first shot at the current position to the steel pipe and define it as H1; Based on the first gun lateral adjustment dimension L1, the linear drive unit 14 is operated; Get the distance from the rotation axis of the first shot at the new position to the steel pipe and define it as H2; The longitudinal adjustment dimension H3 of the first gun is calculated based on the difference between H1 and H2; The linear drive unit 14 is operated based on the first gun longitudinal adjustment dimension H3.

[0034] Since the weld position of the steel pipe does not completely match the position of the steel pipe spiral line in actual use, it is necessary to track the weld and perform welding work according to the actual position of the weld on the steel pipe. After the actual position of the weld changes, the current position of the first gun and the actual position of the weld are obtained, and the distance between the two is calculated to obtain the size of the first gun that needs to be adjusted horizontally. By calculating the height difference from the rotation axis of the first gun to the weld, the size of the first gun that needs to be adjusted longitudinally can be obtained, and finally the linear drive unit 14 is commanded to work.

[0035] After adjusting the horizontal and vertical dimensions, the deflection angle of the welding gun group needs to be adjusted. At this time, the controller configuration is: Get the current first shot position and the axis of the first shot rotation axis, and generate a point based on the axis, and define it as point five D5; Obtain the position of the first gun after the linear drive unit 14 is horizontally adjusted and the axis of the first gun rotation axis at this position, and generate a point based on the axis, and define it as point six D6; Generate a perpendicular line between point five D5 and line one M1, and a perpendicular line between point six D6 and line one M1 in the three-dimensional model, and define them as line seven M7 and line eight M8 respectively; The angle between line seven M7 and line eight M8 is measured to obtain the angle and define the welding gun deflection angle E.

[0036] By obtaining the perpendicular line from the first gun's rotation axis to the center line of the pipe and the perpendicular line from the first gun's rotation axis to the center line of the pipe after the horizontal and vertical adjustments, the 3D model software can be used to measure the included angle, which is the angle at which the first gun needs to be deflected. The angles of the remaining welding guns in the welding gun group are then adjusted according to the angle of the first gun to complete the tracking of the actual weld and perform welding work.

[0037] The above are all preferred embodiments of the present application, and the protection scope of the present application is not limited thereto. Therefore, any equivalent changes made according to the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A welding gun control method applied to a spiral welded pipe welding environment, characterized in that: include: Step 1: Obtain the fixed parameters of the spiral welded pipe, which include: Obtaining and recording the plate width B of the substrate used to form the pipe, the diameter D of the pipe, and the weld spiral line distribution data of the pipe; Step 2: Obtain welding gun offset and welding zone parameters, including: The number of welding guns is defined as n, and the feeding direction of each welding wire corresponds to the center line of each welding gun or intersects with the center line of the welding gun; Define multiple welding guns to be arranged linearly to form a welding gun group, and the welding gun located at the outermost side is the first gun; Obtain and define the distance between two adjacent welding points on the spiral line as A, which is called welding point distance; Get the distance W between the first gun and the mid-perpendicular line when viewing the pipe end, which is called the first wire offset distance; Step 3: Modeling, which includes: generating a three-dimensional model based on the plate width B of the base plate of the pipe, the diameter D of the pipe, and the weld spiral line distribution data of the pipe; Step 4: Calculate the welding gun group adjustment amount, the angle after the first gun is adjusted, and the adjustment amount of each wire; The helix angle α is obtained based on the plate width B and the pipe diameter D as the adjustment amount of the welding gun group; Based on the first wire offset distance W, the rotation angle β when the first gun is offset is analyzed as the adjustment amount of the first gun; The theoretical offset angle θ is analyzed based on the welding point distance A as the adjustment amount of each wire; wherein the theoretical offset angle θ is the angle of each welding wire relative to the welding position of the first wire and the vertical line between the central axis of the steel pipe; Step 5: Perform welding control; Based on the calculated welding gun group adjustment amount, the angle after the first gun adjustment and the adjustment amount of each wire, the welding gun is adjusted and welding work is performed.

2. The welding gun control method applied to the spiral welded pipe welding working environment according to claim 1 is characterized in that: The helix angle α is obtained based on the plate width B and the diameter D of the tube, which includes: The 3D model generates the center line of the pipe and defines it as line 1 M1; The three-dimensional model generates the center line of the substrate and is defined as line 2 M2; The angle between line 1 M1 and line 2 M2 of the unwound section of the substrate is measured to obtain an angle which is defined as the helix angle α.

3. The welding gun control method applied to the spiral welded pipe welding working environment according to claim 2 is characterized in that: The calculation of the rotation angle β when the first gun is offset based on the first wire offset distance W includes: In the three-dimensional model, two endpoints corresponding to the first wire offset distance W are defined as point 1 D1 and point 2 D2 respectively; Generate a perpendicular line between point 1 D1 and line 1 M1, and a perpendicular line between point 2 D2 and line 1 M1 in the three-dimensional model, and define them as line 3 M3 and line 4 M4 respectively; The angle between line three M3 and line four M4 is measured, and the angle is obtained and defined as the rotation angle β when the welding gun is offset.

4. The welding gun control method applied to the spiral welded pipe welding working environment according to claim 2 is characterized in that: The theoretical offset angle θ is analyzed based on the solder joint distance A, which includes: In the three-dimensional model, the welding area is calibrated based on the first wire welding point and the welding point distance A, and the two end points of the welding area on the spiral line are generated and defined as point three D3 and point four D4 respectively; Generate a perpendicular line between point three D3 and line one M1, and a perpendicular line between point four D4 and line one M1 in the three-dimensional model, and define them as line five M5 and line six M6 respectively; The angle between line five M5 and line six M6 is measured to obtain an angle which is defined as a theoretical offset angle θ.

5. A welding gun control system applied to a spiral welded pipe welding operation environment, characterized in that: The invention comprises a movable mechanism (1) and a controller, wherein the movable mechanism (1) comprises a base (11), a movable plate 1 (12), a movable plate 2 (13), a linear drive unit (14) and a rotation drive unit (15), wherein the movable plate 1 (12) is multiple and the number is equal to the number of welding guns / welding wires, the movable plate 1 (12) is slidably connected to the base (11) and the multiple movable plates 1 (12) are parallel to each other, one movable plate 2 (13) matches one movable plate 1 (12), the movable plate 2 (13) is slidably connected to the movable plate 1 (12), and the sliding direction of the movable plate 2 (13) is the same as that of the matching movable plate 1 (13). 12), the sliding direction of the movable plate 2 (13) is perpendicular to that of the movable plate 1, the movable plate 2 (13) is used to install the welding gun and is rotatably connected to the welding gun, the linear drive unit (14) is installed on the base (11) and is used to drive each movable plate 1 (12) and movable plate 2 (13) to slide respectively, the rotary drive unit (15) is installed on the movable plate 2 (13) and is used to drive the welding gun to rotate, the linear drive unit (14) and the rotary drive unit (15) are respectively electrically connected to the controller, and the controller is configured to load and execute a computer program for a welding gun control method applied to a spiral welded pipe welding working environment as described in any one of claims 1 to 4.

6. The welding gun control system for spiral welded pipe welding operation environment according to claim 5 is characterized in that: The rotary drive unit (15) comprises a plurality of subunits, each of which comprises a rotary shaft, a gear set and a motor, wherein the gear set comprises a first gear and a second gear, wherein the first gear meshes with the second gear, and the diameter of the first gear is smaller than the diameter of the second gear. The motor is fixed to the first gear, and the second gear is fixed to the rotary shaft. The rotary shaft is used to fix the welding gun and is rotatably connected to the movable plate 2 (13).

7. The welding gun control system for spiral welded pipe welding environment according to claim 6 is characterized in that: The controller is configured as follows: Obtain the current actual weld position and determine whether it matches the weld spiral line distribution data. If yes, end the process; if not, calculate the weld torsion size L based on the current actual weld position and the theoretical position in the weld spiral line distribution data. Get the current first shot position; The first gun lateral adjustment dimension L1 is calculated based on the first gun position and weld torsion dimension L; Get the distance from the rotation axis of the first shot at the current position to the steel pipe and define it as H1; Based on the first gun lateral adjustment dimension L1, the linear drive unit (14) is operated; Get the distance from the rotation axis of the first shot at the new position to the steel pipe and define it as H2; The longitudinal adjustment dimension H3 of the first gun is calculated based on the difference between H1 and H2; Based on the longitudinal adjustment dimension H3 of the first gun, the linear drive unit (14) is operated.

8. The welding gun control system for spiral welded pipe welding environment according to claim 7, characterized in that: The controller is configured as follows: Get the current first shot position and the axis of the first shot rotation axis, and generate a point based on the axis, and define it as point five D5; Obtain the position of the first gun after the linear drive unit (14) is horizontally adjusted and the axis of the first gun rotation axis at the position, and generate a point based on the axis, and define it as point six D6; Generate a perpendicular line between point five D5 and line one M1, and a perpendicular line between point six D6 and line one M1 in the three-dimensional model, and define them as line seven M7 and line eight M8 respectively; The angle between line seven M7 and line eight M8 is measured to obtain the angle and define the welding gun deflection angle E.

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