A heavy structure gravity auxiliary welding deformation control method and device

Abstract

The application provides a heavy structure gravity auxiliary welding deformation control method and device, the method comprises the following steps: arranging a welding station, so that the first workpiece and the second workpiece are used to form the welding slope of the weld, and the direction of the welding deformation is opposite to the direction of the gravity; fixing the first workpiece on a static plane; arranging a first jacking piece and a second jacking piece at the lower ends of the second workpiece respectively, which are used to support the second workpiece; the first jacking piece and the second jacking piece are provided with a first pressure sensor and a second pressure sensor between the jacking pieces and the second workpiece, which can display the pressure of the second workpiece acting on the jacking pieces in real time; measuring the welding deformation of the first workpiece and the second workpiece in real time during the welding process, and adjusting the height of the first jacking piece and / or the second jacking piece according to the welding deformation, so that the pressure of the first pressure sensor and the second pressure sensor is kept within a reasonable range, the welding deformation of the first workpiece and the second workpiece is controlled within an allowable range, and the welding deformation is effectively reduced.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of welding deformation control, in particular to a gravity-assisted welding deformation control method and device for heavy structure. BACKGROUND

[0002] In the manufacturing process of TF (toroidal field) coil case of fusion reactor, a large number of stainless steel welds are involved, the total height of the TF coil case is about 18 meters, the total width is about 12 meters, the weight of a single workpiece reaches dozens of tons, and the maximum weld thickness reaches 380 mm. Due to the effect of welding stress, the workpiece will produce a large deformation. Symmetrical welding and strong restraint of tooling are usually used to control the deformation of the workpiece, but sometimes symmetrical welding cannot be used to control the deformation of the workpiece (for example, in the case of single-sided welding groove). If strong restraint of tooling is used to control the deformation, there will be unpredictable residual deformation when the strong restraint is released. SUMMARY

[0003] The purpose of the present application is to provide a gravity-assisted welding deformation control method and device for heavy structure, which uses the gravity of the workpiece itself to control the deformation, can effectively reduce the welding deformation, and has the advantages of low cost, convenient operation and good control deformation effect.

[0004] To achieve the above purpose, the present application provides a gravity-assisted welding deformation control method for heavy structure, which includes at least a first workpiece and a second workpiece, and comprises the following steps: arranging a welding station, so that the welding groove of the first workpiece and the second workpiece for forming a weld is directed in a direction opposite to the direction of gravity, or the welding deformation direction is opposite to the direction of gravity; rigidly fixing the first workpiece on a stationary plane, so that the first workpiece remains stationary during welding; arranging a first jacking member and a second jacking member below the second workpiece near the first end of the weld and the second end away from the weld respectively, for jacking the second workpiece; a first pressure sensor and a second pressure sensor are respectively arranged between the first jacking member and the second jacking member and the second workpiece, to display the pressure of the first end and the second end of the second workpiece acting on the first jacking member and the second jacking member in real time; measuring the welding deformation of the first workpiece and the second workpiece in real time during welding, and adjusting the height of the first jacking member and / or the second jacking member according to the welding deformation, so that the pressure of the first pressure sensor and the second pressure sensor is kept within a reasonable range, and the welding deformation of the first workpiece and the second workpiece is controlled within an allowable range.

[0005] Optionally, the welding process real-time measurement of the welding deformation of the first workpiece and the second workpiece comprises the following steps: a plurality of size monitoring points are arranged on the upper surfaces of the first workpiece and the second workpiece, and the size monitoring points are respectively located at the end portions of the first workpiece and the second workpiece; a displacement sensor is arranged on each of the size monitoring points, and the displacement sensor is used for real-time measurement of the deformation data of the first workpiece and the second workpiece in the vertical direction; and the angular deformation and / or the deflection deformation of the first workpiece and the second workpiece are calculated through the deformation data.

[0006] Optionally, the size monitoring points are arranged along the center lines of the first workpiece and the second workpiece, and are used for monitoring the angular deformation of the first workpiece and the second workpiece; and / or the size monitoring points are symmetrically arranged on both sides of the center lines of the first workpiece and the second workpiece with the center lines as the symmetric axes, and are used for monitoring the deflection deformation of the first workpiece and the second workpiece.

[0007] Optionally, the distance between the first jacking member and the welding seam is 200-500 mm.

[0008] Optionally, the distance between each of the size monitoring points arranged at the end portions of the first workpiece and the second workpiece and the corresponding end portion is 200-500 mm.

[0009] Optionally, the height of the first jacking member and / or the second jacking member is adjusted according to the welding deformation of the first workpiece and the second workpiece, so that the pressure of the first pressure sensor and the second pressure sensor is maintained within a reasonable range, and the following cases are included.

[0010] Case 1: when the first workpiece and the second workpiece are fixed through spot welding, there is no welding seam shrinkage force between the first workpiece and the second workpiece, the height of the first jacking member and the second jacking member is kept unchanged, and the pressure of the first pressure sensor and the second pressure sensor is equal to the gravity of the second workpiece.

[0011] Case 2: when the welding seam thickness between the first workpiece and the second workpiece is less than 1 / 3 of the welding groove depth, the welding seam shrinkage force between the first workpiece and the second workpiece is small, the height of the first jacking member is reduced, the support force of the first jacking member to the second workpiece is reduced to control the welding deformation, the pressure of the first pressure sensor is less than the gravity of the second workpiece, the height of the second jacking member is kept unchanged, and the pressure of the second pressure sensor is equal to the gravity of the second workpiece.

[0012] Case 3: when the welding seam thickness between the first workpiece and the second workpiece is greater than or equal to 1 / 3 of the welding groove depth, the first workpiece and the second workpiece are connected into an integral whole, the height of the first jacking member is kept unchanged, the pressure of the first pressure sensor is equal to 0, and the height of the second jacking member is adjusted to control the welding deformation.

[0013] Optionally, in the case 3, when the downward angular deformation occurs at the weld joint of the first workpiece and the second workpiece, the height of the second lifting member is increased to increase the supporting force of the second lifting member on the second workpiece; when the upward angular deformation occurs at the weld joint of the first workpiece and the second workpiece, the height of the second lifting member is reduced to decrease the supporting force of the second lifting member on the second workpiece.

[0014] Optionally, when the weld joint shrinkage force between the first workpiece and the second workpiece makes the pressure of the second pressure sensor equal to 0, the second lifting member is replaced by a pulling member to apply a downward pulling force on the second end of the second workpiece to reduce the upward angular deformation at the weld joint of the second workpiece.

[0015] Optionally, the first lifting member and the second lifting member are jack devices, and the pulling member is a sling device.

[0016] The present application also provides a heavy structure gravity-assisted welding deformation control device suitable for the welding deformation control method, which comprises: fixed support members arranged at both ends below the first workpiece for fixing the first workpiece on a static plane; first and second lifting members arranged at both ends below the second workpiece for supporting the second workpiece; first and second pressure sensors arranged between the first and second lifting members and the second workpiece for displaying the pressure of the second workpiece acting on the first and second lifting members at both ends in real time; a plurality of displacement sensors arranged at intervals along the upper surfaces of the first and second workpieces for measuring the welding deformation of the first and second workpieces in real time; and the height of the first and / or second lifting member is adjusted according to the welding deformation of the first and second workpieces to control the welding deformation.

[0017] In summary, compared with the prior art, the heavy structure gravity-assisted welding deformation control method and device provided by the present application have the following beneficial effects: the welding deformation control method adjusts the supporting force of the first and second lifting members on the second workpiece in real time during the welding process according to the deformation data fed back by the displacement sensors arranged on the upper surfaces of the first and second workpieces, so that the bending moment generated by the weld joint shrinkage force, the gravity of the second workpiece and the supporting force of the first and second lifting members on the weld joint is always balanced, and the stress condition and the welding deformation condition of the first and second workpieces are very intuitive, and the welding deformation can be controlled within a minimum range.

[0018] Secondly, the welding deformation control device can control the welding deformation of heavy and large workpieces, and is low in price and cost saving. Further, the welding deformation control method provided by the present application solves the problems of turning over difficulty and difficult welding position caused by welding of heavy and large workpieces with double-sided groove, does not need to turn over heavy and large workpieces, and does not need to weld at difficult positions, thereby reducing the welding difficulty; at the same time, the deformation of the workpiece can be observed in real time, and there is no residual deformation after the workpiece is welded, so that the welding deformation is intuitive and controllable. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 FIG. 1 is a use schematic diagram of the heavy structure gravity auxiliary welding deformation control device of the present application for welding a BU section final girth joint;

[0020] Figure 2 FIG. 2 is a sectional view of a welding groove of the BU section final girth joint in the embodiment of the present application;

[0021] Figure 3 FIG. 3 is a top view of the first workpiece and the second workpiece of the BU section in the embodiment of the present application, which are respectively provided with two size monitoring points;

[0022] Figure 4 FIG. 4 is a top view of the first workpiece and the second workpiece of the BU section in the embodiment of the present application, which are respectively provided with four size monitoring points. DETAILED DESCRIPTION

[0023] The following will be described in detail with reference to the drawings of the embodiment of the present application. Figure 1 ~Appendix Figure 4 The technical solutions, structural features, purposes achieved and effects of the embodiment of the present application will be described in detail.

[0024] It should be noted that the drawings are very simplified and all use non-precise proportions, only for the purpose of facilitating and clarifying the description of the embodiment of the present application, and are not used to limit the scope of the present application, so they do not have technical significance, any modification of structure, change of proportion relationship or adjustment of size, without affecting the effects and purposes achieved by the present application, should still fall within the scope of the disclosed technical content.

[0025] It should be noted that the relational terms herein, such as first and second, are used solely to distinguish one from another entity or action, without necessarily requiring or implying any actual relationship or order between such entities or actions. Moreover, the terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0026] The embodiment takes the final girth welding of the BU segment of the fusion reactor coil box as an example, the BU segment includes a first workpiece 101 and a second workpiece 102, the weight of the first workpiece 101 is about 95 tons, and the arc length is about 13 meters; the weight of the second workpiece 102 is about 96 tons, and the arc length is about 11 meters. After the BU segment is welded, it is in the shape of "C", as shown in the figure, the welding seam thickness between the first workpiece 101 and the second workpiece 102 is about 268 mm. Figure 1

[0027] If the large BU segment workpiece is controlled by the anti-deformation tool as described above, the size of the anti-deformation tool used will be very large; if the welding deformation is controlled by adopting double-bevel alternating welding, it is necessary to turn over and weld back and forth, but it is very difficult to turn over the BU segment workpiece with such a large volume, and turning over before the BU segment is welded will cause new deformation; if one side is welded in the flat position and the other side is welded in the overhead position, there are defects such as difficulty in welding in the overhead position and inability to guarantee the welding quality. Therefore, the welding process of the BU segment final girth is to use single-bevel welding in the flat position.

[0028] In order to realize that the BU segment final girth can be welded in the flat position, the embodiment of the present application provides a heavy structure gravity-assisted welding deformation control device, as shown in the figure, the device includes a first workpiece 101 and a second workpiece 102, the weight of the first workpiece 101 is about 95 tons, and the arc length is about 13 meters; the weight of the second workpiece 102 is about 96 tons, and the arc length is about 11 meters. Figure 1 ​As shown, it comprises: fixed supports 15 arranged respectively at both ends below the first workpiece 101 for fixing the first workpiece 101 on a static plane; first and second jacks 121 and 122 arranged respectively at both ends below the second workpiece 102 for supporting the second workpiece 102; first and second pressure sensors 123 and 124 arranged between the first and second jacks 121 and 122 and the second workpiece 102 for displaying in real time the pressure of the second workpiece 102 acting on the first and second jacks 121 and 122 respectively; a plurality of displacement sensors arranged along the upper surfaces of the first and second workpieces 101 and 102 for measuring in real time the welding deformation of the first and second workpieces 101 and 102; and the height of the first and / or second jacks 121 and 122 is adjusted according to the welding deformation of the first and second workpieces 101 and 102 to realize the control of the welding deformation.

[0029] Based on the above welding deformation control device, the present application further provides a heavy structure gravity-assisted welding deformation control method for welding the first and second workpieces 101 and 102 of the BU section, which specifically comprises the following steps:

[0030] S1, arranging a welding station so that the welding bevels 103 of the first and second workpieces 101 and 102 for forming the welds 104 face the direction opposite to the direction of gravity, or the welding deformation direction is opposite to the direction of gravity;

[0031] Specifically, in the present embodiment, as shown in Figure 1 , the first and second workpieces 101 and 102 are placed with the openings downward, and the welding bevels 103 of the first and second workpieces 101 and 102 for forming the welds 104 face upward, so that the welding bevels 103 are opposite to the direction of gravity (downward). At the same time, the first and second workpieces 101 and 102 are placed with the openings downward, and the welds 104 are located approximately at the highest points, so that the first and second workpieces 101 and 102 exert the largest moment on the welds 104, thereby improving the stress distribution of the first and second workpieces 101 and 102 in the form of an arc during welding, reducing stress concentration, and improving the stability of the welded structure.

[0032] Further, as shown in Figure 2 , the welding bevels 103 of the first and second workpieces 101 and 102 in the present embodiment are single-face welding bevels of outer walls, and under normal circumstances, the welding deformation trend of the workpieces is that the second workpiece 102 undergoes upward angular deformation relative to the first workpiece 101.

[0033] S2. The first workpiece 101 is rigidly fixed on a stationary plane so that the first workpiece 101 remains stationary during the welding process; wherein the weight of the first workpiece 101 is less than the weight of the second workpiece 102, or the length of the first workpiece 101 is less than the length of the second workpiece 102.

[0034] Specifically, such as Figure 1 As shown, the first workpiece 101 is rigidly fixed at two rigid fixing points, A and B. In this embodiment, since the weight of the first workpiece 101 is less than the weight of the second workpiece 102, fixing supports 15 are used at points A and B respectively to weld the first workpiece 101 to the tooling base. Point A is located at the first end of the first workpiece 101, and point B is located at the second end of the second workpiece 101. The distance from point B to the weld is 200-500mm. By fixing the first workpiece 101 on the tooling base (or the ground in other embodiments), the first workpiece 101 is kept as stationary as possible during the welding process.

[0035] S3. A first lifting member 121 and a second lifting member 122 are respectively provided at the first end (i.e., point C) near the weld and the second end (i.e., point D) away from the weld below the second workpiece 102 to support the second workpiece 102; a first pressure sensor 123 and a second pressure sensor 124 are respectively provided between the first lifting member 121 and the second lifting member 122 and the second workpiece 102 to display the pressure exerted on the first lifting member 121 and the second lifting member 122 at the first end and the second end of the second workpiece 102 in real time.

[0036] Optionally, the distance from the first lifting member 121 to the weld 104 is 200-500mm, that is, the distance from point C to the weld 104 is 200-500mm.

[0037] S4. During the welding process, the welding deformation of the first workpiece 101 and the second workpiece 102 is measured in real time, and the height of the first lifting member 121 and / or the second lifting member 122 is adjusted according to the welding deformation to keep the pressure of the first pressure sensor 123 and the second pressure sensor 124 within a reasonable range, thereby controlling the welding deformation of the first workpiece 101 and the second workpiece 102 within the allowable range. The welding deformation includes angular deformation and flexural deformation of the workpiece.

[0038] Furthermore, the real-time measurement of welding deformation of the first workpiece 101 and the second workpiece 102 during the welding process includes the following steps:

[0039] S41. Two dimension monitoring points are respectively set on the upper surfaces of the first workpiece 101 and the second workpiece 102, such as... Figure 1As shown, the size monitoring points are respectively located at the ends of the first workpiece 101 and the second workpiece 102; specifically, in the embodiment, as shown in Figure 3 As shown, the two size monitoring points on the first workpiece 101 are respectively a first workpiece first size monitoring point 11 and a first workpiece second size monitoring point 12; the two size monitoring points on the second workpiece 102 are respectively a second workpiece first size monitoring point 21 and a second workpiece second size monitoring point 22, and the first workpiece first size monitoring point 11 and the first workpiece second size monitoring point 12 are arranged along the center line (dashed line in the figure) of the first workpiece 101, and the second workpiece first size monitoring point 21 and the second workpiece second size monitoring point 22 are arranged along the center line of the second workpiece 102; Figure 3

[0040] S42, a displacement sensor is arranged on each size monitoring point for measuring the deformation data of the first workpiece 101 and the second workpiece 102 in the vertical direction in real time; specifically, as shown in Figure 1 As shown, the first workpiece first size monitoring point 11 and the first workpiece second size monitoring point 12 are respectively provided with a first displacement sensor 11a and a second displacement sensor 12a for obtaining the first deformation data of the first workpiece 101; the second workpiece first size monitoring point 21 and the second workpiece second size monitoring point 22 are respectively provided with a third displacement sensor 21a and a fourth displacement sensor 22a for obtaining the second deformation data of the second workpiece 102; the first deformation data and the second deformation data are respectively the displacement changes of each size monitoring point of the first workpiece 101 and the second workpiece 102 in the vertical direction.

[0041] In the embodiment, the distance between each size monitoring point arranged at the end of the first workpiece 101 and the second workpiece 102 and the corresponding end is 200-500 mm, i.e. the distance between the first workpiece first size monitoring point 11 and the first end (i.e. point A) of the first workpiece 101 is 200-500 mm, the distance between the first workpiece second size monitoring point 12 and the second end (i.e. the position of the weld) of the first workpiece 101 is 200-500 mm, the distance between the second workpiece first size monitoring point 21 and the first end (i.e. the position of the weld) of the second workpiece 102 is 200-500 mm, and the distance between the second workpiece second size monitoring point 22 and the second end (i.e. point D) of the second workpiece 102 is 200-500 mm.

[0042] ​S43, by the first deformation data and second deformation data, the angular deformation of the first workpiece 101 and the second workpiece 102 can be calculated respectively; specifically, if the first workpiece first size monitoring point 11 and the first workpiece second size monitoring point 12 do not have vertical displacement change, i.e. the first deformation data is 0; the displacement change of the second workpiece first size monitoring point 21 is +0.5mm, and the displacement change of the second workpiece second size monitoring point 22 is +2mm, which constitutes the second deformation data, and the straight line distance between the second workpiece first size monitoring point 21 and the second workpiece second size monitoring point 22 is 5 meters, i.e. the angular deformation of the line connecting the second workpiece first size monitoring point 21 and the second workpiece second size monitoring point 22 and the line connecting the first workpiece first size monitoring point 11 and the first workpiece second size monitoring point 12 is arcsin[(2-0.5) / 5000]=0.01718°.

[0043] In another embodiment, in step S41, four size monitoring points are arranged on the upper surface of the first workpiece 101 and the second workpiece 102 respectively, and the size monitoring points are located at the end of the first workpiece 101 and the second workpiece 102 respectively. Specifically, in this embodiment, as shown in the figure, Figure 4 the four size monitoring points on the first workpiece 101 are the first workpiece first size monitoring point 11, the first workpiece second size monitoring point 12, the first workpiece third size monitoring point 13 and the first workpiece fourth size monitoring point 14; the four size monitoring points on the second workpiece 102 are the second workpiece first size monitoring point 21, the second workpiece second size monitoring point 22, the second workpiece third size monitoring point 23 and the second workpiece fourth size monitoring point 24.

[0044] Further, as shown in the figure, Figure 4As shown, the first workpiece first size monitoring point 11 and the first workpiece second size monitoring point 12 are symmetrically arranged on both sides of the center line of the first workpiece 101, and are located at the first end of the first workpiece 101, and the distance from the corresponding first end (i.e. point A) is 200-500 mm; the first workpiece third size monitoring point 13 and the first workpiece fourth size monitoring point 14 are symmetrically arranged on both sides of the center line of the first workpiece 101, and are located at the second end of the first workpiece 101, and the distance from the corresponding second end (i.e. the position of the weld) is 200-500 mm; the second workpiece first size monitoring point 21 and the second workpiece second size monitoring point 22 are symmetrically arranged on both sides of the center line of the second workpiece 102, and are located at the first end of the second workpiece 101, and the distance from the corresponding first end (i.e. the position of the weld) is 200-500 mm; the second workpiece third size monitoring point 23 and the second workpiece fourth size monitoring point 24 are symmetrically arranged on both sides of the center line of the second workpiece 102, and are located at the second end of the second workpiece 102, and the distance from the corresponding second end (i.e. point D) is 200-500 mm. By symmetrically arranging the size monitoring points along the center line of the workpiece, the deflection deformation of the workpiece can be obtained.

[0045] Similarly, the embodiment also includes a step S42 of arranging a displacement sensor at each of the size monitoring points, for measuring the deformation data of the first workpiece 101 and the second workpiece 102 in the vertical direction in real time, and the deformation data is the displacement change of each size monitoring point in the vertical direction.

[0046] In step S43, the deflection deformation of the first workpiece 101 and the second workpiece 102 can be calculated through the deformation data. Specifically, if the first workpiece first size monitoring point 11, the first workpiece second size monitoring point 12, the first workpiece third size monitoring point 13, the first workpiece fourth size monitoring point 14, the second workpiece first size monitoring point 21 and the second workpiece third size monitoring point 23 do not have displacement changes in the vertical direction, and the displacement changes of the second workpiece second size monitoring point 22 and the second workpiece fourth size monitoring point 24 are both +0.5 mm, and the distance between the second workpiece first size monitoring point 21 and the second workpiece second size monitoring point 22 and the distance between the second workpiece third size monitoring point 23 and the second workpiece fourth size monitoring point 24 are both 1 m, it can be calculated that the deflection deformation of the first workpiece 101 and the second workpiece 102 is arcsin(0.5 / 1000) = 0.02865°.

[0047] Further, as the welding thickness increases, the values of the first pressure sensor 123 and the second pressure sensor 124 will change, in order to keep the first workpiece 101 and the second workpiece 102 from being deformed too much, the height of the first lifting piece 121 and / or the second lifting piece 122 can be adjusted according to the welding deformation of the first workpiece 101 and the second workpiece 102, so that the pressure of the first pressure sensor 123 and the second pressure sensor 124 is kept within a reasonable range, and the bending moment of the weld shrinkage force, the gravity of the second workpiece, and the support force of the first lifting piece and the second lifting piece on the weld is kept in balance. Specifically, the following cases are included:

[0048] Case 1: When the first workpiece 101 and the second workpiece 102 are fixed by spot welding, there is no weld shrinkage force between the first workpiece 101 and the second workpiece 102, the height of the first lifting piece 121 and the second lifting piece 122 remains unchanged, and the pressure of the first pressure sensor 123 and the second pressure sensor 124 is equal to the gravity of the second workpiece 102, that is, the gravity of the second workpiece 102 and the support force of the first lifting piece 121 and the second lifting piece 122 are in balance;

[0049] Case 2: When the weld thickness between the first workpiece 101 and the second workpiece 102 is small, that is, the weld thickness is less than 1 / 3 of the welding groove depth (i.e., the total thickness of the weld), the weld shrinkage force between the first workpiece 101 and the second workpiece 102 is small, the height of the first lifting piece 121 is reduced, and the support force of the first lifting piece 121 on the first end (i.e., point C) of the second workpiece 102 is reduced to control the welding deformation, the pressure of the first pressure sensor 123 is less than the gravity of the second workpiece 102, the height of the second lifting piece 122 remains unchanged, and the pressure of the second pressure sensor 124 is equal to the gravity of the second workpiece 102; At this time, since point C is close to the weld 104, the bending moment of the support force of the first lifting piece 121 on the weld 104 is small, so reducing the support force of the first lifting piece 121 will not damage the weld 104;

[0050] Case 3: As the thickness of the weld 104 gradually increases, when the weld thickness between the first workpiece 101 and the second workpiece 102 is greater than or equal to 1 / 3 of the welding groove depth (i.e. the total thickness of the weld), the first workpiece 101 and the second workpiece 102 are integrated into one, at this time, the pressure of the first pressure sensor 123 slowly becomes 0 while keeping the height of the first jacking piece 121 unchanged, at this time, the support force of the B point of the first workpiece 101 supports the first end (i.e. the C point) of the second workpiece 102, that is, when the pressure of the first pressure sensor 123 is equal to 0, the support force on the second end of the second workpiece 102 can be adjusted by adjusting the height of the second jacking piece 122, thereby controlling the welding deformation. Because when the bending moment generated by the weld shrinkage force, the gravity of the second workpiece and the support force of the D point on the weld position reaches balance, welding deformation will not occur, and at the same time, the distance between the D point and the weld is far, the adjustable range of the bending moment is large, so by adjusting the support force of the D point, the welding deformation of the first workpiece 101 and the second workpiece 102 can be controlled to be basically zero.

[0051] Wherein, when the downward angular deformation occurs at the weld between the first workpiece 101 and the second workpiece 102, the height of the second jacking piece 122 is increased to increase the support force of the second jacking piece 122 on the second workpiece 102; when the upward angular deformation occurs at the weld between the first workpiece 101 and the second workpiece 102, the height of the second jacking piece 122 is reduced to decrease the support force of the second jacking piece 122 on the second workpiece 102.

[0052] Further, when the weld shrinkage force between the first workpiece 101 and the second workpiece 102 makes the pressure of the second pressure sensor 124 equal to 0, the second jacking piece 122 is replaced by a lifting piece to exert a downward pulling force on the second end (i.e. the D point) of the second workpiece 102, thereby reducing the upward angular deformation at the weld of the second workpiece 102. It should be noted that the first jacking piece and the second jacking piece in any of the above embodiments are jack devices, and the lifting piece is a hoist device.

[0053] In summary, compared with the prior art, the heavy structure gravity-assisted welding deformation control method provided by the present application can adjust the support force of the first jacking piece 121 and the second jacking piece 122 on the second workpiece 102 in real time during the welding process according to the deformation data fed back by each displacement sensor arranged on the upper surface of the first workpiece 101 and the second workpiece 102, so that the bending moment generated by the weld shrinkage force, the gravity of the second workpiece and the support force of the first jacking piece and the second jacking piece on the weld is always balanced, so that the stress condition and the welding deformation condition of the first workpiece and the second workpiece are very intuitive, and the welding deformation can be controlled to be within a minimum range. Further, the heavy structure gravity-assisted welding deformation control device provided by the present application can control the welding deformation of heavy and large workpieces, and is low in price and cost-saving.

[0054] While the application has been described in detail by reference to preferred embodiments thereof, it is to be understood that the description is not to be construed as limiting the scope of the application. Various modifications and changes can occur to those skilled in the art, once they learn of the basic concept of the application. Therefore, the scope of the application is to be defined by the appended claims, rather than by the description of the preferred embodiments.

Claims

1. A method for controlling deformation during gravity-assisted welding of heavy structures, wherein the heavy structure comprises at least a first workpiece and a second workpiece, characterized in that, include: Arrange the welding station so that the welding grooves of the first and second workpieces used to form the weld are oriented in the opposite direction to the direction of gravity, or so that the direction of welding deformation is opposite to the direction of gravity. The first workpiece is rigidly fixed on a stationary plane, so that the first workpiece remains stationary during the welding process; A first lifting member and a second lifting member are respectively provided at the first end near the weld and the second end away from the weld below the second workpiece to support the second workpiece; a first pressure sensor and a second pressure sensor are respectively provided between the first lifting member and the second lifting member and the second workpiece to display the pressure exerted on the first lifting member and the second lifting member at the first end and the second end of the second workpiece in real time. During the welding process, the welding deformation of the first and second workpieces is measured in real time, and the height of the first lifting component and / or the second lifting component is adjusted according to the welding deformation to keep the pressure of the first pressure sensor and the second pressure sensor within a reasonable range, thereby controlling the welding deformation of the first and second workpieces within the allowable range. The real-time measurement of welding deformation of the first and second workpieces during the welding process includes the following steps: Multiple dimension monitoring points are set on the upper surfaces of the first workpiece and the second workpiece, and the dimension monitoring points are located at the ends of the first workpiece and the second workpiece, respectively. A displacement sensor is installed at each of the aforementioned size monitoring points to measure the deformation data of the first and second workpieces in the vertical direction in real time. The angular deformation and / or flexural deformation of the first and second workpieces are calculated using the deformation data. The height of the first lifting component and / or the second lifting component is adjusted according to the welding deformation of the first and second workpieces to keep the pressure of the first pressure sensor and the second pressure sensor within a reasonable range, including the following situations: Case 1: After the first workpiece and the second workpiece are fixed by spot welding, there is no weld shrinkage force between the first workpiece and the second workpiece. The height of the first lifting component and the second lifting component remains unchanged, and the pressure of the first pressure sensor and the second pressure sensor is equal to the weight of the second workpiece. Case 2: When the weld thickness between the first and second workpieces is less than 1 / 3 of the weld groove depth, the weld shrinkage force between the first and second workpieces is small. The height of the first lifting component is reduced, and the support force of the first lifting component on the second workpiece is reduced to control the welding deformation. The pressure of the first pressure sensor is less than the weight of the second workpiece. The height of the second lifting component remains unchanged, and the pressure of the second pressure sensor is equal to the weight of the second workpiece. Case 3: When the weld thickness between the first workpiece and the second workpiece is greater than or equal to 1 / 3 of the weld groove depth, the first workpiece and the second workpiece are connected as a whole. While keeping the height of the first lifting component unchanged, when the pressure of the first pressure sensor is equal to 0, the welding deformation is controlled by adjusting the height of the second lifting component.

2. The method for controlling deformation during gravity-assisted welding of heavy structures as described in claim 1, characterized in that, The dimension monitoring points are set along the centerline of the first workpiece and the second workpiece, and are used to monitor the angular deformation of the first workpiece and the second workpiece. And / or the dimensional monitoring points are symmetrically arranged on both sides of the centerline of the first workpiece and the second workpiece, with the centerline of the second workpiece as the axis of symmetry, for monitoring the flexural deformation of the first workpiece and the second workpiece.

3. The method for controlling deformation during gravity-assisted welding of heavy structures as described in claim 1, characterized in that, The distance from the first lifting member to the weld is 200~500 mm.

4. The method for controlling deformation during gravity-assisted welding of heavy structures as described in claim 1, characterized in that, The distance between each of the dimension monitoring points set at the ends of the first and second workpieces and their corresponding ends is 200~500 mm.

5. The method for controlling deformation during gravity-assisted welding of heavy structures as described in claim 1, characterized in that, In case 3, when downward angular deformation occurs at the weld between the first workpiece and the second workpiece, the height of the second lifting member is increased to increase the supporting force of the second lifting member on the second workpiece; when upward angular deformation occurs at the weld between the first workpiece and the second workpiece, the height of the second lifting member is decreased to reduce the supporting force of the second lifting member on the second workpiece.

6. The method for controlling deformation during gravity-assisted welding of heavy structures as described in claim 1, characterized in that, When the shrinkage force of the weld between the first and second workpieces causes the pressure of the second pressure sensor to equal 0, the second lifting component is replaced with a pulling component, and a downward pulling force is applied to the second end of the second workpiece to reduce the upward angular deformation at the weld of the second workpiece.

7. The method for controlling deformation during gravity-assisted welding of heavy structures as described in claim 6, characterized in that, The first and second lifting components are jack devices, and the lifting component is a hoist lifting device.

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