Tube panel welding device and welding method

Abstract

The present invention discloses a pipe screen welding device and a welding method. The pipe screen welding device includes a clamping mechanism, a positioning mechanism, a welding mechanism, a detection mechanism, an early warning mechanism, and a control mechanism. The clamping mechanism is suitable for fixing the workpiece to be welded. The positioning mechanism is suitable for limiting and supporting the workpiece to be welded during the welding process. The control mechanism is suitable for controlling the welding mechanism to weld the joints of the workpiece to be welded, and controlling the flow rate of the cooling medium at the inlet end of the clamping mechanism so that the temperature of the cooling medium at the outlet end of the clamping mechanism is less than a threshold value. The control mechanism is also suitable for keeping the flow rate of the cooling medium in the clamping mechanism unchanged during the welding process, and controlling the welding mechanism to stop running and controlling the early warning mechanism to issue an early warning when it is determined that the steel pipe has leaked according to the pressure change in the steel pipe. The present invention effectively fixes the workpiece to be welded and prevents the pipe screen from twisting or bending. During welding, the workpiece to be welded is cooled and the steel pipe of the workpiece to be welded is effectively leak-detected, thereby improving the quality of the pipe screen.

Description

Technical Field

[0001] The present invention relates to the technical field of welding, and in particular to a tube panel welding device and a welding method. Background Art

[0002] Tube panels are plate-type heating surfaces installed within the furnace. These typically include water-cooled panels (part of a water circulation system) and platen superheaters. Because these heating surfaces are installed within the furnace and are designed as plate-type, they are collectively referred to as tube panels. Currently, as boiler specifications increase, the material quality of tube panels used in boilers is also gradually improving.

[0003] For stainless steel tube screens, such as Figures 1 and 2 As shown, the pipe panel to be welded is composed of multiple steel pipes 91, and the steel pipes 91 are welded and fixed to each other by flat steel 91. If the stainless steel pipe panel products of the above structure are welded by conventional gantry horizontal splicing welding, the pipe panel after gantry welding is very likely to have "S"-shaped side bending in the axial direction or wave distortion in the plane direction (such as Figure 3 As shown in the figure). The tube panel products need to be calibrated and leveled later, which results in a long manufacturing cycle and high manufacturing costs for the tube panel products, which is not conducive to workshop production.

[0004] During the welding process, the temperature of the welded components can affect the final tube panel deformation. Furthermore, there is a risk of leaks in the steel pipe during welding, which can render the resulting tube panel unusable in water circulation systems. Using a leak detection device after welding the components is complete is inefficient.

[0005] In summary, the tube panels produced by the existing welding device are of low quality, and some tube panels have leakage risks. Summary of the Invention

[0006] The technical problem to be solved by the present invention is that the tube panels produced by the existing welding device are of low quality and some of the tube panels have the risk of leakage.

[0007] In one aspect, the present invention discloses a tube panel welding device, which is suitable for welding seams of parts to be welded, wherein the parts to be welded include a plurality of steel pipes and a plurality of flat steels, wherein the plurality of steel pipes are arranged in parallel and spaced apart, and the flat steels are arranged between adjacent steel pipes;

[0008] The tube panel welding device includes: a clamping mechanism, a positioning mechanism, a welding mechanism, a detection mechanism, an early warning mechanism and a control mechanism;

[0009] The clamping mechanism is detachably inserted into the welding mechanism, and the clamping mechanism includes: a first positioning member, a second positioning member and two side positioning members; the first positioning member and the second positioning member are distributed at both ends of the workpiece to be welded, a first cooling channel is provided in the first positioning member, and the first cooling channel is suitable for receiving a cooling medium during the welding process; a second cooling channel is provided in the second positioning member, and the second cooling channel is suitable for discharging a cooling medium during the welding process; the first positioning member and the second positioning member are respectively suitable for fixing the two ends of the steel pipe, and at the same time, the first cooling channel is connected to the second cooling channel through the steel pipe; the two side positioning members are distributed on both sides of the workpiece to be welded, and the two ends of the side positioning member are respectively detachably connected to the first positioning member and the second positioning member, and the two side positioning members are suitable for fixing the two sides of the workpiece to be welded during the welding process;

[0010] The positioning mechanism is detachably arranged between the two side positioning members, and is suitable for limiting and supporting the steel pipe and the flat steel during welding;

[0011] The detection mechanism is suitable for detecting the pressure inside the steel pipe, the flow rate of the cooling medium in the first cooling channel, and the temperature of the cooling medium in the second cooling channel during the welding process;

[0012] The control mechanism is adapted to control the welding mechanism to weld the seams of the workpieces to be welded, and to control the flow rate of the cooling medium in the first cooling channel so that the temperature of the cooling medium in the second cooling channel is less than a threshold value. The control mechanism is also adapted to control the welding mechanism to stop operating and control the early warning mechanism to issue an early warning when the flow rate of the cooling medium in the first cooling channel remains unchanged during the welding process and when a leak in the steel pipe is determined based on the pressure change in the steel pipe. Through the coordination of the clamping mechanism, positioning mechanism, welding mechanism, detection mechanism, early warning mechanism, and control mechanism, the workpieces to be welded are effectively fixed, preventing the tube panel from twisting or bending. Effective cooling of the workpieces to be welded and effective leak detection of the steel pipe are performed during welding, thereby improving the quality of the tube panel.

[0013] Optionally, the first positioning member includes: a first positioning body and a first cooling pipe;

[0014] The first positioning body includes: a first body, a tightening bolt and a plurality of joints;

[0015] Two installation channels are defined on the first body at intervals, and the two installation channels are adapted to be slidably inserted into one end of the two side positioning members, respectively; a cavity is defined in the first body, and the cavity is located between the two installation channels and is not communicated with the installation channels;

[0016] The retaining bolt is threadedly connected to the first body, and the retaining bolt extends along a first direction and extends into the mounting channel; the retaining bolt is adapted to retain the side wall of the side positioning member during welding, so as to fix the side positioning member in the mounting channel;

[0017] The first cooling pipe is provided on the first main body, and the first cooling pipe is communicated with the cavity;

[0018] A plurality of joints are arranged at intervals on the first body, the joints are in communication with the cavity, and the joints are suitable for being detachably connected to the inner hole of the steel pipe during welding;

[0019] The first cooling channel includes the first cooling pipe, the cavity and the joint;

[0020] The second positioning member includes: a second positioning body and a second cooling pipe;

[0021] The second positioning body has the same structure as the first positioning body; the second cooling pipe is arranged on the first body of the second positioning body, and the second cooling pipe is connected to the cavity of the second positioning body;

[0022] The second cooling channel includes the second cooling pipe, the cavity of the second positioning body and the joint of the second positioning body. The above solution can effectively fix the workpiece to be welded.

[0023] Optionally, a rubber ring is mounted on the outside of the joint, and the joint is adapted to be detachably connected to the inner hole of the steel pipe via the rubber ring during welding. The above solution effectively protects the joint and strengthens the connection between the joint and the steel pipe.

[0024] Optionally, the detection mechanism includes a flow meter, a thermometer and a pressure sensor;

[0025] The flow meter is provided at the inlet end of the first cooling pipe, and the flow meter is suitable for detecting the flow rate of the cooling medium in the first cooling pipe during the welding process;

[0026] The thermometer is arranged at the outlet end of the second cooling pipe, and the thermometer is suitable for detecting the temperature of the cooling medium in the second cooling pipe during the welding process;

[0027] The pressure sensor is mounted on the joint of the second positioning body and is suitable for detecting the pressure within the steel pipe during the welding process. This arrangement effectively detects the flow rate of the coolant within the first cooling pipe, the temperature of the coolant within the second cooling pipe, and the pressure within the steel pipe during the welding process.

[0028] Optionally, the side positioning member includes: square steel and a reinforcement plate;

[0029] The two ends of the square steel are detachably connected to the first positioning member and the second positioning member respectively; one side of the square steel is suitable for abutting against one side of the workpiece to be welded during the welding process;

[0030] The reinforcing plate is arranged on the other side of the square steel, and its two ends are adapted to respectively abut against the first and second positioning members during the welding process. With this solution, the square steel is light and easy to carry; the reinforcing plate effectively limits the first and second positioning members.

[0031] Optionally, the positioning mechanism includes: a positioning block;

[0032] The positioning block is detachably arranged between the two side positioning members; a positioning groove and a positioning plane are provided on one side of the positioning block, and the other side of the positioning block is flush with the side positioning member;

[0033] The positioning groove is suitable for limiting the side wall of the steel pipe during welding, and the positioning plane is suitable for supporting the flat steel during welding. The above solution is adopted to achieve support and limitation of the welded parts.

[0034] Optionally, the welding mechanism includes: a base, a drive module and a welding robot;

[0035] The base is provided with a slot, and the slot is suitable for being detachably connected to the clamping mechanism during the welding process;

[0036] The driving module is arranged on the base, and the welding robot is assembled on the driving module. The driving module is suitable for driving the welding robot to move during the welding process.

[0037] Optionally, the clamping mechanism is adapted to be arranged vertically relative to the base during the welding process, and the welding mechanism further comprises: a lifting device;

[0038] The lifting device is provided at one end of the base, and the lifting device is suitable for adjusting the height of one end of the base so that the base is tilted;

[0039] The outlet end of the second cooling channel is arranged upward. The above solution is conducive to the cooling medium being filled into all the steel pipes in the clamping mechanism, so that the parts to be welded are fully cooled.

[0040] Optionally, the control mechanism includes: a regulating valve and a controller;

[0041] The regulating valve is arranged at the inlet end of the first cooling channel;

[0042] The controller is adapted to control the welding mechanism to weld the seam of the workpiece to be welded, and to control the regulating valve to adjust the flow rate of the cooling medium in the first cooling channel so that the temperature of the cooling medium in the second cooling channel is less than a threshold value. The controller is also adapted to control the welding mechanism to stop operation and control the early warning mechanism to issue an early warning when the regulating valve does not adjust the flow rate of the cooling medium in the first cooling channel and the steel pipe is determined to be leaking based on pressure changes within the steel pipe during the welding process. The above solution effectively monitors the cooling status of the workpiece to be welded and whether the steel pipe is leaking.

[0043] On the other hand, the present invention also discloses a welding method using the above-mentioned tube panel welding device, which specifically comprises the following steps:

[0044] S1. Assemble one end of the two side positioning members on the first positioning member;

[0045] S2, detachably disposing the positioning mechanism between the two side positioning members, and then assembling the steel pipe and the flat steel (92) on the first positioning member;

[0046] S3. Assemble the second positioning member at the other end of the two side positioning members so that the clamping mechanism can effectively fix the steel pipe and the flat steel;

[0047] S4. Spot weld the joints between the steel pipe and the flat steel;

[0048] S5, removing the positioning mechanism from the clamping mechanism, and detachably inserting the clamping mechanism into the welding mechanism;

[0049] S6. The control mechanism controls the welding mechanism to weld the joint between the steel pipe and the flat steel, and controls the flow rate of the cooling medium in the first cooling channel so that the temperature of the cooling medium in the second cooling channel is less than a threshold value; at the same time, during the welding process, when the flow rate of the cooling medium in the first cooling channel remains unchanged, and the steel pipe is determined to be leaking based on the pressure change in the steel pipe, the control mechanism controls the welding mechanism to stop operating and controls the early warning mechanism to issue an early warning.

[0050] Due to the adoption of the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0051] Through the coordination of the clamping mechanism, positioning mechanism, welding mechanism, detection mechanism, warning mechanism, and control mechanism, the welded parts are effectively fixed to prevent the tube panel from twisting and bending. During welding, the welded parts are effectively cooled and the steel pipes are effectively leak-tested, thus improving the quality of the tube panel.

[0052] The above description of the disclosed contents and the following description of the embodiments are intended to demonstrate and explain the spirit and principles of the present invention, and to provide further explanation of the scope of the patent application of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0054] Figure 1 Schematic diagram of the three-dimensional structure of the tube panel;

[0055] Figure 2 Schematic diagram of the tube screen;

[0056] Figure 3 This is a schematic diagram of the "S"-shaped side bend on the tube panel;

[0057] Figure 4 It is a schematic diagram of the three-dimensional structure of the tube panel welding device welding the seams of the parts to be welded in the present invention;

[0058] Figure 5 Schematic diagram of the exploded structure of the clamping mechanism and the positioning mechanism in the present invention;

[0059] Figure 6 Schematic diagram of the three-dimensional structure of the clamping mechanism of the present invention;

[0060] Figure 7 is a cross-sectional view of the first positioning member in the present invention;

[0061] Figure 8 is a schematic diagram of the three-dimensional structure of the first positioning member in the present invention;

[0062] Figure 9 Schematic diagram of the three-dimensional structure of the connector in the present invention;

[0063] Figure 10 Schematic diagram of the three-dimensional structure of the positioning block in the present invention;

[0064] Figure 11 This is a cross-sectional schematic diagram of the positioning block installed on the clamping mechanism in the present invention;

[0065] Figure 12 Schematic diagram of the partial structure of the clamping mechanism in the present invention;

[0066] Figure 13 This is a schematic diagram of two side positioning members installed on the first positioning member in the present invention;

[0067] Figure 14 This is a schematic diagram of the steel pipe and flat steel being mounted on the clamping mechanism via positioning blocks in the present invention;

[0068] Figure 15This is a schematic diagram of the second positioning member installed on two side positioning members in the present invention;

[0069] Figure 16 Schematic diagram (1) of the tube panel welding device of the present invention welding the seam of the parts to be welded;

[0070] Figure 17 Schematic diagram (2) of the tube panel welding device of the present invention welding the seam of the parts to be welded;

[0071] Figure 18 Schematic diagram of the parts to be welded in the present invention.

[0072] Description of Figure Numbers:

[0073] 10. First positioning member; 11. First cooling pipe; 12. First main body; 121. Mounting channel; 122. Connecting rod; 123. End rod; 124. First fixing block; 125. Second fixing block; 13. Tightening bolt; 14. Joint; 141. Rubber ring; 20. Second positioning member; 21. Second cooling pipe; 30. Side positioning member; 31. Square steel; 32. Reinforcement plate; 40. Positioning block; 50. Base; 51. Hinge seat; 60. Drive module; 70. Welding robot; 80. Lifting device; 90. Parts to be welded; 91. Steel pipe; 92. Flat steel. DETAILED DESCRIPTION

[0074] The following is an explanation of the embodiments of the present invention by specific specific examples. Those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. Although the description of the present invention will be introduced in conjunction with the preferred embodiment, this does not mean that the features of this invention are limited to this embodiment. On the contrary, the purpose of introducing the invention in conjunction with the embodiment is to cover other options or modifications that may be extended based on the claims of the present invention. In order to provide a deep understanding of the present invention, the following description will contain many specific details. The present invention can also be implemented without using these details. In addition, in order to avoid confusion or blurring the focus of the present invention, some specific details will be omitted in the description. It should be noted that the embodiments of the present invention and the features in the embodiments can be combined with each other without conflict.

[0075] In the description of this embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the inventive product is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limitations on the present invention.

[0076] The terms “first”, “second”, etc. are only used for distinguishing descriptions and should not be understood as indicating or implying relative importance.

[0077] In the description of this embodiment, it should be noted that, unless otherwise expressly specified or limited, the terms "provided with," "disposed," "connected," and "connected" should be understood broadly. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art will understand the specific meanings of the above terms in this embodiment based on the specific circumstances.

[0078] Example 1

[0079] On the one hand, the present invention discloses a tube panel welding device, see Figure 6 As shown, it is suitable for welding the seams of the parts 90 to be welded.

[0080] Among them, see Figures 1 and 2 As shown, the welded component 90 includes several steel pipes 91 and several flat steel bars 92. The steel pipes 91 are arranged in parallel and spaced apart. Flat steel bars 92 are positioned between adjacent steel pipes 91. Flat steel bars 92 are arranged parallel to the steel pipes 91. The tube panel welding apparatus is suitable for welding the joints between the steel pipes 91 and the flat steel bars 92 (i.e., the seams of the welded component 90).

[0081] In this embodiment, the welded component 90 includes eight steel tubes 91 and nine flat steel bars 92. The steel tubes 91 and flat steel bars 92 are arranged alternately. Flat steel bars 92 are located on both sides of the welded component 90. The length of the flat steel bars 92 is equal to or shorter than the length of the steel tubes 91. The end faces of the steel tubes 91 coincide with the end faces of the welded component 90. The flat steel bars 92 are located between the two end faces of the steel tubes 91 and do not protrude beyond them.

[0082] The tube panel welding device includes a clamping mechanism, a positioning mechanism, a welding mechanism, a detection mechanism, an early warning mechanism and a control mechanism.

[0083] The clamping mechanism is suitable for fixing both ends and both sides of the workpiece 90 to be welded during the welding process. Figures 5 and 6As shown, the clamping mechanism includes a first positioning member 10, a second positioning member 20 and two side positioning members 30. The first positioning member 10 and the second positioning member 20 are distributed at both ends of the workpiece 90 to be welded. A first cooling channel is provided in the first positioning member 10, and the first cooling channel is suitable for receiving a cooling medium during the welding process. A second cooling channel is provided in the second positioning member 20, and the second cooling channel is suitable for discharging a cooling medium during the welding process. The first positioning member 10 and the second positioning member 20 are respectively suitable for fixing the two ends of the steel pipe 91, and at the same time, the first cooling channel is connected to the second cooling channel through the steel pipe 91. The two side positioning members 30 are distributed on both sides of the workpiece 90 to be welded. The two ends of the side positioning member 30 are detachably connected to the first positioning member 10 and the second positioning member 20 respectively, and the two side positioning members 30 are suitable for fixing the two sides of the workpiece 90 to be welded during the welding process. In summary, the first positioning member 10, the second positioning member 20 and the two side positioning members 30 form a fixed frame for fixing the workpiece 90 to be welded.

[0084] The cooling medium includes but is not limited to high-pressure cold air, cold water, etc.

[0085] In this embodiment, both ends of the side positioning member 30 are respectively perpendicular to the first positioning member 10 and the second positioning member 20. During the welding process, the length direction of the steel pipe 91 is parallel to the side positioning member 30.

[0086] See also Figure 11 、 Figure 13 As shown, the positioning mechanism is detachably arranged between the two side positioning members 30. The positioning mechanism is suitable for limiting and supporting the steel pipe 91 and the flat steel 92 during the welding process.

[0087] See also Figure 4 As shown, the clamping mechanism is detachably inserted into the welding mechanism. The welding mechanism is suitable for welding the seams of the parts to be welded 90.

[0088] The detection mechanism is suitable for detecting the pressure inside the steel pipe 91, the flow rate of the cooling medium in the first cooling channel, and the temperature of the cooling medium in the second cooling channel during the welding process.

[0089] The control mechanism is electrically connected to the welding mechanism, the detection mechanism, and the warning mechanism. The control mechanism is adapted to control the welding mechanism to weld the seam of the workpiece 90 and to control the flow rate of the coolant in the first cooling channel to maintain the temperature of the coolant in the second cooling channel below a threshold. The control mechanism is further adapted to control the welding mechanism to stop operation and the warning mechanism to issue a warning if, during the welding process, the flow rate of the coolant in the first cooling channel remains constant and a leak in the steel pipe 91 is determined based on pressure changes within the steel pipe 91.

[0090] Further, see Figures 7 and 8As shown, the first positioning member 10 includes a first positioning body and a first cooling pipe 11. Specifically, the first positioning body includes a first body 12, a retaining bolt 13, and a plurality of connectors 14. Two mounting channels 121 are spaced apart on the first body 12. The two mounting channels 121 are adapted to slidably receive one end of each of the two side positioning members 30. A cavity is defined within the first body 12, located between the two mounting channels 121 and not connected to the mounting channels 121. The retaining bolt 13 is threadedly connected to the first body 12. The retaining bolt 13 extends in a first direction and into the mounting channels 121. The retaining bolt 13 is adapted to abut against the sidewall of the side positioning member 30 during welding, thereby securing the side positioning member 30 within the mounting channels 121. The first cooling pipe 11 is disposed on the first body 12 and communicates with the cavity. A plurality of connectors 14 are spaced apart on the first body 12. The connectors 14 communicate with the cavity. The connectors 14 are adapted to be removably connected to the inner bore of the steel pipe 91 during welding. The first cooling channel includes a first cooling pipe 11 , a cavity and a joint 14 .

[0091] In this embodiment, the first positioning member 10 includes one first cooling pipe 11 and eight connectors 14 .

[0092] In this embodiment, the first direction is perpendicular to the length direction of the side positioning member 30 .

[0093] In this embodiment, the first main body 12 includes a connecting rod 122, two end rods 123, two first fixed blocks 124 and two second fixed blocks 125. A cavity is provided in the connecting rod 122. The first cooling pipe 11 is fixed inside the connecting rod 122. The two end rods 123 are fixed at both ends of the connecting rod 122. The end rod 123 extends along the length direction of the connecting rod 122. A slide is provided between the end rod 123 and the connecting rod 122. A first fixed block 124 and a second fixed block 125 are provided on both sides of the slide respectively. Among them, the first fixed block 124 is fixed on the connecting rod 122, and the second fixed block 125 is fixed on the end rod 123. The mounting channel 121 is composed of the gap between the first fixed block 124 and the second fixed block 125 and the slide. The tightening bolt 13 is assembled on the second fixed block 125.

[0094] Furthermore, a through hole is formed on the second fixing block 125, into which a nut is fixed. The tightening bolt 13 is assembled in the nut. Compared with a threaded hole, machining a through hole on the second fixing block 125 can effectively reduce costs.

[0095] Furthermore, in order to effectively protect the joint 14 and strengthen the connection between the joint 14 and the steel pipe 91, please refer to Figure 9As shown, a rubber ring 141 is mounted on the exterior of connector 14. Connector 14 is adapted to be removably connected to the inner bore of steel pipe 91 via rubber ring 141 during the welding process. During the welding process, the cooling medium within the first cooling channel cools connector 14 and rubber ring 141, protecting them and extending their service life.

[0096] Further, see Figure 16 As shown, the second positioning member 20 includes a second positioning body and a second cooling pipe 21. The second positioning body has the same structure as the first positioning body, so a detailed description thereof will not be given. The second cooling pipe 21 is disposed on the first body 12 of the second positioning body and communicates with the cavity of the second positioning body. The second cooling channel includes the second cooling pipe 21, the cavity of the second positioning body, and the connector 14 of the second positioning body.

[0097] In this embodiment, the second positioning member 20 includes one second cooling pipe 21 and eight connectors 14 .

[0098] Further, see Figure 5 As shown, the side positioning member 30 includes a square steel 31 and a reinforcing plate 32. The two ends of the square steel 31 are detachably connected to the first positioning member 10 and the second positioning member 20 respectively. Specifically, the two ends of the square steel 31 can be slidably inserted into the corresponding mounting channels 121, and the tightening bolts 13 press against the side wall of the square steel 31 during the welding process. One side of the square steel 31 is suitable for abutting against one side of the part to be welded 90 during the welding process. The reinforcing plate 32 is provided on the other side of the square steel 31. The two ends of the reinforcing plate 32 are suitable for pressing against the first positioning member 10 and the second positioning member 20 respectively during the welding process.

[0099] In this embodiment, the length of the reinforcing plate 32 is equal to the length of the steel pipe 91 .

[0100] Further, see Figures 10 and 11 As shown, the positioning mechanism includes a positioning block 40. The positioning block 40 is detachably mounted between the two side positioning members 30. When positioned between the two side positioning members 30, one side of the positioning block 40 is provided with a positioning groove and a positioning surface, while the other side of the positioning block 40 is flush with the side positioning member 30. The positioning groove is suitable for limiting and supporting the side wall of the steel pipe 91 during the welding process. The positioning surface is suitable for supporting the flat steel 92 during the welding process.

[0101] In this embodiment, there are three positioning blocks 40 , and the length direction of the positioning blocks 40 is perpendicular to the length direction (ie, the first direction) of the square steel 31 . The three positioning blocks 40 are evenly spaced along the length direction of the square steel 31 .

[0102] The detection mechanism includes a flowmeter, a thermometer, and a pressure sensor (not shown). The flowmeter is located at the inlet of the first cooling tube 11. The flowmeter is suitable for detecting the flow rate of the coolant in the first cooling tube 11 during the welding process. The thermometer is located at the outlet of the second cooling tube 21. The thermometer is suitable for detecting the temperature of the coolant in the second cooling tube 21 during the welding process. The pressure sensor is located on the joint 14 of the second positioning body. The pressure sensor is suitable for detecting the pressure in the steel pipe 91 during the welding process.

[0103] In this embodiment, when the refrigerant medium is high-pressure cold air, the flow meter is a gas flow meter and the pressure sensor is a gas pressure sensor. When the refrigerant medium is cold water, the flow meter is a liquid flow meter and the pressure sensor is a liquid pressure sensor.

[0104] Further, see Figure 4 As shown, the welding mechanism includes a base 50, a drive module 60, and a welding robot 70. The base 50 is provided with a slot adapted to removably connect to the clamping mechanism during the welding process. The drive module 60 is disposed on the base 50, and the welding robot 70 is assembled on the drive module 60. The drive module 60 is adapted to drive the welding robot 70 to move during the welding process.

[0105] In this embodiment, the end portion of the first positioning member 10 and the end portion of the second positioning member 20 are detachably connected to the corresponding slots, respectively.

[0106] Furthermore, the slot on the base 50 is vertically arranged, and a limiting protrusion is provided in the slot to prevent the clamping mechanism from sliding along the length direction of the side positioning member 30 after being installed on the base 50 .

[0107] In this embodiment, the driving module 60 is a linear driving module. The welding robot 70 can be lifted, rotated, and extended according to the position to be welded.

[0108] In this embodiment, there are two drive modules 60 and two welding robots 70. During the welding process, the two drive modules 60 are symmetrically arranged on both sides of the clamping mechanism. The two welding robots 70 are used to weld the seams on both sides of the workpiece 90 to be welded.

[0109] The warning mechanism includes, but is not limited to, a buzzer, an indicator light, and the like (not shown). In this embodiment, the warning mechanism includes a buzzer and an indicator light. Both the buzzer and the indicator light are mounted on the base 50, allowing personnel to promptly inspect the steel pipe 91 for leaks based on the warnings from the warning mechanism.

[0110] The control mechanism includes a regulating valve and a controller (not shown). The regulating valve is located at the inlet of the first cooling pipe 11, upstream of the flowmeter. The controller is adapted to control the welding mechanism to weld the joint of the workpiece 90 and to control the regulating valve to adjust the flow rate of the coolant in the first cooling channel so that the temperature of the coolant in the second cooling channel is below a threshold. In this embodiment, the threshold is between 30°C and 120°C.

[0111] The controller is further adapted to control the welding mechanism to stop operating and the early warning mechanism to issue an early warning when, during the welding process, the regulating valve does not regulate the flow rate of the cooling medium in the first cooling channel and, based on the pressure change within the steel pipe 91, the steel pipe 91 is determined to be leaking, by controlling the welding mechanism to stop operating and the early warning mechanism to issue an early warning. Specifically, when the regulating valve does not regulate the flow rate of the cooling medium in the first cooling channel, the controller determines, based on the pressure change within the steel pipe 91, whether the steel pipe 91 is leaking. When the controller determines, based on the pressure change within the steel pipe 91, that the steel pipe 91 is leaking, the controller controls the welding mechanism to stop operating and the early warning mechanism to issue an early warning, so that workers can promptly repair the leak in the steel pipe 91 and avoid leakage during use of the tube panel after welding.

[0112] In another aspect, the present invention discloses a welding method using the above-mentioned tube panel welding device. The welding method specifically comprises the following steps:

[0113] S1. Assemble one end of the two side positioning members 30 on the first positioning member 10. Figure 12 As shown; in this embodiment, after step S1 is completed, the two side positioning members 30 and the first positioning member 10 are set horizontally.

[0114] S2, the positioning mechanism is detachably arranged between the two side positioning members 30, and then the steel pipe 91 and the flat steel 92 are assembled on the first positioning member 10, as shown in FIG. Figures 13 and 14 As shown; in this embodiment, after step S2 is completed, the positioning block 40 and the workpiece 90 to be welded are arranged horizontally. The bottom of the positioning block 40 is flush with the two side positioning members 30. The staff first places the steel pipe 91 in the positioning groove, and one end of the steel pipe 91 is installed on the corresponding joint 14; then the flat steel 92 is placed on the positioning plane. Among them, the flat steel 92 arranged between the two steel pipes 91, the side walls of the two steel pipes 91 limit the two sides of the flat steel 92. The flat steel 92 arranged between the steel pipe 91 and the square steel 31, the side walls of the steel pipe 91 and the square steel 31 limit the two sides of the flat steel 92.

[0115] S3, assemble the second positioning member 20 at the other end of the two side positioning members 30, so that the clamping mechanism can effectively fix the steel pipe 91 and the flat steel 92, as shown in FIG. Figure 15 As shown;

[0116] S4. Spot weld the joint between the steel pipe 91 and the flat steel 92. During the spot welding process, the workpiece 90 to be welded is positioned horizontally. In this embodiment, the workpiece 90 to be welded has a first side and a second side that are positioned opposite each other. In step S4, the first side of the workpiece 90 to be welded engages the positioning mechanism, and the operator only needs to spot weld the second side of the workpiece 90 to be welded.

[0117] S5. Remove the positioning mechanism from the clamping mechanism and detachably insert the clamping mechanism into the welding mechanism. Figure 16 As shown; in this embodiment, after step S5 is completed, the base 50 is positioned horizontally and the clamping mechanism is positioned vertically, so that the welded part 90 is positioned vertically. At this time, the first cooling pipe 11 is positioned in the middle of the first body 12 of the first positioning body. The second cooling pipe 21 is positioned in the middle of the first body 12 of the second positioning body.

[0118] S6. The control mechanism controls the welding mechanism to weld the joint between the steel pipe 91 and the flat steel 92, and controls the flow rate of the cooling medium in the first cooling channel so that the temperature of the cooling medium in the second cooling channel is less than the threshold value. At the same time, during the welding process, when the flow rate of the cooling medium in the first cooling channel remains unchanged, and when the steel pipe 91 is leaked based on the pressure change in the steel pipe 91, the control mechanism controls the welding mechanism to stop and controls the warning mechanism to issue a warning. During welding, the cooling medium is continuously injected into the inner cavity of the first positioning body by the first cooling pipe 11, and flows through the inner cavity of the first positioning body to the joint 14 of the first positioning body, the steel pipe 91, the joint 14 of the second positioning body, and the inner cavity of the second positioning body in sequence, and finally discharged from the second cooling pipe 21. During the welding process, the cooling medium effectively cools the workpiece 90 to be welded.

[0119] In this embodiment, in step S6, the two welding robots 70 weld the first side and the second side of the workpiece 90 at the same time. Figure 18 The two welding robots 70 then weld the two sides of the joint at a-1, a-4, a-5, a-8, a-9, a-12, a-13 and a-16 in sequence. Figure 18 The welds at a-2, a-3, a-6, a-7, a-10, a-11, a-14, and a-15 are shown on both sides of the weld. The above welding sequence can effectively reduce the deformation of the welded parts 90 and improve the quality of the tube panel.

[0120] This embodiment effectively fixes the weldment 90 to be welded, preventing the tube panel from twisting or bending, by coordinating a clamping mechanism, a positioning mechanism, a welding mechanism, a detection mechanism, an early warning mechanism, and a control mechanism. It also effectively cools the weldment 90 during welding and performs effective leak detection on the steel pipe 91 of the weldment 90, thereby improving the quality of the tube panel.

[0121] Example 2

[0122] The difference between Example 1 and Example 2 is that, in Example 2, please refer to Figure 17 As shown, the clamping mechanism is adapted to be positioned perpendicularly relative to the base 50 during the welding process. The welding mechanism also includes a lifting device 80. The lifting device 80 is disposed at one end of the base 50. The lifting device 80 is adapted to adjust the height of one end of the base 50 so that the base 50 is tilted. The outlet end of the second cooling channel is positioned upward.

[0123] Specifically, the base 50 includes a bottom plate and a hinge seat 51. One end of the bottom plate is hinged to the hinge seat 51, and the other end of the bottom plate is hinged to a lifting device 80. The lifting device 80 drives the other end of the bottom plate to move up and down so that the bottom plate is tilted.

[0124] In this embodiment, after step S5 is completed, the base 50 is tilted, and the clamping mechanism is arranged perpendicularly to the base 50, so that the workpiece 90 to be welded is tilted. The operator can adjust the tilt angle of the base 50 as needed. In this embodiment, the angle between the base 50 and the horizontal plane is 3° to 10°.

[0125] In this embodiment, in step S6, the first cooling pipe 11 is disposed in the upper middle portion of the first main body 12 of the first positioning body, with the inlet end of the first cooling pipe 11 facing upward. The second cooling pipe 21 is disposed in the upper middle portion of the first main body 12 of the second positioning body, with the outlet end of the second cooling pipe 21 facing upward.

[0126] In this embodiment, the positions of the first cooling tube 11 and the second cooling tube 21 are conducive to the cooling medium being filled into all the steel tubes 91 in the clamping mechanism, so that the workpieces 90 to be welded are fully cooled.

[0127] In this embodiment, the inclination angle of the workpiece 90 to be welded is adjusted so that the tube panel welding device can effectively weld the workpiece 90 to be welded, thereby obtaining a tube panel with better quality.

[0128] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed herein are intended to be covered by the claims of the present invention.

Claims

1. A tube panel welding device, suitable for welding the seams of a to-be-welded part (90), wherein the to-be-welded part (90) comprises a plurality of steel tubes (91) and a plurality of flat steels (92), wherein the plurality of steel tubes (91) are arranged in parallel and spaced apart, and the flat steels (92) are arranged between adjacent steel tubes (91), characterized in that: The tube panel welding device includes: a clamping mechanism, a positioning mechanism, a welding mechanism, a detection mechanism, an early warning mechanism and a control mechanism; The clamping mechanism is detachably inserted into the welding mechanism, and the clamping mechanism comprises: a first positioning member (10), a second positioning member (20) and two side positioning members (30); the first positioning member (10) and the second positioning member (20) are distributed at both ends of the workpiece (90) to be welded, a first cooling channel is provided in the first positioning member (10), and the first cooling channel is suitable for receiving a cooling medium during the welding process; the second positioning member (20) is provided in the second cooling channel, and the second cooling channel is suitable for discharging a cooling medium during the welding process; The first positioning member (10) and the second positioning member (20) are respectively suitable for fixing the two ends of the steel pipe (91), and at the same time, the first cooling channel is connected to the second cooling channel through the steel pipe (91); the two side positioning members (30) are distributed on both sides of the part to be welded (90), and the two ends of the side positioning members (30) are respectively detachably connected to the first positioning member (10) and the second positioning member (20), and the two side positioning members (30) are suitable for fixing the two sides of the part to be welded (90) during the welding process; The positioning mechanism is detachably arranged between the two side positioning members (30), and the positioning mechanism is suitable for limiting and supporting the root steel pipe (91) and the root flat steel (92) during the welding process; The detection mechanism is suitable for detecting the pressure inside the steel pipe (91), the flow rate of the cooling medium in the first cooling channel, and the temperature of the cooling medium in the second cooling channel during the welding process; The control mechanism is suitable for controlling the welding mechanism to weld the seam of the workpiece (90) to be welded, and controlling the flow rate of the cooling medium in the first cooling channel so that the temperature of the cooling medium in the second cooling channel is less than a threshold value; the control mechanism is also suitable for controlling the welding mechanism to stop operating and controlling the early warning mechanism to issue an early warning when the flow rate of the cooling medium in the first cooling channel remains unchanged during the welding process and when it is determined based on the pressure change in the steel pipe (91) that the steel pipe (91) is leaking.

2. The tube panel welding device according to claim 1, characterized in that: The first positioning member (10) comprises: a first positioning body and a first cooling pipe (11); The first positioning body comprises: a first body (12), a tightening bolt (13) and a plurality of joints (14); Two installation channels (121) are provided on the first body (12) at intervals, and the two installation channels (121) are respectively adapted to be slidably inserted into one end of the two side positioning members (30); a cavity is provided in the first body (12), and the cavity is located between the two installation channels (121) and is not in communication with the installation channels (121); The holding bolt (13) is threadedly connected to the first main body (12), and the holding bolt (13) extends along a first direction and extends into the installation channel (121); the holding bolt (13) is suitable for holding the side wall of the side positioning member (30) during the welding process, so that the side positioning member (30) is fixed in the installation channel (121); The first cooling pipe (11) is arranged on the first main body (12), and the first cooling pipe (11) is connected to the cavity; A plurality of joints (14) are arranged at intervals on the first main body (12), the joints (14) are in communication with the cavity, and the joints (14) are suitable for being detachably connected to the inner hole of the steel pipe (91) during welding; The first cooling channel comprises the first cooling pipe (11), the cavity and the joint (14); The second positioning member (20) comprises: a second positioning body and a second cooling pipe (21); The second positioning body has the same structure as the first positioning body; the second cooling pipe (21) is arranged on the first body (12) of the second positioning body, and the second cooling pipe (21) is connected to the cavity of the second positioning body; The second cooling channel comprises the second cooling pipe (21), a cavity of the second positioning body, and a joint (14) of the second positioning body.

3. The tube panel welding device according to claim 2, characterized in that: The outside of the joint (14) is equipped with a rubber ring (141), and the joint (14) is suitable for being detachably connected to the inner hole of the steel pipe (91) via the rubber ring (141) during welding.

4. The tube panel welding device according to claim 2, characterized in that: The detection mechanism includes a flow meter, a thermometer and a pressure sensor; The flow meter is arranged at the inlet end of the first cooling tube (11), and the flow meter is suitable for detecting the flow rate of the cooling medium in the first cooling tube (11) during the welding process; The thermometer is arranged at the outlet end of the second cooling tube (21), and the thermometer is suitable for detecting the temperature of the cooling medium in the second cooling tube (21) during the welding process; The pressure sensor is arranged on the joint (14) of the second positioning body, and the pressure sensor is suitable for detecting the pressure inside the steel pipe (91) during the welding process.

5. The tube panel welding device according to claim 1, characterized in that: The side positioning member (30) comprises: a square steel (31) and a reinforcing plate (32); The two ends of the square steel (31) are detachably connected to the first positioning member (10) and the second positioning member (20), respectively; one side of the square steel (31) is suitable for abutting against one side of the workpiece (90) to be welded during the welding process; The reinforcing plate (32) is arranged on the other side of the square steel (31), and both ends of the reinforcing plate (32) are suitable for respectively pressing against the first positioning member (10) and the second positioning member (20) during the welding process.

6. The tube panel welding device according to claim 1, characterized in that: The positioning mechanism comprises: a positioning block (40); The positioning block (40) is detachably arranged between the two side positioning members (30); a positioning groove and a positioning plane are provided on one side of the positioning block (40), and the other side of the positioning block (40) is flush with the side positioning member (30); The positioning groove is suitable for limiting the side wall of the steel pipe (91) during the welding process, and the positioning plane is suitable for supporting the flat steel (92) during the welding process.

7. The tube panel welding device according to claim 1, characterized in that: The welding mechanism comprises: a base (50), a drive module (60) and a welding robot (70); The base (50) is provided with a slot, and the slot is suitable for being detachably connected to the clamping mechanism during the welding process; The driving module (60) is arranged on the base (50), and the welding robot (70) is assembled on the driving module (60). The driving module (60) is suitable for driving the welding robot (70) to move during the welding process.

8. The tube panel welding device according to claim 7, characterized in that: The clamping mechanism is suitable for being arranged vertically relative to the base (50) during the welding process, and the welding mechanism further comprises: a lifting device (80); The lifting device (80) is arranged at one end of the base (50), and the lifting device (80) is suitable for adjusting the height of one end of the base (50) so that the base (50) is tilted; The outlet end of the second cooling channel is arranged upward.

9. The tube panel welding device according to claim 1, characterized in that: The control mechanism includes: a regulating valve and a controller; The regulating valve is arranged at the inlet end of the first cooling channel; The controller is suitable for controlling the welding mechanism to weld the seam of the workpiece (90) to be welded, and controlling the regulating valve to regulate the flow rate of the cooling medium in the first cooling channel so that the temperature of the cooling medium in the second cooling channel is less than a threshold value; the controller is also suitable for controlling the welding mechanism to stop operating and controlling the early warning mechanism to issue an early warning when the regulating valve does not regulate the flow rate of the cooling medium in the first cooling channel and the steel pipe (91) is determined to have a leak based on the pressure change in the steel pipe (91) during the welding process.

10. A welding method using the tube panel welding device according to any one of claims 1 to 9, characterized in that: The specific steps include: S1, assembling one end of the two side positioning members (30) on the first positioning member (10); S2, detachably disposing the positioning mechanism between the two side positioning members (30), and then assembling the steel pipe (91) and the flat steel (92) on the first positioning member (10); S3, assembling the second positioning member (20) at the other end of the two side positioning members (30) so that the clamping mechanism can effectively fix the steel pipe (91) and the flat steel (92); S4, spot welding the joint between the steel pipe (91) and the flat steel (92); S5, removing the positioning mechanism from the clamping mechanism, and detachably inserting the clamping mechanism into the welding mechanism; S6. The control mechanism controls the welding mechanism to weld the joint between the steel pipe (91) and the flat steel (92), and controls the flow rate of the cooling medium in the first cooling channel so that the temperature of the cooling medium in the second cooling channel is less than a threshold value; at the same time, during the welding process, when the flow rate of the cooling medium in the first cooling channel remains unchanged and the steel pipe (91) is determined to be leaking based on the pressure change in the steel pipe (91), the control mechanism controls the welding mechanism to stop operating and controls the warning mechanism to issue a warning.

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