Pipe weld polishing deviation compensation method, control terminal and weld polishing system

Abstract

This invention relates to a method, control terminal, and weld grinding system for compensating for deviations in pipeline weld grinding. The method includes: S1, obtaining the initial radial height between the weld and the pipeline; S2, determining the theoretical grinding depth based on the initial radial height and a preset weld formation height; S3, controlling a grinding device to grind the weld layer by layer according to the theoretical grinding depth; S4, obtaining the real-time radial height between the weld and the pipeline after grinding one layer of weld metal; S5, determining whether the error between the real-time radial height and the preset weld formation height is within a set range. If so, grinding is stopped; otherwise, the radial height of the grinding wheel in the grinding device is compensated based on the real-time radial height, and the grinding device is controlled to continue grinding, returning to step S4. This invention can automatically compensate the radial height of the grinding wheel according to the wear level of the grinding wheel in the grinding device, thereby removing excess weld height and improving grinding quality.

Description

Technical Field

[0001] This invention relates to the field of metal overlay welding technology in nuclear power plants, and in particular to a method for compensating for deviations in pipeline weld grinding, a control terminal, and a weld grinding system. Background Technology

[0002] Nuclear power plants contain numerous pipelines connected by welding, and these welds typically require grinding to ensure quality. However, during automated weld grinding, the grinding wheel experiences varying degrees of wear due to factors such as grinding materials, parameters, duration, and environmental conditions. If this wear is not compensated, issues like weld excess height can occur. Furthermore, traditional uncompensated weld grinding systems do not account for wear-induced errors in the grinding wheel, resulting in incomplete removal of weld excess height after grinding. This leads to an uneven weld connection with the base material and poor grinding results. Compensating for these errors requires stopping the grinding operation and having personnel manually assess the defects and make adjustments on-site. This process is time-consuming and labor-intensive, and the accuracy of the assessment is highly dependent on the operator's experience, which can result in unsatisfactory grinding even after manual adjustments. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a method for compensating for deviations in pipeline weld grinding, a control terminal, and a weld grinding system.

[0004] The technical solution adopted by this invention to solve its technical problem is: constructing a method for compensating for grinding deviations in pipe welds, comprising:

[0005] S1. Obtain the initial radial height between the weld and the pipe;

[0006] S2. Determine the theoretical grinding depth based on the initial radial height and the preset weld formation height;

[0007] S3. The grinding device is controlled to grind the weld layer by layer according to the theoretical grinding depth.

[0008] S4. After grinding a layer of solder, obtain the real-time radial height between the weld and the pipe;

[0009] S5. Determine whether the error between the real-time radial height and the preset weld formation height is within the set range. If yes, end the grinding. Otherwise, compensate the radial height of the grinding wheel of the grinding device according to the real-time radial height, control the grinding device to continue grinding, and return to S4.

[0010] Preferably, in step S3, the step of grinding the weld layer by layer according to the theoretical grinding depth control grinding device includes:

[0011] The weld is divided into several solder layers according to the theoretical grinding depth.

[0012] Determine the theoretical grinding depth corresponding to each solder layer;

[0013] Based on the plurality of solder layers and the theoretical grinding depth of each solder layer, the grinding device grinds the weld layer by layer.

[0014] Preferably, in S5, compensating the radial height of the grinding wheel of the grinding device according to the real-time radial height includes:

[0015] S51. Determine the compensation value based on the real-time radial height obtained historically;

[0016] S52. Adjust the radial height of the grinding wheel according to the compensation value.

[0017] Preferably, in step S51, determining the compensation value based on the historically acquired real-time radial height includes:

[0018] Subtract the latest real-time radial height from the previously obtained real-time radial height to obtain the first difference;

[0019] The first difference is subtracted from the theoretical grinding depth of the next solder layer to be ground to obtain the compensation value;

[0020] In S52, adjusting the radial height of the grinding wheel according to the compensation value includes:

[0021] When the compensation value is greater than 0, the radial height of the grinding wheel is controlled to deviate from the compensation value towards the pipeline;

[0022] When the compensation value is less than 0, the radial height of the grinding wheel is controlled to deviate from the pipeline by the compensation value.

[0023] Preferably, in S51, the method further includes:

[0024] Determine whether the absolute value of the first difference is less than or equal to a set threshold. If so, determine that the radial height of the grinding wheel does not need to be compensated and skip step S52.

[0025] Preferably, the set threshold is 0.1 mm.

[0026] Preferably, in step S1, the method further includes: acquiring the initial radial height using a ranging sensor; wherein the ranging sensor includes a laser ranging sensor.

[0027] The S4 step also includes: acquiring the real-time radial height through the ranging sensor.

[0028] The present invention also constructs a control terminal, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the steps of the above-described pipeline weld grinding deviation compensation method.

[0029] The present invention also provides a weld grinding system, including a grinding device and the control terminal described above.

[0030] Preferably, the weld grinding system further includes: a distance sensor for obtaining the radial height between the weld and the pipe; wherein the distance sensor includes a laser distance sensor.

[0031] The present invention has the following beneficial effects: it can automatically compensate the radial height of the grinding wheel (i.e., the grinding point position) according to the wear degree of the grinding wheel in the grinding device, thereby removing as much weld excess height as possible, keeping the weld and the pipe base material as parallel as possible, improving the efficiency and quality stability of weld grinding, and helping to save manpower and material resources in nuclear power plants. Attached Figure Description

[0032] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the accompanying drawings:

[0033] Figure 1 This is a flowchart of the pipeline weld grinding deviation compensation method in some embodiments of the present invention;

[0034] Figure 2 These are schematic diagrams of the weld structure in some embodiments of the present invention;

[0035] Figure 3 This is a flowchart of step S3 in some embodiments of the present invention;

[0036] Figure 4 This is a flowchart of the procedure for compensating for radial height in some embodiments of the present invention;

[0037] Figure 5 This is a circuit structure block diagram of the control terminal in some embodiments of the present invention;

[0038] Figure 6 This is a schematic diagram of the weld grinding system in some embodiments of the present invention. Detailed Implementation

[0039] To provide a clearer understanding of the technical features, objectives, and effects of the present invention, specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0040] It should be noted that the flowcharts shown in the accompanying drawings are merely illustrative and do not necessarily include all content and operations / steps, nor do they necessarily have to be performed in the described order. For example, some operations / steps can be broken down, while others can be combined or partially combined; therefore, the actual execution order may change depending on the specific circumstances.

[0041] The block diagrams shown in the accompanying drawings are merely functional entities and do not necessarily correspond to physically independent entities. That is, these functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor devices and / or microcontroller devices.

[0042] Figure 1 This is a flowchart illustrating a method for compensating for deviations in pipe weld grinding in some embodiments of the present invention. This method is applied to the control terminal of a weld grinding system. The control terminal controls the grinding device to automatically complete the grinding work on the pipe. By implementing the technical solution of the present invention, the control terminal can automatically compensate for the radial height (i.e., the grinding point position) of the grinding wheel based on the wear level of the grinding wheel in the grinding device, thereby removing as much weld excess height as possible and improving grinding quality. Figure 1 As shown, the pipeline weld grinding deviation compensation method may include steps S1, S2, S3, S4 and S5.

[0043] Step S1 includes: obtaining the initial radial height between the weld and the pipe. In this step, the initial radial height refers to the radial height between the weld and the pipe before the grinding device performs any grinding work on the weld, such as... Figure 2 As shown, H0 corresponds to the initial radial height. It should be noted that in this invention, "radial" refers to the direction consistent with the radial direction of the pipe where the weld being ground is located.

[0044] In some embodiments, in step S1, the initial radial height can be obtained by a ranging sensor. Specifically, the ranging sensor can be an existing ranging sensor capable of measuring the distance to an object, such as a laser ranging sensor, a pyroelectric ranging sensor, or a visual ranging sensor. In this embodiment, the ranging sensor is preferably a laser ranging sensor. The laser ranging sensor can be fixed at a position with a constant radial distance to the pipe, and the laser ranging sensor is oriented towards the weld seam with the laser emission direction aligned with the center of the pipe. In this way, the distance between the weld seam and the laser emission port of the laser ranging sensor (denoted as the measurement distance) can be accurately measured using existing technology. Since the radial distance between the laser ranging sensor and the pipe (denoted as the constant distance) is constant and pre-stored in the control terminal, the constant distance can be subtracted from the measurement distance to obtain the radial height between the weld seam and the pipe.

[0045] Step S2 includes determining the theoretical grinding depth based on the initial radial height and the preset weld formation height. In this step, the theoretical grinding depth can be determined by subtracting the preset weld formation height from the initial radial height. The preset weld formation height can be stored in the control terminal or customized by the operator using a human-machine interface device (such as a mouse or keyboard). Furthermore, the theoretical grinding depth refers to the total radial feed length required by the grinding device to grind the weld when theoretically eliminating weld excess height.

[0046] Step S3 includes: controlling the grinding device to grind the weld layer by layer according to the theoretical grinding depth. In this step, the control terminal will control the grinding device to grind the weld layer by layer from top to bottom according to the theoretical grinding depth. It should be noted that the "from top to bottom" direction can be referenced... Figure 2 The direction f in the middle is consistent with the radial direction of the pipe.

[0047] In some embodiments, such as Figure 3 As shown, the grinding device can be controlled to grind the weld layer by layer according to the theoretical grinding depth by executing steps S31 to S33.

[0048] Step S31: Divide the weld into several solder layers according to the theoretical grinding depth. Specifically, this step can be done by dividing the weld into several solder layers using either an equal division method or an equidistant division method.

[0049] In some embodiments, the equal division method may include: dividing the weld into several solder layers from top to bottom based on the theoretical grinding depth. For example, if the preset number of solder layers is C1 and the theoretical grinding depth is equal to D1, then the height of each solder layer is equal to D1 / C1. Thus, the weld is divided into C parts from top to bottom based on D1 / C1, thereby obtaining C1 solder layers with a consistent height.

[0050] In some embodiments, the equidistant division method may include dividing the weld into several solder layers based on a set spacing, either from top to bottom or from bottom to top. It is readily understood that in this embodiment, the number of solder layers is positively correlated with the theoretical grinding depth, but the height of the final divided solder layers is less than or equal to the set spacing. Specifically, if the weld is divided from top to bottom, the final divided solder layer is the one closest to the pipe surface; if the weld is divided from bottom to top, the final divided solder layer is the one furthest from the pipe surface.

[0051] Step S32: Determine the theoretical grinding depth corresponding to each solder layer. This step can be easily understood as determining the height of each solder layer based on the layering method (such as the equal division method or the equidistant division method) in step S31, and then determining the height of the solder layer as the corresponding theoretical grinding depth.

[0052] Step S33: Based on several solder layers and the theoretical grinding depth of each solder layer, the grinding device grinds the weld layer by layer. Specifically, by adding the theoretical grinding depths of all solder layers, the theoretical grinding point height of the first solder layer (i.e., the uppermost solder layer) can be obtained. Easily understood, without considering the radial height of the compensation grinding wheel, by adding the theoretical grinding depths of all solder layers except the first solder layer, the theoretical grinding point height of the second solder layer can be obtained. Similarly, by adding the theoretical grinding depths of all solder layers except the first and second solder layers, the theoretical grinding point height of the third solder layer can be obtained, and so on, thus determining the theoretical grinding point height of each solder layer. Then, the control terminal controls the grinding device to grind the solder layers from the first to the lowermost layer sequentially based on their theoretical grinding point heights.

[0053] Step S4 includes: after grinding off one layer of solder, obtaining the real-time radial height between the weld and the pipe. In this step, the real-time radial height refers to the radial height after at least one layer of solder has been ground off the weld. The measurement method is the same as that used in step S1 to measure the initial radial height, and will not be repeated here. It should be noted that due to factors such as the material, parameters, duration, and environment of the grinding wheel, the grinding wheel may experience varying degrees of wear during operation. That is, the degree of radius reduction caused by the wear of the grinding wheel is uncertain. Therefore, the degree of residual solder height after each layer of solder is ground may be different. This step obtains the real-time radial height to accurately monitor the degree of residual solder height caused by the wear of the grinding wheel, so as to facilitate targeted compensation work in subsequent steps.

[0054] In some embodiments, the real-time radial height can also be obtained by a ranging sensor in step S4.

[0055] Step S5 includes: determining whether the error between the real-time radial height and the preset weld formation height is within a set range; if so, ending the grinding process; otherwise, compensating the radial height of the grinding wheel of the grinding device based on the real-time radial height, controlling the grinding device to continue grinding, and returning to step S4. In this step, the preset weld formation height can be subtracted from the real-time radial height to obtain the error, thus determining whether the error is within a set range, where the set range can be from -0.1mm to 0.1mm.

[0056] In some embodiments, such as Figure 4As shown, the radial height of the grinding wheel of the grinding device can be compensated according to the real-time radial height by performing steps S51 and S52.

[0057] Step S51 includes: determining a compensation value based on the historically acquired real-time radial height.

[0058] In some embodiments, the compensation value can be determined by performing the following steps: subtracting the latest acquired real-time radial height from the previously acquired real-time radial height to obtain a first difference; and subtracting the first difference from the theoretical grinding depth of the next solder layer to be ground to obtain the compensation value. See also... Figure 2 Taking the second solder layer as an example, it can be understood that since the first solder layer is the top layer, the initial radial height H0 can be regarded as the real-time radial height obtained last time, and the real-time radial height of the second solder layer is H1. Then the first difference Δh = H0 - H1, and the compensation value Δa = a0 - Δh, where a0 represents the theoretical grinding depth of the second solder layer.

[0059] Because the control terminal has limited accuracy in controlling the radial height of the grinding device (or grinding wheel), compensation is unnecessary when the absolute value is small. Furthermore, the radial height (including real-time and initial radial height) inevitably contains errors due to testing equipment and software algorithms during measurement, making it difficult for the first difference to equal the theoretical grinding depth (i.e., the actual grinding depth is completely consistent with the theoretical grinding depth). To avoid unnecessary compensation, in some embodiments, step S51 may further include: determining whether the absolute value of the first difference is less than or equal to a set threshold. If so, it is determined that the radial height of the grinding wheel does not need compensation, and step S52 is skipped, returning to step S4. The set threshold can be 0.1 mm. It is understood that when the absolute value of the first difference is less than or equal to the set threshold, it indicates that the actual grinding depth is almost equal to the theoretical grinding depth, thus eliminating the need to compensate for the radial height of the grinding wheel. Therefore, step S52 can be omitted, which helps reduce the computational load of the control terminal and improve grinding efficiency.

[0060] Step S52 includes: adjusting the radial height of the grinding wheel according to the compensation value.

[0061] In some embodiments, adjusting the radial height of the grinding wheel according to the compensation value in step S52 may include: when the compensation value is greater than 0, controlling the radial height of the grinding wheel to be closer to the pipeline offset compensation value; when the compensation value is less than 0, controlling the radial height of the grinding wheel to be farther away from the pipeline offset compensation value.

[0062] Understandably, after the first layer of solder is ground, the present invention will repeatedly execute steps S3 to S5 to grind the weld layer by layer. After each layer of solder is ground, the radial height of the grinding wheel is compensated according to the latest real-time radial height, thereby eliminating the grinding error caused by damage to the grinding wheel and removing as much weld excess height as possible. This realizes automatic compensation of the radial height of the grinding wheel (i.e., the grinding point position) according to the wear degree of the grinding wheel in the grinding device, so that the weld and the pipe base material are kept as parallel as possible, improving the efficiency and quality stability of weld grinding and helping to save manpower and material resources in nuclear power plants.

[0063] like Figure 5 As shown, the present invention also provides a control terminal, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the steps of the pipeline weld grinding deviation compensation method provided in the embodiments of the present invention.

[0064] like Figure 6 As shown, the present invention also improves a weld grinding system, including a grinding device, a moving mechanism, and a control terminal provided in the embodiments of the present invention.

[0065] It should be noted that the control terminal is not only used to implement the steps of the pipeline weld grinding deviation compensation method provided in the embodiments of the present invention, but also to control the operation of the grinding device, and to drive the grinding device to move on the weld to be ground by controlling the operation of the moving mechanism, so as to achieve the purpose of grinding layer by layer. The grinding device can be a grinding wheel machine. The moving mechanism can be an existing robotic arm or a mobile device.

[0066] In some embodiments, such as Figure 6 As shown, the weld grinding system also includes a distance sensor and a human-machine interaction device.

[0067] The ranging sensor is used to obtain the radial height between the weld and the pipe; the ranging sensor may include a laser ranging sensor.

[0068] The human-machine interface device is used to input operation instructions to the control terminal based on the operator's operation, so as to realize relevant control, including but not limited to setting the preset weld formation height, preset number of layers, setting the spacing, setting the range, and setting the threshold.

[0069] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0070] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0071] The steps of the methods or algorithms described in conjunction with the embodiments disclosed herein can be implemented directly by hardware, a software module executed by a processor, or a combination of both. The software module can be located in random access memory (RAM), main memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disk, removable disk, CD-ROM, or any other form of storage medium known in the art.

[0072] It is understood that the above embodiments only illustrate preferred embodiments of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can freely combine the above technical features without departing from the concept of the present invention, and can also make several modifications and improvements, all of which fall within the protection scope of the present invention. Therefore, all equivalent transformations and modifications made with respect to the scope of the claims of the present invention should fall within the scope of the claims of the present invention.

Claims

1. A method of pipe weld grinding deviation compensation, the method comprising: include: S1. Obtain the initial radial height between the weld and the pipe; S2. Determine the theoretical grinding depth based on the initial radial height and the preset weld formation height; S3. The grinding device is controlled to grind the weld layer by layer according to the theoretical grinding depth. S4. After grinding a layer of solder, obtain the real-time radial height between the weld and the pipe; S5. Determine whether the error between the real-time radial height and the preset weld formation height is within the set range. If yes, end the grinding. Otherwise, compensate the radial height of the grinding wheel of the grinding device according to the real-time radial height, control the grinding device to continue grinding, and return to S4.

2. The method for compensating for grinding deviations in pipe welds according to claim 1, characterized in that, In step S3, the step of grinding the weld layer by layer according to the theoretical grinding depth control grinding device includes: The weld is divided into several solder layers according to the theoretical grinding depth. Determine the theoretical grinding depth corresponding to each solder layer; Based on the plurality of solder layers and the theoretical grinding depth of each solder layer, the grinding device grinds the weld layer by layer.

3. The method for compensating for grinding deviations in pipe welds according to claim 2, characterized in that, In S5, compensating the radial height of the grinding wheel of the grinding device according to the real-time radial height includes: S51. Determine the compensation value based on the real-time radial height obtained historically; S52. Adjust the radial height of the grinding wheel according to the compensation value.

4. The method for compensating for grinding deviations in pipe welds according to claim 3, characterized in that, In step S51, determining the compensation value based on the historically acquired real-time radial height includes: Subtract the latest real-time radial height from the previously obtained real-time radial height to obtain the first difference; The first difference is subtracted from the theoretical grinding depth of the next solder layer to be ground to obtain the compensation value; In S52, adjusting the radial height of the grinding wheel according to the compensation value includes: When the compensation value is greater than 0, the radial height of the grinding wheel is controlled to deviate from the compensation value towards the pipeline; When the compensation value is less than 0, the radial height of the grinding wheel is controlled to deviate from the pipeline by the compensation value.

5. The method for compensating for grinding deviations in pipe welds according to claim 4, characterized in that, S51 also includes: Determine whether the absolute value of the first difference is less than or equal to a set threshold. If so, determine that the radial height of the grinding wheel does not need to be compensated and skip step S52.

6. The method for compensating for grinding deviations in pipe welds according to claim 5, characterized in that, The set threshold is 0.1 mm.

7. The method for compensating for grinding deviations in pipe welds according to any one of claims 1 to 6, characterized in that, S1 further includes: acquiring the initial radial height via a ranging sensor; wherein the ranging sensor includes a laser ranging sensor; The S4 step also includes: acquiring the real-time radial height through the ranging sensor.

8. A control terminal, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the steps of the pipeline weld grinding deviation compensation method according to any one of claims 1 to 7.

9. A weld grinding system, characterized in that, It includes a grinding device and a control terminal as described in claim 8.

10. The weld grinding system according to claim 9, characterized in that, The weld grinding system further includes a distance sensor for obtaining the radial height between the weld and the pipe; wherein the distance sensor includes a laser distance sensor.

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