An apparatus and method for horizontal and vertical automated tube welding of an expanded bellows

Abstract

The present application relates to the technical fields of drilling fluid leakage or sealing complex well section instability, in particular to a kind of expansion bellows horizontal and vertical automatic pipe welding device and method thereof, including the support of basic lifting frame, the lower part of support two sides is respectively provided with horizontal clamping mechanism for the horizontal positioning of expansion bellows, clamping docking mechanism for welding the interface of two expansion bellows is arranged between two horizontal clamping mechanisms, the upper and lower sides of clamping docking mechanism are respectively provided with vertical clamping mechanism for the vertical positioning of expansion bellows, clamping docking mechanism is rotatably connected with adjusting mechanism for controlling the rotation angle of clamping docking mechanism, adjusting mechanism is fixedly connected with driving mechanism, and driving mechanism is fixedly connected with support.The present application can effectively weld expansion bellows in horizontal and vertical directions, and can improve the automatic pipe welding mechanical automation degree and improve welding precision.

Description

Technical Field

[0001] This invention relates to oil and gas drilling engineering, geothermal drilling engineering, geological drilling engineering, etc., and is used to address drilling fluid loss or sealing instability in complex formations and complex well sections. In particular, it relates to an automated horizontal and vertical pipe welding device and method for expansion bellows. Background Technology

[0002] Expandable corrugated pipe technology has important and wide applications in oil and gas drilling engineering. It can seal drilling fluid losses (especially large fractures and cavernous leaks), isolate unstable and collapsed well sections, and repair damaged casing without altering the wellbore structure or reducing wellbore size. Expandable corrugated pipe technology involves cold-pressing a round pipe into a "figure-eight" corrugated cross-section, thereby reducing its diameter to ensure smooth passage through the upper well section to the target formation. During expansionable corrugated pipe construction, multiple corrugated pipes are welded into a string and lowered into the well according to the working length of the target well section. Subsequently, hydraulic expansion and mechanical shaping are used to make the corrugated pipes expand and fit tightly against the well wall, achieving precise sealing of complex formations. Therefore, the welding quality of the multiple welds on the corrugated pipe string is a key factor affecting the strength and reliability of the string.

[0003] To improve construction efficiency, expansion bellows are typically horizontally butt-welded in pairs on the well site before being lowered into the well. They are then hoisted to the wellhead and horizontally welded to the partially lowered bellows. However, this method still relies heavily on manual welding, which suffers from low welding precision, high labor intensity, and high safety risks. Furthermore, the welding quality is overly dependent on the experience and skill of the welders, making it difficult to guarantee the stability of weld strength and quality. This can easily lead to welding defects such as slag inclusions, bubbles, misalignment, and incomplete penetration, severely affecting the overall performance of the bellows string.

[0004] Therefore, there is an urgent need for an automated horizontal and vertical pipe welding device and method for expansion bellows, which can improve the level of automation of automatic pipe welding machinery, ensure welding accuracy, reduce the labor intensity of workers, and protect the life safety of operators. Summary of the Invention

[0005] The purpose of this invention is to provide an automated horizontal and vertical pipe welding device and method for expansion bellows, in order to solve the problems existing in the prior art.

[0006] To achieve the above objectives, the present invention provides the following solution: an automated horizontal and vertical pipe welding device for expansion bellows, comprising a support as a basic lifting frame, horizontal clamping mechanisms for horizontal positioning of the expansion bellows are respectively provided on both sides of the lower part of the support, a clamping and docking mechanism for welding the interfaces of two expansion bellows is provided between the two horizontal clamping mechanisms, vertical clamping mechanisms for vertical positioning of the expansion bellows are respectively provided on the upper and lower sides of the clamping and docking mechanism, an adjusting mechanism for controlling the rotation angle of the clamping and docking mechanism is rotatably connected to the clamping and docking mechanism, a driving mechanism is fixedly connected to the adjusting mechanism, and the driving mechanism is fixedly connected to the support.

[0007] Preferably, the horizontal clamping mechanism includes a lifting frame, in which X-shaped frames are symmetrically arranged. One end of the X-shaped frame is slidably connected to the bottom of the lifting frame, and the other end of the X-shaped frame is slidably connected to a top plate. A first clamping part is provided at the end of the top plate opposite to the X-shaped frame.

[0008] Preferably, the piston end of a first hydraulic cylinder is fixedly connected to one end of the X-shaped frame near the top plate, the fixed end of the first hydraulic cylinder is fixedly connected to the bottom of the lifting frame, and the first hydraulic cylinder is inclined.

[0009] Preferably, the first clamping part includes a first support plate fixedly connected to the top plate, a fixed ring of a first circular guide rail fixedly connected inside the first support plate, and a first pneumatic gripper symmetrically and fixedly connected to the inner wall of a first movable ring inside the first circular guide rail.

[0010] Preferably, the clamping and docking mechanism includes a third support plate rotatably connected to the adjusting mechanism. The third support plate has a fixed ring symmetrically connected to a third circular guide rail at one end opposite to the adjusting mechanism. A third pneumatic gripper is symmetrically connected to the inner wall of a third movable ring within the third circular guide rail.

[0011] Preferably, a robotic arm is mounted on the end of the third support plate away from the adjustment mechanism, and an automated welding torch is mounted on the end of the robotic arm away from the third support plate.

[0012] Preferably, the vertical clamping mechanism includes a second support plate slidably connected to the bracket, a fixed ring of a second circular guide rail is fixedly connected to one end of the second support plate away from the bracket, and a second pneumatic gripper is symmetrically and fixedly connected to the inner wall of the second movable ring inside the second circular guide rail.

[0013] Preferably, the adjustment mechanism includes a movable block slidably connected to the bracket, with one end of the movable block facing the third support plate fixedly connected to the fixed end of the electric turntable, and the movable end of the electric turntable fixedly connected to the third support plate.

[0014] Preferably, the drive mechanism includes a chain conveyor belt for controlling the up and down movement of the third support plate. The chain conveyor belt is installed on the side of the bracket away from the third support plate, and the movable block is fixedly connected to the chain of the chain conveyor belt.

[0015] An automated horizontal and vertical pipe welding method for expansion bellows includes the following steps:

[0016] S1. Determine the number of expansion bellows to be welded based on the length of the complex well section to be sealed downhole, and weld all expansion bellows in pairs by horizontal welding.

[0017] S2. Place the two expansion bellows into the two horizontal clamping mechanisms respectively, and adjust the horizontal clamping mechanisms so that the central axes of the two expansion bellows are on the same central axis.

[0018] S3. Clean the bevels of the two expansion bellows to be welded;

[0019] S4. Insert the two expansion bellows into the clamping and docking mechanism, and leave a welding allowance between the weld bevels of the two expansion bellows;

[0020] S5. Perform horizontal automated welding using the clamping and docking mechanism;

[0021] S6. After welding is completed, take out the welded expansion bellows, and then repeat steps S2-S5 to obtain several sets of welded expansion bellows strings.

[0022] S7. Move the welding device to the wellhead and adjust it to the vertical welding mode to clamp the docking mechanism;

[0023] S8. First, lower one end of a set of welded expansion bellows pipe strings into the wellhead, and then install the other end of the welded expansion bellows pipe strings onto the vertical clamping mechanism located below.

[0024] S9. Place another set of welded expansion bellows pipe strings on the vertical clamping mechanism located above the clamping docking mechanism;

[0025] S10. Clean the bevels at opposite ends of the two welded expansion bellows strings;

[0026] S11. Vertical automated welding is performed using the clamping and docking mechanism, and then the weld quality is inspected using a non-destructive testing device. After confirming that the weld is qualified, it is lowered into the well.

[0027] S12. After welding is completed, the welded expansion bellows is lowered into the well through the wellhead. The vertical clamping mechanism located below clamps the end of the expansion bellows that extends out of the wellhead. Then, another set of welded expansion bellows strings is installed on the vertical clamping mechanism located above, and welding continues.

[0028] S13. Repeat steps S10-S12 to complete the vertical welding and downhole installation of all expansion bellows; then subsequent downhole operations can be carried out.

[0029] The present invention discloses the following technical effects:

[0030] This invention utilizes a horizontal clamping mechanism to clamp and precisely align two expansion bellows horizontally, and a vertical clamping mechanism to accurately position the end faces of the two expansion bellows vertically during downhole installation. Furthermore, a clamping and docking mechanism enables high-quality welding of the expansion bellows. This invention effectively achieves high-precision automated welding of expansion bellows in both horizontal and vertical directions, enabling precise pipe alignment and automated welding. This significantly improves welding accuracy, reduces worker workload, and ensures worker safety. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is a front view structural diagram of the present invention;

[0033] Figure 2 This is a schematic diagram of the structure during horizontal welding of the present invention;

[0034] Figure 3 This is a schematic diagram of the structure during vertical welding of the present invention;

[0035] Figure 4 This is a schematic diagram of the first circular guide rail structure of the present invention;

[0036] Figure 5 This is a schematic diagram of the second circular guide rail structure of the present invention;

[0037] Figure 6 This is a schematic diagram of the third circular guide rail structure of the present invention;

[0038] Figure 7 This is a partial structural diagram of the present invention during vertical welding;

[0039] The components include: 1. Horizontal clamping mechanism; 2. Vertical clamping mechanism; 3. Clamping docking mechanism; 4. Support frame; 11. Lifting frame; 12. X-shaped frame; 13. First hydraulic cylinder; 14. Top plate; 15. First support plate; 16. First circular guide rail; 17. First pneumatic gripper; 18. First moving ring; 21. Second support plate; 22. Second circular guide rail; 23. Second pneumatic gripper; 24. Second moving ring; 31. Third support plate; 32. Third circular guide rail; 33. Third pneumatic gripper; 34. Robotic arm; 35. Automated welding torch; 36. Third moving ring; 41. Linear guide rail. Detailed Implementation

[0040] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0042] Reference Figures 1-7 This invention provides an automated horizontal and vertical pipe welding device for expansion bellows, including a support 4 as a basic lifting frame. Horizontal clamping mechanisms 1 for horizontal positioning of the expansion bellows are respectively provided on both sides of the lower part of the support 4. A clamping and docking mechanism 3 for welding the interfaces of two expansion bellows is provided between the two horizontal clamping mechanisms 1. Vertical clamping mechanisms 2 for vertical positioning of the expansion bellows are respectively provided on the upper and lower sides of the clamping and docking mechanism 3. An adjustment mechanism for controlling the rotation angle of the clamping and docking mechanism 3 is rotatably connected to the clamping and docking mechanism 3. A driving mechanism is fixedly connected to the adjustment mechanism, and the driving mechanism is fixedly connected to the support 4.

[0043] The horizontal clamping mechanism 1 is used to horizontally position the expansion bellows; and the horizontal automated welding operation is realized through the clamping and docking mechanism 3.

[0044] The vertical clamping mechanism 2 is used to vertically position the expansion bellows and to realize vertical automated welding operation through the clamping and docking mechanism 3.

[0045] This invention enables horizontal positioning of two expansion bellows through a horizontal clamping mechanism 1, vertical positioning of two expansion bellows through a vertical clamping mechanism 2, and welding of two expansion bellows through a clamping and docking mechanism 3. This invention can effectively weld expansion bellows in both horizontal and vertical directions, improve the automation level of automatic pipe alignment and welding machinery, increase welding accuracy, reduce the labor intensity of workers, and ensure the safety of operators.

[0046] This invention achieves high-precision automated welding of expansion bellows in both horizontal and vertical directions through system integration and coordinated control.

[0047] The concepts of system integration and cooperative control: System integration refers to the combination of software, hardware, and communication technologies to solve information processing problems for users. The various separate parts of the integration were originally independent systems. Through system integration, these parts can work organically and coordinately to achieve overall benefits and optimization. Cooperative control is a control strategy that aims to achieve efficient system operation through the cooperation of multiple subsystems. In control systems, cooperative control theory is based on the idea of ​​overall optimization. By designing appropriate control strategies, it enables subsystems to cooperate and work together to maximize the performance of the entire system.

[0048] System integration and collaborative control are complementary. System integration provides the hardware and software infrastructure that enables subsystems to communicate and collaborate. Collaborative control, on the other hand, builds upon this foundation by designing control algorithms and strategies to achieve coordinated operation between subsystems, thereby reaching the overall optimization goal of the system.

[0049] This invention enables the horizontal clamping mechanism 1, the vertical clamping mechanism 2, and the clamping docking mechanism 3 to work together through system integration and collaborative control, thereby achieving high-precision automated welding of expansion bellows in both horizontal and vertical directions.

[0050] A further optimized design includes a horizontal clamping mechanism 1 comprising a lifting frame 11, within which X-shaped frames 12 are symmetrically arranged. One end of the X-shaped frames 12 is slidably connected to the bottom of the lifting frame 11, and the other end of the X-shaped frames 12 is slidably connected to a top plate 14. A first clamping part is provided at the end of the top plate 14 opposite to the X-shaped frames 12. The X-shaped frames 12 can drive the top plate 14 to rise and fall.

[0051] In a further optimized design, the piston end of a first hydraulic cylinder 13 is fixedly connected to one end of the X-frame 12 near the top plate 14. The fixed end of the first hydraulic cylinder 13 is fixedly connected to the bottom of the lifting frame 11, and the first hydraulic cylinder 13 is inclined. The extension and retraction of the piston end of the first hydraulic cylinder 13 drives one end of the X-frame 12 to move, and the extension or retraction of the X-frame 12 enables the X-frame 12 to stably drive the top plate 14 to rise and fall.

[0052] A further optimized design includes a first support plate 15 fixedly connected to the top plate 14. A fixed ring of a first circular guide rail 16 is fixedly connected within the first support plate 15. First pneumatic grippers 17 are symmetrically and fixedly connected to the inner wall of a first movable ring 18 within the first circular guide rail 16. The first pneumatic grippers 17 enable effective clamping and positioning of the horizontally positioned expansion bellows.

[0053] The design is further optimized. The clamping and docking mechanism 3 includes a third support plate 31 rotatably connected to the adjusting mechanism. A fixed ring of a third circular guide rail 32 is symmetrically and fixedly connected to the end of the third support plate 31 facing away from the adjusting mechanism. A third pneumatic gripper 33 is symmetrically and fixedly connected to the inner wall of a third moving ring 36 within the third circular guide rail 32. When the opposite ends of the two expansion bellows are tightly abutted, the two third pneumatic grippers 33 can effectively clamp and position the two expansion bellows, preventing them from separating and facilitating welding.

[0054] In a further optimized design, a robotic arm 34 is mounted on the end of the third support plate 31 away from the adjustment mechanism, and an automated welding torch 35 is mounted on the end of the robotic arm 34 away from the third support plate 31. The robotic arm 34 can effectively drive the automated welding torch 35 to perform stable welding at the welding position.

[0055] A robotic arm 34 is a mechanical device that can simulate the movements of a human arm and is commonly used for automated operations in industrial production. It can perform various tasks, such as grasping, handling, assembling, and welding, and can replace humans in hazardous environments, improving production efficiency and quality.

[0056] Robotic arms 34 typically include:

[0057] Actuator: Includes components such as hand, wrist, arm, and body; some also include a walking mechanism. Drive system: Commonly used types include hydraulic transmission, pneumatic transmission, electric transmission, and mechanical transmission.

[0058] Control system: It directs the robotic arm to move according to a prescribed program and memorizes the instructions given to the robotic arm by people.

[0059] Position detection device: controls the movement position of the robot arm's actuator and feeds back the actual position of the actuator to the control system at any time.

[0060] When the robotic arm 34 works in conjunction with an ABB robot and the automated welding torch 35 with a fiber laser multi-axis welding machine, it can perform automatic identification, positioning, and welding actions, resulting in high positioning accuracy, sensitive response, and shock resistance; thus improving the quality of welding.

[0061] Further optimizing the design, the vertical clamping mechanism 2 includes a second support plate 21 slidably connected to the bracket 4. A fixed ring of a second circular guide rail 22 is fixedly connected to the end of the second support plate 21 facing away from the bracket 4. Second pneumatic grippers 23 are symmetrically and fixedly connected to the inner wall of a second movable ring 24 within the second circular guide rail 22. The second pneumatic grippers 23 effectively clamp and position the vertically positioned expansion bellows.

[0062] In order to adjust the height of the second support plate 21, the piston end of the second hydraulic cylinder is fixedly connected to the second support plate 21, and the fixed end of the second hydraulic cylinder is fixedly connected to the bracket 4; the second support plate 21 is moved by the extension and retraction of the piston end of the second hydraulic cylinder, so that the second hydraulic cylinder can adjust the position of the second support plate 21.

[0063] Circular guideways are guide systems used for circular motion, typically consisting of precision circular guideways and ring segments. This type of guide system can achieve 360° or segmented motion and is suitable for a wide range of applications across various industries. The load range of circular guideways is typically between 0-9300N, and the speed range is between 0-5m / s.

[0064] When the circular guide rail is circular, the ring segment moves along the inner wall of the circular guide rail, causing the ring segment to move in a circle.

[0065] The circular guide rail achieves high precision through initial positioning and repeated positioning. Initial positioning is achieved by a servo-driven pulse-driven motor that moves the workstation to the vicinity of the positioning pin. During the secondary positioning, the side cylinder and solenoid valve are activated to extend the positioning cylinder, and then the positioning pin is rotated to perform secondary positioning of the workstation, thus achieving high-precision repeated positioning.

[0066] The scheme is further optimized. The adjustment mechanism includes a movable block slidably connected to the bracket 4. The end of the movable block facing the third support plate 31 is fixedly connected to the fixed end of the electric turntable. The movable end of the electric turntable is fixedly connected to the third support plate 31. The electric turntable drives the movable block to rotate, which in turn drives the third support plate 31 to rotate, allowing the third support plate 31 to be in a horizontal or vertical state. When the third support plate 31 is in a horizontal state, it can automatically weld horizontally placed expansion bellows; when the third support plate 31 is in a vertical state, it can automatically weld vertically placed expansion bellows.

[0067] Electric turntables are used to rotate various objects or workpieces. They are widely used in industrial automated production lines, logistics and warehousing systems, exhibition displays, and other fields. Driven by a motor, the electric turntable enables the object to rotate 360° on a horizontal plane, allowing people to observe or operate the object from different angles.

[0068] The working principle of an electric turntable mainly includes three aspects: motor drive, gear transmission, and control system.

[0069] Motor Drive: The core of an electric turntable is the motor, which converts electrical energy into mechanical energy to drive the turntable's rotation. Common motor types include DC motors and AC motors. DC motors control speed and direction by adjusting voltage or current, while AC motors achieve the same effect by changing the frequency and phase of the voltage. The motor is typically connected to the turntable via a shaft and transmission mechanism.

[0070] Gear drive: Gear drive is a commonly used transmission mechanism in electric turntables, used to convert the high-speed rotation of the motor into a relatively low-speed rotation of the turntable. It consists of one or more pairs of gears, one of which is connected to the motor shaft and is called the driving gear, while the other gear is connected to the turntable shaft and is called the driven gear. When the driving gear rotates, it transmits torque and speed through the gears, driving the driven gear and the turntable to rotate. The size and number of teeth of the gears can be designed according to needs to achieve the required speed and torque ratio.

[0071] Control System: Electric turntables typically require a control system to regulate their rotation direction, speed, and stopping. This control system can be as simple as using a switch to start and stop the motor, or as complex as using a computer or programming logic for precise control. In some applications, the rotation speed of the electric turntable can even be measured and adjusted in real time using sensors to achieve higher accuracy and stability.

[0072] A further optimized design includes a drive mechanism comprising a chain conveyor belt for controlling the vertical movement of the third support plate 31. The chain conveyor belt is installed on the side of the bracket 4 opposite to the third support plate 31, and a movable block is fixedly connected to the chain of the chain conveyor belt. The chain of the chain conveyor belt drives the movable block to rise or fall, which in turn drives the electric turntable to rise or fall, and the electric turntable drives the third support plate 31 to rise or fall.

[0073] Chain conveyor belts include:

[0074] Chain Structure: The chain is the main component of the chain conveyor belt, and it is usually composed of multiple chain links. Each chain link includes components such as inner chain plates, outer chain plates, pins, and rollers. The inner and outer chain plates are connected by pins, and the rollers are fitted onto the pins, allowing the chain to roll smoothly on the sprockets.

[0075] Metal mesh structure: The metal mesh is the load-bearing part of the chain conveyor belt, usually made of woven metal wire, which has good air permeability and wear resistance. The mesh size and shape of the metal mesh can be customized to meet the conveying requirements of different materials.

[0076] Connection Structure: The connection structure of chain conveyor belts typically uses plug-in plates or irregularly shaped connecting plates to connect the support rods to the chain. This connection method has good structural strength and load-bearing capacity, and the installation process is simple, saving labor.

[0077] Attachment Structure: To meet different conveying needs, chain conveyor belts can be equipped with various attachments, such as baffles, sidewalls, and support belts. These attachments can effectively prevent materials from slipping or spilling during conveying, improving conveying efficiency and safety.

[0078] Drive structure: Chain conveyor belts are typically driven by sprockets. The meshing method between the sprocket and the chain can be either chain plates meshing with sprocket teeth, or rollers (or sleeves) meshing with sprocket teeth. The rotation of the drive sprocket drives the chain in a cyclical motion, thereby achieving the conveying of materials.

[0079] Support structure: Chain conveyor belts require a support structure during operation to maintain the normal operating trajectory of the chain. The support structure can be a track or idler rollers, etc., which can bear the weight of the chain and materials and guide the direction of chain movement.

[0080] Tensioning Structure: To ensure the normal operation of the chain conveyor belt, a tensioning device is usually required to adjust the chain tension. The tensioning device can be a screw tensioner, spring tensioner, or counterweight tensioner, etc., which can automatically or manually adjust the chain tension to prevent the chain from becoming too loose or too tight.

[0081] Lubrication System: To reduce wear between the chain and sprockets, chain conveyor belts typically require a lubrication system. This system can be drip lubrication, spray lubrication, or oil bath lubrication, effectively reducing the coefficient of friction between the chain and sprockets and extending their service life. Protective Devices: To protect operator safety and prevent material spillage, chain conveyor belts usually require protective devices such as guards and barriers. These devices effectively prevent accidents and improve workplace safety.

[0082] Control System: Modern chain conveyors are typically equipped with a control system that enables automated operation and monitoring. The control system may include motor controllers, sensors, PLCs, and other devices, and can perform functions such as starting, stopping, speed adjustment, and fault diagnosis of the chain conveyor.

[0083] In order to enable the second support plate 21, the third support plate 31, and the movable block to move stably on the bracket 4, the bracket 4 is symmetrically and fixedly connected to the fixed end of the linear guide rail 41. The moving end of the linear guide rail 41 is fixedly connected to the second support plate 21, the third support plate 31, and the movable block. By moving the moving end of the linear guide rail 41 along the fixed end of the linear guide rail 41, the second support plate 21, the third support plate 31, and the movable block can move stably.

[0084] A guide rail is a mechanical component used to support and guide moving parts in reciprocating linear motion in a given direction. It plays a crucial role in modern industrial automation and precision machinery. Guide rails can be classified into various types, including linear guides, roller linear guides, cylindrical linear guides, and ball linear guides.

[0085] In order to enable the first pneumatic gripper 17, the second pneumatic gripper 23, and the third pneumatic gripper 33 to effectively clamp the expansion bellows, clamping force sensors are installed on the first pneumatic gripper 17, the second pneumatic gripper 23, and the third pneumatic gripper 33 respectively. By monitoring the clamping force through the clamping force sensors, the excessive deformation of the expansion bellows due to excessive clamping force can be effectively avoided.

[0086] An automated horizontal and vertical pipe welding method for expansion bellows includes the following steps:

[0087] S1. Determine the number of expansion bellows to be welded based on the length of the complex well section to be sealed downhole, and then weld all the expansion bellows in pairs by horizontal welding.

[0088] S2. Place the two expansion bellows into the two horizontal clamping mechanisms 1 respectively, and adjust the horizontal clamping mechanisms 1, that is, through the action of the first hydraulic cylinder 13, so that the central axes of the two expansion bellows are on the same central axis.

[0089] S3. Clean the bevels of the two expansion bellows to be welded, that is, remove oil, rust and other impurities from the bevels of the bellows to be welded to ensure welding quality.

[0090] S4. Insert the two expansion bellows into the clamping and docking mechanism 3, and leave a welding allowance between the weld bevels of the two expansion bellows; at this time, the first pneumatic gripper 17 and the third pneumatic gripper 33 move to effectively clamp and position the expansion bellows.

[0091] S5. Reference Figures 1-2 The horizontal automated welding is performed by clamping and docking mechanism 3; the first moving ring 18 of the first circular guide rail 16 drives the first pneumatic gripper 17 to rotate and the third moving ring 36 of the third circular guide rail 32 drives the third pneumatic gripper 33 to rotate, so that the first pneumatic gripper 17 and the third pneumatic gripper 33 can drive the expansion bellows to rotate, and then the robotic arm 34 drives the automated welding gun 35 to weld at the welding position.

[0092] S6. After welding is completed, the first pneumatic gripper 17 and the third pneumatic gripper 33 release the expansion bellows and take out the welded expansion bellows string. Then, repeat steps S2-S5 to obtain several sets of welded expansion bellows strings.

[0093] S7. Move the welding device to the wellhead and adjust it to the vertical welding mode to clamp and dock the mechanism; control the clamping and docking mechanism 3 to rotate 90° by adjusting the mechanism, that is, drive the movable block to rotate by the electric turntable, and drive the third support plate 31 to rotate 90°, so that vertical welding can be performed.

[0094] S8. First, lower one end of a welded expansion bellows string into the wellhead. Then, install the other end of the welded expansion bellows string onto the vertical clamping mechanism 2 located below. And clamp the welded expansion bellows string.

[0095] S9. Place another set of welded expansion bellows pipe strings on the vertical clamping mechanism 2 above the clamping and docking mechanism 3; and clamp the welded expansion bellows pipe strings.

[0096] S10. Clean the bevels at opposite ends of the two sets of welded expansion bellows pipe strings; that is, remove oil, rust and other impurities from the bevels to be welded; then, the second hydraulic cylinder is activated to leave a welding allowance between the opposite ends of the two expansion bellows pipe strings.

[0097] S11. Reference Figure 3 as well as Figure 7 Vertical automated welding is performed through the clamping and docking mechanism 3; the second moving ring 24 of the second circular guide rail 22 drives the second pneumatic gripper 23 to rotate, and the third moving ring 36 of the third circular guide rail 32 drives the third pneumatic gripper 33 to rotate, so that the second pneumatic gripper 23 and the third pneumatic gripper 33 can drive the expansion bellows to rotate, and then the robotic arm 34 drives the automated welding gun 35 to weld the position; after the welding is completed, the weld quality is inspected by a non-destructive testing device, and after it is confirmed to be qualified, it can be lowered into the well.

[0098] S12. After welding, the welded expansion bellows is lowered into the well through the wellhead. The vertical clamping mechanism 2 located below clamps the end of the expansion bellows extending out of the wellhead. That is, the second hydraulic cylinder is activated, causing the two second support plates 21 to move away from each other. Then, the third pneumatic gripper 33 is released, and the chain conveyor belt drives the third support plate 31 to rise. When the third support plate 31 approaches the second support plate 21 located above, the third pneumatic gripper 33 clamps the expansion bellows. At this time, the second pneumatic gripper 23 is released. Then, the chain conveyor belt drives the third support plate 31 to descend, pushing the welded expansion bellows into the wellhead. When the end of the expansion bellows extending out of the wellhead is between the second pneumatic gripper 23 and the third pneumatic gripper 33 located below, the vertical clamping mechanism 2 located below clamps the end of the expansion bellows extending out of the wellhead. Then, another set of welded expansion bellows is installed on the vertical clamping mechanism 2 located above, and welding continues.

[0099] S13. Repeat steps S10-S12 to complete the vertical welding and downhole installation of all expansion bellows; then subsequent downhole operations can be carried out.

[0100] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0101] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. An automated horizontal and vertical pipe welding device for expansion bellows, characterized in that: The system includes a support (4) as a basic lifting frame. The lower two sides of the support (4) are respectively provided with horizontal clamping mechanisms (1) for horizontal positioning of the expansion bellows. Between the two horizontal clamping mechanisms (1) is a clamping docking mechanism (3) for welding the interfaces of the two expansion bellows. The upper and lower sides of the clamping docking mechanism (3) are respectively provided with vertical clamping mechanisms (2) for vertical positioning of the expansion bellows. The clamping docking mechanism (3) is rotatably connected to an adjustment mechanism for controlling the rotation angle of the clamping docking mechanism (3). The adjustment mechanism is fixedly connected to a drive mechanism. The drive mechanism is fixedly connected to the support (4). The clamping and docking mechanism (3) includes a third support plate (31) rotatably connected to the adjustment mechanism. The third support plate (31) is symmetrically and fixedly connected to a third circular guide rail (32) at one end away from the adjustment mechanism. A third pneumatic gripper (33) is symmetrically and fixedly connected to the inner wall of the third moving ring (36) inside the third circular guide rail (32). A robotic arm (34) is installed on the end of the third support plate (31) away from the adjustment mechanism, and an automated welding gun (35) is installed on the end of the robotic arm (34) away from the third support plate (31). The vertical clamping mechanism (2) includes a second support plate (21) that is slidably connected to the bracket (4). The second support plate (21) is fixedly connected to a fixed ring of a second circular guide rail (22) at one end away from the bracket (4). A second pneumatic gripper (23) is symmetrically and fixedly connected to the inner wall of the second movable ring (24) inside the second circular guide rail (22).

2. The automated horizontal and vertical pipe welding device for expansion bellows according to claim 1, characterized in that: The horizontal clamping mechanism (1) includes a lifting frame (11), and X-shaped frames (12) are symmetrically arranged inside the lifting frame (11). One end of the X-shaped frame (12) is slidably connected to the bottom of the lifting frame (11), and the other end of the X-shaped frame (12) is slidably connected to a top plate (14). The top plate (14) is provided with a first clamping part at the end away from the X-shaped frame (12).

3. The automated horizontal and vertical pipe welding device for expansion bellows according to claim 2, characterized in that: The piston end of the first hydraulic cylinder (13) is fixedly connected to one end of the X-shaped frame (12) near the top plate (14). The fixed end of the first hydraulic cylinder (13) is fixedly connected to the bottom of the lifting frame (11). The first hydraulic cylinder (13) is set at an angle.

4. The automated horizontal and vertical pipe welding device for expansion bellows according to claim 2, characterized in that: The first clamping part includes a first support plate (15) fixedly connected to the top plate (14), a fixed ring of a first circular guide rail (16) fixedly connected inside the first support plate (15), and a first pneumatic gripper (17) symmetrically and fixedly connected to the inner wall of the first moving ring (18) inside the first circular guide rail (16).

5. The automated horizontal and vertical pipe welding device for expansion bellows according to claim 1, characterized in that: The adjustment mechanism includes a movable block that is slidably connected to the bracket (4). One end of the movable block facing the third support plate (31) is fixedly connected to the fixed end of the electric turntable. The movable end of the electric turntable is fixedly connected to the third support plate (31).

6. The automated horizontal and vertical pipe welding device for expansion bellows according to claim 5, characterized in that: The drive mechanism includes a chain conveyor belt for controlling the up and down movement of the third support plate (31). The chain conveyor belt is installed on the side of the bracket (4) away from the third support plate (31). The movable block is fixedly connected to the chain of the chain conveyor belt.

7. A method for automated horizontal and vertical butt welding of expansion bellows, based on the automated horizontal and vertical butt welding apparatus for expansion bellows according to any one of claims 1-6, characterized in that: Includes the following steps: S1. Determine the number of expansion bellows to be welded based on the length of the complex well section to be sealed downhole, and weld all expansion bellows in pairs by horizontal welding. S2. Place the two expansion bellows into the two horizontal clamping mechanisms (1) respectively, and adjust the horizontal clamping mechanisms (1) so that the central axes of the two expansion bellows are on the same central axis. S3. Clean the bevels of the two expansion bellows to be welded; S4. Insert the two expansion bellows into the clamping and docking mechanism (3) and leave a welding allowance between the weld bevels of the two expansion bellows; S5. Horizontal automated welding is performed using the clamping and docking mechanism (3); S6. After welding is completed, take out the welded expansion bellows, and then repeat steps S2-S5 to obtain several sets of welded expansion bellows strings. S7. Move the welding device to the wellhead and adjust it to the vertical welding mode to clamp the docking mechanism; S8. First, lower one end of a set of welded expansion bellows pipe strings into the wellhead, and then install the other end of the welded expansion bellows pipe strings onto the vertical clamping mechanism (2) located below. S9. Place another set of welded expansion bellows pipe strings on the vertical clamping mechanism (2) located above the clamping docking mechanism (3); S10. Clean the bevels at opposite ends of the two welded expansion bellows strings; S11. Vertical automated welding is performed through the clamping and docking mechanism (3), and then the weld quality is inspected with a non-destructive testing device. After confirming that it is qualified, it is lowered into the well. S12. After welding is completed, the welded expansion bellows is lowered into the well through the wellhead. The vertical clamping mechanism (2) located below clamps the end of the expansion bellows that extends out of the wellhead. Then, another set of welded expansion bellows strings is installed on the vertical clamping mechanism (2) located above, and welding continues. S13. Repeat steps S10-S12 to complete the vertical welding and downhole installation of all expansion bellows; then subsequent downhole operations can be carried out.

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