A laser-based device and method for preventing and treating long-distance pipeline welding defects

Abstract

The present invention discloses a laser-based device and method for preventing and treating long-distance pipeline welding defects, belonging to the technical field of pipeline welding. The device includes a welding power and power supply device, a welding master control device, and a motion device that moves along the circumference of the pipeline to be welded. The motion device carries a welding device I, a welding device II, and a weld scanning device. Both welding devices I and II are equipped with welding guns, each with a laser emitting device mounted on one side of the gun; welding device II is also equipped with an ultrasonic loader. The present invention uses laser calibration to improve the alignment between the welding guns. Laser scanning also improves the parallelism between the welding gun and the groove, reducing the risk of weld deviation. The weld scanning device scans the weld surface to promptly and comprehensively detect surface welding defects. Based on the location of the weld defect, the ultrasonic loader stirs or vibrates the molten pool to improve its fluidity and fill any unfused or undercut defects.

Description

Technical Field

[0001] The present invention mainly relates to the technical field of pipeline welding, and specifically to a laser-based device and method for preventing and treating welding defects in long-distance pipelines. Background Art

[0002] Ensuring weld quality is crucial in long-distance pipeline welding operations. Currently, the practical application of long-distance pipeline welding systems presents numerous challenges that require urgent resolution. Once the welding system is installed on the pipeline, factors such as measurement errors can make it difficult for the welding torch to maintain absolute parallelism with the pipe opening, leading to slight deviations. This necessitates fine-tuning of the welding torches during the welding process, ensuring that the two torches are aligned and parallel to the groove.

[0003] However, when welding pipes in all positions, some locations are difficult to operate and have poor visibility, which can easily lead to visual errors and large measurement errors. This can cause the welding gun to deviate from the weld, resulting in lack of fusion defects. Furthermore, due to deviations in pipe grooves and gaps, the welding gun's swing and amplitude must be manually adjusted to accommodate them. However, too small an amplitude can easily lead to lack of fusion on the sidewalls, while too large an amplitude can cause undercutting on the sidewalls, preventing the next weld layer from fully penetrating the defect, ultimately resulting in lack of fusion defects.

[0004] Therefore, it is necessary to develop a technology for preventing and treating welding defects in long-distance pipelines. Summary of the Invention

[0005] The technical solution of the present invention addresses the technical problem that the existing technical solutions are too simple, and provides a solution that is significantly different from the existing technology. It mainly provides a laser-based long-distance pipeline welding defect prevention and treatment device and method to solve the technical problem raised in the above background technology that the existing long-distance pipeline welding is more prone to unfusion defects.

[0006] The technical solution adopted by the present invention to solve the above technical problems is:

[0007] A laser-based device for preventing and treating long-distance pipeline welding defects includes a welding power and power supply device, a welding master control device, and a motion device that moves along the circumference of the pipeline to be welded. The motion device carries a welding device I, a welding device II, and a weld scanning device located between the two welding devices. Both welding devices I and II are equipped with welding guns, and a laser emitting device is installed on one side of the welding guns. The welding device II is also equipped with an ultrasonic loader for loading ultrasonic waves onto the welding wire II.

[0008] Furthermore, the welding device I and the welding device II both include a welding gun fixing rod, a welding gun, a welding gun wire feeding mechanism, a welding gun wire box, welding wire and a laser emitting device, wherein the welding gun fixing rod is fixed on the moving device; the welding gun is located near the port side of the pipe to be welded, and the welding gun is clamped and connected to the welding gun fixing rod; the welding gun wire feeding mechanism is located on one side of the welding gun fixing rod, and the welding gun wire feeding mechanism is located on one side of the welding gun fixing rod; the welding gun wire box is located on the top of the welding gun wire feeding mechanism; the welding gun in the welding device I is connected to the welding gun wire feeding mechanism through a welding wire tube; in the welding device II, the ultrasonic loader is located on one side of the welding gun wire feeding mechanism, and the ultrasonic loader is connected to the welding gun wire feeding mechanism through a welding wire tube, and the welding gun and the ultrasonic loader are connected through the welding wire tube.

[0009] Furthermore, the weld scanning device includes a weld scanning probe located between the two welding guns, and the weld scanning probe is connected to the motion device through a scanning device fixing rod.

[0010] Furthermore, the connection structure between the weld scanning probe and the scanning device fixing rod is provided with a height adjustment structure, which includes a ring body sleeved on the weld scanning probe, and a locking bolt threadedly connected to the ring body is passed through one side of the ring body.

[0011] Furthermore, four magnetic universal wheels are installed at the bottom of the movement device.

[0012] Furthermore, the two welding guns are respectively aligned with the magnetic universal wheels on both sides in the length direction of the pipe to be welded.

[0013] Furthermore, the motion device is an arc-shaped plate structure.

[0014] Furthermore, the motion device includes two halves connected by a plug-in structure, the plug-in structure includes an arc guide groove and an arc plate adaptably inserted into the arc guide groove, and the motion device is connected to a fastening bolt that passes through the arc guide groove to lock the arc plate.

[0015] The present invention also provides a laser-based method for preventing and treating long-distance pipeline welding defects, which is characterized by comprising the following steps:

[0016] S1. After the pipes to be welded are paired, turn on the two laser emitting devices and emit line lasers. Adjust the positions of the laser emitting devices and the welding gun to ensure that the line lasers emitted by the two laser emitting devices are in a straight line and the two welding wires are respectively on the line lasers emitted by the corresponding laser emitting devices;

[0017] S2. Start the weld scanning device to scan the situation inside the groove of the pipe to be welded and display it on the welding master control device. Adjust the two welding guns so that the laser line is parallel to the pipe groove before starting welding.

[0018] S3. During welding, adjust the welding gun according to the display of the welding master control device to ensure that the straight line formed by the two welding guns is always parallel to the edge of the groove, so as to prevent welding deviation and the generation of incomplete fusion defects;

[0019] S4. After each weld is completed, the weld scanning device scans the entire weld surface and transmits the scanning data and images to the welding master control device to identify and analyze the location of suspected lack of fusion defects and mark the corresponding welding location;

[0020] S5. When welding device II is about to weld to the welding position where the defect is located, turn on the ultrasonic loader to load ultrasonic waves on welding wire II, and use the ultrasonically loaded welding wire II to stir or vibrate the molten pool to improve the fluidity of the molten pool, thereby filling the area of ​​the unfused defect and eliminating the defect.

[0021] Furthermore, in step S1, the positions of the two laser emitting devices are first adjusted to ensure that the two welding wires are respectively on the straight lines of the line lasers emitted by the corresponding laser emitting devices; then one of the welding guns is adjusted to ensure that the line lasers emitted by the two laser emitting devices are on a straight line.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] (1) The present invention arranges a laser emitting device on one side of the welding gun, and uses the line laser emitted by the laser emitting device to calibrate the position of the welding gun, thereby ensuring that the two welding guns are in a straight line; at the same time, the straight line formed by the line lasers of the two welding guns can be displayed on the welding master control device through the weld seam scanning device for comparison with the area line formed by the pipeline welding groove. By adjusting the position of the welding guns to keep them parallel to each other, the probability of welding deviation is reduced, the occurrence of side wall unfusion is reduced, and the effect of preventing long-distance pipeline welding defects is achieved.

[0024] (2) The present invention is provided with a weld scanning device. After each weld is completed, the weld scanning device scans the entire surface of the weld and marks the location of suspected unfusion defects, so as to timely and comprehensively discover surface welding defects, including minor defects, and realize welding and detection at any time. And through the setting of the ultrasonic loader, when the welding gun welds to the location of suspected unfusion defects, the ultrasonic loader loads ultrasonic waves on the welding wire to stir the molten pool, improve the fluidity of the molten pool, fill the unfusion or undercut defects, and thus eliminate the unfusion defects, achieving the effect of eliminating long-distance pipeline welding defects, and realizing welding, detection and processing at any time, improving welding quality and reducing rework costs.

[0025] (3) In the optimized solution of the present invention, the motion device is set as a length-adjustable structure, and the position of the welding gun is limited. A height-adjustable structure is also set for the weld scanning device, so that the device can be applied to pipes of more different diameters.

[0026] The present invention will be explained in detail below with reference to the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the three-dimensional structure when the present invention is applied;

[0028] Figure 2 A schematic diagram of the three-dimensional structure from another perspective when the present invention is applied;

[0029] Figure 3 This is a schematic diagram of the three-dimensional structure of the motion device in Example 2;

[0030] Figure 4 is a longitudinal cross-sectional schematic diagram of the motion device in Example 2;

[0031] Figure 5 This is a schematic structural diagram of the height adjustment structure in Example 2.

[0032] Figure numerals: 1. Pipe to be welded; 2. Magnetic universal wheel; 3. Welding gun wire feeding mechanism II; 4. Welding gun wire box II; 5. Ultrasonic loader; 6. Welding gun fixing rod II; 7. Welding gun II; 8. Weld seam scanning probe; 9. Welding gun I; 10. Moving device; 101. Arc guide groove; 102. Arc plate; 103. Fastening bolt; 11. Scanning device fixing rod; 111. Ring body; 112. Locking bolt; 12. Laser emitting device II; 13. Laser emitting device I; 14. Welding gun fixing rod I; 15. Welding gun wire box I; 16. Welding gun wire feeding mechanism I. DETAILED DESCRIPTION

[0033] To facilitate understanding of the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. Several embodiments of the present invention are given in the drawings. However, the present invention can be implemented in different forms and is not limited to the embodiments described in the text. On the contrary, these embodiments are provided to make the content disclosed in the present invention more thorough and comprehensive.

[0034] It should be noted that when an element is referred to as being "fixed on" another element, it may be directly on the other element or there may be a central element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a central element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used in this article are for illustrative purposes only.

[0035] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly used by those skilled in the art to which the present invention pertains. The terminology used in the specification of the present invention is for the purpose of describing specific embodiments and is not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more of the related listed items.

[0036] Example 1: Please refer to the attached Figure 1 -Attached Figure 2 , a laser-based long-distance pipeline welding defect prevention and treatment device, comprising:

[0037] The moving device 10 is an arc-shaped plate structure, and four magnetic universal wheels 2 are installed at the bottom thereof for magnetic attraction to the surface of the pipe to be welded 1. The moving device 10 moves along the circumference of the pipe to be welded 1;

[0038] Welding device I, comprising: welding gun fixing rod I 14, welding gun I 9, welding gun wire feeding mechanism I 16, welding gun wire box I 15, laser emitting device I 13, welding wire I;

[0039] Welding device II, including: welding gun fixing rod II 6, welding gun II 7, welding gun wire feeding mechanism II 3, welding gun wire box II 4, laser emitting device II 12, ultrasonic loader 5, welding wire II;

[0040] The welding gun fixing rod Ⅰ14 and the welding gun fixing rod Ⅱ6 are respectively fixed on both sides of the motion device 10; the welding gun Ⅰ9 and the welding gun Ⅱ7 are both located near the end side of the pipe to be welded 1, the welding gun Ⅰ9 is clamped and connected to the welding gun fixing rod Ⅰ14, and the welding gun Ⅱ7 is clamped and connected to the welding gun fixing rod Ⅱ6; the welding gun wire feeding mechanism Ⅰ16 is located on one side of the welding gun fixing rod Ⅰ14, and the welding gun wire feeding mechanism Ⅱ3 is located on one side of the welding gun fixing rod Ⅱ6 (the connecting rod of the welding gun is integrated with the upper structure of the welding gun fixing rod and can be rotatably connected to the lower structure of the welding gun fixing rod. At the same time, a motor is installed on the top of the upper structure of the welding gun fixing rod to control the rotation of the upper structure of the welding gun fixing rod and drive the welding gun to adjust its position. Since the lower structure of the welding gun fixing rod is fixed, the two welding guns can be adjusted. The positions are almost fixed to each other, and only slight adjustments need to be made according to the pipeline, which can be met by rotation adjustment); the welding gun wire box I15 is located on the top of the welding gun wire feeding mechanism I16, and the welding gun wire box II4 is located on the top of the welding gun wire feeding mechanism II3; the laser emitting device I13 is connected to one side of the welding gun I9, and the laser emitting device II12 is connected to one side of the welding gun II7 (the laser emitting device is connected to the welding gun by a clamp, and the position of the laser emitting device can be adjusted by loosening the bolt of the clamp); the welding gun I9 is ​​connected to the welding gun wire feeding mechanism I16 through a welding wire tube; the ultrasonic loader 5 is located on one side of the welding gun wire feeding mechanism II3; the ultrasonic loader 5 is connected to the welding gun wire feeding mechanism II3 through a welding wire tube, and the welding gun II7 is connected to the ultrasonic loader 5 through a welding wire tube. The welding wire I passes through the welding gun wire box I 15 and enters the welding gun wire feeding mechanism I 16, and is then fed to the welding gun I 9; the welding wire II passes through the welding gun wire box II 4 and enters the welding gun wire feeding mechanism II 3, and then passes through the ultrasonic loader 5 and enters the welding gun II 7;

[0041] The weld scanning device includes a weld scanning probe 8 and a scanning device fixing rod 11. The weld scanning probe 8 is located between the welding gun I 9 and the welding gun II 7 and close to the end of the pipe 1 to be welded. The weld scanning probe 8 is fixedly connected to the motion device 10 through the scanning device fixing rod 11.

[0042] Welding power and power supply unit (not shown in the figure), which provides power and power for all movements of the above devices;

[0043] The welding master control device (not shown in the figure) controls all movements and operations of the motion device 10, welding device I, welding device II and weld scanning device.

[0044] A laser-based method for preventing and treating long-distance pipeline welding defects comprises the following steps:

[0045] (1) After the first pair of pipes to be welded is completed, turn on the laser emitting device I13 and the laser emitting device II12 and emit the line laser, adjust the positions of the laser emitting device I13 and the laser emitting device II12 to ensure that the welding wire I is on the line laser straight line emitted by the laser emitting device I13 and the welding wire II is on the line laser straight line emitted by the laser emitting device II12; then adjust the welding gun II7 to ensure that the line laser emitted by the laser emitting device I13 and the line laser emitted by the laser emitting device II12 are on the same straight line;

[0046] (2) Start the weld scanning probe 8, scan the situation inside the groove of the pipe 1 to be welded and display it on the welding master control device, adjust the welding gun I 9 and welding gun II 7 so that the line laser straight line is parallel to the pipe groove, and then start welding;

[0047] (3) During welding, adjust welding gun II7 according to the display of the welding master control device to ensure that the straight line formed by welding guns I9 and II7 is always parallel to the edge of the groove, so as to prevent welding deviation and the generation of incomplete fusion defects;

[0048] (4) After each weld is completed, the weld scanning probe 8 scans the entire weld surface, and transmits the scanning data and image to the welding master control device, manually identifies and analyzes the location of suspected lack of fusion defects, and marks the corresponding welding position;

[0049] (5) When the welding device II is about to weld to the welding position where the defect is located, the ultrasonic loader 5 is turned on to load ultrasonic waves on the welding wire II. The ultrasonically loaded welding wire II is used to stir or vibrate the molten pool to improve the fluidity of the molten pool, thereby filling the area of ​​the unfused defect and eliminating the defect.

[0050] Example 2: This example differs from Example 1 in that:

[0051] Please refer to the attached Figure 3 -Attached Figure 4 In this embodiment, the length of the movement device 10 is adjustable. The specific structure is:

[0052] The motion device 10 comprises two halves connected by a plug-in structure, with welding devices I and II located on each half. The plug-in structure includes an arcuate guide groove 101 and an arcuate plate 102 that fits snugly into the groove. Fastening bolts 103 extending through the groove 101 are connected to the motion device 10 to lock the arcuate plate 102, thereby maintaining the adjustable length of the motion device 10. By adjusting the length of the motion device 10, the spacing between the magnetic universal wheels 2 on both sides can be adjusted, making the motion device 10 applicable to a wider range of pipe diameters.

[0053] The welding guns I9 and II7 are aligned with the magnetic universal wheels 2 on either side along the length of the pipe 1 to be welded, and the working ends of the welding guns I9 and II7 are flush with the bottom of the magnetic universal wheels 2. Therefore, when the length of the motion device 10 is adjusted to any position, as long as the magnetic universal wheels 2 are attached to the surface of the pipe 1 to be welded, the working ends of the welding guns I9 and II7 can contact the groove, without the need to raise or lower the welding guns I9 and II7, making it more convenient to use.

[0054] Please refer to the attached Figure 5 The connection between the weld scanning probe 8 and the scanning device fixing rod 11 is equipped with a height adjustment mechanism to accommodate pipes of varying diameters. The height adjustment mechanism specifically includes a ring body 111 that fits over the weld scanning probe 8 and has a locking bolt 112 threadedly connected to one side of the ring body 111.

[0055] Other details are the same as those in the first embodiment.

[0056] The above description of the present invention is exemplified in conjunction with the accompanying drawings. It is obvious that the specific implementation of the present invention is not limited to the above-mentioned method. As long as such non-substantial improvements are made using the method concept and technical solution of the present invention, or the concept and technical solution of the present invention are directly applied to other occasions without improvement, they are all within the scope of protection of the present invention.

Claims

1. A laser-based device for preventing and treating long-distance pipeline welding defects, characterized by: The invention comprises a welding power and power supply device, a welding master control device and a motion device (10) that moves along the circumferential direction of a pipe to be welded (1), wherein the motion device (10) carries a welding device I, a welding device II and a weld scanning device located between the two welding devices, wherein the welding device I and the welding device II are both provided with welding guns, and a laser emitting device is installed on one side of the welding guns; the welding device II is also provided with an ultrasonic loader (5) for loading ultrasonic waves onto the welding wire II; The welding device I and the welding device II both include a welding gun fixing rod, a welding gun, a welding gun wire feeding mechanism, a welding gun wire box, welding wire and a laser emitting device, wherein the welding gun fixing rod is fixed to the motion device (10); the welding gun is located near the end side of the pipe to be welded (1), and the welding gun is clamped and connected to the welding gun fixing rod; the welding gun wire feeding mechanism is located on one side of the welding gun fixing rod; the welding gun wire box is located on the top of the welding gun wire feeding mechanism; the welding gun in the welding device I is connected to the welding gun wire feeding mechanism through a welding wire tube; in the welding device II, the ultrasonic loader (5) is located on one side of the welding gun wire feeding mechanism, and the ultrasonic loader (5) is connected to the welding gun wire feeding mechanism through a welding wire tube, and the welding gun is connected to the ultrasonic loader (5) through the welding wire tube; After the pipes to be welded (1) are paired, the positions of the two laser emitting devices are adjusted to ensure that the two welding wires are on the straight lines of the laser lines emitted by the corresponding laser emitting devices; then one of the welding guns is adjusted to ensure that the laser lines emitted by the two laser emitting devices are on the same straight line; The position of the welding gun is calibrated using the line lasers emitted by two laser emitting devices to ensure that the two welding guns are in a straight line; at the same time, the straight line formed by the line lasers of the two welding guns can be displayed on the welding master control device through the weld seam scanning device for comparison with the area line formed by the pipeline welding groove, and the position of the welding guns can be adjusted to keep them parallel to each other.

2. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 1 is characterized by: The weld scanning device comprises a weld scanning probe (8) located between two welding guns, and the weld scanning probe (8) is connected to the motion device (10) via a scanning device fixing rod (11).

3. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 2 is characterized in that: The connection structure between the weld scanning probe (8) and the scanning device fixing rod (11) is provided with a height adjustment structure, wherein the height adjustment structure comprises a ring body (111) sleeved on the weld scanning probe (8), and a locking bolt (112) threadedly connected to the ring body (111) is passed through one side of the ring body (111).

4. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 1 is characterized by: Four magnetic universal wheels (2) are installed at the bottom of the motion device (10).

5. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 4 is characterized in that: The two welding guns are respectively aligned with the magnetic universal wheels (2) on both sides in the length direction of the pipe (1) to be welded.

6. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 1 is characterized in that: The motion device (10) is in the form of an arc-shaped plate structure.

7. The laser-based long-distance pipeline welding defect prevention and treatment device according to claim 6 is characterized by: The motion device (10) comprises two halves connected by a plug-in structure, wherein the plug-in structure comprises an arc-shaped guide groove (101) and an arc-shaped plate (102) adapted to be inserted into the arc-shaped guide groove (101), and a fastening bolt (103) is connected to the motion device (10) and passes through the arc-shaped guide groove (101) to lock the arc-shaped plate (102).

8. A laser-based method for preventing and treating long-distance pipeline welding defects, using the laser-based device for preventing and treating long-distance pipeline welding defects according to claim 1, characterized in that: The steps include: S1. After the pipes (1) to be welded are paired, two laser emitting devices are turned on and emit line lasers, and the positions of the laser emitting devices and the welding gun are adjusted to ensure that the line lasers emitted by the two laser emitting devices are on a straight line, and the two welding wires are respectively on the line lasers emitted by the corresponding laser emitting devices; S2. Start the weld scanning device, scan the situation inside the groove of the pipe (1) to be welded and display it on the welding master control device, adjust the two welding guns so that the line laser line is parallel to the pipe groove, and then start welding; S3. During welding, adjust the welding gun according to the display of the welding master control device to ensure that the straight line formed by the two welding guns is always parallel to the edge of the groove, so as to prevent welding deviation and the generation of incomplete fusion defects; S4. After each weld is completed, the weld scanning device scans the entire weld surface and transmits the scanning data and images to the welding master control device to identify and analyze the location of suspected lack of fusion defects and mark the corresponding welding location; S5. When the welding device II is about to weld to the welding position where the defect is located, the ultrasonic loader (5) is turned on to load ultrasonic waves on the welding wire II, and the welding wire II loaded with ultrasonic waves is used to stir or vibrate the molten pool to improve the fluidity of the molten pool, thereby filling the area of ​​the unfused defect and eliminating the defect.

9. The laser-based method for preventing and treating long-distance pipeline welding defects according to claim 8, characterized in that: In step S1, first adjust the positions of the two laser emitting devices to ensure that the two welding wires are respectively on the straight lines of the line lasers emitted by the corresponding laser emitting devices; then adjust one of the welding guns to ensure that the line lasers emitted by the two laser emitting devices are on a straight line.

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