Pipeline all-position laser rotating electric arc composite automatic welding device and method

Abstract

The invention provides a pipeline all-position laser rotating electric arc composite automatic welding device and method. The device comprises a flexible guide rail, a welding trolley, a rotating electric arc welding gun module, a laser module, a sensor module and a controller. The flexible guide rail is annularly arranged and tightly attached to the pipeline and provides a moving path for the welding trolley. The welding vehicle is movably arranged on the flexible guide rail; the rotary arc welding gun module, the laser module and the sensor module are sequentially and adjustably arranged at the front end of the welding vehicle in the circumferential direction of the pipeline; the welding trolley, the rotary arc welding gun module, the laser module and the sensor module are electrically connected with the controller. Two heat sources of laser and rotating arc synergistically act on the same molten pool, the molten pool is deepened by the laser, the melting width is widened by the rotating arc, a large weld depth-to-width ratio is jointly molded, and the distribution uniformity of weld alloy elements is improved through the quenching and tempering treatment of the laser on weld metal and the stirring effect of the molten pool of the rotating arc. And the welding speed and the welding quality are greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of pipeline welding, and in particular to a pipeline all-position laser rotary arc composite automatic welding device and method. Background Art

[0002] Recently, with the increasing mileage of long-distance pipelines, and the gradual development of pipe materials towards large diameter, high-grade steel, and deep wall thickness, welding work has been faced with huge challenges.

[0003] The traditional arc is the main method for all-position welding of pipelines and is widely used. However, it has the disadvantages of small penetration depth, concentrated heat, large heat-affected zone, easy to cause welding deformation, and welding quality problems such as porosity and undercut, and slow welding speed.

[0004] When laser is used as a single heat source, although it has the advantages of deep melting, fine heat source, and high energy density, its bridging ability is poor and it requires high assembly accuracy of welding materials, which limits its application in the field of long-distance pipeline welding.

[0005] Based on the above background and current situation, the present invention innovatively integrates the dual advantages of rotating arc and laser, and designs a pipeline all-position laser rotating arc composite automatic welding device and method, which effectively overcomes the respective shortcomings of traditional single arc and single laser. Through the synergistic effect of two heat sources on the same molten pool, the laser deepens the molten pool, and the rotating arc widens the molten width, together shaping a larger weld depth-to-width ratio, and the laser performs tempering treatment on the weld metal, and the molten pool stirring effect of the rotating arc improves the uniformity of the distribution of alloy elements in the weld, effectively reduces welding defects, and greatly improves the welding speed and welding quality, which is of great significance to promoting the welding technology of my country's long-distance pipelines.

[0006] In view of this, the present invention is proposed. Summary of the invention

[0007] The purpose of the present invention is to provide a pipeline all-position laser rotary arc hybrid automatic welding device and method to solve the technical problems of the welding device in the prior art that the heat source is single and the welding performance is limited due to design defects. The various technical effects that can be produced by the preferred technical solution among the various technical solutions provided by the present invention are described in detail below.

[0008] To achieve the above object, the present invention provides the following technical solutions:

[0009] The present invention provides a pipeline all-position laser rotary arc composite automatic welding device and method, comprising a flexible guide rail, a welding vehicle, a rotary arc welding gun module, a laser module, a sensor module and a controller; the flexible guide rail is arranged around and closely attached to the pipeline, and provides a moving path for the welding vehicle; the welding vehicle is movably arranged on the flexible guide rail; the rotary arc welding gun module, the laser module and the sensor module are adjustably arranged at the front end of the welding vehicle in sequence along the circumference of the pipeline; the welding vehicle, the rotary arc welding gun module, the laser module and the sensor module are electrically connected to the controller respectively.

[0010] Preferably, the flexible guide rail comprises a flexible track, a quick locking mechanism and a swallow-wing spring locking mechanism;

[0011] The free ends of the flexible rails are connected via the quick-locking mechanism to form a continuous and closed annular structure;

[0012] There are multiple swallow-wing spring locking mechanisms, which are arranged sequentially on the inner wall surface of the flexible track along the circumference of the track.

[0013] Preferably, the welding vehicle comprises a base, an arc-shaped slide, a traveling mechanism, a locking mechanism, a horizontal adjustment mechanism and a vertical adjustment mechanism;

[0014] The walking mechanism is arranged below the base and is used to drive the welding vehicle to move along the moving path of the flexible track;

[0015] The locking mechanism is arranged below the base and is locked with the flexible guide rail;

[0016] The horizontal adjustment mechanism is arranged on the base, the vertical adjustment mechanism is connected to the movable end of the horizontal adjustment mechanism, and the arc-shaped slide is connected to the movable end of the vertical adjustment mechanism.

[0017] Preferably, an arc-shaped slide table is provided with an arc-shaped slide groove, and a plurality of sliders are slidably arranged in the arc-shaped slide groove. The sliders are locked with the arc-shaped slide groove by tightening screws, and the rotary arc welding gun module, the laser module and the sensor module are respectively connected to the sliders.

[0018] Preferably, the rotary arc welding gun module comprises a rotary arc welding gun posture adjustment mechanism and a rotary arc welding gun, the rotary arc welding gun is connected to the slider via the rotary arc welding gun posture adjustment mechanism, and the rotary arc welding gun posture adjustment mechanism is used to adjust the posture of the rotary arc welding gun.

[0019] Preferably, the rotary arc welding gun posture adjustment mechanism comprises a rotary arc welding gun rotary slide and a rotary arc welding gun clamping mechanism;

[0020] The rotary slide of the rotary arc welding gun comprises a first fixed circular plate, a first fixed knob, a first rotating circular plate and a first locking assembly, wherein the first fixed circular plate is connected to the sliding block, the first rotating circular plate is rotatably connected to the first fixed circular plate through a rotating column, and the first fixed knob controls the unlocking or locking between the first rotating circular plate and the first fixed circular plate; the first locking assembly is arranged on the first rotating circular plate;

[0021] The rotary arc welding gun clamping mechanism includes a clamping platform, a first quick-release plate and a fixed screw. The clamping platform is detachably connected to the first rotating circular plate through the first quick-release plate, and the first locking knob of the first locking assembly controls the unlocking or locking between the quick-release plate and the rotating circular plate. The clamping platform has a clamping cavity for clamping the rotary arc welding gun, one side of the clamping cavity is open, and the clamping force of the clamping cavity is adjusted by the fixed screw.

[0022] Preferably, the laser module comprises a laser quick-release mechanism, a laser head and a laser;

[0023] The laser quick-release mechanism comprises a fixed square plate, a quick-release square plate and a third locking assembly, wherein the fixed square plate is connected to the slider, a quick-release hole is provided on the fixed square plate, a quick-release column adapted to the quick-release hole is provided on the quick-release square plate, and the unlocking or locking between the fixed square plate and the quick-release square plate is controlled by a rebound quick-release button of the third locking assembly;

[0024] The laser head is mounted on the quick-release square plate and connected to the laser via an optical fiber; the laser focus diameter of the laser head is 0.2 mm, and the laser power is 2000W-6000W.

[0025] Preferably, the sensor module includes a sensor posture adjustment mechanism, a laser sensor and a tilt sensor;

[0026] The laser sensor is arranged on the slider through a sensor posture adjustment mechanism, and is used to scan the weld and obtain weld height and center position information;

[0027] The inclination sensor is arranged on the welding vehicle and is used for monitoring the position of the welding vehicle in real time.

[0028] Preferably, the sensor posture adjustment mechanism comprises a sensor rotating slide and a sensor clamping mechanism;

[0029] The sensor rotating slide comprises a second fixed circular plate, a second fixed knob, a second rotating circular plate and a second locking assembly, wherein the second fixed circular plate is connected to the slider, the second rotating circular plate is rotatably connected to the second fixed circular plate through a rotating column, and the second fixed knob controls the unlocking or locking between the second rotating circular plate and the second fixed circular plate; the second locking assembly is arranged on the second rotating circular plate;

[0030] The sensor clamping mechanism includes a clamping seat and a second quick-release plate, the clamping seat is detachably connected to the second rotating circular plate through the second quick-release plate, and the second locking knob of the second locking assembly controls the unlocking or locking between the second quick-release plate and the second rotating circular plate; the clamping seat is used to clamp and fix the laser sensor.

[0031] A pipeline all-position laser rotary arc composite automatic welding method comprises the following steps:

[0032] S1: Butt two connected pipes and perform pre-welding treatment;

[0033] S2: Install and adjust the flexible track on the outer wall of the pipeline;

[0034] S3: Lock the welding vehicle on the flexible track, install the laser module, the rotating arc welding gun module and the sensor module on the arc slide, and adjust the position and posture;

[0035] S4: Control the welding vehicle to go around the pipeline, and the laser sensor scans the weld in a static scanning mode to obtain weld information and send it to the controller; the controller divides the pipeline into multiple areas and generates corresponding welding planning schemes;

[0036] S5: Control the welding vehicle to return to the welding starting point, adjust the rotation radius and rotation frequency of the rotating arc, start welding in half a cycle, and the horizontal adjustment mechanism and the vertical adjustment mechanism work together to control the swing width and swing frequency of the laser beam and the rotating arc, so that the laser beam and the rotating arc act on the weld at the same time to perform welding operations;

[0037] S6: During the welding process, the inclination sensor detects the position of the welding vehicle in real time and adjusts the welding parameters according to the position information;

[0038] S7: After completing half of the welding work, the welding vehicle returns to the welding starting point and prepares to start the welding work of the other half of the cycle;

[0039] S8: Repeat steps S5 to S7 until the root welding, filling welding and cap welding of the entire pipeline are completed.

[0040] The preferred technical solution of the present invention can at least produce the following technical effects:

[0041] The present invention effectively avoids the technical problems that the heat source of the welding device in the prior art is single and the welding performance is limited due to design defects. The present invention provides a pipeline full-position laser rotary arc composite automatic welding device, and the present invention provides a pipeline full-position laser rotary arc composite automatic welding device and method, including a flexible guide rail, a welding vehicle, a rotary arc welding gun module, a laser module, a sensor module and a controller; the flexible guide rail is arranged around and close to the pipeline, and provides a moving path for the welding vehicle; the welding vehicle is movably arranged on the flexible guide rail; the rotary arc welding gun module, the laser module and the sensor module are sequentially adjustable along the circumference of the pipeline at the front end of the welding vehicle; the welding vehicle, the rotary arc welding gun module, the laser module and the sensor module are electrically connected to the controller respectively. The present invention realizes automatic welding of the pipeline in all positions through the combination of the flexible guide rail and the welding vehicle, and the flexible adjustment of the laser module, the rotary arc welding gun module and the sensor module, without manual intervention, and improves welding efficiency. Moreover, through the synergistic effect of the laser module and the rotating arc welding gun module, that is, through the synergistic effect of the two heat sources of laser and rotating arc on the same molten pool, the laser deepens the molten pool, and the rotating arc widens the molten width, together creating a larger weld depth-to-width ratio. The laser performs tempering treatment on the weld metal, and the molten pool stirring effect of the rotating arc improves the uniformity of the distribution of alloy elements in the weld, effectively reduces welding defects, and greatly improves the welding speed and welding quality, which is of great significance to promoting the welding technology of my country's long-distance pipelines. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0043] Figure 1 It is a structural schematic diagram of a pipeline all-position laser rotary arc composite automatic welding device provided by the present invention;

[0044] Figure 2 It is a structural schematic diagram of a welding vehicle, a rotary arc welding gun module, a laser module and a sensor module of a pipeline all-position laser rotary arc composite automatic welding device provided by the present invention;

[0045] Figure 3 It is a structural schematic diagram of a flexible guide rail of a pipeline all-position laser rotary arc composite automatic welding device provided by the present invention;

[0046] Figure 4 It is a structural schematic diagram of an arc slide table of a pipeline all-position laser rotary arc composite automatic welding device provided by the present invention;

[0047] Figure 5 It is a structural schematic diagram of a rotary arc welding gun posture adjustment mechanism of a pipeline all-position laser rotary arc hybrid automatic welding device provided by the present invention;

[0048] Figure 6 It is a structural schematic diagram of a sensor rotary slide of a pipeline all-position laser rotary arc composite automatic welding device provided by the present invention;

[0049] Figure 7 It is a structural schematic diagram of a laser quick-release mechanism of a pipeline all-position laser rotary arc composite automatic welding device provided by the present invention;

[0050] Figure 8 It is a schematic diagram of the swing of welding heat source;

[0051] Fig. 9 It is a schematic diagram of pipeline partitioning;

[0052] Fig.10 The present invention provides a schematic structural diagram of an adjustment component of an MA400 welding gun of a pipeline all-position laser rotary arc composite automatic welding device.

[0053] In the figure:

[0054] 1. Flexible guide rail; 11. Flexible track; 12. Quick lock mechanism; 13. Swallow-wing spring locking mechanism; 14. Rack;

[0055] 2. Welding vehicle; 21. Base; 22. Arc slide; 221. Arc slide; 222. Sliding block; 223. Fastening screw rod; 23. Traveling mechanism; 231. First moving wheel set; 232. Second moving wheel set; 24. Locking mechanism; 25. Horizontal adjustment mechanism; 26. Vertical adjustment mechanism;

[0056] 3. Rotating arc welding gun module; 31. Rotating arc welding gun; 311. Positioning wheel; 312. Cam; 313. Position indicator; 32. First fixed circular plate; 33. First fixed knob; 34. First rotating circular plate; 35. First locking assembly; 36. First locking knob; 37. Clamping table; 38. First quick release plate; 39. Fixed screw rod;

[0057] 4. Laser module; 41. Laser head; 42. Fixed square plate; 421. Quick release hole; 43. Quick release square plate; 431. Quick release column; 44. Rebound quick release button;

[0058] 5. sensor module; 51. laser sensor; 52. second fixed circular plate; 53. second fixed knob; 54. second rotating circular plate; 55. second locking assembly; 56. second locking knob; 57. clamping seat; 58. second quick release plate;

[0059] 6. Pipeline. DETAILED DESCRIPTION

[0060] To make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be described in detail below. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other implementation methods obtained by ordinary technicians in this field without creative work belong to the scope of protection of the present invention.

[0061] like Figure 1-Figure 9 As shown, the present invention provides a pipeline 6 full-position laser rotary arc hybrid automatic welding device, and the present invention provides a pipeline 6 full-position laser rotary arc hybrid automatic welding device and method, including a flexible guide rail 1, a welding vehicle 2, a rotary arc welding gun module 3, a laser module 4, a sensor module 5 and a controller. The flexible guide rail 1 is arranged around and closely attached to the pipeline 6, and provides a moving path for the welding vehicle 2. The welding vehicle 2 is movably arranged on the flexible guide rail 1. The rotary arc welding gun module 3, the laser module 4 and the sensor module 5 are sequentially adjustable along the circumference of the pipeline 6 at the front end of the welding vehicle 2. The welding vehicle 2, the rotary arc welding gun module 3, the laser module 4 and the sensor module 5 are electrically connected to the controller respectively.

[0062] Through the combination of the flexible guide rail 1 and the welding vehicle 2, and the flexible adjustment of the rotating arc welding gun module 3, the laser module 4 and the sensor module 5, the automatic welding of the pipeline 6 in all positions is realized without manual intervention, thereby improving the welding efficiency. Moreover, through the synergistic effect of the laser module 4 and the rotating arc welding gun module 3, that is, through the synergistic effect of the two heat sources of laser and rotating arc on the same molten pool, the laser deepens the molten pool, and the rotating arc widens the molten width, jointly shaping a larger weld depth-to-width ratio, and the laser performs quenching and tempering treatment on the weld metal, and the molten pool stirring effect of the rotating arc improves the uniformity of the distribution of the alloy elements in the weld, effectively reduces welding defects, and greatly improves the welding speed and welding quality, which is of great significance to promoting the welding technology of my country's long-distance pipeline 6.

[0063] As an optional implementation, Figure 1 , 3 As shown, the flexible guide rail 1 includes a flexible rail 11, a quick lock mechanism 12 and a swallow-wing spring locking mechanism 13. The free ends of the flexible rail 11 are connected by the quick lock mechanism 12 to form a continuous and closed annular structure. There are multiple swallow-wing spring locking mechanisms 13, which are arranged on the inner wall surface of the flexible rail 11 in sequence along the circumference of the flexible rail 11.

[0064] The swallow-wing spring locking mechanism 13 is in press contact with the pipe 6 so that the flexible track 11 is firmly connected to the outer wall of the pipe 6. The clamping force between the flexible track 11 and the pipe 6 can also be adjusted so that pipes 6 of different diameters can be firmly clamped. The specific structures of the flexible track 11, the quick locking mechanism 12 and the swallow-wing spring locking mechanism 13 are prior art and will not be described in detail here.

[0065] As an optional implementation, Figure 1 , 2 As shown, the welding vehicle 2 includes a base 21, an arc-shaped slide 22, a traveling mechanism 23, a locking mechanism 24, a horizontal adjustment mechanism 25, and a vertical adjustment mechanism 26. The traveling mechanism 23 is arranged below the base 21, and is used to drive the welding vehicle 2 to move along the moving path of the flexible track 11. The locking mechanism 24 is arranged below the base 21, and is locked with the flexible guide rail 1. The horizontal adjustment mechanism 25 is arranged on the base 21, the vertical adjustment mechanism 26 is connected to the movable end of the horizontal adjustment mechanism 25, and the arc-shaped slide 22 is connected to the movable end of the vertical adjustment mechanism 26.

[0066] Furthermore, the traveling mechanism 23 includes a first moving wheel set 231 and a second moving wheel set 232. The first moving wheel set 231 is tightly fitted with the outer wall of the pipe 6 so that the welding vehicle 2 can stably move along the surface of the pipe 6. An annular rack 14 is provided on the outer wall of the flexible track 11 to serve as a moving path for the welding vehicle 2. The second moving wheel set 232 is meshed with the rack 14 so that the welding vehicle 2 can move accurately along the rack 14. The driving working principle of the traveling mechanism 23 is the prior art and will not be described in detail here.

[0067] The locking mechanism 24 is disposed on the first moving wheel set 231, and is used to clamp the flexible guide rail 1, so that the welding vehicle 2 is stably maintained on the flexible track 11, and moves circumferentially along the pipe 6, so as to realize the welding operation around the pipe 6. The specific structure of the locking mechanism is prior art, and will not be described in detail here.

[0068] The horizontal adjustment mechanism 25 adjusts the position of the vertical adjustment mechanism 26 in the horizontal direction, thereby adjusting the position of the rotary arc welding gun module 3, the laser module 4 and the sensor module 5 in the horizontal direction. The vertical adjustment mechanism 26 adjusts the position of the arc slide 22 in the vertical direction, thereby adjusting the position of the rotary arc welding gun module 3, the laser module 4 and the sensor module 5 in the vertical direction. The horizontal adjustment mechanism 25 and the vertical adjustment mechanism 26 together form a two-axis mechanism, so that the rotary arc welding gun 31 of the rotary arc welding gun module 3 and the laser head 41 of the laser module 4 can be adjusted in both horizontal and vertical directions to achieve four-way movement. Among them, the specific structures of the horizontal adjustment mechanism 25 and the vertical adjustment mechanism 26 are prior art and are not described in detail here.

[0069] As an optional implementation, Figure 1 , 4 As shown, an arc-shaped slide 22 is provided on the arc-shaped slide 22, and a plurality of sliders 222 are slidably arranged in the arc-shaped slide 221. The sliders 222 are locked with the arc-shaped slide 221 by tightening the screw rods 223, and the rotary arc welding gun module 3, the laser module 4 and the sensor module 5 are respectively connected to the sliders 222.

[0070] The slider 222 slides along the arc path of the arc slot 221, driving the rotary arc welding gun module 3, laser module 4 and sensor module 5 connected thereto to move. The position and posture of the rotary arc welding gun module 3, laser module 4 and sensor module 5 can be adjusted according to usage requirements.

[0071] When the slider 222 slides to the desired position, the slider 222 can be firmly locked on the arc-shaped slide groove 221 by tightening the fastening screw 223, thereby preventing the rotating arc welding gun module 3, the laser module 4 and the sensor module 5 from accidentally moving or deviating during the welding process.

[0072] As an optional implementation, Figure 1 , 5 As shown, the rotary arc welding gun module 3 includes a rotary arc welding gun 31 posture adjustment mechanism and the rotary arc welding gun 31 . The rotary arc welding gun 31 is connected to the slider 222 via the rotary arc welding gun 31 posture adjustment mechanism. The rotary arc welding gun 31 posture adjustment mechanism is used to adjust the posture of the rotary arc welding gun 31 .

[0073] As an optional embodiment, the posture adjustment mechanism of the rotary arc welding gun 31 includes a rotary slide of the rotary arc welding gun 31 and a clamping mechanism of the rotary arc welding gun 31 .

[0074] The rotary slide of the rotary arc welding gun 31 includes a first fixed circular plate 32, a first fixed knob 33, a first rotating circular plate 34 and a first locking assembly 35. The first fixed circular plate 32 is connected to the slider 222. The first rotating circular plate 34 is rotatably connected to the first fixed circular plate 32 through a rotating column, and the first fixed knob 33 controls the unlocking or locking between the first rotating circular plate 34 and the first fixed circular plate 32. The first locking assembly 35 is arranged on the first rotating circular plate 34.

[0075] The clamping mechanism of the rotary arc welding gun 31 includes a clamping platform 37, a first quick release plate 38 and a fixed screw 39. The clamping platform 37 is detachably connected to the first rotating circular plate 34 through the first quick release plate 38, and the first locking knob 36 of the first locking assembly 35 controls the unlocking or locking between the first quick release plate 38 and the first rotating circular plate 34. The clamping platform 37 has a clamping cavity for clamping the rotary arc welding gun 31, one side of the clamping cavity is open, and the clamping force of the clamping cavity is adjusted by the fixed screw 39.

[0076] The first locking assembly 35 is used to realize the quick disassembly and locking between the first quick-release plate 38 and the first rotating circular plate 34, thereby improving the operation efficiency. The specific structure of the first locking assembly 35 adopts the existing technology, which will not be described in detail here.

[0077] After the rotary arc welding gun 31 is inserted into the clamping cavity of the clamping platform 37 , the rotary arc welding gun 31 is stably clamped in the clamping cavity by rotating the fixed screw rod 39 , so as to adapt to rotary arc welding guns 31 of different specifications.

[0078] The first quick-release plate 38 is assembled with the first rotating circular plate 34 , and the first locking knob 36 is rotated to a locked state, so that the clamping platform 37 and the first rotating circular plate 34 are stably connected together, so that the rotary arc welding gun 31 can be quickly assembled or disassembled.

[0079] When the rotation angle of the rotary arc welding gun 31 needs to be adjusted, the first fixing knob 33 is loosened to release the locking state between the first rotating circular plate 34 and the first fixing circular plate 32, and then the first rotating circular plate 34 is rotated to make the rotary arc welding gun 31 reach the desired rotation angle, and then the first fixing knob 33 is tightened to re-lock the position of the first rotating circular plate 34, thereby locking the rotation angle of the rotary arc welding gun 31.

[0080] The rotary arc welding gun module 3 also includes a welding power source and a wire feeder. The welding power source provides stable electric energy for the rotary arc welding gun 31 and the wire feeder. The wire feeder is used to automatically and continuously feed the welding wire into the rotary arc welding gun 31 .

[0081] The rotary arc welding gun 31 is a rotary arc welding gun 31 whose rotation diameter, rotation speed and rotation direction are adjustable.

[0082] The rotary arc welding gun 31 adopts a GMAW rotary arc welding gun with a rotary arc, preferably an MA400 welding gun. The MA400 welding gun has less groove preparation, heat input and welding time, can reduce consumption of materials, effectively improve welding quality, productivity and flexibility, and has good welding process stability. In addition, the MA400 welding gun also has heat input control and material input control functions, realizes a benign interaction between welding shielding gas composition and deep penetration welding, and is suitable for different welding applications, such as cladding, fillet welding and narrow gap welding.

[0083] Since the welding wire of the MA400 welding gun moves at a high speed on a circular track, the centrifugal force further distributes the filler material in the rotating arc, thereby forming a weld. The rotating diameter of the rotating arc of the MA400 welding gun is 1-8mm at the current nozzle, the rotation direction includes clockwise and counterclockwise, the rotation speed is 200-5500 rpm, and the diameter of the welding wire is 0.90-1.6mm. Different rotating diameters, rotation speeds and welding parameters of the welding wire can be set, so that the rotating arc welding gun 31 can adapt to different welding requirements. Among them, the rotating diameter of the rotating arc is jointly determined by the extension length of the welding wire, the rigidity of the welding wire and the rotation speed. For a specific extension length and a specific electrode, if the rotation speed is increased, the rotating diameter will also increase accordingly due to the effect of centrifugal force.

[0084] like Fig.10 As shown, the rotation radius of the MA400 welding gun can be adjusted by specific steps, including loosening the lower cover and rotating it a quarter turn to the left, and then pushing the top cover down to expose the adjustment assembly. Then, hold the center shaft and the positioning wheel 311, and turn the cam 312 with your fingers. The size of the rotation radius is changed by adjusting the position of the cam 312, and aligning the position indicator 313 on the cam 312 with the scale line of the rotation radius required to be set on the positioning wheel 311. Among them, if a standard suction head adapter and a flush contact suction head are used, the rotation diameter increases by about 10%. In addition, due to the design of the rotation mechanism of the MA400 welding gun, the rotation diameter at the end of its electrode must be larger than at its contact tip.

[0085] As an optional implementation, Figure 1 , 7 As shown, the laser module 4 includes a laser quick-release mechanism, a laser head 41 and a laser.

[0086] The laser quick-release mechanism includes a fixed square plate 42, a quick-release square plate 43 and a third locking assembly. The fixed square plate 42 is connected to the slider 222. A quick-release hole 421 is provided on the fixed square plate 42. A quick-release column 431 adapted to the quick-release hole 421 is provided on the quick-release square plate 43. The unlocking or locking between the fixed square plate 42 and the quick-release square plate 43 is controlled by a rebound quick-release button 44 of the third locking assembly.

[0087] The laser head 41 is mounted on the quick-release square plate 43 and connected to the laser through an optical fiber. The laser focus diameter of the laser head 41 is 0.2 mm, and the laser power is 2000W-6000W.

[0088] The third locking assembly includes a buckle or other mechanical locking structure in the prior art. By pressing the rebound quick release button 44, the triggering or release of the third locking assembly is controlled.

[0089] A spring is integrated inside the rebound quick release button 44 so that the rebound quick release button 44 can automatically reset after being pressed.

[0090] When the quick-release column 431 is aligned with the quick-release hole 421, the rebound quick-release button 44 is pressed to trigger the locking mechanism of the third locking component, so that the quick-release square plate 43 and the fixed square plate 42 are tightly fitted and locked; the rebound quick-release button 44 is pressed again to trigger the release mechanism of the locking component, release the lock of the quick-release square plate 43 and the fixed square plate 42, and realize the rapid disassembly of the laser head 41.

[0091] As an optional implementation, Figure 1 , 6 As shown, the sensor module 5 includes a sensor posture adjustment mechanism, a laser sensor 51 and a tilt sensor.

[0092] The laser sensor 51 is arranged on the slider 222 through a sensor posture adjustment mechanism, and is used to scan the weld and obtain the weld height and center position information.

[0093] The inclination sensor is arranged on the welding vehicle 2 and is used for monitoring the position of the welding vehicle 2 in real time.

[0094] As an optional implementation, the sensor posture adjustment mechanism includes a sensor rotating slide and a sensor clamping mechanism.

[0095] The sensor rotating slide comprises a second fixed circular plate 52, a second fixed knob 53, a second rotating circular plate 54 and a second locking assembly 55. The second fixed circular plate 52 is connected to the slider 222. The second rotating circular plate 54 is rotatably connected to the second fixed circular plate 52 through a rotating column, and the second fixed knob 53 controls the unlocking or locking between the second rotating circular plate 54 and the second fixed circular plate 52. The second locking assembly 55 is arranged on the second rotating circular plate 54.

[0096] The sensor clamping mechanism includes a clamping seat 57 and a second quick release plate 58. The clamping seat 57 is detachably connected to the second rotating circular plate 54 through the second quick release plate 58, and the second locking knob 56 of the second locking assembly 55 controls the unlocking or locking between the second quick release plate 58 and the second rotating circular plate 54. The clamping seat 57 is used to clamp and fix the laser sensor 51.

[0097] The second locking assembly 55 is used to realize the quick disassembly and locking between the second quick-release plate 58 and the second rotating circular plate 54, thereby improving the operation efficiency. The specific structure of the second locking assembly 55 adopts the existing technology, which will not be described in detail here.

[0098] The laser sensor 51 is installed in the clamping seat 57. Then, the second quick release plate 58 is assembled with the second rotating circular plate 54, and the second locking knob 56 is rotated to a locked state, so that the clamping seat 57 and the second rotating circular plate 54 are stably connected together, thereby realizing the rapid assembly and disassembly of the laser sensor 51.

[0099] When it is necessary to adjust the rotation angle of the laser sensor 51, loosen the second fixing knob 53, release the locking state between the second rotating circular plate 54 and the second fixing circular plate 52, and then rotate the second rotating circular plate 54 to make the laser sensor 51 reach the desired rotation angle, tighten the second fixing knob 53, re-lock the position of the second rotating circular plate 54, and then lock the rotation angle of the laser sensor 51 to adjust the scanning direction and angle of the laser sensor 51, so as to adapt to the position and direction of different welds.

[0100] The present invention provides a pipeline 6 all-position laser rotary arc composite automatic welding method, comprising the following steps:

[0101] S1: Butt two connected pipes 6 and perform pre-welding treatment such as grinding and cutting the cracks;

[0102] S2: Install and adjust the flexible track 11 on the outer wall of the pipe 6 to ensure that the flexible track 11 is firmly connected to the pipe 6;

[0103] S3: Lock the welding vehicle 2 on the flexible track 11, install the laser module 4, the rotating arc welding gun module 3 and the sensor module 5 on the arc slide 22, and adjust their positions and postures, specifically including adjusting the spatial position and posture of the laser sensor 51 and the rotating arc welding gun 31, and adjusting the angle between the laser beam emitted by the laser head 41 and the weld;

[0104] S4: Control the welding vehicle 2 to go around the pipe 6, and the laser sensor 51 scans the weld in a static scanning mode to obtain weld information such as weld height and weld center position and send it to the controller; the controller divides the pipe 6 into multiple areas according to the above information and generates a corresponding welding plan. Specifically, Fig. 9 As shown, the pipeline 6 is divided into two half-circles in the vertical direction, and the pipeline 6 is divided into 24 areas with an interval of 15°. The welding process of each area is stored in the welding expert library. The controller calculates through the internal algorithm and quickly generates a welding plan.

[0105] S5: Control the welding vehicle 2 to return to the welding starting point, adjust the rotation radius and rotation frequency of the rotating arc, and start welding in units of half a cycle. The horizontal adjustment mechanism 25 and the vertical adjustment mechanism 26 work together to control the swing width and swing frequency of the laser beam and the rotating arc. Figure 8 As shown, the laser beam and the rotating arc are simultaneously applied to the weld to perform welding operations;

[0106] S6: During the welding process, the inclination sensor detects the position of the welding vehicle 2 in real time, and adjusts the welding parameters according to the position information to ensure that appropriate welding parameters are used in each area, thereby ensuring the welding quality;

[0107] S7: After completing half of the welding work, the welding vehicle 2 returns to the welding starting point and prepares to start the welding work of the other half of the cycle;

[0108] S8: Repeat steps S5 to S7 until the root welding, filling welding and cap welding of the entire pipeline 6 are completed.

[0109] It can be understood that the same or similar parts of the above embodiments can be referenced to each other, and the contents not described in detail in some embodiments can refer to the same or similar contents in other embodiments.

[0110] In the description of the present invention, it should be noted that, unless otherwise specified, the meaning of "plurality" is two or more. The orientation or positional relationship indicated by the terms "upper", "lower", "left", "right", "inner", "outer", "front end", "rear end", "head", "tail", etc. is based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", "third", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0111] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "installation", "connection", and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0112] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example" or "an example" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0113] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A pipeline all-position laser rotary arc composite automatic welding device, characterized in that: It comprises a flexible guide rail, a welding vehicle, a rotary arc welding gun module, a laser module, a sensor module and a controller; the flexible guide rail is arranged around and closely attached to the pipeline, and provides a moving path for the welding vehicle; the welding vehicle is movably arranged on the flexible guide rail; the rotary arc welding gun module, the laser module and the sensor module are adjustably arranged at the front end of the welding vehicle in sequence along the circumference of the pipeline; the welding vehicle, the rotary arc welding gun module, the laser module and the sensor module are electrically connected to the controller respectively.

2. The pipeline all-position laser rotary arc hybrid automatic welding device according to claim 1 is characterized in that: The flexible guide rail comprises a flexible track, a quick locking mechanism and a swallow-wing spring locking mechanism; The free ends of the flexible rails are connected via the quick-locking mechanism to form a continuous and closed annular structure; There are multiple swallow-wing spring locking mechanisms, which are arranged sequentially on the inner wall surface of the flexible track along the circumference of the track.

3. The pipeline all-position laser rotary arc hybrid automatic welding device according to claim 2 is characterized in that: The welding vehicle comprises a base, an arc-shaped slide, a traveling mechanism, a locking mechanism, a horizontal adjustment mechanism and a vertical adjustment mechanism; The walking mechanism is arranged below the base and is used to drive the welding vehicle to move along the circumference of the pipeline; The locking mechanism is arranged below the base and is locked with the flexible guide rail; The horizontal adjustment mechanism is arranged on the base, the vertical adjustment mechanism is connected to the movable end of the horizontal adjustment mechanism, and the arc-shaped slide is connected to the movable end of the vertical adjustment mechanism.

4. The pipeline all-position laser rotary arc hybrid automatic welding device according to claim 3 is characterized in that: The arc-shaped slide table is provided with an arc-shaped slide groove, in which a plurality of sliders are slidably arranged, and the sliders are locked with the arc-shaped slide groove by tightening screw rods, and the rotary arc welding gun module, the laser module and the sensor module are respectively connected with the sliders.

5. The pipeline all-position laser rotary arc hybrid automatic welding device according to claim 4 is characterized in that: The rotary arc welding gun module comprises a rotary arc welding gun posture adjustment mechanism and a rotary arc welding gun. The rotary arc welding gun is connected to the slider via the rotary arc welding gun posture adjustment mechanism. The rotary arc welding gun posture adjustment mechanism is used to adjust the posture of the rotary arc welding gun.

6. The pipeline all-position laser rotary arc hybrid automatic welding device according to claim 5 is characterized in that: The rotary arc welding gun posture adjustment mechanism comprises a rotary arc welding gun rotating slide and a rotary arc welding gun clamping mechanism; The rotary slide of the rotary arc welding gun comprises a first fixed circular plate, a first fixed knob, a first rotating circular plate and a first locking assembly, wherein the first fixed circular plate is connected to the sliding block, the first rotating circular plate is rotatably connected to the first fixed circular plate through a rotating column, and the first fixed knob controls the unlocking or locking between the first rotating circular plate and the first fixed circular plate; the first locking assembly is arranged on the first rotating circular plate; The rotary arc welding gun clamping mechanism includes a clamping platform, a first quick-release plate and a fixed screw. The clamping platform is detachably connected to the first rotating circular plate through the first quick-release plate, and the first locking knob of the first locking assembly controls the unlocking or locking between the first quick-release plate and the first rotating circular plate. The clamping platform has a clamping cavity for clamping the rotary arc welding gun, one side of the clamping cavity is open, and the clamping force of the clamping cavity is adjusted by the fixed screw.

7. The pipeline all-position laser rotary arc hybrid automatic welding device according to claim 4 is characterized in that: The laser module includes a laser quick-release mechanism, a laser head and a laser; The laser quick-release mechanism comprises a fixed square plate, a quick-release square plate and a third locking assembly, wherein the fixed square plate is connected to the slider, a quick-release hole is provided on the fixed square plate, a quick-release column adapted to the quick-release hole is provided on the quick-release square plate, and the unlocking or locking between the fixed square plate and the quick-release square plate is controlled by a rebound quick-release button of the third locking assembly; The laser head is mounted on the quick-release square plate and connected to the laser via an optical fiber.

8. The pipeline all-position laser rotary arc hybrid automatic welding device according to claim 4 is characterized in that: The sensor module includes a sensor posture adjustment mechanism, a laser sensor and a tilt sensor; The laser sensor is arranged on the slider through a sensor posture adjustment mechanism, and is used to scan the weld and obtain weld height and center position information; The inclination sensor is arranged on the welding vehicle and is used for monitoring the position of the welding vehicle in real time.

9. The pipeline all-position laser rotary arc hybrid automatic welding device according to claim 1 is characterized in that: The sensor posture adjustment mechanism includes a sensor rotating slide and a sensor clamping mechanism; The sensor rotating slide comprises a second fixed circular plate, a second fixed knob, a second rotating circular plate and a second locking assembly, wherein the second fixed circular plate is connected to the slider, the second rotating circular plate is rotatably connected to the second fixed circular plate through a rotating column, and the second fixed knob controls the unlocking or locking between the second rotating circular plate and the second fixed circular plate; the second locking assembly is arranged on the second rotating circular plate; The sensor clamping mechanism includes a clamping seat and a second quick-release plate, the clamping seat is detachably connected to the second rotating circular plate through the second quick-release plate, and the second locking knob of the second locking assembly controls the unlocking or locking between the second quick-release plate and the second rotating circular plate; the clamping seat is used to clamp and fix the laser sensor.

10. A pipeline all-position laser rotary arc hybrid automatic welding method, characterized in that: The steps include: S1: Butt two connected pipes and perform pre-welding treatment; S2: Install and adjust the flexible track on the outer wall of the pipeline; S3: Lock the welding vehicle on the flexible track, install the laser module, the rotating arc welding gun module and the sensor module on the arc slide, and adjust the position and posture; S4: Control the welding vehicle to go around the pipeline, and the laser sensor scans the weld in a static scanning mode to obtain weld information and send it to the controller; the controller divides the pipeline into multiple areas and generates corresponding welding planning schemes; S5: Control the welding vehicle to return to the welding starting point, adjust the rotation radius and rotation frequency of the rotating arc, start welding in half a cycle, and the horizontal adjustment mechanism and the vertical adjustment mechanism work together to control the swing width and swing frequency of the laser beam and the rotating arc, so that the laser beam and the rotating arc act on the weld at the same time to perform welding operations; S6: During the welding process, the inclination sensor detects the position of the welding vehicle in real time and adjusts the welding parameters according to the position information; S7: After completing half of the welding work, the welding vehicle returns to the welding starting point and prepares to start the welding work of the other half of the cycle; S8: Repeat steps S5 to S7 until the root welding, filling welding and cap welding of the entire pipeline are completed.

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