Boiler separator end socket connecting pipe welding structure and method

Abstract

The invention relates to the technical field of product manufacturing, and discloses a boiler separator end socket connecting pipe welding structure and method.The boiler separator end socket connecting pipe welding structure comprises a rotating disc mechanism, a driving motor, a welding machine mechanism, a separator hemispherical end socket and a connecting pipe; the separator hemispherical seal head is buckled on the turntable mechanism, and the turntable mechanism drives the separator hemispherical seal head to do circular motion; a pipe orifice of the connecting pipe is placed at the top of the separator hemispherical seal head, and a to-be-welded area is formed at the joint of the connecting pipe and the separator hemispherical seal head; the welding machine mechanism is located on one side of the rotary disc mechanism, and the welding end of the welding machine mechanism is aligned with the to-be-welded area of the connecting pipe and the separator hemispherical end socket. The driving motor is arranged on the rotating disc mechanism, and an output shaft of the driving motor is connected with the driving end of the rotating disc mechanism. Through cooperative work of the rotating disc mechanism and the driving motor, the welding machine mechanism can conduct continuous or discontinuous welding operation on the connecting position of the connecting pipe and the end socket at different positions, and therefore the welding efficiency is greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of product manufacturing, and in particular to a welding structure and method for a boiler separator head pipe. Background Art

[0002] As an indispensable key component in supercritical and ultra-supercritical boiler systems, the precision and reliability of the manufacturing process of the steam-water separator is directly related to the overall performance and operational safety of the boiler. In this complex and sophisticated manufacturing process, the welding of large-diameter pipes on the hemispherical head is a crucial link. Traditional automatic welding technology generally uses horizontal welding for the fillet welds of the pipes of this component. This is a process method that has been verified by long-term practice and can meet welding requirements to a certain extent.

[0003] When implementing this welding process, the pipe must first be pre-fixed on the two hemispherical heads by spot welding to ensure that the position of the pipe remains stable during the subsequent welding process. Then, the two hemispherical heads are firmly welded together using a special positioning plate. This ingenious design allows the parts to be welded to move freely in a circular motion along the axis of the head and pipe, greatly improving the flexibility and operability of the welding operation, thereby ensuring the quality and uniformity of the weld.

[0004] However, although this traditional welding method has achieved certain results in practice, it has some drawbacks in the treatment of the positioning plate that cannot be ignored. After the welding is completed, the positioning plate on the head must be carefully removed according to the process requirements. However, since the steam-water separators of supercritical and ultra-supercritical boilers are often made of high-performance, high-grade heat-resistant steel materials such as P91, these materials not only have excellent high-temperature resistance, but also place extremely high demands on the welding process. If the welding and subsequent removal process of the positioning plate is not done carefully, it may leave tiny welding cracks on the surface of the head due to improper operation. Although these cracks are small, they may have an immeasurable impact on the overall strength and sealing performance of the steam-water separator, thereby threatening the safe operation of the boiler.

[0005] In fact, there have been many quality accidents at home and abroad caused by improper handling of counterweights or welding accessories, resulting in cracks. These accidents not only bring huge economic losses to production companies, but more importantly, they pose a serious threat to the safe operation of boilers. Therefore, how to improve the existing welding process and avoid welding cracks on the head surface has become a technical problem that needs to be solved urgently. Summary of the invention

[0006] In order to overcome the defects of the prior art, the purpose of the present invention is to provide a boiler separator head pipe welding structure and method to solve the technical problem of how to avoid cracks caused by counterweight welding accessories in the prior art.

[0007] The present invention is achieved through the following technical solutions: The present invention provides a boiler separator head pipe welding structure, comprising a turntable mechanism, a drive motor, a welding machine mechanism, a separator hemispherical head and a pipe; The separator hemispherical head is buckled on the turntable mechanism, and the turntable mechanism drives the separator hemispherical head to make circular motion; the pipe mouth of the pipe connection is placed on the top of the separator hemispherical head, and the connection with the separator hemispherical head forms a welding area; The welding machine mechanism is located on one side of the turntable mechanism, and the welding end of the welding machine mechanism is aligned with the welding area of ​​the pipe and the hemispherical head of the separator; The driving motor is arranged on the turntable mechanism, and the output shaft of the driving motor is connected to the driving end of the turntable mechanism.

[0008] Preferably, the area to be welded between the pipe opening of the connecting pipe and the top of the hemispherical head of the separator is provided with a groove; the shape and size of the groove correspond to the welding end of the welding machine mechanism.

[0009] Preferably, the area to be welded between the pipe opening of the connecting pipe and the top of the hemispherical head of the separator is parallel to the rotation plane of the turntable mechanism.

[0010] Preferably, the pipe is placed vertically on the top of the hemispherical head of the separator.

[0011] Preferably, the bottom surface of the hemispherical head of the separator and the rotating surface of the turntable mechanism are both planar structures.

[0012] Preferably, the turntable mechanism comprises a turntable support platform, a rotating shaft and a turntable; A groove is provided on the table surface of the turntable support table, the bottom of the rotating shaft is rotatably arranged in the groove, the turntable is fixedly arranged on the top of the rotating shaft, and the input shaft of the rotating shaft is connected to the output shaft of the driving motor; the hemispherical head of the separator is buckled on the disk surface of the turntable.

[0013] Furthermore, the turntable and the rotating shaft are arranged on the same central axis.

[0014] Preferably, the welding machine mechanism comprises a welding machine console, a support frame and a welding pen; One end of the support frame is fixed on the welding machine console, and the other end is connected to the welding pen; the control end of the welding pen is connected to the welding machine console, and the output end of the welding pen is aligned with the welding area of ​​the connecting pipe and the hemispherical head of the separator.

[0015] Preferably, the welding machine mechanism adopts a submerged arc welding mechanism or a gas shielded welding mechanism.

[0016] In a second aspect, the present invention further provides a method for welding a pipe joint of a boiler separator end cap, based on the above-mentioned welding structure of a pipe joint of a boiler separator end cap, comprising the following steps: The separator hemispherical head with the welding groove is turned upside down on the turntable mechanism. The pipe is placed on the top of the separator hemispherical head by its own gravity. The welding end of the welding machine mechanism is spot-welded and fixed on the welding groove of the welding area to be welded between the pipe and the separator hemispherical head. The drive motor is started to make the separator hemispherical head drive the pipe to make a circular motion on the turntable mechanism. The welding machine mechanism is adjusted to weld along the groove to be welded to complete the welding work of the boiler separator head pipe.

[0017] Compared with the prior art, the present invention has the following beneficial technical effects: The present invention provides a welding structure for a pipe of a boiler separator head. Through the coordinated work of a turntable mechanism and a driving motor, the separator hemispherical head can smoothly perform circular motion, which enables the welding mechanism to perform continuous or intermittent welding operations on the connection between the pipe and the head at different positions without frequent manual movement or adjustment of the workpiece position, thereby greatly improving the welding efficiency. The welding end of the welding mechanism can accurately align the connection between the pipe and the separator hemispherical head to ensure the accuracy and consistency of the weld. At the connection between the pipe and the separator hemispherical head, the gravity of the pipe can help maintain close contact between the two. Close contact is the key to high-quality welding. Automatic welding of the hemispherical head and the pipe can be achieved without counterweights, thereby improving the strength and sealing of the welded joint.

[0018] Furthermore, the area to be welded between the pipe opening of the pipe connection and the top of the separator hemispherical head is provided with a groove; the shape and size of the groove correspond to the welding end of the welding machine mechanism. The design of the groove increases the contact area between the pipe connection and the separator hemispherical head, providing a wider molten pool area for the weld. This helps to ensure full fusion of the weld, reduce the generation of welding defects such as lack of fusion and slag inclusion, thereby improving the mechanical properties and sealing of the weld.

[0019] Furthermore, the connection seam formed by the welding area between the pipe opening of the pipe connection and the top of the hemispherical head of the separator is parallel to the rotation plane of the turntable mechanism. The design of the connection seam being parallel to the rotation plane of the turntable mechanism enables the welding machine mechanism to weld along a stable and continuous path, which helps to reduce pauses and turns during the welding process, thereby improving welding efficiency and weld continuity. The connection seam parallel to the rotation plane of the turntable makes the heat input and molten pool flow during the welding process more uniform, which helps to reduce welding deformation and residual stress, while improving the mechanical properties and sealing of the weld. The stable welding path also helps to reduce welding defects.

[0020] Furthermore, the pipe is placed vertically on the top of the separator hemispherical head. The vertically placed pipe enables the welding operation to be carried out under more stable and controllable conditions. Due to the effect of gravity, the molten pool at the weld is easier to maintain stability, reducing welding defects caused by unstable molten pool flow during welding.

[0021] Furthermore, the bottom surface of the separator hemispherical head and the rotating surface of the turntable mechanism are both planar structures. The planar bottom surface makes it easier to accurately position the separator hemispherical head on the turntable mechanism. At the same time, the planar contact also makes it easier to design a clamping device to fix the head to prevent movement or tilting during welding.

[0022] Furthermore, the turntable mechanism composed of the turntable support platform, the rotating shaft and the turntable has a compact structure and can effectively support and drive the hemispherical head of the separator to perform circular motion. The groove increases the stability of the rotating shaft and reduces the motion error caused by vibration or imbalance. The bottom of the rotating shaft is rotatably arranged in the groove, making the installation and debugging process of the turntable mechanism easier; the turntable is fixedly arranged on the top of the rotating shaft, which is convenient for connection and synchronous movement with the drive motor. The input shaft of the rotating shaft is directly connected to the output shaft of the drive motor, which reduces the energy loss in the power transmission process, improves the driving efficiency, and helps to ensure the smooth operation of the turntable mechanism during the welding process.

[0023] Furthermore, the arrangement of the same central axis enhances the stability of the turntable mechanism during rotation. Since the turntable and the rotating shaft are closely connected and rotate around the same axis, motion errors caused by imbalance or vibration are reduced.

[0024] Furthermore, the welding machine console can accurately control the movement of the welding pen and welding parameters, such as welding current, voltage, welding speed, etc., which helps to ensure the stability and consistency of the welding process and improve the welding quality. The support frame allows the welding pen to move flexibly in three-dimensional space to adapt to the connection between the pipe and the separator hemispherical head of different shapes and sizes, improving the adaptability and efficiency of the welding operation. The output end of the welding pen is directly aligned with the connection between the pipe and the separator hemispherical head, reducing waste and unnecessary movement during the welding process, helping to improve welding efficiency and shorten production cycles.

[0025] The present invention also provides a method for welding the pipe of a boiler separator head, which realizes the rapid and continuous welding of the pipe and the hemispherical head of the separator by means of automation and mechanization. After starting the driving motor, the hemispherical head of the separator drives the pipe to make a circular motion on the turntable mechanism, and the welding machine mechanism welds along the groove to be welded. This continuous operation method greatly improves the welding efficiency. The present invention realizes the automatic welding of the head and the pipe by putting the head upside down on the turntable and driving the turntable to make a circular motion parallel to the ground and the weld by the motor. The system solves the problem that the previous welding of the head and the pipe requires the use of a welding counterweight component to realize automatic welding, which saves the process and avoids the welding defects caused by the welding counterweight accessories. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the welding structure of the boiler separator head pipe in an embodiment of the present invention; In the figure: 1. turntable mechanism; 2. drive motor; 3. welding machine mechanism; 4. separator hemispherical head; 5. connecting pipe; 11. turntable support platform; 12. rotating shaft; 13. turntable; 31. welding machine control console; 32. support frame; 33. welding pen. DETAILED DESCRIPTION

[0027] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0028] The object of the present invention is to provide a boiler separator head pipe welding structure and method to solve the technical problem of how to avoid cracks caused by counterweight welding accessories in the prior art.

[0029] The present invention is further described in detail below in conjunction with the accompanying drawings: See also Figure 1In one embodiment of the present invention, a welding structure for a pipe connecting pipe of a boiler separator head is provided, comprising a turntable mechanism 1, a driving motor 2, a welding machine mechanism 3, a separator hemispherical head 4 and a pipe connecting pipe 5; the separator hemispherical head 4 is buckled on the turntable mechanism 1, and the turntable mechanism 1 drives the separator hemispherical head 4 to make a circular motion; the pipe mouth of the pipe connecting pipe 5 is placed on the top of the separator hemispherical head 4, and forms a welding area with the connection of the separator hemispherical head 4; the welding machine mechanism 3 is located on one side of the turntable mechanism 1, and the welding end of the welding machine mechanism 3 is aligned with the connection between the pipe connecting pipe 5 and the separator hemispherical head 4; the driving motor 2 is arranged on the turntable mechanism 1, and the output shaft of the driving motor 2 is connected to the driving end of the turntable mechanism 1.

[0030] Specifically, the area to be welded between the pipe opening of the connecting pipe 5 and the top of the hemispherical head 4 of the separator is provided with a groove; the shape and size of the groove correspond to the welding end of the welding machine mechanism 3.

[0031] In this embodiment, the provision of the groove can increase the fusion area between the connecting pipe 5 and the separator hemispherical head 4, thereby improving the strength and sealing performance of the weld.

[0032] In this embodiment, the groove shape includes a V-shaped groove, a U-shaped groove and an X-shaped groove; the width of the groove depends on the diameter and wall thickness of the pipe to be connected, and a wider groove can provide a larger joint area and better welding strength. The groove depth depends on the pipe wall thickness and the welding method, and a deeper groove can provide a larger weld volume, which is conducive to the filling and penetration of welding materials. The groove angle depends on the welding method and welding materials, and a larger groove angle can provide a larger joint area and better welding quality.

[0033] Specifically, the area to be welded between the pipe opening of the pipe connection 5 and the top of the hemispherical seal head 4 of the separator is parallel to the rotation plane of the turntable mechanism 1. The parallel configuration ensures the uniformity and consistency of the weld. During the rotation of the turntable mechanism 1, the area to be welded can evenly receive the welding heat, avoiding uneven weld quality caused by changes in the welding position. At the same time, the welding machine mechanism 3 can accurately control welding parameters such as welding current, voltage and welding speed, thereby further ensuring the quality of the weld.

[0034] Specifically, the pipe 5 is vertically placed on the top of the separator hemispherical head 4. The vertically placed pipe 5 can provide better support during the welding process, reducing the weld deformation caused by gravity. This helps to enhance the strength of the weld and improve the overall structural stability of the boiler separator.

[0035] Specifically, the bottom surface of the separator hemispherical head 4 and the rotating surface of the turntable mechanism 1 are both planar structures. The contact surface of the planar structure can provide a larger support area, thereby increasing the stability of the separator hemispherical head 4 on the turntable mechanism 1. During the welding process, this stability helps to reduce welding defects caused by vibration or shaking and improve the quality of the weld.

[0036] Specifically, the turntable mechanism 1 includes a turntable support platform 11, a rotating shaft 12 and a turntable 13; a groove is provided on the table surface of the turntable support platform 11, the bottom of the rotating shaft 12 is rotatably set in the groove, the turntable 13 is fixedly set on the top of the rotating shaft 12, and the input shaft of the rotating shaft 12 is connected to the output shaft of the driving motor 2; the separator hemispherical head 4 is buckled on the disk surface of the turntable 13.

[0037] In this embodiment, the table top of the turntable support table 11 is provided with a groove, which provides a stable support for the rotating shaft 12. This design ensures the stability of the turntable mechanism 1 during the rotation process and reduces welding defects caused by vibration or shaking. The turntable 13 is fixedly arranged on the top of the rotating shaft 12. This structure enables the turntable 13 to rotate smoothly, further enhancing the stability during the welding process. The input shaft of the rotating shaft 12 is connected to the output shaft of the drive motor 2. This design enables the turntable mechanism 1 to efficiently receive power from the drive motor 2 and achieve fast and smooth rotation. The precise control of the drive motor 2 enables the rotation speed of the turntable 13 to be adjusted according to the welding requirements, thereby optimizing the welding process and improving the welding efficiency.

[0038] The rotating disk 13 and the rotating shaft 12 are arranged on the same central axis.

[0039] In this embodiment, the turntable 13 and the rotating shaft 12 share the same central axis, ensuring the high stability of the turntable 13 during rotation. The turntable 13 can rotate smoothly and without shaking, reducing welding defects caused by vibration or deviation, thereby improving the quality and uniformity of the weld.

[0040] Specifically, the welding machine mechanism 3 includes a welding machine console 31, a support frame 32 and a welding pen 33; one end of the support frame 32 is fixed on the welding machine console 31, and the other end is connected to the welding pen 33; the control end of the welding pen 33 is connected to the welding machine console 31, and the output end of the welding pen 33 is aligned with the welding area to be welded between the pipe 5 and the separator hemispherical head 4.

[0041] In this embodiment, the welding machine console 31 is the core component of the welding machine mechanism 3, which is responsible for controlling and adjusting various parameters in the welding process, such as welding current, voltage, welding speed, etc. The support frame 32 is used to fix and support the welding pen 33 to ensure that the welding pen 33 can move stably and accurately during the welding process. The welding pen 33 is an executive component in the welding process, and its output end is responsible for generating a high-temperature arc to melt and connect the pipe 5 and the area to be welded of the separator hemispherical head 4.

[0042] In this embodiment, the welding machine mechanism 3 adopts a submerged arc welding mechanism or a gas shielded welding mechanism.

[0043] In summary, the present embodiment provides a welding structure for a pipe of a boiler separator head. Through the coordinated work of the turntable mechanism 1 and the drive motor 2, the separator hemispherical head 4 can smoothly perform circular motion, which enables the welding machine mechanism 3 to perform continuous or intermittent welding operations at the connection between the pipe 5 and the separator hemispherical head 4 at different positions, without the need for frequent manual movement or adjustment of the workpiece position, thereby greatly improving the welding efficiency. The welding end of the welding machine mechanism 3 can accurately align the connection between the pipe 5 and the separator hemispherical head 4 to ensure the accuracy and consistency of the weld. At the connection between the pipe 5 and the separator hemispherical head 4, the gravity of the pipe 5 can help maintain close contact between the two. Close contact is the key to high-quality welding. Automatic welding of the hemispherical head and the pipe 5 can be achieved without counterweights, thereby improving the strength and sealing of the welded joint.

[0044] Example 2 This embodiment provides a method for welding a pipe joint of a boiler separator end cap, based on the above-mentioned welding structure of a pipe joint of a boiler separator end cap, including the following process: The separator hemispherical head 4 with a welding groove is turned upside down on the turntable mechanism 1, and the pipe 5 is placed on the top of the separator hemispherical head 4 by its own gravity. The welding end of the welding machine mechanism 3 is spot-welded and fixed on the welding groove of the area to be welded between the pipe 5 and the separator hemispherical head 4, and the driving motor 2 is started to make the separator hemispherical head 4 drive the pipe 5 to make a circular motion on the turntable mechanism 1, and the welding machine mechanism 3 is adjusted to weld along the groove to be welded to complete the welding work of the boiler separator head pipe 5.

[0045] In summary, the boiler separator head pipe welding method provided in this embodiment realizes the rapid and continuous welding of the pipe 5 and the separator hemispherical head 4 by means of automation and mechanization. After starting the drive motor 2, the separator hemispherical head 4 drives the pipe 5 to make a circular motion on the turntable mechanism 1, and the welding machine mechanism 3 welds along the groove to be welded. This continuous operation method greatly improves the welding efficiency. The present invention realizes the automatic welding of the separator hemispherical head 4 and the pipe 5 by placing the head upside down on the turntable 13 and driving the turntable 13 to make a circular motion parallel to the ground and the weld by the motor. The system solves the problem that the previous welding of the head and the pipe 5 requires the welding of a counterweight component to achieve automatic welding, which saves the process and avoids the welding defects caused by the welding counterweight accessories.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the relevant field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A boiler separator head pipe welding structure, characterized in that: It comprises a turntable mechanism (1), a drive motor (2), a welding machine mechanism (3), a separator hemispherical head (4) and a pipe (5); The separator hemispherical head (4) is buckled onto the turntable mechanism (1), and the turntable mechanism (1) drives the separator hemispherical head (4) to perform circular motion; the pipe opening of the connecting pipe (5) is placed on the top of the separator hemispherical head (4), and the connection with the separator hemispherical head (4) forms a welding area; The welding machine mechanism (3) is located on one side of the turntable mechanism (1), and the welding end of the welding machine mechanism (3) is aligned with the welding area of ​​the pipe (5) and the separator hemispherical head (4); The drive motor (2) is arranged on the turntable mechanism (1), and the output shaft of the drive motor (2) is connected to the drive end of the turntable mechanism (1).

2. A boiler separator head pipe welding structure according to claim 1, characterized in that: The area to be welded between the pipe opening of the connecting pipe (5) and the top of the separator hemispherical head (4) is provided with a groove; the shape and size of the groove correspond to the welding end of the welding machine mechanism (3).

3. A boiler separator head pipe welding structure according to claim 1, characterized in that: The area to be welded between the pipe opening of the connecting pipe (5) and the top of the separator hemispherical head (4) is parallel to the rotation plane of the turntable mechanism (1).

4. A boiler separator head pipe welding structure according to claim 1, characterized in that: The connecting pipe (5) is vertically placed on the top of the separator hemispherical head (4).

5. A boiler separator head pipe welding structure according to claim 1, characterized in that: The bottom surface of the separator hemispherical head (4) and the rotating surface of the turntable mechanism (1) are both planar structures.

6. A boiler separator head pipe welding structure according to claim 1, characterized in that: The turntable mechanism (1) comprises a turntable support platform (11), a rotating shaft (12) and a turntable (13); The table top of the turntable support table (11) is provided with a groove, the bottom of the rotating shaft (12) is rotatably arranged in the groove, the turntable (13) is fixedly arranged on the top of the rotating shaft (12), and the input shaft of the rotating shaft (12) is connected to the output shaft of the driving motor (2); the separator hemispherical head (4) is buckled on the disk surface of the turntable (13).

7. A boiler separator head pipe welding structure according to claim 6, characterized in that: The rotating disk (13) and the rotating shaft (12) are arranged on the same central axis.

8. The boiler separator head pipe welding structure according to claim 1, characterized in that: The welding machine mechanism (3) comprises a welding machine control console (31), a support frame (32) and a welding pen (33); One end of the support frame (32) is fixed on the welding machine console (31), and the other end is connected to a welding pen (33); the control end of the welding pen (33) is connected to the welding machine console (31), and the output end of the welding pen (33) is aligned with the welding area of ​​the pipe (5) and the separator hemispherical head (4).

9. A boiler separator head pipe welding structure according to claim 1, characterized in that: The welding machine mechanism (3) adopts a submerged arc welding mechanism or a gas shielded welding mechanism.

10. A method for welding a pipe joint of a boiler separator end cap, based on a welding structure for a pipe joint of a boiler separator end cap according to any one of claims 1 to 9, characterized in that: The process includes the following: The separator hemispherical head (4) with a weld groove opened is inverted on the turntable mechanism (1), and the pipe (5) is placed on the top of the separator hemispherical head (4) by its own gravity. The welding end of the welding machine mechanism is spot-welded and fixed on the welding groove of the welding area between the pipe (5) and the separator hemispherical head (4), and the driving motor (2) is started so that the separator hemispherical head (4) drives the pipe (5) to perform a circular motion on the turntable mechanism (1). The welding machine mechanism (3) is adjusted to perform welding along the weld groove to be welded, and the welding work of the pipe of the boiler separator head is completed.

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