Weld bead cleaning device and method based on rhombic magnetic wheel layout and double-frequency ultrasonic waves

Abstract

The invention relates to a weld bead cleaning device based on rhombic magnetic wheel layout and double-frequency ultrasonic waves. The weld bead cleaning device comprises a rack, two sets of short-axis magnetic wheels, two long-axis magnetic wheels, an adjustable clamping mechanism, a double-frequency ultrasonic wave disintegrating slag cleaning unit, a driving motor, a power source and a control module. The two groups of short-axis magnetic wheels are arranged front and back, each group comprises two short-axis magnetic wheels which are symmetrically arranged on the left side and the right side of the rack, the driving motor is arranged in the rack and connected with the short-axis magnetic wheels, and the two long-axis magnetic wheels are arranged on the front side and the rear side of the rack respectively and connected with the rack through the adjustable connecting frame so that the long-axis magnetic wheels can be matched with pipelines with different curvatures; the double-frequency ultrasonic disintegrating slag cleaning unit is installed on the machine frame through an adjustable clamping mechanism and can be driven to move in the horizontal direction and the depth direction, and the working end of the double-frequency ultrasonic disintegrating slag cleaning unit is made to directly face a pipeline welding seam and stretch into a welding seam groove. The device is not prone to sliding when working, can be matched with pipelines with different curvatures, is reliable and convenient to use and good in cleaning effect, and improves the welding bead cleaning efficiency.

Description

Technical Field

[0001] The present invention belongs to the technical field of post-welding treatment, and particularly relates to a weld bead cleaning device and method based on a diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves, which are applicable to the automatic cleaning of welds on complex curved workpieces such as power plant pipelines. Background Art

[0002] After the welding of power plant pipelines, the weld beads need to be cleaned. Most traditional weld bead cleaning devices are linear layouts of double magnetic wheels or four magnetic wheels, and are based on single-frequency ultrasonic technology. However, for the weld bead cleaning devices with double magnetic wheel or four magnetic wheel layouts, the magnetic force density is insufficient and the distribution is uneven, the adsorption effect is not good, and slippage is likely to occur when applied to curved pipelines. And the single-frequency ultrasonic technology cannot take into account both the deep welding slag crushing and the surface fine treatment. Therefore, the existing weld bead cleaning devices are inconvenient to use and the cleaning effect needs to be improved. Summary of the Invention

[0003] The purpose of the present invention is to provide a weld bead cleaning device and method based on a diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves. When the device works, it is not easy to slip, can adapt to pipelines with different curvatures, is reliable and convenient to use, has a good cleaning effect, and improves the weld bead cleaning efficiency.

[0004] In order to achieve the above purpose, the technical solution adopted by the present invention is: A weld bead cleaning device based on a diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves, comprising a frame, two groups of short-axis magnetic wheels, 2 long-axis magnetic wheels, an adjustable clamping mechanism, a dual-frequency ultrasonic slag crushing and cleaning unit, a driving motor, and a power supply and control module; the two groups of short-axis magnetic wheels are arranged front and back, each group includes 2 short-axis magnetic wheels and is symmetrically arranged on the left and right sides of the frame to form a double-row redundant adsorption surface, the driving motor is arranged inside the frame and is connected to the short-axis magnetic wheels on both sides to drive them to work, the 2 long-axis magnetic wheels are respectively arranged on the front and back sides of the frame and are respectively connected to the frame through adjustable connecting frames to change the relative positions of the 2 long-axis magnetic wheels and the pipeline, so as to adapt to pipelines with different curvatures; the dual-frequency ultrasonic slag crushing and cleaning unit is installed on the frame through the adjustable clamping mechanism, and the adjustable clamping mechanism can adjust the distances in the horizontal direction and the depth direction to drive the dual-frequency ultrasonic slag crushing and cleaning unit to move, so that its working end faces the pipeline weld and extends into the weld groove for slag crushing and cleaning work; the power supply and control module includes a power supply module and a control module, the control module is electrically connected to the adjustable clamping mechanism, the dual-frequency ultrasonic slag crushing and cleaning unit, and the driving motor respectively to control the operation of the entire device, and the power supply module supplies power to the entire device.

[0005] Furthermore, the two groups of short-axis magnetic wheels are adapted to pipes with different curvatures; the adjustable connecting frame includes a fixed frame, a sliding frame and a threaded fastener. The rear end of the fixed frame is fixedly installed on the machine frame. A bolt through-hole is provided at the front end of the fixed frame. The long-axis magnetic wheel is rotatably connected to the front end of the sliding frame. A chute is provided at the rear section of the sliding frame. The threaded fastener includes a fastening bolt and a fastening nut. The fastening bolt passes through the chute and the bolt through-hole and is cooperatively connected with the fastening nut. By loosening the fastening bolt and sliding and swinging the sliding frame relative to the fixed frame, and then locking the fastening bolt, the relative position of the long-axis magnetic wheel and the pipe is adjusted to adapt to pipes with different curvatures.

[0006] Furthermore, the dual-frequency ultrasonic slag crushing and cleaning unit includes a dual-frequency probe and a horn. The dual-frequency probe includes a low-frequency transducer and a high-frequency transducer. The low-frequency transducer is used for crushing deep-layer welding slag, and the high-frequency transducer is used for surface treatment refinement. The horn is used for amplifying the amplitude to improve the slag crushing and cleaning efficiency.

[0007] Furthermore, the horn adopts a titanium alloy stepped horn. The thick end of the titanium alloy stepped horn, that is, the input end, is connected to the dual-frequency probe through a flange. The thin end of the titanium alloy stepped horn, that is, the output end, extends into the weld groove for slag crushing and cleaning work. The amplitude magnification factor of the horn is determined by the ratio of the cross-sectional area of the input end to the cross-sectional area of the output end: where M is the amplitude magnification factor, A1 is the cross-sectional area of the input end, and A2 is the cross-sectional area of the output end.

[0008] Furthermore, the adjustable clamping mechanism includes a clamping frame, a horizontal adjustment mechanism, a depth adjustment mechanism and a working unit connecting frame. The rear end of the clamping frame is fixedly connected to the machine frame. The horizontal adjustment mechanism is installed at the front part of the clamping frame. The depth adjustment mechanism is installed on the horizontal adjustment mechanism. The rear end of the working unit connecting frame is installed on the depth adjustment mechanism. The dual-frequency ultrasonic slag crushing and cleaning unit is installed on the working unit connecting frame through an elastic connecting piece at the front part of the working unit connecting frame. Thus, through the cooperative work of the horizontal adjustment mechanism and the depth adjustment mechanism, the dual-frequency ultrasonic slag crushing and cleaning unit is driven to move in the horizontal direction and the depth direction.

[0009] Further, the horizontal adjustment mechanism is a manual adjustment mechanism, including a first slider, a first lead screw, and a lead screw fixing bracket. The lead screw fixing bracket is fixedly installed on the clamping bracket. The first slider is slidably connected to the clamping bracket. The first lead screw is in mating connection with the lead screw fixing bracket. The rear end of the first lead screw has an adjustment knob. The front end of the first lead screw is rotatably connected to the first slider, so as to drive the first lead screw to perform a screwing-in and screwing-out movement by rotating the adjustment knob, and further drive the first slider to slide back and forth along the clamping bracket. The depth adjustment mechanism is installed on the first slider.

[0010] Further, the depth adjustment mechanism is an electric adjustment mechanism, including a vertical bracket, a second slider, a second lead screw, an adjustment motor, and a motor fixing bracket. The vertical bracket is fixedly installed on the horizontal adjustment mechanism. The adjustment motor is fixedly installed on the upper part of the vertical bracket through the motor fixing bracket and is connected to the second lead screw downward. The second slider is slidably connected to the vertical bracket. The second lead screw is in mating connection with the second slider, so as to drive the second lead screw to rotate by the adjustment motor and convert the rotational movement of the second lead screw into the up-and-down sliding of the second slider. The rear end of the working unit connecting frame is fixedly connected to the second slider. The control module is electrically connected to the adjustment motor. The control module controls the adjustment motor to work according to the preset downward movement distance of the working end, drives the second slider and the working unit connecting frame and the dual-frequency ultrasonic slag crushing and cleaning unit thereon to move downward by a set distance, so that the working end of the dual-frequency ultrasonic slag crushing and cleaning unit extends into the weld groove for slag crushing and cleaning work.

[0011] Further, it further includes a rotary brushing unit. The rotary brushing unit is arranged beside the dual-frequency ultrasonic slag crushing and cleaning unit and is installed on the adjustable clamping mechanism together with the dual-frequency ultrasonic slag crushing and cleaning unit. The control module is electrically connected to the rotary brushing unit to control its work.

[0012] Further, the frame includes a first housing and a second housing. Two driving motors are arranged front and back in the first housing. The driving motors are installed in the first housing through the motor fixing brackets. The two driving ends of the driving motors respectively penetrate out of the left and right sides of the first housing and are connected to the corresponding short-axis magnetic wheels to drive them to work. The two long-axis magnetic wheels are respectively connected to the first housing through adjustable connecting frames. The second housing is fixedly installed on the upper part of the first housing. The power supply and the control module are installed in the second housing. The adjustable clamping mechanism is fixedly installed on the upper part of the second housing.

[0013] The present invention also provides a weld groove cleaning method based on the above device, including: 1) Place the device on the target pipeline. The two groups of short-axis magnetic wheels adapt to pipelines with different curvatures, and adjust the positions of the two long-axis magnetic wheels until they reliably contact the target pipeline, so as to adapt to the curvature of the target pipeline. 2) Adjust the horizontal and depth positions of the dual-frequency ultrasonic slag crushing and cleaning unit through the adjustable clamping mechanism, so that the working end of the dual-frequency ultrasonic slag crushing and cleaning unit faces the pipeline weld and extends into the weld groove; 3) Start the dual-frequency ultrasonic slag crushing and cleaning unit. First, start the low-frequency mode to crush the deep-layer welding slag, and then start the high-frequency mode for surface treatment; 4) Drive the short-axis magnetic wheel to move along the weld track through the drive motor to complete the cleaning operation.

[0014] Compared with the prior art, the present invention has the following beneficial effects: The present invention provides a weld cleaning device and method based on the diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves. Through the diamond-shaped magnetic wheel layout design of short-axis four wheels and long-axis two wheels, the device not only greatly improves the magnetic suction and its distribution uniformity, but also enables the device to be applicable to pipelines with different curvatures, and can always be reliably adsorbed on the pipeline during the working process to avoid the risk of slippage. In addition, the device realizes the cooperative operation of dual-frequency ultrasonic waves to simultaneously meet the requirements of welding slag crushing and surface fine treatment, greatly improving the cleaning effect and enhancing the weld cleaning efficiency. Therefore, the present invention has strong practicability and broad application prospects. Description of the Drawings

[0015] Figure 1 is the schematic structural diagram (front view) of the device in the embodiment of the present invention; Figure 2 is the schematic structural diagram (top view) of the device in the embodiment of the present invention; Figure 3 is the schematic diagram of the working state of the device in the embodiment of the present invention adapted to a pipeline with a diameter of 400 mm; Figure 4 is the schematic diagram of the working state of the device in the embodiment of the present invention adapted to a pipeline with a diameter of 260 mm; Figure 5 is the schematic structural diagram of the adjustable clamping mechanism in the embodiment of the present invention; Figure 6 is the schematic structural diagram of the depth adjustment mechanism in the embodiment of the present invention; Figure 7 is the schematic installation structure diagram of the dual-frequency ultrasonic slag crushing and cleaning unit and the rotary brushing unit in the embodiment of the present invention; Figure 8 is the schematic structural diagram of the rotary brushing unit in the embodiment of the present invention; Figure 9 is the schematic block diagram of the implementation principle of the power supply and control module in the embodiment of the present invention. Detailed Embodiments

[0016] The present invention will be further described below with reference to the drawings and embodiments.

[0017] It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the technical field to which this application belongs.

[0018] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0019] As Figures 1-9 shown, this embodiment provides a weld bead cleaning device based on a diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves, including a frame, two groups of short-axis magnetic wheels 1, 2 long-axis magnetic wheels 2, an adjustable clamping mechanism, a dual-frequency ultrasonic slag cleaning unit, a driving motor 3, and a power supply and control module 4; the two groups of short-axis magnetic wheels 1 are arranged front and back, each group includes 2 short-axis magnetic wheels and is symmetrically arranged on the left and right sides of the frame to form a double-row redundant adsorption surface, the driving motor 3 is arranged inside the frame and is connected to the short-axis magnetic wheels 1 on both sides to drive them to work, the 2 long-axis magnetic wheels 2 are respectively arranged on the front and back sides of the frame and are respectively connected to the frame through adjustable connecting frames to change the relative position between the 2 long-axis magnetic wheels and the pipeline, so as to adapt to pipelines with different curvatures; the dual-frequency ultrasonic slag cleaning unit is installed on the frame through the adjustable clamping mechanism, and the adjustable clamping mechanism can adjust the distance in the horizontal direction and the depth direction to drive the dual-frequency ultrasonic slag cleaning unit to move, so that its working end faces the pipeline weld 10 and extends into the weld groove for slag crushing and cleaning work; the power supply and control module 4 includes a power supply module and a control module, the control module is electrically connected to the adjustable clamping mechanism, the dual-frequency ultrasonic slag cleaning unit, and the driving motor respectively to control the operation of the entire device, and the power supply module supplies power to the entire device.

[0020] The composition of this device will be further described below.

[0021] 1. Enhanced diamond-shaped magnetic wheel layout Short-axis magnetic wheels (4 in two groups): The two groups of short-axis magnetic wheels 1 adapt to pipelines 5 with different curvatures. Each group of 2 short-axis magnetic wheels is symmetrically distributed on the left and right sides of the frame to form a "double-row redundant adsorption surface".

[0022] Long-axis magnetic wheels (2): Located at the front and rear ends of the bottom of the device and connected to the frame through adjustable connecting frames.

[0023] The adjustable connecting frame includes a fixed frame 6, a sliding frame 7 and a threaded fastener. The rear end of the fixed frame 6 is fixedly installed on the machine frame. A bolt through-hole is provided at the front end of the fixed frame 6. The long-axis magnetic wheel 2 is rotatably connected to the front end of the sliding frame 7. A chute is provided at the rear section of the sliding frame 7. The threaded fastener includes a fastening bolt 8 and a fastening nut 9. The fastening bolt 8 passes through the chute and the bolt through-hole and is connected in cooperation with the fastening nut 9. By loosening the fastening bolt 8 and sliding and swinging the sliding frame relative to the fixed frame, and then tightening the fastening bolt 8, the relative position of the long-axis magnetic wheel 2 and the pipeline 5 is adjusted to adapt to pipelines with different curvatures. The working states of the device adapting to pipelines with diameters of 400 mm and 260 mm are respectively as Figure 3 , 4 shown.

[0024] In this embodiment, the diameters of the short-axis magnetic wheel and the long-axis magnetic wheel are both 60 mm. NdFeB N52 grade magnets are used. The single-wheel adsorption force is ≥150 N, and the total adsorption force of 6 magnetic wheels is ≥900 N.

[0025] 2. Dual-frequency ultrasonic slag crushing unit The dual-frequency ultrasonic slag cleaning and crushing unit includes a dual-frequency probe 11 and a horn 12. The dual-frequency probe 11 includes a low-frequency transducer and a high-frequency transducer. The low-frequency transducer is used to crush deep-layer welding slag, and the high-frequency transducer is used for surface treatment refinement. The horn 12 is used to amplify the amplitude to improve the welding slag crushing and cleaning efficiency.

[0026] In this embodiment, a 20 kHz low-frequency transducer is used for the low-frequency transducer, and a 40 kHz high-frequency transducer is used for the high-frequency transducer. The horn uses a titanium alloy stepped horn. The thick end of the titanium alloy stepped horn, that is, the input end diameter is 25 mm, and it is connected to the dual-frequency probe through a flange. The thin end of the titanium alloy stepped horn, that is, the output end diameter is 5 mm, and it extends into the weld groove for slag crushing and cleaning work.

[0027] The characteristic of the stepped horn is that there is a stepped cross-sectional area change along the axial direction, which can effectively amplify the amplitude of ultrasonic waves, thereby improving the working efficiency of ultrasonic waves. The amplitude amplification multiple of the horn is determined by the ratio of the cross-sectional area of the input end to the cross-sectional area of the output end: where M is the amplitude amplification multiple, A1 is the cross-sectional area of the input end, and A2 is the cross-sectional area of the output end.

[0028] 3. Adjustable clamping mechanism As Figure 5As shown, the adjustable clamping mechanism includes a clamping frame 13, a horizontal adjustment mechanism 14, a depth adjustment mechanism 15, and a working unit connecting frame 16. The rear end of the clamping frame 13 is fixedly connected to the machine frame. The horizontal adjustment mechanism 14 is installed at the front of the clamping frame 13. The depth adjustment mechanism 15 is installed on the horizontal adjustment mechanism 14. The rear end of the working unit connecting frame 16 is installed on the depth adjustment mechanism 15. The front part of the working unit connecting frame 16 has an elastic connecting piece for installing the dual-frequency ultrasonic slag cleaning unit. The dual-frequency ultrasonic slag cleaning unit is installed on the working unit connecting frame 16 through the elastic connecting piece. Thus, through the coordinated operation of the horizontal adjustment mechanism 14 and the depth adjustment mechanism 15, the dual-frequency ultrasonic slag cleaning unit is driven to move in the horizontal direction and the depth direction.

[0029] In this embodiment, the elastic connecting piece can be a double-ring elastic structure. The inner and outer rings are elastically connected by a plurality of springs arranged circumferentially. The inner ring is used to install the working unit connecting frame 16, and the outer ring is fixed to the front part of the working unit connecting frame 16. The reason why the dual-frequency ultrasonic slag cleaning unit is installed on the working unit connecting frame 16 through the elastic connecting piece is that during the operation of the device, there are some undulations on the weld surface. By installing the dual-frequency ultrasonic slag cleaning unit on the working unit connecting frame 16 through the elastic connecting piece, it can have a certain elastic margin, so that the lower end of the horn always remains in contact with the working surface during the operation, and it will not damage related components such as the horn and the adjustment motor during the adjustment and operation of the device due to complete rigid connection.

[0030] The horizontal adjustment mechanism 14 is a manual adjustment mechanism, which includes a first slider 17, a first lead screw 18, and a lead screw fixing frame 19. The lead screw fixing frame 19 is fixedly installed on the clamping frame 13. The first slider 17 is slidably connected to the clamping frame 13. The first lead screw 18 is connected to the lead screw fixing frame 19 in a mating manner. The rear end of the first lead screw 18 has an adjustment knob 20. The front end of the first lead screw 18 is rotatably connected to the first slider 17. By rotating the adjustment knob 20, the first lead screw 18 is driven to perform a screwing-in and screwing-out movement, and then the first slider 17 is driven to slide back and forth along the clamping frame 13. The depth adjustment mechanism 15 is installed on the first slider 17.

[0031] As Figure 6As shown, the depth adjustment mechanism 15 is an electric adjustment mechanism, including a vertical support 21, a second slider 22, a second lead screw 23, an adjustment motor 24 and a motor fixing bracket 25. The vertical support 21 is fixedly installed on the first slider 17 of the horizontal adjustment mechanism 14. The adjustment motor 24 is fixedly installed on the upper part of the vertical support 21 through the motor fixing bracket 25 and is connected downward to the second lead screw 23. The second slider 22 is slidably connected to the vertical support 21. The second lead screw 23 is in mating connection with the second slider 22 to drive the second lead screw 23 to rotate through the adjustment motor 24 and convert the rotational motion of the second lead screw 23 into the up-and-down sliding of the second slider 22. The rear end of the working unit connecting frame 16 is fixedly connected to the second slider 22. The control module 4 is electrically connected to the adjustment motor 24. The control module 4 controls the operation of the adjustment motor 24 according to the preset downward movement distance of the working end, driving the second slider 22, the working unit connecting frame 16 and the dual-frequency ultrasonic slag crushing and cleaning unit thereon to move downward by a set distance, so that the working end of the dual-frequency ultrasonic slag crushing and cleaning unit extends into the weld groove for slag crushing and cleaning work. In addition, the adjustment motor has an overcurrent protection function to avoid motor overload and damage to working components. In this embodiment, two left and right limit guide rails 28 are vertically provided on the vertical support 21. The second slider 22 is slidably engaged with both the left and right limit guide rails 28 at the same time, thereby realizing the sliding connection between the second slider 22 and the vertical support 21, and restricting the second slider 22 to only perform vertical sliding through the guiding action of the limit guide rails 28.

[0032] To strengthen the support strength of the clamping frame, the adjustable clamping mechanism further includes a reinforcing rod 26. One end of the reinforcing rod 26 is fixedly connected to the side of the machine frame, and the other end is fixedly connected to the lower side of the middle part of the clamping frame 13.

[0033] 4. Rotary brushing unit To improve the cleaning effect, the device further includes a rotary brushing unit 27. The rotary brushing unit 27 is arranged beside the dual-frequency ultrasonic slag crushing and cleaning unit and is installed on the adjustable clamping mechanism together with the dual-frequency ultrasonic slag crushing and cleaning unit. As Figure 7 shown, two clamping seats are arranged side by side on the working unit connecting frame 16. One is used to install the dual-frequency ultrasonic slag crushing and cleaning unit, and the other is used to install the rotary brushing unit 27. The control module 4 is electrically connected to the rotary brushing unit 27 to control its operation.

[0034] In this embodiment, the rotary brushing unit uses a silicon carbide fiber brush head. The brush head of the rotary brushing unit can be replaced with a grinding head, a scraper, etc. according to the need for interlayer slag cleaning to improve the cleaning effect.

[0035] As Figure 8As shown, the rotary scrubbing unit 27 mainly consists of a brush head motor 32 and a brush head 33. The clamping seat clamps the brush head motor 32, and the brush head motor 32 drives the brush head 33 to work. The brush head can be replaced with other working parts, such as a grinding head, a scraper, etc., and is quickly replaced through a quick locking device 34.

[0036] 5. Drive System In this device, two drive motors are arranged at the front and rear, respectively used to drive two groups of short-axis magnetic wheels. The drive motors are all servo motors to drive the 4 short-axis magnetic wheels in the two groups to move synchronously, with stepless speed regulation and forward and reverse bidirectional drive.

[0037] 6. Lightweight Frame The frame includes a first housing 29 and a second housing 30. Two drive motors 3 are arranged at the front and rear in the first housing 29. The drive motors 3 are installed in the first housing 29 through motor fixing frames 25. The two drive ends of the drive motors 3 respectively pass through the left and right sides of the first housing 29 and are connected to the corresponding short-axis magnetic wheels 1 to drive them to work. Two long-axis magnetic wheels 2 are respectively connected to the first housing 29 through adjustable connecting frames. The second housing 30 is fixedly installed on the upper part of the first housing 29, and the power supply and control module 4 is installed in the second housing 30. The second housing 30 is a transition piece between the first housing 29 and the clamping frame 13. The adjustable clamping mechanism is fixedly installed on the upper part of the second housing 30.

[0038] In this embodiment, the frame adopts a carbon fiber frame, with a total weight ≤ 22 kg and a torsional stiffness ≥ 200 N•m / rad.

[0039] The working unit connecting frame for clamping the dual-frequency ultrasonic slag cleaning unit and the rotary scrubbing unit adopts a magnesium alloy bracket, and the bracket is provided with reinforcing bars to improve stiffness and stability.

[0040] 7. Power Supply and Control Module In this device, the power supply and control module includes a power supply module and a control module.

[0041] The power supply module is externally connected to 220V alternating current. After the power supply module filters, rectifies, and regulates the voltage of the 220V alternating current, it supplies power to each power-consuming unit in devices such as two drive motors (24V), an adjustment motor (24V), a brush head motor (24V), a low-frequency transducer (pulse voltage: 200V), and a high-frequency transducer (pulse voltage: 100V).

[0042] The control module integrates the control functions of two drive motors, an adjustment motor, a brush head motor, and high- and low-frequency transducers, including: controlling the two drive motors to perform forward and reverse switching and stepless speed regulation (50 - 3000 RPM); controlling the adjustment motor to perform forward and reverse switching and decelerate to 3 mm / s for precise control; controlling the brush head motor to perform stepless speed regulation (50 - 3000 RPM); controlling the low-frequency transducer and high-frequency transducer in the dual-frequency probe to work together (alternately switch between high and low frequencies) or independently at low frequency 20 kHz / high frequency 40 kHz. In addition, the control module is also provided with an interaction module to achieve the interaction function with the user.

[0043] In this embodiment, both the power module and the control module are arranged in the second housing 30, and the interaction module is embedded on one side surface of the second housing 30 to facilitate the user to input control commands and display relevant working parameters.

[0044] This embodiment also provides a weld bead cleaning method based on the above device, and the specific implementation steps are as follows.

[0045] S1. Place the device on the target pipeline. The two groups of short-axis magnetic wheels adapt to pipelines with different curvatures, and adjust the positions of the two long-axis magnetic wheels until they reliably contact the target pipeline, so as to adapt to the curvature of the target pipeline.

[0046] S2. Adjust the positions of the dual-frequency ultrasonic slag crushing and cleaning unit in the horizontal and depth directions through the adjustable clamping mechanism, so that the working end of the dual-frequency ultrasonic slag crushing and cleaning unit faces the pipeline weld and extends into the weld groove.

[0047] In this embodiment, the device is also provided with a rotary brushing unit. Therefore, during the process of adjusting the positions of the dual-frequency ultrasonic slag crushing and cleaning unit in the horizontal and depth directions, the positions of the rotary brushing unit in the horizontal and depth directions are synchronously adjusted.

[0048] During this process, manual adjustment is used in the horizontal direction, and a stepless motor is used to adjust the position in the depth direction, so that the horn moves downward a set distance until its thin end contacts the working surface.

[0049] S3. Start the dual-frequency ultrasonic slag crushing and cleaning unit. If the cooperative working mode is selected, first start the low-frequency mode (20 kHz) to crush the deep-layer welding slag, and crush the welding slag with a depth > 1 mm; then start the high-frequency mode (40 kHz) for surface treatment, and the surface roughness Ra ≤ 6.3 μm after surface treatment.

[0050] During this process, the rotary brushing unit works together with the dual-frequency ultrasonic slag crushing and cleaning unit. While starting the high-frequency mode for surface treatment, start the brushing mode to achieve the purpose of improving the cleaning effect.

[0051] S4. Drive the short-axis magnetic wheel to move along the weld bead trajectory through the drive motor to complete the cleaning operation.

[0052] During this process, by changing the supply voltage of the drive motor power supply, the synchronous speed of the drive motor can be adjusted and the forward and reverse switching can be performed, so as to realize the stepless speed regulation of the magnetic wheel rotation and the forward and reverse drive of the device movement.

[0053] In step S1, after installing the device on the target pipeline, on the premise that the working components (dual-frequency ultrasonic slag crushing and cleaning unit + rotating brush cleaning unit) do not contact the working surface, first perform the magnetic wheel movement test. First, start the drive motor, select the movement direction and start the magnetic wheel movement test at the minimum speed, and then adjust the speed to a suitable speed to start the next step of work.

[0054] In addition, this device has a safety protection mechanism. When the dual-frequency ultrasonic slag crushing and cleaning unit overheats (>80 °C), it will automatically stop running.

[0055] Example 1: Working conditions: Φ260mm×20 pipeline, oxidation layer depth 0.8mm; Settings: The spacing of the long-axis magnetic wheels is 300mm, which is adapted to the pipe diameter; Ultrasonic high frequency 40KHz, pulse voltage 100V; Effect: There is no slip throughout the process, and the surface Ra = 5.5μm after cleaning.

[0056] Example 2: Working conditions: Φ400×35mm pipeline, multi-layer weld beads; Settings: The spacing of the long-axis magnetic wheels is adjusted to 440mm, which is adapted to the pipe diameter; Ultrasonic low frequency 20KHz, pulse voltage 200V; ultrasonic high frequency 40KHz, pulse voltage 100V; start the brush head at the same time; Effect: There is no slip throughout the process, and the weld slag cleaning effect is good.

[0057] The above is only the preferred embodiment of the present invention, and it is not a limitation of the present invention in other forms. Any person skilled in the art may use the disclosed technical content to make changes or modifications into equivalent embodiments with equivalent changes. However, any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention without departing from the technical solution content of the present invention still belong to the protection scope of the technical solution of the present invention.

Claims

1. A bead cleaning device based on a rhombic magnetic wheel layout and dual-frequency ultrasonic waves, characterized in that, It includes a frame, two groups of short-axis magnetic wheels, two long-axis magnetic wheels, an adjustable clamping mechanism, a dual-frequency ultrasonic slag crushing and cleaning unit, a driving motor, and a power supply and control module; the two groups of short-axis magnetic wheels are arranged front and back, each group includes two short-axis magnetic wheels and is symmetrically arranged on the left and right sides of the frame to form a double-row redundant adsorption surface, the driving motor is arranged inside the frame and is connected to the short-axis magnetic wheels on both sides to drive them to work, the two long-axis magnetic wheels are respectively arranged on the front and back sides of the frame and are respectively connected to the frame through adjustable connecting frames to change the relative positions of the two long-axis magnetic wheels and the pipeline, so as to adapt to pipelines with different curvatures; the dual-frequency ultrasonic slag crushing and cleaning unit is installed on the frame through the adjustable clamping mechanism, and the adjustable clamping mechanism can adjust the distances in the horizontal direction and the depth direction to drive the dual-frequency ultrasonic slag crushing and cleaning unit to move, so that its working end is facing the pipeline weld and extends into the weld groove for slag crushing and cleaning work; the power supply and control module includes a power supply module and a control module, the control module is electrically connected to the adjustable clamping mechanism, the dual-frequency ultrasonic slag crushing and cleaning unit and the driving motor respectively to control the operation of the whole device, and the power supply module supplies power to the whole device.

2. The weld bead cleaning device based on the diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves according to claim 1, wherein The two groups of short-axis magnetic wheels adapt to pipelines with different curvatures; the adjustable connecting frame includes a fixed frame, a sliding frame and a threaded fastener, the rear end of the fixed frame is fixedly installed on the frame, a bolt through hole is opened at the front end of the fixed frame, the long-axis magnetic wheel is rotatably connected to the front end of the sliding frame, a sliding groove is opened at the rear section of the sliding frame, the threaded fastener includes a fastening bolt and a fastening nut, the fastening bolt passes through the sliding groove and the bolt through hole and is connected with the fastening nut in cooperation; by loosening the fastening bolt and making the sliding frame slide and swing relative to the fixed frame, and then locking the fastening bolt, the relative position of the long-axis magnetic wheel and the pipeline is adjusted to adapt to pipelines with different curvatures.

3. The weld bead cleaning device based on the diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves according to claim 1, wherein, The dual-frequency ultrasonic slag crushing and cleaning unit includes a dual-frequency probe and a horn, the dual-frequency probe includes a low-frequency transducer and a high-frequency transducer, the low-frequency transducer is used for crushing deep-layer welding slag, the high-frequency transducer is used for surface refinement treatment, and the horn is used for amplifying the amplitude to improve the efficiency of slag crushing and cleaning.

4. The weld bead cleaning device based on the diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves according to claim 3, wherein The horn adopts a titanium alloy stepped horn, the thick end of the titanium alloy stepped horn, that is, the input end is connected to the dual-frequency probe through a flange, and the thin end of the titanium alloy stepped horn, that is, the output end extends into the weld groove for slag crushing and cleaning work; The amplitude magnification factor of the horn is determined by the ratio of the cross-sectional area of the input end to the cross-sectional area of the output end: where M is the amplitude magnification factor, A1 is the cross-sectional area of the input end, and A2 is the cross-sectional area of the output end.

5. The bead cleaning device based on the rhombic magnetic wheel layout and dual-frequency ultrasonic waves according to claim 1, characterized in that, The adjustable clamping mechanism includes a clamping frame, a horizontal adjustment mechanism, a depth adjustment mechanism, and a working unit connecting frame. The rear end of the clamping frame is fixedly connected to the machine frame. The horizontal adjustment mechanism is installed at the front of the clamping frame. The depth adjustment mechanism is installed on the horizontal adjustment mechanism. The rear end of the working unit connecting frame is installed on the depth adjustment mechanism. The dual-frequency ultrasonic slag crushing and cleaning unit is installed on the working unit connecting frame through an elastic connecting piece at the front of the working unit connecting frame. Thus, through the coordinated work of the horizontal adjustment mechanism and the depth adjustment mechanism, the dual-frequency ultrasonic slag crushing and cleaning unit is driven to move in the horizontal direction and the depth direction.

6. The bead cleaning device based on the diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves according to claim 5, characterized in that, The horizontal adjustment mechanism is a manual adjustment mechanism, including a first slider, a first lead screw, and a lead screw fixing frame. The lead screw fixing frame is fixedly installed on the clamping frame. The first slider is slidably connected to the clamping frame. The first lead screw is connected to the lead screw fixing frame in a matching manner. The rear end of the first lead screw has an adjustment knob. The front end of the first lead screw is rotatably connected to the first slider. By rotating the adjustment knob, the first lead screw is driven to perform a screwing-in and screwing-out movement, and then the first slider is driven to slide back and forth along the clamping frame. The depth adjustment mechanism is installed on the first slider.

7. The weld bead cleaning device based on the diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves according to claim 5, characterized in that, The depth adjustment mechanism is an electric adjustment mechanism, including a vertical support, a second slider, a second lead screw, an adjustment motor, and a motor fixing frame. The vertical support is fixedly installed on the horizontal adjustment mechanism. The adjustment motor is fixedly installed on the upper part of the vertical support through the motor fixing frame and is connected to the second lead screw downward. The second slider is slidably connected to the vertical support. The second lead screw is connected to the second slider in a matching manner. By driving the second lead screw to rotate through the adjustment motor, the rotational movement of the second lead screw is converted into the up-and-down sliding of the second slider. The rear end of the working unit connecting frame is fixedly connected to the second slider. The control module is electrically connected to the adjustment motor. The control module controls the operation of the adjustment motor according to the preset downward movement distance of the working end, driving the second slider, the working unit connecting frame and the dual-frequency ultrasonic slag crushing and cleaning unit thereon to move downward by a set distance, so that the working end of the dual-frequency ultrasonic slag crushing and cleaning unit extends into the weld groove for slag crushing and cleaning work.

8. The bead cleaning device based on the diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves according to claim 1, characterized in that, It further includes a rotary brushing unit. The rotary brushing unit is arranged beside the dual-frequency ultrasonic slag crushing and cleaning unit and is installed on the adjustable clamping mechanism together with the dual-frequency ultrasonic slag crushing and cleaning unit. The control module is electrically connected to the rotary brushing unit to control its operation.

9. The weld bead cleaning device based on the diamond-shaped magnetic wheel layout and dual-frequency ultrasonic waves according to claim 1, wherein, The machine frame includes a first housing and a second housing. There are two drive motors arranged front and back in the first housing. The drive motors are installed in the first housing through motor fixing frames. The two drive ends of the drive motors respectively penetrate to the left and right sides of the first housing and are connected to the corresponding short-axis magnetic wheels to drive their operation. The two long-axis magnetic wheels are respectively connected to the first housing through adjustable connecting frames. The second housing is fixedly installed on the upper part of the first housing. The power supply and the control module are installed in the second housing. The adjustable clamping mechanism is fixedly installed on the upper part of the second housing.

10. A method for cleaning a weld bead based on the device according to any one of claims 1-9, characterized in that, Including: 1) Place the device on the target pipeline. The two groups of short-axis magnetic wheels can adapt to pipelines with different curvatures. Adjust the positions of the two long-axis magnetic wheels until they reliably contact the target pipeline, so as to adapt to the curvature of the target pipeline; 2) Adjust the horizontal and depth positions of the dual-frequency ultrasonic slag crushing and cleaning unit through the adjustable clamping mechanism, so that the working end of the dual-frequency ultrasonic slag crushing and cleaning unit faces the pipeline weld and extends into the weld groove; 3) Start the dual-frequency ultrasonic slag crushing and cleaning unit. First start the low-frequency mode to crush the deep-layer welding slag, and then start the high-frequency mode for surface treatment; 4) Drive the short-axis magnetic wheels to move along the weld bead trajectory through the drive motor to complete the cleaning operation.

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