Reducing pipe beam welding device, welding method and control system

Abstract

The invention discloses a reducing pipe beam welding device, a welding method and a control system, and relates to the technical field of pipe beam welding. The device comprises a rack, a pair of horizontal moving mechanisms is symmetrically mounted on the rack; and each pair of horizontal moving mechanisms is connected with the corresponding rotating mechanism. In addition, a pair of limiting mechanisms is further arranged, and the limiting mechanisms are connected with the corresponding rotating mechanisms. The welding mechanism is arranged on the rack and located between the pair of limiting mechanisms. The pair of limiting mechanisms is used for clamping the thick tubular beam and the thin tubular beam respectively. When the welding mechanism conducts welding, the rotating mechanism can drive the limiting mechanism clamping the thick tubular beam and the thin tubular beam to rotate. The control system comprises a processor and a memory, computer programs are stored in the memory, and when the programs are executed by the processor, the following functions of parameter analysis and preprocessing, motion control execution, process monitoring and optimization and system management and tracing are achieved in sequence. Two different tubular beams can be clamped and welded, and the welding quality and the working efficiency are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of pipe beam welding, and particularly relates to a welding device, a welding method and a control system for a pipe beam with different diameters. Background Art

[0002] During the use of pipe beams, due to the limitations of working conditions, pipe beams with different diameters are required to meet the use requirements. The processing of pipe beams with different diameters usually involves splicing two pipe beams with different diameters together and then using manual welding to weld at the splicing position. Manual welding has low efficiency, and only a part of the joint can be welded each time. Therefore, when welding the entire splicing position, the pipe beam needs to be turned over. This not only reduces the work efficiency, but also easily causes installation errors during turning over, resulting in unstable product quality. Summary of the Invention

[0003] In view of this, the present invention provides a welding device for a pipe beam with different diameters to solve the technical problems of low work efficiency and unstable product quality in the existing manual welding.

[0004] To achieve the above object, the present invention provides the following technical solutions: A welding device for a pipe beam with different diameters, comprising: A frame; A pair of horizontal moving mechanisms symmetrically installed on the frame; A pair of rotating mechanisms each connected to a corresponding horizontal moving mechanism; A pair of limiting mechanisms, the limiting mechanisms being connected to the corresponding rotating mechanisms; A welding mechanism disposed on the frame and located between the pair of limiting mechanisms; The pair of limiting mechanisms are respectively used for clamping a thick pipe beam and a thin pipe beam. When the welding mechanism performs welding, the pair of rotating mechanisms drive the pair of limiting mechanisms that respectively clamp the thick pipe beam and the thin pipe beam to rotate.

[0005] Further, the welding mechanism includes: A bracket supported on the frame; A welding torch driven to move by a first cylinder installed on the top of the bracket; A dust suction assembly installed on the bracket, the dust suction assembly being used to clean the dust at the welding position of the welding torch.

[0006] Even further, the dust suction assembly includes: An exhaust fan installed on the bracket; A dust suction box installed on the bracket and close to the welding torch. A suction nozzle is installed on the exhaust fan, and the suction nozzle extends into the dust suction box.

[0007] Further, the rotating mechanism includes: A first mounting plate and a second mounting plate that can be spliced together; A first motor mounted on the sides of the first mounting plate and the second mounting plate, and the limiting mechanism is slidably connected between the first mounting plate and the second mounting plate.

[0008] Furthermore, both ends of the first mounting plate and the second mounting plate are connected by bolts. A docking block is provided at one end of the first mounting plate, and a docking groove adapted to the docking block is provided at one end of the second mounting plate.

[0009] Furthermore, at least two connecting rods are provided on one side of the fixing frame of the limiting mechanism. A sliding block is mounted at the end of the connecting rod, and the sliding block is slidably arranged in a circular chute. The circular chute is formed by splicing a first semi-circular chute on the first mounting plate and a second semi-circular chute on the second mounting plate.

[0010] Furthermore, the horizontal movement mechanism includes: A second motor mounted on the frame; A screw rod connected to the output end of the second motor; A moving seat threadedly connected to the screw rod; A guide rod provided on the frame, and the moving seat is slidably engaged with the guide rod; A connecting block connecting the moving seat and the corresponding first mounting plate.

[0011] Furthermore, the limiting mechanism includes a pair of clamping devices mounted on the fixing frame. The pair of clamping devices are arranged oppositely and can move towards each other synchronously to clamp the pipe beam.

[0012] Furthermore, the clamping device includes: A stepping motor mounted on the fixing frame; A cam connected to the stepping motor; A moving limit assembly abutted against the cam, and the moving limit assembly can clamp the pipe beam.

[0013] Furthermore, the moving limit assembly includes: A push rod slidably arranged on the L-shaped limit plate of the fixing frame; A push plate connected to one end of the push rod; A limit plate connected to the other end of the push rod; A first compression spring sleeved on the push rod, and the first compression spring abuts between the push plate and the L-shaped limit plate.

[0014] The present invention also provides a method for welding a pipe beam with different diameters, including the following steps: Obtain the length and diameter parameters of the thick pipe beam and the thin pipe beam to be welded and input them into the control system; Control the horizontal movement mechanism to adjust the initial position of the limit mechanism, and synchronously drive the lateral support components of the auxiliary support device to a preset spacing; Adjust the clamping height of the lateral support components through the lifting mechanism according to the pipe beam diameter to ensure coaxial positioning of the pipe beam; After starting the clamping device of the limit mechanism to fix the end of the pipe beam, drive the second motor to move the pipe beam along the butt joint direction to the welding position; Control the first motor to drive the pipe beam to rotate, and at the same time, the first cylinder drives the welding torch to move along the welding track to perform full-circle welding; Adsorb the welding fumes in real time through the exhaust fan; After welding is completed, perform the reset operation of each actuator and release the finished pipe beam.

[0015] The present invention also provides a control system for welding pipes with different diameters, including a processor and a memory, characterized in that: the memory stores a computer program, and when the program is executed by the processor, the following functions are implemented in sequence: (1) Parameter parsing and preprocessing Parse the input pipe beam geometric parameters and generate multi-axis motion control instructions; Construct a three-dimensional model of the pipe beam for virtual assembly verification to ensure welding feasibility; (2) Motion control execution Implement a multi-axis linkage motion control algorithm to coordinate the motion timing of the horizontal movement mechanism, the rotation mechanism, and the welding mechanism; Generate an optimal welding path plan based on the welding process database and dynamically adjust the execution track; (3) Process monitoring and optimization Integrate a real-time welding quality detection and defect identification module to synchronously monitor the weld formation quality; According to the feedback of the fume sensor, adjust the power of the exhaust fan in real time to optimize the working environment; Dynamically adjust welding process parameters such as welding current and speed based on welding quality monitoring data; (4) System management and traceability Realize the full closed-loop automatic control of the welding process and early warning of abnormal states; Generate a traceable welding process log including process parameters, environmental data, and quality inspection results; Automatically record abnormal events and generate a maintenance warning report.

[0016] It can be seen from the above technical solutions that the advantages of the present invention are: 1. In the present invention, by providing a pair of horizontal movement mechanisms, the distance between a pair of limiting mechanisms for clamping two pipe beams can be adjusted to accommodate pipe beams of different lengths.

[0017] 2. Through the horizontal movement mechanisms, the distance between the limiting mechanisms can be flexibly adjusted. This adjustment is continuous and can be set arbitrarily within a certain range.

[0018] 3. Since the distance between the pair of limiting mechanisms is adjustable, the device can accommodate pipe beams of the same specification but different lengths. Without replacing different fixtures, welding of multiple lengths of pipe beams can be achieved.

[0019] 4. For welding of pipe beams of different specifications, just replace different limiting plates.

[0020] 5. In the present invention, there is a pair of rotating mechanisms. The pair of rotating mechanisms can drive a pair of limiting mechanisms to rotate, so that the two pipe beams rotate during welding to complete the welding of a complete circumferential surface. With this design, compared with manual welding, there is no need to turn the pipe beam during the welding process, which not only avoids the installation errors generated during turning, but also reduces the process steps and improves the processing efficiency.

[0021] 6. In the present invention, the first mounting plate and the second mounting plate are spliced into an integral component, and convex plates are provided at both ends of the two to be fixed, making the connection reliable.

[0022] 7. One end of the first mounting plate is provided with a docking block, and one end of the second mounting plate is provided with a docking groove. The docking block is adapted to the docking groove. When the docking block is inserted into the docking groove, the two mounting plates are accurately aligned, ensuring the accuracy of the installation position.

[0023] 8. Through the accurate alignment of the docking block and the docking groove, and the firm locking of the convex plate, the connection between the first mounting plate and the second mounting plate becomes very stable. This design reduces the errors and uncertainties during the installation process, and improves the reliability and durability of the overall structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The drawings forming a part of the present invention are used to provide a further understanding of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention.

[0025] Figure 1 is a schematic structural diagram of the present invention.

[0026] Figure 2 is a schematic structural diagram of the welding mechanism of the present invention.

[0027] Figure 3 is Figure 2 a left view of

[0028] Figure 4 It is a schematic structural diagram of the horizontal moving mechanism of the present invention.

[0029] Figure 5 It is a schematic structural diagram of the rotating mechanism of the present invention.

[0030] Figure 6 It is a structural sectional view of the rotating mechanism of the present invention.

[0031] Figure 7 It is a right view of the first mounting plate and the second mounting plate of the present invention.

[0032] Figure 8 It is a schematic structural diagram of the limiting mechanism of the present invention.

[0033] Figure 9 is Figure 8 a partially enlarged schematic diagram of the connection relationship between the docking block and the docking groove in

[0034] Figure 10 It is a sectional view of the limiting plate of the present invention.

[0035] Figure 11 It is a sectional view of the connection relationship among the connection block, the wear-resistant block and the movable hole of the present invention.

[0036] Figure 12 It is a sectional view of the auxiliary support device of the present invention.

[0037] Figure 13 It is a schematic structural diagram of the lateral support assembly in the auxiliary support device of the present invention.

[0038] Description of reference numerals in the drawings: 1 - frame; 11 - movable hole; 2 - welding mechanism; 21 - support rod; 22 - bracket; 23 - first cylinder; 24 - sliding rod; 25 - moving plate; 26 - welding torch; 27 - dust suction assembly; 271 - dust suction box; 2711 - dust suction hole; 272 - exhaust fan; 273 - suction nozzle; 274 - filter plate; 275 - mounting bracket; 3 - rotating mechanism; 31 - first motor; 311 - mounting box; 32 - first mounting plate; 321 - first semi-circular sliding groove; 322 - docking block; 3221 - guiding portion; 3222 - positioning head; 3223 - first arc-shaped guiding surface; 3224 - small hole; 3225 - second compression spring; 323 - guiding hole; 324 - counterbore; 325 - end cap; 33 - second mounting plate; 331 - second semi-circular sliding groove; 332 - docking groove; 3321 - second arc-shaped guiding surface; 34 - convex plate; 35 - bolt; 36 - nut; 37 - connecting rod; 38 - sliding block; 39 - circular sliding groove; 4 - horizontal moving mechanism; 41 - second motor; 42 - screw rod; 43 - first vertical plate; 44 - guiding rod; 45 - moving seat; 46 - connecting block; 461 - wear-resistant block; 6 - limiting mechanism; 61 - fixing bracket; 611 - L-shaped limiting plate; 62 - stepping motor; 63 - cam; 64 - push plate; 65 - push rod; 66 - first compression spring; 67 - limiting plate; 671 - groove; 672 - rubber pad; 673 - convex rib; 8 - auxiliary support device; 81 - housing; 82 - motor base; 83 - servo motor; 84 - lead screw; 85 - lifting plate; 86 - guide rail; 87 - linear slider; 88 - lateral support assembly; 881 - sliding seat; 8811 - sliding groove; 882 - mounting seat; 883 - first cylinder; 884 - support leg; 885 - roller; 100 - thick pipe beam; 200 - thin pipe beam. Detailed implementation manners

[0039] In order to make the objectives, technical solutions, and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below in conjunction with the implementation manners and the drawings. Here, the illustrative implementation manners of the present invention and their descriptions are used to explain the present invention, but do not limit the present invention.

[0040] In the conventional industrial and civil fields, the need for welding of reducing pipes widely exists in scenarios such as building mechanical and electrical installation, municipal pipeline engineering, and general equipment manufacturing. Taking the construction field as an example, scenarios such as the variable-diameter connection of air-conditioning ducts and the transformation of the fire sprinkler system pipelines all require welding of reducing pipes in the range of Φ100 - Φ500 mm. The traditional operation mode relies on manual alignment and segmented welding, and has the following pain points: 1. Efficiency bottleneck: Workers need to weld section by section and manually turn over the workpiece. For example, the welding of a single set of DN200 reducing pipes takes 30 - 40 minutes, and the turning over of large-diameter workpieces requires the assistance of a forklift, increasing the complexity of the process.

[0041] 2. Quality fluctuations. The accuracy of manual matching depends on experience, which is prone to axial deviation (for example, the average measured error of a single group of DN200 reducers is ±1.5mm). The consistency of weld height is poor, and the pass rate of X-ray flaw detection is only about 82%.

[0042] 3. Cost concerns: usually 3-4 skilled welders are required to work in shifts, and labor costs account for 25%-30% of the project budget. In addition, every 1% increase in rework rate will increase the total cost by 0.8-1.2 percentage points.

[0043] In combination with the above technical description, the present invention mainly innovates the following technical problems: 1. Manual welding efficiency bottleneck problem The background technology clearly points out that manual welding adopts the mode of "segment-by-segment welding + flipping", which results in that only partial welding can be completed in a single operation and multiple repeated operations are required. To address this pain point, the present invention drives the pipe beam to rotate around the entire circumference through the rotating mechanism 3, and cooperates with the welding mechanism 2 to move synchronously, so as to achieve one-time full-circle welding and eliminate the flipping process.

[0044] 2. Geometric mismatch caused by flipping operation During the manual turning process, installation errors such as "axial deviation and angular misalignment of the pipe beam" are easily generated (the background art emphasizes that "installation errors are easily caused during turning"), which directly affects the stability of the weld quality. The present invention ensures the coaxiality accuracy of the pipe beam during welding through the three-axis linkage clamping (horizontal movement + rotation + radial positioning) of the limit mechanism 6 and virtual assembly verification.

[0045] 3. Insufficient adaptability of different diameter pipe beams The background technology mentions that different diameter tube beams are needed to meet special working conditions, but traditional tooling has the defects of "strong fixture specialization and difficult specification adjustment". The present invention realizes the rapid adaptation of tube beams with different diameters through a modularly designed limit mechanism 6 and a parametric control system, and supports the special process requirements of "mixed welding of thick / thin tube beams".

[0046] 4. Lack of environmental control during welding There is a lack of effective treatment for the smoke generated by manual welding. The present invention integrates a dust collection component with a dynamic power adjustment system to simultaneously solve the problems of optimizing the working environment and protecting the quality of the weld.

[0047] 5. Low degree of intelligent control of process parameters Traditional welding relies on manual experience and lacks closed-loop control of "welding path planning-execution-monitoring". The present invention builds a welding process database, realizes dynamic path optimization through a multi-axis linkage algorithm, and adjusts parameters such as current and speed in real time based on sensor feedback to solve the problem of process consistency.

[0048] The solutions to these technical problems together constitute an automated welding system for pipes with different diameters, achieving full-process innovation from tooling clamping, motion control to quality monitoring.

[0049] Reference Figures 1 to 13 , such as Figure 1 shown, this embodiment provides a welding device for pipes with different diameters. By splicing two different pipe beams (i.e., the thick pipe beam 100 and the thin pipe beam 200) and welding the splicing part, a concentric pipe beam structure with different diameters is formed. The welding device for pipes with different diameters includes: a frame 1, a pair of horizontal moving mechanisms 4, a pair of rotating mechanisms 3, a pair of limiting mechanisms 6, and a welding mechanism 2. The frame 1 serves as the basic support structure of the entire welding device. A pair of horizontal moving mechanisms 4 are symmetrically installed on the frame 1 and are responsible for moving in the horizontal direction to adjust the position of the pipe beam, so as to realize the splicing of the thick pipe beam 100 and the thin pipe beam 200 and prepare for the next welding. In addition, a pair of horizontal moving mechanisms 4 are installed on the frame 1 and can move, so as to be able to adjust the initial position of the limiting mechanism 6 on the frame 1 to adapt to pipe beams of different lengths.

[0050] The rotating mechanism 3 is connected to the corresponding horizontal moving mechanism 4, and the limiting mechanism 6 is connected to the corresponding rotating mechanism 3. The limiting mechanism 6 can ensure the stable clamping and positioning of the pipe beam during welding; the welding mechanism 2 is arranged on the frame 1 and is located between a pair of limiting mechanisms 6; a pair of limiting mechanisms 6 are respectively used for clamping the thick pipe beam 100 and the thin pipe beam 200. When the welding mechanism 2 welds, a pair of rotating mechanisms 3 drive a pair of limiting mechanisms 6 that respectively clamp the thick pipe beam 100 and the thin pipe beam 200 to rotate, realizing 360° omnidirectional welding.

[0051] Specifically, during operation, the thick pipe beam 100 and the thin pipe beam 200 are respectively placed in the corresponding limiting mechanisms 6 and clamped. The pair of horizontal moving mechanisms 4 are started to make the thick pipe beam 100 and the thin pipe beam 200 butt joint. Subsequently, the welding mechanism 2 is started to start welding the splicing part of the thick pipe beam 100 and the thin pipe beam 200. At the same time, a pair of rotating mechanisms 3 drive the limiting mechanisms 6 (and the pipe beams they clamp) to rotate 360°, realizing omnidirectional welding. After welding is completed, the rotating mechanism 3 and the welding mechanism 2 are stopped, the limiting mechanisms 6 are loosened, and the welded pipe beam with different diameters is taken out.

[0052] It can be seen from the above description that the welding device for pipes with different diameters can realize the efficient and precise welding of two pipe beams with different diameters, forming a concentric pipe beam structure with different diameters.

[0053] A pair of limiting mechanisms 6 are symmetrically arranged left and right. When the left limiting mechanism 6 is used to install the thick pipe beam 100, the right limiting mechanism 6 is used to install the thin pipe beam 200; conversely, if the left limiting mechanism 6 is used to install the thin pipe beam 200, the right limiting mechanism 6 is used to install the thick pipe beam 100, and the specific position can be set according to the usage requirements.

[0054] As Figure 2 shown, the welding mechanism 2 includes: a bracket 22, a welding torch 26, and a dust suction component 27. The bracket 22 is the main supporting structure of the welding mechanism 2 and is stably supported on the frame 1 by a plurality of support rods 21, ensuring the stability during the welding process; the welding torch 26 is connected to a first cylinder 23 installed at the top of the bracket 22. The first cylinder 23 provides the power for the up and down movement of the welding torch 26. Specifically, the welding torch 26 is installed at the front end of the extending rod of the first cylinder 23, and the welding torch 26 can move up and down in the vertical direction under the drive of the first cylinder 23, thereby achieving precise welding of the pipe beam. The dust suction component 27 is installed on the bracket 22, and the dust suction component 27 is used to clean the dust during the welding of the pipe beam, keep the welding environment clean, improve the welding quality, and improve the efficiency.

[0055] As can be seen from the above, the welding mechanism 2 is an efficient welding device integrating the bracket 22, the welding torch 26, and the dust suction component 27. It can not only achieve precise welding operations but also effectively clean the dust during the welding process, ensuring the cleanliness of the welding environment and the welding quality.

[0056] The welding torch 26 is connected to a carbon dioxide shielded welding machine to achieve welding at the joint of the thick pipe beam 100 and the thin pipe beam 200.

[0057] In one embodiment, as Figure 3 shown, a pair of sliding rods 24 spaced front and back are further provided on the bracket 22. A moving plate 25 slidably engaged with the pair of sliding rods 24 is connected to the front end of the extending rod of the first cylinder 23, and the welding torch 26 is installed on the moving plate 25.

[0058] Specifically, the pair of sliding rods 24 provide a sliding track for the moving plate 25, enabling the moving plate 25 to move stably. The moving plate 25 is connected to the front end of the extending rod of the first cylinder 23. When the extending rod of the first cylinder 23 extends and retracts, the moving plate 25 will move up and down along the sliding rods 24, thereby driving the welding torch 26 to move up and down.

[0059] As Figure 3As shown, in the embodiment of the present application, the dust suction assembly 27 includes: a suction fan 272 and a dust suction box 271. The suction fan 272 is installed on the bracket 22 through a mounting bracket 275; the dust suction box 271 is installed on the bracket 22 and is close to the welding position. A suction nozzle 273 is installed on the suction fan 272, and the suction nozzle 273 extends into the dust suction box 271. Among them, a plurality of dust suction holes 2711 are opened on the side wall of one end of the dust suction box 271 close to the welding position, and a filter plate 274 that can block dust to prevent dust from entering the suction fan 272 is arranged between the suction nozzle 273 and the plurality of dust suction holes 2711 in the dust suction box 271.

[0060] After the suction fan 272 is started, the dust around the welding area is adsorbed into the dust suction box 27 through the suction nozzle 273.

[0061] The welding mechanism 2 integrates the suction fan 272 and the dust suction box 271 ( Figure 3 ), and realizes the real-time adsorption of welding fumes through the dust suction holes 2711 and the filter plate 274.

[0062] In one embodiment, as Figure 5 、 Figure 6 and Figure 7 shown, the rotating mechanism 3 includes: a first mounting plate 32, a second mounting plate 33 and a first motor 31. The first mounting plate 32 and the second mounting plate 33 are spliced together to form an integral component, which serves as the main body part of the rotating mechanism 3 and provides installation and support for other components. The first motor 31 is the power source of the rotating mechanism 3. The first motor 31 is installed on the side of the first mounting plate 32 and the second mounting plate 33 away from the welding mechanism 2 through a mounting box 311; the limiting mechanism 6 is connected to the output end of the first motor 31, and the limiting mechanism 6 is slidably engaged with both the first mounting plate 32 and the second mounting plate 33.

[0063] In one embodiment, as Figure 7 shown, convex plates 34 are provided at both ends of the first mounting plate 32 and the second mounting plate 33. The two convex plates 34 are connected by bolts 35 and locked with nuts 36. This connection method ensures the firm connection between the first mounting plate 32 and the second mounting plate 33, preventing loosening or separation during use. A docking block 322 is provided at one end of the first mounting plate 32, and a docking groove 332 is opened at one end of the second mounting plate 33. The docking block 322 is adapted to the docking groove 332, making the installation positions of the first mounting plate 32 and the second mounting plate 33 more accurate. With the installation of the two pairs of convex plates 34, the first mounting plate 32 and the second mounting plate 33 can be firmly locked, so that the installation between the first mounting plate 32 and the second mounting plate 33 is reliable.

[0064] Specifically, the design of the docking block 322 and the docking groove 332 is adapted. During installation, the docking block 322 will accurately insert into the docking groove 332, which ensures the position accuracy of the first mounting plate 32 and the second mounting plate 33 during installation and prevents dislocation or deviation.

[0065] The convex plate 34 and the docking block 322 are arranged at an interval up and down, which can improve the accuracy and reliability of the installation of the first mounting plate 32 and the second mounting plate 33.

[0066] As Figure 9 shown, the docking block 322 has a guiding portion 3221, a positioning head 3222 connected to the front end of the guiding portion 3221. The front end of the positioning head 3222 has a first arc-shaped guiding surface 3223. The first arc-shaped guiding surface 3223 is used to guide the positioning head 3222 to correctly enter the docking position and smoothly insert into the docking groove 332 to achieve docking. The opening of the docking groove 332 has a second arc-shaped guiding surface 3321 for facilitating the introduction of the positioning head 3222. The guiding portion 3221 is in sliding fit with a guiding hole 323 opened on the first mounting plate 32 to guide the movement of the docking block 322. A counterbore 324 is opened at the front end of the guiding hole 323, and an end cap 325 is installed in the counterbore 324. The end cap 325 is used to limit the movement of the docking block 322 and prevent the docking block 322 from detaching from the first mounting plate 32. A plurality of small holes 3224 are opened on the guiding portion 3221, and a second compression spring 3225 is arranged in the small holes 3224. One end of the second compression spring 3225 abuts against the bottom wall of the small hole 3224, and the other end abuts against the bottom wall of the guiding hole 323. The second compression spring 3225 is used to provide a pre-tightening force, which facilitates the positioning head 3222 to extend out of the first mounting plate 32 and also facilitates the positioning head 3222 to reliably and stably insert into the docking groove 332.

[0067] The above structure ensures that after the first mounting plate 32 and the second mounting plate 33 are installed, their relative positions are accurate and no dislocation or deviation will occur.

[0068] In an embodiment, as Figure 5 、 Figure 6 and Figure 7 shown, at least two connecting rods 37 are arranged on one side of the fixing frame 61, and sliding blocks 38 are installed at the ends of the connecting rods 37.

[0069] The first semi-circular sliding groove 321 of the first mounting plate 32 and the second semi-circular sliding groove 331 of the second mounting plate 33 jointly form a circular sliding groove 39. The sliding block 38 is slidably arranged in the circular sliding groove 39, so that the thick pipe beam 100 and the thin pipe beam 200 can rotate to achieve welding.

[0070] In an embodiment, as Figure 8As shown, the limit mechanism 6 further includes a pair of clamping devices that can move synchronously towards each other to clamp the pipe beam. The pair of clamping devices are symmetrically arranged on the fixed frame 61. The clamping device includes: a fixed frame 61, a stepping motor 62, a cam 63, and a moving limit component. An L-shaped limit plate 611 is provided on the fixed frame 61, and the stepping motor 62 is installed on the corresponding L-shaped limit plate 611; the cam 63 is connected to the corresponding stepping motor 62; the moving limit component abuts against the corresponding cam 63, and the pair of moving limit components cooperate to clamp the pipe beam.

[0071] In the embodiment of the present application, the moving limit component includes: a push rod 65, a push plate 64, a limit plate 67, and a first compression spring 66. The push rod 65 is slidably arranged on the L-shaped limit plate 611; the push plate 64 is connected to one end of the push rod 65; the limit plate 67 is connected to the other end of the push rod 65; the first compression spring 66 is sleeved on the push rod 65, and the first compression spring 66 abuts between the push plate 64 and the L-shaped limit plate 611.

[0072] In the embodiment of the present application, when the stepping motor 62 is started, it drives the cam 63 to rotate. The cam 63 presses the push plate 64, so that the push rod 65 drives the limit plate 67 to move towards the pipe beam. The two stepping motors 62 work synchronously, enabling the two limit plates 67 to move synchronously, thereby realizing the clamping and limiting of the pipe beam.

[0073] As Figure 10 shown, a groove 671 for clamping the pipe beam is provided on one side of the limit plate 67. A rubber pad 672 can be pasted in the groove 671. The setting of the rubber pad 672 prevents scratching the surface of the pipe beam when clamping the pipe beam, playing a protective role.

[0074] In order to clamp the pipe beam more tightly, a number of convex ribs 673 are provided on the rubber pad 672. These convex ribs 673 can increase the friction between the rubber pad 672 and the pipe beam, thereby making the clamping more stable.

[0075] With the symmetric limit mechanism 6 design, thick / thin pipe beams can be interchangeably installed on the left and right sides (as Figure 1 ). The limit plate 67 is provided with a groove 671 and a rubber pad 672 is pasted ( Figure 10 ), and the convex ribs 673 are used to enhance the friction, which not only protects the surface of the pipe beam but also ensures the clamping stability.

[0076] In one embodiment, as Figure 4As shown in the figure, the horizontal movement mechanism 4 includes: a second motor 41, a screw 42, a moving seat 45, a guide rod 44, and a connecting block 46. The second motor 41 is installed on the crossbeam of the frame 1; the screw 42 is connected to the output end of the second motor 41; the moving seat 45 is threadedly connected to the screw 42; the guide rod 44 is arranged on the frame 1, and the moving seat 45 is slidably engaged with the guide rod 44; the connecting block 46 is connected between the moving seat 45 and the corresponding first mounting plate 32.

[0077] The rotation mechanism 3 is driven by a first motor 31 ( Figure 5 , Figure 6 , Figure 7 ), and cooperates with the horizontal movement mechanism 4 ( Figure 4 ) to achieve 360° rotary welding after the pipe beam docking. The welding torch 26 moves up and down along the slide rod 24 ( Figure 3 ), and precisely controls the formation of the weld seam.

[0078] In the embodiment of the present application, two movable holes 11 are spaced apart on the frame 1, and the upper end of the connecting block 46 passes through the corresponding movable hole 11 and is connected to the first mounting plate 32.

[0079] Preferably, a first vertical plate 43 is further provided on the crossbeam, and both the screw 42 and the guide rod 44 are connected to the first vertical plate 43. The arrangement of the guide rod 44 makes the movement of the moving seat 45 driven by the screw 42 more stable.

[0080] To improve the stability of the guide rod 44, a second vertical plate 47 is provided on the frame 1, and the lower end of the second vertical plate 47 is connected to the guide rod 44.

[0081] Preferably, as Figure 11 shown, in order to make the connecting block 46 move smoothly on the movable hole 11, a wear-resistant block 461 is installed on the connecting block 46, and the wear-resistant block 461 is slidably engaged with the movable hole 11.

[0082] In one embodiment, as Figure 12As shown in the figure, a pair of auxiliary support devices 8 are further provided on the frame 1. The auxiliary support device 8 includes a housing 81, a motor base 82, a servo motor 83, a lead screw 84, a lifting plate 85, a guide rail 86, a linear slider 87, and a pair of lateral support components 88. The housing 81 is installed on the frame 1. The motor base 82 is installed on the inner bottom wall of the housing 81. The servo motor 83 is installed on the motor base 82. The output shaft of the servo motor 83 is connected to the lead screw 84. The lead screw 84 is threadedly connected to the lifting plate 85 slidably disposed in the housing 81. The servo motor 83 drives the lead screw 84 to rotate, which can drive the lifting plate 85 to move up and down. Linear sliders 87 are installed at both ends of the lifting plate 85. The linear sliders 87 are slidably engaged with the corresponding guide rails 86 in the housing 81. A pair of lateral support components 88 are symmetrically installed on the lifting plate 85. The pair of lateral support components 88 are used to clamp the pipe beam to be welded. Since the diameters of the thick pipe beam 100 and the thin pipe beam 200 are different, in order for the auxiliary support device 8 to support and clamp pipe beams with different diameters, a pair of lateral support components 88 and a lifting mechanism are provided on the auxiliary support device 8. The lifting mechanism can drive the pair of lateral support components 88 to move up and down in the vertical direction. The lifting mechanism is composed of a motor base 82, a servo motor 83, a lead screw 84, and a lifting plate 85.

[0083] The auxiliary support device 8 is close to the splicing position of the pipe beam to ensure the coaxiality of the two pipe beams and the welding reliability.

[0084] As Figure 13 shown in the figure, the lateral support component 88 has a sliding seat 881, a mounting seat 882, and a first cylinder 883. The sliding seat 881 is installed on the lifting plate 85. The mounting seat 882 is slidably disposed on the sliding groove 8811 of the sliding seat 881. The first cylinder 883 is installed on the lifting plate 85. The extending rod of the first cylinder 883 is fixedly connected to the mounting seat 882. A pair of support feet 884 are installed at one end of the mounting seat 882. A roller 885 is movably installed on the support feet 884. The roller 885 can slidably contact the outer peripheral surface of the pipe beam for supporting and clamping the pipe beam. During welding, while the pipe beam rotates, the roller 885 also rotates. When the four rollers 885 support and clamp the pipe beam, the roller 885 is in sliding contact with the outer peripheral surface of the pipe beam. Driven by the horizontal moving mechanism 4, the pipe beam can axially move on the roller 885.

[0085] This embodiment also provides a method for welding pipes with different diameters, including the following steps: Obtain the length and diameter parameters of the thick pipe beam 100 and the thin pipe beam 200 to be welded and input them into the control system; Control the horizontal moving mechanism 4 to adjust the initial position of the limiting mechanism 6, and synchronously drive the lateral support components 88 of the auxiliary support device 8 to a preset spacing; Adjust the clamping height of the lateral support components 88 according to the pipe beam diameter through the lifting mechanism to ensure the coaxial positioning of the pipe beam; After the clamping device of the starting limit mechanism 6 fixes the end of the pipe beam, drive the second motor 41 to move the pipe beam along the docking direction to the welding position; Control the first motor 31 to drive the pipe beam to rotate, and at the same time, the first cylinder 23 drives the welding torch 26 to move along the welding track to perform full-circle welding; Adsorb the welding fumes generated in real time through the exhaust fan 272; After welding is completed, perform the reset operation of each actuator and release the finished pipe beam.

[0086] This embodiment also provides a welding control system for different-diameter pipe beams, including a processor and a memory. The memory stores a computer program, and when the program is executed by the processor, the following functions are implemented in sequence: (I) Parameter parsing and preprocessing Parse the input pipe beam geometric parameters and generate multi-axis motion control instructions; Construct a three-dimensional model of the pipe beam for virtual assembly verification to ensure welding feasibility; (II) Motion control execution Implement a multi-axis linkage motion control algorithm to coordinate the motion timing of the horizontal moving mechanism 4, the rotating mechanism 3, and the welding mechanism 2; Generate an optimal welding path plan based on the welding process database and dynamically adjust the execution track; (III) Process monitoring and optimization Integrate a real-time welding quality detection and defect identification module to synchronously monitor the weld formation quality; Adjust the power of the exhaust fan 272 in real time according to the feedback of the fume sensor to optimize the working environment; Dynamically adjust welding process parameters such as welding current and speed according to the welding quality monitoring data; (IV) System management and traceability Realize the full-closed-loop automatic control of the welding process and early warning of abnormal states; Generate a traceable welding process log containing process parameters, environmental data, and quality inspection results; Automatically record abnormal events and generate a maintenance warning report.

[0087] Working process: 1. Transmit the length and diameter parameters of the to-be-welded thick pipe beam 100 and thin pipe beam 200 to the control system, start the horizontal moving mechanism 4, and adjust the initial positions of the corresponding limit mechanisms 6 on the frame 1.

[0088] 2. At the same time, adjust the positions of the two auxiliary support devices 8 on the frame 1, and adjust the lifting mechanism according to the pipe beam diameter so that a pair of lateral support components 88 can support and clamp the corresponding pipe beam.

[0089] 3. After ensuring that the thick pipe beam 100 and the thin pipe beam 200 are coaxial, the limiting mechanism 6 is activated to clamp the end of the pipe beam.

[0090] 4. A pair of second motors 41 operate to move the thick pipe beam 100 and the thin pipe beam 200 in the same direction until they are joined.

[0091] 5. Two first motors 31 are started to rotate, and the first cylinder 23 drives the welding torch 26 to move down along the welding track to the joint, and full - circumference welding is performed.

[0092] 6. The exhaust fan 272 adsorbs the dust generated during welding in real - time, and the soot sensor feeds back to adjust the power of the exhaust fan 272 in real - time.

[0093] 7. After welding is completed, the horizontal moving mechanism 4, the limiting mechanism 6, and the welding torch 26 return to their original positions.

[0094] 8. The lateral support assembly 88 returns to its original position.

[0095] 9. The welded pipe beam is unloaded, and the welding of the thick pipe beam 100 and the thin pipe beam 200 is completed.

[0096] For the welding scenario of ordinary reducing pipes, the present invention realizes cost reduction and efficiency improvement through "standardized design + modular configuration". The technical advantages of the present invention are: 1. High - efficiency full - circumference welding: The rotating mechanism 3 drives the pipe beam to rotate 360°. In cooperation with the path planning of the welding torch 26, the welding torch 26 moves synchronously along the preset path, and full - circumference welding can be completed with a single clamping, and the efficiency is increased by 3 - 5 times. For example, the welding of a single group of DN200 reducing pipes is compressed to 8 - 10 minutes (including clamping time).

[0097] 2. No need to turn over: The design of the sliding block 38 and the circular chute 39 supports 360° welding coverage, eliminating the error source of secondary clamping.

[0098] 3. Environmental adaptability: The integrated soot purification system (exhaust fan 272 + dust suction box 271) solves the environmental soot problem and enables all - weather operation.

[0099] 4. Intelligent verification: The virtual assembly system pre - rehearses the welding path to avoid interference and collision in scenarios with limited space.

[0100] 5. Intelligent quality control: Automatic centering, fine - tuning driven by servo motors, and the alignment accuracy is improved to ±0.3 mm. Quality traceability, key parameters (temperature field, soot concentration) are recorded in the welding process log, providing a complete data chain for quality inspection.

[0101] 6. Process solidification: A welding parameter library of commonly used building materials (such as Q235 carbon steel) is built - in, and novice welders can also output standardized welds.

[0102] 7. Economic applicability: Tooling reuse: The modular limit component supports full coverage of pipe diameters from Φ100 to Φ500mm, and a single set of equipment can replace 3 - 4 groups of traditional tooling.

[0103] Typical application scenarios Case 1: Air conditioner installation in commercial complex A shopping center needs to weld 200 groups of different - diameter galvanized steel pipes (specifications: Φ250 - Φ150mm). After adopting the present invention: The welding efficiency is increased by 3 times, and the construction period is shortened by 5 days; The qualified rate of weld flaw detection is increased from 85% to 98%; Two full - time welders are reduced, directly saving 68,000 yuan in labor costs.

[0104] Case 2: Municipal water supply pipeline renovation In a municipal water supply pipeline renovation project, it is necessary to complete the welding of 200 groups of different - diameter pipe beams of Φ600×12mm and Φ400×10mm. After adopting the device of the present invention: Efficiency improvement: The welding time for a single group is shortened from 4 hours (manual) to 1.2 hours; Quality upgrade: The first - pass qualified rate of ray flaw detection reaches 99.2% (85% for manual welding); Cost reduction: The manual turning - over link is reduced, and about 350,000 yuan in labor costs is saved for a single project.

[0105] The above are only the preferred embodiments of the present invention and are not used to limit the present invention. For those skilled in the art, various changes and modifications can be made to the embodiments of the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A reducing pipe beam welding device, characterized in that, Including: Frame (1); A pair of horizontally moving mechanisms (4) symmetrically installed on the frame (1); A pair of rotating mechanisms (3) respectively drivingly connected to the corresponding horizontally moving mechanisms (4); A pair of limiting mechanisms (6) respectively rotatably connected to the corresponding rotating mechanisms (3); A welding mechanism (2) fixedly arranged on the frame (1) and located between a pair of the limiting mechanisms (6); Wherein, a pair of the limiting mechanisms (6) respectively clamp a thick pipe beam (100) and a thin pipe beam (200), and when the welding mechanism (2) performs welding, a pair of the rotating mechanisms (3) synchronously drive a pair of the limiting mechanisms (6) to drive the clamped pipe beam to rotate.

2. The reducing pipe beam welding device according to claim 1, wherein The welding mechanism (2) includes: A bracket (22) fixed to the frame (1); A welding torch (26) driven by a first cylinder (23) to move along the bracket (22); A dust suction assembly (27) integrated on the bracket (22), the dust suction port of which is directed at the welding area, and an exhaust fan (272) of the dust suction assembly (27) forms a negative pressure dust suction channel in a dust suction box (271) through a suction nozzle (273).

3. The reducing pipe beam welding device according to claim 1, characterized in that, The rotating mechanism (3) includes: A support frame composed of a first mounting plate (32) and a second mounting plate (33) that can be spliced; A first motor (31) installed on the side of the support frame, the output shaft of which is drivingly connected to the limiting mechanism (6); A circumferential positioning structure is formed by a docking block (322) and a docking groove (332) locked by bolts (35).

4. The reducing pipe beam welding device according to claim 3, characterized in that, The limiting mechanism (6) is connected to the rotating mechanism (3) through a connecting rod assembly, and one ends of at least two connecting rods (37) are fixed to a fixed frame (61), and the other ends are embedded in a circular chute (39) formed by splicing semi-circular chutes through sliding blocks (38).

5. The reducing pipe beam welding device according to claim 4, characterized in that, The horizontally moving mechanism (4) includes: A second motor (41) installed on the frame (1); A screw rod (42) connected to the output end of the second motor (41); A moving seat (45) threadedly connected to the screw rod (42); A guide rod (44) slidably matched with the moving seat (45); A connecting block (46) connecting the moving seat (45).

6. The reducing pipe beam welding device according to claim 5, wherein, The limiting mechanism (6) includes a pair of clamping devices that act synchronously, and the clamping device includes: A stepping motor (62) installed on the fixed frame (61); A cam (63) connected to the stepping motor (62); A push rod (65) slidably arranged on the fixed frame (61); A push plate (64) connected to one end of the push rod (65); A limiting plate (67) connected to the other end of the push rod (65); A first compression spring (66) sleeved on the push rod (65), which abuts between the push plate (64) and an L-shaped limiting plate (611).

7. The reducing pipe beam welding device according to claim 1, characterized in that, It further includes an auxiliary support device (8), including: A lateral support assembly (88) whose height is adjusted by a lifting mechanism; A clamping surface with a telescopic V-shaped bracket, and the clamping surface is adaptively matched with the outer diameter of the pipe beam.

8. A welding method for a reducing pipe beam, characterized in that, Including the following steps: Obtain the length and diameter parameters of the thick pipe beam (100) and the thin pipe beam (200) to be welded and input them into the control system; The control horizontal movement mechanism (4) adjusts the initial position of the limit mechanism (6), and synchronously drives the lateral support assembly (88) of the auxiliary support device (8) to a preset spacing; According to the diameter of the pipe beam, the clamping height of the lateral support assembly (88) is adjusted by the lifting mechanism to ensure the coaxial positioning of the pipe beam; After starting the clamping device of the limit mechanism (6) to fix the end of the pipe beam, the second motor (41) is driven to move the pipe beam to the welding position along the docking direction; Control the first motor (31) to drive the pipe beam to rotate, and at the same time, the first cylinder (23) drives the welding torch (26) to move along the welding track to perform full-circle welding; Adsorb the welding fumes generated in real time through the exhaust fan (272); After welding is completed, perform the reset operation of each actuator and release the finished pipe beam.

9. A reducing pipe beam welding control system, characterized in that, It includes a processor and a memory, and is characterized in that: the memory stores a computer program, and when the program is executed by the processor, the following functions are realized in sequence: (I) Parameter parsing and preprocessing Parse the input pipe beam geometric parameters and generate multi-axis motion control instructions; Construct a three-dimensional model of the pipe beam for virtual assembly verification to ensure welding feasibility; (II) Motion control execution Implement a multi-axis linkage motion control algorithm to coordinate the motion timing of the horizontal movement mechanism (4), the rotation mechanism (3) and the welding mechanism (2); Generate an optimal welding path plan based on the welding process database and dynamically adjust the execution track; (III) Process monitoring and optimization Integrate a real-time welding quality detection and defect identification module to synchronously monitor the weld forming quality; According to the feedback of the fume sensor, adjust the power of the exhaust fan (272) in real time to optimize the working environment; Dynamically adjust welding process parameters such as welding current and speed according to the welding quality monitoring data; (IV) System management and traceability Realize the full-closed-loop automatic control of the welding process and early warning of abnormal states; Generate a traceable welding process log including process parameters, environmental data and quality inspection results; Automatically record abnormal events and generate a maintenance warning report.

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