Pipe all-position submerged arc welding method, device, system and storage medium

Abstract

The application discloses a pipeline all-position submerged arc welding method, device, system and storage medium, relates to the technical field of automatic welding, and the pipeline all-position submerged arc welding method comprises the following steps: centering and correcting a flux holding device, and aligning a welding gun with a cover plate hole of a flux holding box on the flux holding device; under the condition that the welding gun is aligned with the cover plate hole, adjusting a flux hopper to a target height; under the condition that the flux hopper reaches the target height, controlling an electromagnetic valve in the flux hopper according to a capacitance signal fed back by a capacitance probe in the flux holding box, so that the accumulation amount of the flux is adjusted; under the condition that the accumulation amount of the flux reaches a preset accumulation threshold, starting arc striking of the welding gun and synchronously moving the welding gun and the cover plate of the flux holding box until welding is completed. The application realizes accurate synchronous control of uniform flux supply and a welding path in all positions, and guarantees continuity and stability of the welding process.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automatic welding, in particular to a pipeline all-position submerged arc welding method, device, system and storage medium. BACKGROUND

[0002] In the welding operation of complex working conditions such as chemical pipelines, pipeline welding faces the demand for all-position welding, including vertical welding, overhead welding and other welding positions. Especially for non-rotatable chemical pipelines, the traditional welding method is difficult to meet the requirements of welding quality and efficiency.

[0003] At present, the traditional pipeline submerged arc welding technology usually adopts the method of "pipeline rotation, welding gun does not move", which is suitable for most standard pipeline welding conditions. However, in the chemical construction site, especially in pressure pipeline welding, the pipeline cannot be rotated, resulting in the need for all-position welding. In addition, the amount of welding flux is usually controlled by adjusting the physical structure.

[0004] The existing method has many limitations. First, the traditional welding technology cannot guarantee the welding quality and efficiency in the all-position welding of non-rotatable pipelines, and it is difficult to effectively prevent gas hole defects. Second, the existing welding flux anti-falling device may accumulate unevenly due to gravity, or even fall off in all-position welding conditions such as vertical welding and overhead welding, resulting in substandard welding quality. In addition, the existing device lacks real-time adjustment capability, and the welding flux supply cannot be intelligently adjusted according to the real-time changes of the welding flux accumulation. The structure is complex and difficult to maintain, which increases the instability and maintenance cost in the welding process. Therefore, how to realize the precise synchronization control of uniform welding flux supply and welding path has become a problem to be solved.

[0005] The above content is only used to assist in understanding the technical solutions of the present application, and does not represent the acknowledgement of the above content as prior art. SUMMARY

[0006] The present application aims to provide a pipeline all-position submerged arc welding method, device, system and storage medium, which aims to solve the technical problem of how to realize the precise synchronization control of uniform welding flux supply and welding path.

[0007] To achieve the above-mentioned purpose, the present application provides a pipeline all-position submerged arc welding method, which comprises:

[0008] The welding flux scooping device is centered and corrected, and the welding gun is aligned with the cover plate hole of the welding flux scooping box on the welding flux scooping device;

[0009] Under the condition that the welding gun is aligned with the cover plate hole, adjust the welding flux funnel to the target height;

[0010] When the flux hopper reaches the target height, an electromagnetic valve inside the flux hopper is controlled according to a capacitance signal fed back by a capacitance probe inside the flux pocket to adjust the amount of flux accumulation;

[0011] When the amount of flux accumulation reaches a preset accumulation threshold, the welding torch is started to arc and the welding torch and the cover plate of the flux pocket are moved synchronously until the welding is completed.

[0012] In an embodiment, the step of centering and correcting the deviation of the flux pocket device and aligning the welding torch with the cover plate hole of the flux pocket on the flux pocket device comprises:

[0013] A laser is projected along a V-shaped groove of a pipe to be welded by a laser projector;

[0014] A weld seam image containing the laser line is acquired, and edge coordinates of the laser line in the weld seam image are extracted;

[0015] A deviation distance of the edge coordinates from a center line of the weld seam in the weld seam image is calculated;

[0016] The flux pocket device is aligned with the center line of the weld seam according to the deviation distance;

[0017] When the flux pocket device is aligned with the center line of the weld seam, the welding torch is aligned with the cover plate hole of the flux pocket on the flux pocket device.

[0018] In an embodiment, the step of acquiring a weld seam image containing the laser line and extracting edge coordinates of the laser line in the weld seam image comprises:

[0019] A weld seam image containing the laser line is acquired, and a grayscale processing and a Gaussian filtering are performed on the weld seam image to obtain a target image;

[0020] A gradient amplitude and a gradient direction of each pixel point in the target image are calculated;

[0021] The pixel points are subjected to non-maximum suppression according to the gradient amplitude and the gradient direction to obtain suppressed pixel points;

[0022] The suppressed pixel points are screened by a double-threshold detection algorithm, and pixel points with a gradient amplitude greater than a preset high gradient threshold are marked as strong edge points, and pixel points with a gradient amplitude between a preset low gradient threshold and the preset high threshold are marked as weak edge points;

[0023] Edge coordinates of the laser line are obtained according to the weak edge points, the strong edge points, and the weld seam image.

[0024] In an embodiment, the step of obtaining the edge coordinates of the laser line according to the weak edge points, the strong edge points and the weld image comprises:

[0025] connecting the weak edge points with the adjacent strong edge points based on an edge connection algorithm to form a continuous edge contour;

[0026] fitting a straight line equation of the edge contour by a Hough transform;

[0027] determining the edge coordinates of the laser line according to the intersection of the straight line equation and the boundary of the weld image.

[0028] In an embodiment, the step of aligning the flux pocket with the weld centerline according to the offset distance comprises:

[0029] calculating a lateral adjustment amount of the flux pocket according to the offset distance and a preset proportional gain coefficient;

[0030] generating a pulse signal based on the lateral adjustment amount;

[0031] driving a motor of the flux pocket to perform lateral displacement at a preset adjustment period according to the pulse signal until the actual offset distance between the weld centerline and the flux pocket is less than a preset alignment accuracy threshold, and completing the alignment.

[0032] In an embodiment, the step of adjusting the flux funnel to a target height when the welding torch is aligned with the cover plate hole comprises:

[0033] measuring the distance between the flux funnel and the pipe to be welded by a distance measuring camera when the welding torch is aligned with the cover plate hole;

[0034] calculating the target height of the flux funnel based on the distance, a preset flux flowability parameter and a preset hose diameter parameter, and adjusting the flux funnel to the target height.

[0035] In an embodiment, the step of controlling the electromagnetic valve inside the flux funnel to adjust the amount of accumulated flux according to the capacitance signal fed back by the capacitance probe inside the flux pocket when the flux funnel reaches the target height comprises:

[0036] acquiring a plurality of capacitance signals fed back by a plurality of capacitance probes inside the flux pocket when the flux funnel reaches the target height;

[0037] performing weighted average and filtering processing on the capacitance signals to obtain an average feedback signal;

[0038] When the average feedback signal does not reach the preset signal threshold, the electromagnetic valve inside the flux hopper is kept open;

[0039] When the average feedback signal reaches the preset signal threshold, the electromagnetic valve is closed to adjust the amount of accumulated flux.

[0040] In addition, to achieve the above-mentioned purpose, the present application also provides a pipeline all-position submerged arc welding device, which comprises:

[0041] An alignment module is configured to align the welding gun with the cover hole of the flux pocket box on the flux pocket device and to center and correct the flux pocket device.

[0042] A hopper adjustment module is configured to adjust the flux hopper to a target height when the welding gun is aligned with the cover hole.

[0043] A flux control module is configured to control the electromagnetic valve inside the flux hopper to adjust the amount of accumulated flux according to the capacitance signal fed back by the capacitance probe inside the flux pocket box when the flux hopper reaches the target height.

[0044] A welding module is configured to start the welding gun to arc and synchronously move the welding gun and the cover of the flux pocket box until the welding is completed when the amount of accumulated flux reaches a preset accumulation threshold.

[0045] In addition, to achieve the above-mentioned purpose, the present application also provides an automatic submerged arc welding system, which comprises a ring track, a pipeline to be welded, a flux pocket device, a welding gun, a flux hopper, a flux hopper fixing base, a distance measuring camera, a welding trolley ring track base, a welding wire reel, a welding trolley, a welding gun adjustment module, a flux baffle moving module, a flux baffle, a flux pocket box, a flux pocket box driving device, a flux hopper lifting module, a small air pump and an electromagnetic valve. The ring track is installed on the outer surface of the pipeline to be welded, and the flux pocket device is installed on the weld of the pipeline to be welded through a magnetic wheel.

[0046] In addition, to achieve the above-mentioned purpose, the present application also provides a storage medium, which is a computer readable storage medium. The storage medium stores a computer program. When the computer program is executed by a processor, the steps of the pipeline all-position submerged arc welding method described above are implemented.

[0047] In addition, to achieve the above-mentioned purpose, the present application also provides a computer program product, which comprises a computer program. When the computer program is executed by a processor, the steps of the pipeline all-position submerged arc welding method described above are implemented.

[0048] The one or more technical solutions provided in the application have at least the following technical effects:

[0049] Firstly, the system corrects the centering and deviation of the flux pocket device, and aligns the welding gun with the cover hole of the flux pocket box, so that welding defects caused by the deviation of the welding gun during welding can be avoided, and the welding quality and efficiency can be improved. Secondly, under the condition that the welding gun is aligned with the cover hole, the system calculates the target height according to the preset formula, and then controls the motor-driven lifting device to adjust the flux funnel to the height, so as to ensure that the flux can flow smoothly into the flux pocket box, and avoid poor flow or uneven accumulation of the flux due to improper height. Then, after the flux funnel reaches the target height, the system obtains the capacitance signals fed back by the plurality of capacitive probes in the flux pocket box, controls the opening and closing of the electromagnetic valve according to the capacitance signals, realizes accurate control of the accumulation amount of the flux, and ensures that the accumulation amount of the flux always meets the welding process requirements. Finally, when the accumulation amount of the flux reaches the preset accumulation threshold, the system starts the welding gun to arc and synchronously moves the cover plate of the flux pocket box until the welding is completed, realizes the accurate synchronous control of the uniform flux supply and the welding path in all positions, avoids the welding defects caused by uneven flux, and ensures the continuity and stability of the welding process. BRIEF DESCRIPTION OF DRAWINGS

[0050] The accompanying drawings, which are incorporated into and form part of the specification, illustrate embodiments consistent with the present application and, together with the specification, serve to explain the principles of the application.

[0051] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the accompanying drawings needed to be used in the embodiments or prior art description will be briefly introduced. Obviously, for those skilled in the art, other drawings can also be obtained without creative labor.

[0052] Figure 1 The flowchart provided for the pipeline all-position submerged arc welding method embodiment one of the present application;

[0053] Figure 2 The flux pocket device structure schematic diagram provided for the pipeline all-position submerged arc welding method embodiment one of the present application;

[0054] Figure 3 The flux rotating interface structure schematic diagram provided for the pipeline all-position submerged arc welding method embodiment one of the present application;

[0055] Figure 4 The capacitive probe distribution schematic diagram in the flux pocket device provided for the pipeline all-position submerged arc welding method embodiment one of the present application;

[0056] Figure 5The flowchart schematic diagram provided for the second embodiment of the pipeline all-position submerged arc welding method of the present application;

[0057] Figure 6 The module structure schematic diagram of the pipeline all-position submerged arc welding device of the embodiment of the present application;

[0058] Figure 7 The system structure schematic diagram of the submerged arc automatic welding system of the embodiment of the present application.

[0059] Explanation of reference numerals:

[0060] 1, chemical pressure pipeline; 2, welding trolley ring rail base; 3, ring rail; 4, welding wire disc; 5, welding trolley; 6, welding gun adjusting module; 7, welding agent baffle moving module; 8, welding gun; 9, welding agent baffle; 10, welding agent material box; 11, welding agent material box driving device; 12, TOF camera; 13, welding agent hopper lifting module; 14, welding agent hopper fixed base; 15, welding agent hopper; 16, small air pump; 17, electromagnetic valve; 18, industrial camera; 19, cover plate driving device; 20, movable cover plate; 21, welding agent material box body; 22, welding agent universal interface; 23, material inlet fixing ring; 24, rotating sleeve; 25, ceramic bearing; 26, bearing spring retainer ring.

[0061] The purpose realization, functional characteristics and advantages of the present application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0062] It should be understood that the specific embodiments described herein are merely intended to explain the technical solutions of the present application, and are not intended to limit the present application.

[0063] In order to better understand the technical solutions of the present application, the following will be described in detail in conjunction with the drawings and specific embodiments of the specification.

[0064] In chemical pipeline welding, facing the all-position welding requirements such as vertical welding and overhead welding, especially for non-rotatable pressure pipelines, the traditional "pipeline rotation, welding gun does not move" submerged arc welding technology is difficult to meet the quality and efficiency requirements. The existing method is prone to porosity defects when welding in all positions, and the welding quality may be reduced due to uneven accumulation or falling of the welding agent due to gravity. In addition, the lack of real-time adjustment of the welding agent supply, the existing device structure is complex and difficult to maintain, which increases the instability and cost of the welding process.

[0065] The main solution of the embodiment of the present application is that the system first aligns and corrects the flux material holding device, aligns the welding gun with the cover hole, avoids welding defects, and improves quality and efficiency; then, after the welding gun is aligned, the target height is calculated according to the formula and the flux hopper height is adjusted to ensure smooth flow of the flux; then, after the hopper reaches the target height, the solenoid valve is controlled according to the feedback signal of the capacitive probe to accurately control the accumulation amount of the flux; finally, when the accumulation amount of the flux meets the standard, the welding gun is started to arc and the welding gun and the cover are moved synchronously to complete the welding.

[0066] It should be noted that the execution subject of the embodiment of the present application can be a computing service device with data processing, network communication and program running functions, such as a tablet computer, a personal computer, a mobile phone, etc., or an electronic device, a submerged arc automatic welding system, etc. capable of realizing the above functions. The embodiments of the present application and the following embodiments will be described below taking the submerged arc automatic welding system as an example.

[0067] Based on this, the embodiment of the present application provides a pipeline all-position submerged arc welding method, which refers to Figure 1 , Figure 1 The flowchart of the first embodiment of the pipeline all-position submerged arc welding method of the present application.

[0068] In the embodiment, the pipeline all-position submerged arc welding method comprises steps S10-S40:

[0069] Step S10, aligning and correcting the flux material holding device, and aligning the welding gun with the cover hole of the flux material holding box on the flux material holding device.

[0070] It should be noted that the flux material holding device is a component for containing and supplying flux, which ensures that the flux can uniformly and stably cover the welding area during welding. The device is installed on the surface of the pipe to be welded through a magnetic wheel system, which can automatically adjust the suction force according to the shape and material of the pipe to ensure the stability and reliability of the device. The main part of the device is a shell with sufficient strength and high temperature resistance, and the contact surface with the pipe is designed in an arc shape to adapt to pipes of different diameters and shapes.

[0071] The welding gun is used to complete the welding operation and is installed on the welding trolley. It can move up and down, left and right, and rotate through the welding gun adjustment mechanism to realize multi-degree-of-freedom adjustment. The welding gun enters the inside of the flux material holding box through the cover hole to perform welding operation. The flux material holding box is one of the components of the flux material holding device, which is used to contain and store flux. The top of the box is provided with a movable cover, and the cover is provided with a welding gun hole. The cover hole is a through hole on the cover of the flux material holding box, which is used for the welding gun to enter the inside of the flux material holding box for welding operation.

[0072] Please refer to Figure 2 , Figure 2The structure diagram of the flux hopper device provided for the first embodiment of the pipeline all-position submerged arc welding method of the present application, which contains multiple key components to achieve precise control and supply of the flux during the welding process. The device includes an industrial camera (18) for capturing weld images and assisting in centering and correction; a cover plate driving device (19) responsible for driving the movable cover plate (20) to move along the flux hopper box body (21), ensuring that the welding torch can smoothly enter the inside of the flux box for welding operation, while ensuring uniform stacking of the flux in the welding area; the flux hopper box body (21) is designed to accommodate and support the accumulation of flux, and its arc-shaped design is suitable for pipes of different diameters and shapes; the flux universal interface (22) allows the flux supply pipeline to rotate flexibly with the movement of the welding torch during the welding process, avoiding hose entanglement and ensuring the stability of the flux supply. The entire device works cooperatively to provide an innovative solution for all-position submerged arc welding that adapts to complex welding conditions, accurately adjusts flux supply, and reduces flux waste.

[0073] Please refer to Figure 3 , Figure 3 The structure diagram of the flux rotating interface provided for the first embodiment of the pipeline all-position submerged arc welding method of the present application. The interface is a key connection part of the flux hopper device, including a feed port fixing ring (23), a rotating sleeve (24), a ceramic bearing (25), and a bearing spring retainer (26). The function of the feed port fixing ring (23) is to fix the flux conveying pipeline, ensuring its stability during welding operation. The rotating sleeve (24) allows the pipeline to rotate flexibly with the movement of the welding torch during the welding process, while avoiding hose entanglement, ensuring the continuity and stability of the feeding system. The ceramic bearing (25) provides low-friction support for rotating motion, ensuring smooth flux delivery, while the bearing spring retainer (26) ensures that the ceramic bearing remains in a fixed position when rotating, preventing displacement. This design effectively solves the problem of flux supply hose entanglement, ensuring stable flux supply and precise positioning of the welding torch, improving the degree of automation and welding precision in the welding process.

[0074] It can be understood that first, the submerged arc automatic welding system projects a laser line at the weld joint through a laser, and the system calculates the adjustment amount according to the deviation of the laser line from the weld joint, drives the flux hopper device to move to achieve centering and correction, and ensures that the flux hopper device is accurately aligned with the weld joint to provide an accurate flux supply position for subsequent welding. Second, the system adjusts the up-down, left-right position and rotation angle of the welding torch through the servo motor in the welding torch adjustment mechanism according to the relative position of the welding torch and the cover plate hole detected by the proximity switch, so that the welding torch accurately aligns with the hole on the cover plate of the flux hopper box, ensuring that the welding torch can smoothly enter the flux box for welding operation.

[0075] Step S20, adjust the flux hopper to the target height under the condition that the welding torch is aligned with the cover plate hole.

[0076] It should be noted that the flux funnel is mainly used to contain and store the flux, and deliver the flux to the flux hopper through self-weight or auxiliary air pressure. The funnel is installed on a liftable guide rail system, which can be adjusted in height according to the welding working conditions and the requirements of the control system.

[0077] The target height refers to the optimal position that the flux funnel needs to be adjusted to during the welding process, to ensure that the flux can flow smoothly into the flux hopper and meet the requirements of the welding process.

[0078] It can be understood that first, the system measures the distance between the flux funnel and the top of the pipeline using a TOF (Time-of-Flight) camera to obtain basic data. Second, the target height of the flux funnel is calculated through a preset formula. Finally, the system controls the motor-driven belt drive system to adjust the height of the flux funnel to the calculated target position, thereby ensuring the stability of the flux supply and the smooth progress of the welding process.

[0079] As an example, the step of adjusting the flux funnel to the target height when the welding torch is aligned with the cover plate hole includes: measuring the distance between the flux funnel and the pipeline to be welded by a distance measuring camera when the welding torch is aligned with the cover plate hole; calculating the target height of the flux funnel based on the distance, a preset flux flowability parameter and a preset hose diameter parameter, and adjusting the flux funnel to the target height.

[0080] The distance measuring camera refers to a TOF camera installed on the feeding module, which is used to measure the distance between the flux funnel and the pipeline to be welded in real time. The TOF camera emits laser light and receives reflected signals to calculate the optical path and accurately measure the straight-line distance between the two.

[0081] The pipeline to be welded refers to the pipeline that is about to be welded, usually a chemical pipeline or other pipeline structure that needs to be welded.

[0082] The preset flux flowability parameter refers to a parameter that is preset according to the physical properties of the flux, which is used to describe the resistance and flowability of the flux during flow. Flux with poor flowability has a larger flowability coefficient, while flux with good flowability has a smaller flowability coefficient.

[0083] The preset hose diameter parameter refers to the diameter of the flux delivery hose, which is preset in the system. The size of the hose diameter will affect the resistance of the flux flow, and a smaller hose diameter will increase the resistance of the flux flow.

[0084] First, the system activates the distance measuring camera after confirming the alignment of the welding torch and the cover hole, and measures the distance between the flux funnel and the pipe to be welded in real time. Second, the system determines the target height of the flux funnel based on the measured distance, combined with the pre-set flux flowability parameters and hose diameter parameters, through the following calculation formula to ensure smooth flow of flux into the flux hopper:

[0085] H funnelposition = H measured +k f ·D hose +ΔH adjust

[0086] where H measured is the straight-line distance measured by the TOF camera. k f is the flux flowability coefficient, reflecting the flow characteristics of the flux. D hose is the diameter of the delivery hose, and a smaller hose diameter will increase the resistance to flux flow, so the funnel position needs to be appropriately raised. ΔH adjust is the adjustment coefficient of the welding condition, which adjusts the funnel position according to the welding position (such as overhead welding, vertical welding, etc.).

[0087] Finally, the system controls the motor-driven lifting device to adjust the flux funnel to the calculated target height, thereby optimizing the efficiency of flux supply and ensuring the stability of the welding process and the quality of the welding.

[0088] Step S30, in the case where the flux funnel reaches the target height, according to the capacitance signal feedback by the capacitance probe inside the flux hopper, control the electromagnetic valve inside the flux funnel to adjust the accumulation amount of flux.

[0089] It should be noted that the capacitance probe is a sensor installed inside the flux hopper, used to monitor the accumulation height of the flux in real time. The probe measures the capacitance change generated when the flux accumulates to determine the thickness of the flux, and converts these changes into electrical signals to feed back to the submerged arc automatic welding system. These probes are arranged along the arc-shaped bottom surface of the flux box to ensure comprehensive monitoring of the accumulation state of the flux.

[0090] Please refer to Figure 4 , Figure 4The distribution of the capacitive probes in the flux hopper of the first embodiment of the full-position submerged arc welding method of the present application is shown in the figure. The flux hopper is filled with flux, and the capacitive probes are labeled as L1, L2, C, R1, and R2, respectively, and are uniformly distributed inside the flux hopper along the arc-shaped bottom surface of the flux hopper. The sensing surfaces of these probes face the flux accumulation area and can monitor the accumulation height of the flux in real time. When the flux accumulates to a certain height, it will change the capacitance between the flux and the probe, triggering a feedback signal. These signals are used to control the supply of flux, ensuring that the accumulation of flux always maintains within the range required by the welding process. Through such multi-point monitoring, the system can achieve precise control of the flux supply, optimize the use of flux, reduce material waste, and at the same time improve the quality consistency and efficiency of the welding process.

[0091] The capacitive signal refers to the electrical signal generated by the change in the accumulation height of the flux detected by the capacitive probe. When the flux accumulates to a certain height, it will change the capacitance between the flux and the probe, thereby triggering a feedback signal. The triggering threshold of each capacitive probe is calibrated, and the system compares the change value of the capacitance to determine whether the flux meets the set accumulation requirements.

[0092]

[0093] where S i is the capacitive signal feedback by the i-th capacitive probe, C i is the capacitance value of the i-th probe, and the threshold value C threshold .

[0094]

[0095] The solenoid valve is a control device installed inside the flux hopper, used to control the on-off of the flux flowing into the flux hopper. By controlling the opening and closing of the solenoid valve, the system can accurately adjust the flow of flux, ensuring the stability and accuracy of the flux supply.

[0096] The accumulation of flux refers to the actual accumulation height or volume of flux in the flux hopper. During the welding process, the accumulation of flux needs to be maintained within a suitable range, usually 30mm to 50mm, to ensure the consistency and stability of the welding quality.

[0097] It can be understood that first, after the flux hopper is adjusted to the target height, the system starts to monitor the capacitive signal feedback by the capacitive probes inside the flux hopper. Then, the system controls the opening and closing of the solenoid valve according to the capacitive signal, thereby ensuring that the accumulation of flux always maintains within the range required by the welding process.

[0098] As an example, the step of controlling the electromagnetic valve inside the flux hopper to adjust the amount of flux accumulation according to the capacitance signals fed back by the capacitive probes inside the flux pocket when the flux hopper reaches the target height includes: obtaining multiple capacitance signals fed back by multiple capacitive probes inside the flux pocket when the flux hopper reaches the target height; performing weighted averaging and filtering processing on the capacitance signals to obtain an average feedback signal; keeping the electromagnetic valve inside the flux hopper open when the average feedback signal does not reach a preset signal threshold; and closing the electromagnetic valve to adjust the amount of flux accumulation when the average feedback signal reaches the preset signal threshold.

[0099] The average feedback signal refers to a comprehensive signal obtained by the system through weighted averaging and filtering processing on the capacitance signals fed back by multiple capacitive probes. This signal reflects the average state of the amount of flux accumulation inside the flux pocket. The average feedback signal S avg The calculation formula is:

[0100]

[0101] wherein, S avg is the average feedback signal of all detection units, and N is the number of detection units. If S avg = 1, it indicates that the amount of flux accumulation has reached the standard; if S avg = 0, it indicates that the amount of flux accumulation is insufficient.

[0102] The preset signal threshold refers to a standard value set by the system according to the requirements of the welding process, which is used to determine whether the amount of flux accumulation meets the ideal welding conditions.

[0103] Firstly, when the flux hopper is adjusted to the target height, the system immediately collects the capacitance signals fed back by multiple capacitive probes inside the flux pocket, which reflect the accumulation height of flux at different positions. Secondly, the system performs weighted averaging and filtering processing on these capacitance signals to eliminate noise interference in the signals and obtain a more accurate average feedback signal, which represents the overall state of the amount of flux accumulation. Finally, the system compares the average feedback signal with the preset signal threshold. If the average feedback signal does not reach the preset signal threshold, it indicates that the amount of flux accumulation is insufficient, and the system keeps the electromagnetic valve inside the flux hopper open to continue feeding. If the average feedback signal reaches or exceeds the preset signal threshold, it indicates that the amount of flux accumulation has met the requirements of welding, and the system closes the electromagnetic valve to stop feeding, thereby ensuring that the amount of flux accumulation always remains within the optimal range and guaranteeing the stability of the welding process and the quality of the welding.

[0104] Before the step of closing the electromagnetic valve to adjust the amount of flux accumulation when the average feedback signal reaches the preset signal threshold, the method further comprises: obtaining a flux flow rate measured by a flow sensor; and adjusting an output pressure of a gas pump outside the flux hopper according to a difference between the flux flow rate and a preset flow rate threshold.

[0105] The flux flow rate refers to the speed at which the flux flows out of the hopper and into the flux pocket, reflecting the flow state of the flux during the conveying process.

[0106] The preset flow rate threshold refers to a standard value of the flux flow rate preset by the system according to the requirements of the welding process, which is determined based on the required flux supply amount and welding speed during the welding process, ensuring that the flux can flow into the flux pocket at an appropriate rate, thereby meeting the continuity and stability of the welding process.

[0107] The gas pump is an auxiliary device installed outside the flux hopper, which provides additional air pressure when the flux flow is not smooth, helping the flux to flow smoothly into the flux pocket. The output pressure of the gas pump can be dynamically adjusted according to the real-time monitoring results of the flux flow rate, to ensure the stability and continuity of the flux supply.

[0108] The output pressure refers to the air pressure intensity generated by the gas pump when it is working, and by adjusting the output pressure of the gas pump, the flow rate and flow of the flux can be controlled.

[0109] Firstly, the system obtains real-time flux flow rate data through the flow sensor installed on the flux hopper or conveying pipeline, which reflects the actual flow rate of the flux during the conveying process. Secondly, the system compares the measured flux flow rate with the preset flow rate threshold and calculates the difference between the two. Finally, according to this difference, the system automatically adjusts the output pressure of the gas pump outside the flux hopper: if the flux flow rate is lower than the preset threshold, it indicates that the flux flow is not smooth, and the system will increase the output pressure of the gas pump to promote the flux flow; if the flux flow rate is higher than the preset threshold, it indicates that the flux flow is too fast, and the system will reduce the output pressure of the gas pump, thereby ensuring that the flux flow rate is stable within the ideal range and ensuring the smooth progress of the welding process.

[0110] Step S40: When the amount of flux accumulation reaches the preset accumulation threshold, start the welding torch to arc and simultaneously move the welding torch and the cover plate of the flux pocket until the welding is completed.

[0111] It should be noted that the preset accumulation threshold refers to a standard value of the flux accumulation preset by the system according to the requirements of the welding process, which is used to ensure that the accumulation height or volume of the flux during the welding process reaches the ideal range, thereby ensuring the welding quality.

[0112] It can be understood that, first, when the capacitor probe detects that the amount of flux accumulation reaches the preset accumulation threshold, the system confirms that the flux supply is sufficient and uniform, meeting the welding conditions. Second, the system starts the welding gun, causing an electric arc between the electrode of the welding gun and the workpiece, starting the welding process. The welding gun is triggered by the control system sending a signal to the welding power source, causing current to flow between the welding wire and the workpiece, generating a high-temperature arc, thereby starting to melt the welding wire and the workpiece to form a weld. Then, the welding gun and the cover plate of the flux hopper start to move synchronously under the control of the driving system, and the welding gun moves along the welding trajectory, while the cover plate also adjusts its position accordingly to ensure that the flux can uniformly cover the welding area. Finally, the welding gun and the cover plate continue to move synchronously until the entire welding process is completed, ensuring the welding quality and efficiency.

[0113] The embodiment provides a pipeline all-position submerged arc welding method. First, the system centers and corrects the flux hopper device, and aligns the welding gun with the cover plate hole of the flux hopper, which can avoid welding defects caused by the deviation of the welding gun during the welding process, and improve the welding quality and efficiency. Second, under the condition that the welding gun is aligned with the cover plate hole, the system calculates the target height according to a preset formula, and then controls the motor-driven lifting device to adjust the flux funnel to the height, so as to ensure that the flux can flow smoothly into the flux hopper, and avoid poor flux flow or uneven accumulation caused by improper height. Then, after the flux funnel reaches the target height, the system obtains the capacitance signals fed back by the plurality of capacitor probes in the flux hopper, controls the opening and closing of the electromagnetic valve according to the capacitance signals, realizes accurate control of the amount of flux accumulation, and ensures that the amount of flux accumulation always meets the welding process requirements. Finally, when the amount of flux accumulation reaches the preset accumulation threshold, the system starts the welding gun to arc and synchronously moves the welding gun and the cover plate of the flux hopper until the welding is completed, realizes accurate synchronous control of the uniform flux supply and the welding path in all positions, avoids welding defects caused by uneven flux, and ensures the continuity and stability of the welding process.

[0114] Based on the first embodiment of the present application, in the second embodiment of the present application, the same or similar contents as the above-mentioned first embodiment can be referred to the above introduction, and will not be described in detail. On this basis, please refer to Figure 5 , Figure 5 is a flowchart of the second embodiment of the pipeline all-position submerged arc welding method of the present application. The step S10 of the pipeline all-position submerged arc welding method comprises steps S11-S15.

[0115] Step S11, control the laser to project a laser line along the V-shaped groove of the pipe to be welded.

[0116] It should be noted that the V-shaped groove refers to the V-shaped notch pre-processed at the pipe welding position, which is in the shape of a V, usually formed by mechanical processing or cutting process, which helps to fill and fuse the weld, ensures that the weld can be fully penetrated during welding, thereby improving the strength and quality of the welded joint.

[0117] It can be understood that first, the system starts the laser to emit a laser beam. Then, the direction of the laser beam is precisely controlled to project a clear laser line along the V-shaped groove of the pipe to be welded. This laser line will extend along the profile of the V-shaped groove, covering the entire welding area. In this way, the laser line not only clearly indicates the position of the weld, but also provides an accurate positioning reference for subsequent welding operations, ensuring that the welding torch can be accurately aligned with the weld during welding.

[0118] The laser is installed on the top of the flux box, and the laser line is projected along the V-shaped groove of the pipe. The direction of the laser line is aligned with the center line of the pipe, and it will be projected along the profile and edge of the weld to form a clear laser line. The center of the laser line is directly related to the center position of the weld. The projection of the laser line can be regarded as a straight line equation in the direction of the weld, assuming that the coordinates of the weld center line are (x center ,y center ), and the projection angle of the laser line is θ, then the position of the laser line can be represented by the parametric equation:

[0119] x=x center +rcos(θ)

[0120] y=y center +rsin(θ)

[0121] Where r is the offset distance from the weld. Through the projection of the laser line, the accurate position of the weld can be obtained. The projection of the laser line will form a clear light band on the surface of the pipe, and when welding, the image captured by the camera will show a light strip along the profile of the weld. In order to ensure the centering, the image processing system will detect the position of the laser line in the image and calculate the deviation from the center of the weld.

[0122] Step S12, obtaining a weld image containing the laser line, and extracting edge coordinates of the laser line in the weld image.

[0123] It should be noted that the weld image refers to the image containing the weld area captured by the camera installed on the welding equipment. In this embodiment, not only the surface of the pipe to be welded, but also the laser line projected on the V-shaped groove by the laser.

[0124] Edge coordinates refer to the specific position information of the edge of the laser line extracted from the weld image by image processing algorithm. These coordinate points represent the exact position of the laser line in the image, usually expressed in pixels.

[0125] It can be understood that first, the system captures a weld seam image containing the laser line through a camera installed on the welding equipment, ensuring that the image clearly shows the projection of the laser line on the V-shaped groove. Then, an image processing algorithm (such as the Canny edge detection algorithm) is used to analyze the weld seam image and extract the edge coordinates of the laser line.

[0126] As an example, the step of acquiring a weld seam image containing the laser line and extracting the edge coordinates of the laser line in the weld seam image includes: acquiring a weld seam image containing the laser line, and performing grayscale processing and Gaussian filtering on the weld seam image to obtain a target image; calculating the gradient amplitude and gradient direction of each pixel point in the target image; according to the gradient amplitude and the gradient direction, performing non-maximum suppression on the pixel points to obtain suppressed pixel points; through a double-threshold detection algorithm, screening the suppressed pixel points, marking the pixel points with a gradient amplitude greater than a preset high gradient threshold as strong edge points, and marking the pixel points with a gradient amplitude between a preset low gradient threshold and the preset high threshold as weak edge points; and obtaining the edge coordinates of the laser line according to the weak edge points, the strong edge points, and the weld seam image.

[0127] The target image refers to the weld seam image after grayscale processing and Gaussian filtering.

[0128] The gradient amplitude refers to the gradient strength of each pixel point in the image, which reflects the size of the grayscale change around the pixel point. In edge detection, the greater the gradient amplitude, the more intense the grayscale change around the pixel point, and the more likely it is an edge point. Given the image I(x, y) gradient calculation is:

[0129]

[0130] The gradient direction refers to the gradient direction of each pixel point in the image, indicating the direction of grayscale change. In edge detection, the gradient direction is used to determine the direction of the edge, helping the algorithm to more accurately locate the edge. The gradient direction is usually determined by calculating the horizontal and vertical gradient components.

[0131] The preset high gradient threshold refers to a higher threshold set in the double-threshold detection algorithm, used to distinguish strong edge points and non-edge points. In this embodiment, the preset high gradient threshold is 0.8.

[0132] The strong edge point refers to the pixel point with a gradient amplitude greater than the preset high gradient threshold. These points represent areas with very intense grayscale changes in the image and are likely to be part of the edge.

[0133] The preset low gradient threshold refers to a lower threshold set in the double-threshold detection algorithm for distinguishing weak edge points from non-edge points. In this embodiment, the preset low gradient threshold is 0.2.

[0134] Weak edge points refer to pixel points with gradient amplitudes between the preset low gradient threshold and the preset high gradient threshold. These points represent regions with relatively mild gray level changes in the image, which may be part of an edge, but also may be noise or other non-edge features, and need to be further verified. Only when they are connected with strong edge points, they are confirmed as edge points.

[0135] Firstly, the system acquires a weld image containing a laser line through a camera installed on the welding equipment, then performs grayscale processing on the image to convert the color image into a grayscale image to reduce the data volume and simplify the subsequent processing steps, and then applies Gaussian filtering to remove noise in the image and smooth the image to obtain a clear target image, providing a more accurate basis for subsequent edge detection. Secondly, the system calculates the gradient amplitude and gradient direction of each pixel point in the target image, calculates the gradient components of each pixel point in the horizontal and vertical directions through the Sobel operator or other gradient operators, and then calculates the gradient amplitude and gradient direction according to the two components. Then, the system performs non-maximum suppression on each pixel point by comparing the gradient amplitude of each pixel point with that of its adjacent pixel points in the gradient direction. If the gradient amplitude of the pixel point is not the local maximum value, it is suppressed as a non-edge point, thereby retaining the true edge points and removing the pseudo-edge points that may be caused by noise. Finally, the system screens the suppressed pixel points, marks the pixel points with gradient amplitudes greater than the preset high gradient threshold as strong edge points, and marks the pixel points with gradient amplitudes between the preset low gradient threshold and the high gradient threshold as weak edge points. Ultimately, in combination with the strong edge points, the weak edge points, and the original weld image, the system determines the edge coordinates of the laser line, providing accurate positioning information for subsequent weld centering and deviation correction operations.

[0136] As an example, the step of obtaining the edge coordinates of the laser line according to the weak edge points, the strong edge points, and the weld image includes connecting the weak edge points with adjacent strong edge points based on an edge connection algorithm to form a continuous edge contour, fitting a straight line equation of the edge contour through Hough transformation, and determining the edge coordinates of the laser line according to the intersection of the straight line equation and the boundary of the weld image.

[0137] The edge connection algorithm is an image processing technique for connecting weak edge points in an image with adjacent strong edge points to form a continuous edge contour.

[0138] Edge contour refers to the continuous edge line formed by connecting weak edge points and strong edge points through edge connection algorithm, which clearly identifies the boundary or features of objects in the image, such as the specific position of laser line in the weld image.

[0139] Hough transform is an algorithm for detecting straight lines in an image, which converts edge points in the image from Cartesian coordinate system to parameter space (polar coordinate system), thereby realizing the detection of straight lines. In the parameter space, each straight line corresponds to a point, and by counting the distribution of these points, the most likely straight line parameters can be found.

[0140] Straight line equation refers to the mathematical expression describing the position of laser line obtained by Hough transform fitting.

[0141] Firstly, the system traverses all weak edge points through edge connection algorithm, for each weak edge point, checks the pixels in its 8-neighborhood, if a strong edge point is found in the neighborhood, the weak edge point is connected with the strong edge point to form a continuous edge contour, this process effectively fills the possible broken parts in edge detection, ensuring the clear and continuous edge of laser line. Secondly, the system applies Hough transform to the formed edge contour, converts each edge point to a sinusoidal curve in parameter space, counts the intersection points of these curves in parameter space, the region with the most intersection points corresponds to the slope and intercept of the straight line, thereby fitting the straight line equation of the edge contour, this process integrates the discrete edge points into a straight line, providing a mathematical basis for subsequent positioning. Finally, according to the fitted straight line equation, the intersection points of the straight line and the weld image boundary are calculated, these intersection points are the edge coordinates of the laser line, through these coordinates, the position of the laser line in the image can be accurately determined, providing accurate positioning information for subsequent weld centering and correction operation, ensuring the accuracy and stability of the welding process.

[0142] Step S13, calculate the offset distance of the edge coordinates and the weld centerline in the weld image.

[0143] It should be noted that the weld centerline refers to the geometric center position of the weld in the image, which is usually determined by image processing algorithm in advance. In pipe welding, the weld centerline is the key position that needs to be accurately aligned for welding operation, which represents the center trajectory of the weld.

[0144] Offset distance refers to the horizontal or vertical distance between the edge coordinates of the laser line and the weld centerline, reflecting the alignment degree of the laser line and the weld centerline, which is an important basis for the system to judge whether the flux pocket device needs to be corrected.

[0145] It can be understood that first, the system determines the coordinates of the weld center line through image processing algorithms, usually using Hough transform to extract the straight line equation of the center line from the weld image. Second, by calculating the Euclidean distance (or horizontal / vertical distance) between the edge coordinate points of the laser line and the corresponding points of the weld center line, the offset distance of the laser line from the weld center line can be obtained. The calculation formula is:

[0146]

[0147] where d is the offset distance, (x laser ,y laser ) is the center point coordinate of the laser line, and (x center ,y center ) is the coordinate of the weld center.

[0148] Step S14, aligning the flux pocket device with the weld center line according to the offset distance.

[0149] It can be understood that first, the system compares the calculated offset distance with the preset tolerance range to determine whether the position of the flux pocket device needs to be adjusted. Second, if the offset distance exceeds the tolerance range, the system will adjust the position of the flux pocket device according to the direction and size of the offset, so that it moves towards the weld center line direction until the offset distance is within the tolerance range. Finally, the system detects the alignment of the flux pocket device and the weld center line again to ensure accurate alignment, providing accurate positioning for subsequent welding operations, thereby ensuring welding quality and efficiency.

[0150] As an example, the step of aligning the flux pocket device with the weld center line according to the offset distance includes: calculating the lateral adjustment amount of the flux pocket device according to the offset distance and a preset proportional gain coefficient; generating a pulse signal based on the lateral adjustment amount; driving the motor of the flux pocket device to perform lateral displacement at a preset adjustment period according to the pulse signal until the actual offset distance between the weld center line and the flux pocket device is less than a preset alignment accuracy threshold, completing the alignment.

[0151] The preset proportional gain coefficient (K p ) is a coefficient used to adjust the size of the control quantity in the proportional control algorithm. In this embodiment, the value of K p is 0.5, which is used to calculate the lateral adjustment amount of the flux pocket device.

[0152] The lateral adjustment amount (ΔX) is the distance that the flux pocket device needs to move according to the offset distance and the preset proportional gain coefficient, and the calculation formula is ΔX = K pOffset distance. This value determines the amount of movement of the flux pocket device in the lateral direction to ensure accurate alignment with the weld centerline.

[0153] Pulse signal refers to the control signal generated based on the lateral adjustment amount, used to drive the motor to perform specific displacement operations. The frequency and number of pulse signals are directly proportional to the lateral adjustment amount. By controlling the speed and rotation angle of the motor through pulse signals, precise displacement control is achieved.

[0154] The preset adjustment period refers to the time interval between each adjustment operation. In this embodiment, the preset adjustment period is 100 milliseconds. This period determines the frequency of position adjustment by the system, ensuring a smooth adjustment process without being too frequent, thereby improving the stability and response speed of the system.

[0155] Lateral displacement refers to the actual movement distance of the flux pocket device in the lateral direction.

[0156] Actual offset distance refers to the real-time offset distance between the flux pocket device and the weld centerline during the adjustment process. The system recalculates the actual offset distance after each adjustment to ensure the accuracy and effectiveness of the adjustment process.

[0157] The preset alignment accuracy threshold refers to the minimum offset distance at which the system considers the flux pocket device to be aligned with the weld centerline. In this embodiment, the preset alignment accuracy threshold is 0.5 millimeters.

[0158] First, the system calculates the lateral adjustment amount through a proportional control algorithm, specifically by multiplying the offset distance by a preset proportional gain coefficient to obtain the distance the flux pocket device needs to move. The calculation formula is:

[0159]

[0160] Where k is the proportional coefficient, d x and d y are the deviation distances along the X and Y axes, respectively.

[0161] Then, the system generates a corresponding number of pulse signals based on this lateral adjustment amount, with each pulse signal corresponding to a step angle or movement unit of the motor, ensuring that the angle of motor rotation accurately corresponds to the lateral adjustment amount. Finally, the system sends pulse signals to drive the motor of the flux pocket device to perform lateral displacement at a preset adjustment period of 100 milliseconds. The displacement direction is determined by the positive or negative of the offset distance, with positive offset moving left and negative offset moving right. After each adjustment, the system recalculates the actual offset distance until the actual offset distance is less than the preset alignment accuracy threshold of 0.5 millimeters, completing the alignment operation and ensuring accurate alignment of the flux pocket device with the weld centerline, providing accurate positioning for subsequent welding operations.

[0162] Step S15, align the welding gun with the cover hole of the flux pocket box on the flux pocket device when the flux pocket device is aligned with the weld centerline.

[0163] It can be understood that first, the system starts the welding gun alignment program after confirming that the flux pocket device is aligned with the weld centerline, adjusts the up and down position of the welding gun through the servo motor in the welding gun adjustment mechanism according to the position information fed back by the proximity switch, ensures that the welding gun height is consistent with the cover hole, and then adjusts the left and right position of the welding gun through the servo motor to align the center of the welding gun with the center of the cover hole, and adjusts the rotation angle of the welding gun to ensure that the welding gun can smoothly enter the cover hole.

[0164] The embodiment first controls the laser to project a laser line along the V-shaped groove of the pipe to be welded, clearly marks the weld position, provides a high-contrast reference for subsequent operations, and improves the positioning accuracy. Then, the weld image containing the laser line is obtained, the image is subjected to grayscale and Gaussian filtering processing, the edge coordinates of the laser line are extracted through gradient calculation and double-threshold detection, accurate data for centering of the flux pocket device is provided. Then, the offset distance of the edge coordinates from the weld centerline is calculated, the transverse adjustment amount is calculated through a proportional control algorithm, a pulse signal is generated to drive the motor to adjust the position of the flux pocket device, until the offset distance is less than a preset threshold, accurate centering is achieved, and welding deviation is reduced. Finally, the up and down, left and right positions and the rotation angle of the welding gun are adjusted through the servo motor when the flux pocket device is aligned with the weld centerline, so that the welding gun is accurately aligned with the cover hole of the flux pocket box, and the welding gun can smoothly enter the cover hole for welding, avoiding welding defects and further improving the welding quality and efficiency.

[0165] It should be noted that the above examples are only used to understand the present application and do not constitute a limitation on the pipeline all-position submerged arc welding method of the present application. More forms of simple transformation based on this technical concept are within the protection scope of the present application.

[0166] The present application also provides a pipeline all-position submerged arc welding device, please refer to Figure 6 The pipeline all-position submerged arc welding device comprises:

[0167] The alignment module 10 is used for centering and correcting the flux pocket device, and aligning the welding gun with the cover hole of the flux pocket box on the flux pocket device.

[0168] The funnel adjustment module 20 is used for adjusting the flux funnel to a target height when the welding gun is aligned with the cover hole.

[0169] The flux control module 30 is configured to control the electromagnetic valve inside the flux hopper to adjust the amount of flux accumulation according to the capacitance signal fed back by the capacitance probe inside the flux pocket when the flux hopper reaches the target height.

[0170] The welding module 40 is configured to start the arc of the welding torch and simultaneously move the welding torch and the cover plate of the flux pocket until the welding is completed when the amount of flux accumulation reaches the preset accumulation threshold.

[0171] In an embodiment, the alignment module 10 is further configured to control the laser to project a laser line along the V-shaped groove of the pipe to be welded, acquire a weld image containing the laser line, and extract edge coordinates of the laser line in the weld image; calculate the offset distance between the edge coordinates and the center line of the weld in the weld image; align the flux pocket device with the center line of the weld according to the offset distance; and align the welding torch with the cover plate hole of the flux pocket on the flux pocket device when the flux pocket device is aligned with the center line of the weld.

[0172] In an embodiment, the alignment module 10 is further configured to acquire a weld image containing the laser line, and perform grayscale processing and Gaussian filtering on the weld image to obtain a target image; calculate the gradient amplitude and gradient direction of each pixel point in the target image; perform non-maximum suppression on the pixel points according to the gradient amplitude and the gradient direction to obtain suppressed pixel points; screen the suppressed pixel points through a double-threshold detection algorithm, mark the pixel points with a gradient amplitude greater than a preset high gradient threshold as strong edge points, and mark the pixel points with a gradient amplitude between a preset low gradient threshold and the preset high threshold as weak edge points; and obtain the edge coordinates of the laser line according to the weak edge points, the strong edge points, and the weld image.

[0173] In an embodiment, the alignment module 10 is further configured to connect the weak edge points and adjacent strong edge points based on an edge connection algorithm to form a continuous edge contour; fit a straight line equation of the edge contour through Hough transformation; and determine the edge coordinates of the laser line according to the intersection of the straight line equation and the boundary of the weld image.

[0174] In an embodiment, the alignment module 10 is further configured to calculate the lateral adjustment amount of the flux pocket device according to the offset distance and a preset proportional gain coefficient; generate a pulse signal based on the lateral adjustment amount; and drive the motor of the flux pocket device to perform lateral displacement at a preset adjustment period according to the pulse signal until the actual offset distance between the center line of the weld and the flux pocket device is less than a preset alignment accuracy threshold, thereby completing the alignment.

[0175] In an embodiment, the funnel adjustment module 20 is further configured to measure the distance between the flux funnel and the pipe to be welded by the distance measuring camera when the welding torch is aligned with the cover plate hole; calculate the target height of the flux funnel based on the distance, a preset flux flowability parameter and a preset hose diameter parameter, and adjust the flux funnel to the target height.

[0176] In an embodiment, the flux control module 30 is further configured to obtain a plurality of capacitance signals fed back by a plurality of capacitance probes in the flux hopper when the flux funnel reaches the target height; perform weighted average and filtering processing on the capacitance signals to obtain an average feedback signal; keep the electromagnetic valve in the flux funnel open when the average feedback signal does not reach a preset signal threshold; and close the electromagnetic valve to adjust the flux accumulation amount when the average feedback signal reaches the preset signal threshold.

[0177] The pipeline all-position submerged arc welding device provided by the present application adopts the pipeline all-position submerged arc welding method in the above embodiments, and can solve the technical problem of how to realize uniform flux supply and precise synchronous control of the welding path. Compared with the prior art, the pipeline all-position submerged arc welding device provided by the present application has the same beneficial effects as the pipeline all-position submerged arc welding method provided by the above embodiments, and other technical features of the pipeline all-position submerged arc welding device are the same as the features disclosed in the above embodiment method, which will not be described here.

[0178] The present application provides a kind of submerged arc automatic welding system, the submerged arc automatic welding system includes annular track, pipe to be welded, flux hopper device, welding torch, flux funnel, flux funnel fixed base, distance measuring camera, welding trolley annular track base, welding wire reel, welding trolley, welding torch adjustment module, flux baffle moving module, flux baffle, flux hopper, flux hopper drive device, flux funnel lifting module, small air pump and electromagnetic valve, the annular track is installed on the outer surface of the pipe to be welded, and the flux hopper device is installed on the weld of the pipe to be welded by magnetic attraction wheel.

[0179] Please refer to Figure 7 , Figure 7 The system structure diagram of the embodiment of the present application is the system structure diagram of the submerged arc automatic welding system. As can be seen from the figure, the chemical pressure pipeline (1) is the object to be welded, which is located at the bottom of the figure. The welding trolley annular track base (2) is stably installed on the pipeline to provide a moving track for the welding trolley (5). The annular track (3) surrounds the pipeline, and the welding trolley moves along the track to realize all-position welding of the pipeline.

[0180] The welding wire reel (4) is installed on the welding trolley, providing the welding wire required for welding. The welding gun adjustment module (6) is located at the front end of the welding trolley, used to accurately adjust the position and angle of the welding gun (8), ensuring the accuracy of welding. The flux baffle moving module (7) and the flux baffle (9) work together to control the flow and coverage of the flux.

[0181] The flux pocket (10) is installed on the welding trolley, used to collect and guide the flux. The flux pocket drive device (11) controls the movement of the pocket, ensuring that the flux can uniformly cover the welding area. The TOF camera (12) is installed on the outside of the flux pocket, used to monitor the position of the weld, helping the system to center and correct the flux pocket device.

[0182] The flux hopper lifting module (13) and the flux hopper fixed base (14) work together to make the flux hopper (15) able to lift according to the welding requirements, to adjust the supply amount of flux. The small air pump (16) and the electromagnetic valve (17) are installed in the flux hopper, used to control the flow of flux, ensuring that the flux can flow smoothly into the flux pocket.

[0183] The whole system significantly improves the welding precision and consistency by accurately controlling the flux supply amount and real-time monitoring the flux accumulation state. The system can perform full-position welding at various positions of the pipe, especially suitable for non-rotating chemical pipes or pressure pipes, solving the problem of not being able to adapt to non-rotating pipes in traditional welding methods.

[0184] The present application provides a computer readable storage medium having stored thereon computer readable program instructions (i.e., computer programs) for performing the pipe full-position submerged arc welding method in the above embodiments.

[0185] The computer readable storage medium provided in the application may be, for example, a U disk, but is not limited to an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, system, or device, or any combination of the above. More specific examples of the computer readable storage medium may include, but are not limited to, an electrical connection with one or more conductive wires, a portable computer disk, a hard disk, a RAM (Random Access Memory), a ROM (Read Only Memory), an EPROM (Erasable Programmable Read Only Memory or flash memory), an optical fiber, a CD-ROM (CD-Read Only Memory), an optical storage device, a magnetic storage device, or any suitable combination of the above. In the embodiment, the computer readable storage medium may be any tangible medium containing or storing a program that can be used by or in combination with an instruction execution system, system, or device. The program code contained on the computer readable storage medium can be transmitted by any suitable medium, including but not limited to an electrical wire, an optical cable, an RF (Radio Frequency), and the like, or any suitable combination of the above.

[0186] The computer readable storage medium described above may be contained in a pipe all-position submerged arc welding device, or may exist separately without being assembled into the pipe all-position submerged arc welding device.

[0187] The computer readable storage medium described above carries one or more programs, which, when executed by the pipe all-position submerged arc welding device, cause the pipe all-position submerged arc welding device to: center and correct the flux pocket device, and align the welding torch with the cover hole of the flux pocket box on the flux pocket device; adjust the flux hopper to a target height when the welding torch is aligned with the cover hole; control the electromagnetic valve inside the flux hopper according to the capacitance signal fed back by the capacitance probe inside the flux pocket box to adjust the flux accumulation amount when the flux hopper reaches the target height; start the welding torch to arc and synchronously move the welding torch and the cover plate of the flux pocket box until the welding is completed when the flux accumulation amount reaches a preset accumulation amount threshold.

[0188] Computer program code for carrying out operations of the present application can be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the "C" programming language or similar programming languages. The program code can execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer can be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection can be made to an external computer (for example, through the Internet using an Internet Service Provider).

[0189] The computer program instructions can also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0190] The modules involved in the embodiments of the present application can be implemented in software or hardware. In some cases, the names of the modules do not constitute a limitation on the modules themselves.

[0191] The readable storage medium provided by the present application is a computer readable storage medium, which stores computer readable program instructions (i.e., a computer program) for executing the pipeline all-position submerged arc welding method, and can solve the technical problem of how to realize the uniform supply of welding flux and the precise synchronization control of the welding path. Compared with the prior art, the computer readable storage medium provided by the present application has the same beneficial effects as the pipeline all-position submerged arc welding method provided by the above-mentioned embodiments, and will not be described here.

[0192] The application further provides a computer program product comprising a computer program which, when executed by a processor, implements the steps of the pipe all-position submerged arc welding method as described above.

[0193] The computer program product provided by the application can solve the technical problem of how to realize the uniform supply of welding flux and the precise synchronization control of the welding path. Compared with the prior art, the beneficial effects of the computer program product provided by the application are the same as those of the pipe all-position submerged arc welding method provided by the above-mentioned embodiments, and are not described here.

[0194] The above only describes some embodiments of the application, and does not limit the patent scope of the application. Any equivalent structural transformation, direct / indirect application in other related technical fields, or direct / indirect application in other related technical fields within the technical concept of the application, including in the patent protection scope of the application.

Claims

1. A method of pipe all position submerged arc welding characterized by, The method comprises: centering and correcting the flux pocket device, and aligning the welding torch with the cover hole of the flux pocket box on the flux pocket device; adjusting the flux funnel to the target height when the welding torch is aligned with the cover hole; controlling the electromagnetic valve inside the flux funnel according to the capacitance signal fed back by the capacitance probe inside the flux pocket box when the flux funnel reaches the target height, to adjust the flux accumulation amount; starting the welding torch arc and synchronously moving the welding torch and the cover plate of the flux pocket box until the welding is completed when the flux accumulation amount reaches the preset accumulation threshold; wherein the step of controlling the electromagnetic valve inside the flux funnel according to the capacitance signal fed back by the capacitance probe inside the flux pocket box when the flux funnel reaches the target height to adjust the flux accumulation amount comprises: acquiring multiple capacitance signals fed back by multiple capacitance probes inside the flux pocket box when the flux funnel reaches the target height; performing weighted average and filtering processing on the capacitance signals to obtain an average feedback signal; keeping the electromagnetic valve inside the flux funnel open when the average feedback signal does not reach the preset signal threshold; closing the electromagnetic valve to adjust the flux accumulation amount when the average feedback signal reaches the preset signal threshold.

2. The method of claim 1, wherein, The step of centering and correcting the flux pocket device, and aligning the welding torch with the cover hole of the flux pocket box on the flux pocket device comprises: controlling the laser to project a laser line along the V-shaped groove of the pipe to be welded; acquiring a weld seam image containing the laser line, and extracting the edge coordinates of the laser line in the weld seam image; calculating the offset distance between the edge coordinates and the center line of the weld seam in the weld seam image; aligning the flux pocket device with the center line of the weld seam according to the offset distance; aligning the welding torch with the cover hole of the flux pocket box on the flux pocket device when the flux pocket device is aligned with the center line of the weld seam.

3. The method of claim 2, wherein, The step of acquiring a weld seam image containing the laser line, and extracting the edge coordinates of the laser line in the weld seam image comprises: acquiring a weld seam image containing the laser line, and performing grayscale processing and Gaussian filtering on the weld seam image to obtain a target image; calculating the gradient amplitude and gradient direction of each pixel point in the target image; performing non-maximum suppression on the pixel points according to the gradient amplitude and gradient direction to obtain suppressed pixel points; screening the suppressed pixel points by a double-threshold detection algorithm, marking the pixel points with a gradient amplitude greater than a preset high gradient threshold as strong edge points, and marking the pixel points with a gradient amplitude between a preset low gradient threshold and the preset high gradient threshold as weak edge points; obtaining the edge coordinates of the laser line according to the weak edge points, the strong edge points, and the weld seam image.

4. The method of claim 3, wherein, The step of obtaining the edge coordinates of the laser line according to the weak edge points, the strong edge points, and the weld seam image comprises: connecting the weak edge point with the adjacent strong edge point based on an edge connection algorithm to form a continuous edge contour; fitting a straight line equation of the edge contour through a Hough transform; determining the edge coordinates of the laser line according to the intersection of the straight line equation and the boundary of the weld seam image.

5. The method of claim 2, wherein, The step of aligning the flux pocket device with the weld seam centerline according to the offset distance comprises: calculating a lateral adjustment amount of the flux pocket device according to the offset distance and a preset proportional gain coefficient; generating a pulse signal based on the lateral adjustment amount; driving a motor of the flux pocket device to perform lateral displacement at a preset adjustment period according to the pulse signal until the actual offset distance between the weld seam centerline and the flux pocket device is less than a preset alignment accuracy threshold, and completing the alignment.

6. The method of claim 1, wherein, The step of adjusting the flux funnel to a target height under the condition that the welding torch is aligned with the cover hole of the flux pocket device comprises: measuring the distance between the flux funnel and the pipe to be welded through a distance measuring camera under the condition that the welding torch is aligned with the cover hole of the flux pocket device; calculating the target height of the flux funnel based on the distance, a preset flux flowability parameter and a preset hose diameter parameter, and adjusting the flux funnel to the target height.

7. A pipe all-position submerged arc welding apparatus characterized by comprising: The pipe all-position submerged arc welding device is used to implement the pipe all-position submerged arc welding method as claimed in any one of claims 1 to 6, and the device comprises: an alignment module configured to align and correct the flux pocket device, and align the welding torch with the cover hole of the flux pocket box of the flux pocket device; a funnel adjustment module configured to adjust the flux funnel to a target height under the condition that the welding torch is aligned with the cover hole of the flux pocket device; a flux control module configured to control an electromagnetic valve inside the flux funnel to adjust the flux accumulation amount according to the capacitance signal fed back by the capacitance probe inside the flux pocket box under the condition that the flux funnel reaches the target height; a welding module configured to start the welding torch to arc and synchronously move the welding torch and the cover of the flux pocket box until the welding is completed under the condition that the flux accumulation amount reaches a preset accumulation amount threshold.

8. A storage medium, characterized by The storage medium is a computer readable storage medium, and the storage medium stores a computer program. The computer program is executed by a processor to implement the steps of the pipe all-position submerged arc welding method as claimed in any one of claims 1 to 6.

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