Low-noise high-heat-dissipation large-diameter steel pipe seam welding machine and using method thereof

Abstract

The invention discloses a low-noise high-heat-dissipation large-diameter steel pipe seam welding machine and a using method thereof, and relates to the technical field of welding equipment.The low-noise high-heat-dissipation large-diameter steel pipe seam welding machine comprises a rack, a welding mechanism and a noise reduction mechanism, the welding mechanism is fixedly installed at the bottom end of the outer wall of the rack, and the noise reduction mechanism is fixedly installed on the side face of the outer wall of the rack; the noise reduction mechanism comprises a sound insulation cover, a shock pad and a composite silencer, the sound insulation cover is composed of an outer layer steel plate with the thickness of 1.5 mm, an inner layer glass wool and a middle damping paint layer, the sound insulation cover covers the welding head and the welding wire conveying mechanism, and the shock pad is arranged between the bottom end of the outer wall of the rack and the ground. The composite silencer is fixedly installed on the inner wall of the welding flux conveying pipeline. By means of the sound insulation cover, high-frequency noise in the welding process is attenuated in a gradient mode, the problem that noise pollution of a welding machine is serious is solved, the working environment is effectively improved, and noise decibel is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of welding equipment, and particularly to a low-noise, high-heat dissipation large-diameter steel pipe seam welder and its usage method. Background Art

[0002] In modern industrial production, large-diameter steel pipes are widely used in many fields such as petroleum, natural gas, water conservancy, and construction. Their quality directly affects the safety and reliability of projects. Seam welding, as a key process in the production of large-diameter steel pipes, poses extremely high requirements for the performance of welding equipment. Traditional steel pipe seam welders often have problems such as high noise and poor heat dissipation effect when facing the welding of large-diameter steel pipes. This not only harms the physical health of operators but also leads to unstable welding quality due to overheating of the equipment, affecting production efficiency and the overall performance of steel pipes.

[0003] Patent CN108890079B discloses an automatic seam welder and its automatic seam welding method. The above patent realizes high welding efficiency, good quality, low labor intensity for the metal corrugated core body, the welding quality is not affected by human factors, and it has automated operation without quality hidden dangers.

[0004] In the above patent, the workpiece is fixed by a moving support on the platform, and the driving of the moving support is realized by the meshing of the profiling gear ring and the driving wheel. With the cooperation of the inner pushing cylinder, the steering cylinder and the edge-finding mechanism, the automatic seam welding of the metal corrugated core body can be realized. However, for the welding of large-diameter steel pipes, the heat input is large, and there is a lack of an efficient heat dissipation structure, which easily leads to overheating of the welding head and surrounding components, and the noise generated during the welding process is not effectively suppressed, affecting the equipment stability and welding quality.

[0005] Therefore, the present application proposes a low-noise, high-heat dissipation large-diameter steel pipe seam welder and its usage method that can achieve multi-stage noise reduction of a double-layer sound insulation structure and a composite muffler, and at the same time rely on the reverse convection heat dissipation mechanism of the serpentine water channels and spiral air guiding grooves in the liquid cooling plate to quickly conduct the welding heat source. Summary of the Invention

[0006] The purpose of the present invention is to provide a low-noise, high-heat dissipation large-diameter steel pipe seam welder and its usage method to solve the technical problems of high noise and poor heat dissipation effect existing in the steel pipe seam welder when facing the welding of large-diameter steel pipes as mentioned in the above background art.

[0007] To achieve the above purpose, the present invention provides the following technical solution: A low-noise, high-heat dissipation large-diameter steel pipe seam welder, comprising a frame, a welding mechanism and a noise reduction mechanism. The welding mechanism is fixedly installed at the bottom end of the outer wall of the frame, and the noise reduction mechanism is fixedly installed on the side surface of the outer wall of the frame; The noise reduction mechanism includes a sound insulation cover, a shock pad and a composite muffler. The sound insulation cover is composed of an outer layer of 1.5 mm thick steel plate, an inner layer of glass wool and an intermediate damping paint layer. The sound insulation cover covers the welding head and the wire feeding mechanism. The shock pad is arranged between the bottom end of the outer wall of the frame and the ground. The composite muffler is fixedly installed on the inner wall of the flux conveying pipeline.

[0008] Preferably, the frame includes a base, columns and a cross beam. The columns are vertically welded on both sides of the outer wall of the base. The cross beam is horizontally erected on the top end of the outer wall of the columns. The base and the columns are connected by submerged arc welding and flush welds. The cross beam and the columns are connected by fillet welds of carbon dioxide shielded welding to strengthen the ribs.

[0009] Preferably, the welding mechanism is fixedly installed at the bottom end of the outer wall of the cross beam through a sliding guide rail. The welding mechanism includes a welding head, a wire feeding mechanism, a flux feeding mechanism and a welding tracker. The welding head is connected to the cross beam through a sliding guide rail. The wire feeding mechanism and the flux feeding mechanism are installed side by side on the top end of the outer wall of the cross beam; The welding tracker includes a double-joint rotating shaft, a cross slide and a contact head. The cross slide is fixedly installed on the sliding guide rail. The double-joint rotating shaft is fixedly installed at the center of the cross slide through a bearing. The contact head is fixedly installed at the front end of the outer wall of the welding head; The output ends of the wire feeding mechanism and the flux feeding mechanism are respectively aligned with the wire inlet and the weld area of the welding head.

[0010] Preferably, the sound insulation cover is set as a top block and a front side block. The top block is connected to the cross beam through a pneumatic telescopic rod. The front side block is provided with a double-layer sliding and push-pull maintenance door. The inner layer door is a micro-perforated sound absorption board, and the outer layer door is a sealed steel plate. An air sound insulation layer is formed between the two doors.

[0011] Preferably, a cooling mechanism is fixedly installed at the bottom end of the outer wall of the cross beam. The cooling mechanism includes a liquid cooling plate, a cooling fan and a circulator. The liquid cooling plate is fixedly installed at the bottom end of the outer wall of the welding head. A serpentine cooling water channel is arranged inside the liquid cooling plate. The cooling fans are fixedly installed on both sides of the outer wall of the frame. The circulator is horizontally arranged directly above the liquid cooling plate. The circulator is fixedly installed on the side of the outer wall of the cross beam through a bracket. A pipeline is arranged inside the circulator. The pipeline is connected to an atomizer. The atomizer is fixedly installed at the output end of the circulator; The inside of the liquid cooling plate is composed of spherical sub-units arranged in a matrix. Ventilation channels are formed between adjacent sub-units. The serpentine cooling water channel penetrates through the sub-units. The air outlet of the cooling fan is aligned with the ventilation channel inlet of the liquid cooling plate. The atomizer is connected to a cooling water tank through a pipeline. A circulating water pump is fixedly installed in the middle section of the outer wall of the pipeline.

[0012] Preferably, a circular double-layer water cooling channel is provided at the bottom end of the inner wall of the liquid cooling plate. The inner layer of the circular double-layer water cooling channel is a spiral copper guide water pipe, and the spiral copper guide water pipe is externally connected to a circulating pump. The outer layer of the circular double-layer water cooling channel is an aluminum heat dissipation fin, and spiral air guide grooves are formed between the aluminum heat dissipation fins; The air guide groove inlet is opposite to the radial fan air outlet of the cooling fan, and the end of the air guide groove communicates with the exhaust hole opened at the rear end of the outer wall of the frame, and a filter screen is fixedly installed inside the exhaust hole; The contact area between the liquid cooling plate and the sound insulation cover is covered with a heat insulation layer, and the heat insulation layer is pasted by a ceramic fiber board and an aluminum foil reflection layer through a high-temperature resistant adhesive.

[0013] Preferably, clamping mechanisms are symmetrically arranged at the top end of the outer wall of the base. The clamping mechanisms include an adaptive jaw group, a three-dimensional locator and a connecting seat. The receiving component and the transmitting component of the three-dimensional locator are respectively embedded at the top end and the bottom end of the outer wall of the adaptive jaw group. The connecting seat is arranged between the base of the adaptive jaw group and the base, and the adaptive jaw group is symmetrically and fixedly installed at the front end of the base.

[0014] Preferably, the shock pad is arranged as a three-layer composite structure. The upper spring support frame is fixedly installed at the bottom end of the outer wall of the frame through bolts. The middle hydraulic damper vertically penetrates the lower rubber cushion layer, and the bottom end of the outer wall of the rubber cushion layer is connected to the ground support seat.

[0015] Preferably, the usage method includes the following steps: S1. The adaptive jaw group positions and clamps the large-diameter steel pipe. The transmitting component of the three-dimensional locator emits a laser beam to the receiving component, and the servo motor of the connecting seat is driven according to the reflected light intensity deviation value to adjust the position of the jaw group; S2. The welding head moves along the sliding guide rail to the position to be welded. The contact head of the welding tracker contacts the weld to generate a displacement signal and transmits it to the double-joint rotating shaft, and the double-joint rotating shaft drives the cross slide to adjust the posture of the welding head; S3. The wire feeding mechanism and the flux feeding mechanism respectively feed the wire and the flux to the wire inlet of the welding head and the weld area; S4. During the welding process, the top block of the sound insulation cover covers the frame through the pneumatic telescopic rod, the double-layer push-pull type maintenance door of the front side block is closed, and an air sound insulation layer is formed by the inner micro-perforated sound absorption board and the outer sealing steel plate; S5. The cooling fan conveys air flow to the ventilation channel of the liquid cooling plate, and the atomizer in the circulator atomizes the coolant and then conveys it to the welding area through a pipeline; S6. The serpentine cooling water channel inside the liquid cooling plate performs liquid cooling circulation through a circulating water pump. At the same time, the inner spiral copper guide water pipe of the circular double-layer water cooling channel performs secondary water cooling, and the outer aluminum heat dissipation fins discharge the hot air through the spiral air guide grooves; S7. The upper spring support frame of the shock pad buffers vertical vibrations, the middle hydraulic damper suppresses horizontal swaying, and the lower rubber cushion layer isolates the transmission of ground vibrations; S8. The composite silencer performs multi-stage attenuation on the airflow noise in the flux delivery pipeline.

[0016] Preferably, the usage method further includes the following steps: S31. The wire feeding speed of the wire feeding mechanism is synchronized with the moving speed of the welding head, and the flow rate of the flux delivery mechanism forms a closed-loop control with the welding current; S51. The air outlet wind speed of the cooling fan is automatically adjusted according to the size of the welding current, and the liquid spraying amount of the atomizer is linked with the data of the temperature sensor of the liquid cooling plate; S61. The spiral air guiding groove of the annular double-layer water cooling channel guides the airflow direction to form a reverse convection with the moving direction of the welding head; S71. The hydraulic damper of the shock pad automatically adjusts the damping coefficient according to the vibration frequency of the frame.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. Through the sound insulation cover, the present invention achieves gradient attenuation of high-frequency noise during the welding process, solves the problem of serious noise pollution of the welding machine, effectively improves the working environment, and reduces the noise decibel; 2. Through the clamping mechanism, the present invention achieves precise positioning and clamping of large-diameter steel pipes, solves the problems of low precision and cumbersome adjustment of traditional positioning methods, ensures the alignment of the steel pipe axis with the welding path, and improves the welding positioning accuracy; 3. Through the welding tracker, the present invention enables the welding head to adjust its posture in real time according to the undulation of the weld seam, solves the problems of welding deviation and unstable welding torch distance caused by the uneven surface of the weld seam, and improves the stability of the welding process and the welding quality; 4. Through the liquid cooling plate, the present invention achieves efficient heat exchange in the welding area, solves the problem of overheating of the equipment caused by high heat accumulation during the welding of large-diameter steel pipes, and improves the continuous operation ability of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 is the front view structural schematic diagram of the present invention; Figure 2 is the structural schematic diagram of the welding mechanism of the present invention; Figure 3 is the structural schematic diagram of the sound insulation cover of the present invention; Figure 4 is the structural schematic diagram of the noise reduction mechanism of the present invention; Figure 5 is the structural schematic diagram of the clamping mechanism of the present invention; Figure 6 is the structural schematic diagram of the cooling mechanism of the present invention; Figure 7 Schematic diagram of the liquid cooling plate structure of the present invention.

[0019] In the figure: 1, frame; 2, welding mechanism; 3, base; 4, noise reduction mechanism; 5, column; 6, cross beam; 7, sound insulation cover; 8, shock pad; 9, steel plate; 10, glass wool; 11, damping paint layer; 12, welding head; 13, wire feeding mechanism; 14, composite muffler; 15, flux feeding mechanism; 16, contact; 17, liquid cooling plate; 18, cooling fan; 19, serpentine cooling water channel; 20, welding tracker; 21, double joint rotating shaft; 22, cross slide; 23, circulator; 24, annular double-layer water cooling channel; 25, adaptive jaw group; 26, three-dimensional locator; 27, connecting seat; 28, cooling mechanism. Specific embodiments

[0020] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0021] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms "upper", "lower", "inner", "outer", "front end", "rear end", "both ends", "one end", "the other end", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance.

[0022] In the description of the present invention, it should be noted that unless otherwise clearly defined and limited, the terms "installation", "provided with", "connection", etc. should be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0023] Please refer to Figure 1 , Figure 2 , Figure 3 and Figure 6, an embodiment provided by the present invention: a large-diameter steel pipe seam welder with low noise and high heat dissipation, and the usage method includes the following steps: S1. The adaptive jaw group positions and clamps the large-diameter steel pipe. The emitting component of the three-dimensional positioner emits a laser beam to the receiving component, and drives the servo motor of the connecting seat to adjust the position of the jaw group according to the reflected light intensity deviation value; S2. The welding head moves along the sliding guide rail to the welding position to be welded. The contact head of the welding tracker contacts the weld seam to generate a displacement signal and transmits it to the double-joint rotating shaft, and the double-joint rotating shaft drives the cross slide to adjust the attitude of the welding head; S3. The wire feeding mechanism and the flux feeding mechanism respectively feed the wire and the flux to the wire inlet of the welding head and the weld seam area; S4. During the welding process, the top block of the sound insulation cover covers the machine frame through the pneumatic telescopic rod, and the double-layer push-pull maintenance door on the front side block is closed, and an air sound insulation layer is formed by the inner micro-perforated sound absorption board and the outer sealing steel plate; S5. The cooling fan conveys air flow to the ventilation channel of the liquid cooling plate, and the atomizer in the circulator atomizes the coolant and conveys it to the welding area through a pipeline; S6. The serpentine cooling water channel inside the liquid cooling plate performs liquid cooling circulation through the circulating water pump. At the same time, the inner spiral copper guide water pipe of the annular double-layer water cooling channel performs secondary water cooling, and the outer aluminum heat dissipation fins export hot air through the spiral air guide groove; S7. The upper spring support frame of the shock pad buffers the vertical vibration, the middle hydraulic damper suppresses the horizontal shaking, and the lower rubber cushion layer isolates the vibration transmission from the ground; S8. The composite muffler performs multi-stage attenuation on the air flow noise in the flux conveying pipeline.

[0024] The usage method further includes the following steps: S31. The wire feeding speed of the wire feeding mechanism is synchronized with the moving speed of the welding head, and the flow rate of the flux feeding mechanism and the welding current form a closed-loop control; S51. The air outlet wind speed of the cooling fan is automatically adjusted according to the magnitude of the welding current, and the liquid spraying amount of the atomizer is linked with the data of the temperature sensor of the liquid cooling plate; S61. The spiral air guide groove of the annular double-layer water cooling channel guides the air flow direction to form a reverse convection with the moving direction of the welding head; S71. The hydraulic damper of the shock pad automatically adjusts the damping coefficient according to the vibration frequency of the machine frame. Further, first, the large-diameter steel pipe is transported to the top of the base 3 of the frame 1. The transmitting component of the three-dimensional locator 26 uses a semiconductor laser, and the laser beam projects downward at a fan-shaped angle to form a dense laser grid that covers the outer wall surface of the steel pipe. When the laser grid projects onto the surface of the steel pipe, the receiving component captures the deformation and position offset of the reflected light spot in real time. When the position of the steel pipe is offset, the coordinate data of the reflected light spot is processed by the chip to calculate the deviation between the central axis of the steel pipe and the theoretical axis. The receiving component detects the reflected light intensity deviation value and generates a pulse signal. The pulse signal is transmitted to the servo controller of the connecting seat 27. The servo controller is connected to the ball screw through a harmonic reducer. According to the three-dimensional numerical deviation amount, a motor rotation instruction is generated using the PID algorithm to drive the base of the jaw group 25 to move along the guide rail of the base 3, realizing the precise positioning and clamping of the steel pipe. The laser grid is scanned twice to confirm the position, and the jaw posture is fine-tuned through the fuzzy control algorithm to ensure that the axis of the steel pipe is aligned with the welding path; Then, the welding head 12 of the welding mechanism 2 moves along the sliding guide rail at the bottom of the cross beam 6 to the starting point of the weld. When the contact head 16 of the welding tracker 20 touches the surface of the weld, a displacement signal is generated due to the undulation of the weld. The displacement signal is transmitted to the double-joint rotating shaft 21 to drive the cross slide 22 to finely adjust the posture of the welding head 12 horizontally or vertically along the guide rail, so that the welding torch is perpendicular to the weld and the distance is constant; An encoder is installed at the end of the sliding guide rail of the welding head 12, and the encoder transmits the signal to the servo motor controller of the wire feeding mechanism 13. The servo motor dynamically adjusts the rotation speed of the wire feeding roller according to the preset wire feeding rate - moving speed proportional relationship. A tension sensor is set at the wire outlet, and the feedback data of the tension sensor corrects the rotation speed of the servo motor through the PID algorithm, so that the wire feeding mechanism 13 transports the welding wire to the wire inlet at a wire feeding rate synchronized with the moving speed of the welding head 12, avoiding wire accumulation or breakage; A Hall current sensor is connected in series at the output end of the welding power supply and converts the analog signal into a digital signal and inputs it into the PLC controller. The current - flow relationship curve is pre-stored in the PLC. The feeding motor of the flux feeding mechanism 15 drives the screw feeder using a stepping motor. The PLC calculates the target flow according to the current value and outputs a pulse signal to the stepping motor driver to control the rotation speed of the feeder. A mass flow meter is installed on the flux outlet pipeline. If the deviation exceeds ±3%, the adaptive algorithm is triggered to adjust the pulse frequency of the stepping motor, so that the flow of the flux feeding mechanism 15 is adjusted in real time according to the welding current; After welding is started, the top block of the sound insulation cover 7 of the noise reduction mechanism 4 quickly presses down through the pneumatic telescopic rod to cover the welding head 12 and the wire feeding mechanism 13. The double-layer push-pull maintenance door on the front side block is closed. The outer sealing steel plate 9 blocks the outward radiation of high-frequency noise. The inner micro-perforated sound absorption plate consumes the mid-low frequency sound energy through the friction of sound waves in the micro-holes. The air sound insulation layer between the two doors further attenuates the residual noise. The composite muffler 14 attenuates the airflow noise by more than 20 decibels through the combined structure of multi-stage perforated plates and sound absorption materials in the flux delivery pipeline; Finally, the current sensor converts the current value into a 4-20 mA analog signal and transmits it to the PLC controller, which generates a PWM control signal and sends it to the frequency converter of the cooling fan 18. The frequency converter adjusts the input frequency of the three-phase motor of the cooling fan 18 according to the duty cycle of the PWM signal. The change in speed directly changes the centrifugal force of the fan blades, thereby adjusting the air velocity at the air outlet. After the airflow generated by the cooling fan 18 is accelerated by the rectangular-section duct, it is laterally injected from the entrance of the matrix ventilation channel of the liquid cooling plate 17. The airflow passes through the gaps between the spherical sub-units, taking away the heat conducted from the welding head 12 to the liquid cooling plate 17. The atomizer in the circulator 23 atomizes the coolant into micron-sized particles, which are sprayed onto the welding area through a pipeline. The local rapid cooling is achieved by the evaporation heat absorption of the atomized droplets. The serpentine cooling water channel 19 inside the liquid cooling plate 17 drives the cooling water circulation through a circulating water pump. The spiral copper duct enhances the heat exchange efficiency. The aluminum heat dissipation fins guide the hot air through the spiral air guide grooves to form forced convection with the reverse airflow of the cooling fan 18. Finally, the hot air is exhausted through the filter exhaust holes at the rear end of the frame 1.

[0025] Please refer to Figure 1 、 Figure 3 and Figure 7 As shown in and

[0026] An embodiment provided by the present invention: a low-noise, high-heat-dissipation, large-diameter steel pipe seam welder, comprising a frame, a welding mechanism, and a noise reduction mechanism. The welding mechanism is fixedly installed at the bottom end of the outer wall of the frame, and the noise reduction mechanism is fixedly installed on the side surface of the outer wall of the frame; the noise reduction mechanism includes a sound insulation cover, a shock pad, and a composite muffler. The sound insulation cover is composed of an outer layer of 1.5 mm thick steel plate, an inner layer of glass wool, and an intermediate damping paint layer. The sound insulation cover covers the welding head and the wire feeding mechanism. The shock pad is arranged between the bottom end of the outer wall of the frame and the ground. The composite muffler is fixedly installed on the inner wall of the flux conveying pipeline; Then, the welding head 12 moves along the weld seam. When the local bulge of the weld seam causes the contact to shift upward, the displacement sensor transmits a signal to the two servo motors of the double-joint rotating shaft 21. The upper joint motor drives the cross slide 22 to rotate around the X-axis according to the X-axis displacement, and at the same time, the lower joint motor adjusts the Z-axis position of the welding head 12 through the screw-nut mechanism to restore the distance between the welding torch nozzle and the weld seam to the initial distance. The pitch angle and deflection angle of the double-joint rotating shaft 21 are adjusted by the pulse control of the servo motor; The carbide wire feeding wheel of the wire feeding mechanism 13 is driven by a servo motor connected by a synchronous belt. The wire feeding speed is matched with the moving speed of the welding head in real time at a ratio of 1.2:1. When the welding head moves at 3 m / min, the wire feeding speed is automatically adjusted to 3.6 m / min. When the encoder monitors that the wire feeding error exceeds ±2%, an alarm is triggered and the welding is paused. The electromagnetic flowmeter of the flux feeding mechanism 15 detects the flow rate in real time. When the welding current increases from 300 A to 330 A, the controller commands the diaphragm pump to increase the flux flow rate from 15 L / min to 15.75 L / min, and the PID algorithm is used to ensure that the molten pool surface is completely covered with flux to avoid porosity defects; During the welding process, the three-layer sound insulation cover 7 of the noise reduction mechanism 4 is completely closed. The outer 1.5 mm steel plate 9 reflects high-frequency arc noise, the middle damping paint layer 11 converts the structural vibration energy into heat energy and dissipates it, and the inner glass wool 10 absorbs medium and low-frequency noise through fiber friction. The composite muffler 14 sets three perforated plates in the flux delivery pipeline, and the sound wave refracts repeatedly between the perforated plates and the sound-absorbing cotton behind, attenuating the air flow noise; Finally, the serpentine cooling water channel 19 of the liquid cooling plate 17 circulates cooling water. The ventilation channels between the spherical sub-units form turbulence under the action of the cooling fan 18, so that the surface temperature of the liquid cooling plate is stabilized below 45°C. The atomizer of the circulator 23 atomizes the coolant into particles with a particle size of 20 μm and directly sprays them into the welding area, using the phase change endotherm to reduce the local temperature by 80 - 100°C. The spiral air guiding grooves of the aluminum heat dissipation fins guide the hot air to convect reversely with the air flow of the cooling fan.

[0027] Please refer to Figure 1 、 Figure 2 and Figure 7 As shown in At the top of the outer wall of the base, clamping mechanisms are symmetrically arranged. The clamping mechanism includes an adaptive jaw group, a three-dimensional positioner, and a connecting seat. The receiving component and the transmitting component of the three-dimensional positioner are respectively embedded in the top and bottom of the outer wall of the adaptive jaw group. The connecting seat is arranged between the base of the adaptive jaw group and the base. The adaptive jaw group is symmetrically and fixedly installed at the front end of the base; Further, first, place the large-diameter steel pipe to be welded horizontally between the two groups of adaptive jaw groups 25 at the front end of the base 3. The air cylinder of the jaw group 25 drives the arc-shaped clamping block to contact the outer wall of the steel pipe. The transmitting component of the three-dimensional positioner 26 emits a fan-shaped laser beam to the receiving component. The laser beam covers the weld area of the steel pipe. The receiving component converts the reflected light intensity signal into an electrical signal and transmits it to the controller; Then, when the controller detects that the reflected light intensity deviation value exceeds 5%, it determines that the jaw group 25 is offset in the X-axis direction, and drives the servo motor in the connecting seat 27 to adjust the position of the jaw group through the ball screw pair. During the adjustment process, the three-dimensional positioner 26 real-time feeds back data to form a closed-loop control. When the steel pipe deflects clockwise, the Z-axis servo motor synchronously adjusts the height of the jaw group to make the laser beam perpendicular to the weld plane until the light intensity uniformity meets the standard; Finally, when the light intensity deviation value is stable within 3%, the air cylinder pressure of the jaw group 25 rises to 0.8 MPa. The anti-slip lines on the inner side of the clamping block form a mechanical bite with the surface of the steel pipe. The positioning pin of the connecting seat 27 is inserted into the positioning hole of the base 3 and fixed by 4 M16 bolts.

[0028] Please refer to Figure 1 、 Figure 3 and Figure 4 As shown in, an embodiment provided by the present invention: a large-diameter steel pipe seam welder with low noise and high heat dissipation. At the bottom of the outer wall of the cross beam, a cooling mechanism is fixedly installed. The cooling mechanism includes a liquid cooling plate, a cooling fan, and a circulator. The liquid cooling plate is fixedly installed at the bottom of the outer wall of the welding head. A serpentine cooling water channel is arranged inside the liquid cooling plate. The cooling fans are fixedly installed on both sides of the outer wall of the frame. The circulator is horizontally arranged directly above the liquid cooling plate. The circulator is fixedly installed on the side of the outer wall of the cross beam through a bracket. A pipeline is arranged inside the circulator. The pipeline is connected to an atomizer. The atomizer is fixedly installed at the output end of the circulator; the inside of the liquid cooling plate is composed of spherical sub-units arranged in a matrix. A ventilation channel is formed between adjacent sub-units. The serpentine cooling water channel penetrates the sub-units. The air outlet of the cooling fan is aligned with the ventilation channel inlet of the liquid cooling plate. The atomizer is connected to a cooling water tank through a pipeline. A circulating water pump is fixedly installed in the middle section of the outer wall of the pipeline; At the bottom end of the inner wall of the liquid cooling plate, there is an annular double-layer water cooling channel. The inner layer of the annular double-layer water cooling channel is a spiral copper guide water pipe, and the spiral copper guide water pipe is externally connected to a circulating pump. The outer layer of the annular double-layer water cooling channel is an aluminum heat dissipation fin, and spiral air guide grooves are formed between the aluminum heat dissipation fins; the inlet of the air guide groove is opposite to the radial fan air outlet of the cooling fan, and the end of the air guide groove communicates with the exhaust hole opened at the rear end of the outer wall of the frame. A filter screen is fixedly installed inside the exhaust hole; the contact area between the liquid cooling plate and the sound insulation cover is covered with a heat insulation layer, and the heat insulation layer is pasted by a ceramic fiber board and an aluminum foil reflective layer through a high-temperature resistant adhesive; Further, first, 10 seconds before the welding start instruction is issued, the PLC controller sends a closing signal to the pneumatic telescopic rod. The telescopic rod drives the top block to translate towards the center along the linear guide rails on both sides of the cross beam 6. When the elastic sealing rubber strip provided at the edge of the top block contacts the side plate of the frame 1, the limit switch is triggered to feedback a closing in place signal; the servo motor drives the double-layer push-pull maintenance door to slide along the horizontal guide rail through the synchronous belt pulley. The inner micro-perforated sound absorption panel and the outer sealing steel plate 9 are connected through the stainless steel hinge of the door frame. After the two doors are closed, the middle air layer forms a sealed cavity through the peripheral rubber sealing ring to prevent the transmission of noise. Using the Helmholtz resonance principle of the micro-perforated plate and combining with the mass law of the sealing steel plate, a gradient attenuation structure for medium and high frequency noise is formed; Then, the hydraulic damper vertically penetrates the rubber cushion layer. The upper end of the piston rod is connected to the frame 1 through a spherical bearing, and the lower end is fixed to the ground support seat to ensure independent control of horizontal / vertical vibration; the spring support frame adopts a disc spring group, and the eccentric load is prevented through the guide column. The rotation angle of the preloading nut is fed back by an absolute encoder; the acceleration sensors installed at the four corners of the bottom of the frame 1 monitor the vibration data in real time. When the horizontal vibration frequency > 20 Hz and the amplitude > 0.3 mm, the controller sends a high-pressure instruction to the hydraulic damper, the solenoid valve spool moves to reduce the opening of the throttle hole, the flow rate of the silicone oil flowing through the damping hole decreases, the damping coefficient increases, and the horizontal displacement of the frame is suppressed through viscous resistance; if the vertical vibration amplitude > 0.5 mm, the electric push rod drives the preloading nut of the spring support frame to rotate, the spring compression amount is further increased, the spring stiffness is further increased, and the lower rubber cushion layer absorbs the low-frequency vibration energy through non-linear elastic deformation. After Fourier analysis, the vibration transmission rate in the 5 - 50 Hz frequency band drops from 0.6 to 0.25; Finally, the compressed air in the flux delivery pipeline first enters the diversion section of the composite muffler 14. The 3 groups of diversion plates inclined at 30° decompose the main air flow into 6 branches. The air flow velocity of each branch decreases, and part of the kinetic energy noise is dissipated through the turbulence effect. The branch air flow impacts the first layer of perforated plate and is converted into heat energy through the friction of the hole neck. The remaining air flow enters the sound absorption cotton layer, and the medium and high frequency components are absorbed by the viscous resistance of the porous material. Finally, it enters the expansion chamber and reflects at the interface between the expansion chamber and the contraction section to form a standing wave attenuation. The inner wall of the expansion chamber is sprayed with a damping coating to suppress the vibration of the cavity.

[0029] Please refer toFigure 1 , Figure 3 , Figure 5 and Figure 6 , an embodiment provided by the present invention: a large-diameter steel pipe seam welder with low noise and high heat dissipation, the sound insulation cover is set as a top block and a front side block, the top block is connected to the cross beam through a pneumatic telescopic rod, the front side block is provided with a double-layer push-pull type maintenance door, the inner layer door is a micro-perforated sound-absorbing board, the outer layer door is a sealed steel plate, and an air sound insulation layer is formed between the two doors; The shock pad is set as a three-layer composite structure. The upper spring support frame is fixedly installed at the bottom end of the outer wall of the frame through bolts. The middle hydraulic damper vertically penetrates the lower rubber cushion layer, and the bottom end of the outer wall of the rubber cushion layer is connected to the ground support seat; Further, first, the radial fan of the cooling fan 18 is driven by a frequency converter to deliver air to the ventilation channel of the liquid cooling plate 17. The ventilation channel is formed by spacing spherical sub-units arranged in a matrix. The distance between adjacent sub-units is 25 mm, forming a rectangular channel with a cross-sectional size of 40×15 mm. The inner wall is anodized to reduce wind resistance. The air flow enters from the air inlets on both sides of the frame 1, and after the flow direction is adjusted by the guide plate, it is vertically aligned with the ventilation channel inlet; The circulating water pump is powered on to drive a 50% ethylene glycol aqueous solution to circulate in the serpentine cooling water channel 19. The water channel is made of copper and spirally penetrates the spherical sub-units. The length of a single water channel is 8 m, the total volume is 0.226 L, and the initial flow rate is monitored in real time by an electromagnetic flowmeter at the water pump outlet. The controller adjusts the water pump speed through the PID algorithm to monitor that the coolant forms turbulence in the water channel and enhances the heat exchange efficiency.

[0030] Then, when the Hall current sensor detects that the welding current of the welding head 12 ≥ 200 A, the controller sends a start signal to the ultrasonic atomizer in the circulator 23. The transducer in the atomizer converts electrical energy into high-frequency vibration, causing the coolant to break into droplets in the atomization chamber and be transported to the nozzle above the welding area through a polytetrafluoroethylene pipe. The initial atomization amount is controlled by a mass flowmeter, so that the atomized particles are evenly distributed at a distance of 100 mm from the welding torch and cover a 50 mm area in front of the molten pool; Three groups of temperature sensors are embedded at the bottom surface of the liquid cooling plate 17. The temperature sensors collect the surface temperature in real time and transmit it to the controller; When any sensor detects that the temperature exceeds the preset warning value, a frequency increase command is sent to the frequency converter of the cooling fan to increase the motor speed, and the servo metering pump of the atomizer is synchronously commanded to increase the plunger rod stroke to increase the atomization amount. The atomized particles quickly vaporize after contacting the welding arc, removing 30% of the heat in the welding area; The outer aluminum heat dissipation fins of the annular double-layer water cooling channel 24 are welded to the bottom surface of the liquid cooling plate to form a spiral air guide groove. When the welding head 12 is set to move from right to left, the spiral direction of the air guide groove is opposite to the moving direction, causing the air flow delivered by the cooling fan to form a 180° reverse convection in the air guide groove; Finally, the spiral copper water guide pipe is connected to an external circulation pump through a quick-change joint to form an independent water cooling loop. The coolant enters through the central water inlet hole of the liquid cooling plate, absorbs the heat transferred by the serpentine water channel along the spiral path, and then returns to the cooling water tank from the edge water outlet hole. The airflow carrying heat is accelerated through the spiral air guide groove and discharged from the exhaust hole at the rear end of the frame 1. A stainless steel filter screen is installed inside the exhaust hole, which is installed by spring snap fasteners to filter welding slag particles with a size of ≥50μm. A double-layer heat insulation material is pasted on the contact area between the liquid cooling plate 17 and the sound insulation cover 7. The bottom layer is a ceramic fiber board, which is fully coated and pasted with high-temperature resistant silica gel; the surface layer is covered with an aluminum foil reflective layer, which is bonded to the ceramic fiber board through pressure-sensitive adhesive to prevent high temperature from affecting the service life of the noise reduction structure.

[0031] Working principle: First, transfer the large-diameter steel pipe to the top of the base 3 of the frame 1. The adaptive jaw group 25 clamps the steel pipe. The emitting component of the three-dimensional locator 26 emits a fan-shaped laser beam to form a laser grid covering the outer wall of the steel pipe. The receiving component captures the deformation and position offset of the reflected light spot, calculates the deviation between the central axis of the steel pipe and the theoretical axis, and drives the servo motor of the connecting seat 27 according to the reflected light intensity deviation value. Adjust the position of the jaw group 25 through the harmonic reducer and ball screw to achieve precise positioning and clamping of the steel pipe. The laser grid is scanned twice to confirm and fine-tune the jaw posture to ensure that the axis of the steel pipe is aligned with the welding path; at the same time, input the parameters of the steel pipe diameter and the starting position of the weld seam through the human-machine interface. The PLC controller drives the servo motor of the sliding guide rail to drive the welding head 12 to move along the cross beam 6 to the starting point of the weld seam. The contact 16 of the welding tracker 20 touches the surface of the steel pipe to trigger the initial calibration signal.

[0032] Then, the welding head 12 moves along the sliding guide rail at the bottom end of the cross beam 6 to the position to be welded. The contact head 16 of the welding tracker 20 touches the weld seam. The displacement signal generated due to the undulation of the weld seam is transmitted to the double-joint rotating shaft 21, which drives the cross slide 22 to finely adjust the posture of the welding head 12, so that the welding torch is perpendicular to the weld seam and the distance is constant. The wire feeding speed of the wire feeding mechanism 13 and the moving speed of the welding head 12 are synchronized through the feedback of the encoder and the tension sensor. The flow rate of the flux feeding mechanism 15 is controlled by calculating the target flow rate through the PLC controller according to the welding current value detected by the Hall current sensor, and the rotation speed of the feeder is controlled and adjusted through the feedback of the mass flow meter. After the welding is started, the top block of the sound insulation cover 7 of the noise reduction mechanism 4 covers the frame 1 through the pneumatic telescopic rod, and the double-layer push-pull maintenance door on the front side is closed. The inner micro-perforated sound absorption plate and the outer sealing steel plate 9 form an air sound insulation layer, and the composite muffler 14 attenuates the air flow noise in the flux feeding pipeline in multiple stages. The cooling fan 18 conveys air flow to the ventilation channel of the liquid cooling plate 17. The atomizer in the circulator 23 atomizes the coolant and then conveys it to the welding area through the pipeline. The serpentine cooling water channel 19 inside the liquid cooling plate 17 conducts liquid cooling circulation through the circulating water pump. The inner layer spiral copper guide water pipe of the annular double-layer water cooling channel 24 conducts secondary water cooling, and the outer layer aluminum heat dissipation fins export the hot air through the spiral air guide groove. The upper spring support frame of the shock pad buffers the vertical vibration, the middle hydraulic damper suppresses the horizontal shaking, and the lower rubber cushion layer isolates the vibration transmission from the ground.

[0033] Finally, during the welding process, the air outlet wind speed of the cooling fan 18 is automatically adjusted by generating a PWM signal through the PLC controller according to the welding current magnitude. The liquid spraying amount of the atomizer is linked with the data of the temperature sensor of the liquid cooling plate 17. The spiral air guide groove of the annular double-layer water cooling channel 24 guides the air flow direction to form a reverse convection with the moving direction of the welding head 12. The hydraulic damper of the shock pad automatically adjusts the damping coefficient according to the vibration frequency of the frame 1 to reduce the influence of vibration on the welding quality.

[0034] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and without departing from the spirit or basic characteristics of the present invention, the present invention can be implemented in other specific forms. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present invention. Any reference signs in the claims should not be regarded as limiting the claimed rights.

Claims

1. A large-diameter steel pipe seam welder with low noise and high heat dissipation, characterized in that: It includes a frame (1), a welding mechanism (2) and a noise reduction mechanism (4). The welding mechanism (2) is fixedly installed at the bottom end of the outer wall of the frame (1), and the noise reduction mechanism (4) is fixedly installed on the side of the outer wall of the frame (1). The noise reduction mechanism (4) includes a sound insulation cover (7), a shock pad (8) and a composite muffler (14). The sound insulation cover (7) is composed of an outer layer of 1.5 mm thick steel plate (9), an inner layer of glass wool (10) and an intermediate damping paint layer (11). The sound insulation cover (7) covers the welding head (12) and the wire feeding mechanism (13). The shock pad (8) is arranged between the bottom end of the outer wall of the frame (1) and the ground. The composite muffler (14) is fixedly installed on the inner wall of the flux conveying pipeline.

2. The low-noise and high-heat-dissipation large-diameter steel pipe seam welder according to claim 1, characterized in that: The frame (1) includes a base (3), columns (5) and a cross beam (6). The columns (5) are vertically welded on both sides of the outer wall of the base (3). The cross beam (6) is horizontally erected at the top end of the outer wall of the columns (5). The base (3) and the columns (5) are connected by submerged arc welding and flat welds. The cross beam (6) and the columns (5) are connected by fillet welds of carbon dioxide shielded welding to strengthen the ribs.

3. The low-noise and high-heat-dissipation large-diameter steel pipe seam welder according to claim 1, wherein: The welding mechanism (2) is fixedly installed at the bottom end of the outer wall of the cross beam (6) through a sliding guide rail. The welding mechanism (2) includes a welding head (12), a wire feeding mechanism (13), a flux feeding mechanism (15) and a welding tracker (20). The welding head (12) is connected to the cross beam (6) through a sliding guide rail. The wire feeding mechanism (13) and the flux feeding mechanism (15) are installed side by side at the top end of the outer wall of the cross beam (6). The welding tracker (20) includes a double-joint rotating shaft (21), a cross slide (22) and a contact head (16). The cross slide (22) is fixedly installed on the sliding guide rail. The double-joint rotating shaft (21) is fixedly installed at the center of the cross slide (22) through a bearing. The contact head (16) is fixedly installed at the front end of the outer wall of the welding head (12). The output ends of the wire feeding mechanism (13) and the flux feeding mechanism (15) are respectively aligned with the wire inlet of the welding head (12) and the weld area.

4. A large-diameter steel pipe seam welder with low noise and high heat dissipation according to claim 1, characterized in that: The sound insulation cover (7) is set as a top block and a front side block. The top block is connected to the cross beam (6) through a pneumatic telescopic rod. The front side block is provided with a double-layer push-pull type maintenance door. The inner layer door is a micro-perforated sound absorption board, and the outer layer door is a sealed steel plate (9). An air sound insulation layer is formed between the two doors.

5. The low-noise and high-heat-dissipation large-diameter steel pipe seam welder according to claim 2, wherein: A cooling mechanism (28) is fixedly installed at the bottom end of the outer wall of the cross beam (6). The cooling mechanism (28) includes a liquid cooling plate (17), a cooling fan (18) and a circulator (23). The liquid cooling plate (17) is fixedly installed at the bottom end of the outer wall of the welding head (12). A serpentine cooling water channel (19) is arranged inside the liquid cooling plate (17). The cooling fan (18) is fixedly installed on both sides of the outer wall of the frame (1). The circulator (23) is horizontally arranged directly above the liquid cooling plate (17). The circulator (23) is fixedly installed on the side of the outer wall of the cross beam (6) through a bracket. A pipeline is arranged inside the circulator (23). The pipeline is connected to an atomizer. The atomizer is fixedly installed at the output end of the circulator (23). The inside of the liquid cooling plate (17) is composed of spheroid-like subunits arranged in a matrix. Ventilation channels are formed between adjacent subunits. The serpentine cooling water channel (19) runs through the subunits. The air outlet of the cooling fan (18) is aligned with the ventilation channel inlet of the liquid cooling plate (17). The atomizer is connected to the cooling water tank through a pipeline, and a circulating water pump is fixedly installed in the middle section of the outer wall of the pipeline.

6. The large-diameter steel pipe seam welder with low noise and high heat dissipation according to claim 5, characterized in that: At the bottom end of the inner wall of the liquid cooling plate (17), there is an annular double-layer water cooling channel (24). The inner layer of the annular double-layer water cooling channel (24) is a spiral copper water guide pipe, and the spiral copper water guide pipe is externally connected to a circulating pump. The outer layer of the annular double-layer water cooling channel (24) is an aluminum heat dissipation fin, and spiral air guide grooves are formed between the aluminum heat dissipation fins; The air guide groove inlet is opposite to the radial air outlet of the cooling fan (18). The end of the air guide groove is connected to the exhaust hole opened at the rear end of the outer wall of the frame (1), and a filter screen is fixedly installed inside the exhaust hole; The contact area between the liquid cooling plate (17) and the sound insulation cover (7) is covered with a heat insulation layer, which is formed by pasting a ceramic fiber board and an aluminum foil reflection layer with a high-temperature resistant adhesive.

7. A large-diameter steel pipe seam welder with low noise and high heat dissipation according to claim 2, characterized in that: At the top end of the outer wall of the base (3), clamping mechanisms are symmetrically arranged. The clamping mechanism includes an adaptive jaw group (25), a three-dimensional locator (26), and a connecting seat (27). The receiving component and the transmitting component of the three-dimensional locator (26) are respectively embedded at the top end and the bottom end of the outer wall of the adaptive jaw group (25). The connecting seat (27) is arranged between the base of the adaptive jaw group (25) and the base (3). The adaptive jaw group (25) is symmetrically and fixedly installed at the front end of the base (3).

8. A large-diameter steel pipe seam welder with low noise and high heat dissipation according to claim 1, characterized in that: The shock pad (8) is arranged as a three-layer composite structure. The upper spring support frame is fixedly installed at the bottom end of the outer wall of the frame (1) through bolts. The middle hydraulic damper vertically penetrates the lower rubber cushion layer, and the bottom end of the outer wall of the rubber cushion layer is connected to the ground support seat.

9. A method for using a large-diameter steel pipe seam welder with low noise and high heat dissipation, applicable to a large-diameter steel pipe seam welder with low noise and high heat dissipation according to any one of claims 1-8, characterized in that: The usage method includes the following steps: S1. The adaptive jaw group (25) positions and clamps the large-diameter steel pipe. The transmitting component of the three-dimensional locator (26) emits a laser beam to the receiving component, and the servo motor of the connecting seat (27) is driven according to the reflected light intensity deviation value to adjust the position of the jaw group; S2. The welding head (12) moves along the sliding guide rail to the welding position to be welded. The contact head (16) of the welding tracker (20) contacts the weld seam to generate a displacement signal and transmits it to the double-joint rotating shaft (21), and the double-joint rotating shaft (21) drives the cross slide (22) to adjust the posture of the welding head (12); S3. The wire feeding mechanism (13) and the flux feeding mechanism (15) respectively feed the wire and the flux to the wire inlet of the welding head (12) and the weld seam area; S4. During the welding process, the top block of the sound insulation cover (7) covers the frame (1) through the pneumatic telescopic rod, and the double-layer push-pull type maintenance door of the front side block is closed, and an air sound insulation layer is formed by the inner micro-perforated sound absorption board and the outer sealing steel plate (9); S5. The cooling fan (18) conveys air flow to the ventilation channel of the liquid cooling plate (17), and the atomizer in the circulator (23) atomizes the coolant and conveys it to the welding area through the pipeline; S6. The serpentine cooling water channels (19) inside the liquid cooling plate (17) conduct liquid cooling circulation through a circulating water pump. At the same time, the inner layer of the annular double-layer water cooling channel (24), which is a spiral copper guide water pipe, conducts secondary water cooling, and the outer layer of aluminum heat dissipation fins exports hot air through spiral air guide grooves; S7. The upper spring support frame of the shock pad (8) buffers vertical vibrations, the middle hydraulic damper suppresses horizontal shaking, and the lower rubber cushion layer isolates the transmission of ground vibrations; S8. The composite silencer (14) performs multi-stage attenuation on the airflow noise in the flux delivery pipeline.

10. The method for using a large-diameter steel pipe seam welder with low noise and high heat dissipation according to claim 9, characterized in that: The usage method further includes the following steps: S31. The wire feeding speed of the wire feeding mechanism (13) is synchronized with the moving speed of the welding head (12), and the flow rate of the flux delivery mechanism (15) forms a closed-loop control with the welding current; S51. The air outlet wind speed of the cooling fan (18) is automatically adjusted according to the magnitude of the welding current, and the liquid spraying amount of the atomizer is linked with the temperature sensor data of the liquid cooling plate (17); S61. The spiral air guide grooves of the annular double-layer water cooling channel (24) guide the airflow direction to form a reverse convection with the moving direction of the welding head (12); S71. The hydraulic damper of the shock pad (8) automatically adjusts the damping coefficient according to the vibration frequency of the frame (1).

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