Automatic pipe alignment welding device and method

Abstract

The embodiments of the present invention relate to the technical field of pipe welding devices, and provide an automatic pipe alignment welding device and method. The device is used to place a first pipe body and a second pipe body with a gap between them and perform butt welding. The device includes: a first bracket, the first bracket is used to support the first pipe body; an adjustment bracket, the adjustment bracket is movable relative to the first bracket, and after moving, it moves closer to or away from the first bracket; a second bracket, the second bracket is adjustable and arranged on the adjustment bracket to support the second pipe body; an annular rail, the annular rail is arranged between the first bracket and the second bracket; a mobile bracket, the mobile bracket is slidably arranged on the annular rail; a welding gun, the welding gun is arranged on the mobile bracket and faces between the first bracket and the second bracket; a gap detection member, the gap detection member is arranged on the mobile bracket and is located at the front side of the welding gun following the movement of the mobile bracket. The above technical solution solves the technical problem in the prior art that the support structure cannot be dynamically adjusted during pipe butt welding.

Description

Technical Field

[0001] The embodiments of the present invention relate to the technical field of pipe welding devices, and in particular, to an automatic pipe alignment welding device and method. Background Art

[0002] Pipe welding is a key link in industrial manufacturing. Traditional manual welding or semi-automatic equipment has problems such as low alignment accuracy, poor adaptability, and low efficiency. For example, existing technologies often use mechanical clamps to fix pipes, but multiple manual adjustments are required to achieve coaxial alignment, and it is difficult to adapt to pipes of different diameters or shapes. Although some automatic welding equipment has introduced laser sensors or vision systems for centering, it is limited by the limitations of a single sensing technology. Pipe welding is usually divided into socket welding and butt welding. For butt welding, traditional support devices are used for support during welding. It lacks dynamic adjustment capabilities and cannot compensate in real time for errors caused by thermal deformation or pipe displacement during welding. Sometimes it is necessary to stop the machine for calibration, which affects production efficiency. Summary of the Invention

[0003] To overcome the above-mentioned defects, an embodiment of the present invention provides an automatic pipe alignment welding device and method, which solves the technical problem in the prior art that the support structure cannot be dynamically adjusted during pipe butt welding.

[0004] According to one aspect, at least one embodiment of the present invention provides an automatic pipe alignment welding device for placing a first pipe body and a second pipe body with a gap therebetween and performing butt welding, comprising:

[0005] a first bracket, the first bracket being used to support the first tube body;

[0006] an adjustment frame, the adjustment frame being movably arranged relative to the first bracket and moving closer to or away from the first bracket;

[0007] a second bracket, the second bracket being arranged on the adjustment frame in an adjustable manner and configured to support the second tube body;

[0008] an annular rail, the annular rail being arranged between the first bracket and the second bracket;

[0009] A movable frame, wherein the movable frame is slidably arranged on the annular rail;

[0010] a welding gun, the welding gun being arranged on the movable frame and facing between the first bracket and the second bracket;

[0011] A gap detection member is provided on the movable frame and is located at the front side of the welding gun following the movement of the movable frame.

[0012] For example, at least one embodiment of the present invention provides an automatic pipe alignment welding device, further comprising:

[0013] a first driving member connected to the adjustment frame and configured to drive the adjustment frame to move;

[0014] A second driving member is provided on the adjusting frame and connected to the second bracket, and is used for driving the second bracket to move up and down.

[0015] For example, in at least one embodiment of the present invention, a pipe automatic alignment welding device is provided, wherein the gap detection component includes:

[0016] There are a plurality of movable probes arranged in a direction parallel to the axial direction of the first tube body, and the plurality of movable probes are movably arranged on the movable frame, and are used to determine the width of the gap according to the number of movable probes inserted into the gap;

[0017] A first elastic member, wherein one end of the first elastic member acts on the movable probe and the other end acts on the movable frame, providing a force for the movable probe to approach the gap, the first tube body and the second tube body.

[0018] For example, in at least one embodiment of the present invention, an automatic pipe alignment welding device is provided, wherein the movable probe is an insulating member and has a first conductive portion and a second conductive portion arranged in sequence and spaced apart, and the conductivity of the second conductive portion is greater than the conductivity of the first conductive portion; and the gap detection member further includes:

[0019] Conductive members, wherein the conductive members are arranged in sequence with the movable probe at intervals, and the movable probe is configured such that after the movable probe moves, one of the first conductive portion and the second conductive portion is electrically connected to the conductive member, and the plurality of conductive members are connected in series with one of the first conductive portion and the second conductive portion;

[0020] A current detecting member is connected to the conductive members at both ends and is used to detect the magnitude of the current passing through the conductive members.

[0021] For example, at least one embodiment of the present invention provides an automatic pipe alignment welding device, wherein the first conductive part and the second conductive part are arranged in sequence, the cross-sectional area of ​​the first conductive part is a long strip, and the cross-sectional area of ​​the second conductive part is a circle.

[0022] For example, at least one embodiment of the present invention provides an automatic pipe alignment welding device, further comprising a coaxiality detection component, wherein the coaxiality detection component comprises:

[0023] a rotation detection rod, the rotation detection rod being rotatably disposed on the movable frame and being located in front of the gap detection member following the movement of the movable frame, with both ends of the rotation detection rod being respectively used to relatively abut against the first tube body and the second tube body;

[0024] An angle detection member is provided on the movable frame and is used for detecting the rotation angle of the rotation detection rod.

[0025] For example, in at least one embodiment of the present invention, a pipe automatic alignment welding device is provided, wherein the coaxiality detection component further includes:

[0026] A first guide wheel and a second guide wheel are respectively rotatably arranged at both ends of the rotation detection rod, the first guide wheel is used to roll on the outer wall of the first tube body, and the second guide wheel is used to roll on the outer wall of the second tube body.

[0027] For example, at least one embodiment of the present invention provides an automatic pipe alignment welding device, wherein the movable frame includes a base and a sliding portion slidably arranged relative to the base, the rotation detection rod is rotatably arranged on the sliding portion, and the angle detection member is arranged on the sliding portion, and further includes:

[0028] A second elastic member, one end of the second elastic member acts on the base, and the other end acts on the sliding portion, for providing a force for the sliding portion to move away from the base.

[0029] For example, in at least one embodiment of the present invention, an automatic pipe alignment welding device is provided, wherein the angle detection element is an angular displacement sensor, and further includes:

[0030] The controller is electrically connected to the angular displacement sensor and the current detection element, and is used to receive the angular displacement signal detected by the angular displacement sensor and the detection current signal of the current detection element. The controller is used to control the actions of the first driving element and the second driving element.

[0031] At least one embodiment of the present invention provides a method for automatic pipe alignment welding, comprising the following steps:

[0032] S1. Place the first tube on the first bracket and fix it, and place the second tube on the second bracket;

[0033] S2. Start the adjustment frame to move it, driving the second bracket and the second tube body to move closer to or away from the first bracket, and at the same time start the lifting adjustment of the second bracket to preliminarily adjust the positions of the two tube bodies;

[0034] S3, the moving frame slides along the circular rail, driving the gap detection component to detect the gap between the two pipe bodies. According to the detection results, the movement of the adjustment frame and the lifting and lowering of the second bracket are further fine-tuned until the gap reaches the preset range;

[0035] S4. When the gap is adjusted to the right position, start the welding gun. At the same time, the moving frame drives the welding gun along the circular rail to weld around the two pipe bodies. During the welding process, the gap detection piece and the second bracket are used until the butt welding is completed.

[0036] The beneficial effects of the embodiments of the present invention are:

[0037] In this invention, a first bracket and a second bracket on the adjustment frame respectively support the first and second tube bodies, enabling adjustment of their relative positions to accommodate pipes of varying diameters and shapes, improving alignment accuracy and adaptability. The design of the circular rail and movable frame allows the welding gun to encircle the pipe during welding, ensuring weld uniformity. A gap detector, positioned at the front of the welding gun, monitors the gap between the first and second tube bodies in real time, enabling timely adjustments to compensate for errors caused by thermal deformation or pipe displacement, ensuring weld quality, reducing downtime for calibration, and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] To more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly describes the drawings required for describing the embodiments of the present invention. Obviously, the drawings described below are merely exemplary embodiments of the present invention. Those skilled in the art can, without inventive effort, derive other drawings based on the contents of the exemplary embodiments of the present invention and these drawings.

[0039] Figure 1 Schematic diagram of the structure of an automatic pipe alignment welding device in one embodiment of the present invention;

[0040] Figure 2 for Figure 1 A side structural diagram of the annular rail and the mobile frame in the embodiment;

[0041] Figure 3 for Figure 1 Schematic diagram of the internal structure of the gap detection member in the embodiment;

[0042] Figure 4 for Figure 1 A schematic diagram of the three-dimensional structure of the ring rail and the mobile frame in the embodiment;

[0043] Figure 5 for Figure 4 Middle A is a schematic diagram of a partially enlarged structure;

[0044] Figure 6 for Figure 1Schematic diagram of the internal structure of the coaxiality detection member in the embodiment;

[0045] In the figure: first bracket 100, adjustment bracket 200, second bracket 300, circular rail 400, movable bracket 500, base 501, sliding portion 502, welding gun 600, gap detection member 700, movable probe 701, first conductive portion 7011, second conductive portion 7012, first elastic member 702, conductive member 703, current detection member 704, first driving member 800, second driving member 900, coaxiality detection member 1000, rotation detection rod 1001, angle detection member 1002, first guide wheel 1003, second guide wheel 1004, second elastic member 1100, controller 1200. DETAILED DESCRIPTION

[0046] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention.

[0047] To simplify the drawings, only portions relevant to the invention are schematically depicted in each figure; they do not represent the actual structure of the product. Furthermore, to simplify the drawings and facilitate understanding, in some figures, only one component with the same structure or function is schematically depicted or labeled. In this document, "one" not only means "only one" but also "more than one," and "several" includes "two" and "more than two."

[0048] It should be noted that, unless otherwise specified or limited, the terms "mounted," "connected," and "connected" should be understood broadly. For example, they can refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediary; and internal communication between two components. Those skilled in the art will understand the specific meanings of these terms in the present invention based on the specific circumstances.

[0049] In the present invention, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Furthermore, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0050] In the description of this embodiment, the terms "up", "down", "left", "right", etc., and the orientation or position relationship are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be understood as a limitation on the present invention.

[0051] In addition, in the description of the present application, the terms "first", "second", etc. are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0052] like Figures 1 to 6 As shown, it shows an automatic pipe alignment welding device in one embodiment of the present invention, which is used to place the first pipe body and the second pipe body with a gap between them and perform butt welding, so as to solve the problems of low alignment accuracy, poor adaptability and lack of dynamic adjustment ability in the traditional pipe welding process. By setting the first bracket 100 and the second bracket 300 on the adjustment bracket 200, the first pipe body and the second pipe body are supported respectively, and the relative positions can be adjusted to adapt to pipes of different diameters and shapes, thereby improving alignment accuracy and adaptability. The design of the annular rail 400 and the movable bracket 500 enables the welding gun 600 to surround the pipe for welding, ensuring the uniformity of the welding. The gap detection part 700 is set on the front side of the moving welding gun 600 to monitor the changes in the gap between the first pipe body and the second pipe body in real time so as to make timely adjustments and compensate for errors caused by thermal deformation or pipe displacement, ensure welding quality, reduce the number of shutdowns and calibrations, and improve production efficiency.

[0053] The first bracket 100 needs to be able to stably support the first tube body. Its main structure is a frame type. Two support rods are set on the top of the frame. The two support rods are used to support the first tube body. The support rods are wrapped with a wear-resistant rubber layer, which can increase the friction with the tube to prevent the tube from sliding and avoid damage to the surface of the tube.

[0054] The adjustment frame 200 is connected to the first bracket 100 via linear slides, which are mounted on either side of the first bracket 100. The adjustment frame 200 engages the slides via sliders, enabling linear movement relative to the first bracket 100. The drive system can be a motorized screw or a hydraulic cylinder. For example, the motorized screw is mounted at the bottom of the first bracket 100 and connected to the motor via a coupling. When the motor rotates, it drives the screw, which then rotates. The nut on the screw securely connects to the adjustment frame 200, enabling forward and backward movement of the adjustment frame 200.

[0055] To ensure smooth and accurate movement of the adjustment frame 200, a guide rod is installed between the adjustment frame 200 and the first bracket 100. The guide rod is parallel to the linear slide rail and fixed to the first bracket 100 at both ends. The adjustment frame 200 is slidably connected to the guide rod via guide sleeves. Furthermore, limit switches are installed at both ends of the movement path of the adjustment frame 200. When the adjustment frame 200 reaches the limit position, the limit switch triggers, stopping the motor rotation and preventing the adjustment frame 200 from deviating from the slide rail.

[0056] The second bracket 300 is mounted on the adjustment frame 200, and an electric lifting mechanism is used to achieve height adjustment. The electric lifting mechanism can be a screw lift, which consists of a motor, a screw, a nut and a guide column. The motor is installed on the top of the adjustment frame 200, the screw is vertically installed inside the adjustment frame 200, and the nut is fixedly connected to the second bracket 300. When the motor rotates, the screw drives the nut up and down, thereby achieving the lifting and lowering of the second bracket 300. The guide column is installed at the four corners of the adjustment frame 200 and cooperates with the guide sleeve on the second bracket 300 to ensure the stability of the lifting process of the second bracket 300. The lifting range can be designed according to the actual length of the pipe and the welding requirements.

[0057] A semicircular support groove can be set on the top of the second bracket 300. The radius of the support groove is designed according to the diameter range of common pipes. A layer of wear-resistant rubber pad is laid in the support groove to increase the friction with the pipe to prevent the pipe from sliding and avoid damage to the pipe surface.

[0058] The shape of the annular rail 400 is a complete circle, and its inner diameter is designed according to the outer diameter of the pipe and the welding operation space. The annular rail 400 is fixed between the first bracket 100 and the second bracket 300 through multiple support seats, and the support seats are connected with bolts for easy installation and adjustment.

[0059] To ensure that the welding gun 600 is always aligned with the welding surface of the pipe, a posture adjustment device is installed on the mobile frame 500. The posture adjustment device uses a motorized pan / tilt platform. Three motors control the horizontal, vertical, and rotational angles of the welding gun 600, ensuring that the welding gun 600 can adapt to the welding needs of pipes of different diameters and shapes.

[0060] Depending on the pipe material and welding process requirements, an appropriate type of welding torch 600 is selected, such as a gas metal arc welding torch or a tungsten arc welding torch. The welding torch 600 is mounted on the posture adjustment device of the mobile frame 500 using a fixture. The fixture features a quick-release clamping structure, facilitating replacement and adjustment of the welding torch 600. The electrode or nozzle of the welding torch 600 maintains an appropriate distance from the welding surface of the pipe, controlled by the posture adjustment device.

[0061] The gap detector 700 can be a laser displacement sensor, utilizing the principle of laser ranging to detect the gap width between the first and second tubes in real time. Laser displacement sensors offer the advantages of high precision, high speed, and non-contact detection. The sensor is mounted on the mobile frame 500, located in front of the welding gun 600. The laser beam it emits is perpendicular to the welding surface of the pipe, ensuring accurate detection of the gap width.

[0062] The laser displacement sensor transmits the detected gap width data to the control system, which analyzes and processes the data. If the gap width is detected to be outside a preset range, the control system automatically adjusts the position of the adjustment bracket 200 or the height of the second bracket 300 to compensate for gap changes caused by thermal deformation or pipe displacement, ensuring that the gap width remains within the appropriate range during welding.

[0063] During the preparation phase, the first tube is placed in the support groove of the first bracket 100 and secured according to the diameter of the first tube to ensure stability. The second tube is placed in the support groove of the second bracket 300. The electric lifting mechanism is activated, and the height of the second bracket 300 is adjusted so that the second tube is at the same level as the first tube. Simultaneously, the angle of the second tube is adjusted according to its diameter to achieve adaptive support and centering of the second tube. The drive mechanism of the adjustment bracket 200 is activated, allowing it to drive the second bracket 300 closer to the first bracket 100 until a suitable gap is formed between the first and second tubes.

[0064] During the welding phase, the drive motor of the movable frame 500 is activated, causing it to begin circular motion on the circular rail 400. Simultaneously, the welding torch 600 is activated, and welding parameters such as welding current, voltage, wire feed speed, and gas flow rate are set according to the pipe material and welding process requirements. As the movable frame 500 drives the welding torch 600 around the pipe, the gap detector 700 monitors the width of the gap between the first and second pipe bodies in real time and transmits the detected data to the control system. Based on this detected data, the control system adjusts the position of the adjustment frame 200 or the height of the second support 300 in real time to compensate for gap variations caused by thermal deformation or pipe displacement, thereby ensuring weld quality. For example, if the gap is detected to be widening, the control system drives the adjustment frame 200 toward the first support 100 to restore the gap width to within a preset range. If the gap is detected to be narrowing, the control system drives the adjustment frame 200 away from the first support 100.

[0065] At the end of the welding process, after the mobile frame 500 drives the welding gun 600 to complete a full weld, the drive motors for the welding gun 600 and the mobile frame 500 are turned off. The weld quality, such as the appearance and strength of the weld, is inspected. If the weld quality meets the requirements, the drive mechanism of the adjustment frame 200 is activated, causing the adjustment frame 200 to move the second bracket 300 away from the first bracket 100, and the welded pipe is removed. The welding equipment is cleaned and maintained, such as by removing weld spatter from the circular rail 400, inspecting the connections for looseness, and lubricating any areas that require lubrication, in preparation for the next welding cycle.

[0066] The first and second brackets 100, 300, provide positioning, support, and alignment for the pipes, as well as the movement of the adjustment frame 200 and the height adjustment of the second bracket 300. This improves alignment accuracy compared to traditional manual alignment methods, effectively reducing welding defects caused by alignment errors and improving weld quality.

[0067] The device can adapt to the welding needs of pipes of varying diameters and shapes by adjusting the support structure of the first and second brackets 100 and 300, as well as the position of the adjustment bracket 200. In practical applications, it can accommodate a wide range of pipe diameters and shapes, including circular and elliptical ones, improving adaptability and expanding the device's application range.

[0068] The gap detector 700 monitors the gap width in real time and, through a control system, adjusts the positions of the adjustment bracket 200 and the second bracket 300 to compensate for gap variations caused by thermal deformation or pipe displacement during welding. Compared to traditional welding equipment, this reduces downtime for calibration, improves production efficiency, and ensures consistent weld quality.

[0069] The design of the circular rail 400 and the mobile frame 500 enables the welding gun 600 to surround the pipe and weld evenly. Combined with the alignment and real-time dynamic adjustment functions, the welding quality is significantly improved, and the strength and appearance quality of the weld are improved.

[0070] In some examples, such as Figure 1 As shown, the first drive member 800 and the second drive member 900 can further enhance the automation and real-time adjustment capabilities of the device. The first drive member 800 is connected to the adjustment frame 200 and can drive the adjustment frame 200 to move in real time based on the information fed back by the gap detection member 700, thereby controlling the width of the gap between the first tube body and the second tube body. The second drive member 900 is mounted on the adjustment frame 200 and connected to the second bracket 300. Based on the detection feedback, it also drives the second bracket 300 to rise and fall in real time, compensating for the height difference caused by thermal deformation or displacement of the pipe, ensuring that the two pipes are always in the best alignment and gap state during the welding process, and comprehensively improving the welding quality and efficiency.

[0071] The first drive member 800 can be an electric push rod connected to a control system. When the gap detection member 700 detects that the gap width between the first and second tubes deviates from a preset range, the control system sends a control command to the servo motor of the first drive member 800 based on the size and direction of the deviation. The servo motor controls the direction and number of turns of the lead screw according to the command, thereby adjusting the extension and retraction length of the push rod, driving the adjustment frame 200 toward or away from the first bracket 100, and restoring the gap width to the preset value.

[0072] The second drive member 900 can use a ball screw lift to meet the requirements of the lifting and lowering adjustment of the second bracket 300. The ball screw lift is composed of a motor, a ball screw, a nut, a worm gear mechanism and a guide device. The second drive member 900 is also connected to the control system to receive signals from the gap detection member 700 and the control system. When it is detected that the height of the second tube body relative to the first tube body changes due to thermal deformation or displacement of the pipe, which affects the welding quality, the control system sends a control instruction to the servo motor of the second drive member 900 based on the height deviation information. The servo motor drives the ball screw to rotate, and drives the second bracket 300 to rise or fall along the linear guide rail through the nut, compensating for the height difference in real time to ensure that the two pipes always remain coaxially aligned during the welding process.

[0073] In some examples, such as Figures 1 to 5As shown, a gap detection member 700 in the form of a mechanical structure is designed to detect the width of the gap between the first tube body and the second tube body more stably and reliably to avoid being affected by welding dust pollutants in the welding workshop. By setting a plurality of movable probes 701 that are arranged axially parallel to the first tube body and can move on the movable frame 500, the force provided by the first elastic member 702 is used to make the movable probe 701 approach the gap, the first tube body and the second tube body. According to the different widths of the gap, a corresponding number of movable probes 701 will be extended into the gap to judge the width of the gap. This method is more stable and reliable. Compared with the laser displacement sensor, it will not be affected by welding dust pollutants in the welding workshop. It can more reliably detect the actual situation of the gap, provide a more reliable adjustment basis for the first drive member 800 and the second drive member 900, and further improve the welding quality.

[0074] The movable probes 701 are made of high-strength, wear-resistant metal materials, such as tungsten steel, to ensure that detection accuracy is not affected by wear during long-term use. Each movable probe 701 is slender and cylindrical, with a length that ensures it can effectively penetrate gaps for detection. The tip of the movable probe 701 is machined into a sharp cone to facilitate insertion into the gap.

[0075] Several movable probes 701 are evenly arranged on the movable frame 500, parallel to the axial direction of the first tube, with adjacent movable probes 701 closely spaced. One end of a first elastic member 702 is sleeved onto the movable probe 701. A retaining ring or groove is provided on the movable probe 701 to prevent the spring from falling off the movable probe 701, ensuring a secure installation and providing a stable force for the movable probe 701 to approach the gap, the first tube, and the second tube.

[0076] During the welding stage, the mobile frame 500 drives the welding gun 600, the mobile probe 701 and other components to start circular motion on the circular rail 400. During the movement, the mobile probe 701 approaches the gap between the first tube body and the second tube body, and part of the mobile probe 701 extends into the gap. The mobile probes 701 on both sides are supported by the first tube body and the second tube body, causing the mobile probe 701 to retract. According to the width of the gap, a corresponding number of mobile probes 701 will be located in the gap, and the remaining mobile probes 701 will be located outside the gap. For example, when the gap is wider, more mobile probes 701 can extend into the gap; when the gap is narrower, only fewer mobile probes 701 can extend into the gap. By detecting the number of mobile probes 701 extending into different positions, the width of the gap at that position can be determined.

[0077] In order to accurately obtain the insertion status of the mobile probe 701, corresponding detection can be performed and the actual situation can be transmitted to the control system, which analyzes and determines the gap width information at different positions. The control system calculates the deviation value of the gap width based on the gap width information and the preset gap width standard range. If the deviation value exceeds the allowable range, the control system sends corresponding control instructions to the first drive member 800 and the second drive member 900. The first drive member 800 pushes the adjustment frame 200 to move through the electric push rod to adjust the gap width between the two pipes; the second drive member 900 adjusts the height of the second bracket 300 through the ball screw lift to compensate for the height difference caused by thermal deformation or displacement of the pipe, ensuring that the gap width always remains within the appropriate range during welding.

[0078] After welding is complete, the mobile frame 500 stops moving. The gap detector 700 is cleaned, and any weld spatter or impurities that may have adhered to the mobile probe 701 are removed. The mobile probe 701 is inspected for wear or deformation and replaced if necessary. After cleaning and inspection, the device is reset and ready for the next welding session.

[0079] The design of multiple movable probes 701 arranged parallel to the pipe axis enables multi-point detection along the pipe's circumference, providing a more comprehensive assessment of the gap width. This approach effectively reflects actual gap variations, providing more reliable data support for real-time adjustments during the welding process, further reducing welding defects caused by gap width deviations and improving welding quality.

[0080] Based on the gap width information acquired by the mobile probe 701, the control system can better control the movement of the first and second drive members 800, 900, and adjust the position of the pipe. This improves the adjustment reliability of the adjustment frame 200 and the second bracket 300, making pipe alignment and gap control more reliable during welding, further enhancing welding quality and production stability.

[0081] In some examples, such as Figure 3 As shown, the movable probe 701 is an insulating part and has a first conductive part 7011 and a second conductive part 7012 arranged in sequence at intervals. The conductivity of the second conductive part 7012 is greater than the conductivity of the first conductive part 7011; the gap detection part 700 also includes a conductive part 703, and there are several conductive parts 703. The conductive parts 703 and the movable probe 701 are arranged in sequence at intervals. After the movable probe 701 moves, one of the first conductive part 7011 and the second conductive part 7012 is electrically connected to the conductive part 703, and the several conductive parts 703 are maintained in series with one of the first conductive part 7011 and the second conductive part 7012; the current detection part 704 is connected to the conductive parts 703 at both ends for detecting the magnitude of the current passing through the conductive part 703.

[0082] By providing a first conductive portion 7011 and a second conductive portion 7012 of different conductivities on the movable probe 701, in conjunction with a conductive element 703 and a current detector 704, the conductivity difference and current detection are used to more stably determine the gap width. When the movable probe 701 moves in response to changes in the gap width, the different conductive portions electrically connect with the conductive element 703, forming a series circuit with different resistances. The current detector 704 indirectly reflects the change in gap width by detecting the current in the circuit, providing the control system with more stable gap width data, enabling adjustments to the pipe position during welding and further improving weld quality.

[0083] The movable probe 701 can be made of a high-strength, wear-resistant insulating material, such as ceramic or high-strength engineering plastic, to ensure its mechanical and insulating properties. A first conductive portion 7011 and a second conductive portion 7012 are mounted on the movable probe 701 in an alternately spaced arrangement. The first conductive portion 7011 can be made of a relatively low-conductivity metal material, such as nickel-chromium alloy, while the second conductive portion 7012 can be made of a relatively high-conductivity metal material, such as aluminum or copper.

[0084] The first conductive portion 7011 and the second conductive portion 7012 are arranged along the axis of the movable probe 701. When the movable probe 701 is inserted into the gap, depending on the gap width, different numbers of the first conductive portions 7011 or second conductive portions 7012 will contact and electrically connect with the conductive element 703. Because the conductivity of the second conductive portion 7012 is greater than that of the first conductive portion 7011, different contact combinations will cause the resistance of the entire series circuit to change, thereby affecting the current flow and reflecting the change in gap width.

[0085] The conductive member 703 is made of a highly conductive metal material, such as copper or aluminum, and is shaped like a long, thin strip. Several conductive members 703 and the movable probe 701 are sequentially spaced apart on the movable frame 500 to ensure that when the movable probe 701 moves, its first conductive portion 7011 or second conductive portion 7012 can make good contact and be electrically connected to the conductive member 703. The conductive members 703 at the two ends are connected to the current detection member 704 via wires to form a circuit capable of current detection, thereby achieving current measurement. The settings of the power supply and voltage regulating resistor are well understood by those skilled in the art and can be set as needed.

[0086] Current detection element 704 can be a Hall effect current sensor or shunt, capable of detecting minute current changes. For example, a Hall effect current sensor has a measurement range determined by the expected circuit current. Current detection element 704 has a fast response characteristic, capable of detecting current changes in the circuit in real time, providing timely and accurate data to the control system.

[0087] The current detector 704 is mounted on the mobile frame 500 near the conductive elements 703 at both ends. It fits over the wires connected to the conductive elements 703, ensuring stable signal transmission and current measurement. To prevent external electromagnetic interference from affecting current detection accuracy, the current detector 704 is housed in a shielded housing and the connecting wires are shielded. A filtering circuit is also incorporated into the circuit design to further improve detection accuracy.

[0088] During the welding phase, the movable frame 500 drives the welding gun 600, movable probe 701, conductive member 703, and current detection member 704 to begin circular motion on the circular rail 400. The first elastic member 702 pushes the movable probe 701 toward the gap between the first and second tubes. Depending on whether the movable probe 701 contacts the surface of the first and second tubes or extends into the gap, the conductive member 703 will be electrically connected to the first conductive portion 7011 or the second conductive portion 7012. The first and second conductive portions 7011, 7012 on the movable probe 701 will form different electrical connection combinations with the conductive member 703, thereby enabling detection of the gap width.

[0089] For example, when the gap is narrow, the movable probe 701 extends into a smaller area, and there may be only a few first conductive parts 7011 electrically connected to the conductive part 703. At this time, the resistance of the entire series circuit is large, and the current detected by the current detection part 704 is small; when the gap is wider, the movable probe 701 extends into a larger area, and more second conductive parts 7012 are electrically connected to the conductive part 703. The circuit resistance becomes smaller, and the current detected by the current detection part 704 increases.

[0090] The current detection element 704 transmits the real-time detected current magnitude signal to the control system. The control system converts the current signal into gap width information based on a pre-established current-gap width correspondence model, which can be derived through experiments and data analysis. The control system then compares the actual detected gap width with a preset standard gap width range and calculates the gap width deviation.

[0091] If the deviation exceeds the allowable range, the control system sends corresponding control instructions to the first and second actuators 800 and 900. The first actuator 800 uses an electric push rod to move the adjustment bracket 200, adjusting the gap width between the two pipes. The second actuator 900 uses a ball screw to adjust the height of the second bracket 300, compensating for height differences caused by thermal deformation or displacement of the pipes, ensuring that the gap width remains within the appropriate range during welding.

[0092] After welding is complete, the movable frame 500 stops moving. The movable probe 701, conductive member 703, and current detector 704 are cleaned and inspected. Any weld spatter or impurities that may have adhered to the movable probe 701 and conductive member 703 are removed. The conductive portion of the movable probe 701 and conductive member 703 are inspected for wear or damage, and replaced if necessary. The current detector 704 is recalibrated to ensure accuracy. After cleaning and inspection, the device is reset and ready for the next welding session.

[0093] Based on the principles of conductivity difference and current detection, changes in gap width can be detected more stably, enabling the control system to obtain more accurate gap width information, thereby achieving more precise adjustment of the pipe position, greatly reducing welding defects caused by gap width deviation, and significantly improving welding quality.

[0094] The mechanical structure combined with conductivity detection is less susceptible to environmental factors and effectively avoids the effects of dust and vibration, making it more suitable for dusty welding environments. Compared to laser displacement sensor detection, it offers greater stability and reliability. In actual welding environments, the device's improved detection stability reduces the need for frequent adjustments and fluctuations in weld quality caused by detection errors, thereby improving production process stability and product consistency.

[0095] In some examples, such as Figure 3 As shown, the structures of the first conductive part 7011 and the second conductive part 7012 on the movable probe 701 are designed, arranged in sequence, and designed with different cross-sectional shapes. This optimizes the accuracy and reliability of detecting the gap width through current changes. The elongated cross-sectional area of ​​the first conductive part 7011 can, to a certain extent, increase the length of the contact position with the conductive member 703, so that the movable probe 701 can ensure that the first conductive part 7011 and the conductive member 703 remain conductive in many positions. The second conductive part 7012 with a circular cross-sectional area ensures that the second conductive part 7012 and the conductive member 703 remain conductive only when the movable probe 701 moves downward to the lowest end, that is, when it is only subjected to the elastic force of the first elastic member 702 and not to the force of the first tube body and the second tube body. The combination of the two can make the current change more accurately reflect the change in the gap width, provide better gap width data for the control system, and further improve the control accuracy of welding quality.

[0096] The structural design of the first conductive portion 7011 and the second conductive portion 7012 establishes a more accurate correspondence between current changes and gap width changes. This provides the control system with better gap width data, improving the accuracy of gap width control during welding, virtually eliminating welding defects caused by gap width deviation, and significantly improving welding quality.

[0097] The stable electrical connection provided by the elongated first conductive portion 7011 and the conductive condition of the circular second conductive portion 7012 ensure that the detection system responds more stably and reliably to variations in gap width. During actual welding, even in complex welding environments such as high temperature and vibration, detection reliability is enhanced, effectively avoiding frequent adjustments and fluctuations in welding quality caused by detection errors, ensuring a stable production process and highly consistent product quality.

[0098] In some examples, such as Figure 2 、 Figure 5 and Figure 6 As shown, a coaxiality detection member 1000 is designed to detect the coaxiality of the first tube body and the second tube body, thereby better ensuring the welding quality. By arranging a rotation detection rod 1001 on the movable frame 500, so that its two ends are respectively abutted against the first tube body and the second tube body, when the two tube bodies are not coaxial, the rotation detection rod 1001 will rotate. The angle detection member 1002 detects the rotation angle of the rotation detection rod 1001 in real time and feeds back the angle information to the control system. The control system determines the coaxiality deviation of the two tube bodies based on this information, and then better controls the first drive member 800 and the second drive member 900 to adjust the adjustment frame 200 and the second bracket 300, ensuring that the two tube bodies always maintain good coaxiality during the welding process, reducing welding defects caused by coaxiality deviation, and improving welding quality and efficiency.

[0099] The rotating detection rod 1001 maintains sufficient strength while reducing its own weight, thereby minimizing the impact on the movement of the mobile frame 500. The detection rod is generally slender, with replaceable contacts mounted on both ends. The contacts are made of wear-resistant materials, such as cemented carbide, and their shape is designed according to the surface shape of the pipe. For circular pipes, the contacts are designed to be arc-shaped to increase the contact area with the pipe surface, thereby improving the stability and accuracy of the detection.

[0100] Rotation detection rod 1001 is rotatably mounted on mobile frame 500. Angle detection element 1002 can utilize a high-precision rotary encoder capable of measuring the rotation angle of rotation detection rod 1001. The resolution of the rotary encoder is determined based on the required detection accuracy, ensuring accurate detection of even minute angle changes in rotation detection rod 1001. The encoder's output signal type is selected based on the control system's interface requirements. Common options include incremental pulse output or absolute value output, facilitating data transmission and processing with the control system.

[0101] Angle detection element 1002 is mounted on the mobile frame 500 near the rotation detection rod 1001 and connected to the shaft of the rotation detection rod 1001 via a coupling. This coupling is elastic, compensating for any coaxial errors between the rotation detection rod 1001 and the encoder shaft, reducing the effects of vibration and shock on encoder measurement accuracy. The encoder is connected to the control system via a cable. To ensure stable signal transmission, the cable is shielded and securely fastened to prevent cable movement during the movement of the mobile frame 500, which could affect signal transmission.

[0102] During the welding phase, the moving frame 500 drives the welding gun 600, the gap detection member 700, the rotation detection rod 1001 and the angle detection member 1002 to start circular motion on the annular rail 400. During the movement, both ends of the rotation detection rod 1001 always abut against the first tube body and the second tube body.

[0103] When the first and second tubes are in good coaxial alignment, rotation detection rod 1001 maintains a relatively stable angle, and the rotation angle detected by angle detection element 1002 changes slightly. However, if the two tubes deviate from coaxiality, rotation detection rod 1001 rotates in response to the misalignment of the tubes, and angle detection element 1002 detects the change in rotation angle in real time. Angle detection element 1002 converts the detected rotation angle signal into a pulse signal and transmits it to the control system.

[0104] The control system converts the pulse signal into coaxiality deviation information based on a pre-established rotation angle-coaxiality deviation correspondence model, which was obtained through theoretical calculations and actual testing. The control system then compares the actual coaxiality deviation detected with the preset coaxiality standard range to calculate the coaxiality deviation value.

[0105] If the coaxiality deviation exceeds the allowable range, the control system, combined with the gap width information detected by the gap detector 700, sends corresponding control instructions to the first and second actuators 800 and 900. The first actuator 800 uses an electric push rod to move the adjustment bracket 200, adjusting the relative position of the two pipes. The second actuator 900 uses a ball screw to adjust the height of the second bracket 300, compensating for the height difference caused by the misalignment of the pipes, ensuring that the two pipes maintain good coaxiality and an appropriate gap width during welding.

[0106] The combination of rotation detection rod 1001 and angle detection element 1002 effectively detects coaxial deviations between the first and second tubes. Compared to traditional coaxiality detection methods, this method can promptly and accurately detect coaxiality changes between the two tubes during welding, providing a basis for adjustment in the control system. This effectively reduces welding defects caused by coaxiality deviations, such as weld eccentricity and incomplete penetration, and significantly improves welding quality. Rotation detection rod 1001 utilizes mechanical contact detection, offering excellent detection stability and adaptability even in dusty welding environments.

[0107] By detecting coaxiality deviation in real time and combining it with gap width detection information, the control system can more comprehensively and accurately control the adjustment of the adjustment frame 200 and the second bracket 300. Compared to adjustments based solely on gap detection, the adjustment accuracy of the adjustment frame 200 and the second bracket 300 is improved, enabling accurate adjustment of the pipe position, ensuring optimal pipe alignment during welding, and further improving welding quality and production efficiency.

[0108] The installation of the coaxiality detector 1000 makes the welding device more adaptable to pipes of varying diameters and materials. Regardless of changes in the specific parameters of the pipe, it can accurately detect coaxiality deviations and make corresponding adjustments. Furthermore, during the actual welding process, the device significantly enhances its stability in the face of complex conditions such as thermal deformation and vibration of the pipe. It can stably maintain the pipe's coaxiality and gap width within the appropriate range, reducing fluctuations in welding quality caused by external factors and improving the stability and reliability of the production process.

[0109] In some examples, such as Figure 5 and Figure 6 As shown, on the basis of the automatic pipe alignment welding device equipped with a coaxiality detection part 1000, a first guide wheel 1003 and a second guide wheel 1004 are provided to optimize the contact mode between the rotating detection rod 1001 and the pipe, thereby improving the accuracy and stability of the coaxiality detection. The first guide wheel 1003 and the second guide wheel 1004 are respectively rotatably arranged at the two ends of the rotating detection rod 1001. During the welding process, they can roll on the outer walls of the first pipe body and the second pipe body. Compared with direct abutment, this rolling contact method can more smoothly follow the changes in the shape of the pipe surface and reduce the interference of the uneven surface of the pipe or small displacement on the detection results. At the same time, the rolling of the guide wheel can reduce the friction with the surface of the pipe, avoid damage to the surface of the pipe, improve the stability and reliability of the detection, and provide more accurate coaxiality deviation data for the control system, thereby more effectively ensuring the welding quality.

[0110] The first guide wheel 1003 and the second guide wheel 1004 share the same design, consisting of a hub, rim, and rolling bearings. The hub is constructed of high-strength engineering plastics or lightweight metals, such as aluminum alloy, to reduce weight while ensuring sufficient strength. The rim is made of wear-resistant rubber, tightly bonded to the hub through a vulcanization process. The rubber rim offers excellent elasticity and friction, ensuring stable rolling on the pipe surface while avoiding scratches.

[0111] The rolling contact between first guide wheel 1003 and second guide wheel 1004 enables rotating detection rod 1001 to more sensitively and accurately detect pipe coaxiality deviations. Compared to a direct contact method without guide wheels, coaxiality detection accuracy is further improved, enabling better detection of minor coaxiality variations between the two pipes during the welding process, providing more accurate data support for the control system, thereby more effectively avoiding welding defects caused by coaxiality deviations and improving welding quality.

[0112] The rolling of the guide wheel effectively reduces interference with test results caused by uneven pipe surfaces or minor displacements, lowering friction with the pipe surface and preventing damage. During the actual welding process, facing complex conditions such as thermal deformation and vibration, the detection system's improved stability and reliability enable it to more consistently provide accurate coaxial deviation data to the control system, ensuring a smooth welding process and consistent weld quality.

[0113] The design of the first guide wheel 1003 and the second guide wheel 1004 allows them to better adapt to pipes of varying diameters and surface roughness. Whether it is a small, thin-walled pipe, a large, thick-walled pipe, or a pipe with a high surface roughness, the guide wheels can roll stably along the outer wall and accurately detect coaxial deviations.

[0114] In some examples, such as Figure 5 and Figure 6 As shown, based on the automatic pipe alignment welding device that already has a coaxiality detection member 1000 and is equipped with a guide wheel, the mobile frame 500 is structurally optimized and designed to include a base 501 and a sliding portion 502. A rotation detection rod 1001 is set to rotate on the sliding portion 502, and a second elastic member 1100 is added. This improves the accuracy and adaptability of coaxiality detection. The second elastic member 1100 provides a force for the sliding portion 502 to move away from the base 501, so that the guide wheels at both ends of the rotation detection rod 1001 can always fit closely to the outer wall of the pipe. Even if the pipe has a certain radial size change or a slight position offset, the continuity and stability of the detection can be guaranteed. The rotation detection rod 1001 that is rotated can better adapt to the movement generated when the pipe is not coaxial, thereby providing more accurate rotation angle information for the angle detection member 1002, enabling the control system to better adjust the pipe position and further improve the welding quality.

[0115] The base 501 serves as the main structure of the mobile frame 500, supporting the weight of the entire mobile frame 500 and its connected components, and ensuring stability during movement. The shape of the base 501 is designed based on the shape of the annular rail 400 and the installation requirements of other components, generally adopting an arc-shaped structure that adapts to the annular rail 400. The sliding portion 502 is slidably connected to the base 501 via a linear slide rail. The linear slide rail is installed at a specific position on the base 501. The sliding portion 502 cooperates with the slide rail via a slider to achieve linear sliding relative to the base 501.

[0116] A dedicated mounting seat is provided on the sliding portion 502, which is machined with an axial hole and a slide groove for mounting the rotation detection rod 1001. One end of the second elastic member 1100 is mounted within the spring seat, while the other end rests on a boss provided on the sliding portion 502, ensuring a secure installation and providing a stable force to move the sliding portion 502 away from the base 501.

[0117] During the welding phase, the mobile frame 500 drives the welding gun 600, the gap detection member 700, the rotation detection rod 1001, and the first and second guide wheels 1003, 1004 to begin circular motion on the annular rail 400. During this motion, the second elastic member 1100 continuously provides a force for the sliding portion 502 to move away from the base 501, ensuring that the first and second guide wheels 1003, 1004 at both ends of the rotation detection rod 1001 are tightly attached to the outer walls of the first and second tubes.

[0118] When the pipe diameter changes slightly or experiences a certain amount of radial displacement, the sliding portion 502 slides accordingly under the action of the second elastic member 1100, ensuring good contact between the guide wheel and the outer wall of the pipe. For example, when the pipe expands due to heat, the sliding portion 502 slides away from the base 501 under the action of the spring force, allowing the guide wheel to continue to roll stably on the outer wall of the pipe.

[0119] Through the rotational arrangement of the sliding portion 502, the rotation detection rod 1001, and the action of the second elastic member 1100, the accuracy of coaxiality detection can be further improved. This improves the stability of detection when facing various complex dimensional changes and positional deviations of pipes, enabling more accurate and stable detection of coaxiality deviations between two pipes. This provides more realistic data to the control system, reduces welding defects caused by coaxiality issues, and improves welding quality.

[0120] This allows the device to better adapt to pipes of varying diameters and materials, as well as various changes that may occur during the welding process. Whether it's dimensional changes caused by thermal expansion or contraction, or minor displacements due to external forces, the device can ensure the accuracy of coaxiality testing by flexibly adjusting the sliding portion 502 and rotating the detection rod 1001.

[0121] In some examples, the angle detection member 1002 can also be an angular displacement sensor, and an intelligent collaborative control system is constructed through the controller 1200. The angular displacement sensor can measure the change in the rotation angle of the rotation detection rod 1001 and convert it into an angular displacement signal. The current detection member 704 detects the circuit current change signal caused by the change in the gap width. The controller 1200 receives these two signals, and through the internal preset algorithm and logic, comprehensively analyzes the coaxiality deviation and gap width information, and then accurately controls the action of the first drive member 800 and the second drive member 900. This collaborative control method can adjust the position of the pipe more comprehensively and in real time, ensuring that the pipe always maintains good coaxiality and appropriate gap width during welding, thereby significantly improving welding quality and production efficiency.

[0122] The angular displacement sensor can be a photoelectric type, which offers advantages such as high precision, fast response, and strong anti-interference capabilities. This allows the sensor to meet the range of possible rotation angles of the rotation detection rod 1001. It also has high resolution, capable of capturing even the slightest rotational changes of the rotation detection rod 1001. The output signal is a digital pulse signal, facilitating fast and accurate data transmission with the controller 1200.

[0123] The angular displacement sensor is mounted on the sliding portion 502 and tightly connected to the shaft of the rotation detection rod 1001 via a coupling. This coupling utilizes an elastic coupling to compensate for minor misalignment between the shafts, ensuring that the angular displacement sensor can accurately measure the rotation angle of the rotation detection rod 1001. Using a high-precision turntable, the rotation detection rod 1001 is rotated in known angular increments. The number of pulses output by the angular displacement sensor is recorded, establishing a correspondence between angle and pulse number to ensure measurement accuracy.

[0124] Controller 1200 utilizes a programmable logic controller (PLC) equipped with multiple analog input modules for receiving analog current signals from current detector 704 and converting them into digital signals for processing. It also includes a digital input module for receiving digital pulse signals from the angular displacement sensor. It also includes multiple digital output modules for sending control commands to first and second drive elements 800, 900, to control the start / stop, speed, and direction of their motors.

[0125] During the welding phase, the moving frame 500 drives the various components in circular motion on the annular rail 400. During this motion, the angular displacement sensor monitors the rotation angle of the rotation detection rod 1001 in real time and transmits the angular displacement signal in the form of digital pulses to the controller 1200. Simultaneously, the current detection element 704 detects the circuit current changes caused by the gap width changes in real time and transmits the analog current signal to the controller 1200.

[0126] After receiving the angular displacement signal and current signal, the controller 1200 rapidly processes them according to a preset algorithm. The angular displacement signal is converted into a rotation angle value, which is then used to calculate the coaxiality deviation; the current signal is converted into a gap width value. For example, when the angular displacement sensor detects that the rotation detection rod 1001 has rotated a certain angle, the controller 1200 uses calibration data and a mathematical model to determine that the pipe's coaxiality deviation is a certain value. Simultaneously, the current detection element 704 detects a change in current, and the controller 1200 calculates the gap width using a corresponding relationship model.

[0127] The controller 1200 compares the calculated coaxiality deviation and gap width values ​​with the preset standard range. If the coaxiality deviation exceeds the allowable range and the gap width is not within the appropriate range, the controller 1200 generates a control instruction according to the control logic based on the specific situation of the deviation. For example, if the coaxiality deviation shows that the first tube body is offset to the left relative to the second tube body and the gap width is too large, the controller 1200 sends an instruction to the first drive member 800 to extend its electric push rod and push the adjustment frame 200 to the right. At the same time, it sends an instruction to the second drive member 900 to adjust the height of the second bracket 300 to reduce the gap width, thereby adjusting the position of the pipe and ensuring that the pipe always maintains good coaxiality and appropriate gap width during the welding process.

[0128] Data from the angular displacement sensor and current detector 704 are processed collaboratively by controller 1200, improving both coaxiality and gap width detection accuracy. Based on this high-precision data, controller 1200 can more precisely control first and second drive members 800 and 900, improving pipe position adjustment accuracy compared to previous designs.

[0129] This embodiment also provides a method for automatic pipe alignment welding, comprising the following steps:

[0130] S1: Place the first tube on the first bracket 100 and fix it with a positioning device to ensure that the first tube is in a stable position. Place the second tube on the second bracket 300 to ensure that it is placed stably.

[0131] S2: Start the adjustment frame 200, and the first driving member 800 drives the adjustment frame 200 to move relative to the first bracket 100, driving the second bracket 300 and the second tube body to move closer to or away from the first bracket 100. At the same time, start the second driving member 900, adjust the height of the second bracket 300, and preliminarily adjust the positions of the two tube bodies so that the relative positions of the two tube bodies are close to the preset alignment requirements. In this process, if equipped with a coaxiality detection member 1000, the first guide wheel 1003 and the second guide wheel 1004 at both ends of the rotation detection rod 1001 roll on the outer walls of the first tube body and the second tube body respectively, and the angle detection member 1002 detects the rotation angle of the rotation detection rod 1001 in real time, and transmits the angular displacement signal to the controller 1200. The controller 1200 preliminarily adjusts the movement of the adjustment frame 200 and the second bracket 300 according to the coaxiality deviation.

[0132] S3: The movable frame 500 slides along the annular rail 400, driving the gap detection member 700 to detect the gap between the two tubes. Under the action of the first elastic member 702, the movable probe 701 approaches the gap. Depending on the width of the gap, the first conductive portion 7011 and the second conductive portion 7012 on the movable probe 701 form different electrical connection combinations with the conductive member 703. The current detection member 704 detects different current signals and transmits them to the controller 1200. Based on the coaxiality detection information and the test results, the controller 1200 controls the first and second drive members 800 and 900 to further fine-tune the movement of the adjustment frame 200 and the raising and lowering of the second bracket 300 until the gap reaches the preset range and the coaxiality of the two tubes meets the requirements.

[0133] S4: When the gap and coaxiality are adjusted to the right position, start the welding gun 600, and at the same time, the moving frame 500 drives the welding gun 600 to weld along the circular rail 400 around the two pipe bodies. During the welding process, the gap detection component 700 continuously detects the gap changes in real time, and the coaxiality detection component 1000 continuously monitors the coaxiality. If the gap deviates from the preset range or the coaxiality deviates, the angular displacement sensor transmits the coaxiality deviation signal and the current detection component 704 transmits the gap width change signal to the controller 1200 in a timely manner. The controller 1200 quickly analyzes and processes, accurately controls the actions of the first drive member 800 and the second drive member 900, adjusts the adjustment frame 200 and the second bracket 300, and compensates in real time for the gap and coaxiality changes caused by factors such as thermal deformation and pipe displacement until the butt welding is completed.

[0134] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. An automatic pipe alignment welding device for placing a first pipe body and a second pipe body with a gap between them and performing butt welding, characterized in that: include: A first bracket (100), the first bracket (100) being used to support the first tube body; an adjustment frame (200), the adjustment frame (200) being movably arranged relative to the first bracket (100), and moving closer to or farther away from the first bracket (100); a second bracket (300), the second bracket (300) being arranged on the adjustment frame (200) in a manner so as to be adjustable in height and used for supporting the second tube body; an annular rail (400), the annular rail (400) being arranged between the first bracket (100) and the second bracket (300); A movable frame (500), the movable frame (500) being slidably disposed on the annular rail (400); a welding gun (600), the welding gun (600) being arranged on the movable frame (500) and facing between the first bracket (100) and the second bracket (300); a gap detection member (700), the gap detection member (700) being arranged on the movable frame (500) and being located at the front side of the welding gun (600) following the movement of the movable frame (500); The gap detection member (700) comprises: A plurality of movable probes (701) are arranged in a direction parallel to the axial direction of the first tube body. The plurality of movable probes (701) are movably arranged on the movable frame (500) and are used to judge the width of the gap according to the number of movable probes (701) inserted into the gap. The movable probe (701) is an insulating member and has a first conductive portion (7011) and a second conductive portion (7012) arranged in sequence and spaced apart. The conductivity of the second conductive portion (7012) is greater than the conductivity of the first conductive portion (7011). a first elastic member (702), one end of the first elastic member (702) acting on the movable probe (701) and the other end acting on the movable frame (500), providing a force for the movable probe (701) to approach the gap, the first tube body and the second tube body; A conductive member (703), wherein the conductive members (703) are multiple, and the conductive members (703) and the movable probe (701) are sequentially spaced apart, and the movable probe (701) is configured such that after the movable probe (701) moves, one of the first conductive portion (7011) and the second conductive portion (7012) is electrically connected to the conductive member (703), and multiple conductive members (703) are connected in series with one of the first conductive portion (7011) and the second conductive portion (7012); a current detection member (704), the current detection member (704) being connected to the conductive members (703) at both ends and used to detect the magnitude of the current passing through the conductive member (703); It also includes a coaxiality detection component (1000), the coaxiality detection component (1000) including: a rotation detection rod (1001), the rotation detection rod (1001) being rotatably disposed on the movable frame (500) and being located at the front side of the gap detection member (700) following the movement of the movable frame (500), the two ends of the rotation detection rod (1001) being respectively used for relatively abutting against the first tube body and the second tube body; An angle detection member (1002), the angle detection member (1002) being arranged on the movable frame (500) and being used to detect the rotation angle of the rotation detection rod (1001); A first guide wheel (1003) and a second guide wheel (1004) are rotatably arranged at two ends of the rotation detection rod (1001), respectively; the first guide wheel (1003) is used to roll on the outer wall of the first tube body, and the second guide wheel (1004) is used to roll on the outer wall of the second tube body.

2. The automatic pipe alignment welding device according to claim 1, characterized in that: Also includes: a first driving member (800), the first driving member (800) being connected to the adjustment frame (200) and being used to drive the adjustment frame (200) to move; A second driving member (900) is provided on the adjustment frame (200) and is connected to the second bracket (300), and is used to drive the second bracket (300) to rise and fall.

3. The automatic pipe alignment welding device according to claim 1, characterized in that: The first conductive part (7011) and the second conductive part (7012) are arranged in sequence, the cross-sectional area of ​​the first conductive part (7011) is a long strip, and the cross-sectional area of ​​the second conductive part (7012) is a circle.

4. The automatic pipe alignment welding device according to claim 1, characterized in that: The movable frame (500) comprises a base (501) and a sliding portion (502) slidably arranged relative to the base (501), the rotation detection rod (1001) is rotatably arranged on the sliding portion (502), the angle detection member (1002) is arranged on the sliding portion (502), and further comprises: A second elastic member (1100), one end of the second elastic member (1100) acts on the base (501), and the other end acts on the sliding portion (502), for providing a force to move the sliding portion (502) away from the base (501).

5. The automatic pipe alignment welding device according to claim 2, characterized in that: The angle detection element (1002) is an angular displacement sensor, and further comprises: The controller (1200) is electrically connected to the angular displacement sensor and the current detection member (704), and is used to receive the angular displacement signal detected by the angular displacement sensor and the detection current signal of the current detection member (704). The controller (1200) is used to control the actions of the first driving member (800) and the second driving member (900).

6. A method for automatic pipe alignment welding, using the automatic pipe alignment welding device according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1, placing the first tube on the first bracket (100) and fixing it, and placing the second tube on the second bracket (300); S2, starting the adjustment frame (200) to move it, driving the second bracket (300) and the second tube body to move closer to or away from the first bracket (100), and simultaneously starting the lifting adjustment of the second bracket (300) to preliminarily adjust the positions of the two tube bodies; S3, the moving frame (500) slides along the annular rail (400), driving the gap detection member (700) to detect the gap between the two tubes, and further fine-tuning the movement of the adjustment frame (200) and the lifting and lowering of the second bracket (300) according to the detection result until the gap reaches a preset range; S4. When the gap is adjusted to the desired position, the welding gun (600) is started, and the movable frame (500) drives the welding gun (600) to weld the two pipe bodies along the annular rail (400). During the welding process, the gap detection member (700) detects the gap change before welding. If the gap deviates from the preset range, the adjustment frame (200) and the second bracket (300) are adjusted until the butt welding is completed.

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