High-precision transmission high-frequency straight seam pipe unit

Abstract

The application discloses a high-precision transmission high-frequency straight seam welded pipe unit, relates to the control technical field of the straight seam welded pipe unit, and reflects the influence of carbon equivalent and the thickness of the steel pipe on the welding process through a dynamic adaptation welding value calculated by a dynamic adaptation welding value algorithm unit, so that the control system automatically adjusts the welding speed according to the influence value, ensures that the welding process is always carried out in the best state, improves the high-frequency straight seam welded pipe welding and the high precision of transmission, and the mode of intelligently controlling and dynamically adjusting the welding parameters in the straight seam welded pipe unit can reduce the downtime adjustment time caused by different steel pipe parameters, reduces unnecessary energy consumption, and the environmental adaptability welding value is calculated by considering the deviation degree of the environmental temperature and humidity from the ideal value during welding, so that the welding process can be kept stable under different environmental conditions, and welding defects caused by environmental factors are reduced.

Description

Technical Field

[0001] This invention relates to the field of straight seam welded pipe unit technology, specifically a high-precision transmission high-frequency straight seam welded pipe unit. Background Technology

[0002] Straight seam welded pipe refers to any pipe made by welding hot-rolled or cold-rolled steel plates or strips into straight seams on a welding equipment.

[0003] Currently, existing straight seam welded pipe units have difficulty quantifying the impact of steel pipe thickness, carbon equivalent, ambient temperature, and humidity on the welding process and adjusting the welding speed. As a result, workers need to frequently stop the machine to adjust welding parameters based on their operating experience to adapt to different steel pipe thicknesses and carbon equivalents. Frequent shutdowns reduce the welding efficiency of the straight seam welded pipe unit and increase energy consumption.

[0004] Therefore, there is an urgent need for a high-precision transmission high-frequency straight seam welded pipe unit to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a high-precision transmission high-frequency straight seam welded pipe unit to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a high-precision transmission high-frequency straight seam welded pipe unit, comprising a control system, wherein the control system specifically includes:

[0007] The data collection module is used to collect welding information from the high-frequency straight seam welded pipe unit. The collected welding information includes steel pipe thickness, welding speed, carbon equivalent, ambient temperature, ambient humidity, and current load power.

[0008] The data preprocessing module decodes and preprocesses the welding information to obtain the calculation parameters in the calculation processing module.

[0009] The computational processing module includes:

[0010] The dynamic adaptive welding value algorithm unit is used to calculate the dynamic adaptive welding value Wda based on the adjustment value of the welding speed relative to the reference speed under the influence of the steel pipe thickness, combined with the carbon equivalent of the steel pipe to be processed. By using different dynamic adaptive welding values ​​Wda for different steel pipes to be processed, the welding parameters are automatically adjusted to reduce downtime and improve the utilization rate and production efficiency of the unit.

[0011] The environmental adaptability welding value algorithm unit is used to take the dynamically adapted welding value Wda as an input parameter and combine it with the degree of deviation of the ambient temperature and humidity from the optimal value to calculate the environmental adaptability welding value Wca after adjustment of ambient temperature and humidity, so as to reduce welding defects caused by environmental factors and improve the welding quality of finished welded pipes.

[0012] The welding speed adjustment algorithm unit is used to calculate the adjusted welding speed Vnew when the environmental adaptability welding value Wca is less than 0.6 times the dynamic adaptation welding value Wda. This is done by taking the dynamic adaptation welding value Wda and the environmental adaptability welding value Wca as input parameters and combining them with the unit's current load power. Subsequent welding speeds are then reduced based on the adjusted welding speed Vnew to improve welding accuracy and reduce welding defects caused by environmental changes and high unit loads.

[0013] Optionally, the collection of welding information by the high-frequency straight seam welded pipe unit specifically includes:

[0014] The welding speed Vw is obtained in real time by a wheel encoder installed inside the welding assembly;

[0015] The thickness Mt of the steel pipe is obtained by measuring with a laser thickness gauge.

[0016] The carbon equivalent Cmn is obtained from the material quality certificate that comes with the steel pipe when it leaves the factory.

[0017] The ambient temperature Ta is obtained in real time through a temperature sensor;

[0018] The ambient humidity Ha is obtained in real time through a humidity sensor;

[0019] The current load power Lp and maximum load power Tp of the unit are obtained by monitoring with a power meter.

[0020] Optionally, the calculation logic of the dynamic adaptation welding value algorithm unit is as follows:

[0021] S11, the arctangent value of the ratio of welding speed Vw to reference speed V0 is calculated by the arctangent function. It is used to reflect the influence of the deviation of welding speed Vw from reference speed V0 on the dynamic adaptation welding value Wda. When the deviation is low, the characteristics of the arctangent function can sensitively reflect small changes in speed. When the speed difference is large, the rate of change will gradually slow down to avoid excessive influence on the dynamic adaptation welding value Wda in the calculation when the speed difference is large.

[0022] S12, by adding a zero constant 1 to the steel pipe thickness Mt, the influence of the steel pipe thickness Mt on the dynamic adaptation welding value Wda is mapped to the logarithmic growth range through a logarithmic function, so as to reflect the nonlinear influence of the steel pipe thickness Mt on the dynamic adaptation welding value Wda.

[0023] Optionally, the nonlinear effect of the steel pipe thickness Mt on the dynamically adapted welding value Wda is as follows:

[0024] Since the effect of steel pipe thickness Mt on the welding process is nonlinear, thinner steel pipes are more sensitive to changes in welding speed, while thicker steel pipes, due to their larger heat capacity, are relatively less responsive to changes in welding speed. The properties of the logarithmic function are used to smooth out this nonlinear effect, making the adjustment of welding parameters more in line with actual process requirements.

[0025] Optionally, the calculation logic of the environmental adaptability welding value algorithm unit is as follows:

[0026] S21, the absolute difference between ambient temperature Ta and ideal temperature Topt is standardized by using the temperature deviation from the reference value Trange to reflect the impact of the ambient temperature Ta deviating from the ideal temperature Topt on the calculation of the environmental adaptability welding value Wca.

[0027] S22, the absolute difference between ambient humidity Ha and ideal humidity Hopt is standardized by the humidity deviation from the reference value Hrange, so as to reflect the impact of the ambient humidity Ha deviating from the ideal humidity Hopt on the calculation of the environmental adaptability welding value Wca.

[0028] Optionally, the calculation logic of the welding speed adjustment value algorithm unit is as follows:

[0029] S31, the ratio obtained by dividing the environmentally adaptable welding value Wca by the dynamically adapted welding value Wda, represents the deviation of the environmentally adaptable welding value Wca from the dynamically adapted welding value Wda after being affected by environmental temperature and humidity.

[0030] As the ratio decreases, the larger the deviation value of the deviation term, the greater the influence of ambient temperature and humidity on the straight seam welded pipe unit. This reduces the calculated adjusted welding speed Vnew and improves welding accuracy, thereby reducing the adverse effects of ambient temperature and humidity on the straight seam welded pipe.

[0031] Optionally, the calculation logic of the welding speed adjustment value algorithm unit includes:

[0032] S32 uses a logarithmic function to map the influence value of the deviation term to the logarithmic interval. As the ratio decreases, the calculated adjusted welding speed Vnew decreases, and the decrease slows down to avoid over-adjustment of the welding speed Vw.

[0033] Optionally, the calculation logic of the welding speed adjustment value algorithm unit also includes:

[0034] S33, by dividing the current load power Lp by the maximum load power Tp, reflects the ratio between the current load and the maximum load. Specifically:

[0035] When the current load power Lp approaches the maximum load power Tp, it means that the load power of the straight seam welded pipe unit has reached its limit. In order to reduce the load power of the straight seam welded pipe unit, the welding speed is adjusted to half of the original speed.

[0036] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0037] I. This invention, through the cooperation of a dynamic adaptation welding value algorithm unit, an environmental adaptability welding value algorithm unit, and a welding speed adjustment value algorithm unit within the calculation processing module, constitutes the core architecture of a high-precision transmission high-frequency straight seam welded pipe unit control system. The dynamic adaptation welding value Wda calculated by the dynamic adaptation welding value algorithm unit comprehensively reflects the influence of carbon equivalent and steel pipe thickness on the welding process. Based on this influence value, the control system automatically adjusts the welding speed, ensuring that welding is always performed in the optimal state, improving the high precision of high-frequency straight seam welded pipe welding and transmission. Furthermore, this method of intelligently controlling and dynamically adjusting welding parameters in the straight seam welded pipe unit can reduce downtime caused by different parameters of the processed steel pipes, improve equipment utilization and production efficiency, reduce unnecessary energy consumption, and thus reduce production costs. It solves the problem that traditional straight seam welded pipe units require workers to frequently stop the machine to adjust welding parameters based on operational experience during the straight seam welded pipe process to adapt to different steel pipe thicknesses and carbon equivalents.

[0038] Second, this invention uses an environmental adaptability welding value algorithm unit to comprehensively consider the deviation of ambient temperature Ta from the ideal temperature Topt and the deviation of ambient humidity Ha from the ideal temperature Hopt, and calculates the environmental adaptability welding value Wca. This allows the control system within the high-frequency straight seam welded pipe unit to dynamically adjust the welding parameters of the high-frequency straight seam welded pipe unit according to changes in ambient temperature and humidity. This dynamic adjustment method ensures that the welding process remains stable under different environmental conditions, reduces welding defects caused by environmental factors, improves the internal and external quality of the weld, and guarantees the high precision of the straight seam welded pipe unit welding.

[0039] Third, this invention uses the welding speed adjustment algorithm unit as the basis for calculation, taking into account the deviation of the environmentally adaptable welding value Wca from the dynamically adapted welding value Wda after the influence of ambient temperature and humidity, as well as the ratio between the current load and the maximum load, to calculate the adjusted welding speed Vnew. This allows the welding speed to more accurately match the current welding conditions, helping to reduce welding defects caused by environmental changes and high unit loads, improving the accuracy of the welded pipe after welding. Furthermore, reducing the welding speed through the calculation of the welding speed adjustment algorithm unit can reduce the load on the unit and avoid overload operation of the equipment. This helps protect the key components of the unit, extend the service life of the equipment, and monitor the load power in real time and adjust the welding speed to keep the unit operating within a safe and stable load range. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the overall structure of a high-precision transmission control system for a high-frequency straight seam welded pipe unit. Detailed Implementation

[0041] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] Example 1, please refer to Figure 1 The present invention provides a high-precision transmission high-frequency straight seam welded pipe unit, including a control system, which specifically includes;

[0043] The data collection module is used for collecting welding information from the high-frequency straight seam welded pipe unit, specifically including:

[0044] The welding speed Vw is obtained in real time by a wheel encoder installed inside the welding assembly;

[0045] The thickness Mt of the steel pipe is obtained by measuring with a laser thickness gauge.

[0046] The carbon equivalent Cmn is obtained from the material quality certificate that comes with the steel pipe when it leaves the factory.

[0047] The ambient temperature Ta is obtained in real time through a temperature sensor;

[0048] The ambient humidity Ha is obtained in real time through a humidity sensor;

[0049] The current load power Lp and maximum load power Tp of the unit are obtained by monitoring with a power meter.

[0050] The computational processing module includes:

[0051] The dynamic adaptive welding value algorithm unit is used to calculate the dynamic adaptive welding value Wda based on the adjustment value of the welding speed relative to the reference speed under the influence of the steel pipe thickness, combined with the carbon equivalent of the steel pipe to be processed. By using different dynamic adaptive welding values ​​Wda for different steel pipes to be processed, the welding parameters are automatically adjusted to reduce downtime and improve the utilization rate and production efficiency of the unit.

[0052] The environmental adaptability welding value algorithm unit is used to take the dynamically adapted welding value Wda as an input parameter and combine it with the degree of deviation of the ambient temperature and humidity from the optimal value to calculate the environmental adaptability welding value Wca after adjustment of ambient temperature and humidity, so as to reduce welding defects caused by environmental factors and improve the welding quality of finished welded pipes.

[0053] The welding speed adjustment algorithm unit is used to calculate the adjusted welding speed Vnew by taking the dynamic adaptation welding value Wda and the environmental adaptation welding value Wca as input parameters and combining them with the current load power of the unit when the environmental adaptability welding value Wca is less than 0.6 times the dynamic adaptation welding value Wda. The subsequent welding speed is then reduced according to the adjusted welding speed Vnew to improve welding accuracy and reduce welding defects caused by environmental changes and high unit load.

[0054] In this embodiment:

[0055] This invention utilizes a dynamic adaptive welding value (Wda) calculated by a dynamic adaptive welding value algorithm unit. This value comprehensively reflects the influence of carbon equivalent and steel pipe thickness on the welding process, ensuring that the welding process is always performed under optimal conditions. This reduces downtime and improves equipment utilization and production efficiency. This method of dynamically adjusting welding parameters through intelligent control in straight seam welded pipe units reduces unnecessary energy consumption, thereby lowering production costs. It solves the problem of traditional straight seam welded pipe units requiring workers to frequently stop the machine to adjust welding parameters based on operational experience to adapt to different steel pipe thicknesses and carbon equivalents. Furthermore, the intelligent control of this system improves the stability and consistency of the welding process, reduces the impact of human factors on welding quality, ensures high precision in the quality of each welded pipe, and significantly improves the quality and stability of the weld.

[0056] The environmental adaptability welding value algorithm unit calculates the environmental adaptability welding value Wca by comprehensively considering the deviation of the ambient temperature Ta from the ideal temperature Topt and the deviation of the ambient humidity Ha from the ideal temperature Hopt. This allows the control system within the high-frequency straight seam welded pipe unit to dynamically adjust the welding parameters of the high-frequency straight seam welded pipe unit according to changes in ambient temperature and humidity. This dynamic adjustment method ensures that the welding process remains stable under different environmental conditions, reduces welding defects caused by environmental factors, such as porosity and cracks, and guarantees the high precision of the finished product after welding.

[0057] The welding speed adjustment algorithm unit uses the baseline welding speed V0 as the calculation basis and comprehensively considers the deviation of the environmentally adaptable welding value Wca from the dynamically adapted welding value Wda after the influence of ambient temperature and humidity, as well as the ratio between the current load and the maximum load, to calculate the adjusted welding speed Vnew. This allows the welding speed to more accurately match the current welding conditions, helping to reduce welding defects caused by environmental changes (such as temperature and humidity fluctuations) or high unit loads, and improving the quality of the welded pipe after welding. Furthermore, reducing the welding speed through the calculation of the welding speed adjustment algorithm unit can reduce the unit load and avoid equipment overload operation. This helps protect the unit's key components (such as motors and transmission systems), extend the service life of the equipment, and monitor the load power in real time and adjust the welding speed to keep the unit operating within a safe and stable load range.

[0058] Please see Figure 1 The algorithm unit for dynamically adapting welding values ​​is as follows:

[0059]

[0060] in:

[0061] Wda represents the dynamically adapted welding value;

[0062] Vw represents the welding speed, which is monitored and obtained in real time by a wheel encoder installed inside the welding assembly;

[0063] V0 represents the reference speed, which is the reference speed for welding. The preset value is 2m / min.

[0064] Mt represents the thickness of the steel pipe, which refers to the thickness of the steel pipe being processed, obtained by measuring it with a laser thickness gauge;

[0065] Cmn represents carbon equivalent, which refers to the carbon equivalent of the steel pipe to be processed. The higher the carbon equivalent, the greater the hardening tendency of the material and the stronger the sensitivity to welding cracks. It can be obtained from the material quality certificate that comes with the steel pipe when it leaves the factory.

[0066] α represents the sensitivity coefficient, with a default value of 1.2;

[0067] This section calculates the arctangent value of the ratio of welding speed Vw to reference speed V0 using the arctangent function. This reflects the impact of the deviation of welding speed Vw from the reference speed V0 on the dynamically adapted welding value Wda. Specifically:

[0068] Due to the properties of the arctangent function, in When this ratio is close to 1, the change is steep, and when the ratio is far from 1, the change is gradual. This means that when the welding speed Vw is not much different from the reference speed V0, the arctangent function can more sensitively reflect small changes in speed. When the speed difference is large, its rate of change will gradually slow down to avoid excessive influence in the calculation of the dynamically adapted welding value Wda, so as to make the control of the welding process more stable and reasonable.

[0069] This section maps the influence of the steel pipe thickness Mt on the dynamically adapted welding value Wda to a logarithmic growth range by adding a zero constant 1 to the steel pipe thickness Mt, and then using a logarithmic function. This reflects the nonlinear influence of the steel pipe thickness Mt on the dynamically adapted welding value Wda. Specifically:

[0070] Since the influence of steel pipe thickness Mt on the welding process is often non-linear, thinner materials may be more sensitive to changes in welding speed, while thicker materials, due to their larger heat capacity, may respond relatively slowly to changes in welding speed. Using a logarithmic function can smooth out this non-linear effect, making the adjustment of welding parameters more in line with actual process requirements. When the steel pipe thickness Mt is small... This portion increases rapidly with the increase of steel pipe thickness Mt, reflecting the sensitivity of thin plates to changes in welding speed. However, when the steel pipe thickness Mt is large, The slowdown in this growth rate reflects the relative insensitivity of thick plates to changes in welding speed;

[0071] pass This part of the molecule is divided by This denominator, this ratio, represents the dynamic adjustment value of the welding speed relative to the reference speed under the influence of the steel pipe thickness Mt. As the welding speed Vw increases or the steel pipe thickness Mt decreases, the calculated dynamic adaptation welding value Wda increases.

[0072] This part uses a logarithmic transformation by adding a division constant of 1 to the carbon equivalent Cmn, which is used to compress the dynamic range of the data. Even if the carbon equivalent value is very large, the value of its logarithmic term will not increase indefinitely, thus avoiding excessive influence on the dynamically adapted welding value Wda when the carbon equivalent Cmn reaches an extreme value. Specifically:

[0073] The logarithmic effect term of the carbon equivalent Cmn in this part indicates that as the carbon equivalent Cmn of the steel pipe to be processed increases, the hardening tendency of the steel pipe to be processed is greater, the sensitivity to cold cracking during welding is stronger, and the welding difficulty increases. It is necessary to compensate for the process difficulty by reducing the welding rate. The value of this denominator is increased to reduce the calculated dynamic adaptation welding value Wda;

[0074] In this embodiment:

[0075] The dynamically adapted welding value Wda, calculated by the dynamic adaptation welding value algorithm unit, comprehensively reflects the influence of welding speed and steel pipe thickness on the welding process. By adjusting key parameters such as welding current and welding speed in real time, it can ensure that the welding process is always carried out in the optimal state, significantly improving the quality and stability of the weld. Carbon equivalent is a key indicator for measuring the weldability of steel. It comprehensively reflects the influence of carbon and other alloying elements in steel on the hardening tendency and cold crack sensitivity of the weld heat-affected zone. By incorporating the carbon equivalent Cmn of the steel pipe to be processed into the calculation of the dynamic adaptation welding value algorithm unit, welding defects (such as cold cracks and porosity) caused by excessive carbon equivalent can be effectively avoided, thereby significantly improving the internal and external quality of the weld.

[0076] Traditional straight seam welded pipe units without a control system require workers to frequently stop the machine to adjust welding parameters based on their experience during the welding process, adapting to different steel pipe thicknesses and carbon equivalents. However, the dynamic adaptation welding value algorithm unit can calculate and adjust welding parameters in real time, reducing downtime and improving equipment utilization and production efficiency. This method of dynamically adjusting welding parameters through intelligent control in straight seam welded pipe units can reduce unnecessary energy consumption, thereby lowering production costs. Furthermore, the intelligent control of this system can improve the stability and consistency of the welding process, reduce the impact of human factors on welding quality, and ensure that the quality of each welded pipe meets high standards.

[0077] Please see Figure 1 The environmental adaptability welding value algorithm unit is as follows:

[0078]

[0079] in:

[0080] Wca represents the environmentally adaptable welding value;

[0081] Wda represents the dynamically adapted welding value, which is calculated by the dynamic adapted welding value algorithm unit;

[0082] Ta represents the ambient temperature, which is the temperature during the straight seam welding of the steel pipe. It is obtained in real time through a temperature sensor. Ta∈[20,30]. When the ambient temperature is below 20 degrees, the value is 20, and when the ambient temperature is above 30 degrees, the value is 30.

[0083] Topt represents the ideal temperature, which is the ideal value of the ambient temperature. It is taken as the median value of the suitable temperature range for straight seam welded pipe operation. Specifically:

[0084] When the ambient temperature is low, the metal cools down faster, which can lead to abnormal metallographic structure and a decrease in the mechanical properties of the weld, such as increased brittleness, reduced impact resistance, and even cold cracking. When the ambient temperature is too high, it will accelerate the thermal aging of equipment (such as the accelerated aging of circuit boards and cable insulation), increase the discomfort of workers, and indirectly affect the accuracy of operation. It is necessary to strengthen ventilation and heat dissipation. The most suitable ambient temperature range for straight seam welding of steel pipes is 15℃ to 35℃. The ideal temperature Topt = (15+35) / 2 = 25℃. When the temperature is below 5℃, the induction heater should be turned on to preheat the welding material. When the temperature exceeds 40℃, the workshop ventilation should be strengthened and the air conditioning system should be configured to lower the workshop temperature.

[0085] Trange represents the temperature deviation from the reference value, which is half of the suitable temperature range for straight seam welded pipe operation. The temperature deviation from the reference value Trange = (35-15) / 2 = 10.

[0086] Ha represents the ambient humidity, which is the air humidity during the straight seam welding of the steel pipe. It is obtained in real time through a humidity sensor. Ha∈[45, 55]. When the ambient humidity is below 45 degrees, the value is 45, and when the ambient humidity is above 55 degrees, the value is 55.

[0087] Hopt represents ideal humidity, which is the ideal value of ambient humidity. It is taken as the median value of the suitable humidity range for straight seam welded pipe operation. Specifically:

[0088] When the humidity in the workshop is too high, water vapor will seep into the molten pool, forming hydrogen porosity defects. At the same time, it will increase the hydrogen content of the weld metal, reduce toughness, and increase the risk of delayed cracking. When the humidity is too low, the risk of static electricity accumulation will increase, which will interfere with the stability of electronic components of the equipment. The most suitable ambient temperature range for straight seam welding of steel pipes is 40% to 60%, and the ideal humidity Hopt = (40 + 60) / 2 = 50.

[0089] Hrange represents the humidity deviation from the baseline value, which is half of the suitable temperature range for straight seam welded pipe operation. The humidity deviation from the baseline value Hrange = (60-40) / 2 = 10.

[0090] This part, obtained by subtracting the ideal temperature Topt from the ambient temperature Ta, is standardized using the temperature deviation from the baseline value Trange. This reflects the impact of the ambient temperature deviating from the optimal value on the environmental adaptability welding value. The square of this standardized difference is used as the minuend of 1. This represents the degree of deviation between the ambient temperature Ta and the ideal temperature Topt. The greater the deviation of the ambient temperature Ta from the ideal temperature Topt, the greater this deviation becomes. Environmental adaptability welding value Wca;

[0091] Similarly, this part The degree of deviation between ambient humidity (Ha) and ideal temperature (Hopt) is as greater as the deviation of ambient humidity (Ha) from ideal temperature (Hopt) increases. The lower the value, the lower the calculated environmental adaptability welding value Wca;

[0092] In this embodiment, the environmental adaptability welding value algorithm unit calculates the environmental adaptability welding value Wca by comprehensively considering the deviation of ambient temperature Ta from the ideal temperature Topt and the deviation of ambient humidity Ha from the ideal temperature Hopt. This enables the control system within the high-frequency straight seam welded pipe unit to dynamically adjust the welding parameters of the unit according to changes in ambient temperature and humidity. This dynamic adjustment ensures that the welding process remains stable under different environmental conditions, thereby reducing welding defects caused by environmental factors, such as porosity and cracks, and significantly improving the internal and external quality of the weld. Furthermore, the environmental adaptability welding value Wca calculated by the algorithm unit comprehensively reflects the adaptability of the welding process under the current environmental conditions. Based on the environmental adaptability welding value Wca, key parameters such as welding current and welding speed of the high-frequency straight seam welded pipe unit can be further optimized to ensure that the welding process is always carried out in the best condition.

[0093] Please see Figure 1 The algorithm unit for adjusting the welding speed is as follows:

[0094]

[0095] in:

[0096] Vnew represents the adjusted welding speed;

[0097] V0 represents the reference speed, which is the reference speed for welding. The preset value is 2m / min.

[0098] Wda represents the dynamically adapted welding value;

[0099] Wca represents the environmentally adaptable welding value;

[0100] Lp represents the current load power, which is the actual power consumed by the straight seam welded pipe unit during operation, and is obtained through monitoring by a power meter;

[0101] Tp represents the maximum load power, which is the load power of the straight seam welded pipe unit at full power output. It is obtained through monitoring by a power meter.

[0102] This part, calculated by dividing the environmentally adaptable welding value Wca by the dynamically adapted welding value Wda, represents the deviation of the environmentally adaptable welding value Wca from the dynamically adapted welding value Wda after being affected by ambient temperature and humidity. Specifically:

[0103] along with The decrease in this ratio means that the greater the difference between the environmentally adaptable welding value Wca and the dynamically adapted welding value Wda, the greater the deviation of the deviation term, which means that the straight seam welded pipe unit is more affected by the ambient temperature and humidity at this time. This reduces the calculated adjusted welding speed and improves the welding accuracy in order to reduce the adverse effects of ambient temperature and humidity on the straight seam welded pipe.

[0104] Using a logarithmic function, the influence value of this deviation term is mapped to the logarithmic interval, as... The reduction in this ratio will decrease the calculated adjusted welding speed Vnew, but the reduction will be slower to avoid over-adjustment of the welding speed.

[0105] This part reflects the ratio between the current load power Lp and the maximum load power Tp. Specifically:

[0106] When the current load power Lp approaches the maximum load power Tp, it means that the load power of the straight seam welded pipe unit has reached its limit. The value approaches The load power of the straight seam welded pipe unit is adjusted so that the welding speed is reduced to half of its original value. Here, the square root function is used to amplify the effect of adjusting the welding speed under low load, making the influence of load changes on the welding speed more sensitive.

[0107] In this embodiment:

[0108] When the environmental adaptability welding value Wca is less than 0.6 times the dynamic adaptation welding value Wda, the calculation within the welding speed adjustment algorithm unit is triggered. The welding speed adjustment algorithm unit uses the reference speed V0 during welding as the calculation basis and comprehensively considers the deviation of the environmental adaptability welding value Wca from the dynamic adaptation welding value Wda after the influence of environmental temperature and humidity, as well as the ratio between the current load and the maximum load, to calculate the adjusted welding speed Vnew. This allows the welding speed to more accurately match the current welding conditions, which helps to reduce welding defects caused by environmental changes (such as temperature and humidity fluctuations) or high unit loads, and improves the quality of the welded pipe after welding.

[0109] Furthermore, when the load power Lp is close to the maximum load power Tp, it indicates that the unit is under a large load. At this time, the welding speed can be reduced by calculating the welding speed adjustment value algorithm unit, which can reduce the load on the unit and avoid overload operation of the equipment. This helps to protect the key components of the unit (such as motors, transmission systems, etc.) and extend the service life of the equipment. Real-time monitoring of load power and adjustment of welding speed can keep the unit operating within a safe and stable load range, which helps to reduce equipment failures and downtime caused by overload, and improve equipment utilization and production efficiency.

[0110] This dynamic parameter adjustment method enables the control system within the straight seam welded pipe unit to form an adjustable closed-loop framework, allowing the straight seam welded pipe unit to adapt to various complex operating environments, making it worthy of promotion and use.

[0111] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-precision transmission high-frequency straight seam welded pipe unit, characterized in that, The system includes a control system, which specifically includes: The data collection module is used to collect welding information of the high-frequency straight seam welded pipe unit. The welding information includes steel pipe thickness, welding speed, carbon equivalent, ambient temperature, ambient humidity and current load power. The data preprocessing module decodes and preprocesses the welding information to obtain the calculation parameters in the calculation processing module. The computational processing module includes: The dynamic adaptation welding value algorithm unit is used to calculate the dynamic adaptation welding value Wda based on the adjustment value of the welding speed relative to the reference speed under the influence of the steel pipe thickness, combined with the carbon equivalent of the steel pipe to be processed. By using different dynamic adaptation welding values ​​Wda for different steel pipes to be processed, the welding parameters are automatically adjusted to reduce downtime. Specifically, the formula for calculating the dynamic adaptation welding value Wda is as follows: ； in: Vw represents welding speed, V0 represents reference speed, Mt represents steel pipe thickness, Cmn represents carbon equivalent, and α represents sensitivity coefficient. The environmental adaptability welding value algorithm unit is used to take the dynamically adapted welding value Wda as input parameter and combine it with the degree of deviation of the ambient temperature and humidity from the optimal value to calculate the environmental adaptability welding value Wca after adjustment of ambient temperature and humidity, so as to reduce welding defects caused by environmental factors. Specifically, the formula for calculating the environmental adaptability welding value Wca is as follows: ； in: Ta represents ambient temperature, Topt represents ideal temperature, Trange represents temperature deviation from the baseline value, Ha represents ambient humidity, Hopt represents ideal humidity, and Hrange represents humidity deviation from the baseline value. The welding speed adjustment algorithm unit is used to calculate the adjusted welding speed Vnew by taking the dynamic adaptation welding value Wda and the environmental adaptation welding value Wca as input parameters when the environmental adaptability welding value Wca is less than 0.6 times the dynamic adaptation welding value Wda. The adjusted welding speed Vnew is then used to reduce the subsequent welding speed to improve welding accuracy. Specifically, the formula for calculating the adjusted welding speed Vnew is as follows: ； in: V0 represents the base speed, Lp represents the current load power, and Tp represents the maximum load power.

2. The high-precision transmission high-frequency straight seam welded pipe unit according to claim 1, characterized in that: The collection of welding information for the high-frequency straight seam welded pipe unit specifically includes: The welding speed Vw is obtained in real time by a wheel encoder installed inside the welding assembly; The thickness Mt of the steel pipe is obtained by measuring with a laser thickness gauge. The carbon equivalent Cmn is obtained from the material quality certificate that comes with the steel pipe when it leaves the factory. The ambient temperature Ta is obtained in real time through a temperature sensor; The ambient humidity Ha is obtained in real time through a humidity sensor; The current load power Lp and maximum load power Tp of the unit are obtained by monitoring with a power meter.

3. The high-precision transmission high-frequency straight seam welded pipe unit according to claim 1, characterized in that: The calculation logic of the dynamic adaptation welding value algorithm unit is as follows: S11, the arctangent value of the ratio of welding speed Vw to reference speed V0 is calculated by the arctangent function. It is used to reflect the influence of the deviation of welding speed Vw from reference speed V0 on the dynamic adaptation welding value Wda. When the deviation is low, the characteristics of the arctangent function can sensitively reflect small changes in speed. When the speed difference is large, the rate of change will gradually slow down to avoid excessive influence on the dynamic adaptation welding value Wda in the calculation when the speed difference is large. S12, by adding a zero constant 1 to the steel pipe thickness Mt, the influence of the steel pipe thickness Mt on the dynamic adaptation welding value Wda is mapped to the logarithmic growth range through a logarithmic function, so as to reflect the nonlinear influence of the steel pipe thickness Mt on the dynamic adaptation welding value Wda.

4. The high-precision transmission high-frequency straight seam welded pipe unit according to claim 3, characterized in that: The nonlinear effect of the steel pipe thickness Mt on the dynamically adapted welding value Wda is specifically addressed by the fact that the influence of the steel pipe thickness Mt on the welding process is nonlinear. Thinner steel pipes are more sensitive to changes in welding speed, while thicker steel pipes, due to their larger heat capacity, are relatively less responsive to changes in welding speed. The characteristics of a logarithmic function are used to smooth out this nonlinear effect.

5. The high-precision transmission high-frequency straight seam welded pipe unit according to claim 1, characterized in that: The calculation logic of the environmental adaptability welding value algorithm unit is as follows: S21, the absolute difference between ambient temperature Ta and ideal temperature Topt is standardized by using the temperature deviation from the reference value Trange to reflect the impact of the ambient temperature Ta deviating from the ideal temperature Topt on the calculation of the environmental adaptability welding value Wca. S22, the absolute difference between ambient humidity Ha and ideal humidity Hopt is standardized by the humidity deviation from the reference value Hrange, so as to reflect the impact of the ambient humidity Ha deviating from the ideal humidity Hopt on the calculation of the environmental adaptability welding value Wca.

6. The high-precision transmission high-frequency straight seam welded pipe unit according to claim 1, characterized in that: The calculation logic of the welding speed adjustment value algorithm unit includes: S31, the ratio obtained by dividing the environmentally adaptable welding value Wca by the dynamically adapted welding value Wda, represents the deviation of the environmentally adaptable welding value Wca from the dynamically adapted welding value Wda after being affected by environmental temperature and humidity. As the ratio decreases, the larger the deviation value of the deviation term, the greater the influence of ambient temperature and humidity on the straight seam welded pipe unit. This reduces the calculated adjusted welding speed Vnew and improves welding accuracy, thereby reducing the adverse effects of ambient temperature and humidity on the straight seam welded pipe.

7. A high-precision transmission high-frequency straight seam welded pipe unit according to claim 6, characterized in that: The calculation logic of the welding speed adjustment value algorithm unit also includes: S32 uses a logarithmic function to map the influence value of the deviation term to the logarithmic interval. As the ratio decreases, the calculated adjusted welding speed Vnew decreases, and the decrease slows down to avoid over-adjustment of the welding speed Vw.

8. A high-precision transmission high-frequency straight seam welded pipe unit according to claim 6, characterized in that, The calculation logic of the welding speed adjustment value algorithm unit also includes: S33, by dividing the current load power Lp by the maximum load power Tp, reflects the ratio between the current load and the maximum load. Specifically: When the current load power Lp approaches the maximum load power Tp, it means that the load power of the straight seam welded pipe unit has reached its limit. In order to reduce the load power of the straight seam welded pipe unit, the welding speed is adjusted to half of the original speed.

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