A method for rapid back welding of long welds in metal structures based on automatic welding machines

Abstract

The present application relates to the field of welding, in particular to a kind of long weld of metal structure based on automatic welding machine Quick back-off welding method.The automatic welding method used includes track and trolley, trolley is sequentially installed with scanning equipment, heat treatment equipment, welding equipment and inspection equipment in the direction of travel.The equipment moves from one end of weld to the other end in section when running, scanning equipment is mapped and modeled to the new section of passage each time, then by heat treatment equipment, welding equipment and inspection equipment respectively to the weld in the task section where each is located and carries out pre-welding task heat treatment, welding and post-welding quality inspection, wherein, any one task section can complete all welding procedures after three consecutive task periods.Long weld containing N task sections also only needs N+2 task periods to complete all welding operations.The technical scheme provided by the present application can effectively shorten the welding time of long weld, improve welding efficiency and safety.

Description

Technical Field

[0001] This invention relates to the field of welding, and in particular to a rapid unwelding method for long welds in metal structures based on an automatic welding machine. Background Technology

[0002] The installation of large metal structures is frequently involved in water conservancy and hydropower engineering projects. For example, the installation of metal structures in hydropower stations includes protective pressure pipes, gates, trash racks, and various opening and closing devices. Except for the pressure pipes, which are mostly manufactured on-site, the majority of these components are manufactured in factories, arriving as finished or semi-finished products, and then assembled and installed on-site. Large metal structural components are typically fabricated in the factory as modular units, then welded together on-site for installation. Therefore, metal structure installation often involves a large number of long weld seams.

[0003] When welding metal structures, the weld seam is heated and then cooled back to room temperature. Due to the principle of thermal expansion and contraction, the material generally deforms after welding. The amount of deformation in localized areas is affected by the welding position, welding speed, and changes in weld heat. Therefore, to avoid localized deformation affecting project quality, welding of long weld seams in metal structures is usually not done in a single operation, but rather using a segmented back-welding process. The segmented back-welding process involves dividing the weld joint into several segments and welding each segment separately, with the welding direction of each segment opposite to the overall weld growth direction.

[0004] Many engineering construction projects have strict construction period requirements. For example, certain water conservancy facilities need to complete certain project milestones before the flood season. Therefore, the welding of metal structural components also needs to be carried out with maximum efficiency and completed within a short period of time. However, the special requirements of welding technology for long welds in metal structural components mean that construction units cannot simultaneously arrange multiple welders to perform welding to improve efficiency. In addition, welding tasks for such large metal structures generally involve high operational difficulty and limited operating environment. Welding operations may also require heat treatment of the workpiece and heat preservation during the welding process. For these reasons, the welding cycle for metal structural components with numerous long welds is often relatively long. How to effectively improve the welding efficiency of such welding tasks has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] To address the challenges of welding long weld seams in metal structures, including high welding difficulty and low welding efficiency, this invention provides a rapid unwelding method for long weld seams in metal structures based on an automatic welding machine.

[0006] The technical solution provided by this invention is as follows:

[0007] A rapid uncoiling method for long welds in metal structures based on an automatic welding machine is disclosed. The automatic welding machine comprises a track extending along the weld direction and a trolley mounted on it. A scanning device is installed at the front of the trolley. The trolley contains three adjacent working chambers, each with a length ΔL along the track direction. Heat treatment equipment, welding equipment, and inspection equipment are sequentially installed in these chambers from front to back. The trolley, scanning equipment, heat treatment equipment, welding equipment, and inspection equipment are electrically connected to a host computer.

[0008] Using the aforementioned automatic welding machine, the rapid unsoldering method provided by this invention includes the following steps:

[0009] The automatic welding machine is mounted on a support frame above the target area to be welded. The weld seam to be welded is divided into N task segments according to ΔL.

[0010] At the start of each work cycle, the trolley is driven forward a distance ΔL, and the morphology of the i-th task segment along the path is scanned by the scanning device. The host computer analyzes the scan data to generate the operating parameters of the heat treatment equipment, welding equipment and inspection equipment when processing the corresponding task segment, thereby completing the scanning task.

[0011] After the scanning task is completed, the trolley remains braked and simultaneously performs the following actions to complete the processing task:

[0012] A. Drive the heat treatment equipment to perform pre-welding heat treatment on the i-th task segment that has been scanned, according to the preset operating parameters.

[0013] B. Drive the welding equipment to weld the (i-1)th task segment that has completed pre-welding heat treatment in the opposite direction to the trolley's forward direction according to the preset operating parameters.

[0014] C. Drive the inspection equipment to perform flaw detection on the i-2th task segment that has been welded, according to the preset operating parameters.

[0015] The drive trolley moves step by step from the start point to the end point of the weld, repeating the above process, and then the welding task is completed after N+2 working cycles.

[0016] As a further improvement of the present invention, the scanning device employs a depth camera; the scanning direction of the depth camera is directed towards the area to be welded below the trolley.

[0017] The host computer acquires point cloud data of the target area collected by the scanning device and performs spatial modeling of the target area based on the point cloud data. Alternatively, the host computer acquires a pre-established BIM model and obtains the spatial information of the target area based on the BIM model.

[0018] The host computer runs a weld seam recognition algorithm based on depth images. The weld seam recognition algorithm is used to identify the weld seam to be welded in the target area based on the depth image obtained by the scanning device, and to locate the weld seam by combining the modeling information or spatial information of the target area.

[0019] As a further improvement of the present invention, in each scanning task, if the trolley fails to identify and locate the weld seam after reaching the end point from the start point of the current work cycle, the trolley is driven back to the end point of the previous work cycle, and then the trolley's running speed is reduced before rescanning.

[0020] As a further improvement of the present invention, the total duration T of any working cycle is equal to the sum of the scanning task duration Ta and the processing task duration Tb.

[0021] The processing time Tb = max{t1, t2, t3}; where t1 represents the shortest heat treatment time for the current task segment; t2 represents the shortest welding time for the current task segment; and t3 represents the shortest flaw detection time for the current task segment.

[0022] As a further improvement of the present invention, the heat treatment equipment includes a flame heater and a first actuator. The nozzle of the flame heater is a linear nozzle containing multiple flame outlets, and is arranged in a direction perpendicular to the track within the trolley. Each flame outlet in the nozzle is controlled to be shut off by a solenoid valve, and the first actuator is used to drive the nozzle to move in a direction parallel to the track within the corresponding working chamber of the trolley.

[0023] The operating parameters of the heat treatment equipment generated by the host computer include: the on / off status code of the flame nozzle, the movement trajectory and speed of the nozzle, the start and end times of the heat treatment, and the opening degree of the gas valve at the supply end.

[0024] As a further improvement of the invention, the first actuator in the heat treatment equipment is a linear slide; the nozzle of the flame heater is mounted inside the trolley via the linear slide. The fuel tank of the flame heater is located outside the trolley and is connected to the nozzle via pipes and a gas valve.

[0025] As a further improvement of the present invention, the welding equipment includes a welding system and a second actuator, the second actuator being used to drive the welding torch in the welding system to move freely within the corresponding working chamber in the trolley.

[0026] The operating parameters of the welding equipment generated by the host computer include: welding current, wire feed speed, welding torch position and movement speed.

[0027] As a further improvement of the present invention, the second actuator in the heat treatment equipment adopts a bionic robotic arm or a gantry manipulator; the welding torch in the welding system is installed inside the trolley via a bionic robotic arm or a gantry manipulator. The welding machine, wire feeder, and shielding gas storage tank in the welding system are located outside the trolley. The welding body is electrically connected to the welding torch via a cable, and the shielding gas storage tank is connected to the welding torch via a pipeline; the wire feeder is used to feed welding rods to the welding torch.

[0028] As a further improvement of the present invention, the inspection equipment includes a flaw detector and a third actuator. The third actuator is used to drive the probe in the flaw detector to move freely within the corresponding working chamber of the trolley. The operating parameters of the inspection equipment generated by the host computer include: the start and end times of the flaw detection operation, as well as the movement trajectory and speed of the probe.

[0029] As a further improvement of the present invention, the third actuator in the inspection equipment is a bionic robotic arm or a gantry manipulator; the probe in the flaw detector is mounted inside the trolley via the bionic robotic arm or gantry manipulator. The data processing equipment of the flaw detector is mounted outside the trolley, and the probe and the data processing equipment are connected via cable communication.

[0030] The present invention has the following beneficial effects:

[0031] The technical solution provided by this invention divides a long weld into multiple segments, and then utilizes an automated welding machine containing heat treatment equipment, welding equipment, and inspection equipment to process each task segment in parallel using a pipeline parallel strategy. As the automated welding machine moves from one end of the long weld to the other, within each task cycle, it can simultaneously perform pre-weld heat treatment, welding, and post-weld quality inspection on three adjacent different task segments. Furthermore, after the automated welding reaches the end of the long weld, the heat treatment, welding, and quality inspection operations for all task segments can be completed. Compared with the conventional segmented back-welding process, the new method provided by this invention can significantly improve the efficiency of welding operations and shorten the overall task time while ensuring welding quality. Attached Figure Description

[0032] Figure 1 This is a flowchart of the steps of the rapid unwelding method for long welds in metal structures based on an automatic welding machine provided in Embodiment 1 of the present invention.

[0033] Figure 2 This is a schematic diagram of the automatic welding machine in Embodiment 1 of the present invention.

[0034] Figure 3 This is a schematic diagram of the welding process of a welding machine task comprising four task segments in Embodiment 1 of the present invention.

[0035] Figure 4This is a schematic diagram of the heat treatment equipment in the automatic welding machine of Embodiment 1 of the present invention.

[0036] Figure 5 This is an assembly diagram of the welding equipment in the automatic welding machine of Embodiment 1 of the present invention.

[0037] The diagram is marked as follows:

[0038] 1. Track; 2. Trolley; 3. Scanning equipment; 41. Flame heater; 42. First actuator; 51. Welding torch; 52. Second actuator; 61. Probe; 62. Third actuator. Detailed Implementation

[0039] 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.

[0040] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the specification of this invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "or / and" as used herein includes any and all combinations of one or more of the associated listed items.

[0041] Example 1

[0042] This embodiment provides a rapid unwelding method for long welds in metal structures based on an automatic welding machine. This method utilizes a newly designed automatic welding machine to quickly perform segmented unwelding of metal structures with long welds, thereby significantly improving the welding efficiency of such metal structures while ensuring welding quality. In traditional methods, welding long welds in metal structures requires welders to weld each segment of the weld sequentially. Each segment requires not only high-quality welding but also pre-weld heat treatment and post-weld quality inspection, which is time-consuming and labor-intensive.

[0043] In the technical solution provided in this embodiment, construction workers can use automatic welding machines to replace manual welding tasks, and use assembly line processes to process different stages of the welding operation in parallel, thereby significantly shortening the welding time of long weld metal structures. Specifically, as... Figure 1 As shown, the rapid desoldering method provided in this embodiment includes the following process:

[0044] First, construction workers can use a scaffold to mount the automatic welding machine above the target area to be welded. In this embodiment, as... Figure 2 As shown, the automatic welding machine includes a track 1 extending along the weld direction and a trolley 2 mounted on it. A scanning device 3 is installed in front of the trolley 2. The trolley 2 includes three adjacent working chambers, each with a length ΔL along the track 1. Heat treatment equipment, welding equipment, and inspection equipment are installed sequentially from front to back in these three chambers. The trolley 2, scanning device 3, heat treatment equipment, welding equipment, and inspection equipment are electrically connected to a host computer.

[0045] In practical applications, the trolley 2 can move along the track 1. During the movement of the trolley 2, the scanning device 3 can perform a spatial scan of the area it passes through below, thereby identifying the weld seams that need to be welded and determining the spatial position and shape distribution of the weld seam area relative to the equipment coordinate system of the automatic welding machine. Next, when the trolley 2 moves to the corresponding position, the heat treatment equipment can perform heat treatment on the area around the weld seam; the welding equipment can then automatically weld the weld seam after heat treatment, based on the known spatial position and shape of the weld seam; finally, the inspection equipment is used to perform quality inspection on the weld seam after welding.

[0046] Specifically, the automatic welding machine provided in this embodiment installs the heat treatment equipment, welding equipment, and inspection equipment sequentially in three different working chambers along the forward direction of the trolley 2. This ensures that when the trolley 2 advances the same distance as the length of the working chamber each time, the heat treatment equipment reaches a new area, the welding equipment reaches the area previously occupied by the heat treatment equipment, and the inspection equipment reaches the area previously occupied by the welding equipment.

[0047] Based on the aforementioned characteristics of the automatic welding machine, this embodiment further draws on pipeline technology in processor design to redesign the program for the segmented back-welding process of long weld seams in metal structures. Before welding, technicians can divide the weld seam to be welded into N task segments according to ΔL and send the corresponding welding tasks to the host computer of the automatic welding machine. After receiving the corresponding tasks, the host computer can process each task segment according to four procedures: "scanning-heat treatment-welding-quality inspection". In the working logic of the automatic welding machine designed in this embodiment, the scanning, heat treatment, welding, and quality inspection procedures required for each task segment are implemented in different task cycles; while in the same task cycle, the automatic welding machine can simultaneously perform heat treatment, welding, and quality inspection operations on three adjacent different task segments. This parallel pipeline working strategy shortens the overall welding time of long weld seams, thereby improving the execution efficiency of the segmented back-welding process for long weld seams.

[0048] Specifically, when the entire welding task comprises N task segments, the newly designed automatic welding machine described above, along with the multi-task parallel processing operation logic of the welding process provided in this embodiment, can drive the trolley 2 to move segment by segment along the track 1 from one end of the weld to the other, starting from the beginning of the weld. Once the automatic welding machine leaves the end of the weld, the welding operation for the entire long weld is completed. In the working logic of this embodiment, the entire welding operation is divided into multiple consecutive work cycles. Each work cycle includes two sub-tasks: a scanning task and a processing task, which need to be completed independently within different time sequences.

[0049] In each work cycle, the host computer drives the trolley 2 forward a distance ΔL. During this forward movement, the scanning device 3 installed at the front of the trolley passes through a completely new task segment that has not been reached before. During this process, the scanning device 3 can perform a topographic scan of the i-th task segment. The purpose of the scanning action in this embodiment is to enable the host computer to accurately model the working environment of the current task segment and identify the location coordinates and spatial distribution of the weld seams requiring welding operations within that environment. Based on the relevant information obtained from analyzing the scan data, the host computer can further generate the operating parameters for the heat treatment equipment, welding equipment, and inspection equipment when processing the corresponding task segment.

[0050] For example, the host computer can determine the location distribution of the area surrounding the weld that needs heat treatment based on information such as the weld's location; and then plan the processing area of ​​the heat treatment equipment. The trajectory of the welding torch 51 during welding is determined based on the weld's location and shape. Different welding methods are used for welds of different widths. Finally, the host computer needs to determine the area requiring weld quality inspection after welding based on the weld's location and shape, and control the flaw detector to scan the entire area completely along the corresponding trajectory.

[0051] After the scanning task is completed, trolley 2 remains braked. At this point, assuming the area scanned by trolley 2 is the i-th task segment, then the first working chamber in trolley 2 is located in the i-th task segment, the second working chamber is located in the (i-1)-th task segment, and the third working chamber is located in the (i-2)-th task segment. Next, the automatic welding machine synchronously performs the following actions to complete the processing task:

[0052] A. Drive the heat treatment equipment to perform pre-welding heat treatment on the i-th task segment that has been scanned, according to the preset operating parameters.

[0053] B. Drive the welding equipment to weld the (i-1)th task segment that has completed pre-welding heat treatment in the opposite direction to the forward direction of the trolley 2 according to the preset operating parameters.

[0054] C. Drive the inspection equipment to perform flaw detection on the i-2th task segment that has been welded, according to the preset operating parameters.

[0055] The drive trolley 2 moves from the start point to the end point of the weld seam, repeating the above process, and thus the welding task of a long weld seam containing N task segments can be completed after N+2 working cycles.

[0056] To more clearly demonstrate the advantages of the rapid unwelding method for long weld seams in metal structures based on an automatic welding machine provided in this embodiment, the following example uses a welding task comprising four task segments (denoted as L1, L2, L3, and L4) as a case study. Figure 3 The execution process of the solution in this embodiment will be described in detail below:

[0057] During the first task cycle, the automatic welding machine can scan and heat treat segment L1.

[0058] During the second task cycle, the automatic welding machine can scan and heat treat segment L2 and weld segment L1.

[0059] During the third task cycle, the automatic welding machine can scan and heat treat segment L3, weld segment L2, and perform quality inspection on segment L1.

[0060] During the fourth task cycle, the automatic welding machine can scan and heat treat segment L4, weld segment L3, and perform quality inspection on segment L2.

[0061] During the fifth task cycle, the automatic welding machine can weld the L4 segment and perform quality inspection on the L3 segment.

[0062] During the sixth task cycle, the automatic welding machine can perform quality inspection on segment L4. At this point, all segments have completed the four processes of scanning, heat treatment, welding, and quality inspection, and the welding task is successfully completed.

[0063] Analysis of the above process reveals that the rapid unwelding method provided in this embodiment can complete the rapid segmented unwelding of a long weld containing N segments in N+2 cycles. Assuming that the efficiency value obtained for completing the heat treatment, welding, and quality inspection of each task segment is 1, then in the technical solution provided in this embodiment, the heat treatment task of the first segment can be completed in the first cycle; the total efficiency value is 1. The heat treatment of the first segment and the welding task of the second segment can be completed in the second cycle; the total efficiency value is 2. The quality inspection of the last segment can only be completed in the last cycle; the total efficiency value is 1. The second-to-last cycle can only complete the welding of the penultimate segment and the quality inspection of the penultimate segment; the total efficiency value is 2. In the remaining cycles, heat treatment, welding, and quality inspection tasks can be performed simultaneously in three consecutive different segments. The total efficiency value is 3.

[0064] In the segmented back-welding process for long welds, heat treatment, welding, and post-weld quality inspection are three essential steps, and theoretically, each step must be performed in a specified order. Therefore, assuming the theoretical minimum task time for these three steps is T1, T2, and T3, then for a task comprising four segments, the total task time T required for traditional manual welding is... total For: T total = 4 × (T1 + T2 + T3).

[0065] In the solution provided in this embodiment, after adopting the aforementioned parallel pipeline working mode, the total duration T of any working cycle is equal to the sum of the scanning task duration Ta and the processing task duration Tb. When multiple tasks need to be processed in parallel, the corresponding processing cycle is equal to the task with the longest processing time. Therefore, the processing task duration Tb = max{t1, t2, t3}; where t1 represents the shortest heat treatment time of the current task segment; t2 represents the shortest welding time of the current task segment; and t3 represents the shortest flaw detection time of the current task segment.

[0066] Therefore, the total task time T required for the above four work cycles is as follows. total for:

[0067] T total =4×Ta+T1+max{T1,T2}+max{T1,T2,T3}+max{T1,T2,T3}+max{T2,T3}+T3.

[0068] In practical applications, the time required for heat treatment, welding, and quality inspection usually follows a certain relationship:

[0069] T2 > T1 > T3,

[0070] Therefore, in this embodiment,

[0071] T total = 4×Ta + T1 + 4×T2 + T3,

[0072] Compared to the total task time of traditional processes, the solution in this embodiment can shorten the process time by ΔT as follows:

[0073] △T=3×T1+3×T3-4×Ta.

[0074] In this embodiment, the scanning task only requires processing the relevant data collected by the scanning device 3 while the trolley 2 is running. The time taken for this process is much less than that taken for operations such as welding and heat treatment. Therefore, this time period Ta can be regarded as 0.

[0075] In summary, assuming a long weld seam needs to be divided into N segments during welding, the solution in this embodiment can shorten the process time of the traditional process by (N-1)T1 + (N-1)T3. Furthermore, it should be noted that when comparing the process time of this invention with the traditional process, it is assumed that the shortest time for heat treatment, welding, and quality inspection is the same for both. In practice, this embodiment uses an automatic welding machine to replace manual operations, and the operating efficiency of an automatic welding machine is generally higher than that of manual labor. Therefore, the rapid weld removal method provided in this embodiment actually shortens the process time even more than the theoretical analysis above.

[0076] In this embodiment, the scanning device 3, heat treatment device, welding device, and inspection device in the automatic welding machine respectively complete the scanning, heat treatment, welding, and quality inspection operations described above in each task segment. In practical applications, the scanning device 3 can be a depth camera; the scanning direction of the depth camera is pointed towards the area to be welded below the trolley 2.

[0077] In this embodiment, the scanning device 3 scans the target area to obtain relevant spatial and image information, thereby assisting the host computer in spatial modeling of the target area and identifying and locating welds. Therefore, the host computer can choose to acquire point cloud data of the target area collected by the scanning device 3 and perform spatial modeling of the target area based on the point cloud data. In other solutions, considering that the design unit of the metal structure to be welded in the engineering project usually provides the construction unit with a BIM model related to the metal structure, the host computer can also directly acquire a pre-established BIM model of the metal structure to be welded, and then obtain the spatial information of the target area based on the BIM model.

[0078] In addition, the host computer in this embodiment also runs a weld seam recognition algorithm based on depth images; the weld seam recognition algorithm is used to identify the weld seam to be welded in the target area based on the depth image obtained by the scanning device 3, and to realize weld seam positioning by combining the modeling information or spatial information of the target area.

[0079] In each scanning task of this embodiment, if the weld identification and positioning are not achieved after the trolley 2 reaches the end point from the start point of the current work cycle, the trolley 2 can be driven back to the end point of the previous work cycle, and then the running speed of the trolley 2 is reduced before rescanning.

[0080] In this embodiment, the function of the heat treatment equipment is to preheat the metal around the weld before welding, thereby reducing the cooling rate of the weld joint, avoiding the formation of hardened structures, reducing welding stress and deformation, and preventing welding cracks. In practical applications, this embodiment uses flame heating to heat treat the weldment. The heat treatment equipment includes a flame heater 41 and a first actuator 42, wherein, as... Figure 4 As shown, the flame heater 41 uses a linear nozzle with multiple flame outlets, arranged perpendicular to the track 1 within the trolley 2. Each flame outlet in the nozzle is controlled to shut off by a solenoid valve, and the first actuator 42 drives the nozzle to move parallel to the track 1 within its corresponding working chamber in the trolley 2. The operating parameters of the heat treatment equipment generated by the host computer include: the on / off status code of the flame outlets, the movement trajectory and speed of the nozzle, the start and end times of the heat treatment, and the opening degree of the gas valve at the supply end.

[0081] In the typical solution provided in this embodiment, the first actuator 42 in the heat treatment equipment can be a linear slide; the nozzle of the flame heater 41 is mounted inside the trolley 2 via the linear slide. The fuel tank of the flame heater 41 is located outside the trolley 2 and is connected to the nozzle via a pipe and a gas valve.

[0082] Considering that the heat treatment time in each task cycle is usually shorter than the welding time, the host computer needs to flexibly allocate the start-up timing of the heat treatment equipment based on the working time of the welding equipment. This ensures that when the current task cycle ends and the next task cycle begins, the temperature of the corresponding task segment is exactly at the target temperature suitable for welding. In practical applications, the range of the heat treatment area varies depending on the width of the weld. To address this issue, this embodiment can control the on / off state of each nozzle in the nozzle via the host computer, and coordinate with the linear slide to drive the nozzle to reciprocate along the extension direction of the weld, thereby achieving heating of an area of ​​a specified width. When the number of open nozzles changes, the host computer also needs to synchronously switch the opening degree of the gas inlet to ensure that the fuel supply adapts to the heating demand.

[0083] In this embodiment, the welding equipment is used to weld the preheated workpieces, connecting the workpieces on both sides of the weld. In traditional processes, welding requires a welding system, such as CO2 shielded welding or TIG welding. Such a welding system includes a welding torch 51, a welding machine, a wire feeder, and a shielding gas tank. The wire feeder continuously supplies welding wire to the welding torch 51. The welding machine is electrically connected to the welding torch 51, thereby providing a large current during the welding process to instantly fuse the welding wire and the workpieces together. The shielding gas tank is used to supply shielding gases such as carbon dioxide and argon to the welding area when the welding torch 51 is started, preventing localized oxidation of the material.

[0084] In this embodiment, such as Figure 5 As shown, the welding equipment includes a welding system and a second actuator 52. The second actuator 52 is used to drive the welding torch 51 in the welding system to move freely within the corresponding working chamber of the trolley 2. In practical applications, the second actuator 52 in the heat treatment equipment can be a bionic robotic arm or a gantry manipulator; the welding torch 51 in the welding system is mounted inside the trolley 2 via a bionic robotic arm or gantry manipulator. The welding machine, wire feeder, and shielding gas tank in the welding system are located outside the trolley 2. The welding body is electrically connected to the welding torch 51 via a cable, and the shielding gas tank is connected to the welding torch 51 via a pipeline; the wire feeder is used to feed welding electrodes to the welding torch 51.

[0085] At this point, the host computer can adaptively plan the movement trajectory and spatial posture of the welding torch 51 during the welding task based on the spatial information of the area to be welded already acquired in the scanning task. Then, it issues corresponding control commands to the bionic robotic arm or gantry robot. Simultaneously, the host computer also coordinates the control of the welding machine, wire feeder, and shielding gas switch on the welding torch 51, thereby automatically completing the corresponding welding task instead of manually. Typically, the operating parameters of the welding equipment generated by the host computer include: welding current, wire feed speed, welding torch 51's posture and movement speed, etc. The related technical solutions for using robotic arms to replace manual welding tasks are already very mature in fields such as automotive processing and equipment manufacturing. The technical details of this part will not be elaborated in this embodiment.

[0086] In this embodiment, the inspection equipment performs post-weld quality inspection on the corresponding task section after welding, thereby identifying potential welding defects such as porosity, slag inclusions, incomplete penetration, lack of fusion, and cracks. In practical applications, this embodiment can employ non-destructive testing methods based on X-rays or ultrasound. The inspection equipment includes a flaw detector and a third actuator 62, which drives the probe 61 in the flaw detector to move freely within the corresponding working chamber of the trolley 2. Similar to the welding equipment, the third actuator 62 in this embodiment can also be a bionic robotic arm or a gantry manipulator; the probe 61 in the flaw detector is mounted inside the trolley 2 via the bionic robotic arm or gantry manipulator. The data processing equipment of the flaw detector is mounted outside the trolley 2, and the probe 61 is connected to the data processing equipment via a cable.

[0087] In practical applications, the host computer flexibly controls the third actuator 62 to move the flaw detector to the corresponding position based on the distribution area of ​​the weld after welding, and completes the flaw detection task according to the detection path planned by the host computer. Furthermore, since the processing time of the inspection task in each task segment is shorter than that of the welding task, the host computer can also flexibly select the start time of the flaw detection task based on the task cycle length for each task cycle. Therefore, the operating parameters of the inspection equipment generated by the host computer include: the start and end times of the flaw detection operation, as well as the movement trajectory and speed of the probe 61.

[0088] In practical applications, when the flaw detector's results indicate a welding quality defect in a certain section, the higher-level operator records the relevant information and generates a quality inspection report after welding is completed. Relevant technical personnel verify the contents of the quality inspection report after welding, then make decisions based on the actual situation and implement corresponding corrective measures.

[0089] Finally, it is important to emphasize that the rapid segmented annealing method using parallel pipeline technology provided in this embodiment can be applied not only to the automatic welding machines described earlier for rapid automatic welding, but also to manual welding operations. For example, a construction team can divide its workers into three groups: heat treatment, welding, and quality inspection. The long weld can be divided into multiple task segments, and a similar strategy can be used to arrange for the three groups to work together on different task segments of the long weld to improve work efficiency. Of course, compared to machinery, manual collaborative operations are still limited by factors such as worker efficiency and operational safety, affecting the feasibility and efficiency of the solution; however, the solution based on an automatic welding machine provided earlier in this embodiment is not subject to these limitations.

[0090] The above-described embodiments are merely one implementation of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the inventive concept, and these all fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the appended claims.

Claims

1. A rapid unwelding method for long welds in metal structures based on an automatic welding machine, characterized in that, The automatic welding machine includes a track extending along the weld direction and a trolley mounted on it. A scanning device is installed in front of the trolley. The trolley contains three adjacent working chambers, each with a length of ΔL along the track direction. The three chambers are installed in sequence from front to back, including heat treatment equipment, welding equipment, and inspection equipment. The trolley, scanning device, heat treatment equipment, welding equipment, and inspection equipment are electrically connected to the host computer. Rapid desoldering methods include: The automatic welding machine is mounted on a support frame above the target area to be welded; the weld seam to be welded is divided into N task segments according to △L; At the start of each work cycle, the trolley is driven forward a distance of △L, and the path is scanned by a scanning device. i Each task segment undergoes a topographic scan; the host computer analyzes the scan data to generate operating parameters for the heat treatment equipment, welding equipment, and inspection equipment when processing the corresponding task segment, thereby completing the scanning task; After the scanning task is completed, the trolley remains braked and simultaneously performs the following actions to complete the processing task: A. Drive the heat treatment equipment to process the scanned part according to the preset operating parameters. i Each task segment undergoes pre-welding heat treatment; B. Drive the welding equipment according to the preset operating parameters in the opposite direction to the trolley's forward direction to the first stage that has completed pre-welding heat treatment. i -1 task segment is used for welding; C. Drive the inspection equipment to inspect the completed welding sections according to preset operating parameters. i - Two task segments are used for flaw detection; The drive trolley moves step by step from the start point to the end point of the weld, repeating the above process, and then the welding task is completed after N+2 working cycles.

2. The rapid unwelding method for long welds in metal structures based on an automatic welding machine according to claim 1, characterized in that: The scanning device uses a depth camera; the scanning direction of the depth camera is directed towards the area to be welded below the trolley. The host computer acquires point cloud data of the target area collected by the scanning device; The target area is spatially modeled based on point cloud data; or, the host computer acquires a pre-established BIM model and obtains the spatial information of the target area based on the BIM model. The host computer runs a weld seam recognition algorithm based on depth images; the weld seam recognition algorithm is used to identify the weld seam to be welded in the target area based on the depth image obtained by the scanning device, and to realize weld seam positioning by combining the modeling information or spatial information of the target area.

3. The rapid unwelding method for long welds in metal structures based on an automatic welding machine according to claim 1, characterized in that: In each scanning task, if the trolley fails to identify and locate the weld after reaching the end point from the start of the current work cycle, the trolley is driven back to the end point of the previous work cycle, and then the trolley's running speed is reduced before rescanning.

4. The rapid unwelding method for long welds in metal structures based on an automatic welding machine according to claim 1, characterized in that: The total duration T of any work cycle is equal to the sum of the scanning task duration Ta and the processing task duration Tb; The processing time Tb = max{t1, t2, t3}; where t1 represents the shortest heat treatment time of the current task segment; t2 represents the shortest welding time of the current task segment; and t3 represents the shortest flaw detection time of the current task segment.

5. The rapid unwelding method for long welds in metal structures based on an automatic welding machine according to claim 1, characterized in that: The heat treatment equipment includes a flame heater and a first actuator. The flame heater has a nozzle with multiple nozzles arranged in a straight line within the trolley in a direction perpendicular to the track. Each nozzle in the nozzle is shut off by a solenoid valve. The first actuator is used to drive the nozzle to move in the corresponding working chamber within the trolley in a direction parallel to the track. The operating parameters of the heat treatment equipment generated by the host computer include: the on / off status code of the flame nozzle, the movement trajectory and speed of the nozzle, the start and end times of the heat treatment, and the opening degree of the gas valve at the supply end.

6. The rapid unwelding method for long welds in metal structures based on an automatic welding machine according to claim 5, characterized in that: The first actuator in the heat treatment equipment is a linear slide; the nozzle of the flame heater is installed inside the trolley via the linear slide; the fuel tank of the flame heater is located outside the trolley and is connected to the nozzle via a pipe and a gas valve.

7. The rapid unwelding method for long welds in metal structures based on an automatic welding machine according to claim 1, characterized in that: The welding equipment includes a welding system and a second actuator, the second actuator being used to drive the welding torch in the welding system to move freely within the corresponding working chamber of the trolley; The operating parameters of the welding equipment generated by the host computer include: welding current, wire feed speed, welding torch position and movement speed.

8. The rapid unwelding method for long welds in metal structures based on an automatic welding machine according to claim 7, characterized in that: The second actuator in the heat treatment equipment is a bionic robotic arm or a gantry manipulator; the welding torch in the welding system is installed inside the trolley via a bionic robotic arm or a gantry manipulator; the welding machine, wire feeder, and shielding gas storage tank in the welding system are located outside the trolley, the welding machine body is electrically connected to the welding torch via a cable, and the shielding gas storage tank is connected to the welding torch via a pipeline; the wire feeder is used to feed welding rods to the welding torch.

9. The rapid unwelding method for long welds in metal structures based on an automatic welding machine according to claim 1, characterized in that: The inspection equipment includes a flaw detector and a third actuator, the third actuator being used to drive the probe in the flaw detector to move freely within the corresponding working chamber of the trolley; The operating parameters of the inspection equipment generated by the host computer include: the start and end times of the flaw detection operation, as well as the movement trajectory and speed of the probe.

10. The rapid unwelding method for long welds in metal structures based on an automatic welding machine according to claim 9, characterized in that: The third actuator in the inspection equipment is a bionic robotic arm or a gantry manipulator; the probe in the flaw detector is installed inside the trolley via a bionic robotic arm or a gantry manipulator; the data processing equipment of the flaw detector is installed outside the trolley, and the probe and the data processing equipment are connected via cable communication.

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