Welding device and method for factory piping special-shaped pipe section

Abstract

The invention discloses a factory piping special-shaped pipe section welding device and method.The welding device comprises a stand column, a cross beam capable of moving up and down is arranged on the stand column, a rotating disc is arranged on the cross beam and connected with one end of a to-be-welded steel pipe, and the other end of the to-be-welded steel pipe is provided with a to-be-welded special-shaped pipe section; a main body of the steel pipe to be welded is arranged on the rotating tire; the welding method comprises the following steps that S1, a three-dimensional model is established; s2, correcting the three-dimensional model; s3, assigning the quality of the three-dimensional model; s4, determining the gravity center of the three-dimensional model; s5, balancing the weight of the three-dimensional model; and S6, automatic welding is conducted. The automatic welding device has the beneficial effects that through the arrangement of the balance weight part, the overall gravity center of the to-be-welded steel pipe, the to-be-welded special-shaped pipe section and the balance weight part is adjusted to the rotation center line of the to-be-welded steel pipe, and the welding quality problem and the operation safety problem caused by unstable clamping of the to-be-welded steel pipe in the automatic welding process are avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of factory piping automatic welding, and in particular to a welding device and method for factory piping special-shaped pipe sections. Background Art

[0002] Factory-based piping is a modern construction model that transfers the pipeline installation process to the factory for standardized, modular design and prefabrication to improve efficiency, quality, and safety. It is a key technical direction in engineering fields such as the power, petroleum, chemical, marine, and nuclear industries. Submerged arc welding is an efficient and stable welding method that plays a vital role in factory-based piping. In industrial automated welding, a welding positioner's rotary table typically clamps the pipe ends for rotational welding. This method is suitable for regular pipe sections with axisymmetric geometry. When welding irregularly shaped structures with large eccentricities, such as heavy elbows or tees, manual welding is often used. Traditional submerged arc welding clamping processes face two technical challenges: Regarding mechanical system stability, the rated load of the rotary table clamping mechanism is mismatched with the dynamic imbalance characteristics of eccentric pipe fittings. The dynamic imbalance caused by the eccentricity of the pipe structure results in cyclical alternating stresses in the transmission system. This asymmetric loading not only accelerates fatigue fracture in the transmission gears but also leads to progressive instability in the fixture system, posing a risk of workpiece loss. In terms of welding process stability, the angular velocity fluctuations caused by the rotational motion of the eccentric pipe directly interfere with the steady-state operation of the wire feeding mechanism. At the same time, the dynamic spacing changes between the welding gun and the weld trajectory change the arc characteristics, resulting in the destruction of welding parameter stability, and ultimately causing quality problems such as poor weld formation and uneven penetration.

[0003] The patent with publication number "CN118543938" discloses "a welding method for a catheter with a TKY node", which adjusts the center of gravity of the node segment by welding a counterweight branch pipe to the catheter. However, it mainly focuses on the welding of double straight pipe structures and does not conduct in-depth discussion of complex structures and calculation details, resulting in certain limitations in its application scenarios.

[0004] Patent publication number "CN117773434" discloses a "roller weld counterweight device, installation method, and arc-shaped weldment welding method." This method primarily utilizes a counterweight mounting frame to mount a counterweight on an arc-shaped weldment with an eccentric moment, thereby adjusting the center of gravity of the roller weld assembly containing the arc-shaped weldment. However, the counterweight mounting frame is complex and difficult to install, resulting in numerous problems during use.

[0005] Patent publication number "CN206811405" discloses "an automatic welding counterweight device". By adding a counterweight device at the other end of the eccentric end of the pipe to be welded, the weights can be increased or decreased according to actual needs, thereby eliminating various problems caused by the eccentricity of the pipe. However, when it is used, a lot of time is required to increase or decrease the weights, affecting the company's production efficiency.

[0006] The paper, "Application of a Balanced Counterweight Method for Submerged Arc Automatic Welding of Ultra-Large Diameter Pipes" (Welding Technology, published in September 2024), utilizes the lever principle to offset the eccentric moment during rotary welding by welding an elbow of the same material and specification as the pipe to be welded at the end point of the straight pipe. However, this method requires the provision of components of the same specifications and spot welding on the parent material, which results in insufficient flexibility and localized thermal damage to the parent material. Summary of the Invention

[0007] The purpose of the present invention is to provide a welding device and method for factory-produced special-shaped pipe sections, which can calculate the center of gravity of the pipe section to be welded in advance, thereby conveniently and quickly installing the counterweight part and greatly improving the welding efficiency.

[0008] To achieve the above object, the present invention adopts the following technical solutions:

[0009] A welding device for factory-produced special-shaped pipe sections includes a column, a horizontal beam that can move up and down is provided on the column, a turntable is provided on the horizontal beam, the turntable is connected to one end of the steel pipe to be welded, the other end of the steel pipe to be welded is provided with the special-shaped pipe section to be welded, the main body of the steel pipe to be welded is provided on the turntable, and the steel pipe to be welded is provided with a counterweight.

[0010] Preferably, the device further comprises a track for reciprocating movement of a rotor, wherein the rotor has a rotating wheel in contact with the outer edge of the steel pipe to be welded.

[0011] Preferably, the counterweight portion includes a counterweight block, which is arranged on a counterweight frame, and the counterweight frame is further provided with a chain which is sleeved on the outside of the steel pipe to be welded.

[0012] Preferably, the present application also provides a method for welding factory-produced special-shaped pipe sections, based on the aforementioned welding device for factory-produced special-shaped pipe sections, comprising the following steps:

[0013] S1. 3D model establishment: Based on the design drawings, a combined 3D model of the steel pipe to be welded and the special-shaped pipe section to be welded is established;

[0014] S2. 3D model correction: Correct the details of the 3D model based on the on-site measurement data;

[0015] S3, 3D model quality assignment: assigning quality attributes to the modified 3D model;

[0016] S4. Determine the center of gravity of the 3D model: Import the 3D model into the finite element software and assign mass attributes to determine the center of gravity of the 3D model;

[0017] S5. Balance weight of the three-dimensional model: According to the principle of moment balance, analyze and calculate the parameters of the required counterweight part, and correct the center of gravity of the three-dimensional model to the cross-sectional center of the steel pipe to be welded;

[0018] S6. Automatic welding: hoist the steel pipe to be welded onto the turntable and fix it through the turntable, lock the counterweight part at the determined position of the steel pipe to be welded, and rotate the steel pipe to be welded to complete the welding work of the girth weld.

[0019] Preferably, in step S5, the three-dimensional model balancing weight further comprises the following steps:

[0020] S51. Selection of counterweights: Determine the mass values ​​of the steel pipes to be welded and the special-shaped pipe sections to be welded using finite element software, and select counterweights with similar mass;

[0021] S52, counterweight three-dimensional model establishment, correction and mass assignment: the counterweight block, counterweight frame and chain are respectively subjected to three-dimensional model establishment, correction and mass assignment according to the requirements of the above steps S1, S2 and S3;

[0022] S53, Discrete Component Gravity Center Positioning: Based on the finite element software analysis, determine the mass and gravity center coordinates of the steel pipe to be welded, the special-shaped pipe section to be welded, and the counterweight;

[0023] S54. Calculation of centroid of combined pipe sections: Simplify the welded structure of the steel pipe to be welded, the special-shaped pipe section to be welded, and the counterweight, and analyze and calculate the coordinates of the overall centroid of the three using finite element software;

[0024] S55. Determine the coordinates of the counterweight: Calculate the coordinates of the center of mass of the counterweight based on the moment balance principle, and adjust the center of mass of the steel pipe to be welded, the special-shaped pipe section to be welded, and the counterweight to the center axis of the displacement movement of the three as a whole;

[0025] S56. Safety verification of pipe segment displacement: Based on the established finite element models of the steel pipe to be welded, the special-shaped pipe segment to be welded and the counterweight part, set appropriate boundary conditions, simulate the actual welding displacement process, and verify the correction effect of the counterweight scheme.

[0026] Preferably, in steps S4 and S54, the calculation formula for the overall centroid coordinates is:

[0027]

[0028] Preferably, in step S56, the specific steps of the safety verification are: according to the coordinates of the counterweight part calculated in step S55, and in combination with the finite element model established in the above steps S4 and S52, appropriate boundary conditions are set to simulate the pipe section welding displacement process, and at the same time, stress monitoring points are defined on the turntable, and the rotation angle-stress curve of the pipe section welding and the stress cloud map of the key orientation are drawn, and then the stress change law and trend of the pipe section during the welding displacement process are analyzed to verify the correction effect of the counterweight scheme.

[0029] Preferably, in step S6, the automatic welding further comprises the following steps:

[0030] S61. Hoisting of pipes to be welded: hoist the preliminarily connected steel pipes to be welded and the special-shaped pipe sections to be welded to the turntable, and clamp the ends of the steel pipes to be welded by the turntable;

[0031] S62, counterweight installation: Fix the counterweight block to the counterweight frame by spot welding, hoist the counterweight frame onto the steel pipe to be welded, and use chains for preliminary fixation. Then, accurately position and adjust according to the calculation results of step S5, and finally use chains to firmly lock the counterweight;

[0032] S63. Welding of special-shaped pipe sections: Use a turntable to rotate the steel pipe to be welded and monitor its operating parameters. After it reaches a stable state, start welding work.

[0033] Preferably, the operating parameters in step S63 include the current, electromagnetic torque and input power of the motor.

[0034] The beneficial effects of the present invention are:

[0035] 1. Significant equipment cost advantages: Based on the modular upgrade and transformation of the existing submerged arc automatic welding equipment in the workshop, the overall center of gravity of the steel pipe to be welded, the special-shaped pipe section to be welded, and the counterweight unit is adjusted to the rotation center line of the steel pipe to be welded through the setting of the counterweight unit, avoiding welding quality problems and operation safety issues caused by unstable clamping of the steel to be welded during the automated welding process.

[0036] 2. Low material loss and labor cost: The counterweight part and the steel pipe to be welded adopt a detachable connection design and are fixed by temporary welding points. After welding, they can be quickly separated by simply grinding and removing the welding points, thus realizing the complete recovery and recycling of the counterweight unit. The counterweight block can be made of the leftover material processed by the piping factory, without the need for additional procurement or customization, and no usage cost.

[0037] 3. High welding efficiency: 3D models and finite element models of special-shaped pipe segments are established. The center of gravity is located and corrected based on the finite element model. The counterweight parameters are analyzed and calculated and used in welding. This significantly expands the application scope of submerged arc automatic welding, reduces on-site adjustment time, improves overall construction efficiency, and reduces enterprise production costs.

[0038] 4. High forming quality: Mathematical models are used to accurately predict and adjust the balance state of special-shaped components. Combined with measured dimensional data and component material properties, a dedicated counterweight solution is developed to effectively reduce trial and error costs, avoid local thermal damage to the parent material caused by spot welding, and enhance the stability of welding parameters to ensure good weld formation and uniform penetration.

[0039] 5. Good equipment stability and safety: The present invention uses model simulation technology to effectively avoid the welding risk of pipe sections when the eccentric torque is too large, eliminate in advance the stability imbalance of the mechanical system that may occur during construction, ensure the stable and reliable operation of the equipment, and effectively prevent the workpiece from falling off, greatly improving the safety during the construction process. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 Schematic diagram of the structure for welding a tee joint to a steel pipe;

[0041] Figure 2 Schematic diagram of the structure for welding an elbow to a steel pipe.

[0042] The accompanying drawings are for illustrative purposes only and are not to be construed as limitations on this patent. To better illustrate this embodiment, some components of the accompanying drawings may be omitted, enlarged, or reduced in size, and do not represent the actual dimensions of the product. For those skilled in the art, it is understandable that some well-known structures and their descriptions may be omitted from the accompanying drawings. DETAILED DESCRIPTION

[0043] The present invention will be further described below with reference to the accompanying drawings.

[0044] Example 1

[0045] like Figure 1 and Figure 2 As shown, a welding device for factory-produced special-shaped pipe sections of piping includes a column 11, a crossbeam 12 that can move up and down is provided on the column 11, a turntable 10 is provided on the crossbeam 12, the turntable 10 is connected to one end of the steel pipe 3 to be welded, and the other end of the steel pipe 3 to be welded is provided with a special-shaped pipe section to be welded, the main body of the steel pipe 3 to be welded is provided on the turntable 6, and a counterweight portion is provided on the steel pipe 3 to be welded.

[0046] In this embodiment, the column 11, the crossbeam 12, and the turntable 10 form a welding positioner. The crossbeam 12 can drive the turntable 10 to move up and down along the column 11 under motor control. The turntable 10 is similar to the chuck of a lathe and can be opened (to remove or insert the steel pipe 3 to be welded) or clamped (to fix the inserted steel pipe 3 to be welded), and drives the steel pipe 3 to be welded to rotate. This equipment is conventional equipment in the workshop and will not be described in detail in this embodiment.

[0047] In this embodiment, the special-shaped pipe sections to be welded are mainly divided into two types, namely Figure 1 The three-way component 100 or Figure 2 In the elbow component 200, the part indicated by the number 2 is the weld between the special-shaped pipe section to be welded and the steel pipe 3 to be welded. Before welding, the two are preliminarily connected by spot welding, and then the two are hoisted onto the turntable 6 by the overhead crane, and one end of the turntable 10 is clamped and fixed. Then, the counterweight part is installed at the appropriate position, and the steel pipe 3 to be welded is driven to rotate by the turntable 10. At this time, the annular weld 2 can be automatically welded by the welding machine.

[0048] In this embodiment, the steel pipe 3 to be welded is a homogeneous regular geometric body, that is, the density at any position of the steel pipe is uniformly distributed without gradient changes, and the cross-sectional dimensions at any position along the longitudinal direction are consistent without local differences.

[0049] This device also includes a track 9 for the reciprocating movement of the tire 6. According to the length of the steel pipe 3 to be welded, the tire 6 can reciprocate along the track 9 to achieve reliable support for steel pipes of different lengths. Moreover, according to the length of the steel pipe 3 to be welded, the number of tires 6 can also be freely set. Figure 1 and Figure 2 The turntable 6 has two rotating wheels that contact the outer edge of the steel pipe 3 to be welded. The two rotating wheels are provided. The steel pipe 3 to be welded is hoisted into the gap between the two rotating wheels and can be stably rotated under the drive of the turntable 10.

[0050] The counterweight section includes a counterweight block 4, which is mounted on a counterweight frame 5. The counterweight frame 5 is also provided with a chain that is sleeved around the outside of the steel pipe 3 to be welded. One end (fixed end) of the chain is fixedly connected to the counterweight frame 5, and the other end (movable end) is detachably connected to the counterweight frame 5. When in use, the counterweight block 4 is first spot-welded to the counterweight frame 5, and the movable end of the chain is then removed from the counterweight frame 5. The chain is then wrapped around the outside of the steel pipe 3 to be welded. After the counterweight frame 5 is moved to a designated position, the chain is tightened and its movable end is fixed to the counterweight frame 5, thereby fixing the counterweight section to the steel pipe 3 to be welded. In this embodiment, in order to better secure the counterweight section, the chains are symmetrically arranged at two locations, namely a first chain 7 and a second chain 8. The structure of the counterweight section is conventional technology and will not be described in detail in this embodiment.

[0051] The present application also provides a method for welding factory-produced special-shaped pipe sections, based on the aforementioned factory-produced special-shaped pipe section welding device, comprising the following steps:

[0052] S1. 3D model establishment: Based on the design drawings, a combined 3D model of the steel pipe 3 to be welded and the special-shaped pipe section to be welded is established;

[0053] The special-shaped pipe sections to be welded are mainly tees 100 or elbows 200. First, combining the design institute's blueprints and factory configuration drawings, a three-dimensional model of the steel pipes, elbows, tees and other component models and the combined models of each component is established. That is, using interactive drawing software such as Revit, SolidEdge, SolidWorks and AutoCAD, the shape design of each component and the combined pipe section is completed to obtain a three-dimensional model of the pipe section to be welded.

[0054] S2. 3D model correction: Correct the details of the 3D model based on the on-site measurement data;

[0055] According to the design drawings, the actual dimensions of the pipelines and various combined structural parts are measured using measuring tools such as laser rangefinders, tape measures and levels. The on-site measurement data are compared with the dimensional data in the model. Each component in the model is corrected and standardized one by one, and the model data of each component is organized and archived to facilitate the retrieval and management of subsequent piping process data.

[0056] S3, 3D model quality assignment: assigning quality attributes to the modified 3D model;

[0057] For each combined component of the factory piping, the steel grade of the component in the design drawing is checked to see whether it corresponds to the three-dimensional model in the above step S2.

[0058] S4. Determine the center of gravity of the 3D model: Import the 3D model into the finite element software and assign mass attributes to determine the center of gravity of the 3D model;

[0059] Select appropriate structural analysis finite element software, such as ANSYS, Abaqus, or SolidWorks Simulation. Import the 3D model created by the drawing software in step S2 into the finite element software. Select an appropriate mesh type and size based on the geometric characteristics of the pipe segment and the required calculation accuracy. At the same time, assign the mass attributes determined in step S3 to the model to determine the center of gravity of the entire special-shaped pipe segment.

[0060] S5. Balance the weight of the 3D model: Based on the principle of moment balance, the fixed position, mass, and locking angle of the weight are determined through analysis and calculation. The center of gravity of the 3D model is corrected to the cross-sectional center of the steel pipe to be welded. The finite element software is used for simulation verification. This step also includes the following detailed steps:

[0061] S51. Selection of counterweights: Determine the mass values ​​of the steel pipes and special-shaped pipe sections to be welded using finite element software, and select counterweights with similar masses. To facilitate subsequent model establishment and calculation of the center of mass of the counterweight device, the counterweights should be homogeneous and regularly shaped geometric bodies, such as steel pipe sections, cubic iron blocks, etc.

[0062] S52, counterweight three-dimensional model establishment, correction and mass assignment: according to the requirements of the steel pipe to be welded and the special-shaped pipe section to be welded in steps S1, S2 and S3 above, the counterweight block, counterweight frame and chain are respectively subjected to three-dimensional model establishment, correction and mass assignment;

[0063] S53, Discrete Component Gravity Center Positioning: Based on the finite element software analysis, determine the mass and gravity center coordinates of the steel pipe to be welded, the special-shaped pipe section to be welded, and the counterweight;

[0064] S54. Calculation of centroid of combined pipe sections: Simplify the welded structure of the steel pipe to be welded, the special-shaped pipe section to be welded, and the counterweight, and analyze and calculate the coordinates of the overall centroid of the three using finite element software;

[0065] The geometric center of the steel pipe 3 to be welded is stipulated as the coordinate origin O(0,0,0). Since the steel pipe 3 to be welded is a homogeneous regular geometric body, its center of mass coordinates are (0,0,0) and its mass is m0; the center of mass coordinates of the special-shaped pipe section to be welded are (x1,y1,z1) and its mass is m1; the center of mass coordinates of the counterweight block 4 are (x2,y2,z2) and its mass is m2; the center of mass coordinates of the counterweight frame 5 are (x3,y3,z3) and its mass is m3; the center of mass coordinates of the first chain 7 are (x4,y4,z4) and its mass is m4; the center of mass coordinates of the second chain 8 are (x5,y5,z5) and its mass is m5.

[0066] like Figure 1 As shown, in this embodiment, the origin 0 of the coordinate system is located at the geometric center of the steel pipe 3 to be welded, wherein the extension direction of the x-axis is consistent with the extension direction of the steel pipe 3 to be welded, the extension direction of the z-axis is consistent with the extension direction of the column 11, and the extension direction of the y-axis is parallel to the line connecting the two wheels of the tire 6.

[0067] To facilitate analysis and calculation, the special-shaped pipe section is simplified into a system composed of multiple mass points. The calculation formula of the overall centroid coordinates is:

[0068]

[0069] S55. Determine the coordinates of the counterweight: Based on the principle of moment balance, calculate the coordinates of the center of mass of the counterweight. Correct the center of gravity of the steel pipe 3 to be welded, the special-shaped pipe section to be welded, and the counterweight to the center axis of displacement motion of the three as a whole. This means that the center of mass coordinates of the rotating whole must be (x, 0, 0). The displacement motion center axis here is the center line of the steel pipe 3 to be welded (parallel to the extension direction of the steel pipe 3 to be welded), which is also the center line of rotation of the pipe section during welding. This step ensures that the center of mass coordinates of the rotating whole are located on the center line of the steel pipe 3 to be welded.

[0070] In the above step S51, it is stipulated that the counterweight block should be a homogeneous and regular-shaped geometric body. For the convenience of calculation, the counterweight block 4, the counterweight frame 5, the first chain 7 and the second chain 8 can be simplified into an integral structure. The coordinates of the center of mass of the integral counterweight structure are (x p ,y p , z p ), the total mass is m p According to the above moment balance conditions: y = 0, z = 0, so:

[0071] m1y1+m p y p =0

[0072] m1z1+m p z p =0

[0073]

[0074] According to the moment balance, the coordinates of the center of mass of the counterweight are (x, y p , z p ), no eccentric torque will be generated during the rotation and position welding of the pipe section.

[0075] S56. Safety verification of pipe segment displacement: Based on the established finite element model of the steel pipe to be welded 3, the special-shaped pipe segment to be welded and the counterweight part, set appropriate boundary conditions, simulate the actual welding displacement process, and verify the correction effect of the counterweight scheme.

[0076] According to the coordinates of the counterweight part calculated in step S55, and in combination with the finite element model established in the above steps S4 and S52, appropriate boundary conditions are set to simulate the pipe section welding displacement process. At the same time, stress monitoring points are defined on the turntable 10, and the rotation angle-stress curve of the pipe section welding and the stress cloud diagram of the key orientation are drawn. Then, the stress change law and trend of the pipe section during the welding displacement process are analyzed to verify the correction effect of the counterweight scheme.

[0077] After the special-shaped pipe section and the counterweight are accurately positioned and safety calculated, automatic welding of the pipe section can be performed in the factory piping scenario, that is, step S6.

[0078] S6. Automatic welding: hoist the steel pipe 3 to be welded onto the turntable 6 and fix it through the turntable 10, lock the counterweight part at a determined position of the steel pipe 3 to be welded, and rotate the steel pipe 3 to complete the welding work of the girth weld 2.

[0079] In step S6, the automatic welding further comprises the following steps:

[0080] S61. Hoisting the Pipes to Be Welded: The preliminarily connected steel pipes 3 and the irregularly shaped pipe sections to be welded are hoisted onto the turntable 6, and the ends of the steel pipes 3 to be welded are clamped by the turntable 10. During the factory piping process, before the automated welding process, the preliminarily connected steel pipes 3 and the irregularly shaped pipe sections to be welded are firstly connected through assembly and manual welding.

[0081] S62, counterweight installation: Fix the counterweight block 4 to the counterweight frame 5 by spot welding, hoist the counterweight frame 5 onto the steel pipe 3 to be welded, and use chains to preliminarily fix it. Then, accurately position and adjust it according to the calculation results of step S5, and finally use chains to firmly lock the counterweight;

[0082] S63, special-shaped pipe welding: Use the turntable 10 to rotate the steel pipe 3 to be welded, monitor its operating parameters, and start welding after it reaches a stable state. The operating parameters include the motor current, electromagnetic torque, and input power.

[0083] The present application solves the following problems through the above welding device and welding method:

[0084] 1. In order to solve the eccentric moment problem in the welding of special-shaped components, the purpose of symmetrical geometric compensation is achieved by spot welding components of the same specifications. However, there are problems such as insufficient flexibility and local thermal damage to the base material.

[0085] 2. The center of gravity offset of the weldment is estimated based on manual experience, and the counterweight compensation is performed through trial and error. The construction process is cumbersome and may lead to poor welding quality due to excessive correction errors, and even require weld repair.

[0086] 3. Due to the lack of model simulation analysis, welding is performed under conditions where the eccentric torque is too large, and there is a potential risk of sudden failure of the entire component.

[0087] The above embodiments do not impose any formal restrictions on the shape, material, structure, etc. of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are within the scope of protection of the technical solution of the present invention.

[0088] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the protection content of the present invention.

[0089] If words such as "A" and "B" are used in this document to limit components, those skilled in the art should know that the use of "A" and "B" is only for the convenience of describing the present invention and simplifying the description. Unless otherwise stated, the above words have no special meaning.

[0090] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A welding device for factory-produced special-shaped pipe sections, comprising a column, characterized in that: The column is provided with a beam that can move up and down, and the beam is provided with a turntable. The turntable is connected to one end of the steel pipe to be welded, and the other end of the steel pipe to be welded is provided with a special-shaped pipe section to be welded. The main body of the steel pipe to be welded is provided on the turntable, and the steel pipe to be welded is provided with a counterweight.

2. The welding device for special-shaped pipe sections of factory-produced piping according to claim 1, characterized in that: The utility model also comprises a track for reciprocating movement of a rotor, wherein the rotor has a rotor in contact with the outer edge of the steel pipe to be welded.

3. The welding device for factory-produced special-shaped pipe sections according to claim 1, characterized in that: The counterweight part includes a counterweight block, which is arranged on a counterweight frame. The counterweight frame is also provided with a chain which is sleeved on the outside of the steel pipe to be welded.

4. A method for welding factory-produced special-shaped pipe sections, based on the welding device for factory-produced special-shaped pipe sections according to claim 3, characterized in that: The following steps are involved: S1. 3D model establishment: Based on the design drawings, a combined 3D model of the steel pipe to be welded and the special-shaped pipe section to be welded is established; S2. 3D model correction: Correct the details of the 3D model based on the on-site measurement data; S3, 3D model quality assignment: assigning quality attributes to the modified 3D model; S4. Determine the center of gravity of the 3D model: Import the 3D model into the finite element software and assign mass attributes to determine the center of gravity of the 3D model; S5. Balance weight of the three-dimensional model: According to the principle of moment balance, analyze and calculate the parameters of the required counterweight part, and correct the center of gravity of the three-dimensional model to the cross-sectional center of the steel pipe to be welded; S6. Automatic welding: hoist the steel pipe to be welded onto the turntable and fix it through the turntable, lock the counterweight part at the determined position of the steel pipe to be welded, and rotate the steel pipe to be welded to complete the welding work of the girth weld.

5. The method for welding special-shaped pipe sections in factory piping according to claim 4, characterized in that: In step S5, the three-dimensional model balancing weight further includes the following steps: S51. Selection of counterweights: Determine the mass values ​​of the steel pipes to be welded and the special-shaped pipe sections to be welded using finite element software, and select counterweights with similar mass; S52, counterweight three-dimensional model establishment, correction and mass assignment: the counterweight block, counterweight frame and chain are respectively subjected to three-dimensional model establishment, correction and mass assignment according to the requirements of the above steps S1, S2 and S3; S53, Discrete Component Gravity Center Positioning: Based on the finite element software analysis, determine the mass and gravity center coordinates of the steel pipe to be welded, the special-shaped pipe section to be welded, and the counterweight; S54. Calculation of centroid of combined pipe sections: Simplify the welded structure of the steel pipe to be welded, the special-shaped pipe section to be welded, and the counterweight, and analyze and calculate the coordinates of the overall centroid of the three using finite element software; S55. Determine the coordinates of the counterweight: Calculate the coordinates of the center of mass of the counterweight based on the moment balance principle, and adjust the center of mass of the steel pipe to be welded, the special-shaped pipe section to be welded, and the counterweight to the center axis of the displacement movement of the three as a whole; S56. Safety verification of pipe segment displacement: Based on the established finite element models of the steel pipe to be welded, the special-shaped pipe segment to be welded and the counterweight part, set appropriate boundary conditions, simulate the actual welding displacement process, and verify the correction effect of the counterweight scheme.

6. The method for welding special-shaped pipe sections in factory piping according to claim 5, characterized in that: In steps S4 and S54, the calculation formula for the overall centroid coordinates is:

7. The method for welding special-shaped pipe sections in factory piping according to claim 5, characterized in that: In step S56, the specific steps of the safety verification are: according to the coordinates of the counterweight part calculated in step S55, and in combination with the finite element model established in the above steps S4 and S52, appropriate boundary conditions are set to simulate the pipe section welding displacement process, and at the same time, stress monitoring points are defined on the turntable, and the rotation angle-stress curve of the pipe section welding and the stress cloud diagram of the key orientation are drawn, and then the stress change law and trend of the pipe section during the welding displacement process are analyzed to verify the correction effect of the counterweight scheme.

8. The method for welding special-shaped pipe sections in factory piping according to claim 4, characterized in that: In step S6, the automatic welding further comprises the following steps: S61. Hoisting of pipes to be welded: hoist the preliminarily connected steel pipes to be welded and the special-shaped pipe sections to be welded to the turntable, and clamp the ends of the steel pipes to be welded by the turntable; S62, counterweight installation: Fix the counterweight block to the counterweight frame by spot welding, hoist the counterweight frame onto the steel pipe to be welded, and use chains for preliminary fixation. Then, accurately position and adjust according to the calculation results of step S5, and finally use chains to firmly lock the counterweight; S63. Welding of special-shaped pipe sections: Use a turntable to rotate the steel pipe to be welded and monitor its operating parameters. After it reaches a stable state, start welding work.

9. The method for welding special-shaped pipe sections in factory piping according to claim 8, characterized in that: The operating parameters in step S63 include the current, electromagnetic torque and input power of the motor.

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