Submerged-arc welding agent laying device for transverse thick plate groove and thick plate welding method

Abstract

The invention discloses a submerged arc welding agent laying device for a transverse thick plate groove and a thick plate welding method, and relates to the technical field of transverse thick plate welding. The device comprises a welding flux discharging box which is located on one side of a transverse thick plate welding seam and provided with a first discharging opening and a second discharging opening which are used for discharging welding flux; the moving mechanism is used for driving the welding flux discharging box to move equidistantly in the welding seam direction; the welding mechanism is connected to the moving mechanism and used for executing the welding step after the groove is filled with the welding flux; and the controller is electrically connected to the moving mechanism and the welding mechanism. And in the first direction, perpendicular to the welding seam, of the transverse thick plate from the inside to the outside of the groove, the first discharging opening conducts discharging to form a first stacking area, the second discharging opening conducts discharging to form a second stacking area, and forming of the first stacking area lags behind the second stacking area. According to the method, automation, precision and high adaptability of the whole process of transverse thick plate groove submerged arc welding from welding flux laying to welding can be achieved, and the welding quality, efficiency and safety are remarkably improved.

Description

Technical Field

[0001] The present application relates to the technical field of horizontal thick plate welding, and in particular to a submerged arc welding flux laying device for a horizontal thick plate groove and a thick plate welding method. Background Art

[0002] The conventional submerged arc welding flux funnel achieves controllable flux release through a structure fixedly connected to the conductive nozzle. Its compact design is suitable for flat plate butt welding, flat fillet welds and ordinary fillet welds, and can meet the flux laying and quality control requirements under conventional working conditions. Currently, when welding horizontal thick plate fillet welds with small groove angles (groove angles of 30-35°), the rigid connection between the flux funnel and the conductive nozzle results in a large welding gun, making it difficult for the welding wire to penetrate the small groove, resulting in poor welding accessibility at the root of the groove. Furthermore, the horizontal flow channel is affected by gravity during horizontal welding, and flux tends to accumulate on one side of the groove, disrupting the uniformity of the flux spread and causing unstable arc coverage. Uneven flux distribution can cause arc deviation, resulting in fluctuations in weld size and imbalanced welding parameters, exacerbating process instability. During welding, gravity and the groove angle combine to cause slag accumulation or segregation, which weakens the protective effect of the molten pool and increases the risk of forming defects. Insufficient flux coverage at the root of the small-angle groove can also lead to defects such as lack of fusion, incomplete penetration, and porosity. Summary of the Invention The purpose of the embodiments of the present invention is to provide a submerged arc welding flux laying device for a horizontal thick plate groove and a thick plate welding method, which can solve the above-mentioned problems existing in the prior art.

[0003] To achieve the above objectives, this application adopts the following technical solutions: On the one hand, a submerged arc welding flux laying device for a horizontal thick plate groove is provided, comprising: A flux discharge box is located on one side of the weld of the horizontal thick plate and is provided with a first discharge port and a second discharge port for discharge of flux, wherein the first discharge port is located inside the welding groove of the horizontal thick plate and the second discharge port is located outside the welding groove of the horizontal thick plate; A moving mechanism, connected to the flux discharge box, for driving the flux discharge box to move equidistantly along the direction of the weld; a welding mechanism connected to the moving mechanism, configured to perform a welding step after the groove is filled with flux; and a controller electrically connected to the moving mechanism and the welding mechanism; Among them, in the first direction of the horizontal thick plate from the inside to the outside of the groove and perpendicular to the weld, the first cutting port forms a first stacking area, and the second cutting port forms a second stacking area, and the formation of the first stacking area lags behind the second stacking area.

[0004] Preferably, a storage cavity is provided in the flux discharge box, and the storage cavity is divided into a first cavity and a second cavity by a partition, the first cavity is connected to the first discharge port, and the second cavity is connected to the second discharge port.

[0005] Preferably, along the second direction of the horizontal thick plate weld, the first blanking port and the second blanking port are spaced apart, and the second blanking port is located at the front end of the moving direction of the first blanking port.

[0006] Preferably, the first discharge port and the second discharge port are respectively provided with a flow regulating mechanism, and the flow regulating mechanism comprises: an adjusting plate pivotally connected to the flux discharge box and covering the corresponding discharge opening; and A driving member, provided in the flux unloading box and driving the adjusting plate to rotate; The regulating plate adjusts the flux flow rate of the corresponding discharge port by rotating.

[0007] Preferably, the driving member is a servo motor or a stepping motor, and the adjustment plate realizes linear adjustment of the opening of the feed opening by rotating an angle θ, where θ∈[0°,90°].

[0008] Preferably, the flux discharge box is provided with a first rotating part which is relatively rotatable, the first discharge port is opened on the first rotating part, and the first rotating part is used to adjust the discharge angle of the first discharge port.

[0009] Preferably, the moving mechanism includes: A connecting box body is connected to the flux discharge box; A plurality of magnetic wheels are provided at the bottom of the connection box and are adsorbed on the surface of the horizontal thick plate; and A power source is provided on the magnetic wheel and drives the magnetic wheel to rotate, and the power source is electrically connected to the controller.

[0010] Preferably, the welding mechanism includes: a welding gun, connected to the connection box in an angle-adjustable manner; a wire feeding mechanism connected to the welding gun and feeding the welding wire; and The welding power supply is electrically connected to the welding gun, the wire feeding mechanism and the controller.

[0011] Preferably, it further comprises a sensing unit electrically connected to the controller for detecting and acquiring in real time first detection data of the flux spreading state and second detection data of the position of the flux discharge box on the horizontal thick plate; Wherein, the controller adjusts the moving speed of the moving mechanism and the discharge angle of the first discharge port in real time based on the first detection data and the second detection data.

[0012] On the other hand, the present disclosure further provides a thick plate welding method using a submerged arc welding flux laying device applied to any of the above-mentioned horizontal thick plate grooves, comprising: The flux discharge box is placed on one side of the horizontal thick plate weld so that the flux discharge box can move along the weld direction; Based on the groove angle of the horizontal thick plate, the angle of the first blanking opening is adjusted, and the first blanking opening is set inside the welding groove, and the second blanking opening is located outside the groove; Based on preset welding parameters, the discharge flow rates of the first discharge port and the second discharge port of the flux discharge box are adjusted, and the flux discharge box is driven to move equidistantly along the weld direction to form a second stacking area outside the groove and a first stacking area inside the groove; When the groove is filled with flux, the welding step is performed on the groove position of the transverse thick plate.

[0013] The beneficial effects of this application are: 1. Through the dual-stack area coordination solution, that is, through the timing and spatial coordination of "outside first, then inside", the second stacking area forms a "retaining wall" outside the groove, effectively preventing the outflow of flux from the first stacking area inside the groove, ensuring sufficient flux filling in the groove, and avoiding defects such as incomplete fusion and porosity caused by insufficient flux from the source.

[0014] 2. The dual-cavity isolation design enables classified storage of different fluxes. The flow regulating mechanism can be adjusted linearly from 0° to 90°. Combined with the angle adaptation of the first rotating part, it can accurately control the feeding rate for 30° to 90° groove angles and adapt to the filling requirements of different groove depths.

[0015] 3. The sensor unit collects the spreading status and equipment parameters in real time. The controller automatically adjusts the moving speed, material flow rate and welding gun angle through dynamic algorithms, realizing seamless connection of "detection-analysis-adjustment" and effectively avoiding manual intervention.

[0016] 4. The magnetic wheel adsorption design breaks through the limitation of horizontal working surface and can stably adapt to non-horizontal thick plate welding such as horizontal and vertical positions. The adsorption force is monitored in real time to prevent the equipment from slipping, adapt to the working conditions of uneven plate surface, and ensure the stability of equipment operation.

[0017] 5. Through structural innovation, intelligent control and process coordination, the entire process of horizontal thick plate groove submerged arc welding from flux laying to welding is automated, precise and highly adaptable, significantly improving welding quality, efficiency and safety. It is especially suitable for the high-quality welding needs of heavy structures such as ships. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The present application is further described in detail below with reference to the accompanying drawings and examples.

[0019] Figure 1 This is a schematic structural diagram of a submerged arc welding flux laying device for a horizontal thick plate groove according to an embodiment of the present application; Figure 2 This is a structural schematic diagram of a flux discharge box of a submerged arc flux laying device for a horizontal thick plate groove according to an embodiment of the present application; Figure 3 This is a structural schematic diagram of the positions of the first and second discharge ports of a flux discharge box in a submerged arc flux laying device for a horizontal thick plate groove according to an embodiment of the present application; Figure 4 This is a structural schematic diagram of the welding process of a submerged arc welding flux laying device for a horizontal thick plate groove according to an embodiment of the present application; Figure 5 This is a structural schematic diagram of a submerged arc welding flux laying device for a horizontal thick plate groove in a welding state according to an embodiment of the present application; Figure 6 This is a schematic diagram of the welding process of a horizontal thick plate according to an embodiment of the present application.

[0020] In the picture: 10. First welding plate; 11. Second welding plate; 13. Welding groove; 14. First stockpiling area; 15. Second stockpiling area; DX, first direction; DY, second direction; 100, flux discharge box; 101, first discharge port; 102, second discharge port; 110, storage chamber; 111, partition; 112, first cavity; 113, second cavity; 120, flow regulating mechanism; 121, regulating plate; 122, driving member; 130, first rotating part; 200, moving mechanism; 210, connecting box; 220, magnetic wheel; 230, power source; 300, welding mechanism; 310, welding gun; 320, wire feeding mechanism; 330, welding power source; 400. Controller. DETAILED DESCRIPTION

[0021] To make the technical problems solved by this application, the technical solutions adopted, and the technical effects achieved more clearly, the technical solutions of the embodiments of this application are further described in detail below. Obviously, the embodiments described are only part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without making any creative efforts shall fall within the scope of protection of this application.

[0022] In the description of this application, unless otherwise expressly specified or limited, the terms "connected," "connected," and "fixed" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integration; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and can refer to internal communication between two components or interaction between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0023] In this application, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Moreover, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0024] See also Figures 1 to 5 The present disclosure provides a submerged arc flux laying device for a horizontal thick plate groove, comprising a flux discharge box 100, a moving mechanism 200, a welding mechanism 300, and a controller 400. The flux discharge box 100 is located on one side of a horizontal thick plate weld and is provided with a first discharge port 101 and a second discharge port 102. The first discharge port 101 is located within the weld groove 13 of the horizontal thick plate, and the second discharge port 102 is located outside the weld groove 13 of the horizontal thick plate.

[0025] Among them, in the first direction DX of the horizontal thick plate from the inside to the outside of the groove and perpendicular to the weld, the first unloading port 101 unloads to form a first stacking area 14, and the second unloading port 102 unloads to form a second stacking area 15, and the formation of the first stacking area 14 lags behind the second stacking area 15.

[0026] Furthermore, along the second direction DY of the horizontal thick plate weld, the first unloading opening 101 and the second unloading opening 102 are spaced apart, and the second unloading opening 102 is located at the front end of the moving direction of the first unloading opening 101. With the above arrangement, the first stacking area 14 can be formed after the second stacking area 15.

[0027] It can be understood that the second feed port 102 is located outside the groove and forms the second stacking area 15 before the first feed port 101. A "retaining wall" structure can be pre-formed on the outside of the groove to effectively block the subsequent first feed port 101 from laying the flux in the groove out of the groove, ensuring that the amount of flux in the first stacking area 14 in the groove is sufficient to meet the submerged arc welding requirement for flux coverage in the groove and avoid welding defects caused by insufficient flux.

[0028] Specifically, by positioning the second discharge port 102 at the front end of the movement along the weld seam, the second stockpiling area 15 outside the groove is laid first, and the first discharge port 101 subsequently lays the first stockpiling area 14 inside the groove, forming an orderly "outside first, inside later" laying sequence. This coordination of timing and space effectively prevents interference between the fluxes from the two discharge ports, ensuring precise placement of flux both inside and outside the groove, improving laying efficiency and accuracy.

[0029] Furthermore, the first stockpiling area 14 focuses on the core welding area within the groove, ensuring sufficient flux coverage during welding, ensuring target penetration and a well-formed weld. The second stockpiling area 15 provides auxiliary protection outside the groove, helping to reduce arc leakage and protect the groove edge, further improving welding stability, reducing the risk of defects such as porosity and cracks, and overall optimizing the welding quality of horizontal thick plate grooves.

[0030] The horizontal thick plate may include a first welding plate 10 and a second welding plate 11, which are arranged vertically. A weld groove 13 is provided at the weld between the first welding plate 10 and the second welding plate 11, and the angle of the weld groove 13 is within a range of 0-45 degrees. Preferably, the angle of the weld groove 13 is 30 degrees. Therefore, during the actual welding process, flux can flow through the first discharge port 101 to form a first accumulation area 14 within the weld groove 13, and flux can flow through the second discharge port 102 to form a second accumulation area 15 outside the weld groove 13.

[0031] The moving mechanism 200 is connected to the flux discharge box 100 and drives the flux discharge box 100 to move equidistantly along the direction of the weld. By moving the flux discharge box 100 equidistantly along the direction of the weld, the flux deposited in the weld by the flux discharge box 100 can be effectively ensured to be uniform, thereby improving the subsequent welding quality.

[0032] Furthermore, the welding mechanism 300 is connected to the moving mechanism 200 and is used to perform the welding process after the groove is filled with flux. The controller 400 is electrically connected to the moving mechanism 200 and the welding mechanism 300 to control the movement speed of the moving mechanism 200 on the horizontal thick plate and to adjust the welding parameters of the welded structure during the welding process.

[0033] Specifically, to meet the welding requirements of the vertically arranged first welding plate 10 and second welding plate 11, the angle of the weld groove 13 is limited to 0-45 degrees, preferably 30 degrees. This adapts to the structural characteristics of the vertical connection between the two plates, while reducing the weld filler volume through a smaller groove angle. It also ensures the fusion depth on both sides of the groove, avoids welding material waste or welding deformation caused by an excessively large groove, and strikes a balance between welding efficiency and joint strength. It is particularly suitable for the structural stability requirements of vertical welding of thick horizontal plates.

[0034] Furthermore, the moving mechanism 200 drives the flux discharge box 100 to move equidistantly along the weld seam, ensuring uniform flux density in the first accumulation area 14 within the groove and the second accumulation area 15 outside the groove, thereby avoiding waste caused by excessive flux in certain areas or insufficient protection caused by insufficient flux. This also ensures stable flux coverage and protection of the molten pool during welding, reducing defects such as porosity and lack of fusion.

[0035] The controller 400 coordinates and controls the movement speed of the moving mechanism 200 and the welding parameters of the welding mechanism 300, such as welding current, welding voltage, and welding speed, to precisely match flux placement with the welding process. The movement speed is adapted to the flux feed rate to avoid uneven flux accumulation. Furthermore, welding parameters are dynamically adjusted based on the groove characteristics to ensure that penetration depth and weld width meet the required standards.

[0036] In one embodiment, a flux discharge box 100 is provided with a storage chamber 110. This storage chamber 110 is divided into a first chamber 112 and a second chamber 113 by a partition 111. The first chamber 112 is connected to the first discharge port 101, and the second chamber 113 is connected to the second discharge port 102. Therefore, by dividing the storage chamber 110 into two mutually isolated chambers, different types of flux can be stored within the chambers, thereby improving the actual welding effect. Furthermore, by providing two mutually isolated chambers, the first discharge port 101 and the second discharge port 102 do not interfere with each other during the discharge process.

[0037] In order to facilitate the regulation of the flux discharge rate at the first and second discharge ports 101, 102, flow rate adjustment mechanisms 120 may be provided at the first and second discharge ports 101, 102. The flow rate adjustment mechanisms 120 adjust the flux discharge rate at the first and second discharge ports 101, 102 to accommodate the flux amount required for grooves of different angles. The flux discharge rate can be precisely adjusted based on the flux amount requirements for grooves of different angles, thereby improving adaptability.

[0038] Specifically, the flow rate adjustment mechanism 120 includes an adjustment plate 121 and a driver 122. The adjustment plate 121 is pivotally connected to the flux discharge box 100 and covers the corresponding first and second discharge openings 101, 102. Thus, by rotating the adjustment plate 121, the opening size of the first or second discharge opening 101, 102 can be adjusted, thereby adjusting the flux discharge rate. The driver 122 is disposed on the flux discharge box 100 and connected to the adjustment plate 121. The driver 122 is electrically connected to the controller 400 and is used to drive the adjustment plate 121 to rotate.

[0039] Drive element 122 can be a servo motor or a stepper motor, which offers excellent controllability and can precisely adjust the rotation angle of adjustment plate 121, thereby achieving precise control of the flux feed rate. It should be noted that adjustment plate 121 linearly adjusts the feed opening opening by rotating the angle θ, where θ∈[0°,90°]. When the rotation angle is 90 degrees, the flow rate of the feed opening is maximum, and when the rotation angle is 0 degrees, the flow rate of the feed opening is zero.

[0040] Specifically, the flux feeding rate is directly controlled by pivoting the adjustment plate 121 to cover the discharge opening, changing the opening size by rotating the angle. Simultaneously, the drive member 122 is electrically connected to the controller 400, enabling automatic actuation of the adjustment plate 121, reducing manual intervention and improving operational convenience and system automation.

[0041] In one embodiment, the flux discharge box 100 is provided with a relatively rotatable first rotating portion 130, and the first discharge port 101 is formed on the first rotating portion 130. The first rotating portion 130 can rotate relative to the first discharge port 101, driving the first discharge port 101 to adjust the discharge angle, accurately adapting to grooves of different angles, ensuring that the flux fills the groove at the optimal angle, reducing problems such as uneven filling or missing fill, and significantly improving the groove filling effect.

[0042] Furthermore, the moving mechanism 200 is connected to the flux feeding box 100 and is used to drive the flux feeding box 100 to move equidistantly along the direction of the weld. By moving the flux feeding box 100 equidistantly relative to the direction of the weld, the flux filling in the groove can be effectively ensured to be evenly distributed.

[0043] As can be appreciated, the combination of the angle adjustment of the first rotating portion 130 and the equidistant movement of the moving mechanism 200 enables the device to flexibly accommodate welding requirements of varying groove angles and weld lengths, expanding its applicability. The synergistic effect of angle adaptation and uniform movement also reduces welding defects caused by flux filling issues, improving the stability and reliability of the overall welding process.

[0044] In one embodiment, the moving mechanism 200 includes a connecting box 210, a plurality of magnetic wheels 220 and a power source 230. The connecting box 210 is connected to the flux discharge box (100), and the plurality of magnetic wheels 220 are rotatably arranged at the bottom of the connecting box 210. The power source 230 is transmission-connected to the magnetic wheels 220 to drive the magnetic wheels 220 to rotate. In actual use, the magnetic wheels 220 are adsorbed on the surface of the horizontal thick plate to ensure that the moving mechanism 200 can move along the horizontal thick plate in a non-horizontal state. The magnetic wheels 220 are adsorbed on the surface of the horizontal thick plate, so that the moving mechanism 200 can move stably along the thick plate in a non-horizontal state, breaking through the dependence of traditional equipment on a horizontal working surface and being suitable for multi-angle welding scenarios. At the same time, the magnetic wheels 220 provide reliable adsorption force to prevent the equipment from slipping or offsetting during movement, ensuring that the flux discharge box 100 moves accurately and equidistantly along the weld direction, thereby improving the uniformity of flux filling.

[0045] It should be noted that power source 230 utilizes a servo motor and is electrically connected to controller 400. In actual practice, controller 400 can be used to adjust the speed of flux feed box 100 across the horizontal thick plate by regulating power source 230. The servo motor, acting as power source 230, works in conjunction with controller 400 to precisely control the speed of movement. This allows for dynamic adjustment based on welding process requirements, adapting to varying welding speed requirements and optimizing welding quality.

[0046] In one embodiment, to improve the effectiveness of the device during actual use, the submerged arc flux placement device for a horizontal thick plate groove provided herein further includes a sensing unit electrically connected to a controller 400. The sensing unit is configured to detect and acquire, in real time, first detection data of the flux spreading state and second detection data of the flux discharge box 100 on the horizontal thick plate. Based on the first and second detection data, the controller 400 adjusts the movement speed of the moving mechanism 200 and the discharge speed of the first discharge port 101 in real time.

[0047] Specifically, the sensing unit includes a visual sensor and a laser rangefinder, both of which are electrically connected to the controller 400. The visual sensor can be used with an industrial camera, which captures the flux spreading pattern, thickness distribution, and groove filling status in real time. The controller 400 uses image processing algorithms to analyze spreading uniformity, coverage, and stacking height. Furthermore, the laser rangefinder measures the distance between the flux discharge box 100 and the groove surface, ensuring a constant discharge height and preventing spread deviations due to height variations.

[0048] Furthermore, to improve the performance of the device during actual use, the sensing unit may also include a pressure sensor and a position encoder. The pressure sensor, integrated into the magnetic wheel 220 or the connection box 210, is used to monitor changes in the magnetic wheel 220's suction force, preventing device drift due to uneven plate surfaces or magnetic failure. Simultaneously, the position encoder accurately records the real-time position and speed of the moving mechanism 200, forming a closed-loop feedback system.

[0049] Specifically, the controller 400 automatically calculates the optimal movement speed based on the groove angle and weld width, for example, reducing the speed in deep grooves to increase the flux loading. Furthermore, a machine learning algorithm establishes a prediction model for spreading parameters, adjusting the feed speed in real time based on the plate material and thickness. If flux agglomeration or blockage is detected, the controller automatically triggers a vibration clearing mechanism or adjusts the feed angle.

[0050] As you can see, real-time data collection on spreading status and equipment position enables dynamic adjustment of welding parameters, significantly reducing defects such as lack of fusion and porosity. Furthermore, real-time monitoring of adsorption force combined with visual anomaly detection can further prevent the risk of equipment slippage and reduce the risk of safety accidents caused by operational errors.

[0051] In one embodiment, the welding mechanism 300 is connected to the moving mechanism 200 and can move synchronously with the moving mechanism 200. It can be understood that when the moving mechanism 200 is moving, the flux feeding box 100 feeds the weld and then performs welding through the welding mechanism 300, thereby realizing automatic welding and welding of the weld.

[0052] Specifically, welding mechanism 300 includes a welding gun 310, a wire feeder 320, and a welding power source 330. The welding gun 310 is connected to the connection box 210 with an adjustable angle, while the wire feeder 320 is connected to the welding gun 310 and feeds the welding wire. The welding power source 330 is electrically connected to the welding gun 310, the wire feeder 320, and the controller 400.

[0053] Furthermore, since the welding gun 310 is connected to the connection box 210 with adjustable angles, a dual-joint robotic arm structure can be installed on the connection box 210, with the welding gun 310 connected to the dual-joint robotic arm. The dual-joint robotic arm allows the welding gun 310 to be adjusted within ±15° in the X, Y, and Z axes, thereby adjusting the welding angle of the welding gun 310 to suit different grooves.

[0054] The wire feeding mechanism 320 can be driven by dual servo motors, so that the fluctuation of the wire feeding force can be effectively controlled, thereby ensuring the stability of the welding wire feeding process.

[0055] In the actual welding process, adaptive adjustment of welding parameters is achieved through the mapping comparison table of welding current, welding voltage, wire feeding speed and moving speed multi-dimensional parameters preset in the controller 400.

[0056] See also Figure 6 Based on the submerged arc welding flux laying device for the horizontal thick plate groove disclosed in the above embodiment, the present disclosure also provides a welding method for the horizontal thick plate groove.

[0057] The above-mentioned welding method comprises at least the following steps.

[0058] In step S10, the flux discharge box 100 is placed on one side of the weld seam of the horizontal thick plate so that the flux discharge box 100 can move along the weld seam. The flux discharge box 100 is connected to the weld seam of the horizontal thick plate via a moving mechanism 200, and the moving mechanism 200 drives the flux discharge box 100 to move along the weld seam of the horizontal thick plate.

[0059] Step S20 , based on the groove angle of the horizontal thick plate, adjust the angle of the first blanking opening 101 , and set the first blanking opening 101 inside the welding groove 13 , and the second blanking opening 102 outside the groove.

[0060] It is understandable that different thicknesses of transverse thick plates will have different angles of the corresponding welding grooves 13 during welding. Therefore, by adjusting the blanking angle of the first blanking port 101, the groove required for welding can be quickly filled.

[0061] In step S30, based on the preset welding parameters, the discharge flow rates of the first discharge port 101 and the second discharge port 102 of the flux discharge box 100 are adjusted, and the flux discharge box 100 is driven to move equidistantly along the weld direction to form a second stacking area 15 outside the groove and a first stacking area 14 inside the groove.

[0062] It should be noted that the second stacking area 15 is formed prior to the first stacking area 14, and the flow regulating mechanism 120 of the first discharge port 101 and the second discharge port 102 can be adjusted separately by the controller 400 so that the flux flow Q2 of the second discharge port 102 meets certain conditions. Specifically, the conditions include: Q2=k·Q1, where Q1 is the flux flow rate of the first discharge port 101, and k∈[1.2,1.5].

[0063] It can be understood that when the height of the second stacking area 15 reaches the preset value H2, the first unloading port 101 is triggered to start unloading.

[0064] Furthermore, the height, width, and distribution of the first and second stacking areas 14, 15 are detected in real time by the sensor unit to obtain first detection data. Based on the first detection data, the flow control mechanism 120 of the first and second discharge ports 101, 102 is dynamically adjusted by the controller 400 so that the height H1 of the first stacking area 14 satisfies: H1=(0.8-0.9)・H2, where H2 is the height of the second stacking area 15.

[0065] In step S30 , the welding parameters mainly include the material flow rates of the first material discharge port 101 and the second material discharge port 102 . In the actual adjustment process, the adjustment is achieved by adjusting the opening and closing angles of the adjustment plate 121 .

[0066] Finally, step S40 is executed, and after the groove is filled with flux, the groove position of the transverse thick plate is welded.

[0067] Specifically, during the actual welding process, controller 400 first adjusts the angle α of welding gun 310 relative to the horizontal direction based on the second detection data obtained by the sensor unit, so that α∈[30°,60°]. Next, wire feeder 320 is controlled to deliver the welding wire at a speed of 8-15 m / min. Finally, welding power supply 330 is activated, and welding is performed at an arc voltage of 28-34 V and a welding current of 500-650 A.

[0068] It should be noted that the time difference Δt between the formation of the first material accumulation area 14 and the formation of the second material accumulation area 15 satisfies: Δt=L / v, where L is the distance between the first material discharge port 101 and the second material discharge port 102 along the weld direction, v is the moving speed of the moving mechanism 200, and v∈[200,400] mm / min.

[0069] During the welding process, the controller 400 compares the first detection data with the preset threshold in real time. When the height deviation of the first stacking area 14 exceeds ±5% or the width deviation exceeds ±8%, the angle of the first rotating part 130 is automatically adjusted so that the blanking angle β of the first blanking port 101 satisfies: β=arctan(ΔH / ΔW), where ΔH is the height deviation and ΔW is the width deviation.

[0070] In summary, the present disclosure provides a submerged arc flux laying device for a horizontal thick plate groove and a thick plate welding method. Through a dual-stack area coordination scheme, that is, through the "outside first, inside later" timing (the second stacking area 15 is formed first) and space (the second discharge port 102 is located at the front end of the movement), the second stacking area 15 forms a "retaining wall" outside the groove, effectively preventing the flux in the first stacking area 14 inside the groove from flowing out, ensuring that the flux filling amount in the groove is sufficient, and avoiding defects such as unfusion and air holes caused by insufficient flux from the source.

[0071] Secondly, the dual-cavity isolation design realizes the classified storage of different fluxes. The flow regulating mechanism 120 can be adjusted through a linear angle of 0°-90°. Combined with the angle adaptation of the first rotating part 130, the material discharge rate can be accurately controlled for a groove angle of 30°-90° to adapt to the filling requirements of different groove depths.

[0072] The sensor unit collects the spreading status and equipment parameters in real time, and the controller 400 automatically adjusts the moving speed, material flow rate and welding gun 310 angle through dynamic algorithms, realizing seamless connection of "detection-analysis-adjustment" and effectively avoiding human intervention.

[0073] The 220-degree magnetic wheel adsorption design breaks through the limitation of the horizontal working surface and can stably adapt to non-horizontal thick plate welding such as horizontal and vertical positions. The adsorption force is monitored in real time to prevent the equipment from slipping, adapt to the uneven surface of the plate, and ensure the stability of the equipment operation.

[0074] It can be foreseen that this solution realizes the automation, precision and high adaptability of the entire process of submerged arc welding of horizontal thick plate grooves from flux laying to welding through structural innovation, intelligent control and process coordination, significantly improving welding quality, efficiency and safety, and is especially suitable for the high-quality welding needs of heavy structures such as ships.

[0075] In the description herein, it should be understood that the terms "upper," "lower," "left," "right," and other positions or relationships are used solely for ease of description and simplified operation, and are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first" and "second" are used solely for descriptive purposes and have no special meaning.

[0076] In this specification, reference to terms such as "one embodiment" or "example" means that a specific feature, structure, material, or characteristic described in conjunction with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example.

[0077] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.

[0078] The technical principles of the present application have been described above in conjunction with specific embodiments. These descriptions are intended solely to explain the principles of the present application and are not to be construed in any way as limiting the scope of protection of the present application. Based on the explanations herein, those skilled in the art will be able to devise other specific implementations of the present application without inventive effort, and such implementations will fall within the scope of protection of the present application.

Claims

1. A submerged arc welding flux laying device for horizontal thick plate groove, characterized in that: include: A flux discharge box (100) is located on one side of the weld of the horizontal thick plate and is provided with a first discharge port (101) and a second discharge port (102) for discharge of flux, wherein the first discharge port (101) is located inside the welding groove (13) of the horizontal thick plate, and the second discharge port (102) is located outside the welding groove (13) of the horizontal thick plate; A moving mechanism (200) is connected to the flux discharge box (100) and is used to drive the flux discharge box (100) to move equidistantly along the direction of the weld; A welding mechanism (300) connected to the moving mechanism (200) is used to perform a welding step after the welding groove (13) is filled with flux; and a controller (400) electrically connected to the moving mechanism (200) and the welding mechanism (300); Wherein, in a first direction (DX) perpendicular to the weld from the inside to the outside of the welding groove (13) of the horizontal thick plate, the first unloading port (101) unloads to form a first stockpiling area (14), and the second unloading port (102) unloads to form a second stockpiling area (15), and the formation of the first stockpiling area (14) lags behind that of the second stockpiling area (15).

2. The submerged arc welding flux laying device for horizontal thick plate groove according to claim 1, characterized in that: A storage chamber (110) is provided in the flux discharge box (100), and the storage chamber (110) is divided into a first cavity (112) and a second cavity (113) by a partition (111), the first cavity (112) is connected to the first discharge port (101), and the second cavity (113) is connected to the second discharge port (102).

3. The submerged arc welding flux laying device for horizontal thick plate groove according to claim 1, characterized in that: Along the second direction (DY) of the transverse thick plate weld, the first blanking opening (101) and the second blanking opening (102) are spaced apart, and the second blanking opening (102) is located at the front end of the moving direction of the first blanking opening (101).

4. The submerged arc welding flux laying device for horizontal thick plate groove according to claim 1, characterized in that: The first discharge port (101) and the second discharge port (102) are respectively provided with a flow regulating mechanism (120), and the flow regulating mechanism (120) comprises: An adjustment plate (121) is pivotally connected to the flux discharge box (100) and covers the corresponding discharge port; and A driving member (122) is provided on the flux discharge box (100) and drives the adjustment plate (121) to rotate; The regulating plate (121) is rotated to regulate the flux flow rate of the corresponding discharge port.

5. The submerged arc welding flux laying device for horizontal thick plate groove according to claim 4, characterized in that: The driving member (122) is a servo motor or a stepping motor, and the regulating plate (121) realizes linear regulation of the opening of the feed opening by rotating an angle θ, wherein θ∈[0°,90°].

6. The submerged arc welding flux laying device for horizontal thick plate groove according to claim 1, characterized in that: The flux discharge box (100) is provided with a first rotating part (130) that can rotate relatively, and the first discharge port (101) is opened on the first rotating part (130); The first rotating portion (130) is used to adjust the blanking angle of the first blanking opening (101).

7. The submerged arc welding flux laying device for horizontal thick plate groove according to claim 1, characterized in that: The moving mechanism (200) comprises: A connecting box (210) is connected to the flux discharge box (100); A plurality of magnetic wheels (220) are provided at the bottom of the connection box (210) and are adsorbed on the surface of the horizontal thick plate; and A power source (230) is provided on the magnetic wheel (220) and drives the magnetic wheel (220) to rotate, and the power source (230) is electrically connected to the controller (400).

8. The submerged arc welding flux laying device for horizontal thick plate groove according to claim 7, characterized in that: The welding mechanism (300) comprises: A welding gun (310), connected to the connection box (210) in an angle-adjustable manner; a wire feeding mechanism (320), connected to the welding gun (310) and feeding welding wire; and A welding power source (330) is electrically connected to the welding gun (310), the wire feeding mechanism (320), and the controller (400).

9. The submerged arc welding flux laying device for horizontal thick plate groove according to claim 1, characterized in that: It also includes a sensing unit electrically connected to the controller (400) for real-time detection and acquisition of first detection data of the flux spreading state and second detection data of the position of the flux discharge box (100) on the horizontal thick plate; The controller (400) adjusts the moving speed of the moving mechanism (200) and the blanking angle of the first blanking port (101) in real time based on the first detection data and the second detection data.

10. A thick plate welding method applied to the submerged arc welding flux laying device for horizontal thick plate grooves as claimed in any one of claims 1 to 9, characterized in that: include: Step S10, placing the flux discharge box (100) on one side of the horizontal thick plate weld, so that the flux discharge box (100) can move along the weld direction; Step S20, adjusting the angle of the first blanking opening (101) based on the groove angle of the horizontal thick plate, and setting the first blanking opening (101) inside the welding groove (13), and the second blanking opening (102) outside the groove; Step S30, based on preset welding parameters, adjusting the discharge flow rates of the first discharge port (101) and the second discharge port (102) of the flux discharge box (100), and driving the flux discharge box (100) to move equidistantly along the weld direction to form a second stacking area (15) outside the groove and a first stacking area (14) inside the groove; Step S40: After the groove is filled with flux, a welding step is performed on the groove position of the horizontal thick plate.

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