A submerged arc welding flux laying device for a transverse thick plate groove and a thick plate welding method

Abstract

This application discloses a submerged arc welding flux application device and a welding method for transverse thick plate bevels, relating to the technical field of transverse thick plate welding. The device includes a flux feeding box located on one side of the weld seam of the transverse thick plate, with a first feeding port and a second feeding port for flux feeding; a moving mechanism for driving the flux feeding box to move equidistantly along the weld seam direction; a welding mechanism connected to the moving mechanism for performing the welding step after the bevel is filled with flux; and a controller electrically connected to the moving mechanism and the welding mechanism. Specifically, in a first direction perpendicular to the weld seam from the inside to the outside of the bevel, the flux is fed through the first feeding port to form a first material accumulation area, and the flux is fed through the second feeding port to form a second material accumulation area, with the formation of the first material accumulation area lagging behind the formation of the second material accumulation area. This disclosure can achieve full automation, precision, and high adaptability in the entire process of transverse thick plate bevel submerged arc welding from flux application to welding, significantly improving welding quality, efficiency, and safety.

Description

Technical Field

[0001] This application relates to the technical field of horizontal thick plate welding, and more particularly to a submerged arc welding flux application device and a thick plate welding method for horizontal thick plate bevels. Background Technology

[0002] The conventional submerged arc welding flux funnel achieves controlled flux release through a structure that is fixedly connected to the conductive nozzle. Its compact design is suitable for butt welding of flat plates, fillet welds, and ordinary fillet welds, and can meet the flux laying and quality control requirements under normal working conditions. Currently, in horizontal welding of thick plates with small-angle bevels (30-35°), the rigid connection between the flux funnel and the contact tip results in a large welding torch size, making it difficult for the welding wire to penetrate deep into the small-angle bevel, leading to poor weld accessibility at the bevel root. Simultaneously, the flow channel designed for horizontal welding is affected by gravity, causing flux to accumulate on one side of the bevel, disrupting uniform distribution and resulting in unstable arc coverage. Uneven flux distribution can cause arc deviation, leading to weld size fluctuations and welding parameter imbalances, exacerbating process instability. During welding, gravity and the bevel angle together cause slag accumulation or segregation, weakening the molten pool protection and increasing the risk of forming defects. Furthermore, insufficient flux coverage at the root of the small-angle bevel easily leads to defects such as incomplete fusion, incomplete penetration, and porosity. Summary of the Invention The purpose of this invention is to provide a submerged arc welding flux application device and a thick plate welding method for a horizontal thick plate bevel, which can solve the above-mentioned problems existing in the prior art.

[0003] To achieve the above objectives, this application adopts the following technical solution: On the one hand, a submerged arc welding flux application device for a transverse thick plate bevel is provided, comprising: The flux feeding box is located on one side of the weld seam of the transverse thick plate. It has a first feeding port and a second feeding port for feeding flux. The first feeding port is located inside the welding bevel of the transverse thick plate, and the second feeding port is located outside the welding bevel of the transverse thick plate. A moving mechanism, connected to the flux feeding box, is used to drive the flux feeding box to move equidistantly along the weld direction; A welding mechanism, connected to the moving mechanism, is used to perform the welding step after the bevel is filled with flux; and The controller is electrically connected to the moving mechanism and the welding mechanism; In the first direction of the horizontal thick plate from the inside to the outside of the bevel and perpendicular to the weld, the first discharge port forms a first material accumulation area, the second discharge port forms a second material accumulation area, and the formation of the first material accumulation area lags behind the formation of the second material accumulation area.

[0004] Preferably, the flux feeding box is provided with a storage chamber, which is divided into a first chamber and a second chamber by a partition. The first chamber is connected to the first feeding port, and the second chamber is connected to the second feeding port.

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

[0006] Preferably, a flow regulating mechanism is provided at both the first discharge port and the second discharge port, and the flow regulating mechanism includes: An adjusting plate, pivotally connected to the flux feeding box and covering the corresponding feeding port; and A driving component is provided in the flux feeding box and drives the adjusting plate to rotate; The adjusting plate adjusts the flux flow rate through the corresponding feed port by rotating it.

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

[0008] Preferably, the flux feeding box is provided with a first rotating part that can rotate relative to it, and the first feeding port is opened on the first rotating part. The first rotating part is used to adjust the feeding angle of the first feeding port.

[0009] Preferably, the moving mechanism includes: Connect the housing to the flux feeding box; Multiple magnetic rollers are located at the bottom of the connecting box and adhere to the surface of the horizontal thick plate; and A power source is connected to the magnetic chuck for driving the magnetic chuck to rotate, and the power source is electrically connected to the controller.

[0010] Preferably, the welding mechanism includes: A welding torch is connected to the connecting housing at an adjustable angle; Wire feeding mechanism, connected to the welding torch and feeding the welding wire; and The welding power source is electrically connected to the welding torch, the wire feeding mechanism, and the controller.

[0011] Preferably, it also includes a sensing unit electrically connected to the controller, used to detect and acquire first detection data of flux spreading status and second detection data of the position of flux feeding box on the horizontal thick plate in real time; The controller adjusts the moving speed of the moving mechanism and the feeding angle of the first feeding port in real time based on the first detection data and the second detection data.

[0012] On the other hand, this disclosure also provides a method for welding thick plates using a submerged arc flux application device applied to any of the above-described transverse thick plate bevels, comprising: The flux feeding box is placed on one side of the horizontal thick plate weld, so that the flux feeding box can move along the weld direction; Based on the bevel angle of the horizontal thick plate, adjust the angle of the first discharge port and set the first discharge port inside the welding bevel, while the second discharge port is located outside the bevel; Based on preset welding parameters, the discharge flow rate of the first and second discharge ports of the flux feeding box is adjusted, and the flux feeding box is driven to move equidistantly along the weld direction to form a second material accumulation area outside the bevel and a first material accumulation area inside the bevel. After the bevel is filled with flux, the welding step is performed on the bevel position of the horizontal thick plate.

[0013] The beneficial effects of this application are as follows: 1. By using a dual-stack area coordination scheme, namely, by coordinating the timing and space of "outer first, then inner", the second stack area forms a "barrier" outside the bevel, effectively preventing the flux from flowing out of the first stack area inside the bevel, ensuring sufficient flux filling inside the bevel, and avoiding defects such as incomplete fusion and porosity caused by insufficient flux from the source.

[0014] 2. The dual-cavity isolation design enables the classified storage of different fluxes. The flow regulation 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 bevel angles from 30° to 90°, adapting to the filling requirements of different bevel depths.

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

[0016] 4. The magnetic suction wheel adsorption design overcomes the limitations of horizontal working surfaces, 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, adapting to uneven plate surface conditions and ensuring the stability of equipment operation.

[0017] 5. Through structural innovation, intelligent control and process synergy, the entire process of horizontal thick plate bevel submerged arc welding, from flux laying to welding, has been automated, precise and highly adaptable, which significantly improves welding quality, efficiency and safety, and is especially suitable for the high-quality welding needs of heavy structures such as ships. Attached Figure Description

[0018] The present application will now be described in further detail with reference to the accompanying drawings and embodiments.

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

[0020] In the picture: 11. First welding plate; 12. Second welding plate; 13. Welding bevel; 14. First stockpiling area; 15. Second stockpiling area; DX, first direction; DY, second direction; Flux feeding box; 101, first feeding port; 102, second feeding port; 110, storage chamber; 111, partition plate; 112, first cavity; 113, second cavity; 120, flow regulation mechanism; 121, regulating plate; 122, driving component; 130, first rotating part; 210. Moving mechanism; 220. Connecting housing; 230. Magnetic wheels; 24. Power source; Welding mechanism; 310. Welding torch; 320. Wire feeding mechanism; 330. Welding power source; 400. Controller. Detailed Implementation

[0021] To make the technical problems solved by this application, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the embodiments of this application are further described in detail below. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0022] In the description of this application, unless otherwise expressly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0023] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0024] Please see Figures 1 to 5 This disclosure provides a submerged arc welding flux application device for a horizontal thick plate bevel, comprising a flux feeding box 100, a moving mechanism 200, a welding mechanism 300, and a controller 400. The flux feeding box 100 is located on one side of the horizontal thick plate weld, and a first feeding port 101 and a second feeding port 102 are provided on the flux feeding box 100. The first feeding port 101 is located inside the welding bevel 13 of the horizontal thick plate, and the second feeding port 102 is located outside the welding bevel 13 of the horizontal thick plate.

[0025] In the first direction DX of the horizontal thick plate from the inside to the outside of the bevel and perpendicular to the weld, the first discharge port 101 discharges material to form the first material accumulation area 14, and the second discharge port 102 discharges material to form the second material accumulation area 15, and the formation of the first material accumulation area 14 lags behind the formation of the second material accumulation area 15.

[0026] Furthermore, along the second direction DY of the transverse thick plate weld, the first discharge port 101 and the second discharge port 102 are spaced apart, with the second discharge port 102 located at the front end of the first discharge port 101 in the moving direction. Through this arrangement, the first stockpiling area 14 can be formed after the second stockpiling area 15.

[0027] Understandably, the second discharge port 102 is located outside the bevel and forms the second material accumulation area 15 before the first discharge port 101. It can pre-form a "barrier" structure on the outside of the bevel, effectively preventing the flux laid from the first discharge port 101 from flowing out of the bevel. This ensures that the flux in the first material accumulation area 14 inside the bevel is sufficient, meeting the requirements of submerged arc welding for flux coverage inside the bevel, and avoiding welding defects caused by insufficient flux.

[0028] Specifically, by positioning the second discharge port 102 along the weld direction at the front of the moving part, the second material accumulation area 15 outside the bevel is laid first, followed by the first material accumulation area 14 inside the bevel at the first discharge port 101, forming an orderly laying sequence of "outside first, inside later". Through this coordination of timing and space, the flux from the two discharge ports can be effectively prevented from interfering with each other, ensuring that the flux inside and outside the bevel can be accurately placed, thus improving laying efficiency and accuracy.

[0029] Furthermore, the first material stacking area 14 focuses on the core welding area within the bevel, ensuring sufficient flux coverage during the welding process to guarantee adequate penetration and good weld formation. The second material stacking area 15 forms auxiliary protection outside the bevel, which can help reduce arc leakage during welding, protect the bevel edge, further improve the stability of the welding process, reduce the risk of defects such as porosity and cracks, and optimize the overall welding quality of the horizontal thick plate bevel.

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

[0031] The moving mechanism 200 is connected to the flux feeding box 100 and drives the flux feeding box 100 to move equidistantly along the direction of the weld. By moving the flux feeding box 100 equidistantly along the direction of the weld, the flux accumulated in the flux feeding box 100 within the weld 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 step after the bevel is filled with flux. The controller 400 is electrically connected to the moving mechanism 200 and the welding mechanism 300 to control the moving speed of the moving mechanism 200 on the transverse thick plate and to control the welding parameters of the welding structure during the welding process.

[0033] Specifically, for the welding requirements of the vertically positioned first welding plate 10 and second welding plate 11, the angle of the welding bevel 13 is limited to 0-45 degrees, preferably 30 degrees. This can adapt to the structural characteristics of the vertical connection of the two plates, and the smaller bevel angle reduces the amount of weld filler, while ensuring the fusion depth on both sides of the bevel. It avoids waste of welding materials or welding deformation caused by an excessively large bevel, and balances welding efficiency and joint strength. It is especially suitable for the structural stability requirements of vertical welding of horizontal thick plates.

[0034] Furthermore, the moving mechanism 200 drives the flux feeding box 100 to move equidistantly along the weld direction, ensuring that the flux accumulation density in the first stacking area 14 inside the bevel and the second stacking area 15 outside the bevel is uniform and consistent, avoiding waste caused by excessive flux in some areas or insufficient protection caused by insufficient flux. It can also ensure stable coverage and protection of the molten pool by the flux during the welding process, reducing defects such as porosity and lack of fusion.

[0035] The controller 400 coordinates and regulates the moving speed of the moving mechanism 200 and the welding parameters of the welding mechanism 300, such as welding current, welding voltage, and welding speed, thereby achieving precise matching between flux application and the welding process. The moving speed is matched with the flux amount to avoid uneven flux accumulation. Simultaneously, the welding parameters are dynamically adjusted according to the bevel characteristics to ensure that the weld penetration and width meet the standards.

[0036] In one embodiment, the flux feeding box 100 is provided with a storage chamber 110, which 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 feeding port 101, and the second chamber 113 is connected to the second feeding port 102. Therefore, by dividing the storage chamber 110 into two mutually isolated chambers, different types of flux can be stored in the chambers to improve the actual welding effect. At the same time, by dividing it into two mutually isolated chambers, the first feeding port 101 and the second feeding port 102 do not interfere with each other during the feeding process.

[0037] To facilitate the control of the flux feeding rate at the first and second feeding ports 101 and 102, flow regulation mechanisms 120 may be installed at these ports. The flow regulation mechanisms 120 adjust the flux feeding rate at the first and second feeding ports 101 and 102 to accommodate the flux dosage required for different bevel angles, and to precisely adjust the feeding flow rate according to the flux dosage requirements of different bevel angles, thereby improving adaptability.

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

[0039] The drive unit 122 can be a servo motor or a stepper motor, offering excellent controllability and precise adjustment of the rotation angle of the adjustment plate 121, thereby achieving precise control of the flux feeding rate. It is important to note that the adjustment plate 121 achieves linear adjustment of the discharge port opening through a rotation angle θ, where θ∈[0°, 90°]. The flow rate at the discharge port is maximum when the rotation angle is 90 degrees, and zero when the rotation angle is 0 degrees.

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

[0041] In one embodiment, the flux feeding box 100 is provided with a first rotating part 130 that can rotate relative to it, and a first feeding port 101 is opened on the first rotating part 130. The first rotating part 130 can rotate relative to it, thereby driving the first feeding port 101 to adjust the feeding angle, which can accurately adapt to different bevel angles, ensure that the flux fills the bevel at the optimal angle, reduce uneven filling or missing filling problems, and significantly improve the bevel filling effect.

[0042] Furthermore, the moving mechanism 200 is connected to the flux dispensing box 100 and is used to drive the flux dispensing box 100 to move equidistantly along the weld direction. By moving the flux dispensing box 100 equidistantly relative to the weld direction, the uniform filling of flux within the bevel can be effectively ensured.

[0043] Understandably, the combination of the angle adjustment of the first rotating part 130 and the equidistant movement of the moving mechanism 200 enables the equipment to flexibly meet the welding needs of welds with different bevel angles and lengths, thus expanding the equipment's applicability. Through the synergistic effect of angle adaptation and uniform movement, welding defects caused by flux filling issues can also be reduced, improving the stability and reliability of the overall welding process.

[0044] In one embodiment, the moving mechanism 200 includes a connecting housing 210, multiple magnetic rollers 220, and a power source 230. The connecting housing 210 is connected to the flux dispensing box (100), and the multiple magnetic rollers 220 are rotatably disposed at the bottom of the connecting housing 210. The power source 230 is driven to the magnetic rollers 220 to drive their rotation. In actual use, the magnetic rollers 220 adhere to the surface of the horizontal thick plate to ensure that the moving mechanism 200 can move along the non-horizontal horizontal thick plate. The magnetic rollers 220 adhere to the surface of the horizontal thick plate, enabling the moving mechanism 200 to move stably along the non-horizontal thick plate, breaking through the dependence of traditional equipment on a horizontal working surface, and is suitable for multi-angle welding scenarios. At the same time, the magnetic rollers 220 provide reliable adsorption force to prevent the equipment from slipping or shifting during movement, ensuring that the flux dispensing box 100 moves accurately and equidistantly along the weld direction, and improving the uniformity of flux application.

[0045] It is important to note that the power source 230 is a servo motor, electrically connected to the controller 400. In practical applications, the controller 400 can be used to adjust the moving speed of the flux feeding box 100 on the horizontal thick plate by regulating the power source 230. The servo motor, as the power source 230, works in conjunction with the controller 400 to achieve precise control of the moving speed, which can be dynamically adjusted according to welding process requirements to adapt to different welding speed demands and optimize welding quality.

[0046] In one embodiment, to improve the effectiveness of the device in actual use, the submerged arc welding flux application device for the bevel of a horizontal thick plate provided in this disclosure further includes a sensing unit, which is electrically connected to the controller 400. The sensing unit is used to detect and acquire first detection data of the flux spreading state and second detection data of the flux feeding box 100 on the horizontal thick plate in real time. Based on the first and second detection data, the controller 400 adjusts the moving speed of the moving mechanism 200 and the feeding speed of the first feeding port 101 in real time.

[0047] Specifically, the sensing unit includes a vision sensor and a laser rangefinder, both electrically connected to the controller 400. The vision sensor allows the use of an industrial camera to capture the flux spread pattern, thickness distribution, and bevel filling status in real time. The controller 400 uses image processing algorithms to analyze spread uniformity, coverage, and build-up height. Furthermore, the laser rangefinder measures the distance between the flux dispensing bin 100 and the bevel surface to ensure a constant dispensing height and prevent spread deviations due to height variations.

[0048] Furthermore, to improve the effectiveness of this device in actual use, the sensing unit may also include a pressure sensor and a position encoder. The pressure sensor is integrated into the magnetic roller 220 or the connecting housing 210 to monitor changes in the magnetic force of the roller 220, preventing device misalignment due to unevenness of the plate surface 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 can automatically calculate the optimal moving speed based on the bevel angle and weld width, such as reducing the speed in deep bevel areas to increase flux filling. Simultaneously, it establishes a spreading parameter prediction model through machine learning algorithms, adjusting the feeding speed in real time according to the plate material and thickness. When flux clumping or blockage is detected, it automatically triggers a vibration unblocking mechanism or adjusts the feeding angle.

[0050] Understandably, by collecting real-time data on the spreading status and equipment position, welding parameters can be dynamically adjusted, significantly reducing defects such as incomplete fusion and porosity. Furthermore, by combining real-time detection of adsorption force with visual anomaly detection, the risk of equipment slippage can be further prevented, reducing the accident rate 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, after the flux feeding box 100 feeds the weld seam, the welding mechanism 300 performs the welding, thereby realizing automated material feeding and welding of the weld seam.

[0052] Specifically, the welding mechanism 300 includes a welding torch 310, a wire feeding mechanism 320, and a welding power source 330. The welding torch 310 is angle-adjustably connected to the connecting housing 210, and the wire feeding mechanism 320 is connected to the welding torch 310 and feeds the welding wire. The welding power source 330 is electrically connected to the welding torch 310, the wire feeding mechanism 320, and the controller 400.

[0053] Furthermore, since the welding torch 310 is angle-adjustable and connected to the connecting housing 210, a dual-joint robotic arm structure can be installed on the connecting housing 210, and the welding torch 310 is connected to the dual-joint robotic arm. The dual-joint robotic arm enables ±15° angle adjustment of the welding torch 310 in the X, Y, and Z axis directions, allowing for adjustment of the welding angle of the welding torch 310 to accommodate different bevels.

[0054] The wire feeding mechanism 320 can be driven by dual servo motors, which effectively controls the fluctuation of the wire feeding force and ensures the stability of the welding wire feeding process.

[0055] In the actual welding process, the welding parameters are adaptively adjusted by using a mapping table of multi-dimensional parameters such as welding current, welding voltage, wire feeding speed, and moving speed preset in the controller 400.

[0056] Please see Figure 6 Based on the submerged arc welding flux application device for horizontal thick plate bevels disclosed in the above embodiments, this disclosure also provides a welding method for horizontal thick plate bevels.

[0057] The welding method described above includes at least the following steps.

[0058] Step S10: The flux dispensing box 100 is placed on one side of the weld seam of the transverse thick plate, so that the flux dispensing box 100 can move along the weld seam direction. The flux dispensing box 100 is connected to one side of the weld seam of the transverse thick plate through a moving mechanism 200, and the moving mechanism 200 drives the flux dispensing box 100 to move along the weld seam direction of the transverse thick plate.

[0059] Step S20: Based on the bevel angle of the horizontal thick plate, adjust the angle of the first discharge port 101 and set the first discharge port 101 inside the welding bevel 13, while the second discharge port 102 is located outside the bevel.

[0060] Understandably, the angle of the welding bevel 13 will differ depending on the thickness of the transverse thick plate during welding. Therefore, by adjusting the feeding angle of the first feeding port 101, the required welding bevel can be quickly filled.

[0061] Step S30: Based on preset welding parameters, adjust the discharge flow rate of the first discharge port 101 and the second discharge port 102 of the flux discharge box 100, and drive the flux discharge box 100 to move equidistantly along the weld direction to form a second stacking area 15 outside the bevel and a first stacking area 14 inside the bevel.

[0062] It should be noted that the second stockpiling area 15 is formed prior to the first stockpiling area 14, allowing the flow regulation mechanisms 120 of the first discharge port 101 and the second discharge port 102 to be adjusted by the controller 400 respectively, so that the flux flow rate Q2 of the second discharge port 102 meets certain conditions. Specifically, these conditions include: Q2=k Q1, where Q1 is the flux flow rate at the first discharge port 101, k∈[1.2,1.5].

[0063] Understandably, when the height of the second stacking area 15 reaches the preset value H2, the first discharge port 101 is triggered to start discharging.

[0064] Furthermore, the height, width, and distribution of the first and second stockpiling areas 14 and 15 are detected in real time by the sensing unit to obtain first detection data. Based on the first detection data, the flow regulation mechanism 120 of the first discharge port 101 and the second discharge port 102 is dynamically adjusted by the controller 400 to ensure that the height H1 of the first stockpiling area 14 meets the following requirements: H1 = (0.8 - 0.9) H2, where H2 is the height of the second stockpile zone 15.

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

[0066] Finally, step S40 is performed, where the bevel is filled with flux and then welded to the bevel position of the transverse thick plate.

[0067] Specifically, in the actual welding process, firstly, based on the second detection data acquired by the sensing unit, the controller 400 adjusts the angle α of the welding torch 310 relative to the horizontal direction, so that α∈[30°, 60°]. Secondly, the wire feeding mechanism 320 is controlled to feed the welding wire at a speed of 8-15 m / min. Finally, the welding power supply 330 is started, and welding is performed with an arc voltage of 28-34V and a welding current of 500-650A.

[0068] It should be noted that the time difference Δt between the formation of the first stockpile zone 14 and the second stockpile zone 15 satisfies: Δt=L / v, where L is the distance between the first discharge port 101 and the second 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 a preset threshold in real time. When the height deviation of the first material 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 feeding angle β of the first feeding port 101 satisfies: β = arctan(ΔH / ΔW), where ΔH is the height deviation and ΔW is the width deviation.

[0070] In summary, this disclosure provides a submerged arc welding flux laying device and a thick plate welding method for a horizontal thick plate bevel. Through a dual-stacking zone collaborative scheme, namely, by coordinating the timing (second stacking zone 15 is formed first) and space (second discharge port 102 is located at the moving front end) of the "outer first, inner last" sequence, the second stacking zone 15 forms a "barrier" outside the bevel, effectively preventing the flux from flowing out of the first stacking zone 14 inside the bevel, ensuring sufficient flux filling in the bevel, and avoiding defects such as incomplete fusion and porosity caused by insufficient flux from the source.

[0071] Secondly, the dual-cavity isolation design enables the classified storage of different fluxes. The flow regulation mechanism 120 can adjust the linear angle from 0° to 90°, combined with the angle adaptation of the first rotating part 130, to precisely control the feeding rate for bevel angles from 30° to 90°, so as to adapt to the filling requirements of different bevel depths.

[0072] By collecting the spreading status and equipment parameters in real time through the sensing unit, the controller 400 automatically adjusts the moving speed, feeding flow rate and welding torch 310 angle through dynamic algorithms, realizing a seamless connection between "detection-analysis-adjustment", which can effectively avoid manual intervention.

[0073] The magnetic roller 220 adsorption design overcomes the limitations of horizontal working surfaces, 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, adapting to uneven plate surface conditions and ensuring the stability of equipment operation.

[0074] It is foreseeable that this solution, through structural innovation, intelligent control and process synergy, has achieved full automation, precision and high adaptability of the entire process of horizontal thick plate bevel submerged arc welding from flux laying to welding, 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 orientations or positional relationships are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first" and "second" are used merely for descriptive distinction and have no special meaning.

[0076] In the description of this specification, references to terms such as "an embodiment," "example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example.

[0077] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style of the specification is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

[0078] The technical principles of this application have been described above with reference to specific embodiments. These descriptions are merely for explaining the principles of this application and should not be construed as limiting the scope of protection of this application in any way. Based on this explanation, those skilled in the art can readily conceive of other specific embodiments of this application without inventive effort, and these embodiments will all fall within the scope of protection of this application.

Claims

1. A device for applying submerged arc welding flux to a bevel of a horizontal thick plate, characterized in that, include: A flux feeding box (100) is located on one side of the weld seam of a transverse thick plate, and has a first feeding port (101) and a second feeding port (102) for feeding flux. The first feeding port (101) is located inside the welding bevel (13) of the transverse thick plate, and the second feeding port (102) is located outside the welding bevel (13) of the transverse thick plate. A 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 weld seam direction. A welding mechanism (300) is connected to the moving mechanism (200) and is used to perform the welding step after the welding bevel (13) is filled with flux. A controller (400) is electrically connected to the moving mechanism (200) and the welding mechanism (300). The controller is located on the transverse thick plate from the inside to the outside of the welding bevel (13) and perpendicular to the weld seam. In the first direction, the first discharge port (101) discharges material to form a first stockpiling area (14), and the second discharge port (102) discharges material to form a second stockpiling area (15), and the formation of the first stockpiling area (14) lags behind the formation of the second stockpiling area (15); the flux discharge box (100) is provided with a storage cavity (110), and the storage cavity (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); along the second direction of the transverse thick plate weld, the first discharge port (101) and the second discharge port (102) are spaced apart, and the second discharge port (102) is located at the front end of the moving direction of the first discharge port (101).

2. The submerged arc welding flux application device for a horizontal thick plate bevel according to claim 1, characterized in that, A flow rate regulating mechanism (120) is provided at the first discharge port (101) and the second discharge port (102). The flow rate regulating mechanism (120) includes: an regulating plate (121), which is pivotally connected to the flux discharge box (100) and covers the corresponding discharge port; and a driving member (122), which is located in the flux discharge box (100) and drives the regulating plate (121) to rotate; wherein the regulating plate (121) adjusts the flux flow rate of the corresponding discharge port by rotating.

3. The submerged arc welding flux laying device for a transverse thick plate bevel according to claim 2, characterized in that, The driving component (122) is a servo motor or a stepper motor, and the adjusting plate (121) achieves linear adjustment of the opening of the feed port by rotating the angle θ, where θ∈[0°,90°].

4. The submerged arc welding flux laying device for the bevel of a horizontal thick plate according to claim 1, characterized in that, The flux feeding box (100) is provided with a first rotating part (130) that can rotate relative to it, and the first feeding port (101) is opened on the first rotating part (130); the first rotating part (130) is used to adjust the feeding angle of the first feeding port (101).

5. The submerged arc welding flux laying device for the bevel of a horizontal thick plate according to claim 1, characterized in that, The moving mechanism (200) includes: a connecting box (210) connected to the flux feeding box (100); a plurality of magnetic rollers (220) located at the bottom of the connecting box (210) and adsorbed onto the surface of the horizontal thick plate; and a power source (230) connected to the magnetic rollers (220) for driving the magnetic rollers (220) to rotate, and the power source (230) is electrically connected to the controller (400).

6. The submerged arc welding flux laying device for a horizontal thick plate bevel according to claim 5, characterized in that, The welding mechanism (300) includes: a welding torch (310) which is angle-adjustably connected to the connecting housing (210); a wire feeding mechanism (320) which is connected to the welding torch (310) and feeds welding wire; and a welding power source (330) which is electrically connected to the welding torch (310), the wire feeding mechanism (320) and the controller (400).

7. The submerged arc welding flux laying device for a horizontal thick plate bevel 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 flux spreading status and second detection data of the position of flux feeding box (100) on the horizontal thick plate; wherein, the controller (400) adjusts the moving speed of the moving mechanism (200) and the feeding angle of the first feeding port (101) in real time based on the first detection data and the second detection data.

8. A method for welding thick plates using a submerged arc flux application device applied to the bevel of a thick plate as described in any one of claims 1 to 7, characterized in that, include: Step S10: Place the flux feeding box (100) on one side of the weld seam of the transverse thick plate, so that the flux feeding box (100) can move along the weld seam direction; Step S20: Based on the bevel angle of the transverse thick plate, adjust the angle of the first feeding port (101) and set the first feeding port (101) inside the welding bevel (13), and the second feeding port (102) is located outside the bevel; Step S30: Based on the preset welding parameters, adjust the feeding flow rate of the first feeding port (101) and the second feeding port (102) of the flux feeding box (100), and by driving the flux feeding box (100) to move equidistantly along the weld seam direction, a second material accumulation area (15) is formed outside the bevel and a first material accumulation area (14) is formed inside the bevel; Step S40: After the bevel is filled with flux, perform the welding step on the bevel position of the transverse thick plate.

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