Automatic preheating and temperature control device and method for submerged-arc welding of boiler header barrel

Abstract

The invention discloses an automatic preheating and temperature control device and method for submerged-arc welding of a boiler header barrel. The automatic preheating and temperature control device comprises a barrel, a roller carrier, a cross beam, a sliding guide rail, a flame spray gun, an infrared temperature measuring element and a control system. The barrel is located on the roller carrier, the sliding guide rail is installed on the cross beam, the flame spray gun is located on the sliding guide rail and right faces a splicing circular seam preheating area of the barrel, the infrared temperature measuring element is installed on the cross beam, and the output end of the infrared temperature measuring element and the control end of the flame spray gun are connected with the control system. The device and the method can avoid the problem of poor welding quality caused by temperature drop of the welding area.

Description

Technical Field

[0001] This invention belongs to the field of header cylinders for large-capacity thermal power boilers, and relates to an automatic preheating and temperature control device and method for submerged arc welding of boiler header cylinders. Background Technology

[0002] Submerged arc welding (SAW) is a crucial process in the manufacturing of power plant boilers. SAW is a welding method where an electric arc burns beneath a layer of flux. It utilizes the high temperature of the arc to melt the welding wire and base metal, forming a molten pool. The welding wire is continuously fed into the arc zone by a wire feeder, while granular flux is evenly applied to the workpiece area through a flux funnel and hose. Under the heat of the arc, the flux melts, producing a large amount of gas and slag, forming a layer of liquid slag that surrounds the arc and molten pool, isolating the arc from the air. After the molten welding wire and base metal are melted by the high temperature of the arc, the slag floats on the surface of the molten pool, protecting the weld metal from contact with air and allowing the molten pool metal to cool slowly. As the arc moves forward, the liquid slag subsequently solidifies to form a slag shell, while the weld metal solidifies to form the weld. SAW is widely used for welding the splicing of header cylinders themselves, as well as the circumferential seams between the cylinder and tees, elbows, end caps, transition pipes, etc. The welding process requires preheating of the welding area and the surrounding base material. Reasonable preheating temperature and uniform temperature distribution are key to ensuring the quality and performance of the container equipment.

[0003] With the construction of supercritical and ultra-supercritical thermal power plant units, the size of the power plant header cylinders has increased, requiring preheating before welding large-diameter, thick-walled cylinders. Typically, this is done manually with flame heating, which is time-consuming, labor-intensive, has poor operability, and demands highly skilled operators. Because the preheating temperature range is quite demanding, insufficient preheating or inadequate preheating temperatures are common. Furthermore, with increased welding filler volume and working hours, submerged arc welding machines may malfunction under prolonged high-load operation, or manual shifts may occur, causing welding interruptions. During the reassembly of the preheating device, the temperature in the welding area can drop rapidly, even falling below the minimum preheating temperature, easily leading to porosity and slag inclusions in the weld, resulting in cold cracking. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide an automatic preheating and temperature control device and method for submerged arc welding of boiler header cylinders. This device and method can avoid the problem of poor welding quality caused by the temperature drop in the welding area.

[0005] To achieve the above objectives, the present invention discloses an automatic preheating and temperature control device for submerged arc welding of boiler header cylinder, including cylinder, roller frame, crossbeam, sliding guide rail, flame torch, infrared temperature measuring element and control system. The cylinder is located on the roller frame, the sliding guide rail is installed on the crossbeam, the flame gun is located on the sliding guide rail, the flame gun is directly facing the preheating area of ​​the splicing circumferential seam of the cylinder, the infrared temperature measuring element is installed on the crossbeam, and the output end of the infrared temperature measuring element and the control end of the flame gun are connected to the control system.

[0006] A further improvement of the automatic preheating and temperature control device for submerged arc welding of boiler header cylinders described in this invention is as follows: Furthermore, the infrared temperature measuring element is mounted on the crossbeam via a slider.

[0007] Furthermore, it also includes a servo motor and a lead screw. The output shaft of the servo motor is connected to the lead screw, which passes through the slider, and the lead screw and the slider are threaded together.

[0008] Furthermore, the control terminal of the servo motor is connected to the output terminal of the control system.

[0009] Furthermore, it also includes a trolley, on which a crossbeam is located.

[0010] Furthermore, the control system is located on the crossbeam.

[0011] Furthermore, it also includes a welding wire feeding device, which cooperates with the cylinder.

[0012] Furthermore, the control system is connected to the infrared temperature measuring element via wireless communication.

[0013] Furthermore, the control system is connected to the control terminal of the flame gun via wireless communication.

[0014] Furthermore, the control system is connected to a display.

[0015] The automatic preheating and temperature control method for submerged arc welding of boiler header cylinders according to the present invention includes: Set the upper and lower limits of the preheating temperature and welding parameters; The temperature of the preheated area of ​​the splicing ring seam is obtained by measuring the infrared temperature measuring element; When the temperature measured by the infrared temperature measuring element is lower than the lower limit, the flame gun is controlled to spray flame into the preheating area of ​​the splicing ring seam, and then the flame gun is turned off. At the same time, the welding wire feeding device is started to feed the welding wire for submerged arc welding. During the welding process, when the temperature measured by the infrared temperature measuring element is lower than the lower limit, the flame gun is activated to ensure that the temperature measured by the infrared temperature measuring element is within the preset temperature range, thus ensuring that the surface temperature of the cylinder is within the set temperature range.

[0016] The present invention has the following beneficial effects: In specific operation, the automatic preheating and temperature control device and method for submerged arc welding of boiler header shells described in this invention measures the temperature of the preheating area of ​​the splicing circumference seam using an infrared temperature measuring element. When the temperature measured by the infrared temperature measuring element is lower than the lower limit, the flame gun is controlled to spray flames onto the preheating area of ​​the splicing circumference seam. This avoids the problem of poor welding quality caused by the temperature drop in the welding area, reduces reliance on manual labor, lowers labor intensity, and improves production efficiency.

[0017] Furthermore, the output shaft of the servo motor is connected to the lead screw, which passes through the slider and is threaded together with the slider. The infrared temperature measuring element is mounted on the crossbeam via the slider. The servo motor drives the lead screw to rotate, and the lead screw drives the infrared temperature measuring element to slide via the slider, thereby adjusting the position of the infrared temperature measuring element.

[0018] Furthermore, the output end of the infrared temperature measuring element and the control end of the flame gun are connected to the control system. The control system is connected to a display, which displays the temperature measured by the infrared temperature measuring element and the status of the flame gun, thus realizing information visualization. Attached Figure Description

[0019] The accompanying drawings, which form part of this specification, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a result diagram of the present invention.

[0020] Among them, 1 is the roller frame, 2 is the cylinder, 3 is the welding wire feeding device, 4 is the trolley, 5 is the flame gun, 6 is the sliding guide rail, 7 is the infrared temperature measuring element, 8 is the control system, 9 is the slider, and 10 is the servo motor. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] In the description of this invention, it should be understood that the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0023] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0024] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination and all possible combinations of one or more of the associated listed items, and includes such combinations. For example, A and / or B can represent three cases: A alone, A and B simultaneously, and B alone. Additionally, the character " / " in this invention generally indicates that the preceding and following objects have an "or" relationship.

[0025] It should be understood that although terms such as first, second, third, etc., may be used in the embodiments of the present invention to describe the preset range, these preset ranges should not be limited to these terms. These terms are only used to distinguish the preset ranges from one another. For example, without departing from the scope of the embodiments of the present invention, the first preset range may also be referred to as the second preset range, and similarly, the second preset range may also be referred to as the first preset range.

[0026] Depending on the context, the word "if" as used here can be interpreted as "when," "when," "in response to determination," or "in response to detection." Similarly, depending on the context, the phrase "if determination" or "if detection (of the stated condition or event)" can be interpreted as "when determination," "in response to determination," "when detection (of the stated condition or event)," or "in response to detection (of the stated condition or event)."

[0027] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0028] The accompanying drawings illustrate various structural schematic diagrams according to embodiments disclosed in this invention. These drawings are not to scale, and some details have been enlarged for clarity, and some details may have been omitted. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.

[0029] Example 1 refer to Figure 1 The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder of the present invention includes a roller frame 1, a cylinder 2, a welding wire feeding device 3, a trolley 4, a flame torch 5, a sliding guide rail 6, an infrared temperature measuring element 7, a control system 8, a slider 9, and a servo motor 10. A sliding guide rail 6 is mounted on a crossbeam at the top of the trolley 4. A flame gun 5 is positioned on the sliding guide rail 6. The flame gun 5 moves along the sliding guide rail 6 to adjust to the preheating area of ​​the splicing circumferential seam of the cylinder 2. An infrared temperature measuring element 7 is mounted on the crossbeam via a slider 9. The output end of the infrared temperature measuring element 7 and the control end of the flame gun 5 are connected to the control system 8. The control end of the servo motor 10 is connected to the output end of the control system 8. The output shaft of the servo motor 10 is connected to a lead screw, which passes through the slider 9, and the lead screw and slider 9 are threaded together. During operation, the rotation of the servo motor 10 drives the lead screw to rotate, which in turn drives the slider 9 to slide, thereby adjusting the appropriate distance between the infrared temperature measuring element 7 and the surface of the cylinder 2. The cylinder 2 is located on the roller frame 1.

[0030] In one embodiment of the present invention, the control system 8 is connected to the infrared temperature measuring element 7 via wireless communication.

[0031] In one embodiment of the present invention, the control system 8 is connected to the control terminal of the flame gun 5 via wireless communication.

[0032] In one embodiment of the present invention, the control system 8 is connected to a display, which displays the status of the flame gun 5 and the temperature measured by the infrared temperature measuring element 7, thereby realizing the visualization of information.

[0033] In this invention, when the temperature measured by the infrared temperature measuring element 7 is lower than the lower limit of the temperature, the flame gun 5 is controlled to spray flames onto the preheating area of ​​the splicing ring seam, so as to avoid the problem of poor welding quality caused by the temperature drop in the welding area. This can reduce the dependence on manual labor, reduce labor intensity, and improve production efficiency.

[0034] Example 2 This embodiment discloses an automatic preheating and temperature control method for submerged arc welding of boiler header cylinder. The automatic preheating and temperature control method for submerged arc welding of boiler header cylinder is based on the automatic preheating and temperature control device for submerged arc welding of boiler header cylinder described in Embodiment 1. The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder includes a cylinder 2, a roller frame 1, a crossbeam, a sliding guide rail 6, a flame gun 5, an infrared temperature measuring element 7, and a control system 8. The cylinder 2 is located on the roller frame 1, the sliding guide rail 6 is installed on the crossbeam, the flame gun 5 is located on the sliding guide rail 6, and the flame gun 5 is directly facing the preheating area of ​​the splicing circumferential seam of the cylinder 2. The infrared temperature measuring element 7 is installed on the crossbeam, and the output end of the infrared temperature measuring element 7 and the control end of the flame gun 5 are connected to the control system 8.

[0035] Specifically, the automatic preheating and temperature control method for submerged arc welding of the boiler header cylinder includes: The control system 8 sets the upper and lower limits of the preheating temperature and welding parameters. The infrared thermometer 7 measures the temperature of the preheating area of ​​the splicing circumferential seam. When the temperature measured by the infrared thermometer 7 is lower than the lower limit, the flame torch 5 is controlled to spray flame into the preheating area of ​​the splicing circumferential seam, and then the flame torch 5 is turned off. Simultaneously, the welding wire feeder 3 is activated to feed the welding wire for submerged arc welding. Furthermore, during the welding process, when the temperature of the infrared thermometer 7 is lower than the lower limit, the flame torch 5 is activated to ensure that the temperature measured by the infrared thermometer 7 is within the preset temperature range, thus ensuring that the surface temperature of the cylinder 2 is within the set temperature range.

[0036] Example 3 A computer device includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the steps of an automatic preheating and temperature control method for submerged arc welding of a boiler header shell. For example, this includes: setting upper and lower limits for preheating temperature and welding parameters; acquiring the temperature of the preheating area of ​​the splicing circumferential seam measured by an infrared thermometer 7; when the temperature measured by the infrared thermometer 7 is lower than the lower limit, controlling a flame torch 5 to spray flame into the preheating area of ​​the splicing circumferential seam, then turning off the flame torch 5, and simultaneously starting the wire feeding device 3 to feed the welding wire for submerged arc welding; during the welding process, when the temperature measured by the infrared thermometer 7 is lower than the lower limit, starting the flame torch 5 to ensure that the temperature measured by the infrared thermometer 7 is within a preset temperature range, and to ensure that the surface temperature of the shell 2 is within the set temperature range. The memory may include main memory, such as high-speed random access memory (RAM), or non-volatile memory, such as at least one disk storage device. The processor, network interface, and memory are interconnected via an internal bus, which may be an industry-standard architecture bus, a peripheral component interconnection standard bus, or an extended industry-standard architecture bus. The bus can be categorized as an address bus, data bus, or control bus. The memory stores programs; specifically, the program may include program code, which includes computer operation instructions. The memory may include main memory and non-volatile memory, and provides instructions and data to the processor.

[0037] Example 4 A computer-readable storage medium stores a computer program that, when executed by a processor, implements the steps of an automatic preheating and temperature control method for submerged arc welding of a boiler header shell. For example, the method includes: setting upper and lower limits for preheating temperature and welding parameters; acquiring the temperature of the preheating area of ​​the splicing circumferential weld seam measured by an infrared thermometer 7; when the temperature measured by the infrared thermometer 7 is lower than the lower limit, controlling the flame torch 5 to spray flame into the preheating area of ​​the splicing circumferential weld seam, then turning off the flame torch 5, and simultaneously starting the wire feeding device 3 to feed the welding wire for submerged arc welding; during the welding process, when the temperature measured by the infrared thermometer 7 is lower than the lower limit, starting the flame torch 5 to ensure that the temperature measured by the infrared thermometer 7 is within a preset temperature range, and to ensure that the surface temperature of the shell 2 is within the set temperature range. Specifically, the computer-readable storage medium includes, but is not limited to, volatile memory and / or non-volatile memory. The volatile memory may include random access memory (RAM) and / or cache memory, etc. The non-volatile memory may include read-only memory (ROM), hard disk, flash memory, optical disk, magnetic disk, etc.

[0038] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0039] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0040] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0041] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0042] It should be noted that this invention can reduce reliance on manual labor, lower labor intensity, and improve production efficiency. Through infrared temperature measurement and automatic control, it can achieve precise control of preheating before welding, reduce welding defect rate, and is highly practical.

[0043] Other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and disclosure of the invention. This application is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of the invention are indicated by the following claims.

[0044] It should be understood that the present invention is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

[0045] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the present invention. Any simple modifications, alterations, or equivalent structural changes made to the above embodiments based on the technical essence of the present invention shall still fall within the protection scope of the present invention.

Claims

1. An automatic preheating and temperature control device for submerged arc welding of boiler header cylinder, characterized in that, Includes cylinder (2), roller frame (1), crossbeam, sliding guide rail (6), flame gun (5), cylinder (2), infrared temperature measuring element (7) and control system (8); The cylinder (2) is located on the roller frame (1), the sliding guide rail (6) is installed on the crossbeam, the flame gun (5) is located on the sliding guide rail (6), the flame gun (5) is facing the preheating area of ​​the splicing ring seam of the cylinder (2), the infrared temperature measuring element (7) is installed on the crossbeam, and the output end of the infrared temperature measuring element (7) and the control end of the flame gun (5) are connected to the control system (8).

2. The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder according to claim 1, characterized in that, The infrared temperature measuring element (7) is mounted on the crossbeam via a slider (9).

3. The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder according to claim 2, characterized in that, It also includes a servo motor (10) and a lead screw. The output shaft of the servo motor (10) is connected to the lead screw, which passes through the slider (9) and is threadedly connected to the slider (9).

4. The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder according to claim 3, characterized in that, The control terminal of the servo motor (10) is connected to the output terminal of the control system (8).

5. The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder according to claim 1, characterized in that, It also includes a trolley (4), with a crossbeam located on the trolley (4).

6. The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder according to claim 1, characterized in that, The control system (8) is located on the crossbeam.

7. The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder according to claim 1, characterized in that, It also includes a wire feeding device (3), which works in conjunction with the cylinder (2).

8. The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder according to claim 1, characterized in that, The control system (8) is connected to the infrared temperature measuring element (7) via wireless communication.

9. The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder according to claim 1, characterized in that, The control system (8) is connected to the control terminal of the flame gun (5) via wireless communication; the control system (8) is connected to a display.

10. An automatic preheating and temperature control method for submerged arc welding of boiler header cylinders, characterized in that, The automatic preheating and temperature control device for submerged arc welding of boiler header cylinder as described in claim 1 includes: Set the upper and lower limits of the preheating temperature and welding parameters; The temperature of the preheated area of ​​the splicing ring seam is obtained by the infrared thermometer (7); When the temperature measured by the infrared temperature measuring element (7) is lower than the lower limit of the temperature, the flame gun (5) is controlled to spray flames into the preheating area of ​​the splicing ring seam, and then the flame gun (5) is turned off. At the same time, the wire feeding device (3) is started to feed the wire for submerged arc welding. During the welding process, when the temperature measured by the infrared temperature measuring element (7) is lower than the lower limit, the flame gun (5) is activated to ensure that the temperature measured by the infrared temperature measuring element (7) is within the preset temperature range, and to ensure that the surface temperature of the cylinder (2) is within the set temperature range.

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