Welding device and method for light-weight ship steel machining

Abstract

The invention discloses a welding device and method for light-weight ship steel machining. The welding device comprises a rack, a plurality of sets of lateral clamping mechanisms are symmetrically arranged above the rack, and a gate-type cross beam is arranged above the rack; a rotating motor is suspended below the gate-type cross beam, and a rotating table is fixedly mounted at the output end of the rotating motor; a welding mechanism and a contact type cooling mechanism are arranged on one side of the rotating table side by side, and the contact type cooling mechanism is located behind the welding mechanism. By means of the unique structure that the hoisting rotary table is hung on the door-type cross beam, interference-free and efficient welding of a single set of welding mechanism on double-face welding seams is achieved, the equipment structure is more compact, and the cost is lower; and meanwhile, double heat management of'regional cooling and local quenching 'is adopted, a'high-frequency micro-swing' process of the welding gun is combined, and low deformation and high quality are cooperatively guaranteed from two levels of heat input control and weld structure optimization.

Description

Technical Field

[0001] This invention relates to the field of shipbuilding technology, and in particular to a welding apparatus and method for processing lightweight ship steel. Background Technology

[0002] In shipbuilding, T-sections (composed of web and bottom plates) are the main structural framework; the quality of the fillet welds at the connection between the web and bottom plates directly determines the structural strength and safety of the hull. With the development of lightweight ships, thin-walled high-strength steel is being used extensively, which places higher demands on welding technology.

[0003] In existing technologies, for automated welding of long T-sections, in order to control the welding deformation of thin-walled high-strength steel, low current, fast welding or segmented welding is usually used, but this seriously sacrifices welding efficiency. Conversely, high current continuous welding, which pursues efficiency, generates huge heat in a narrow area. Due to uneven heating, the thin-walled web and base plate are prone to irreversible plastic deformation such as warping and angular deformation, which affects the structural accuracy, and the subsequent straightening work is huge, or even causes the workpiece to be scrapped. Moreover, welding, cooling and slag removal processes are often separated, requiring multiple clamping or manual intervention, resulting in low automation and integration, which affects the overall production efficiency. Summary of the Invention

[0004] The purpose of this invention is to provide a welding apparatus and method for lightweight ship steel processing, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A welding apparatus for lightweight ship steel processing includes a frame and a T-shaped profile disposed above the frame's worktable, and further includes: Multiple sets of lateral clamping mechanisms are symmetrically arranged on both sides of the frame to alternately position and clamp the web of the T-profile. A portal beam is mounted above the frame via a linear drive mechanism and moves along the length of the T-profile. A rotary motor is suspended and installed below the portal beam via a motor mounting bracket. A rotary table is fixedly installed at the output end of the rotary motor, and the rotary table is driven by the rotary motor to rotate in the horizontal plane. A welding mechanism is fixedly installed on one side of the rotary table. The welding mechanism is driven to rotate by the rotary table and is used to weld the welds on both sides of the T-profile. A contact cooling mechanism is arranged side by side behind the welding mechanism and is movably connected to the side of the rotary table. It is used to adaptively press onto the weld surface to provide contact cooling with high thermal conductivity. The central controller is fixedly installed on one side of the frame and is electrically connected to the lateral clamping mechanism, the linear drive mechanism, the rotary motor, the welding mechanism, and the contact cooling mechanism.

[0006] Based on the above technical solution, the present invention can be further improved as follows.

[0007] Furthermore, an adaptive clamping roller is provided below the rotary table, wherein the adaptive clamping roller makes rolling contact with the upper end of the web of the T-profile.

[0008] Furthermore, the upper end of the worktable of the frame is provided with a positioning groove for accommodating the T-shaped base plate, and the lateral clamping mechanism is respectively arranged on both sides of the positioning groove.

[0009] Furthermore, the lateral clamping mechanism includes: The telescopic cylinder has its cylinder body fixedly connected to the frame via a cylinder mounting base. The composite clamping plate is connected to the top of the piston rod of the telescopic cylinder and is used to clamp and fix the web of the T-profile.

[0010] Furthermore, the composite clamping plate includes a copper alloy heat-conducting block, the clamping surface of which is in contact with the surface of the web of the T-profile, and permanent magnet blocks are provided on both sides of the clamping surface of the copper alloy heat-conducting block, wherein the copper alloy heat-conducting block has a micro-channel embedded inside.

[0011] Furthermore, the clamping surface of the copper alloy heat-conducting block is covered with an insulating and wear-resistant layer, wherein the insulating and wear-resistant layer is made of aluminum nitride ceramic material.

[0012] Furthermore, the welding device also includes a coolant circulation mechanism, which is fixedly installed below the frame; the coolant circulation mechanism is connected to the microchannels embedded inside the copper alloy heat-conducting block through delivery pipelines, and is used to deliver coolant to the microchannels to cool the T-profile.

[0013] Furthermore, a pressure sensor is provided between the piston rod of the telescopic cylinder and the composite clamping plate.

[0014] Furthermore, the welding mechanism includes: The linear screw module has its fixed base fixedly connected to the side of the rotary table, so that the rotary table can drive the linear screw module to rotate. A piezoelectric ceramic actuator is fixedly mounted on the slide table of the linear screw module via a right-angle bracket; the housing of the piezoelectric ceramic actuator is fixedly connected to the right-angle bracket, wherein the output end of the piezoelectric ceramic actuator passes through the right-angle bracket and extends downward; A support arm is disposed below a right-angle support. The middle part of the support arm is connected to the lower end of the right-angle support via a flexible hinge. One end of the support arm is a power arm, which is in contact with the output end of the piezoelectric ceramic actuator. The other end of the support arm is a resistance arm, and a welding torch is installed at the end of the resistance arm.

[0015] Furthermore, the length ratio of the resistance arm to the power arm of the support arm is 2:1 to 5:1.

[0016] Furthermore, the contact cooling mechanism includes: A follower swing arm, wherein the upper end of the follower swing arm is connected to the side wall of the rotary table via a spring hinge; A heat-conducting head is disposed at the lower end of the follower swing arm. The heat-conducting head has a cavity inside and an arc-shaped heat-conducting surface at the lower end of the heat-conducting head. The arc-shaped heat-conducting surface faces the weld seam and is in contact with it. A miniature circulating cooler is positioned above the rotating platform and is connected to the internal cavity of the heat-conducting head via pipes.

[0017] Furthermore, the contact surfaces of the heat-conducting head with the web and bottom plate of the T-profile are respectively provided with ball wheels.

[0018] Furthermore, the welding device also includes a waste slag synchronous recycling mechanism, which is fixed to the portal beam by a mounting bracket and located behind the contact cooling mechanism to adsorb and recycle welding slag debris generated during welding.

[0019] Furthermore, the waste residue synchronous recycling mechanism includes a negative pressure fan, wherein the negative pressure fan is fixedly installed on the side of the portal beam via a fan mounting bracket; the air inlet of the negative pressure fan is connected to a cyclone separator; the air inlet of the cyclone separator is connected to a recycling pipe, wherein a composite suction nozzle is connected to the front end of the recycling pipe; and the slag outlet of the cyclone separator is connected to a waste residue recycling box via a discharge pipe.

[0020] A welding method for processing lightweight ship steel includes the following steps: S10. Position the T-profile on the frame and clamp the web plate using the lateral clamping mechanism on its first side. At the same time, the adaptive clamping roller at the bottom of the rotary table clamps the upper part of the web plate. S20. Control the rotary motor to drive the rotary table to rotate, thereby rotating the welding mechanism and the contact cooling mechanism to the second side of the T-profile. S30. Start the welding mechanism and the contact cooling mechanism, and drive the gantry beam to move along the length of the T-profile through the linear drive mechanism, so that the welding mechanism can complete the welding of the second side weld. S40. After the second side welding is completed, loosen the lateral clamping mechanism on the first side of the T-profile and activate the lateral clamping mechanism on the second side of the T-profile to clamp the web. S50: Control the rotary motor to drive the rotary table to rotate, causing the welding mechanism and the contact cooling mechanism to rotate to the first side of the T-profile; S60. Start the welding mechanism and the contact cooling mechanism, and drive the gantry beam to move along the length of the T-profile through the linear drive mechanism, so that the welding mechanism can complete the welding of the first side weld.

[0021] Furthermore, during the welding process in steps S30 and S60, the waste slag synchronous recycling mechanism is activated simultaneously to recycle the waste slag generated during welding.

[0022] Furthermore, in steps S30 and S60, the piezoelectric ceramic actuator drives the welding torch to perform high-frequency micro-amplitude oscillation, forming a Z-shaped welding trajectory.

[0023] Compared with existing technologies, the beneficial effects of this invention are as follows: This invention achieves interference-free and efficient welding of double-sided welds with a single welding mechanism through a unique configuration of suspending a rotating platform on a portal beam. The equipment structure is more compact and the cost is lower. Simultaneously, it employs dual thermal management of "regional cooling + local rapid cooling," combined with the "high-frequency micro-oscillation" process of the welding torch, synergistically ensuring low deformation and high quality from two levels: heat input control and weld microstructure optimization. By integrating clamping, welding, oscillation, cooling, and slag removal functions into one unit and using a central controller to achieve intelligent linkage throughout the entire process, production efficiency is significantly improved. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the welding device for lightweight ship steel processing according to the present invention; Figure 2 This is a schematic diagram of the frame structure of the present invention; Figure 3 This is a schematic diagram of the lateral clamping mechanism of the present invention; Figure 4 This is an exploded view of the lateral clamping mechanism of the present invention; Figure 5 This is a schematic diagram of the portal beam structure of the present invention; Figure 6 This is a schematic diagram of the structure connecting the rotary table with the welding mechanism and the contact cooling mechanism of the present invention; Figure 7 This is a schematic diagram of the welding mechanism of the present invention; Figure 8 This is a schematic diagram of the contact cooling mechanism of the present invention; Figure 9 This is a schematic diagram of the structure of the heat-conducting head of the present invention; Figure 10 This is a schematic diagram of the waste residue synchronous recycling mechanism of the present invention; Figure 11 This is a process flow diagram of the welding method for lightweight ship steel processing according to the present invention.

[0025] The components include: 1. Frame; 2. T-profile; 3. Lateral clamping mechanism; 301. Telescopic cylinder; 302. Composite clamping plate; 3021. Copper alloy heat-conducting block; 3022. Permanent magnet block; 3023. Micro-flow channel; 3024. Insulating wear-resistant layer; 303. Pressure sensor; 4. Portal beam; 5. Linear drive mechanism; 6. Rotary motor; 7. Rotary table; 8. Welding mechanism; 801. Linear screw module; 802. Piezoelectric ceramic actuator; 803. Right-angle support; 804. Support arm; 805. Flexible hinge. Chain; 806, Welding torch; 9, Contact cooling mechanism; 901, Follow-up swing arm; 902, Spring hinge; 903, Heat-conducting head; 904, Arc-shaped heat-conducting surface; 905, Micro circulating cooler; 10, Central controller; 11, Adaptive clamping roller; 12, Positioning groove; 13, Coolant circulation mechanism; 14, Ball wheel; 15, Waste residue synchronous recycling mechanism; 1501, Negative pressure fan; 1502, Cyclone separator; 1503, Recycling pipe; 1504, Composite suction nozzle; 1505, Waste residue recycling box. Detailed Implementation

[0026] The present invention will now be described in further detail with reference to the accompanying drawings.

[0027] Please refer to the following: Figures 1 to 10 To achieve the above objectives, the present invention provides the following technical solution: A welding apparatus for lightweight ship steel processing includes a frame 1 and a T-shaped profile 2 mounted above the worktable of the frame 1. The frame 1 is welded from structural steel and has sufficient rigidity and stability to withstand the weight and inertial forces of moving parts such as the portal beam 4 and the welding mechanism 8, ensuring a smooth welding process. It also includes: Multiple sets of lateral clamping mechanisms 3 are symmetrically arranged on both sides of the frame 1 to alternately position and clamp the web of the T-profile 2. The lateral clamping mechanism 3 is an intelligent unit that integrates mechanical constraint, force control feedback and active thermal management. The lateral clamping mechanism 3 not only physically fixes the web of the T-profile 2, but also controls the overall temperature field of the T-profile 2 from the "surface" through active cooling, realizing large-area and regional forced cooling of the T-profile 2, effectively reducing the overall temperature of the welding heat-affected zone of the T-profile 2, and fundamentally suppressing wave deformation or angular deformation caused by uneven thermal expansion. The portal beam 4 is mounted above the frame 1 via a linear drive mechanism 5 and moves along the length of the T-profile 2. Driven by the linear drive mechanism 5 (which consists of a servo motor and a precision ball screw pair), the portal beam 4 moves linearly along the guide rail laid on the top of the frame 1, providing feed along the weld length for welding. The rotary motor 6 is suspended and installed below the portal beam 4 via a motor mounting bracket. A rotary table 7 is fixedly installed at the output end of the rotary motor 6, and the rotary table 7 is driven by the rotary motor 6 to rotate in the horizontal plane. Welding mechanism 8 is fixedly installed on one side of rotary table 7. The rotary table 7 drives the welding mechanism 8 to rotate, and it is used to weld the welds on both sides of T-profile 2. The combination of rotary motor 6 driving rotary table 7 can realize flexible control of the position and attitude of welding mechanism 8 in three-dimensional space. Rotary motor 6 and rotary table 7 form a "mechanical wrist joint". Through the rotational movement of rotary table 7, welding mechanism 8 can "go around" from one side of T-profile 2 to the other side, rather than trying to physically "pass through" T-profile 2. It can quickly and accurately switch welding mechanism 8 and contact cooling mechanism 9 from one welding side to another, completely avoiding interference between welding mechanism 8 and lateral clamping mechanism 3 or T-profile 2 itself. The contact cooling mechanism 9 is arranged side by side behind the welding mechanism 8 and is movably connected to the side of the rotary table 7. It is used to adaptively press onto the weld surface to perform contact-type high thermal conductivity cooling on the weld. The contact cooling mechanism 9 achieves efficient heat transfer from the high-temperature weld to the low-temperature heat conduction head through physical contact, and its efficiency is far superior to convection heat transfer. The contact cooling mechanism 9 performs local "rapid cooling" of the weld and the lateral clamping mechanism 3 performs "slow cooling" of the web of the T-profile 2 in combination, which together finely controls the thermal cycle process of the entire T-profile 2, minimizing residual stress and deformation. The central controller 10 is fixedly installed on one side of the frame 1 and is electrically connected to the lateral clamping mechanism 3, the linear drive mechanism 5, the rotary motor 6, the welding mechanism 8, and the contact cooling mechanism 9. The central controller 10 serves as the "brain" of the entire welding device, integrating all independent hardware units into an intelligent whole. According to the preset program, it precisely controls the entire process sequence and timing of "clamping -> rotational positioning -> welding feed -> oscillation -> cooling -> slag removal -> side switching -> re-welding". Based on the welding process database, it collaboratively sets and adjusts key parameters such as welding current and voltage, travel speed, oscillation frequency and amplitude, and coolant flow rate in real time to achieve the best welding effect.

[0028] In a preferred embodiment, the present invention may be further configured as follows: Figure 5 and Figure 6As shown; an adaptive clamping roller 11 is provided below the rotary table 7, wherein the adaptive clamping roller 11 rolls in contact with the upper end of the web of the T-profile 2 through an elastic element; the adaptive clamping roller 11 presses down on the web of the T-profile 2 from above during welding, and works in conjunction with the lateral clamping mechanism 3 to form a three-dimensional constraint, effectively suppressing the upward warping deformation that may occur in the web of the T-profile 2 during the welding process.

[0029] When the T-profile 2 is placed in the positioning slot 12 of the frame 1 and the web is clamped by the lateral clamping mechanism 3 on one side, the portal beam 4 moves to the starting position. At this time, no matter which side the rotary table 7 rotates to, the adaptive clamping roller 11 below it will extend downward under the preload of the elastic element and press steadily against the upper edge of the web of the T-profile 2. This clamping action is completed automatically without additional control, ensuring that the T-profile 2 is constrained in the vertical direction before welding begins. After welding starts, the portal beam 4, carrying the rotary table 7 and the adaptive clamping roller 11, moves at a constant speed along the weld direction. During this process, the adaptive clamping... Roller 11 always rolls on the upper surface of the web of T-profile 2, rather than sliding. The elastic element continuously provides a constant or adaptively variable pressure to the adaptive clamping roller 11, ensuring that the adaptive clamping roller 11 does not detach from the web surface of T-profile 2. If there are minor unevennesses in T-profile 2 or welding thermal deformation has begun to appear, the elastic element can absorb this height change through its own expansion and contraction, ensuring the continuity and stability of the clamping force. When the weld on one side is completed and the welding mechanism 8 needs to be rotated to the other side, the adaptive clamping roller 11 will rotate with the rotary table 7 and press down again to continue performing the same clamping task.

[0030] In a preferred embodiment, the present invention may be further configured as follows: Figure 2 As shown, the upper end of the worktable of the frame 1 is provided with a positioning groove 12 for accommodating the base plate of the T-profile 2, and the lateral clamping mechanism 3 is respectively set on both sides of the positioning groove 12. The operator only needs to put the base plate into the groove to complete the initial positioning in the horizontal plane without repeated measurement and adjustment. The side wall and end face of the positioning groove 12 form a two-dimensional positioning reference, which restricts the degree of freedom of movement and rotation of the base plate of the T-profile 2 in the horizontal plane, realizing fast and highly repeatable positioning, thereby ensuring the consistency of the subsequent welding trajectory.

[0031] In a preferred embodiment, the present invention may be further configured as follows: Figure 3 and Figure 4 As shown; the lateral clamping mechanism 3 includes: The telescopic cylinder 301 has its cylinder body fixedly connected to the frame 1 via a cylinder mounting seat; The composite clamping plate 302 is connected to the top of the piston rod of the telescopic cylinder 301 and is used to clamp and fix the web of the T-profile 2. The telescopic cylinder 301 serves as a power source, driving the composite clamping plate 302 to contact and press the web of the T-profile 2. The composite clamping plate 302 provides a flat clamping surface that contacts the web of the T-profile 2, which is used to evenly distribute the clamping force over a large area of ​​the web of the T-profile 2, greatly reducing the pressure and avoiding indentations. During the entire welding process, the lateral clamping mechanism 3 provides a stable and reliable clamping force, which can prevent the web of the T-profile 2 from moving under vibration or thermal stress, ensuring the accuracy of the weld trajectory, and also avoid deformation of the thin plate due to excessive clamping force.

[0032] In a preferred embodiment, the present invention may be further configured as follows: Figure 4 As shown; the composite clamping plate 302 includes a copper alloy heat-conducting block 3021, the clamping surface of which contacts the surface of the web of the T-profile 2, and permanent magnet blocks 3022 are provided on both sides of the clamping surface of the copper alloy heat-conducting block 3021, wherein a micro-flow channel 3023 is embedded inside the copper alloy heat-conducting block 3021; ​​the composite clamping plate 302 serves as the end actuator of the piston rod of the telescopic cylinder 301, used to uniformly and stably transfer the thrust generated by the telescopic cylinder 301 through its own robust structure. The magnetic force is transmitted and applied to the side surface of the web of the T-profile 2, completing the most basic physical fixing function. When the composite clamping plate 302 approaches the web of the steel T-profile 2, the permanent magnets 3022 on both sides emit strong magnetic lines of force, silently and continuously adsorbing onto the web of the T-profile 2. The magnetic force acts on a certain area, providing distributed adsorption force. This, combined with the concentrated force point of the telescopic cylinder 301, makes the clamping more balanced and reduces the risk of the thin plate denting due to excessive local pressure. The combined action of the clamping force and the mechanical clamping force creates a "rigid yet flexible" clamping effect. The copper alloy heat-conducting block 3021 acts as a highly efficient "heat transporter," with its internal micro-channels 3023 continuously flowing with low-temperature coolant from the external coolant circulation mechanism 13. During welding, heat is conducted along the web of the T-profile 2. Due to its excellent thermal conductivity, the copper alloy heat-conducting block 3021 at the core of the composite clamping plate 302 quickly absorbs the heat from the web of the T-profile 2. The low-temperature coolant from the coolant circulation mechanism 13 continuously flows in its internal micro-channels 3023, directly transferring the welding heat energy away from the T-profile 2. This reduces the overall temperature of the T-profile 2 around the weld, creating a steeper temperature gradient between the weld and the T-profile 2, making it less likely for heat to diffuse outward. By reducing the overall average temperature and temperature unevenness of the welded T-profile 2, the welding thermal stress and the resulting wave deformation, angular deformation, etc., are significantly reduced.

[0033] In a preferred embodiment, the present invention may be further configured as follows: Figure 4As shown, the clamping surface of the copper alloy heat-conducting block 3021 is covered with an insulating and wear-resistant layer 3024, which is made of aluminum nitride ceramic material. By using aluminum nitride ceramic to make the insulating and wear-resistant layer 3024, the copper alloy heat-conducting block 3021 is protected, and the influence of stray current on the T-shaped material 2 to be welded is prevented.

[0034] In a preferred embodiment, the present invention may be further configured as follows: Figure 1 As shown; the welding device also includes a coolant circulation mechanism 13, which is fixedly installed below the frame 1; the coolant circulation mechanism 13 is connected to the micro-channels 3023 embedded inside the copper alloy heat-conducting block 3021 through delivery pipelines, and is used to deliver coolant to the micro-channels 3023 to cool the T-profile 2; the coolant circulation mechanism 13 is an independent, closed fluid circulation system, which is connected to the micro-channels 3023 inside the copper alloy heat-conducting block 3021 in the lateral clamping mechanism 3 through delivery pipelines (usually including supply pipes and return pipes). The flow channels 3023 are connected to form a complete cooling circuit; the coolant circulation mechanism 13 is responsible for driving, cooling and distributing the coolant, establishing an efficient "heat transport pipeline" between the welding area and the external environment; through a set of delivery pipelines, valves and joints, the coolant is accurately and reliably delivered to each side clamping mechanism 3 that needs cooling, and the returned coolant is collected; its core task is to drive the coolant to flow continuously in the circuit, thereby efficiently transferring the welding heat from the workpiece and dissipating it to the outside.

[0035] In a preferred embodiment, the present invention may be further configured as follows: Figure 4 As shown, a pressure sensor 303 is installed between the piston rod of the telescopic cylinder 301 and the composite clamping plate 302. At the moment the telescopic cylinder 301 drives the composite clamping plate 302 to contact and press against the web of the T-profile 2, and throughout the entire welding process, the pressure sensor 303 continuously measures the clamping force it bears. The pressure sensor 303 converts this physical pressure into a standard electrical signal with high precision and in real time and sends it to the central controller 10. The central controller 10 compares the received actual force value with the preset target force value in the program. If the actual force value is lower than the target value, the central controller 10 issues a command to increase the air pressure to the telescopic cylinder 301, increasing the piston rod thrust. If the actual force value is higher than the target value (or the force value increases abnormally due to thermal expansion), the central controller 10 issues a command to decrease the air pressure to the telescopic cylinder 301, reducing the clamping force. Through this rapid and dynamic adjustment, the clamping force is precisely stabilized within the preset optimal range.

[0036] In a preferred embodiment, the present invention may be further configured as follows: Figure 6 and Figure 7 As shown; welding mechanism 8 includes: The linear screw module 801 has its fixed base fixedly connected to the side of the rotary table 7 so that the linear screw module 801 can be rotated by the rotary table 7; wherein the linear screw module 801 is used to precisely adjust the initial height of the welding torch 806 before welding to adapt to different specifications of T-profiles 2. The piezoelectric ceramic actuator 802 is fixedly mounted on the slide of the linear screw module 801 via a right-angle support 803; the housing of the piezoelectric ceramic actuator 802 is fixedly connected to the right-angle support 803, wherein the output end of the piezoelectric ceramic actuator 802 passes through the right-angle support 803 and extends downward. A support arm 804 is positioned below a right-angle support 803. The middle of the support arm 804 is connected to the lower end of the right-angle support 803 via a flexible hinge 805. One end of the support arm 804 is a power arm, which contacts the output end of the piezoelectric ceramic actuator 802. The other end of the support arm 804 is a resistance arm, with a welding torch 806 mounted at its end. Driven by a high-frequency electrical signal provided by a controller, the piezoelectric ceramic actuator 802 generates precise, micron-level telescopic motion. This motion is amplified into a controllable lateral oscillation of several hundred hertz at the tip of the welding torch 806 through an amplification lever mechanism composed of the support arm 804 and the flexible hinge 805. By utilizing the inverse piezoelectric effect of the piezoelectric ceramic actuator 802, electrical energy is directly converted into mechanical energy, achieving high-frequency, fast-response micro-displacement.

[0037] Before welding begins, according to the specifications of the T-profile 2 to be welded, the central controller 10 instructs the servo motor of the linear lead screw module 801 to rotate, driving the slide table and the entire welding torch 806 on it to rise or fall, thereby adjusting the welding torch 806 to the preset, optimal initial working height. Before welding, if the T-profile 2 has minor unevenness or deformation, the system can fine-tune the height of the welding torch 806 according to the preset program or feedback from the central controller 10 to ensure a stable arc length. During welding, the central controller 10 applies a high-frequency alternating voltage signal to the piezoelectric ceramic actuator 802, wherein the piezoelectric ceramic actuator 802 responds to the signal... The signal generates a high-frequency, micron-level axial extension and contraction motion. This micro-motion is amplified by the lever mechanism formed by the support arm 804, and finally converted into a high-frequency reciprocating oscillation of the tip of the welding torch 806 in a direction perpendicular to the welding direction, with an amplitude of millimeters. This allows the welding torch 806 to no longer simply travel along a straight line, but to oscillate in a "Z" shape at a frequency of hundreds of hertz. This oscillation can effectively widen the weld, stir the molten pool, expel gas, and refine the grains, thereby significantly improving the weld formation quality, penetration depth, and mechanical properties without increasing heat input. At the same time, it helps to disperse the heat source and reduce welding stress and deformation.

[0038] In a preferred embodiment, the present invention may be further configured as follows: Figure 7As shown; the length ratio of the resistance arm to the power arm of the support arm 804 is 2:1 to 5:1; the support arm 804 is connected to the right-angle support 803 through a flexible hinge 805 to form a fulcrum, the output end of the piezoelectric ceramic actuator 802 is pressed against one end of the power arm of the support arm 804, and the welding torch 806 is installed at one end of the resistance arm; the core function of the lever ratio mechanism is to efficiently convert the micron-level, high-thrust displacement output by the piezoelectric ceramic actuator 802 into the millimeter-level, moderate-force oscillation required by the welding torch 806 according to a preset and optimized multiple; for example, with a lever ratio of 1:5, a 10μm input can produce a 50μm oscillation of the welding torch 806; ensuring that the entire high-frequency micro-oscillation system can produce a sufficiently wide weld seam while maintaining high rigidity and fast response, thereby stably outputting a high-quality welding trajectory.

[0039] In a preferred embodiment, the present invention may be further configured as follows: Figure 8 and Figure 9 As shown; the contact cooling mechanism 9 includes: Follower swing arm 901, wherein the upper end of follower swing arm 901 is connected to the side wall of rotary table 7 via spring hinge 902; A heat-conducting head 903 is disposed at the lower end of the follower swing arm 901. The heat-conducting head 903 has a cavity inside. The lower end of the heat-conducting head 903 has an arc-shaped heat-conducting surface 904, which faces the weld seam side and is in contact with it. The miniature circulating cooler 905 is located above the rotating table 7 and is connected to the internal cavity of the heat-conducting head 903 via a pipe.

[0040] When welding begins, as the contact cooling mechanism 9 moves to the weld start point, the follower arm 901 swings downwards under the pre-pressure of the spring hinge 902, causing the arc-shaped heat-conducting surface 904 of the heat-conducting head 903 to stably adhere to the freshly welded weld. During welding, the spring hinge 902 acts as a "flexible joint," automatically compensating for minor unevenness on the surface of the T-profile 2, changes in weld formation height, and vibrations of the equipment itself. This ensures that the heat-conducting head 903, like being attracted by a magnet, always maintains a constant and gentle pressure, firmly "biting" the weld trajectory without detachment or jamming. The arc-shaped heat-conducting surface 904 at the lower end of the heat-conducting head 903 closely matches the geometry of the fillet weld, maximizing the contact area. When the weld pool, exceeding 1000°C, solidifies and cools to several hundred degrees behind the welding torch 806, the heat-conducting head 903, through direct contact with the weld surface, acts as a "heat sink," rapidly dissipating the large amount of heat from the weld and its heat-affected zone. The coolant is rapidly and in situ absorbed into its own interior. The micro-circulating cooler 905, as the "heart" of the cooling system, drives the coolant to flow into the cavity inside the heat-conducting head 903 through flexible pipes. The coolant undergoes intense heat exchange with the high-temperature inner wall of the heat-conducting head 903, "transferring" the heat from the solid heat-conducting head 903 to the liquid coolant. The heated coolant flows back to the micro-circulating cooler 905 for cooling. After being cooled, the coolant is pumped back into the circulation, thus forming a closed, continuously operating heat transport chain. The contact cooling mechanism 9, through local rapid cooling of the weld and in coordination with the regional cooling of the lateral clamping mechanism 3, precisely controls the overall temperature field of the workpiece, which is the core means to suppress weld angular deformation and bending deformation. It accelerates the weld through the brittle temperature zone, reducing the risk of hot cracking. Optimizing the cooling rate can improve the microstructure of the weld metal and enhance its mechanical properties. It allows for higher welding heat input or faster welding speed, improving work efficiency.

[0041] In a preferred embodiment, the present invention may be further configured as follows: Figure 9 As shown, ball wheels 14 are provided on the contact surfaces of the heat-conducting head 903 with the web and bottom plate of the T-profile 2. The ball wheels 14 serve as the actual contact points between the heat-conducting head 903 and the surfaces of the web and bottom plate of the high-temperature T-profile 2. When the portal beam 4 drives the entire welding mechanism 8 and the contact cooling mechanism 9 forward, the ball wheels 14 support most of the weight of the heat-conducting head 903 and the downward pressure applied by the spring hinge 902 by rolling on the surface of the T-profile 2. This ensures that the heat-conducting head 903 will not jam, jump, or detach due to excessive resistance, allowing the heat-conducting head 903 to move smoothly along the weld contour, thereby ensuring the continuity and stability of the cooling effect.

[0042] In a preferred embodiment, the present invention may be further configured as follows: Figure 5 and Figure 10As shown; the welding device also includes a waste slag synchronous recovery mechanism 15, which is fixed to the portal beam 4 by a mounting bracket and located behind the contact cooling mechanism 9 for adsorbing and recovering welding slag debris generated during welding; the waste slag synchronous recovery mechanism 15 includes a negative pressure fan 1501, which is fixedly installed on the side of the portal beam 4 by a fan mounting bracket; the air inlet of the negative pressure fan 1501 is connected to a cyclone separator 1502; the air inlet of the cyclone separator 1502 is connected to a recovery pipe 1503, and the front end of the recovery pipe 1503 is connected to a composite suction nozzle 1504; the slag outlet of the cyclone separator 1502 is connected to a waste slag recovery box 1505 through a discharge pipe.

[0043] During operation, the negative pressure fan 1501 creates a stable high negative pressure zone at its air inlet, thereby generating a powerful suction airflow throughout the entire recovery pipe 1503. The composite suction nozzle 1504, located at the very front, has its opening precisely aligned with the area behind the welding and contact cooling mechanism 9. Under the negative pressure, air containing welding slag, metal spatter particles, and fumes is drawn into the composite suction nozzle 1504 at high speed and transported over a long distance through the recovery pipe 1503 to the cyclone separator 1502. Inside the cyclone separator 1502, welding slag and particles, which are much denser than air, are thrown against the inner wall of the cyclone separator 1502 under the action of enormous centrifugal force, and finally fall into the waste slag recovery box 1505 at the bottom. The separated welding slag continuously accumulates in the waste slag recovery box 1505. When a certain amount is reached, the waste slag recovery box 1505 is cleaned or replaced periodically by the operator. This eliminates the heavy manual cleaning work, making the entire welding process continuous and efficient.

[0044] Please see Figure 11 A welding method for processing lightweight ship steel includes the following steps: S10. Position the T-profile 2 on the frame 1, and clamp the web plate by the lateral clamping mechanism 3 on its first side. At the same time, the adaptive pressure roller 11 at the bottom of the rotary table 7 presses the upper end of the web plate. S20. Control the rotary motor 6 to drive the rotary table 7 to rotate, thereby causing the welding mechanism 8 and the contact cooling mechanism 9 to rotate to the second side of the T-profile 2; S30. Start the welding mechanism 8 and the contact cooling mechanism 9. Drive the portal beam 4 along the length of the T-profile 2 through the linear drive mechanism 5. Drive the welding gun 806 to perform high-frequency micro-amplitude oscillation through the piezoelectric ceramic actuator 802 to form a Z-shaped welding trajectory, so that the welding mechanism 8 completes the welding of the second side weld. Simultaneously start the waste slag recovery mechanism 15 to recover the waste slag generated during welding. S40. After the second side welding is completed, loosen the lateral clamping mechanism 3 on the first side of the T-profile 2, and activate the lateral clamping mechanism 3 on the second side of the T-profile 2 to clamp the web. S50, control the rotary motor 6 to drive the rotary table 7 to rotate, thereby driving the welding mechanism 8 and the contact cooling mechanism 9 to rotate to the first side of the T-profile 2; S60. Start the welding mechanism 8 and the contact cooling mechanism 9. Drive the portal beam 4 along the length of the T-profile 2 through the linear drive mechanism 5. Drive the welding gun 806 to perform high-frequency micro-amplitude oscillation through the piezoelectric ceramic actuator 802 to form a Z-shaped welding trajectory, so that the welding mechanism 8 completes the welding of the first side weld. Simultaneously start the waste slag synchronous recycling mechanism 15 to recycle the waste slag generated during welding.

[0045] The specific working principle of the welding device for lightweight ship steel processing of the present invention is as follows: Before the welding device starts working, first place the bottom plate of the T-profile 2 into the positioning groove 12 of the frame 1, and adjust its web to a vertical position. Next, the device is activated. The telescopic cylinder 301 of the lateral clamping mechanism 3 located on the first side of the T-profile 2 is activated, pushing the composite clamping plate 302 to press the web plate. The pressure sensor 303 monitors the clamping force in real time and feeds it back to the central controller 10 to ensure that the clamping force is stable at the set value. At the same time, the adaptive clamping roller 11 under the rotary table 7 presses the upper edge of the web plate under the action of the spring. The central controller 10 controls the welding mechanism 8 and the contact cooling mechanism 9 to be precisely positioned on the second side of the T-profile 2. Subsequently, the linear screw module 801 actuates, fine-tuning the welding torch 806 to the optimal welding height; welding begins, the central controller 10 issues a command, and the gantry beam 4 moves forward at a constant speed under the drive of the linear drive mechanism 5; simultaneously, the welding torch 806 performs welding, the piezoelectric ceramic actuator 802 starts synchronously, and the drive support arm 804 drives the welding torch 806 to perform high-frequency micro-amplitude oscillation; following closely behind, the heat-conducting head 903 of the contact cooling mechanism 9 rolls tightly against the weld seam under the pressure of the spring hinge 902, implementing forced cooling; the waste slag synchronous recycling mechanism 15 starts synchronously to collect the generated welding slag; After the second side welding is completed, the first side clamping mechanism is released and reset, and the second side clamping mechanism clamps the web plate. Subsequently, the central controller 10 controls the rotary motor 6 to drive the rotary table 7 to rotate 180°, so that the welding mechanism 8 and the contact cooling mechanism 9 are switched to the first side, and the welding of the first side weld is completed with the same welding process. At this point, the double-sided fillet weld of the entire T-profile 2 is completed, and the whole process is automated without the need for manual intervention to turn it over or adjust it.

[0046] While specific embodiments of the present invention have been described above, those skilled in the art should understand that these are merely illustrative examples, and the scope of protection of the present invention is defined by the appended claims. Those skilled in the art can make various changes or modifications to these embodiments without departing from the principles and essence of the present invention, but all such changes and modifications fall within the scope of protection of the present invention.

Claims

1. A welding apparatus for lightweight ship steel processing, comprising a frame (1) and a T-shaped profile (2) disposed above the worktable of the frame (1), characterized in that, Also includes: Multiple sets of lateral clamping mechanisms (3) are symmetrically arranged on both sides of the frame (1) for alternately positioning and clamping the web of the T-profile (2); A portal beam (4) is mounted above the frame (1) via a linear drive mechanism (5) and moves along the length of the T-profile (2); A rotary motor (6) is suspended and installed below the portal beam (4) via a motor mounting base. A rotary table (7) is fixedly installed at the output end of the rotary motor (6), wherein the rotary table (7) is driven by the rotary motor (6) to rotate in the horizontal plane. The welding mechanism (8) is fixedly installed on one side of the rotary table (7). The welding mechanism (8) is driven by the rotary table (7) to rotate and is used to weld the welds on both sides of the T-shaped material (2). A contact cooling mechanism (9) is arranged side by side behind the welding mechanism (8). It is movably connected to the side of the rotary table (7) and is used to adaptively press onto the weld surface to provide contact cooling with high thermal conductivity. The central controller (10) is fixedly installed on one side of the frame (1) and is electrically connected to the lateral clamping mechanism (3), the linear drive mechanism (5), the rotary motor (6), the welding mechanism (8), and the contact cooling mechanism (9).

2. The welding apparatus for lightweight ship steel processing according to claim 1, characterized in that, The rotary table (7) is provided with an adaptive pressing roller (11) below it, wherein the adaptive pressing roller (11) makes rolling contact with the upper end of the web of the T-profile (2).

3. The welding apparatus for lightweight ship steel processing according to claim 1, characterized in that, The upper end of the workbench of the frame (1) is provided with a positioning groove (12) for accommodating the bottom plate of the T-shaped material (2), and the lateral clamping mechanism (3) is respectively arranged on both sides of the positioning groove (12).

4. The welding apparatus for lightweight ship steel processing according to claim 3, characterized in that, The lateral clamping mechanism (3) includes: Telescopic cylinder (301), the cylinder body of which is fixedly connected to the frame (1) through a cylinder mounting seat; The composite clamp (302) is connected to the top of the piston rod of the telescopic cylinder (301) and is used to clamp and fix the web of the T-profile (2).

5. The welding apparatus for lightweight ship steel processing according to claim 4, characterized in that, The composite clamping plate (302) includes a copper alloy heat-conducting block (3021), the clamping surface of which is in contact with the web surface of the T-profile (2), and permanent magnet blocks (3022) are provided on both sides of the clamping surface of the copper alloy heat-conducting block (3021), wherein a micro-channel (3023) is embedded inside the copper alloy heat-conducting block (3021).

6. The welding apparatus for lightweight ship steel processing according to claim 5, characterized in that, The clamping surface of the copper alloy heat-conducting block (3021) is covered with an insulating and wear-resistant layer (3024), wherein the insulating and wear-resistant layer (3024) is made of aluminum nitride ceramic material.

7. The welding apparatus for lightweight ship steel processing according to claim 1, characterized in that, The welding mechanism (8) includes: The linear screw module (801) has its fixed base fixedly connected to the side of the rotary table (7) so as to drive the linear screw module (801) to rotate through the rotary table (7); A piezoelectric ceramic actuator (802) is fixedly mounted on the slide of the linear lead screw module (801) via a right-angle support (803); the housing of the piezoelectric ceramic actuator (802) is fixedly connected to the right-angle support (803), wherein the output end of the piezoelectric ceramic actuator (802) passes through the right-angle support (803) and extends downward; A support arm (804) is disposed below a right-angle support (803). The middle part of the support arm (804) is connected to the lower end of the right-angle support (803) via a flexible hinge (805). One end of the support arm (804) is a power arm, which is in contact with the output end of the piezoelectric ceramic actuator (802). The other end of the support arm (804) is a resistance arm, and a welding torch (806) is installed at the end of the resistance arm.

8. The welding apparatus for lightweight ship steel processing according to claim 7, characterized in that, The length ratio of the resistance arm to the power arm of the support arm (804) is 2:1 to 5:

1.

9. The welding apparatus for lightweight ship steel processing according to claim 1, characterized in that, The contact cooling mechanism (9) includes: Follower arm (901), wherein the upper end of the follower arm (901) is connected to the side wall of the rotary table (7) via a spring hinge (902); A heat-conducting head (903) is disposed at the lower end of the follower swing arm (901). The heat-conducting head (903) has a cavity inside. The lower end of the heat-conducting head (903) is provided with an arc-shaped heat-conducting surface (904). The arc-shaped heat-conducting surface (904) faces the weld seam and is in contact with it. A miniature circulating cooler (905) is disposed above the rotating table (7) and is connected to the internal cavity of the heat-conducting head (903) via a pipeline.

10. A welding method for processing lightweight ship steel as described in any one of claims 1-9, characterized in that, Includes the following steps: S10. Position the T-profile (2) on the frame (1) and clamp the web plate by the lateral clamping mechanism (3) on its first side. At the same time, the adaptive pressing roller (11) at the bottom of the rotary table (7) presses the upper end of the web plate. S20. Control the rotary motor (6) to drive the rotary table (7) to rotate, thereby driving the welding mechanism (8) and the contact cooling mechanism (9) to rotate to the second side of the T-profile (2); S30. Start the welding mechanism (8) and the contact cooling mechanism (9), and drive the portal beam (4) to move along the length of the T-profile (2) through the linear drive mechanism (5), so that the welding mechanism (8) can complete the welding of the second side weld. S40. After the second side welding is completed, loosen the lateral clamping mechanism (3) on the first side of the T-profile (2) and activate the lateral clamping mechanism (3) on the second side of the T-profile (2) to clamp the web. S50, control the rotary motor (6) to drive the rotary table (7) to rotate, and drive the welding mechanism (8) and the contact cooling mechanism (9) to rotate to the first side of the T-profile (2); S60. Start the welding mechanism (8) and the contact cooling mechanism (9), and drive the portal beam (4) to move along the length of the T-profile (2) through the linear drive mechanism (5), so that the welding mechanism (8) can complete the welding of the first side weld.

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